DT125RE DT125X 2005 1D01-AE1 SERVICE MANUAL
EAS00001 DT125RE/X 1D01-1D02/2C81 SERVICE MANUAL © 2005 Yamaha Motor España, S.A. 1st Edition, January 2005 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor España, S.A. is expressly prohibited. Printed in Spain.
EAS00002 NOTICE This manual was produced by the Yamaha Motor España S.A. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS”. Each chapter is divided into sections.
EAS00008 GEN INFO SYMBOLS The following symbols are not relevant to every vehicle. SPEC Symbols to chapter.
EAS00010 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM CARBURETOR ELECTRICAL SYSTEM TROUBLESHOOTING GEN INFO 1 SPEC 2 CHK ADJ 3 CHAS 4 ENG 5 COOL 6 CARB 7 ELEC 8 TRBL SHTG 9
GEN INFO
1
GEN INFO CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ……………………………………………1-1 FRAME SERIAL NUMBER ……………………………………………………1-1 ENGINE SERIAL NUMBER……………………………………………………1-1 IMPORTANT INFORMATION …………………………………………………1-2 PREPARATION FOR REMOVAL ……………………………………………1-2 ALL REPLACEMENT PARTS …………………………………………………1-2 GASKETS, OIL SEALS AND O-RINGS ……………………………………1-2 LOCK WASHERS/PLATES AND COTTER PINS……………………………1-2 BEARINGS AND OIL SEALS …………………………………………………1-3 CIRCLIP …………………………………………………………………………1-3 CHECKING THE CONN
MOTORCYCLE IDENTIFICATIONS GEN INFO EAS00014 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION FRAME SERIAL NUMBER The frame IDENTIFICATION number is stamped onto the steering head pipe. NOTE: The frame serial number is used to identify the motorcycle and therefore it can be used for the enrollment in the face of the competent authority. ENGINE SERIAL NUMBER The engine serial number is stamped onto the left side of the crankcase.
IMPORTANT INFORMATION GEN INFO IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to the “SPECIAL TOOLS”. 3. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly. 4.
IMPORTANT INFORMATION GEN INFO EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate. Oil seal CAUTION Do not spin the bearing with compressed air because this will damage the bearing surfaces.
CHECKING THE CONNECTIONS GEN INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector Moisture Dry with an air blower. Rust/stains Connect and disconnect several times. 3. Check: • all connections Loose connection Connect properly. NOTE: If the pin on the terminal is flattened, bend it up. 4.
SPECIAL TOOLS GEN INFO EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes. Tool No.
SPECIAL TOOLS Tool No. 90890-01135 Tool name / Usage Illustration Crankcase separation tool This tool is used to remove the crankshaft or separate the crankcase. 90890-01274 (1) -01275 (2) -01278 (3) Cranckshaft intalling tool Crankshaft pin Adapter(M12) 90890-01326 T-Handle This tool is used for holding the damper rod holder when removing or installing the damper rod holder. 90890-01367 -01381 Fork seal driver weight Fork seal driver attachment This tool is used when installing the fork seal.
SPEC
2
SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS …………………………………………………2-1 ENGINE SPECIFICATIONS……………………………………………………2-4 CHASSIS SPECIFICATIONS …………………………………………………2-6 ELECTRICAL SPECIFICATIONS ……………………………………………2-8 CONVERSION TABLE …………………………………………………………2-10 GENERAL TIGHTENING TORQUE SPECIFICATIONS ……………………2-10 ENGINE ………………………………………………………………………2-11 CHASSIS ……………………………………………………………………2-11 COOLANT FLOW CHART ……………………………………………………2-13 LUBRICATION POINTS AND LUBRICANT TYPE …………………………2-14 ENGINE ……………………………………
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Model Model code Dimensions: Overall lenght Overall width Overall height Seatheight Wheelbase Minimum ground clearance Minimum turning radius Basic weight: With oil and full fuel tank Engine: Engine type: Induction system Cylinder arrangement Displacement BorexStroke Compression ratio Maximum power Maximum torque Idle speed Starting system Lubrication system Oil type or grade: Engine oil Total amount Transmission oil Periodic oil change To
Model code Spark plug: Type Manufacturer Spark plug gap Clutch type Transmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio: 1ª 2ª 3ª 4ª 5ª 6ª Chassis: Frame type: Castor angle Trail Tire: Type Size Front Rear Manufacturer Cold tire pressure: Front 0~90kg Rear 0~90kg Front 90~178kg Rear 90~178kg Off road riding: Front Rear Brakes: Front brake type Front brake operation Rear brake type Rear brake operation Susp
Model code Wheel travel: Front wheel travel Rear wheel travel Electrical: Ignition system Charging system Battery type Capacity Headlight: Bulb wattage x quantity: Headlight Tail/Brake light Turn signal indicator light GENERAL SPECIFICATIONS SPEC 1D01/1D02 2C81 270mm(10.63in) 260mm(10.
