2005 Yamaha DT125 RE - Service ManualScribd Subir un documento Buscar Documentos Explorar DocumentosLibros - FiccinLibros - No ficcinSalud y medicinaFolletos/CatlogosDocumentos del

gobiernoGuas/Manuales de procedimientosRevistas/PeridicosRecetas/MensTrabajos escolares+ todas las categorasDestacadosNuevoPersonasAutoresEstudiantesInvestigadoresEditoresGobiern o y entidades sin fines de lucroComerciosMsicosArtistas y diseadoresProfesores+ todas las categorasLos ms buscadosPopularEnmanuel Serrano Ca... CuentaInicioMis documentosMis coleccionesMi estanteVer perfil pblicoMensajesNotificacionesConfiguracinAyudaCerrar sesin 1Primera pgina Pgina anterior Pgina siguiente / 320 Secciones no disponibles Alejar Acercar Pantalla completa Salir de pantalla completaSeleccionar modo de vista Modo de vistaSlideshowScroll Readcast Agregar un comentario Incluir y compartir La lectura debe ser social! Publique un mensaje en sus redes sociales para que los dems sepan lo que est leyendo. Seleccione los siguientes sitios y empiece a compartir.Vincular la cuentaReadcast este documentoReadcast completo!Haga clic en "enviar" para presentar una lectura!editar las preferenciasEstablezca sus preferencias para la prxima vez ...Elija 'auto' para readcast sin que se lo indiquen.Enmanuel Ser...Vincular la cuentaAdvancedCancelar Agregar un comentarioEnviarcompartir:Caracteres: 400 Compartir e incluirAgregar a Colecciones Descargar gratis este documentoOcultar automticamente: el This is a collapser for 728x90 SERVICE MANUALDT125RE1D01-AE1DT125X2005 DT125RE/X1D01-1D02/2C81SERVICE MANUAL 2005 Yamaha Motor Espaa, S.A.1st Edition, January 2005 All rights reserved. Any reprinting orunauthorized use without the writtenpermission of Yamaha Motor Espaa, S.A.is expressly prohibited.Printed in Spain.EAS00001 EAS00002NOTICEThis manual was produced by the Yamaha Motor Espaa S.A. primarily for use by Yamaha dealersand their qualified mechanics. It is not possible to include all the knowledge of a mechanic in onemanual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamahavehicles should have a basic understanding of mechanics and the techniques to repair these typesof vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely torender the vehicle unsafe and unfit for use.Yamaha Motor Espaa S.A is continually striving to improve all of its models. Modifications and sig-nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealersand will appear in future editions of this manual where applicable.NOTE:Designs and specifications are subject to change without notice.TECHNICAL PUBLICATIONSYAMAHA MOTOR ESPAA, S.A.EAS00004IMPORTANT MANUAL INFORMATIONParticularly important information is distinguished in this manual by the following.The Safety Alert Symbol means ATTENTION! BECOME ALERT!YOUR SAFETY IS INVOLVED!Failure to follow WARNING instructions could result in severe injuryor death to the motorcycle operator, a bystander or a person chec-king or repairing the motorcycle. A CAUTION indicates special precautions that must be taken toavoid damage to the motorcycle. A NOTE

provides key information to make procedures easier or cle-arer.t sWARNING CAUTIONNOTE : EAS00007HOW TO USE THIS MANUALThis manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensiveexplanations of all installation, removal, disassembly, assembly, repair and check procedures arelaid out with the individual steps in sequential order. The manual is divided into chapters. An abbreviation and symbol in the upper right cor-ner of each page indicate the current chapter.Refer to SYMBOLS. Each chapter is divided into sections. The current section title is shown at the top of eachpage, except in Chapter 3 (PERIODIC CHECKS AND ADJUSTMENTS), where the sub-section title(s) appears. Sub-section titles appear in smaller print than the section title. To help identify parts and clarify procedure steps, there are exploded diagrams at the startof each removal and disassembly section. Numbers are given in the order of the jobs in the exploded diagram. A circled number indi-cates a disassembly step. Symbols indicate parts to be lubricated or replaced.Refer to SYMBOLS. A job instruction chart accompanies the exploded diagram, providing the order of jobs,names of parts, notes in jobs, etc. Jobs requiring more information (such as special tools and technical data) are describedsequentially. EAS00008SYMBOLSThe following symbols are not relevant toevery vehicle.Symbols to indicate the subject of eachchapter. General information Specifications Periodic checks and adjustments Chassis Engine Cooling system Carburetor(s) Electrical system TroubleshootingSymbolsk10tok17indicate the following.k10Serviceable with engine mountedk11Filling fluidk12Lubricantk13Special toolk14Tightening torquek15Wear limit, clearancek16Engine speedk17Electrical dataSymbolsk18tok23in

the exploded diagramsindicate the types of lubricants and lubrica-tion points.k18Engine oilk19Gear oilk20Molybdenum-disulfide oilk21Wheel-bearing greasek22Lithium-soap- based greasek23Molybdenum-disulfide greaseSymbolsk24tok25in the exploded diagramsindicate the following.k24 Apply locking agent (LOCTITE)k25Replace the partCHK ADJENGCARBTRBLSHTGSPECCHASCOOLELECGENINFONew k11k13k16k18k21k24 k10k12k15k17k25k20k2 k14 SPEC2SPECIFICATIONSCHK ADJ3PERIODIC CHECKS AND ADJUSTMENTSCHAS4CHASSISENG5ENGINECOOL6COOLING SYSTEMCARB7CARBURETORELEC8ELECTRICAL SYSTEMEAS00010TABLE OF CONTENTSTRBLSHTG9TROUBLESHOOTINGGENERAL INFORMATIONGENINFO1 GENINFO 1 GENINFOCHAPTER 1GENERAL INFORMATIONMOTORCYCLE IDENTIFICATION1-1FRAME SERIAL NUMBER1-1ENGINE SERIAL NUMBER1-1IMPORTANT INFORMATION1-2PREPARATION FOR REMOVAL1-2 ALL REPLACEMENT PARTS1-2GASKETS, OIL SEALS AND O-RINGS1-2LOCK WASHERS/PLATES AND COTTER PINS1-2BEARINGS AND OIL SEALS1-3CIRCLIP1-3CHECKING THE CONNECTIONS1-4SPECIAL TOOLS1-5 SPEC 2 SPECCHAPTER 2SPECIFICATIONSGENERAL SPECIFICATIONS2-1ENGINE SPECIFICATIONS2-4CHASSIS SPECIFICATIONS2-6ELECTRICAL SPECIFICATIONS2-8CONVERSION TABLE2-10GENERAL TIGHTENING TORQUE SPECIFICATIONS2-10ENGINE2-11CHASSIS

