Instruction/ maintenance manual of the product DT125R (2004) Yamaha
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1D0-F8199-E2 DT125R DT125X OWNER’S MANUAL 1D0-F8199-E2.qxd 20/9/04 11:32 Página 1.
1D0-F8199-E2.qxd 20/9/04 11:32 Página 2.
EAU10100 W elcome to the Y amaha world of motorcycling! As the owner of the DT125R/X, you are benefiting fr om Y amaha’ s vast experience and newest technology regar ding the design and manufacture of high-quality pr oducts, which have ear ned Y amaha a reputation for dependability .
EAU10150 Particularly important information is distinguished in this manual by the following notations: IMPOR T ANT MANUAL INFORMA TION CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. NOTE: A NOTE provides key information to make pr ocedures easier or clearer .
EAUS1171 IMPOR T ANT MANUAL INFORMA TION DT125R/X OWNER’S MANUAL ©2004 by Y AMAHA MOTOR SP AIN S.A. 1st edition, July 2004 All rights reserved Any reprinting or unauthorized use without the written permission of Y AMAHA MOTOR SP AIN S.A. is expressly pr ohibited.
SAFETY INFORMA TION .....................1-1 DESCRIPTION .....................................2-1 Left view ...........................................2-1 Right view .........................................2-2 Controls and instruments ...............
Front wheel .....................................6-26 Rear wheel ......................................6-28 T roubleshooting ..............................6-29 MOTORCYCLE CARE AND STORAGE ........................................7-1 Care ..............
EAU10310 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPER A TION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPE R TISE OF THE OPER A TOR. EVE R Y OPER A TOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCY- CLE.
• Always obey the speed limit and never travel faster than warranted by road and traf fic conditions. • Always signal before turning or changing lanes. Make sure that other motorists can see you. ● The posture of the operator and passenger is important for proper control.
Loading and accessories Adding accessories or car go to your motorcycle can adversely af fect sta- bility and handling if the weight distri- bution of the motorcycle is changed. T o avoid the possibility of an acci- dent, use extreme caution when adding car go or accessories to your motorcycle.
• Bulky or large accessories may seriously affect the stability of the motorcycle due to aer ody- namic effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross winds. These accessories may also cause instability when passing or being passed by lar ge vehicles.
EAU10410 Left view DESCRIPTION 2-1 2 1 7 2 8 5 63 4 9 1. Headlight (page 6-24) 2. Radiator cover (page 6-5) 3. Fuel cock (page 3-7) 4. Air filter (page 6-10) 5. Choke lever (page 3-8) 6. Shift pedal (page 3-4) 7. Y .E.I.S (page 3-9) 8. Y .P .V .S. (page 3-9) 9.
EAU10420 Right view DESCRIPTION 2-2 2 13 11 12 14 11. T ool kit (page 6-1) 12. Fuse (page 6-24) 13. Coolant tank (page 6-8) 14. Rear brake pedal (page 3-5) 1D0-F8199-E2.
EAU10430 Controls and instruments DESCRIPCION 2-3 2 0 k m / h 40 60 80 100 120 130 20 y 0 0 0 0 1 5 000 8 16 17 18 19 20 22 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.
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 .
EAU11002 Indicator and warning lights 1. T ur n signal indicator light “ b ” 2. Dimmer indicator light “ j ” 3. Neutral indicator light “ N ” 4.
EAU11640 Speedometer unit 1. Odometer 2. T ripmeter 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.
stop the engine in case of an emer- gency , such as when the motorcycle overturns or when the throttle cable is stuck. EAU12710 Start switch “ g ” Push this switch to crank the engine with the starter . ECA10050 CAUTION See page 5-1 for starting instruc- tions prior to starting the engine.
EAU12890 Brake lever 1. Brake lever The brake lever is located at the right handlebar grip. T o apply the fr ont 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.
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 befor e riding.