GENERAL SPECIFICATIONS SPEC ENGINE Item Cylinder head: Warpage limit Cylinder: Bore size Taper limit Out of round limit Standard Limit * Lines indicate straightedge measurement. 0,03mm 56.00~56.02mm 0.05mm 0.01mm *** *** *** Piston: Piston size “D” Measurement point* Piston to cylinder clearance Piston Offset 55.950~55.955 10mm *** *** 0.045~0.050mm 0.5mm 0.
GENERAL SPECIFICATIONS Item SPEC Standard Limit 57.90~57.95mm *** 0.2~0.7mm 0.026~0.040mm *** 0.03mm *** *** 2.9~3.1mm 7pcs 1.05~1.35mm 6pcs 34.5mm 5pcs 32mm 0.15mm 2.7mm *** 0.05mm *** *** *** *** *** *** *** 0.08mm 0.08mm TM28-92/1 1DO #210 0.7 5J40-2 Q2M (#939) 0.6 #17.5 1.6 1/4 2.8 #40 #60 15.5~16.5mm 1.5~2.5mm 1250~1450r.p.m *** *** *** *** *** *** *** *** *** *** *** *** *** *** Wet element Foam air filter oil or SAE10W30SE *** *** 0.5mm 8.8mm 0.5mm *** *** *** * Dark blue 0.15~0.
GENERAL SPECIFICATIONS SPEC CHASSIS Item Standard Limit Model code Front wheel: Type Rim Size Rim Material Front wheel travel: Max. Radial wheel runout Max. Lateral wheel runout 1D0 2C81 Spoke wheels 21x1.60 Steel 270mm 1mm 0.5mm Spoke wheels 17 x 3.00 Steel 270mm 1mm 0.5mm Rear wheel: Type Rim size Rim material Rear wheel travel Max. Radial wheel runout Max. Lateral wheel runout Spoke wheels 18x1.85 Steel 260mm(10.24in) 1mm(0.04in) 0.5mm(0.02in) Spoke wheels 17x3.50 Steel 260mm(10.24in) 1mm(0.
GENERAL SPECIFICATIONS Item Model code Rear suspension: Type Rear shock absorber assemby travel Spring free lenght Installed lenght Spring preload (spring lenght) Spring rate K1 Spring stroke K1 Optional spring available Enclosed gas/air pressure (STD) Tightening torque spring preload Drive chain: Type/Manufacturer Link quantity Drive chain slack SPEC Standard Limit 1D0 2C81 Swingarm (link suspension) 93mm 245mm 230mm Hard/Soft (220/235mm) 68.
GENERAL SPECIFICATIONS GEN INFO ELECTRICAL Model System voltage 1D01/1D02 2C81 12 V Ignition system: Ignition system type Ignition timing (B.T.D.C.) ((º)) Advancer type C.D.I. 17 /1500r/min Digital C.D.I.