2-11COOLANT FLOW CHART2-13LUBRICATION POINTS AND LUBRICANT TYPE2-14ENGINE2-14CHASSIS2ROUTING2-16 SPECGENERAL SPECIFICATIONS2-1SPECIFICATIONSGENERAL SPECIFICATIONSModelDT125REDT125XModel code1D01/1D022C81Dimensions:Overall lenght2210mm2139mmOverall width795mm1121mmOverall height1200mm1200mmSeatheight900mm886mmWheelbase1415mm1396mmMinimum ground clearance300mm271 mmMinimum turning radius2100mm2016mmBasic weight:With oil and full fuel tank126kg134 kgEngine:Engine type: 2 strokes, liquid cooledInduction systemReed valveCylinder arrangementForward-inclined single cylinderDisplacement124cm3BorexStroke56,0x50,7Compression ratio6,7:1Maximum power11kW /8000rpmMaximum torque13Nm/8000rpmIdle speed1250~1450r/minStarting systemElectric starterLubrication systemYamaha AutolubeOil type or grade:Engine oil2T motor oil (JASO grade FC)Total amount1,3LTransmission oilType SE motor oilPeriodic oil change0,75L (0,79 us. qt.)Total amount0,8L (0,85 us.qt.)Radiator capacity:Total amount (including all routes)0,92LCoolant reservoir capacity 0,30L Air filter:Wet type elementFuelTypeRegular unleaded gasolineFuel tank capacity:10,7LReserve1,8LCarburetor:Type/quantityTM28-92 / 1Manufacturer:MIKUNI

SPECGENERAL SPECIFICATIONS2-2Model code1D01/1D022C81Spark plug:TypeBR8ESManufacturerNGKSpark plug gap0,7~0,8mm (0,0276~0,03315in)Clutch typeWet, multiple discTransmission:Primary reduction systemHelical gearPrimary reduction ratio71/22(3,227)Secondary reduction systemchain driveSecondary reduction ratio57/16(3,563)Transmission typeConstant mesh, 6 speedOperationLeft foot operationGear ratio:1 34/12(2.833)2 30/16(1.875)3 24/17(1.412)4 24/21(1.143)5 22/23(0.957)6 18/22(0.818)C assis:Frame type:Semi double cradleSemi double cradleCastor angle27 24,5Trail107mm73,1 mmTire:TypeWith tubeWith tubeSizeFront80/90-21 48P120/70-17 58HRear110/80-18 58P140/70-17 66HManufacturerMichelin /T63Pirelli/ Sport DemonCold tire pressure:Front0~90kg150kPa (1.5kgf/cm2 )180kPa (1.8kgf/cm2 )Rear0~90kg175kPa (1.75kgf/cm2 )200kPa (2.0kgf/cm2 )Front90~178kg175kPa (1.75kgf/cm2 )180kPa (1.8kgf/cm2 )Rear90~178kg200kPa (2.0kgf/cm2 )200kPa (2.0kgf/cm2 )Off road riding:Front150kPa (1.5kgf/cm2 )Rear175kPa(1.75kgf/cm2 )Brakes:Front brake typeSingle disc brake Single disc brake230mm diameter298 mm diameterFront brake operationRight hand operationRight hand operationRear brake typeSingle disc brake Single disc brake220mm diameter220 mm diameterRear brake operationRight foot operationRight foot operationSuspensions:FrontTelescopic forkRearSwingarm (monocross suspension)Shock absorber:FrontCoil-air spring/Oil damperRearCoil and gas spring/Oil damper SPECGENERAL SPECIFICATIONS2-3Model code1D01/1D022C81Wheel travel:Front wheel travel270mm(10.63in)200mm (7,87in)Rear wheel travel260mm(10.24in)230mm (9.05in)Electrical:Ignition systemCDICharging systemAC MagnetoBattery typeGT6B-3Capacity12V 6AhHeadlight:bulb typeBulb wattage x quantity:Headlight12V60W/55W x 1Tail/Brake light12V21W/5W x 1Turn signal indicator lightFront12V10W x 1Rear12V10W x 1MeterLEDControl lights:OIL 12V3W X 1TURN 12V3W X 1NEUTRAL12V3W X 1HIGH BEAM12V3W X 1LOW BEAM12V3W X 1 Amperages:Principal fuse15A SPECGENERAL SPECIFICATIONS2-4ItemStandardLimitCylinder head:Warpage limit* Lines indicate 0,03mmstraightedgemeasurement.Cylinder:Bore size56.00~56.02mm***Taper limit0.05mm***Out of round limit0.01mm***Piston:Piston size D55.950~55.955***Measurement point*10mm***Piston to cylinderclearance 0.045~0.050mm0.10mmPiston Offset 0.5mm***Piston ring:TypeKeystone***Dimensions(BxT):**Top ring1.2x2.4mm***2nd ring1.20x1.89mm***End gap (installed):**Top ring0.30~0.45mm***2nd

ring0.30~0.45mm***Side clearance:**Top ring0.02~0.06mm***2nd ring0.035~0.070mm***Cooling system:Radiator capacity (including all routes)0.92L***Reservoir tank capacity 0.3L*Radiator cap opening pressure 75~105kPa ***(0.75~1.05kgf/cm2)Radiator core width 110mm***Radiator core height280mm***Radiator core thickness 32mm***Water pump typeSingle-suction centrifugalpumpENGINE CHAPTER 3PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION3-1ENGINE3-2Y.P.V.S. CABLE ADJUSTMENT3-2IDLE SPEED ADJUSTMENT3-3THROTTLE CABLE FREE PLAY ADJUSTMENT3-4CARBURETOR CABLE FREE PLAY ADJUSTMENT3-5 AUTOLUBE PUMP STROKE ADJUSTMENT3-6 AUTOLUBE PUMP AIR BLEEDING3-6SPARK PLUG INSPECTION3-7IGNITION TIMING CHECK3-8ENGINE OIL LEVEL INSPECTION3-9TRANSMISSION OIL LEVEL INSPECTION3-11TRANSMISSION OIL REPLACEMENT3-11CLUTCH ADJUSTMENT3-12 AIR FILTER CLEANING3-16CARBURETOR JOINT INSPECTION3-18FUEL LINE INSPECTION3-18CHECKING THE CRANKCASE BREATHER HOSE3-18EXHAUST SYSTEM INSPECTION3-19ENGINE OIL LINE INSPECTION3-19COOLANT LEVEL INSPECTION3-19COOLANT REPLACEMENT3-20COOLING SYSTEM INSPECTION3-23CHASSIS3-24FRONT BRAKE ADJUSTMENT3-24REAR BRAKE ADJUSTMENT3-24BRAKE FLUID INSPECTION3-25BRAKE PAD INSPECTION3-27BRAKE LIGHT SWITCH ADJUSTMENT3-27BRAKE HOSE INSPECTION3-28DRIVE CHAIN SLACK ADJUSTMENT3-28DRIVE CHAIN LUBRICATION3-30STEERING HEAD ADJUSTMENT3-30FRONT FORK INSPECTION3-32REAR SHOCK ABSORBER ADJUSTMENT3-33TIRE INSPECTION3-34WHEEL INSPECTION3-36CABLE INSPECTION AND LUBRICATION3-37ELECTRICAL3-39BATTERY INSPECTION3-39FUSE INSPECTION3-42HEADLIGHT BULB REPLACEMENT3-43HEADLIGHT BEAM ADJUSTMENT3-44CHK ADJ CHK ADJINTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION INTERVALS3-1PERIODIC CHECKS AND ADJUSTMENTSNOTE:The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.From 30000 km, repeat the maintenance intervals starting from 6000 km.Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and tech-nical skills.ODOMETER READING ANUAL( x 1.000 km)CHECKNoITEMCHECK OR MAINTENANCE JOB161218241*Fue lineCheck fuel hoses and vacuum hose for cracks or damage. 2Spark plug Check condition. Clean and regap. Replace. 3Air filter element Clean. Replace. 4Clutch Check operation. Adjust.5*Front brake Check operation and adjust brake lever free play. Replace brake shoes. Whenever worn to the limit6*Rear brake Check operation, fluid level and vehicle for fluid leakage. Replace brake pads. Whenever worn to the limit7*Brake hoses Check for cracks or damage. Replace. Every 4 years8*Wheels Check runout, spoke tightness andfor damage. Tighten spokes if necessary.9*Tires Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary.10*Wheel Check bearing for looseness or damage. bearings11*Swingarm Check operation and for excessive play. Lubricate with lithium-soap-based grease. Every 24,000 km12Drive chain Check chain slack. Make sure that the rear wheel is properly aligned.Every 500 km and after

