2005 YAMAHA DT125R check engine

ODOMETER READING (x 1000 Km) ANNUAL
CHECK
NoITEM CHECK OR MAINTENANCE JOB 1 6 12 18 24
9*Tires• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.√√√√ √
• Correct if necessary.
10 *Wheel bearings• Check bearing for looseness or damage.√√√√
11 *Swingarm• Check operation and for excessive play.√√√√• Lubricate with lithium-soap-based grease. Every 24000 km
• Check chain slack, alignment and condition.
12Drive chain• Adjust and lubricate chain with a special O-ring chain Every 500 km and after washing the
lubricant thoroughly.motorcycle or riding in the rain
13 *Steering bearings• Check bearing play and steering for roughness.√√ √ √√• Lubricate with lithium-soap-based grease. Every 50000 km
14 *Chassis fasteners• Make sure that all nuts, bolts and screws
√√√√ √
are properly tightened.
15Sidestand• Check operation.
• Lubricate.√√√√ √
16 *Sidestand switch• Check operation.√√ √ √√ √
17 *Front fork• Check operation and for oil leakage.√√√√
18 *Shock absorber assembly•Check operation and shock absorber for oil leakage.√√√√
Rear suspension relay • Check operation.√√√√
19 *arm and connecting arm
• Lubricate with lithium-soap-based grease.
√√
pivoting points
20 *Carburetor• Check starter (choke) operation.
• Adjust engine idling speed.√√ √ √√ √
21 *Autolube pump• Check operation.
• Bleed if necessary.√√√√
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EAU19292
Panels D and E
1. Screw
To remove one of the panels
Remove the screw, and then pull the
panel off as shown.
T
o install the panel
Place the panel in the original posi-
tion, and then install the screw.
EAU19620
Checking the spark plug
1. Spark plug inspection
The spark plug is an important engine
component, which should be chec-
ked periodically, preferably by a
Yamaha dealer. Since heat and depo-
sits will cause any spark plug to
slowly erode, it should be removed
and checked in accordance with the
periodic maintenance and lubrication
chart. In addition, the condition of the
spark plug can reveal the condition of
the engine.The porcelain insulator around the
center electrode of the spark plug
should be a medium-to-light tan (the
ideal color when the vehicle is ridden
normally). If the spark plug shows a
distinctly different color, the engine
could be defective. Do not attempt to
diagnose such problems yourself.
Instead, have a Yamaha dealer check
the vehicle.
If the spark plug shows signs of elec-
trode erosion and excessive carbon
or other deposits, it should be repla-
ced.
Specified spark plug:
BR8ES (NGK)
Before installing a spark plug, the
spark plug gap should be measured
with a wire thickness gauge and, if
necessary, adjusted to specification.
Spark plug gap:
0,7-0,8 mm (0,0276-0,0315 in)
Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
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Tightening torque:
Spark plug:
20 Nm (2 m•kgf)
NOTE:
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is
1/4–1/2 turn past finger tight. Howe-
ver, the spark plug should be tighte-
ned to the specified torque as soon
as possible.
EAU19950
Transmission oil
1. Oil level window
2. Maximum level mark
3. Minimum level mark
The transmission oil level should be
checked before each ride. In addition,
the transmission oil must be changed
at the intervals specified in the perio-
dic maintenance and lubrication
chart.
To check the transmission oil level
1. Place the vehicle on a level surfa-
ce and hold it in an upright posi-
tion.
NOTE:
Make sure that the vehicle is positio-
ned straight up when checking the oil
level. A slight tilt to the side can result
in a false reading.
1. Plug to fill with oil
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil
settles, and then check the oil
level through the check window
located at the right side of the
crankcase.
NOTE:
The transmission oil should be at or
above the minimum level mark.
4. If the oil is below the minimum
level mark, remove the oil filler
cap, add sufficient oil of the
recommended type to raise it to
the correct level, and then install
and tighten the cap.
To change the transmission oil
1. Drain bolt
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1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the trans-
mission to collect the used oil.
3. Remove the oil filler cap and
drain bolt to drain the oil from the
transmission.
4. Install the transmission oil drain
bolt, and then tighten it to the
specified torque.
Tightening torque:
Transmission oil drain bolt:
15 Nm (1,5 m•kgf)
5. Add the specified amount of the
recommended transmission oil,
and then install and tighten the oil
filler cap.
Recommended transmission oil:
See page 8-1.
Oil change quantity:
0,8 L (0,85 US qt)
ECA10450
CAUTION
In order to prevent clutch slip-
page (since the transmission
oil also lubricates the clutch),
do not mix any chemical additi-
ves with the oil.
Make 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, imme-
diately turn off the engine and
check for the cause.
EAU20070
Coolant
The coolant level should be checked
before each ride. In addition, the coo-
lant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU20170
To check the coolant level
1. Place the vehicle on a level surfa-
ce and hold it in an upright posi-
tion.
NOTE:
The coolant level must be chec-
ked on a cold engine since the
level varies with engine tempera-
ture.
Make sure that the vehicle is
positioned straight up when
checking the coolant level. A
slight tilt to the side can result in
a false reading.
2. Remove panel D. (See page 6-6.)
3. Check the coolant level in the
coolant reservoir.
FULL
LOW
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NOTE:
The coolant should be between the
minimum and maximum level marks.
4. If the coolant is at or below the
minimum level mark, open the
reservoir cap, add coolant to the
maximum level mark, and then
close the reservoir cap.
Coolant reservoir capacity:
0,3 L (0,32 US qt)
ECA10470
CAUTION
If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
If water has been used instead
of coolant, replace it with coo-
lant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the coo-
ling system will not be protec-
ted against frost and corrosion.