ECA10700 CAUTION The following precautions must be observed to prevent a fir e hazard or other damages. ● Use only unleaded gasoline. The use of leaded gasoline will cause unrepairable damage to the catalytic converter . ● Never park the vehicle near possible fire hazar ds such as grass or other materials that easily burn.
RES This indicates reserve. If you run out of fuel while riding, move the lever to this position. Fill the tank at the first opportunity . Be sure to set the lever back to “ON” after refueling! EAU13590 Starter (choke) lever “ q ” 1.
EAU15090 Shock absorber EWA10220 s s WARNING This shock absorber contains highly pressurized nitr ogen gas. For proper handling, r ead and understand the following informa- tion before handling the shock absorber . The manufacturer cannot be held responsible for pr operty damage or personal injury that may result fr om improper handling.
ECA10150 CAUTION The YPVS has been set and exten- sively tested at the Y amaha factory . Changing these settings without sufficient technical knowledge may result in poor performance of or damage to the engine. YPVS operation noises can be heard in the following instances: ● When the key is turned to “ON” and the engine is started.
NOTE: This check is most r eliable if performed with a warmed-up engine. INSTRUMENT AND CONTROL FUNCTIONS 3-11 3 With the engine tu r ned off: 1. M o v e the sidestand d o wn. 2. Ma k e sure that the engine stop s witch is tu r ned on. 3. T u r n the ke y on.
EAU15591 The condition of a vehicle is the owner’ s responsibility . Vital compo- nents can start to deteriorate quickly and unexpectedly , even if the vehicle remains unused (for example, as a result of exposur e to the elements). Any damage, fluid leakage or loss of tire air pr essure could have serious consequences.
PRE-OPERA TION CHECKS 4-2 4 EAU15603 Pre-operation check list ITEM CHECKS P AGE • 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.
Control cables • Make sure that operation is smooth. 6-21 • Lubricate if necessary . • Check chain slack. Drive chain • Adjust if necessary . 6-19/6-20 • Check chain condition. • Lubricate if necessary . • Check for damage. Wheels and tires • Check tire condition and tr ead depth.
EAU15950 EWA10270 s s WARNING ● Become thoroughly familiar with all operating controls and their functions before riding. Consult a Y amaha dealer regar ding any control or func- tion that you do not thoroughly understand. ● Never start the engine or ope- rate it in a closed area for any length of time.
7. When the engine is warm, turn the starter (choke) off. NOTE: The engine is warm when it responds normally to the throttle with the starter (choke) turned off. EAU16640 Starting a warm engine Follow the same procedur e as for starting a cold engine with the excep- tion that the starter (choke) is not requir ed when the engine is warm.
After every hour of operation, stop the engine, and then let it cool for five to ten minutes. V ary the engine speed from time to time. Do not operate the engine at one set throttle position. 150–500 km (90–300 mi) Avoid pr olonged operation above 1/2 throttle.
EAU17240 Safety is an obligation of the owner . Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condi- tion possible. The most important points of inspection, adjustment, and lubrication are explained on the follo- wing pages.
EAU17710 Periodic maintenance and lubrication chart NOTE: ● The annual checks must be performed every year , except if a kilometer -based maintenance is performed instead.
ODOMETER READING (x 1000 Km) ANNUAL CHECK No ITEM CHECK OR MAINTENANCE JOB 1 6 12 18 24 9* Tires • Check tread depth and for damage. • Replace if necessary . • Check air pressur e. √√√ √ √ • Correct if necessary . 10 * Wheel bearings • Check bearing for looseness or damage.
ODOMETER READING (x 1000 Km) ANNUAL CHECK No ITEM CHECK OR MAINTENANCE JOB 1 6 12 18 24 22 T ransmission oil • Check oil level. √√ √ √ √ √ • Change. √√ 23 * Cooling system • Check coolant level and vehicle for coolant leakage. √√√ √ √ • Change.
EAU18711 Removing and installing cowlings and panels 1. Cowling A 2. Cowling B 3. Panel D 1. Cowling C 2. Panel E The cowlings and panels shown need to be removed to perform some of the maintenance jobs described in this chapter . Refer to this section each time a cowling or panel needs to be removed and installed.