GENERAL SPECIFICATIONS Indicator light Neutral indicator light Turn indicator light Oil level indicator light High beam indicator light GEN INFO 12V3Wx1 12V3Wx1 12V3Wx1 12V3Wx1 Starting system: System type Electric starter Starter motor: Model/Manufacturer Power output Armature coil resistance Brush overal lenght Brush spring force Commutator diameter Mica undercut (depth) 3MB / Moric 0.2kW 0.0315~0.0385 20ºC 5X7X7 3,5 4.9N ±20% 3.92N 17.6mm 16.6mm 1.
CONVERSION TABLE / GENERAL TIGHTENING TORQUES SPECIFICATIONS SPEC EAS00028 EAS00029 CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual.
SPEC DEFINITION OF UNITS TIGHTENING TORQUES ENGINE Part to be tightened Spark plug Tightening torque Nm m•kg Remarks Q’ty Thread size 1 M14x1.25 20 2,0 Cylinder head Nut 5 M8x1.25 22 2,2 Cylinder Stud bolt 9 M8X1.25 13 1,3 Nut 4 M8x1.25 28 2,8 6 M5x0.8 7 0,7 Power valve holder, Valve cover LOCTITE screw glue Cap seal Bolt Power valve pully Bolt M6x1.0 10 1,0 Thermostat valve cover Screw 3 M6x1.0 8 0,8 Housing cover Screw 2 M6x1.
DEFINITION OF UNITS SPEC CHASSIS Parts to be tightened Thread size Tightened torque Nm m•kg Engine stay (Top) and frame Cylinder head stay (Top) and frame Bottom screw (front) engine and frame Bottom screw (front) engine to swingarm Steering nut M10 M10 M10 M10 M25 30-35 30-35 60-78 30-35 120-155 Fuel cock lever Upper bracket and meter holder Rear bolt fuel tank to frame Footrest security pins Front brake holder Front brake pipe Handlebar holder bolts to handlebars Main switch M6 M6 M6 — M10 M10 M
COOLANT FLOW CHART SPEC COOLANT FLOW CHART Water pump Crankcase cover Crankcase Cylinder Cylinder head Bypass hose (Thermostatic valve) Outlet hose Radiator Thermostatic valve Inlet hose Coolant cold (Less than 65°C (149°F)) Coolant hot (165°(149°F) or more) 2-13
LUBRICATION POINTS AND LUBRICANT TYPES SPEC EAS00031 ENGINE Lubrication points (part name) Lubricant Type Oil seal lips (All) Apply lightweight lithium-soap base grease O-Rings (All) Apply lightweight lithium-soap base grease Bearing retainer Crankshaft bearings (Left and center) Apply engine oil Needle bearings (Connecting rod) Apply engine oil Main axle bearings Apply gear oil Drive axle bearings Apply gear oil Push lever bearings Apply gear oil Crank pins Apply engine oil Piston rin
LUBRICATION POINTS AND LUBRICANT TYPES SPEC EAS00032 CHASSIS Lubrication points (part name) Lubricant Type Ball bearing (Steering shaft) Apply lightweight lithium-soap base grease Bearing (Steering shafts) Apply lightweight lithium-soap base grease Oil seal clutch to lever Apply lightweight lithium-soap base grease Clutch lever axle free play Apply lightweight lithium-soap base grease Throttle guide bar Apply lightweight lithium-soap base grease Oil seal throttle wire to guide Apply lightwe
SPEC CABLE ROUTING CABLE ROUTING A Cover with cap after connecting wires. B Route the installation between lower brac- Clutch wire Right turn signal lead Left turn signal lead Throttle cable Indicator light wire lead Meter wire lead Headlight bulb wire Handle wire lead (right) ket and headlight bottom holder. C Clamp connection wire.
SPEC CABLE ROUTING CABLE ROUTING A Turn the hose to obtain the desired angle. B Route clutch wire first for the inside, after Master cylinder Front brake hose Wire throttle Clutch sw wire lead SW handle wire lead (left) Clip A.I.S. Pipe overflow Pipe to air filter Pipe I License light wire lead Oil gauge route the throttle wire. C Clamp handle wire lead (L). D Clamp handle wire lead (R). E Clamp pipe overflow to the frame clamp. F Hold hoses on chassis clamp.