washing Clean and lubricate.the motorcycle or riding in the rain13*Steering Check bearing play and steering for roughness. bearings Lubricate with lithium-soap-based grease. Every 24,000 km14*Chassis Make sure that all nuts, bolts and screws fastenersare properly tightened.15Sidestand Check operation. Lubricate.16*Sidestand Check operation. switch17*Front fork Check operation and for oil leakage. 18*Shock absorber Check operation and shock absorber assemblyfor oil leakage.19*Rear suspension Check operation. relay arm and Lubricate with lithium-soap-based grease. connecting armpivoting points20*Carburetor Check starter (choke) operation. Adjust engine idling speed.21Engine oil Change.When the oil change indicator light comes on(every 3,000 km) Check oil level and vehicle for oil leakage. Every 3,000 km22*Autolube pump Check operation. Bleed if necessary.23Transmission oil Check oil level. Change. 24*Cooling system Check coolant level and vehicle for coolantleakage. Change. Every 3 years25*Throttle grip Check operation and free play.housing and Adjust the throttle cable free play if necessary. cable Lubricate the throttle grip housing and cable. CHK ADJ Y.P.V.S. CABLE ADJUSTMENT3-22 1 ENGINE Y.P.V.S. CABLE ADJUSTMENT1.Removepulley cover (power valve) 2.Turn on the main switchNOTEIf the Y.P.V.S. Doesnt operate, refeer to theY.P.V.S. SYSTEM in CHAPTER 93.Checkalignment mark Not aligned Adjust the Y.P.V.S. Cables4.AdjustY.P.V.S. Cables Adjustments steps:Loosen both locknuts and turn in bothadjusters .Insert a pin [fl 0,16 in.)] through the aligningindent in the pulley and into the hole to lockthe pulley.Turn both adjusters, counterclockwise sothat the cable free play becomes zero mm(zero in.) with fingers.Turn both adjusters 1/4 turn clockwise.Tighten the locknuts.Turn on the main switch and check taht thealignment mark is aligned.If not, rpeat the above steps. 5.Installpulley cover (Power valve) 1Locknuts:8 Nm (0,8 mkg, 5,8 ftlb)1Locknuts:7 Nm (0,7 mkg, 5,1 ftlb)213 CHK ADJIDLE SPEED ADJUSTMENT3-3IDLE SPEED ADJUSTMENT1.Adjust:engine idle speedEAS00054 ADJUSTING THE ENGINE IDLING SPEEDNOTE:Prior to adjusting the engine idling speed, theair filter element should be clean, and the engi-ne should have adequate compression.1.Start the engine and let it warm up for seve-ral minutes.2.Connect:engine tachometer(onto the spark plug lead of cylinder #1)3.Check:engine idling speedOut of specification Adjust.4.Adjust:engine idling speed a.Turn the pilot screw in or out until it islightly seated.b.Turn the pilot screw out the specified num-ber of turns.c.Turn the throttle stop screw in directionka orkb until the specified engine idlingspeed is obtained. 5.Adjust:throttle cable free playRefer to ADJUSTING THE THROTTLECABLE FREE PLAY.Engine tachometer90890-03113Engine idling speed1250 ~ 1450 r/minDirectionka Engine idling speed isincreased.Directionkb Engine idling speed isdecreased.Throttle cable free play (at theflange of the throttle grip)3 ~ 5 mm (0,11 ~ 0,18 in)Pilot screw setting1/4 turns out21(a)(b) CHK ADJ ADJUSTING THE THROTTLE CABLE FREE PLAY3-4EAS00058 ADJUSTING THE THROTTLE CABLE FREEPLAYNOTE:Prior to adjusting the throttle cable free play,the engine idling speed and carburetor synch-ronization should be adjusted properly.1.Check:throttle cable free playkaOut of specification Adjust.2.Adjust:throttle cable free play Handlebar sidea.Loosen the locknut .b.Turn the adjusting nut in directionka orkb until the specified throttle cable free playis obtained.c.Tighten the locknut.sWARNING After adjusting the throttle cable free play,start the engine and turn the handlebar tothe right or left to ensure that this does notcause the engine idling speed to change. Throttle cable free play (at theflange of the throttle grip)3 ~ 5 mm (0,11 ~ 0,19 in)12Directionka Throttle cable free