EAU19292 Panels D and E 1. Screw T o r emove one of the panels Remove the screw , and then pull the panel off as shown. T o install the panel Place the panel in the original posi- tion, and then install the screw .
Tightening torque: Spark plug: 20 Nm (2 m•kgf) NOTE: If a torque wr ench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. Howe- ver , the spark plug should be tighte- ned to the specified torque as soon as possible.
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.
NOTE: The coolant should be between the minimum and maximum level marks. 4. If the coolant is at or below the minimum level mark, open the reservoir cap, add coolant to the maximum level mark, and then close the reservoir cap.
Tightening torque: Coolant drain bolt: 10 Nm (1,0 m•kgf) 8. Connect the coolant reservoir hose. 9. Pour the recommended coolant into the radiator until it is full.
T o clean the air filter element 1. Remove panel E. (See page 6-6.) 2. Remove the air filter case cover by removing the scr ews. 3. Pull the air filter element out. 1. Guide 2. Filter 4. Remove the sponge material from the air filter element frame, clean it with solvent, and then squeeze the remaining solvent out.
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.
EAU21590 Tires T o maximize the performance, durabi- lity , and safe operation of your motorcycle, note the following points regar ding the specified tires. Tire air pr essure The tire air pr essure should be chec- ked and, if necessary , adjusted befo- re each ride.
Tire inspection 1.W ear limit 2. Side wall The tires must be checked befor e each ride. If the center tread depth reaches the specified limit, if the tir e has a nail or glass fragments in it, or if the sidewall is cracked, have a Y ama- ha dealer replace the tir e immediately .
EWA10570 s s WARNING ● Have a Y amaha 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.
NOTE: If the specified clutch lever free play could be obtained as described abo- ve, tighten the locknut and skip the rest of the pr ocedure, otherwise pro- ceed as follows. 3. Fully turn the adjusting bolt at the clutch lever in direction (a) to loo- sen the clutch cable.
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 Y amaha 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.
T urn the adjusting nut while holding the rear brake light switch in place. T o make the brake light come on earlier , turn the adjusting nut in direction (a). T o make the brake light come on later , turn the adjusting nut in direction (b). EAU22340 Checking the front and r ear brake pads 1.
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.
EAU22960 T o adjust the drive chain slack 1. Axle nut 2. Chain tensioner 1. Loosen the axle nut. 2. T o tighten the drive chain, turn the adjusting plate on each side of the swingarm in direction (a). T o loosen the drive chain, turn the adjusting plate on each side of the swingarm in direction (b), and then push the rear wheel for- ward.
EAU23100 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary . If a cable is damaged or does not move smoothly , have a Y amaha dealer check or repla- ce it.
Recommended lubricant: Lithium-soap-based grease (all-pur- pose grease) EAU23271 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the perio- dic maintenance and lubrication chart.
2. Hold the lower ends of the front fork legs and try to move them forward and backwar d. If any free play can be felt, have a Y amaha dealer check or repair the stee- ring. EAU23290 Checking the wheel bearings The front and r ear wheel bearings must be checked at the intervals spe- cified in the periodic maintenance and lubrication chart.
2. If the battery will be stored for more than two months, check it at least once a month and fully char ge it if necessary . 3. Fully char ge the battery before installation. 4. After installation, make sure that the battery leads are properly connected to the battery termi- nals.
This model is equipped with quartz bulb headlights. If a headlight bulb burns out, replace it as follows. 1. Remove cowling A. (See page 6-5.) 2. Disconnect the headlight coupler , and then remove the headlight bulb cover . 3. Remove the headlight bulb hol- der according to the following illustration, and then remove the defective bulb.
ECA10680 CAUTION Do not overtighten the screws, otherwise the lens may break. EAU24201 Replacing a turn signal light bulb 1. Screw 2. Lens 3. Bulb 1. Remove the turn signal light lens by removing the scr ew . 2. Remove the defective bulb by pushing it in and turning it coun- terclockwise.
