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DTR 125
Yamaha DTR 125 Service Manual
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SERVICE MANUAL
DT125RE
1D01-AE1
DT125X
2005
2
Table of Contents
Table of Contents
6
Specifications
3
Periodic Checks and
4
Chassis
5
Engine
5
Table of Contents
6
Periodic Checks and Adjustments
5
Chapter 1 General Information
10
Motorcycle Identification
10
Frame Serial Number
10
Engine Serial Number
10
Important Information
11
Preparation for Removal
11
Gaskets, Oil Seals and O-Rings
11
Bearings and Oil Seals
12
Circlip
12
Checking the Connections
13
Cooling System
14
Special Tools
14
Gen Info
15
Spec
17
Spec Chapter 2 Specifications
19
Chapter 2 Specifications
20
General Specifications
20
Conversion Table
29
General Tightening Torque Specifications
29
Engine
30
Chassis
31
Coolant Flow Chart
32
Lubrication Points and Lubricant Type
33
Engine
33
Chassis
34
Cable Routing
35
Chk Adj
39
Chapter 3 Periodic Checks and Adjustments
41
Introduction/Periodic Maintenance/Lubrication
42
Engine
43
Y.p.V.s. Cable Adjustment
43
Idle Speed Adjustment
44
Throttle Cable Free Play Adjustment
44
Carburetor Cable Free Play Adjustment
46
Autolube Pump Stroke Adjustment
47
Autolube Pump Air Bleeding
48
Spark Plug Inspection
48
Ignition Timing Check
50
Engine Oil Level Inspection
51
Transmission Oil Level Inspection
52
Transmission Oil Replacement
52
Carburetor Joint Inspection
59
Fuel Line Inspection
59
Checking the Crankcase Breather Hose
59
Exhaust System Inspection
60
Engine Oil Line Inspection
60
Coolant Level Inspection
61
Cooling System Inspection
64
Chassis
65
Adjusting the Rear Brake Light Switch
68
Brake Hose Inspection
69
Drive Chain Slack Adjustment
70
Lubricating the Drive Chain
71
Steering Head Adjustment
71
Checking the Tires
77
Checking the Front and Rear Brake Pads
68
Electrical
80
Checking the Fuses
84
Headlight Beam Adjustment
85
Chas
86
Installing the Front Wheel
93
Installing the Rear Wheel
97
Rear Brake Caliper
115
Front Forks
125
Assembling the Front Fork Legs
132
Steering Head and Handlebars
133
Rear Shock Absorber and Swingarm
143
Installing the Swingarm
153
Eng
160
Chapter 5 Engine
162
Coolant
163
Engine Overhaul
163
Engine Removal
163
Side Covers
163
Transmission Oil
163
Autolube Pump Cable and Hose
164
Carburetor
164
Exhaust Pipe
164
Clutch Cable
165
Y.p.V.s. Cables
165
Leads
166
Radiator Hose
166
Engine Disassembly
168
Cylinder Head, Cylinder and Piston
168
Clutch, Primary Drive Gear and Balancer Gear
170
Clutch Push Lever
173
Shift Sahft and Stopper Lever
173
Reed Valve
174
Crankcase (Right)
175
Shifter, Transmission and Balancer Weight
176
Power Valve
177
Autolube Pump Assembly
178
Inspection and Repair
189
Crankshaft
190
Autolube Pump
193
Power Valve
195
Crankcase (Right)
201
Reed Valve
202
Magneto Rotor
203
Stopper Lever and Shift Shaft
206
Clutch Push Lever
206
Balancer Gear, Primary Drive Gear and Clutch
209
Piston Cylinder and Cylinder Head
215
Remounting Engine
218
Cool
223
Cool Chapter 6 Cooling System
225
Chapter 6 Cooling System
226
Water Pump
226
Removal
227
Thermostatic Valve and Radiator
232
Removal
233
Installation
236
Carb
239
Carb Chapter 7 Carburetor
241
Carburetor
242
Chapter 7
243
Removal
243
Disassembly
244
Inspection
245
Assembly
247
Installation
249
Adjustment
250
Reed Valve
251
Removal
252
Disassembly
252
Inspection
253
Assembly
253
Installation
254
Elec
255
Chapter 8 Electrical System
257
Dt125Re Circuit Diagram
258
Electrical Components
259
Checking Switch Continuity
261
Checking the Switches
262
Ignition System
263
Circuit Diagram
271
Charging System
271
Circuit Diagram
273
Lighting System
273
Circuit Diagram
283
Signaling System
283
Circuit Diagram
295
Cooling System
295
Circuit Diagram
299
Meter Assembly
303
Trbl Shtg
307
Trbl Shtg Chapter 9 Troubleshooting
309
Chapter 9 Troubleshooting
310
Starting Failure/Hard Starting
310
Fuel System
310
Electrical System
311
Poor Idle Speed Performance
312
Poor Medium and High Speed Performance
312
Fuel System
312
Electrical System
312
Compression System
313
Clutch Slipping/Dragging
314
Clutch Slipping
314
Clutch Dragging
315
Faulty Gear Shifting
314
Hard Shifting
314
Jump out Gear
314
Faulty Brake
315
Poor Braking Effect
315
Front Fork Oil Leakage and Front Fork Malfunction
315
Oil Leakage
315
Malfunction
315
Instable Handling
316
Faulty Signal and Lighting System
317
Headlight Dark
317
Bulb Burnt out
317
Flasher Does Not Light
317
Flasher Keeps on
317
Flasher Winks Slower
317
Flasher Winks Quicker
317
Horn Is Inoperative
317
Faulty Y.p.V.s
318
Overheating or Overcooling
318
Overheating
318
Overcooling
318
Dt125 Wiring Diagram
319
4
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Yamaha DTR 125 Specifications
General
Ignition
CDI
Front Brake
Single disc
Fuel System
Carburetor
Front Suspension
Telescopic fork
Rear Suspension
Swingarm
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