2006 YAMAHA DT125R lock

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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EAU10460
Main switch/steering lock
The main switch/steering lock con-
trols the ignition and lighting systems,
and is used to lock the steering. The
various positions are described
below.
EAU10550
ON
All electrical circuits are supplied with
power, the meter lighting, taillight,
license plate light and auxiliary lights
come on, and the engine can be star-
ted. The key cannot be removed.
NOTE:
The headlights come on automatically
when the engine is started and stay
on until the key is turned to “OFF”,
even if the engine stalls.
EAU10660
OFF
All electrical systems are off. The key
can be removed.
EAU10680
LOCK
The steering is locked, and all electri-
cal systems are off. The key can be
removed.
T
o lock the steering
1. Turn the handlebars all the way to
the left.
2. Push the key in from the “OFF”
position, and then turn it to
“LOCK” while still pushing it.
3. Remove the key.
T
o unlock the steering
Push the key in, and then turn it to
“OFF” while still pushing it.
EWA10060
s s
WARNING
Never turn the key to “OFF” or
“LOCK” while the vehicle is
moving, otherwise the electrical
systems will be switched off, which
may result in loss of control or an
accident. Make sure that the vehi-
cle is stopped before turning the
key to “OFF” or “LOCK”.
ONOFF
PUSHLOCKIGNITION
3
INSTRUMENT AND CONTROL FUNCTIONS
3-1
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EAU12890
Brake lever
1. Brake lever
The brake lever is located at the right
handlebar grip. To apply the front bra-
ke, pull the lever toward the handle-
bar grip.
EAU12941
Brake pedal
1. Brake pedal
The brake pedal is on the right side of
the motorcycle. To apply the rear bra-
ke, press down on the brake pedal.
EAU13150
Fuel tank cap
To remove the fuel tank cap
1. Insert the key into the lock and
turn it 1/4 turn counterclockwise.
2. Turn the fuel tank cap 1/3 turn
counterclockwise and pull it off.
1. Fuel tank cap
2. Unlock
3. Open
To install the fuel tank cap
1. Insert the fuel tank cap into the
tank opening with the key inser-
ted in the lock, and then turn the
cap 1/3 turn clockwise.
2. Turn the key 1/4 turn clockwise,
and then remove it.
3
INSTRUMENT AND CONTROL FUNCTIONS
3-5
1
1
2
31
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NOTE:
The fuel tank cap cannot be installed
unless the key is in the lock. In addi-
tion, the key cannot be removed if the
cap is not properly installed and loc-
ked.
EWA10120
s s
WARNING
Make sure that the fuel tank cap is
properly closed and locked before
riding.
EAU13220
Fuel
Make sure that there is sufficient fuel
in the tank. When refueling, be sure to
insert the pump nozzle into the fuel
tank filler hole and to fill the tank to
the bottom of the filler tube as shown.
1. Filing pipe
2. Fuel level
EWA10880
s s
WARNING
Do not overfill the fuel tank,
otherwise it may overflow
when the fuel warms up and
expands.
Avoid spilling fuel on the hot
engine.
ECA10070
CAUTION
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted surfa-
ces or plastic parts.
EAU13320
Recommended fuel:
REGULAR UNLEADED GASOLINE
ONLY
Fuel tank capacity:
10,7 L (2,82 US gal) (2,35 Imp.gal)
Fuel reserve amount:
1,8 L (0,48 US gal) (0,40 Imp.gal)
ECA11400
CAUTION
Use only unleaded gasoline. The
use of leaded gasoline will cause
severe damage to internal engine
parts, such as the valves and piston
rings, as well as to the exhaust sys-
tem.
Your Yamaha engine has been desig-
ned to use regular unleaded gasoline
with a research octane number of 91
or higher. If knocking (or pinging)
occurs, use a gasoline of a different
brand or premium unleaded fuel. Use
of unleaded fuel will extend spark
plug life and reduce maintenance
costs.
EAU13430
Catalytic converter
This model is equipped with a cataly-
tic converter in the exhaust chamber.
EWA10860
s s
WARNING
The exhaust system is hot after
operation. Make sure that the
exhaust system has cooled down
before doing any maintenance
work.
3
INSTRUMENT AND CONTROL FUNCTIONS
3-6
1
2
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EAU21340
Adjusting the engine idling
speed
1. Idle adjusting bolt
The engine idling speed must be
checked and, if necessary, adjusted
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
The engine should be warm before
making this adjustment.
NOTE:
The engine is warm when it
quickly responds to the throttle.
A diagnostic tachometer is nee-
ded to make this adjustment.
1. Attach the tachometer to the
spark plug lead.2. Check the engine idling speed
and, if necessary, adjust it to spe-
cification by turning the throttle
stop screw. To increase the engi-
ne idling speed, turn the screw in
direction (a). To decrease the
engine idling speed, turn the
screw in direction (b).
Engine idling speed:
1250-1450 r/min
NOTE:
If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment.
EAU21370
Adjusting the throttle cable
free play
(a) Free play
The throttle cable free play should
measure 3-5 mm (0,11-0,19 in) at the
throttle grip. Periodically check the
throttle cable free play and, if neces-
sary, adjust it as follows.
