2006 YAMAHA DT125R transmission

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
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EAU11002
Indicator and warning lights
1. Turn signal indicator light “b”
2. Dimmer indicator light “j”
3. Neutral indicator light “N”
4. Oil level warning light “z”
EAU11030
Turn signal indicator lights “c” and
“d”
The corresponding indicator light flas-
hes when the turn signal switch is
pushed to the left or right.
EAU11070
Neutral indicator light “N”
This indicator light comes on when
the transmission is in the neutral posi-
tion.
EAU11080
High beam indicator light “j”
This indicator light comes on when
the high beam of the headlight is swit-
ched on.
EAU11180
Oil level warning light “z”
This warning light comes on when the
key is in the “ON” position or when
the oil level in the 2-stroke engine oil
tank is low during operation. If the
warning light comes on during opera-
tion, stop immediately and fill the oil
tank with Yamalube 2 or equivalent 2-
stroke engine oil of either JASO grade
“FC” or ISO grades “EG-C” or “EG-
D”. The warning light should go off
after the 2-stroke engine oil tank has
been refilled.
NOTE:
If the warning light does not come on
when the key is in the “ON” position
or does not go off after the 2-stroke
engine oil tank has been refilled, have
a Yamaha dealer check the electrical
circuit.
ECA10010
CAUTION
Do not operate the vehicle until you
know that the engine oil level is suf-
ficient.
EAU11430
Coolant temperature warning light
“y”
This warning light comes on when the
engine overheats. When this occurs,
stop the engine immediately and
allow the engine to cool.
ECA10020
CAUTION
Do not operate the engine if it is
overheated.
0km/h406080
100
120
130 20
y
00001
5
0008
bj
zN
3
INSTRUMENT AND CONTROL FUNCTIONS
3-2
1
234
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stop the engine in case of an emer-
gency, such as when the motorcycle
overturns or when the throttle cable is
stuck.
EAU12710
Start switch “g”
Push this switch to crank the engine
with the starter.
ECA10050
CAUTION
See page 5-1 for starting instruc-
tions prior to starting the engine.
EAU12763
Hazard switch “ ”
With the key in the “ON” position, turn
this switch to “ ” to turn on the
hazard lights (simultaneous flashing
of all turn signal lights).
The hazard lights are used in case of
an emergency or to warn other drivers
when your vehicle is stopped where it
might be a traffic hazard.
ECA10060
CAUTION
Do not use the hazard light for an
extended length of time, otherwi-
sethe battery may discharge.
EAU12820
Clutch lever
1. Clutch lever
The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the hand-
lebar grip. To engage the clutch, rele-
ase the lever. The lever should be
pulled rapidly and released slowly for
smooth clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the
ignition circuit cut-off system. (See
page 3-11.)
EAU12880
Shift pedal
N. Neutral
1. Shift pedal
The shift pedal is located on the left
side of the engine and is used in com-
bination with the clutch lever when
shifting the gears of the 6-speed
constant-mesh transmission equip-
ped on this motorcycle.
NOTE:
Use your toes or heel to shift up and
your toes to shift down.
3
INSTRUMENT AND CONTROL FUNCTIONS
3-4
1
1
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ECA10150
CAUTION
The YPVS has been set and exten-
sively tested at the Yamaha factory.
Changing these settings without
sufficient technical knowledge may
result in poor performance of or
damage to the engine.
YPVS operation noises can be heard
in the following instances:
When the key is turned to “ON”
and the engine is started.
When the engine stalls with the
key in the “ON” position.
ECA10160
CAUTION
If the YPVS does not operate, have
a Yamaha dealer check it.
EAU15300
Sidestand
The sidestand is located on the left
side of the frame. Raise the sidestand
or lower it with your foot while holding
the motorcycle upright.
NOTE:
The built-in sidestand switch is part of
the ignition circuit cut-off system,
which cuts the ignition in certain
situations. (See further down for an
explanation of the ignition circuit cut-
off system.)