playis increased.Directionkb Throttle cable free playis decreased. CHK ADJ ADJUSTING THE THROTTLE CABLE FREE PLAY/CARBURETOR CABLE FREE PLAY ADJUSTMEN3-5CARBURETOR CABLE FREE PLAY ADJUSTMENTNOTE:Before adjusting carburetor cable, throttlecable free play should be adjusted.1.Pull back the adjuster cover.2.Check:carburetor cable free playkaOut of specification adjust3.Adjust:Caburetor free play Adjustment steps:Loosen the locknut Turn the adjuster in or out until thecorrect free play obtained.Tighten the locknuts 4.Push in the adjuster cover.Carburetor Cable Free Play:1,0 mm (0,04 in)Turn inFree play is increased.Turn outFree play is decreased.23 CHK ADJ ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/CHECKING THE TIRES3-342. Tighten:Tighten the locknutEAS00164CHECKING THE TIRESThe following procedure applies to both of thetires.1. Check:tire pressureOut of specification Regulate.sWARNINGThe tire pressure should only be checkedand regulated when the tire temperatureequals the ambient air temperature.The tire pressure and the suspensionmust be adjusted according to the totalweight (including cargo, rider, passengerand accessories) and the anticipatedriding speed.Operation of an overloaded motorcyclecould cause tire damage, an accident oran injury.NEVER OVERLOAD THE MOTORCYCLE.Tire air pressure (measured on cold tires):DT125RUp to 90 kg (198 lb):Front:150 kPa (21,8 psi) (1,5 kgf/cm2 )Rear:175 kPa (25,4 psi) (1,75 kgf/cm2 )90 kg (198 lb) to maximum load:Front:175 kPa (25,4 psi) (1,75 kgf/cm2 )Rear:200 kPa (28,9 psi) (2 kgf/cm2 )Maximum load*:178 kg (392 lb)DT125XUp to 90 kg (198 lb):Front:180 kPa (26,1 psi) (1,8 kgf/cm2 )Rear:200 kPa (28,9 psi) (2 kgf/cm2 )90 kg (198 lb) to maximum load:Front:180 kPa (26,1 psi) (1,8 kgf/cm2 )Rear:200 kPa (28,9 psi) (2 kgf/cm2 )Maximum load*:180 kg (396 lb)*Total weight of rider, passenger, cargo andaccessories CHK ADJCHECKING THE TIRES3-35sWARNINGIt is dangerous to ride with a worn-out tire.When the tire tread reaches the wear limit,replace the tire immediately.2. Check:tire surfacesDamage/wear Replace the tire. Tire tread depth Sidewall sWARNINGDo not use a tubeless tire on a wheeldesigned only for tube tires to avoid tirefailure and personal injury from suddendeflation.When using tube tires, be sure to installthe correct tube.Always replace a new tube tire and a newtube as a set.To avoid pinching the tube, make surethe wheel rim band and tube are cente-red in the wheel groove.Patching a punctured tube is not recom-mended. If it is absolutely necessary todo so, use great care and replace thetube as soon as possible with a goodquality replacement. sWARNINGAfter extensive tests, the tires listed belowhave been approved by Yamaha MotorEspaa, S.A. for this model. The front andrear tires should always be by the samemanufacturer and of the same design. Noguarantee concerning handling characteris-tics can be given if a tire combination otherthan one approved by Yamaha is used onthis motorcycle.Minimum tire tread depth1.6 mm (0.04 in)12Tube wheelTube tire onlyTubeless wheelTube or tubeless tire CHK ADJCHECKING THE TIRES/CHECKING AND TIGHTENING THE SPOKES3-36sWARNINGNew tires have a relatively low grip onthe road surface until they have beenslightly worn. Therefore, approximately100 km should be traveled at normalspeed before any high-speed riding isdone.After a tire has been repaired or repla-ced, be sure to tighten the tire air valvestem nut and locknut to specifica-tion.EAS00169CHECKING AND TIGHTENING THESPOKESThe following procedure applies to all of thespokes.1.Check:spoke Bends/damage Replace.Loose Tighten.Tap the spokes with a screwdriver.NOTE: A tight spoke will emit a clear, ringing tone; aloose spoke will sound flat.Tire air valve stem (front wheelonly) Valve stem lock nut1.5 Nm (0.15 mkg, 1.1 ftlb)Front tireManufacturerModelSizeDT125REMICHELIN T6380/90-21 48PDT125XPIRELLI Sport Demon120/70-17 58HRear tireManufacturerModelSizeDT125REMICHELIN T63110/80-18 58PDT125XPIRELLI Sport Demon140/70-17 66H1

CHK ADJCHECKING AND TIGHTENING THE SPOKES/CHECKING AND LUBRICATING THE CABLES3-372.Tighten:spoke(with a spoke wrench)NOTE:Be sure to tighten the spokes before and afterbreak-in.EAS00170CHECKING AND LUBRICATING THECABLESThe following procedure applies to all of theinner and outer cables.sWARNINGDamaged outer cable may cause the cableto corrode and interfere with its movement.Replace damaged outer cable and innercables as soon as possible.1.Check:outer cableDamage Replace.2.Check:cable operationRough movement Lubricate.NOTE:Hold the cable end upright and pour a fewdrops of lubricant into the cable sheath or usea suitable lubricating device.2~3.5 Nm (0.2~0.35 mkg,1.42~2.49 ftlb)Recommended lubricantSAE 10W30 Motor Oil CHK ADJLUBRICATING THE LEVERS AND PEDALS/LUBRICATING THESIDESTAND/LUBRICANTING THE REAR SUSPENSION3-38EAS00171LUBRICATING THE LEVERS AND PEDALSLubricate the pivoting point and metal-to-metal moving parts of the levers and pedals.EAS00172LUBRICATING THE SIDESTANDLubricate the pivoting point and metal-to-metal moving parts of the sidestand.EAS00174LUBRICATING THE REAR SUSPENSIONLubricate the pivoting point and metal-to-metal moving parts of the rear suspension.Recommended lubricantSAE 10W30 Motor OilRecommended lubricantSAE 10W30 Motor OilRecommended lubricantMolybdenum disulfide grease CHK ADJELECTRICAL SYSTEM3-39EAS00178ELECTRICAL SYSTEMCHECKING AND CHARGING THEBATTERYsWARNINGBatteries generate explosive hydrogen gasand contain electrolyte which is made ofpoisonous and highly caustic sulfuric acid.Therefore, always follow these preventivemeasures:Wear protective eye gear when handlingor working near batteries.Charge batteries in a well-ventilatedarea.Keep batteries away from fire, sparks oropen flames (e.g., welding equipment,lighted cigarettes).DO NOT SMOKE when charging or hand-ling batteries.KEEP BATTERIES AND ELECTROLYTEOUT OF REACH OF CHILDREN.Avoid bodily contact with electrolyte as itcan cause severe burns or permanenteye injury.FIRST AID IN CASE OF BODILY CONTACT:EXTERNALSkin <> Wash with water.Eyes <> Flush with water for 15 minu-tes and get immediate medical attention.INTERNALDrink large quantities of water or milkfollowed with milk of magnesia, beatenegg or vegetable oil. Get immediatemedical attention. CAUTIONThis is a sealed battery. Never removethe sealing caps because the balancebetween cells will not be maintained andbattery performance will deteriorate.Charging time, charging amperage andcharging voltage for an MF battery aredifferent from those of conventional bat-teries. The MF battery should be chargedas explained in the charging methodillustrations. If the battery is overchar-ged, the electrolyte level will drop consi-derably. Therefore, take special carewhen charging the battery. CHASDISASSEMBLY/CHECKING THE FRONT FORK LEGS4-407.Remove:Inner fork tube a. Hold the front fork leg horizontally.b. Securely clamp the brake caliper bracket ina vise with soft jaws.c. Separate the inner tube from the outer tubeby pulling the inner tube forcefully but care-fully.CAUTIONExcessive force will damage the oil sealand bushing. A damaged oil seal or bus-hing must be replaced.Avoid bottoming the inner tube into theouter tube during the above procedure,as the oil flow stopper will be damaged. EAS00656CHECKING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1.Check:inner tube outer tube Bends/damage/scratches Replace.sWARNINGDo not attempt to straighten a bent innertube as this may dangerously weaken it.2.Measure:spring free lengthkaOut of specification Replace.Spring free lengthDT125RE 503mm (19.8 in)DT125X 501mm (19.7 in)12 CHASCHECKING THE FRONT FORK LEGS/ASSEMBLINGTHE FRONT FORK LEGS4-413.Check:damper rod piston ring Damage/wear Replace.Obstruction Blow out all of the oil pas-sages with compressed air.rebound spring Damage Replace.4.Check:cap bolt O-ringDamage/wear Replace.EAS00659 ASSEMBLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.sWARNINGMake sure the oil levels in both front forklegs are

