2005 YAMAHA DT125R brake pads

SAFETY INFORMATION.....................1-1
DESCRIPTION.....................................2-1
Left view ...........................................2-1
Right view .........................................2-2
Controls and instruments .................2-3
INSTRUMENTS AND CONTROL
FUNCTIONS........................................3-1
Main switch/steering lock .................3-1
Indicator and warning lights .............3-2
Speedometer unit .............................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
Catalytic converter............................3-6
2-stroke engine oil ............................3-7
Fuel cock ..........................................3-7
Starter (choke) lever..........................3-8
Seat...................................................3-8
Shock absorber ................................3-9
YEIS handling precautions ...............3-9
YPVS .................................................3-9
Sidestand ........................................3-10
Ignition circuit cut-off system .........3-10
PRE-OPERATION CHECKS...............4-1
Pre-operation check list....................4-2OPERATION AND IMPORTANT RIDING
POINTS................................................5-1
Starting a cold engine ......................5-1
Starting a warm engine ....................5-2
Shifting ..............................................5-2
Engine break-in.................................5-2
Parking ..............................................5-3
PERIODIC MAINTENANCE AND
MINOR REPAIR...................................6-1
Owner’s tool kit .................................6-1
Periodic maintenance and
lubrication chart ............................6-2
Removing and installing cowlings
and panels .....................................6-5
Checking the spark plug ..................6-6
Transmission oil ................................6-7
Coolant .............................................6-8
Cleaning the air filter element
and check hose ...........................6-10
Ajusting the carburetor ...................6-11
Adjusting the engine idling
speed...........................................6-12
Ajusting the throttle cable free
play ..............................................6-12
Tires ................................................6-13
Spoke wheels .................................6-15
Adjusting the clutch lever free
play ..............................................6-15
Adjusting the brake lever free
play ..............................................6-16Adjusting the brake pedal position
and free play................................6-17
Adjusting the rear brake light
switch ..........................................6-17
Checking the front and rear
brake pads ..................................6-18
Changing the brake fluid ................6-19
Checking the drive chain slack ......6-19
Adjusting the drive chain slack.......6-20
Lubricating the drive chain .............6-20
Checking and lubricating the
cables ..........................................6-21
Checking and lubricating the
throttle grip and cable .................6-21
Adjusting the autolube pump .........6-21
Checking and lubricating the
brake and shift pedals.................6-21
Checking and lubricating the
breake and clutch levers .............6-21
Checking and lubricating the
sidestand .....................................6-21
Checking the front fork ...................6-22
Checking the steering.....................6-22
Checking the wheel bearings .........6-23
Replacing the fuse ..........................6-24
Replacing the headlight bulb..........6-24
Replacing the tail/brake light
bulb .............................................6-25
Replacing the turn signal light
bulb .............................................6-26
Supporting the motorcycle .............6-26
TABLE OF CONTENTS
1D0-F8199-E2.qxd 20/9/04 11:32 Página 4

PRE-OPERATION CHECKS
4-2
4
EAU15603
Pre-operation check list
ITEM CHECKS PAGE
• Check fuel level in fuel tank.
Fuel• Refuel if necessary.3-6
• Check fuel line for leakage.
• Check oil level in oil tank.
2-stroke engine oil• If necessary, add recommended oil to specified level. 3-7
• Check vehicle for oil leakage.
Transmission oil• Check oil level in transmission case.
6-7
• If necessary, add recommended oil to specified level.
• Check coolant level in reservoir.
Coolant• If necessary, add recommended coolant to specified level. 6-8
• Check cooling system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
Front brake• Check brake pads for wear.
6-16/6-18
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
Rear brake• Check brake pads for wear.
6-16/6-18
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Check operation.
Clutch• Lubricate cable if necessary.
6-15
• Check lever free play.
• Adjust if necessary.
• Make sure that operation is smooth.
Throttle grip• Check cable free play.
6-12/6-21
• If necessary, have Yamaha dealer adjust cable free play and lubricate
cable andgrip housing.
1D0-F8199-E2.qxd 20/9/04 11:32 Página 25

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.√√√√
1D0-F8199-E2.qxd 20/9/04 11:32 Página 33

