2002 YAMAHA DT125R coolant

EAU00009
TABLE OF CONTENTS
GIVE SAFETY THE RIGHT OF WAY ............... 1-1
DESCRIPTION .................................................. 2-1
Left view ......................................................... 2-1
Right view ....................................................... 2-2
Controls and instruments ............................... 2-3
INSTRUMENT AND CONTROL FUNCTIONS .. 3-1
Main switch ..................................................... 3-1
Indicator and warning lights ............................ 3-1
Speedometer unit .......................................... 3-2
Tachometer .................................................... 3-2
Coolant temperature gauge ............................ 3-3
Handlebar switches ........................................ 3-3
Clutch lever .................................................... 3-4
Shift pedal ...................................................... 3-4
Brake lever ..................................................... 3-5
Brake pedal .................................................... 3-5
Fuel tank cap .................................................. 3-5
Fuel (except for Switzerland and Austria) ...... 3-6
Fuel (for Switzerland and Austria) ................. 3-6
Catalytic converter
(for Switzerland and Austria) ....................... 3-7
2-stroke engine oil .......................................... 3-8
Fuel cock ........................................................ 3-9
Starter (choke) lever ..................................... 3-10Kickstarter .................................................... 3-10
Steering lock ................................................. 3-10
Seat .............................................................. 3-11
Helmet holder ............................................... 3-12
Adjusting the shock absorber assembly ....... 3-12
Carrier .......................................................... 3-14
YEIS handling precautions .......................... 3-14
YPVS ............................................................ 3-14
Sidestand ..................................................... 3-15
Ignition circuit cut-off system ........................ 3-16
PRE-OPERATION CHECKS ............................. 4-1
Pre-operation check list .................................. 4-1
OPERATION AND IMPORTANT
RIDING POINTS ............................................... 5-1
Starting a cold engine .................................... 5-1
Starting a warm engine .................................. 5-2
Shifting ........................................................... 5-2
Recommended shift points
(for Switzerland only) .................................. 5-3
Tips for reducing fuel consumption ................ 5-3
Engine break-in .............................................. 5-4
Parking ........................................................... 5-5
123
45
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PERIODIC MAINTENANCE AND
MINOR REPAIR ................................................ 6-1
Owner’s tool kit ............................................... 6-1
Periodic maintenance and lubrication chart ... 6-2
Removing and installing cowlings .................. 6-5
Removing and installing panels ...................... 6-7
Checking the spark plug ................................. 6-9
Transmission oil ........................................... 6-10
Coolant ......................................................... 6-12
Changing the coolant ................................... 6-14
Cleaning the air filter element........................ 6-16
Adjusting the carburetor ............................... 6-17
Adjusting the engine idling speed ................ 6-17
Adjusting the throttle cable free play ............ 6-18
Tires ............................................................. 6-19
Spoke wheels ............................................... 6-21
Adjusting the clutch lever free play ............... 6-22
Adjusting the brake lever free play ............... 6-23
Adjusting the brake pedal position ............... 6-23
Adjusting the rear brake light switch ............. 6-24
Checking the front and rear brake pads ....... 6-24
Checking the brake fluid level ...................... 6-25
Changing the brake fluid .............................. 6-26
Drive chain slack .......................................... 6-27
Lubricating the drive chain ........................... 6-28
Checking and lubricating the cables ............. 6-29Checking and lubricating the
throttle grip and cable ................................ 6-29
Adjusting the Autolube pump ....................... 6-30
Checking and lubricating the brake and
shift pedals ................................................ 6-30
Checking and lubricating the brake and
clutch levers .............................................. 6-30
Checking and lubricating the sidestand ....... 6-31
Checking the front fork ................................. 6-31
Checking the steering ................................... 6-32
Checking the wheel bearings ....................... 6-32
Battery .......................................................... 6-33
Replacing the fuse ....................................... 6-35
Replacing the headlight bulb ........................ 6-36
Replacing a turn signal light bulb ................. 6-37
Replacing the tail/brake light bulb ................ 6-38
Supporting the motorcycle ............................ 6-39
Front wheel ................................................... 6-39
Rear wheel ................................................... 6-42
Troubleshooting ............................................ 6-43
Troubleshooting charts ................................. 6-44
MOTORCYCLE CARE AND STORAGE ........... 7-1
Care ................................................................ 7-1
Storage ........................................................... 7-4
TABLE OF CONTENTS6
7
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2-1
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DESCRIPTION
2
1. Headlight (page 6-36)
2. Radiator cap (page 6-14)
3. Fuel cock (page 3-9)
4. Air filter element (page 6-16)
5. Coolant reservoir tank (page 6-12)6. Helmet holder (page 3-12)
7. Starter (choke) lever (page 3-10)
8. Shift pedal (page 3-4, 5-2)
9. YEIS (page 3-14)
10. YPVS (page 3-14)
1
23 4 5 6
7 8
9 10
Left view
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2-3
DESCRIPTION
2
1. Clutch lever (page 3-4, 6-22)
2. Left handlebar switches (page 3-3)
3. Speedometer unit (page 3-2)
4. Coolant temperature gauge (page 3-3)
5. Tachometer (page 3-2)6. Right handlebar switch (page 3-4)
7. Brake lever (page 3-5, 6-23)
8. Throttle grip (page 6-18, 6-29)
9. Fuel tank cap (page 3-5)
10. Main switch (page 3-1)
12 34 5
67
8 9
10
Controls and instruments
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3-3
INSTRUMENT AND CONTROL FUNCTIONS
3
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Coolant temperature gaugeWith the key in the “ON” position, the
coolant temperature gauge indicates
the temperature of the coolant. The
coolant temperature varies with
changes in the weather and engine
load. If the needle reaches or enters
the red zone, stop the motorcycle
and let the engine cool. (See page
6-45 for further instructions.)