SPEC CABLE ROUTING CABLE ROUTING A Route speedometer cable to frame guide. B Route pipe overflow behind engine holder. C Screw ground wire and rectifier with the same bolt. D Pipe overflow pass behind oil hose. E Route carburetor breather hose between rear shock absorber and swingarm. F Route pipe overflow between rear shock absorber and swingarm.
CABLE ROUTING SPEC CABLE ROUTING A Route brake hose through the guide. B Clamp clutch wire. C Guide wire (chassis): SW handle wire lead (R), SW handle wire lead (L), clutch SW wire lead, front stop SW wire lead, wire throttle, wire clutch. D Insert installation clip to frame hole. E Route clutch wire through the guides. F Connect ground on the front part of the coil. Install screw and wire terminal. G Cover thermo-switch with cap. H Insert connector to frame clamp (X3).
CHK ADJ
3
CHK ADJ CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION …………………3-1 ENGINE ……………………………………………………………………………3-2 Y.P.V.S.
INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS CHK ADJ PERIODIC CHECKS AND ADJUSTMENTS NOTE: • • • 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 technical skills. ANUAL ODOMETER READING ( x 1.
Y.P.V.S. CABLE ADJUSTMENT CHK ADJ ENGINE Y.P.V.S. CABLE ADJUSTMENT 1. Remove • pulley cover (power valve) 2. Turn on the main switch 1 NOTE If the Y.P.V.S. Doesn’t operate, refeer to the “Y.P.V.S. SYSTEM” in CHAPTER 9 3. Check • alignment mark Not aligned Adjust the Y.P.V.S. Cables 2 3 1 4. Adjust • Y.P.V.S. Cables 2 Adjustments steps: • Loosen both locknuts and turn in both adjusters . • Insert a pin [fl 0,16 in.
CHK ADJ IDLE SPEED ADJUSTMENT IDLE SPEED ADJUSTMENT 1. Adjust: • engine idle speed (a) 2 (b) EAS00054 1 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the air filter element should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for several minutes. 2. Connect: • engine tachometer (onto the spark plug lead of cylinder #1) Engine tachometer 90890-03113 3. Check: • engine idling speed Out of specification Adjust.
ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ EAS00058 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed and carburetor synchronization should be adjusted properly. 1. Check: • throttle cable free play a Out of specification Adjust. Throttle cable free play (at the flange of the throttle grip) 3 ~ 5 mm (0,11 ~ 0,19 in) 2 2. Adjust: • throttle cable free play 1 Handlebar side a.
ADJUSTING THE THROTTLE CABLE FREE PLAY/ CARBURETOR CABLE FREE PLAY ADJUSTMEN CHK ADJ CARBURETOR CABLE FREE PLAY ADJUSTMENT NOTE: Before adjusting carburetor cable, throttle cable free play should be adjusted. 1. Pull back the adjuster cover. 3 2. Check: • carburetor cable free play a Out of specification adjust 2 Carburetor Cable Free Play: 1,0 mm (0,04 in) 3.
AUTOLUBE PUMP STROKE ADJUSTMEN/ AUTOLUBE PUMP AIR BLEEDING CHK ADJ AUTOLUBE PUMP STROKE ADJUSTMENT 1. Remove: • Autolube pump cover 2. Adjusting mark Not aligned Adjust the Autolube Pump 1 3. Adjust • Autolube pump The adjusting marks a and b has to match when the throttle cable free play ends. (a) Adjustment steps: a. Loosen the locknut b. Turn the adjuster until the correct adjustment is obtained c. Tighten the locknut.
AUTOLUBE PUMP AIR BLEEDING/ CHECKING THE SPARK PLUG CHK ADJ 3. Air blled: • pump case and/or oil pipe Air bleeding steps • Remove the bleed cap • Start the engine. • Keep the oil running out until air bubbles dissapear. • Keep the engine running at about 2.000r/min for two minutes or so • When air bubbles are expelled completely, install the bleed cap. 1 NOTE: Place a rag or oil pan under the autolube pump to catch the oil.