NOTE:
The engine idling speed must be
correctly adjusted before checking
and adjusting the throttle cable free
play.
1. Lock nut
2. Adjusting nut
1. Loosen the locknut.
2. To increase the throttle cable free
play, turn the adjusting nut in
direction (a). To decrease the
throttle cable free play, turn the
adjusting nut in direction (b).
3. Tighten the locknut.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
1
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EWA10570
s s
WARNING
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding
stability and can lead to loss of
control.
The replacement of all wheel-
and brake-related parts, inclu-
ding the tires, should be left to
a Yamaha dealer, who has the
necessary professional know-
ledge and experience.
It is not recommended to patch
a punctured tube. If unavoida-
ble, however, patch the tube
very carefully and replace it as
soon as possible with a high-
quality product.
EAU21940
Spoke wheels
To maximize the performance, durabi-
lity, and safe operation of your
motorcycle, note the following points
regarding the specified wheels.
The wheel rims should be chec-
ked for cracks, bends or warpa-
ge, and the spokes for looseness
or damage before each ride. If
any damage is found, have a
Yamaha dealer replace the whe-
el. Do not attempt even the sma-
llest repair to the wheel. A defor-
med or cracked wheel must be
replaced.
The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced.
An unbalanced wheel can result
in poor performance, adverse
handling characteristics, and a
shortened tire life.
Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for
it to develop its optimal characte-
ristics.
EAU22041
Adjusting the clutch lever
free play
1. Lock nut
2. Adjusting bolt
3. Free play
The clutch lever free play should mea-
sure 10-15 mm (0,34-0,59 in) as
shown. Periodically check the clutch
lever free play and, if necessary,
adjust it as follows.
1. Loosen the locknut at the clutch
lever.
2. To increase the clutch lever free
play, turn the adjusting bolt in
direction (a). To decrease the
clutch lever free play, turn the
adjusting bolt in direction (b).6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
1
2 3
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NOTE:
If the specified clutch lever free play
could be obtained as described abo-
ve, tighten the locknut and skip the
rest of the procedure, otherwise pro-
ceed as follows.
3. Fully turn the adjusting bolt at the
clutch lever in direction (a) to loo-
sen the clutch cable.
1. Lock nut
2. Adjusting nut
4. Loosen the locknut at the crank-
case.
5. To increase the clutch lever free
play, turn the adjusting nut in
direction (a). To decrease the
clutch lever free play, turn the
adjusting nut in direction (b).6. Tighten the locknut at the clutch
lever and the crankcase.
EAU22092
Adjusting the brake lever
free play
1. Lock nut
2. Adjusting bolt
3. Free play
The brake lever free play should mea-
sure 2-5 mm (0,07 ~ 0,19 in) as
shown. Periodically check the brake
lever free play and, if necessary,
adjust it as follows.
1. Loosen the locknut at the brake
lever.2. To increase the brake lever free
play, turn the adjusting screw in
direction (a). To decrease the bra-
ke lever free play, turn the adjus-
ting screw in direction (b).
3. Tighten the locknut.
EWA10630
s s
WARNING
After adjusting the brake lever
free play, check the free play
and make sure that the brake is
working properly.
A soft or spongy feeling in the
brake lever can indicate the
presence of air in the hydraulic
system. If there is air in the
hydraulic system, have a
Yamaha dealer bleed the sys-
tem before operating the
motorcycle. Air in the hydraulic
system will diminish the bra-
king performance, which may
result in loss of control and an
accident.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
2
1
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EAU22192
Adjusting the brake pedal
position and free play
1. Footrest
(a) Brake pedal position
EWA10670
s s
WARNING
It is advisable to have a Yamaha
dealer make these adjustments.
Brake pedal position
The top of the brake pedal should be
positioned approximately 12-15 mm
(0,47-0,49 in) below the top of the
footrest. Periodically check the brake
pedal position and, if necessary,
adjust it as follows.
1. Loosen the locknut at the brake
pedal.2. To raise the brake pedal, turn the
adjusting bolt in direction (a). To
lower the brake pedal, turn the
adjusting bolt in direction (b).
3. Tighten the locknut.
EWA11230
s s
WARNING
After adjusting the brake pedal
position, the brake pedal free play
must be adjusted.
Brake pedal free play
The brake pedal free play should
measure 10-15 mm (0,34-0,59 in) as
shown. Periodically check the brake
pedal free play and, if necessary,
adjust it as follows.
To increase the brake pedal free play,
turn the adjusting nut at the brake rod
in direction (a). To decrease the brake
pedal free play, turn the adjusting nut
in direction (b).
EWA10680
s s
WARNING
After adjusting the drive chain
slack or removing and installing
the rear wheel, always check
the brake pedal free play.
If proper adjustment cannot be
obtained as described, have a
Yamaha dealer make this
adjustment.
After adjusting the brake pedal
free play, check the operation
of the brake light.
EAU22270
Adjusting the rear brake light
switch
1. Brake light swicht
2. Adjusting nut
The rear brake light switch, which is
activated by the brake pedal, is pro-
perly adjusted when the brake light
comes on just before braking takes
effect. If necessary, adjust the brake
light switch as follows.
6
PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
1
1
2
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