equal.Uneven oil levels can result in poor hand-ling and a loss of stability.NOTE:When assembling the front fork leg, besure to replace the following parts:- inner tube bushing- outer tube bushing- oil seal- dust sealBefore assembling the front fork leg, makesure all of the components are clean.1.Install:damper rod assembly CAUTION Allow the damper rod assembly to slideslowly down the inner tube until it pro-trudes from the bottom of the inner tube. Becareful not to damage the inner tube.23112 CHAS ASSEMBLING THE FRONT FORK LEGS4-422.Lubricate:inner tubes outer surface3.Tighten:damper rod assembly boltNOTE:While holding the damper rod assembly withthe damper rod holder and T-handle, tightenthe damper rod assembly bolt.4.Install:outer tube bushing (with the fork seal driver weight and forkseal driver attachment)5.Install:washeroil seal (with the fork seal driver weight and forkseal driver attachment)CAUTIONMake sure the numbered side of the oil sealfaces up.Recommended lubricantFork oil 10W or equivalent62 Nm (6.2 mkg, 45 ftlb)LOCTITEDamper rod holder90890-01388T-handle90890-01326Fork seal driver weight90890-01367Fork seal driver attachment90890-01381 CHAS ASSEMBLING THE FRONT FORK LEGS4-43NOTE:Before installing the oil seal, lubricate itslips with lithium-soap-based grease.Lubricate the outer surface of the inner tubewith fork oil.Before installing the oil seal, cover the topof the front fork leg with a plastic bag 2 toprotect the oil seal during installation.6.Install:oil seal clipNOTE: Adjust the oil seal clip so that it fits into theouter tubes groove.7.Install:dust seal (with the fork seal driver weight)8.Fill:front fork leg(with the specified amount of the recom-mended fork oil)Fork seal driver weight90890-01367Quantity (each front fork leg)DT125RE 0.495 LDT125X 0.6 LRecommended oil Yamaha fork and shock oil 10Wor equivalentFront fork leg oil level (from thetop of the inner tube, with theinner tube fully compressed andwithout the fork spring)DT125RE 165.5 mm (6.52 in)DT125X 140mm (5.52 in) CHAS ASSEMBLING THE FRONT FORK LEGS4-44NOTE:While filling the front fork leg, keep itupright.After filling, slowly pump the front fork legup and down to distribute the fork oil.9.Install:spring spring seat spacer cap bolt NOTE:Install the spring with the smaller pitchfacing up.Before installing the cap bolt, lubricate itsO-ring with grease.Temporarily tighten the cap bolt.4321 CHASSTEERING HEAD AND HANDLEBARS4-45STERING HEAD AND HADLEBARS Handlebar Handlebar grip (Right) Handlebar grip (Left) Handlebar holder (Upper) Handlebar crown Ring nutk10Coverk11Bearing racek12Headlight stay ATIGHTENING STEPSTightening ring nut35Nm to 40Nm (3.5 to 4.0 mkg, 25.6 to 29.3 ftlb)Loosen it fullyRetighten it3Nm to 5Nm (0.3 to 0.5 mkg, 2.2 to 3.6 ftlb)120 to 155 Nm (12 to 15,5 m kg,88 to 110 ftlb)12 to 28 Nm (1,2 to 2,8 m kg,8,8 to 20,5 ftlb)120 to 155 Nm(12 to 15,5 m kg,88 to 110 ftlb) CHASREAR SHOCK ABSORBER AND SWINGARM4-55REAR SHOCK ABSORBER AND SWINGARM Rear shock absorber assembly Spring Bush ASPRING PRELOAD (INSTALLED):FOR DT125RESTANDARD LENGTH:230 mmMINIMUM LENGTH:220 mmMAXIMUM LENGTH:235 mm30 to 35 Nm (3,0 to 3,5 m kg,22 to 25,6 ftlb) ASPRING PRELOAD (INSTALLED):FOR DT125XSTANDARD LENGTH:244 mmMINIMUM LENGTH:234 mmMAXIMUM LENGTH:249 mm CHASREAR SHOCK ABSORBER AND SWINGARM4-56 Swingarm Relay arm Connecting arm Chain case Chain guard Chain guide Collar Bearing Oil sealk10Bushk11Plain washerk12Shimk13Thrust cover45 to 70 Nm (4,5 to 7 m kg,33 to 51,3 ftlb)45 to 70 Nm (4,5 to 7 m kg,33 to 51,3 ftlb)80 to 100 Nm (8 to 10 m kg,58,6 to 73,3 ftlb)3 to 5 Nm (0,3 to 0,5 m kg,2,2 to 3,6 ftlb)2 to 4 Nm (0,2 to 0,4 m kg,1,46 to 2,9 ftlb)3 to 5 Nm (0,3 to 0,5 m kg,2,2 to 3,6 ftlb) CHASHANDLING THE REAR SHOCK ABSORBER/DISPO-SING OF A REAR SHOCK ABSORBER/REMOVING4-57EAS00686HANDLING THE REAR SHOCK ABSORBERsWARNINGThis rear shock absorber contains highlycompressed nitrogen gas. Before handlingthe rear shock absorber, read and makesure you understand the following informa-tion. The manufacturer cannot be held res-ponsible for property damage or personalinjury that may result from improper hand-ling of the rear shock absorber.Do not