EWA10240
s s
WARNING
The vehicle must not be ridden with
the sidestand down, or if the sides-
tand cannot be properly moved up
(or does not stay up), otherwise the
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control. Yama-
ha’s ignition circuit cut-off system
has been designed to assist the
operator in fulfilling the responsibi-
lity of raising the sidestand before
starting off. Therefore, check this
system regularly as described
below and have a Yamaha dealer
repair it if it does not function pro-
perly.
EAU15311
Ignition circuit cut-off
system
The ignition circuit cut-off system
(comprising the sidestand switch,
clutch switch and neutral switch) has
the following functions.
It prevents starting when the
transmission is in gear and the
sidestand is up, but the clutch
lever is not pulled.
It prevents starting when the
transmission is in gear and the
clutch lever is pulled, but the
sidestand is still down.
It cuts the running engine when
the transmission is in gear and
the sidestand is moved down.
Periodically check the operation of
the ignition circuit cut-off system
according to the following procedure.
EWA10250
s s
WARNING
If a malfunction is noted, have a
Yamaha dealer check the system
before riding.
3
INSTRUMENT AND CONTROL FUNCTIONS
3-10
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NOTE:
This check is most reliable if performed with a warmed-up engine.
INSTRUMENT AND CONTROL FUNCTIONS
3-11
3
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is turned on.
3. Turn the key on.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
The system is OK. The motorcycle can be ridden.
This check is most reliable if performed with
a warmed-up engine.
The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The sidestand switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The clutch switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
YES NO YES NO YES NO NOTE:
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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.
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EAU15950
EWA10270
s s
WARNING
Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer
regarding any control or func-
tion that you do not thoroughly
understand.
Never start the engine or ope-
rate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of cons-
ciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised comple-
tely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
EAU16060
Starting a cold engine
In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
The transmission is in the neutral
position.
The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EWA10290
s s
WARNING
Before starting the engine,
check the function of the igni-
tion circuit cut-off system
according to the procedure
described on page 3-11.
Never ride with the sidestand
down.
1. Turn the fuel cock lever to “ON”.
2. Turn the key to “ON” and make
sure that the engine stop switch
is set to “f”.
3. Shift the transmission into the
neutral position.
NOTE:
When the transmission is in the neu-
tral position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical
circuit.
4. Turn the starter (choke) on and
completely close the throttle.
(See page 3-8.)
5. Start the engine by pushing the
start switch.
NOTE:
If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the
engine more than 10 seconds on any
one attempt.
6. After starting the engine, move
the starter (choke) back halfway.
ECA11040
CAUTION
For maximum engine life, never
accelerate hard when the engine is
cold!
5
OPERATION AND IMPORTANT RIDING POINTS
5-1
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7. When the engine is warm, turn
the starter (choke) off.
NOTE:
The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off.
EAU16640
Starting a warm engine
Follow the same procedure as for
starting a cold engine with the excep-
tion that the starter (choke) is not
required when the engine is warm.
EAU16671
Shifting
Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing
hills, etc.
The gear positions are shown in the
illustration.
N. Neutral
1. Shift pedal
NOTE:
To shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.
ECA10260
CAUTION
Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long
distances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.
Always use the clutch while
changing gears to avoid dama-
ging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
EAU16830
Engine break-in
There is never a more important
period in the life of your engine than
the period between 0 and 1000 km
(600 mi). For this reason, you should
read the following material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1000 km (600 mi). The various parts in
the engine wear and polish themsel-
ves to the correct operating clearan-
ces. During this period, prolonged
full-throttle operation or any condition
that might result in engine overhea-
ting must be avoided.
EAU17150
0–150 km (0–90 mi)
Avoid prolonged operation above 1/3
throttle.
5
OPERATION AND IMPORTANT RIDING POINTS
5-2
1
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