EC000002
cCDo not operate the engine if it is
overheated.
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Turn signal switch “4/6”
To signal a right-hand turn, push this
switch to “6”. To signal a left-hand
turn, push this switch to “4”. When
released, the switch returns to the
center position. To cancel the turn
signal lights, push the switch in after
it has returned to the center position.
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Horn switch “*”
Press this switch to sound the horn.
1
2
1. Coolant temperature gauge
2. Red zone
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Handlebar switches
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Light switch “9/
'
/:”
Set this switch to “'
” to turn on
the auxiliary light, meter lighting and
taillight. Set the switch to “:” to turn
on the headlight also. Set the switch
to “9” to turn off all the lights.
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Dimmer switch “&/%”
Set this switch to “&” for the high
beam and to “%” for the low beam.
2
1
3
4
1. Light switch “9/
'
/:”
2. Dimmer switch “&/%”
3. Turn signal switch “4/6”
4. Horn switch “*”
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4-1
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PRE-OPERATION CHECKS
4The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpect-
edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak-
age or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thor-
ough visual inspection, to check the following points before each ride.
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Pre-operation check list
ITEM CHECKS PAGE
Fuel•Check fuel level in fuel tank.
•Refuel if necessary.
•Check fuel line for leakage.3-5–3-7
2-stroke engine oil•Check oil level in oil tank.
•If necessary, add recommended oil to specified level.
•Check vehicle for oil leakage.3-8
Transmission oil•Check oil level in transmission case.
•If necessary, add recommended oil to specified level.6-10–6-12
Coolant•Check coolant level in reservoir.
•If necessary, add recommended coolant to specified level.
•Check cooling system for leakage.6-12–6-15
Front brake•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
•Check lever free play.
•Adjust if necessary.
•Check fluid level in reservoir.
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.3-5, 6-23, 6-24–6-26
Rear brake•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
•Check fluid level in reservoir.
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.3-5, 6-23–6-26
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6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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NOTE:
8The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8Hydraulic brake service
9Regularly check and, if necessary, correct the brake fluid level.
9Every two years replace the internal components of the brake master cylinders and calipers, and change the
brake fluid.
9Replace the brake hoses every four years and if cracked or damaged.21
*Carburetor•Check starter (choke) operation.
•Adjust engine idling speed.√√√√√ √
22*Autolube pump•Check operation.
•Bleed if necessary.√√√√
23 Transmission oil•Check oil level.√√√√√ √
•Change.√√
24*Cooling system•Check coolant level and vehicle for coolant leakage.√√√√ √
•Change.Every 3 years
25*Front and rear brake
switches•Check operation.√√√√√ √
26 Moving parts and cables•Lubricate.√√√√ √
27*Lights, signals and
switches•Check operation.
•Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 6 12 18 24
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6-12
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EC000077
cC8In order to prevent clutch slip-
page (since the transmission
oil also lubricates the clutch),
do not mix any chemical addi-
tives with the oil.
8Make sure that no foreign
material enters the transmis-
sion.6. Start the engine, and then let it
idle for several minutes while
checking the transmission for oil
leakage. If oil is leaking, immedi-
ately turn off the engine and
check for the cause.
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CoolantTo check the coolant level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:
8The coolant level must be
checked on a cold engine since
the level varies with engine tem-
perature.
8Make sure that the motorcycle is
positioned straight up when
checking the coolant level. A
slight tilt to the side can result in
a false reading.
2. Remove panel A. (See page 6-8
for panel removal and installation
procedures.)
3. Check the coolant level in the
coolant reservoir.NOTE:
The coolant should be between the
minimum and maximum level marks.
2
1
1. Maximum level mark
2. Minimum level mark
Recommended transmission oil:
See page 8-1.
Oil quantity:
Periodic oil change:
0.75 L
Total amount (dry transmission):
0.8 L
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