tamper or attempt to open therear shock absorber.Do not subject the rear shock absorberto an open flame or any other source ofhigh heat. High heat can cause an explo-sion due to excessive gas pressure.Do not deform or damage the rear shockabsorber in any way. Rear shock absor-ber damage will result in poor dampingperformance.EAS00688DISPOSING OF A REAR SHOCK ABSORBERGas pressure must be released before dispo-sing of a rear shock absorber. To release thegas pressure, drill a 2 ~ 3-mm hole through therear shock absorber at a point 15 ~ 20 mmfrom its end as shown. sWARNINGWear eye protection to prevent eye damagefrom released gas or metal chips.EAS00690REMOVING THE REAR SHOCK ABSORBER ASSEMBLY1.Stand the motorcycle on a level surface. sWARNINGSecurely support the motorcycle so thatthere is no danger of it falling over. CHASREMOVING THE REAR SHOCK ABSORBER ASSEMBLY4-58NOTE:Place the motorcycle on a suitable stand sothat the rear wheel is elevated.2.Remove:Bolt (Connecting arm swingarm) (from swingarm side)3.Remove:Bolt (Shock absorber Lower)sWARNINGWhen removing the lower bolt hold theswingarm so that it does not drop down-wards when the lower bolt is removed.4.Remove:Bolt (Shock absorber Upper) 5.Remove:Rear shock absorberNOTE:Pull up the swingarm, then remove the rearshock absorber, through between the swin-garm and relay arm1211 CHASREMOVING THE SWINGARM ASSEMBLY4-59REMOVING THE SWINGARM ASSEMBLYsWARNINGSecurely support the motorcycle so there isno danger of falling it over1.Elevate the rear wheel by placing a suitablestand under the engine.2.Remove:Rear shock absorberRefer to the REAR SHOCK ABSORBERsection.3.Remove:Rear wheelRefer to the REAR WHEEL REMOVALsection.4.Remove:Brake hose guides Mud guard5.Remove:Protector (Brake caliper) Brake caliper assembly 6.Remove:Chain case Chain guide Chain guard 312211 CHASREMOVING THE SWINGARM ASSEMBLY4-607.Check:Swingarm free play Inspection stepsCheck the tightening torque of the pivotshaft (swingarm) securing nut Check the swingarm side play by moving itfrom side to side.If side play noticeable, check the innercollar, bearing, bushing and thrust over, oradjust the shim.Check the swingarm vertical movementby moving it up and down.If vertical movement is tight, binding orrough, check the inner collar, bearing, bus-hing and thrust cover or adjust the shim. 8.Remove:Pivot shaft Swingarm9.Remove:Connecting arm Nut (Swingarm-Pivot shaft):80 to 100Nm (8 to 10 m kg; 58.6to 73.3lb ft)Side play (At the end of the swin-garm):1mm (0.04in)111 CHASREMOVING THE DRIVE CHAIN4-67REMOVING THE DRIVE CHAIN1.Stand the motorcycle on a level surface.sWARNINGSecurely support the motorcycle so thatthere is no danger of it falling over.NOTE:Place the motorcycle on a suitable stand sothat the rear wheel is elevated.2.Remove:Crankcase cover (left) 3.Straighten:Lock washer tab 4.Loosen:Nut (drive sprocket) NOTE:When loosening the drive sprocket nut, applythe rear brake pedal and transmission gear tothe 6th position.5.Remove:Clip (master link) Plate (master link) master link O-rings Drive chain6.Remove:Chain guide Drive sprocket7.Remove:Rear wheelRefer to the REAR WHEEL REMOVALsection.1 23442111 CHASREMOVING THE DRIVE CHAIN/CHECKING THE DRIVECHAIN4-688.Remove:Chain guide rollers (Upperand lower)EAS00709CHECKING THE DRIVE CHAIN1. Measure:ten-link sectionka of the drive chainOut of specification Replace the drivechain.2.Check:drive chainStiffness Clean and lubricate or repla-ce.3.Clean:drive chain a. Wipe the drive chain with a clean cloth.b. Put the drive chain in kerosene and removeany remaining dirt.c. Remove the drive chain from the keroseneand completely dry it.Ten-link drive chain section limit(maximum)120 mm (4.72 in)

CHASCHECKING THE DRIVE CHAIN4-69CAUTIONThis motorcycle has a drive chain withsmall rubber O-rings between the drivechain side plates. Never use high-pressurewater or air, steam, gasoline, certain sol-vents (e.g., benzine), or a coarse brush toclean the drive chain. High-pressure met-hods could force dirt or water into the drivechains internals, and solvents will deterio-rate the O-rings. A coarse brush can alsodamage the O-rings. Therefore, use onlykerosene to clean the drive chain. Dontsoak drive chain in kerosine more them tenminutes. O-ring is damage by kerosine. 4.Check:O-rings Damage Replace the drive chain.drive chain rollers Damage/wear Replace the drive chain.drive chain side plates Damage/wear Replace the drive chain.Cracks Replace the drive chain andmake sure the battery breather hose isproperly routed away from the drive chainand below the swingarm.5. Lubricate:drive chain6.Check:drive sprocketrear wheel sprocketMore than 1/4 toothka wear Replacethe drive chain sprockets as a set.Bent teeth Replace the drive chainsprockets as a set.kb Correct Drive chain roller Drive chain sprocketRecommended lubricantEngine oil or chain lubricant sui-table for O-ring chains CHASINSTALLING THE DRIVE CHAIN4-70EAS00713INSTALLING THE DRIVE CHAIN1.Lubricate:drive chainmaster link <NEW>2.Install:drive chaindrive sprocket washer drive sprocket nut NOTE:While applying the rear brake, tighten the drivesprocket nut.3.Install:master link O-ring master link plate (with a drive chain cutter)CAUTIONNever install a new drive chain onto worndrive chain sprockets; this will dramaticallyshorten the drive chains life.4.Adjust:drive chain slackRefer to ADJUSTING THE DRIVE CHAINSLACK in chapter 3.Recommended lubricantEngine oil or chain lubricant sui-table for O-ring chains60 Nm (6.0 mkg, 43 ftlb)Drive chain slack DT125RE45 ~ 55 mm (1.77 ~ 2.16 in)Drive chain slack DT125X25 ~ 40 mm (0.984 ~ 1.575 in)423123 CHASINSTALLING THE DRIVE CHAIN4-71CAUTION A drive chain that is too tight will overloadthe engine and other vital parts, and onethat is too loose can skip and damage theswingarm or cause an accident. Therefore,keep the drive chain slack within the speci-fied limits. ENG 5 CHAPTER 5ENGINEENGINE REMOVAL5-1SIDE COVERS5-1COOLANT5-1TRANSMISSION OIL5-1EXHAUST PIPE5-2CARBURETOR5-2 AUTOLUBE PUMP CABLE AND HOSE5-2CLUTCH CABLE5-3Y.P.V.S. CABLES5-3RADIATOR HOSE5-4LEADS5-4DRIVE CHAIN5-5ENGINE DISASSEMBLY5-6CYLINDER HEAD, CYLINDER AND PISTON5-8CLUTCH, PRIMARY DRIVE GEAR AND BALANCER GEAR5-8CLUTCH PUSH LEVER5-11SHIFT SAHFT AND STOPPER LEVER5-11MAGNETO ROTOR5-12REED VALVE5-12CRANKCASE (RIGHT)5-13SHIFTER, TRANSMISSION AND BALANCER WEIGHT5-14CRANKSHFT5-15POWER VALVE5-15 AUTOLUBE PUMP ASSEMBLY5-16INSPECTION AND REPAIR5-17CYLINDER HEAD5-17CYLINDER AND PISTON5-18PISTON RINGS5-19PISTON PIN AND BEARING5-21CLUTCH5-21PRIMARY DRIVE5-24TRANSMISSION AND SHIFTER5-25SHIFT SHAFT AND STOPPER LEVER5-27CRANKSHAFT5-27 AUTOLUBE PUMP5-28POWER

