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Yamaha DT125RE 2005 User Manual

Yamaha DT125RE 2005
320 pages
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SERVICE MANUAL
DT125RE
1D01-AE1
DT125X
2005

Table of Contents

Questions and Answers:

Yamaha DT125RE 2005 Specifications

General IconGeneral
Fuel SystemCarburetor
IgnitionCDI
Starting SystemKick
Transmission6-speed
Final DriveChain
Front SuspensionTelescopic fork
Front BrakesSingle disc
Rear BrakesSingle disc
Front Tire90/90-21
Displacement124 cc
Bore x Stroke56.0 mm x 50.0 mm
Rear SuspensionSwingarm
Fuel Capacity10 liters
Engine TypeSingle-cylinder, 2-stroke

Summary

Chapter 2: Specifications

Chapter 3: Periodic Checks and Adjustments

Periodic Checks and Adjustments Schedule

Detailed schedule of maintenance tasks based on odometer reading.

Checking the Brake Fluid Level

How to check and maintain brake fluid levels.

Adjusting the Drive Chain Slack

Procedure to adjust drive chain slack.

Checking and Adjusting the Steering Head

Inspection and adjustment of the steering head bearings.

Checking the Tires

Inspection of tire pressure, tread depth, and sidewalls.

Chapter 4: Chassis

Front and Rear Brake

Covers components and specifications for front and rear brakes.

Replacing the Front Brake Pads

Procedure to replace front brake pads.

Replacing the Rear Brake Pads

Procedure to replace rear brake pads.

Front Forks

Information on front fork components, oil capacity, and spring length.

Steering Head and Handlebars

Procedures for steering head and handlebar installation and tightening.

Steering Head Inspection

Inspection of bearings, races, dust seals, and handlebar crown.

Steering Head Installation

Steps to install steering head bearings and components.

Rear Shock Absorber and Swingarm

Information on rear shock absorber preload and swingarm components.

Chapter 5: Engine

Engine Disassembly: Cylinder Head, Cylinder and Piston

Steps to disassemble the cylinder head, cylinder, and piston.

Clutch, Primary Drive Gear and Balancer Gear Disassembly

Steps to disassemble clutch, primary drive gear, and balancer gear.

Shifter, Transmission and Balancer Weight Disassembly

Steps to disassemble shifter, transmission, and balancer weight.

Checking the Cylinder and Piston

Inspection of cylinder bore, piston, and clearance.

Checking the Transmission

Inspection of transmission gears, engagement, movement, and circlips.

Checking the Crankshaft and Connecting Rod

Measurement of crankshaft runout, side clearance, and width.

Checking the Crankshaft

Inspection of crankshaft sprocket, bearings.

Crankshaft, Piston, Balancer Assembly

Assembly of crankshaft, piston, and balancer components.

Transmission Assembly

Assembly of transmission components including gears and axles.

Clutch and Primary Drive Gear Assembly

Steps to assemble clutch and primary drive gear components.

Balancer Gear, Primary Drive Gear and Clutch Assembly

Steps to install balancer gear, primary drive gear, and related parts.

Cylinder Head and Cylinder Assembly

Steps to assemble cylinder head and cylinder.

Piston, Cylinder and Cylinder Head Assembly

Installation of piston, pin, and rings.

Remounting the Engine

Steps to reinstall the engine into the chassis.

Chapter 6: Cooling System

Chapter 7: Carburetor

Carburetor

Diagram and specifications of the carburetor.

Carburetor Inspection

Inspection of carburetor components like starter plunger, throttle stop screw, pilot air screw, jet needle.

Carburetor Assembly

Steps to assemble the carburetor.

Fuel Level Adjustment

Procedure to measure and adjust carburetor fuel level.

Chapter 8: Electrical System

Troubleshooting: Ignition System

Diagnostic steps for ignition system failures like no spark.

Troubleshooting: Charging System

Diagnostic steps for charging system failures like battery not charging.

Troubleshooting: Lighting System (Bulb Issues)

Diagnostic steps for lighting failures like bulb not working.

Troubleshooting: Lighting System (Wiring)

Checking lighting system wiring.

Troubleshooting: Meter Light Not Coming On

Diagnostic steps for meter light failure.

Troubleshooting: Meter Light (Wiring)

Checking meter light wiring.

Troubleshooting: Tail/Auxiliary Light Not Coming On

Diagnostic steps for tail/auxiliary light failure.

Troubleshooting: Tail/Auxiliary Light (Wiring)

Checking tail/auxiliary light system wiring.

Troubleshooting: Signaling System (Wiring)

Checking signaling system wiring.

Troubleshooting: Flasher Light Does Not Blink

Diagnostic steps for flasher light issues, including bulb and socket.

Troubleshooting: Flasher Light (Wiring)

Checking flasher light system wiring.

Troubleshooting: Brake Light Does Not Come On (Bulb)

Diagnostic steps for brake light failure - bulb.

Troubleshooting: Neutral Indicator Light Not Coming On (Bulb)

Diagnostic steps for neutral indicator light failure - bulb.

Troubleshooting: Neutral Indicator Light Not Coming On (Wiring)

Checking neutral indicator light system wiring.

Troubleshooting: Oil Indicator Light Not Coming On (Bulb)

Diagnostic steps for oil indicator light failure - bulb.

Troubleshooting: Oil Indicator Light Not Coming On (Wiring)

Checking oil indicator light system wiring.

Troubleshooting: Horn Does Not Sound

Diagnostic steps for horn failure - voltage.

Troubleshooting: Cooling System (Thermo Switch)

Diagnostic steps for the thermo switch.

Troubleshooting: Cooling System (Thermo Unit)

Checking thermo unit resistance.

Troubleshooting: Cooling System (Wiring)

Checking cooling system wiring.

Troubleshooting: Servomotor Does Not Move (Fuse)

Diagnostic steps for servomotor failure - fuse.

Troubleshooting: Servomotor Does Not Move (Wiring)

Checking servomotor system wiring.

Chapter 9: Troubleshooting

Starting Failure / Hard Starting

Troubleshooting steps for engine starting problems.

Troubleshooting: Starting Failure / Hard Starting - Fuel System

Diagnosing fuel system issues causing starting problems.

Troubleshooting: Starting Failure / Hard Starting - Electrical System

Diagnosing electrical system issues causing starting problems.

Troubleshooting: Starting Failure / Hard Starting - Compression System

Diagnosing compression issues causing starting problems.

Troubleshooting: Poor Idle Speed Performance

Diagnosing issues related to poor idle speed.

Troubleshooting: Poor Medium and High Speed Performance

Diagnosing issues affecting performance at medium and high speeds.

Troubleshooting: Faulty Gear Shifting

Diagnosing problems with gear shifting.

Troubleshooting: Jump Out Gear

Diagnosing issues where gears jump out.

Troubleshooting: Clutch Slipping/Dragging

Diagnosing clutch slipping or dragging problems.

Troubleshooting: Faulty Brake

Diagnosing issues with the braking system, like poor braking effect.

Troubleshooting: Front Fork Oil Leakage and Malfunction

Diagnosing front fork oil leaks and malfunctions.

Troubleshooting: Instable Handling

Diagnosing causes of unstable motorcycle handling.

Troubleshooting: Faulty Signal and Lighting System

Diagnosing issues with lights, flashers, and horn.

Troubleshooting: Faulty Y.P.V.S.

Diagnosing problems with the Y.P.V.S. system.

Troubleshooting: Overheating or Over-Cooling

Diagnosing engine overheating or over-cooling issues.

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