Turn the adjusting nut while holding
the rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction (a).
To make the brake light come on later,
turn the adjusting nut in direction (b).
EAU22340
Checking the front and rear
brake pads
1. Wear limit indicator
The front and rear brake pads must
be checked for wear at the intervals
specified in the periodic maintenance
and lubrication chart. To check the
brake pad wear, measure the lining
thickness. If the lining thickness is
less than 0,8 mm (0,03 in), have a
Yamaha dealer replace the brake
pads as a set.
EWA10250
s s
WARNING
If a malfunction is noted, have a
Yamaha dealer check the system
before riding.
1. Wear indicator
EAU22580
Checking the brake fluid level
1. Minimum level mark
Insufficient brake fluid may allow air
to enter the brake system, possibly
causing it to become ineffective.Before riding, check that the brake
fluid is above the minimum level mark
and replenish if necessary. A low bra-
ke fluid level may indicate worn brake
pads and/or brake system leakage. If
the brake fluid level is low, be sure to
check the brake pads for wear and
the brake system for leakage.
Observe these precautions:
When checking the fluid level,
make sure that the top of the
brake fluid reservoir is level.
1. Minimum level mark

Use only the recommended qua-
lity brake fluid, otherwise the rub-
ber seals may deteriorate, cau-
sing leakage and poor braking
performance.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
FRONTREAR
FRONTREAR
11
11
1D0-F8199-E2.qxd 20/9/04 11:32 Página 49

Recommended brake fluid:
DOT 4
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performan-
ce.
Be careful that water does not
enter the brake fluid reservoir
when refilling. Water will signifi-
cantly lower the boiling point of
the fluid and may result in vapor
lock.
Brake fluid may deteriorate pain-
ted surfaces or plastic parts.
Always clean up spilled fluid
immediately.
As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if
the brake fluid level goes down
suddenly, have a Yamaha dealer
check the cause.
EAU22730
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addi-
tion, have the oil seals of the master
cylinders and calipers as well as the
brake hoses replaced at the intervals
listed below or whenever they are
damaged or leaking.
Oil seals: Replace every two
years.
Brake hoses: Replace every four
years.
EAU22770
To check the drive chain slack
(a) Chain tension
1. Place the motorcycle on a level
surface and hold it in an upright
position.
NOTE:
When checking and adjusting the dri-
ve chain slack, the motorcycle should
be positioned straight up and there
should be no weight on it.
2. Shift the transmission into the
neutral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tigh-
test portion of the drive chain,
and then measure the drive chain
slack as shown.
Drive chain slack:
45-55 mm (1,76-2,15 in)
4. If the drive chain slack is inco-
rrect, adjust it as follows.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
1D0-F8199-E2.qxd 20/9/04 11:32 Página 50

EWA10820
s s
WARNING
It is advisable to have a Yama-
ha dealer service the wheel.
Securely support the motorcy-
cle so that there is no danger of
it falling over.
1. Disconnect the speedometer
cable from the front wheel.
2. Loosen the wheel axle holder
nuts, then the wheel axle.
3. Lift the front wheel off the ground
according to the procedure on
page 6-26.
4. Pull the wheel axle out, and then
remove the wheel.
ECA11070
CAUTION
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
EAU24950
To install the front wheel
1. Install the speedometer gear unit
into the wheel hub so that the
projections mesh with the slots.
2. Lift the wheel up between the
fork legs.
NOTE:
Make sure that there is enough space
between the brake pads before inser-
ting the brake disc and that the slot in
the speedometer gear unit fits over
the retainer on the fork leg.
3. Insert the wheel axle.
4. Lower the front wheel so that it is
on the ground.
5. Tighten the wheel axle to the
specified torque.
Tightening torque:
Wheel axle:
55 Nm (5,5 m•kgf)
6. Tighten the axle holder nuts to
the specified tightening torque. Tigh-
ten the upper nuts first and then lower
ones. When tightened in this sequen-
ce, there should be a gap formed at
the bottom of the axle holder.
Tightening torque:
Axle holder nut:
10 Nm (1,0 m•kgf)
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
1D0-F8199-E2.qxd 20/9/04 11:32 Página 58