CHECKING THE SPARK PLUG/ CHECKING THE IGNITION TIMING CHK ADJ 6. Measure: • spark plug gap a (with a wire Thickness gauge) Out of specification Regap. Spark plug gap 0,7-0,8mm (0,0276-0,03315in) 7. Install: • spark plug Spark plug 20Nm (2,0m·kg, 14ft·lb) NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 8.
CHECKING THE IGNITION TIMING/ ENGINE OIL LEVEL INSPECTION CHK ADJ 3. Check: • ignition timing a. Start the engine, warm it up for several minutes, and then let it run at the specified engine idling speed. Engine idling speed 1250-1450 r/min b. Check that the stationary pointer is within the firing range on the generator rotor. Incorrect firing range Check the ignition system. NOTE: The ignition timing is not adjustable. 4.
CHK ADJ ENGINE OIL LEVEL INSPECTION OIL WARNING LIGHT CHECKING METHOD Main Switch “ON” Gears in “NEUTRAL” Oil warning indicator light come on Oil warning indicator light does not come on Shift into gear Oil warning indicator light does not come on Refeer to CHAPTER 8 “SIGNAL SYSTEM” y 60 80 100 40 000015 120 20 km/h Engine oil level and electrical circuit are OK 0008 Supply engine oil CAUTION b j z Always use the same type of engine oil; mixing oils may result in a harmful chemical reaction a
TRANSMISSION OIL LEVEL INSPECTION/ TRANSMISSION OIL REPLACEMENT CHK ADJ TRANSMISSION OIL LEVEL INSPECTION 1. Inspect: • transmission oil level Oil level low Add sufficient oil Transmission oil level steps: • Place the machine on a level surface. • Warm up the engine for several minutes and stop it. • Visually check the oil level through the level window . NOTE: • Check the oil level just one minute after stopping the engine.
TRANSMISSION OIL REPLACEMENT/ ADJUSTING THE CLUTCH CABLE FREE PLAY CHK ADJ 5. Install: • Drain plug Spark plug 15Nm (1,5m·kg, 11ft·lb) 6. Fill: • Crankcase Recomended oil: SAE 10W30 Type SE Motor Oil Periodic oil change: 0,75L CAUTION • Do not add any chemical additives. Transmission oil also lubricates the clutch and additives could cause clutch slippage. • Be sure no foreign materials enters the crankcase. 7. Install: • Oil filler cap 8.
ADJUSTING THE CLUTCH CABLE FREE PLAY Direction a Direction b CHK ADJ Clutch cable free play is increased. Clutch cable free play is decreased. c. Tighten the locknut. NOTE: 1 If the specified clutch cable free play cannot be obtained on the handlebar side of the cable, use the adjusting nut on the engine side. 1 Engine side a. Loosen the locknuts . b. Turn the adjusting bolt in direction a or b until the specified clutch cable free play is obtained.
ADJUSTING THE CLUTCH CABLE FREE PLAY CHK ADJ 7. Disconnect: • Autolube pump cable • Autolube pump hose Refer to the “AUTOLUBE PUMP CABLE AND HOSE” section in the CHAPTER 4. 1 2 8. Drain: • Transmission oil Refer to the ”TRANSMISSION OIL REPLACEMENT” section. 9. Remove: • Return spring • Bolt (master cylinder) • Brake pedal • Crankcase cover (Right) 2 4 1 3 10.
ADJUSTING THE CLUTCH CABLE FREE PLAY CHK ADJ NOTE: • When installing the crankcase cover, engage the autolube pump drive gear with its driven gear as slowly turn the autolube pump shaft. • Tighten the screws (Crankcase cover) in stage, using a crisscross pattern. • Before installing the brake pedal apply the lithium soap base grease to the brake pedal pivot shaft. 3 1 2 12. Install: • Gasket (Autolube pump cover) 13. Connect: • Autolube pump hoses • Autolube pump cable 14.