If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possi-
ble, otherwise the effective-
ness of the coolant will be
reduced.
EWA10380
s s
WARNING
Never attempt to remove the radia-
tor cap when the engine is hot.
5. Install the panel.
NOTE:
If the engine overheats, see page
6-31 for further instructions.
EAU20370
To change the coolant
1. Radiator cap bolt
2. Radiador cap
1. Put the vehicle on a level place.
2. Remove cowling C and panel D.
(See page 6-5 ~ 6-6.)
3. Remove the radiator cap stopper
bolt and the radiator cap.
1. Drain bolt
4. Place a container under the engi-
ne and remove the coolant drain
bolt.
5. Disconnect the coolant reservoir
hose on the reservoir side and
drain the coolant from the reser-
voir.
6. After draining the coolant, tho-
roughly flush the cooling system
with clean tap water.
7. Replace the coolant drain bolt
washer if it is damaged, and then
tighten the coolant drain bolt to
the specified torque.6
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Tightening torque:
Coolant drain bolt:
10 Nm (1,0 m•kgf)
8. Connect the coolant reservoir
hose.
9. Pour the recommended coolant
into the radiator until it is full.
Recommended antifreeze:
High quality ethylene glycol antifree-
ze containing corrosion inhibitors for
aluminum engines
Antifreeze/water mixing ratio:
1:1
Coolant quantity:
Radiator capacity (including all rou-
tes):
0,92 L (0,97 US qt)
Coolant reservoir capacity:
0,3 L (0,32 US qt)
ECA10470
CAUTION
If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
If water has been used instead
of coolant, replace it with coo-
lant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the coo-
ling system will not be protec-
ted against frost and corrosion.
If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possi-
ble, otherwise the effective-
ness of the coolant will be
reduced.
10. Install the radiator cap.
11. Run the engine several minutes.
Stop the engine and recheck the
coolant level in the radiator. If it is
low, add more coolant until it rea-
ches the top of the radiator.
12. Install the radiator cap stopper
bolt.
13. Fill the coolant reservoir with
coolant up to maximum level.
14. Install the coolant reservoir cap
and check for coolant leakage.
NOTE:
If any leakage is found, ask a Yamaha
dealer to inspect the cooling system.
15. Install the cowling and the panel.
EAU20831
Cleaning the air filter
element and check hose
The air filter element should be clea-
ned at the intervals specified in the
periodic maintenance and lubrication
chart. Clean the air filter element more
frequently if you are riding in unu-
sually wet or dusty areas. In addition,
the air filter check hose must be fre-
quently checked and cleaned if
necessary.
1. Screws (x3)
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To clean the air filter element
1. Remove panel E. (See page 6-6.)
2. Remove the air filter case cover
by removing the screws.
3. Pull the air filter element out.
1. Guide
2. Filter
4. Remove the sponge material
from the air filter element frame,
clean it with solvent, and then
squeeze the remaining solvent
out.5. Apply oil of the recommended
type to the entire surface of the
sponge material, and then sque-
eze the excess oil out.
NOTE:
The sponge material should be wet
but not dripping.
Recommended oil:
Foam air filter oil
6. Pull the sponge material over the
air filter element frame.
7. Insert the element into the air fil-
ter case.
ECA10480
CAUTION
Make sure that the air filter ele-
ment is properly seated in the
air filter case.
The engine should never be
operated without the air filter
element installed, otherwise
the piston(s) and/or cylinder(s)
may become excessively worn.
8. Install the air filter case cover by
installing the screws.
9. Install the panel.To clean the air filter check hose
1. Check the hose at the bottom of
the air filter case for accumulated
dirt or water.
2. If dirt or water is visible, remove
the hose, clean it, and then install
it.
EAU21280
Adjusting the carburetor
The carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, most
carburetor adjustments should be left
to a Yamaha dealer, who has the
necessary professional knowledge
and experience. The adjustment des-
cribed in the following section, howe-
ver, may be serviced by the owner as
part of routine maintenance.
ECA10550
CAUTION
The carburetor has been set and
extensively tested at the Yamaha
factory. Changing these settings
without sufficient technical know-
ledge may result in poor perfor-
mance of or damage to the engine.
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EAU21340
Adjusting the engine idling
speed
1. Idle adjusting bolt
The engine idling speed must be
checked and, if necessary, adjusted
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
The engine should be warm before
making this adjustment.
NOTE:
The engine is warm when it
quickly responds to the throttle.
A diagnostic tachometer is nee-
ded to make this adjustment.
1. Attach the tachometer to the
spark plug lead.2. Check the engine idling speed
and, if necessary, adjust it to spe-
cification by turning the throttle
stop screw. To increase the engi-
ne idling speed, turn the screw in
direction (a). To decrease the
engine idling speed, turn the
screw in direction (b).
Engine idling speed:
1250-1450 r/min
NOTE:
If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment.
EAU21370
Adjusting the throttle cable
free play
(a) Free play
The throttle cable free play should
measure 3-5 mm (0,11-0,19 in) at the
throttle grip. Periodically check the
throttle cable free play and, if neces-
sary, adjust it as follows.
NOTE:
The engine idling speed must be
correctly adjusted before checking
and adjusting the throttle cable free
play.
1. Lock nut
2. Adjusting nut
1. Loosen the locknut.
2. To increase the throttle cable free
play, turn the adjusting nut in
direction (a). To decrease the
throttle cable free play, turn the
adjusting nut in direction (b).
3. Tighten the locknut.
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