ECA11070
CAUTION
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
EAU25530
To install the rear wheel
1. Install the drive chain onto the
rear sprocket, and then insert the
wheel axle from the left-hand
side.
NOTE:
Make sure that there is enough space
between the brake pads before inser-
ting the brake disc between the brake
pads.
2. Install the drive chain adjusting
plates.
NOTE:
Make sure that the drive chain adjus-
ting plates are installed with the pun-
ched side facing to the outside.
3. Install the swingarm end bolts.4. Adjust the drive chain slack. (See
page 6-19.)
5. Tighten the axle nut and the
swingarm end bolts to the speci-
fied torques, and then install the
cotter pin.
EWA10700
s s
WARNING
Always use a new cotter pin for the
axle nut.
Tightening torque:
Axle nut:
90 Nm (9,0 m•kgf)
Swingarm end bolt:
3 Nm (0,3 m•kgf)
EAU25850
Troubleshooting
Although Yamaha motorcycles recei-
ve a thorough inspection before ship-
ment from the factory, trouble may
occur during operation. Any problem
in the fuel, compression, or ignition
systems, for example, can cause poor
starting and loss of power.The following troubleshooting chart
represents a quick and easy procedu-
re for checking these vital systems
yourself. However, should your
motorcycle require any repair, take it
to a Yamaha dealer, whose skilled
technicians have the necessary tools,
experience, and know-how to service
the motorcycle properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
1D0-F8199-E2.qxd 20/9/04 11:32 Página 60

AAdjusting the autolube pump ..................6-21
Adjusting the brake lever free play ..........6-16
Adjusting the brake pedal position and
free play .................................................6-17
Adjusting the clutch lever free play .........6-15
Adjusting the drive chain slack ................6-20
Adjusting the engine idling speed ...........6-12
Adjusting the rear brake light switch .......6-17
Ajusting the carburetor ............................6-11
Ajusting the throttle cable free play .........6-12
BBrake lever .................................................3-5
Brake pedal ................................................3-5
CCare............................................................7-1
Catalytic converter .....................................3-6
Changing the brake fluid..........................6-19
Checking and lubricating the brake and
shift pedals ............................................6-21
Checking and lubricating the breake and
clutch levers...........................................6-21
Checking and lubricating the cables .......6-21
Checking and lubricating the sidestand ..6-21
Checking and lubricating the throttle grip
and cable ...............................................6-21
Checking the drive chain slack ................6-19
Checking the front and rear brake
pads .......................................................6-18
Checking the front fork ............................6-22
Checking the spark plug ............................6-6
Checking the steering ..............................6-22
Checking the wheel bearings ..................6-23Cleaning the air filter element and check
hose .......................................................6-10
Clutch lever ................................................3-4
Controls and instruments ..........................2-3
Coolant.......................................................6-8
D2-stroke engine oil .....................................3-7
EEngine break-in ..........................................5-2
FFront wheel ..............................................6-26
Fuel cock....................................................3-7
Fuel tank cap .............................................3-5
H
Handlebar switches ...................................3-3
IIdentification numbers ...............................9-1
Ignition circuit cut-off system ..................3-10
Indicator and warning lights ......................3-2
LLeft view .....................................................2-1
Lubricating the drive chain ......................6-20
MMain switch/steering lock ..........................3-1
OOwner’s tool kit ..........................................6-1
PParking .......................................................5-3
Periodic maintenance and lubrication
chart .........................................................6-2
Pre-operation check list .............................4-2
RRear wheel ...............................................6-28Removing and installing cowlings and
panels ......................................................6-5
Replacing the fuse ...................................6-24
Replacing the headlight bulb ...................6-24
Replacing the tail/brake light bulb ...........6-25
Replacing the turn signal light bulb .........6-26
Right view ..................................................2-2
SSeat ............................................................3-8
Shift pedal ..................................................3-4
Shifting .......................................................5-2
Shock absorber..........................................3-9
Sidestand .................................................3-10
Specifications.............................................8-1
Speedometer unit ......................................3-3
Spoke wheels...........................................6-15
Starter (choke) lever ...................................3-8
Starting a cold engine ................................5-1
Starting a warm engine ..............................5-2
Storage.......................................................7-3
Supporting the motorcycle ......................6-26
TTires .........................................................6-13
Transmission oil .........................................6-7
Troubleshooting .......................................6-29
YYEIS handling precautions.........................3-9
YPVS ..........................................................3-9
INDEX
1D0-F8199-E2.qxd 20/9/04 11:32 Página 72