2006 YAMAHA DT125R coolant

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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EAU10420
Right view
DESCRIPTION
2-2
2
13
11
12 14
11. Tool kit (page 6-1)
12. Fuse (page 6-24)
13. Coolant tank (page 6-8)
14. Rear brake pedal (page 3-5)
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EAU10430
Controls and instruments
DESCRIPCION
2-3
2
0km/h406080
100
120
130 20y0
0
0
0
1
5000
8
16171819
2022
23
21
16. Clutch lever (page 3-4)
17. Left handlevar swicht (page 3-3)
18. Speedometer (Page 3-3)
19. Coolant temperature warning lamp (page 3-3)
20. Indicators (page 3-2)
21. Right handlevar swicht (page 3-3)
22. Front brake lever (page 3-5)
23. Throttle grip (page 6-12)
24. Fuel tank cap (page 3-5)
25. Main Switch (page 3-1)
2524
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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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EAU11640
Speedometer unit
1. Odometer
2. Tripmeter
3. Reset button
4. Coolant temperature warning lamp
The speedometer unit is equipped
with a speedometer, an odometer and
a tripmeter. The speedometer shows
riding speed. The odometer shows
the total distance traveled. The trip-
meter shows the distance traveled
since it was last set to zero with the
reset knob. The tripmeter can be used
to estimate the distance that can be
traveled with a full tank of fuel. This
information will enable you to plan
future fuel stops.
NOTE:
Only for the German model equipped
with a speed limiter:
The speed limiter prevents the vehicle
from exceeding a riding speed of 80
km/h.
EAU12343
Handlebar switches
1. Dimmer switch “j/k”
2. Horn switch “a”
3. Turn signal switch “c/d”
4. Hazard switch “ ”
EAU12400
Dimmer switch “j/k”
Set this switch to “j” for the high
beam and to “k” for the low beam.
EAU12460
Turn signal switch “c/d”
To signal a right-hand turn, push this
switch to “d”. To signal a left-hand
turn, push this switch to “c”. When
released, the switch returns to the
center position. To cancel the turn
signal lights, push the switch in after it
has returned to the center position.
EAU12500
Horn switch “a”
Press this switch to sound the horn.
EAU12660
Engine stop switch “f/e”
1. Stop switch “f/e”
2. Start switch “g”
Set this switch to “f” before starting
the engine. Set this switch to “e” to
0km
/h406080
100
120
130 20
y
00001
5
0008
bj
zN
3
INSTRUMENT AND CONTROL FUNCTIONS
3-3
1
23
4
1
2 41
3
2
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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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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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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
6-8
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