ADJUSTING THE CLUTCH CABLE FREE PLAY/ CLEANING THE AIR FILTER ELEMENT CHK ADJ 20. Air bleeding: • Autolube pump Refer to the “AUTOLUBE PUMP AIR BLEEDING section. 21. Install: • Autolube pump cover 1 Screw (autolube pump cover) 5 Nm (0,5 m • kg, 3,6 ft • lb) EAS00089 CLEANING THE AIR FILTER ELEMENT NOTE: On the bottom of the air filter case is a check hose . If dust or water or both collects in this hose, clean the air filter element and air filter case. 1 1. Remove: • Side cover (left) 1 2.
CLEANING THE AIR FILTER ELEMENT CHK ADJ CAUTION 1 Do not twist the air filter element when squeezing it. 2 4. Check: • air filter element Damage Replace. 5. Apply the recommended oil to the entire surface of the air filter element and squeeze out the excess oil. The air filter element should be wet but not dripping. 1 Recommended oil SAE10W30 6. Install: • air filter element • air filter element (to element guide) NOTE: Install the washer with its bent fringe upwards as shown.
CARBURETOR JOINT INSPECTIONS /FUEL LINE INSPECTION/CHECKING THE CRANKCASE BREATHER HOSE CHK ADJ CARBURETOR JOINT INSPECTION 1. Inspect: • Carburetor joint Crack-damage Replace Refer to the “REED VALVE” section in chapter 7 for replacement 1 2. Check the tightening torque of the carburetor joint securing bolts. Bolt (Carburetor joint) 8 Nm (0,8 m • kg, 5,8 ft • lb) FUEL LINE INSPECTION 1.
EXHAUST SYSTEM INSPECTION/ENGINE OIL LINE INSPECTION/ COOLANT LEVEL INSPECTION CHK ADJ EXHAUST SYSTEM INSPECTION 1 .Inspect: • Gasket (exhaust pipe) • Joint (Silencer) Damage Replace Exhaust gas leakage Repair • Exhaust pipe • Silencer Cracked/Dent/Damage Repair or replace 2.
COOLANT LEVEL INSPECTION/ CHANGING THE COOLANT CHK ADJ s WARNING Do not remove the radiator cap when the engine is hot. CAUTION Hard water or salt water is harmful to the engine parts; use boiled or distilled water if you can’t get soft water. 4. Add: • Soft water (tap water) Until the coolant level reaches “FULL” level line. Reservoir tank capacity Total 0,30 L From “LOW” to “FULL” Level 0,24 L 5. Install: • Side cover (Left). EAS00105 CHANGING THE COOLANT 1.
CHANGING THE COOLANT CHK ADJ tor cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the radiator cap and turn it counterclockwise to remove. 2 1 The following procedure applies to all of the coolant drain bolts and copper washers. 5. Remove: • coolant drain bolt (engine) (along with the copper washer) 6. Drain: • coolant (from the engine and radiator) 7.
CHANGING THE COOLANT CHK ADJ with soap and water. • If coolant is swallowed, induce vomiting and get immediate medical attention. CAUTION • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant. • Use only distilled water. However, if distilled water is not available, soft water may be used.
COOLING SYSTEM INSPECTION CHK ADJ COOLING SYSTEM INSPECTION 1. Inspect: • radiator • inlet hose • outlet hose • water outlet pipe cracks-damage Replace Refer to the “COOLING SYSTEM” section ins CHAPTER 6.
ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE CHK ADJ EAS00108 CHASSIS 3 ADJUSTING THE FRONT BRAKE 1. Check: • brake lever free play Out of specification Adjust. 1 2 Brake lever free play (at the end of the brake lever) 2 ~ 5mm (0,08 ~ 0,20in) 2. Adjust: • brake lever free play a. Loosen the locknut . b. Turn the adjusting bolt in direction a or b until the specified brake lever free play is obtained.
ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL CHK ADJ 2. Adjust: • brake pedal position 2 a. Loosen the locknut . b. Turn the adjusting bolt in direction a or b until the specified brake pedal position is obtained. Direction a Direction b 1 Brake pedal is raised. Brake pedal is lowered. s WARNING After adjusting the brake pedal position, check that the end of the adjusting bolt protrudes 2 mm (0,08 in) from the bottom of the set nut. c.
