2005 YAMAHA DT125R Owners Manual

EAU17710
Periodic maintenance and lubrication chart
NOTE:
The annual checks must be performed every year, except if a kilometer-based maintenance is performed
instead.
From 30000 km, repeat the maintenance intervals starting from 6000 km.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
ODOMETER READING (x 1000 Km) ANNUAL
CHECK
NoITEM CHECK OR MAINTENANCE JOB 1 6 12 18 24
1*Fuel line• Check fuel hoses for cracks or damage.√√√√ √
2Spark plug• Replace.√√√√ √
3Air filter element• Clean.√√• Replace.√√
4Clutch• Check operation.
• Adjust.√√ √ √√
5*Front brake• Check operation, fluid level and vehicle for fluid leakage.√√ √ √√ √• Replace brake pads. Whenever worn to the limit
6*Rear brake• Check operation, fluid level and vehicle for fluid leakage.√√ √ √√ √• Replace brake pads. Whenever worn to the limit
7*Brake hoses• Check for cracks or damage.√√√√ √• Replace. Every 4 years
8*Wheels• Check runout, spoke tightness and for damage.
• Tighten spokes if necessary.√√√√
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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.√√√√
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
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ODOMETER READING (x 1000 Km) ANNUAL
CHECK
NoITEM CHECK OR MAINTENANCE JOB 1 6 12 18 24
22Transmission oil• Check oil level.√√ √ √√ √• Change.√√
23 *Cooling system• Check coolant level and vehicle for coolant leakage.√√√√ √• Change. Every 3 years
24 *Front and rear
• Check operation.√√ √ √√ √
brake switches
25Moving parts and cables• Lubricate.√√√√ √
Throttle grip • Check operation and free play.
26 * •Adjust the throttle cable free play if necessary.√√√√ √
housing and cable
• Lubricate the throttle grip housing and cable.
27 *Muffler and exhaust pipe• Check the screw clamp for looseness.√√ √ √√
28 *Lights, signals • Check operation.
and switches• Adjust headlight beam.√√ √ √√ √
PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU18670
NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinders and calipers, and change the bra-
ke fluid.
• Replace the brake hoses every four years and if cracked or damaged.
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EAU18711
Removing and installing
cowlings and panels
1. Cowling A
2. Cowling B
3. Panel D
1. Cowling C
2. Panel E
The cowlings and panels shown need
to be removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each
time a cowling or panel needs to be
removed and installed.
EAU18890
Cowling A
1. Screws (x 3)
To remove the cowling
Remove the cowling screws, and then
pull the cowling off as shown.
T
o install the cowling
Place the cowling in the original posi-
tion, and then install the screws.
EAU18980
Cowlings B and C
T
o remove one of the cowlings
Remove the cowling screws, and then
pull the cowling off as shown.
1. Screws (x3)
To install the cowling
Place the cowling in the original posi-
tion, and then install the screws.
1. Screws (x3)
6
PERIODIC MAINTENANCE AND MINOR REPAIR
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321
121
1
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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.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
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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
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
2
3
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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
6
PERIODIC MAINTENANCE AND MINOR REPAIR
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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
PERIODIC MAINTENANCE AND MINOR REPAIR
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