VALVE5-29CRANKCASE5-30ENGINE ASSEMBLY AND ADJUSTMENTS5-31 AUTOLUBE PUMP5-31POWER VALVE5-33CRANKSHAFT AND BALANCER5-35TRANSMISSION AND SHIFTER5-36CRANKCASE (RIGHT)5-39REED VALVE5-40MAGNETO ROTOR5-41STOPPER LEVER AND SHIFT SHAFT5-43CLUTCH PUSH LEVER5-46BALANCER GEAR, PRIMARY DRIVE GEAR AND CLUTCH5-47PISTON CYLINDER AND CYLINDER HEAD5-52REMOUNTING ENGINE5-56ENG ENGENGINE REMOVAL5-1ENGINE OVERHAULENGINE REMOVALNOTE:Its not necessary to remove the engine inorder to remove the following components:Cylinder headCylinderPiston and piston ringPower valveClutchPrimary drive gearKick axleShift shaftMagneto rotorStatorAutolube pumpSIDE COVERS1.Remove:Side cover (right)Side cover (left)SeatCOOLANT1.Drain:CoolantRefer to the COOLANT REPLACEMENTsection in chapter 3.TRANSMISSION OIL1.Drain:Transmission oilRefer to the TRANSMISSION OIL REPLA-CEMENT section in chapter 3. ENGENGINE REMOVAL5-2EXHAUST PIPE1.Loosen:Bolts (Exhaust holder)Screw (muffler joint) 2.Remove:A.I.S. hose Bolts (Exhaust pipe) Exhaust pipe CARBURETOR1.Remove:Fuel tankCarburetorRefer to the CARBURETOR REMOVALsection in chapter 6. AUTOLUBE PUMP CABLE AND HOSE1.Remove:Autolube pump cover 2.Disconnect:hose (from autolube pump and hose guide)Gasket (autolube pump cover NOTE:Plug the oil hose so that oil will not run out ofthe oil tank.3.Remove:Pump cable NOTE:Turn the pump pulley clockwise by finger tomake the pump cable loose enough for its endto be removed from the pulley.11211213 ENGENGINE REMOVAL5-32 1 CLUTCH CABLE1.Loosen:Adjuster (Clutch cable) 2.Loosen:Adjuster lock nuts (Clutch cable) 3.Disconnect:Clutch cable (from clutch push lever and cable guide ). Y.P.V.S. CABLES1.Remove:Pulley cover (Power valve) 2.Remove:Pulley (Power valve) Removal stepsLoosen both locknuts and turn in bothadjusters .Insert a pin (4mm.(0.16in)) through thealigning indent in the pulley and into thehole to lock the pulley.Remove the pulley from the power valveand then disconnect the Y.P.V.S. cables from the pulley.Remove the pin 125514234213 ENGENGINE REMOVAL5-43.Disconnect:Servomotor unit leads4.Remove:Servomotor unit Adjuster (Y.P.V.S. cable) Pulley housingRADIATOR HOSES1.Disconnect:Radiator hose (Inlet) 2.Disconnect:Radiator hose (Outlet) LEADS1.Disconnect:Battery lead (Negative) 2.Disconnect:Spark plug lead Thermo unit lead 1321121 ENGENGINE REMOVAL5-53.Disconnect:CDI magneto leads 4.Remove:BandsDRIVE CHAIN1.Remove:Change pedal Crankcase cover (Left) Gasket (Crankcase cover)2.Straighten:Lock washer tab 3.Loosen:Nut (Drive sprocket) NOTE:When loosening the nut (Drive sprocket) applythe rear brake pedal and transmission gear tothe 6th position4.Remove:Drive chainNut (Drive sprocket) Lock washer Drive sprocket Spacer collar ENGINE REMOVAL1.Remove:Bolts (Engine stay Upper) Bolts (Engine mount Front) 211211542312 ENGENGINE REMOVAL/ENGINE DISASSEMBLY5-62.Remove:Bolt (Engine mount Rear lower) Pivot shaft NOTE:The engine and swingarm are installed usingthe same pivot shaft. Therefore, take care sothat the pivot shaft is pulled, not entirely, out,but for enough to set the engine free.3.Remove:Engine assembly(from right side)ENGINE DISASSEMBLYCYLINDER HEAD, CYLINDER AND PISTONNOTE:With the engine mounted, the cylinder head,cylinder and piston can be maintained byremoving the following parts.Side covers (Right and left)SeatRadiator coverOil tank coverFuel tankRadiator hose (inlet)Servomotor unit (Y.P.V.S.)Engine stay (Upper)Exhaust pipe1.Remove:Hoses (Inlet and Outlet )1212 ENGENGINE DISASSEMBLY5-72.Remove:Spark plug Thermo unit sWARNINGHandle the