CHECKING THE BRAKE FLUID LEVEL 2. Check: • brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level. B REAR CHK ADJ 1 Recommended brake fluid DOT 4 A B Front brake Rear brake s WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system.
CHECKING THE FRONT AND REAR BRAKE PADS/ ADJUSTING THE REAR BRAKE LIGHT SWITCH EAS00119 A FRONT CHECKING THE FRONT AND REAR BRAKE PADS The following procedure applies to all of the brake pads. 1. Remove: • Rubber plug 2. Operate the brake. 3. Check: • front brake pad • rear brake pad Wear indicators almost touch the brake disc Replace the brake pads as a set. Refer to “REPLACING THE FRONT BRAKE PADS” and “REPLACING THE REAR BRAKE PADS” in chapter 4.
CHECKING THE FRONT AND REAR BRAKE HOSES/ ADJUSTING THE DRIVE CHAIN SLACK CHK ADJ EAS00131 CHECKING THE FRONT AND REAR BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps. 1. Check: • brake hose Cracks/damage/wear Replace. 2. Check: • brake hose clamp Loose Tighten the clamp bolt. 3. Hold the motorcycle upright and apply the brake several times. 4. Check: • brake hose Brake fluid leakage Replace the damaged hose.
ADJUSTING THE DRIVE CHAIN SLACK CHK ADJ 3. Check: • drive chain slack a Out of specification Adjust. Drive chain slack 25 ~ 40 mm (0,9842 ~ 1,5748 in) 45 ~ 55 mm (1,7716 ~ 2,1653 in) DT125X DT125RE 4. Remove: • cotter pin 5. Loosen: • wheel axle nut 6. Adjust: • drive chain slack 2 a. Loosen both locknuts. b. Turn both adjusters in direction a or b until the specified drive chain slack is obtained.
LUBRICATING THE DRIVE CHAIN/ CHEEKING AND ADJUSTING THE STEERING HEAD CHK ADJ EAS00142 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained properly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the motorcycle is used in dusty areas. This motorcycle has a drive chain with small rubber O-rings between each side plate.
CHEEKING AND ADJUSTING THE STEERING HEAD CHK ADJ a. Remove the lock washer , the upper ring nut , and the rubber washer . b. Loosen the lower ring nut and then tighten it to specification with a steering nut wrench. Steering nut wrench 90890-01403 Lower ring nut (initial tightening torque) 35 Nm (3.5 m • kg, 24.8 ft • lb) 2 1 c. Loosen the lower ring nut completely, then tighten it to specification. 3 4 s WARNING Do not overtighten the lower ring nut.
CHEEKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK CHK ADJ 6. Measure: • steering head tension NOTE: Make sure all of the cables and wires are properly routed. a. Point the front wheel straight ahead. b. Install a plastic locking tie loosely around the end of the handlebar as shown. c. Hook a spring gauge onto the plastic locking tie. d.
CHECKING THE FRONT FORK/ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY CHK ADJ 2. Check: • inner tube Damage/scratches Replace. • oil seal Oil leakage Replace. 3. Hold the motorcycle upright and apply the front brake. 4. Check: • front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly. Rough movement Repair. Refer to “FRONT FORK” in chapter 4.
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/CHECKING THE TIRES CHK ADJ 2. Tighten: • Tighten the locknut EAS00164 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: • tire pressure Out of specification Regulate. s WARNING • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature.
CHECKING THE TIRES CHK ADJ s WARNING It is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately. 2. Check: • tire surfaces Damage/wear 1 Replace the tire. Minimum tire tread depth 1.6 mm (0.04 in) 2 Tire tread depth Sidewall s WARNING • Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. • When using tube tires, be sure to install the correct tube.
CHECKING THE TIRES/ CHECKING AND TIGHTENING THE SPOKES CHK ADJ Front tire Manufacturer Model Size DT125RE MICHELIN T63 80/90-21 48P DT125X PIRELLI Sport Demon 120/70-17 58H Rear tire Manufacturer Model Size DT125RE MICHELIN T63 110/80-18 58P DT125X PIRELLI Sport Demon 140/70-17 66H s WARNING • New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done.
