2002 YAMAHA DT125R steering

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
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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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3-10
INSTRUMENT AND CONTROL FUNCTIONS
3
EAU03839
Starter (choke) lever“1”Starting a cold engine requires a rich-
er air-fuel mixture, which is supplied
by the starter (choke).
Move the lever in direction ato turn
on the starter (choke).
Move the lever in direction bto turn
off the starter (choke).
a
b
1
1. Starter (choke) lever “1”
EAU00212
KickstarterTo start the engine, fold out the kick-
starter lever, move it down lightly with
your foot until the gears engage, and
then push it down smoothly but force-
fully. This model is equipped with a
primary kickstarter, allowing the
engine to be started in any gear if the
clutch is disengaged. However, shift-
ing the transmission into the neutral
position before starting is recom-
mended.
1
1. Kickstarter
EAU02934
Steering lockTo lock the steering
1. Turn the handlebar all the way to
the right.
2. Open the steering lock cover,
and then insert the key.
3. Turn the key 1/8 turn counter-
clockwise, push it in while turning
the handlebar slightly to the left,
and then turn the key 1/8 turn
clockwise.
4. Check that the steering is locked,
remove the key, and then close
the lock cover.
2
1
1. Steering lock cover
2. Steering lock
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3-11
INSTRUMENT AND CONTROL FUNCTIONS
3 To unlock the steering
1. Open the steering lock cover,
and then insert the key.
2. Push the key in, turn it 1/8 turn
counterclockwise so that it
moves out, and then release it.
3. Remove the key, and then close
the lock cover.
EAU01648
SeatTo remove the seat
1. Remove panels A and B. (See
page 6-8 for panel removal and
installation procedures.)
2. Remove the bolts and pull the
seat off.
1
1. Bolt (
×2)
To install the seat
1. Insert the projections on the front
of the seat into the seat holders
as shown.
2. Place the seat in the original
position, and then tighten the
bolts.
3. Install the panels.NOTE:
Make sure that the seat is properly
secured before riding.
1
2
1. Projection (×2)
2. Holder (×2)
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6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
6
9
*Wheels•Check runout, spoke tightness and for damage.
•Tighten spokes if necessary.√√√√
10*Tires•Check tread depth and for damage.
•Replace if necessary.
•Check air pressure.
•Correct if necessary.√√√√ √
11*Wheel bearings•Check bearing for looseness or damage.√√√√
12*Swingarm•Check operation and for excessive play.√√√√
13 Drive chain•Check chain slack.
•Make sure that the rear wheel is properly aligned.
•Clean and lubricate.Every 500 km and after washing
the motorcycle or riding in the rain.
14*Steering bearings•Check bearing play and steering for roughness.√√√√√
•Lubricate with lithium-soap-based grease.Every 24,000 km
15*Chassis fasteners•Make sure that all nuts, bolts and screws are properly tightened.√√√√ √
16 Sidestand•Check operation.
•Lubricate.√√√√ √
17*Sidestand switch•Check operation.√√√√√ √
18*Front fork•Check operation and for oil leakage.√√√√
19*Shock absorber
assembly•Check operation and shock absorber for oil leakage.√√√√
20*Rear suspension relay
arm and connecting arm
pivoting points•Check operation.√√√√
•Lubricate with lithium-soap-based grease.√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 6 12 18 24
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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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9-1
EAU01039
CONSUMER INFORMATION
9
EAU02944
Identification numbersRecord the key identification number,
vehicle identification number and
model label information in the spaces
provided below for assistance when
ordering spare parts from a Yamaha
dealer or for reference in case the
vehicle is stolen.
1. KEY IDENTIFICATION
NUMBER:
2. VEHICLE IDENTIFICATION
NUMBER:
3. MODEL LABEL INFORMATION:
EAU01042
Key identification numberThe key identification number is
stamped into the key.
Record this number in the space pro-
vided and use it for reference when
ordering a new key.
1
1. Key identification number
EAU01043
Vehicle identification numberThe vehicle identification number is
stamped into the steering head pipe.
Record this number in the space pro-
vided.NOTE:
The vehicle identification number is
used to identify your motorcycle and
may be used to register your motor-
cycle with the licensing authority in
your area.
1
1. Vehicle identification number
1
6
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