2002 YAMAHA DT125R maintenance

6-30
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00774
Adjusting the Autolube
pumpThe Autolube pump is a vital and
sophisticated component of the
engine, which must be adjusted by a
Yamaha dealer at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
EAU03370
Checking and lubricating the
brake and shift pedalsThe operation of the brake and shift
pedals should be checked before
each ride, and the pedal pivots
should be lubricated if necessary.
EAU03164
Checking and lubricating the
brake and clutch leversThe operation of the brake and clutch
levers should be checked before
each ride, and the lever pivots should
be lubricated if necessary.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
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6-31
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU02939
Checking the front forkThe condition and operation of the
front fork must be checked as follows
at the intervals specified in the peri-
odic maintenance and lubrication
chart.
To check the condition
EW000115
wSecurely support the motorcycle
so that there is no danger of it
falling over.Check the inner tubes for scratches,
damage and excessive oil leakage.To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and
rebounds smoothly.
EC000098
cCIf any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
EAU03165
Checking and lubricating the
sidestandThe operation of the sidestand
should be checked before each ride,
and the sidestand pivot and metal-to-
metal contact surfaces should be
lubricated if necessary.
EW000113
wIf the sidestand does not move up
and down smoothly, have a
Yamaha dealer check or repair it.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
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6-32
PERIODIC MAINTENANCE AND MINOR REPAIR
6 2. Hold the lower ends of the front
fork legs and try to move them
forward and backward. If any
free play can be felt, have a
Yamaha dealer check or repair
the steering.
EAU01144
Checking the wheel bearingsThe front and rear wheel bearings
must be checked at the intervals
specified in the periodic maintenance
and lubrication chart. If there is play
in the wheel hub or if the wheel does
not turn smoothly, have a Yamaha
dealer check the wheel bearings.
EAU00794
Checking the steeringWorn or loose steering bearings may
cause danger. Therefore, the opera-
tion of the steering must be checked
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
1. Place a stand under the engine
to raise the front wheel off the
ground.
EW000115
wSecurely support the motorcycle
so that there is no danger of it
falling over.
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6-33
PERIODIC MAINTENANCE AND MINOR REPAIR
6
NOTE:
Make sure that the motorcycle is
positioned straight up when checking
the electrolyte level.2. Check the electrolyte level in the
battery.NOTE:
The electrolyte should be between
the minimum and maximum level
marks.
1
2
1. Maximum level mark
2. Minimum level mark
EAU01071
BatteryA poorly maintained battery will cor-
rode and discharge quickly. The elec-
trolyte level, battery lead connections
and breather hose routing should be
checked before each ride and at the
intervals specified in the periodic
maintenance and lubrication chart.
To check the electrolyte level
1. Place the motorcycle on a level
surface and hold it in an upright
position.
12
1. Battery
2. Battery breather hose
3. If the electrolyte is at or below
the minimum level mark, add dis-
tilled water to raise it to the maxi-
mum level mark.
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6-34
PERIODIC MAINTENANCE AND MINOR REPAIR
6 To store the battery
1. If the motorcycle will not be used
for more than one month,
remove the battery, fully charge
it, and then place it in a cool, dry
place.
2. If the battery will be stored for
more than two months, check the
specific gravity of the electrolyte
at least once a month and fully
charge the battery whenever
necessary.
3. Fully charge the battery before
installation.
4. After installation, make sure that
the battery leads are properly
connected to the battery termi-
nals and that the breather hose
is properly routed, in good condi-
tion, and not obstructed. 8Take care not to spill elec-
trolyte on the drive chain, as
this may weaken it, shorten
chain life and possibly result
in an accident.
8KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
EC000100
cCUse only distilled water, as tap
water contains minerals that are
harmful to the battery.4. Check and, if necessary, tighten
the battery lead connections and
correct the breather hose rout-
ing.
EW000117
w8Electrolyte is poisonous and
dangerous since it contains
sulfuric acid, which causes
severe burns. Avoid any con-
tact with skin, eyes or clothing
and always shield your eyes
when working near batteries.
In case of contact, administer
the following FIRST AID.
9EXTERNAL: Flush with plen-
ty of water.
9INTERNAL: Drink large quan-
tities of water or milk and
immediately call a physician.
9EYES: Flush with water for
15 minutes and seek prompt
medical attention.
8Batteries produce explosive
hydrogen gas. Therefore, keep
sparks, flames, cigarettes,
etc., away from the battery and
provide sufficient ventilation
when charging it in an
enclosed space.
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6-35
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EC000103
cCDo not use a fuse of a higher
amperage rating than recommend-
ed to avoid causing extensive
damage to the electrical system
and possibly a fire.3. Turn the key to “ON” and turn on
the electrical circuits to check if
the devices operate.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
EAU01307
Replacing the fuseThe fuse holder is located behind
panel B. (See page 6-8 for panel
removal and installation procedures.)
If the fuse is blown, replace it as fol-
lows.
1. Turn the key to “OFF” and turn
off all electrical circuits.
2. Remove the blown fuse, and
then install a new fuse of the
specified amperage.
1
1. Fuse
EC000099
cCIf the breather hose is positioned
in such a way that the frame is
exposed to electrolyte or gas
expelled from the battery, the
frame could suffer structural and
external damages.
Specified fuse:
10 A
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PERIODIC MAINTENANCE AND MINOR REPAIR
6 4. Remove the headlight bulb hold-
er by turning it counterclockwise,
and then remove the defective
bulb.
1
1. Headlight bulb holder
3. Disconnect the headlight cou-
pler, and then remove the head-
light bulb cover.
1
2
1. Headlight coupler
2. Headlight bulb cover
EAU01158
Replacing the headlight bulbIf the headlight bulb burns out,
replace it as follows.
1. Remove cowling A. (See page
6-5 for cowling removal and
installation procedures.)
2. Remove the headlight unit by
removing the bolts.
1
1. Bolt (×2)
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6-37
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03497
Replacing a turn signal light
bulb1. Remove the turn signal light lens
by removing the screw.
2. Remove the defective bulb by
pushing it in and turning it coun-
terclockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screw.
1
2
3
1. Screw
2. Lens
3. Bulb
7. Install the headlight unit by
installing the bolts.
8. Install the cowling.
9. Have a Yamaha dealer adjust
the headlight beam if necessary.
EW000119
wHeadlight bulbs get very hot.
Therefore, keep flammable prod-
ucts away from a lit headlight bulb,
and do not touch the bulb until it
has cooled down.5. Place a new bulb into position,
and then secure it with the bulb
holder.
6. Install the bulb cover, and then
connect the coupler.
a
a. Do not touch this area.
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