EWA10820 s s WARNING ● It is advisable to have a Y ama- ha dealer service the wheel. ● Securely support the motor cy- cle so that there is no danger of it falling over . 1. Disconnect the speedometer cable from the fr ont wheel. 2. Loosen the wheel axle holder nuts, then the wheel axle.
1. Gap 7. After tightening the axle holder nuts, push down hard on the handlebars several times while applying the front brake to check if the front fork compr esses and rebounds smoothly . 8. Connect the speedometer cable. EAU25080 Rear wheel EAU25230 T o r emove the rear wheel 1.
ECA11070 CAUTION Do not apply the brake after the wheel has been removed together with the brake disc, otherwise the brake pads will be forced shut. EAU25530 T o install the r ear wheel 1. Install the drive chain onto the rear spr ocket, and then insert the wheel axle from the left-hand side.
EAU25921 T r oubleshooting charts Starting problems or poor engine performance EWA10840 s s WARNING Keep away open flames and do not smoke while checking or working on the fuel system. PERIODIC MAINTENANCE AND MINOR REP AIR 6-30 6 Check the fuel level in the fuel tank.
NOTE: If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the r ecommended coolant as soon as possible. PERIODIC MAINTENANCE AND MINOR REP AIR 6-31 6 Wait until the engine has cooled. Check the coolant level in the reservoir and radiator.
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.
ve any marks. If the windshield is scratched, use a quality plastic polishing compound after washing. After normal use Remove dirt with warm water , a mild deter gent, and a soft, clean sponge, and then rinse thoroughly with clean water . Use a toothbrush or bottle- brush for hard-to-r each areas.
ECA10800 CAUTION ● Apply spray oil and wax spa- ringly and make sure to wipe off any excess. ● Never apply oil or wax to any rubber and plastic parts, but treat them with a suitable car e product. ● Avoid using abrasive polishing compounds as they will wear away the paint.
EWA10950 s s WARNING T o pr event damage or injury from sparking, make sure to gr ound the spark plug electrodes while turning the engine over . 6. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/centerstand.
Dimensions Overall length DT125RE 2210 mm DT125X 2139 mm Overall width 795 mm Overall height DT125RE 1200 mm DT125X 1121 mm Seat height DT125RE 900 mm DT125X 886 mm Wheelbase DT125RE 1415 mm DT125X 1396 mm Ground clearance DT125RE 300 mm DT125X 271 mm Minimum turning radius DT125RE 2100 mm DT125X 2016 mm W eight With oil and fuel DT125RE 126.
5th 22/23 (0.957) 6th 18/22 (0.818) Chassis Frame type Semi double cradle Caster angle DT125RE 27.00 degree DT125X 24.50 degree T rail DT125RE 107.0 mm DT125X 73.
Charging system AC magneto Battery Model GT6B-3 V oltage, capacity 12 V , 6.0 Ah Headlight Bulb type Halogen bulb Bulb voltage, wattage x quantity Headlight 12 V , 600 W/55.0 W x 1 T ail/brake light 12 V , 21.0 W/5.0 W x 1 Front turn signal light 12 V , 10.
EAU26351 Identification numbers Record the key identification number , vehicle identification number and model label information in the spaces provided below for assistance when ordering spar e parts from a Y amaha dealer or for refer ence in case the vehicle is stolen.
EAU26440 Engine serial number 1. Engine serial number The engine serial number is stamped into the crankcase. EAU26480 Model label 1. Model label The model label is affixed to the frame under the seat. (See page 3-8.) Record the information on this label in the space provided.
A Adjusting the autolube pump ..................6-21 Adjusting the brake lever free play ..........6-16 Adjusting the brake pedal position and free play .................................................6-17 Adjusting the clutch lever free play .......
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Y AMAHA MOTOR ESP AÑA, S.A. PRINTED IN SP AIN 2004-07-Bengar Gràfiques, S.L. (E) 1D0-F8199-E2.qxd 20/9/04 11:32 Página 74.
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