thermo unit with special care.Never subject it to strong or allow it to bedropped. In case of being dropped, it mustbe replaced.3.Remove:Cover (thermostatic valve)4.Remove:Gasket Thermostatic valve O-ring 5.Remove:Cylinder headGasket (Cylinder head)NOTE:Loosen the nuts starting with the highestnumbered one.Loosen each nut 1/4 turn, and remove themafter all nuts are loosened.6.Remove:Clutch cable guideCylinder Gasket (Cylinder)Dowel pinsNOTE:Loosen each nut 1/4 turn, and remove themafter all nuts are loosened.21 321524131 ENGENGINE DISASSEMBLY5-8EAS00253REMOVING THE CYLINDER AND PISTON1. Remove:piston pin clip piston pin piston CAUTIONDo not use a hammer to drive the piston pinout.NOTE:Before removing the piston pin clip, coverthe crankcase opening with a clean rag toprevent the piston pin clip from falling intothe crankcase.Before removing the piston pin, deburr thepiston pin clips groove and the pistonspin bore area. If both areas are deburredand the piston pin is still difficult to remo-ve, remove it with the piston pin puller set.2. Remove:top ring2nd ringoil ringNOTE:When removing a piston ring, open the endgap with your fingers and lift the other side ofthe ring over the piston crown.CLUTCH, PRIMARY DRIVE GEAR ANDBALANCER GEARNOTE:With the engine mounted, the clutch, primarydrive gear and balancer gear can be maintai-ned by removing the following parts:Brake pedalRadiator hose (Outlet)Autolube pump cable and hosesCrankcase cover (Right)Piston pin puller set90890-01304321 ENGENGINE DISASSEMBLY5-91.Remove:Water outlet pipe O-Ring (from water outlet pipe) Right side Left side2.Remove:Crankcase cover (Right)Dowel pinsGasket (Crankcase cover)3.Remove:Bolts Clutch springs Pressure plate Push rod #1 Friction plates Clutch plates Clutch dumper Nut (Clutch boss) Lock washer Clutch bossk10Thrust washerk11Clutch housingk12Thrust platek13Conical spring washerk14Bollk15Push rod #2k161238976510111213144151621 ENGENGINE DISASSEMBLY5-10NOTE:Before loosening the nut (Clutch boss) straighten the lock washer tab.Hold the clutch boss to loosen the nut(Clutch boss) by the universal Clutch hol-der 4.Straighten:Lock washer tab 5.Loosen:Nut (Primary drive gear) Nut (Balancer gear) NOTE:Hold the magneto rotor to loosen the nut (pri-mary drive gear) and nut (Balancer drivengear) by the universal rotor holder6.Remove:Nut (Balancer driven gear) Lock washer Driven gear (Balancer weight) Straight keyNut (Primary drive gear) Plain washer Primary drive gear Baffle plate 7.Remove:Drive gear (Balancer weight) Straight key Universal Clutch Holder90890-04086Universal Rotor Holder90890-0123513232165721218 ENGENGINE DISASSEMBLY5-118.Remove:Spacer collar Oil seal retainer CLUTCH PUSH LEVER1.Unhook:Return spring (Push lever) 2.Remove:Push lever (Clutch) Return spring Washer SHIFT SHAFT AND STOPPER LEVERNOTE:With the engine mounted, the shift shaft canbe maintained by removing the following parts.Brake pedalRadiator hose (Outlet)Autolube pump cable and hosesCrankcase cover (Right)Clutch1.Remove:Shift shaft CAUTIONWhen removing the shift shaft, hold theguide bar (shift fork) 2 in place. Otherwise,the guide bar will come loose with the shiftshaft, leaving the shift fork out of order inthe crankcase.2.Remove:Stopper lever Return spring 234121121 ENGENGINE DISASSEMBLY5-12ROTORNOTE:With the engine mounted, the rotor can bemaintained by removing the following parts:Crankcase cover (Left).1.Remove:Nut (Rotor)Plain washerNOTE:Hold the rotor to loosen the nut (Rotor) by theUniversal Rotor Holder2.Remove:RotorWoodruff key3.Disconnect:Neutral switch lead4.Remove:StatorREED VALVENOTE:With the engine mounted, the reed valve canbe maintained by removing the following parts:Side covers (Right and Left)SeatRadiator coverOil tank coverFuel tankCarburetorUniversal Rotor Holder90890-01235Rotor Puller90890-01189 ENGENGINE DISASSEMBLY5-131.Remove:Carburetor joint Reed valve assemby Gasket CRANKCASE RIGHT1.Remove:Crankcase (Right)NOTE:Loosen the bolts starting with the highestnumbered one.Loosen each bolt 1/4 turn and removethem after all bolts are loosened. Removal

steps:Attach the Crankcase Separating Tool NOTE:Fully tighten the tool holding bolts, but makesure the tool body is parallel with the case. Ifnecessary, one screw may be backed outslightly to evel tool body.As pressure is applied alternately tap onthe front engine mounting boss, transmis-sion shafts and shift cam.Then remove the crankcase (Right).NOTE:Turn the shift cam to the position shown inthe figure so that it doesnt contact the crank-case when separating the crankcase.Crankcase Separating Tool:90890-0113513211 2005 Yamaha DT125 RE - Service Manual Descargar gratis este documentoImprimirMvilColeccionesDenunciar documentoQuiere denunciar este documento?Por favor, indique los motivos por los que est denunciando este documento Spam o correo basura Contenido para adultos con pornografa Detestable u ofensivoIf you are the copyright owner of this document and want to report it, please follow these directions to submit a copyright infringement notice.Denunciar Cancelar Este es un documento privado. Informacin y clasificacin Lecturas:7,465Subido:05/28/2010Categora:Guas/Manuales de procedimientos>AutomvilesClasificacin:(1 Rating)Derechos de autor:Funciones no comerciales2005 Yamaha DT125 RE - Service Manual 2005 Yamaha DT125X - Service Manual Just_Docs This is a collapser for Adult Compartir e incluir Documentos relacionados AnteriorSiguiente p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. p. Ms material de este usuario AnteriorSiguiente15 p.456 p.354 p.357 p.391 p.395 p.10 p.10 p.16 p.32 p.524 p.320 p.8 p.12 p.279 p.148 p.450 p.249 p.416 p.219 p.20 p.134 p.14 p.280 p.227 p. Readcasters nuevos Agregar un comentario Enviarcompartir:Caracteres: 400 Imprimir este documentoAlta calidadOpen the downloaded document, and select print from the file menu (PDF reader required).Descargar e imprimir Agregar este documento a sus coleccionesEste es un documento privado, por lo tanto slo puede agregarse a colecciones privadas.+ Crear Nueva ColeccinNombre:Descripcin:Tipo de coleccin:public - locked pblico moderado privatecerrado al pblico: slo usted puede agregar elementos a esta coleccin, sin embargo otras personas pueden verla pblico controlado: otras personas pueden agregar elementos a esta coleccin, sin embargo usted puede aprobar o rechazar adiciones privado: slo usted puede agregar elementos a esta coleccin y slo usted puede verlaGuardar coleccinCancelarFinished? Back to Document Subir un documento Buscar Documentos Sganos!scribd.com/scribdtwitter.com/scribdfacebook.com/scribdA cerca de PrensaBlogSociosScribd 101Material de la webAsistencia tcnicaPreguntas ms frecuentesDesarrolladores / APIPuestos de trabajoCondicionesDerecho de autorPrivacidadCopyright 2011 Scribd Inc.Idioma:Espaol Elija el idioma en el que desea experimentar Scribd:EnglishEspaolPortugus (Brasil)

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