2006 YAMAHA DT125R brake fluid

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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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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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
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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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
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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
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EAU26000
Care
While the open design of a motorcy-
cle reveals the attractiveness of the
technology, it also makes it more vul-
nerable. Rust and corrosion can
develop even if high-quality compo-
nents are used. A rusty exhaust pipe
may go unnoticed on a car, however,
it detracts from the overall appearan-
ce of a motorcycle. Frequent and pro-
per care does not only comply with
the terms of the warranty, but it will
also keep your motorcycle looking
good, extend its life and optimize its
performance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and
covers as well as all electrical
couplers and connectors, inclu-
ding the spark plug cap, are
tightly installed.3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such pro-
ducts onto seals, gaskets, sproc-
kets, the drive chain and wheel
axles. Always rinse the dirt and
degreaser off with water.
Cleaning
ECA10770
CAUTION
Avoid using strong acidic whe-
el cleaners, especially on spo-
ked wheels. If such products
are used on hard-to-remove
dirt, do not leave the cleaner on
the affected area any longer
than instructed. Also, tho-
roughly rinse the area off with
water, immediately dry it, and
then apply a corrosion protec-
tion spray.
Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or spon-
ge with mild detergent and
water to clean plastic.
Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust
removers or inhibitors, brake
fluid, antifreeze or electrolyte.
Do not use high-pressure was-
hers or steam-jet cleaners sin-
ce they cause water seepage
and deterioration in the follo-
wing areas: seals (of wheel and
swingarm bearings, fork and
brakes), electric components
(couplers, connectors, instru-
ments, switches and lights),
breather hoses and vents.
For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or scrat-
ching. Some cleaning com-
pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid-
den part of the windshield to
make sure that it does not lea-
7
MOTORCYCLE CARE AND STORAGE
7-1
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5th
22/23 (0.957)
6th
18/22 (0.818)
ChassisFrame type
Semi double cradle
Caster angle
DT125RE 27.00 degree
DT125X 24.50 degree
Trail
DT125RE 107.0 mm
DT125X 73.1 mm
Front tireType
With tube
Size
DT125RE 80/90-21 48P
DT125X 120/70-17 58H
Manufacturer/model
DT125RE MICHELIN/T63
DT125X PIRELLI/Sport Demon
Rear tireType
With tube
Size
DT125RE 110/80-18 58P
DT125X 140/70-17 66H
Manufacturer/model
DT125RE MICHELIN/T63
DT125X PIRELLI/Sport Demon
Maximum load
DT125RE 178 kg
DT125X 180 kg
Tire air pressure (measured on cold
tires)
Loading condition
0-90 kg
Front
DT125RE 150 kPa
DT125X 180 kPa
Rear
DT125RE 175 kPa
DT125X 200 kPa
Loading condition
90-178 kg
Front
DT125RE 175 kPa
DT125X 180 kPa
Rear
200 kPa
Off-road ridingFront
DT125RE 150 kPa
Rear
DT125RE 175 kPa
Front wheelWheel type
Spoke wheel
Rim size
DT125RE 21x1.60
DT125X 17x3.00
Rear wheelWheel type
Spoke wheel
Rim size
DT125RE 18x1.85
DT125X 17x3.50
Front brakeType
Single disc brake
Operation
Right hand operation
Recommended fluid
DOT 4
Rear brakeType
Single disc brake
Operation
Right foot operation
Recommended fluid
DOT 4
Front suspensionType
Telescopic fork
Spring/shock absorber type
Coil spring/oil damper
Wheel travel
DT125RE 270.0 mm
DT125X 200.0 mm
Rear suspensionType
Swingarm (link suspension)
Spring/shock absorber type
Coil spring/gas-oil damper
Wheel travel
DT125RE 260.0 mm
DT125X 230.0 mm
Electrical systemIgnition system
CDI
8
SPECIFICATIONS
8-2
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