CHECKING AND TIGHTENING THE SPOKES/ CHECKING AND LUBRICATING THE CABLES CHK ADJ 2. Tighten: • spoke (with a spoke wrench) 2~3.5 Nm (0.2~0.35 m•kg, 1.42~2.49 ft•lb) NOTE: Be sure to tighten the spokes before and after break-in. EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables. s WARNING Damaged outer cable may cause the cable to corrode and interfere with its movement. Replace damaged outer cable and inner cables as soon as possible. 1.
LUBRICATING THE LEVERS AND PEDALS/LUBRICATING THE SIDESTAND/LUBRICANTING THE REAR SUSPENSION CHK ADJ EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal-tometal moving parts of the levers and pedals. Recommended lubricant SAE 10W30 Motor Oil EAS00172 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-tometal moving parts of the sidestand.
ELECTRICAL SYSTEM CHK ADJ EAS00178 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY s WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries. • Charge batteries in a well-ventilated area. • Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes).
CHECKING AND CHARGING THE BATTERY CHK ADJ NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Remove: • Rear side cover (right) • Battery cover 2. Disconnect: • battery leads (from the battery terminals) CAUTION First, disconnect the negative battery lead , and then the positive battery lead . 3.
CHECKING AND CHARGING THE BATTERY CHK ADJ s WARNING Do not quick charge a battery. CAUTION • Never remove the MF battery sealing caps. • Do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage. • If it is impossible to regulate the charging current on the battery charger, be careful not to overcharge the battery. • When charging a battery, be sure to remove it from the motorcycle.
CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 1 CHK ADJ CAUTION 2 First, connect the positive battery lead , and then the negative battery lead . 8. Check: • battery terminals Dirt Clean with a wire brush. Loose connection Connect properly. 9. Lubricate: • battery terminals Recommended lubricant Dielectric grease 10. Install: • Battery cover • Rear side cover (right) EAS00181 CHECKING THE FUSES The following procedure applies to all of the fuses.
CHECKING THE FUSES/ REPLACING THE HEADLIGHT BULB CHK ADJ 3. Replace: • blown fuse 2 a. Set the main switch to “OFF”. b. Install a new fuse of the correct amperage rating. c. Set on the switches to verify if the electrical circuit is operational. d. If the fuse immediately blows again, check the electrical circuit. 1 Fuses Main Reserve Amperage rating 15A 15A Q'ty 1 1 s WARNING Never use a fuse with an amperage rating other than that specified.
REPLACING THE HEADLIGHT BULB/ ADJUSTING THE HEADLIGHT BEAM CHK ADJ 5. Install: • headlight bulbNew Secure the new headlight bulb with the headlight bulb holder. CAUTION Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 6. Install: • headlight bulb holder 7.
CHAS
4
CHAS CHAPTER 4 CHASSIS FRONT WHEEL …………………………………………………………………4-1 REMOVAL ………………………………………………………………………4-2 INSPECTION……………………………………………………………………4-3 INSTALLATION …………………………………………………………………4-5 REAR WHEEL ……………………………………………………………………4-7 REMOVAL ………………………………………………………………………4-8 INSPECTION……………………………………………………………………4-9 INSTALLATION …………………………………………………………………4-9 FRONT AND REAR BRAKE …………………………………………………4-11 BRAKE PAD REPLACEMENT ………………………………………………4-13 CALIPER DISASSEMBLY ……………………………………………………4-18 MASTER CYLINDER DISASSEMBLY………
FRONT WHEEL CHAS CHASSIS FRONT WHEEL Cap Collar Dust cover 10 Wheel axle 11 Cap 12 Gear unit (speedometer) Hub Bearing Collar Oil Seal Rim Spoke Basic weight: With oil and full fuel tank Maximum load* DT125RE 126 kg DT125X 134 kg 178 kg (392 lb) 180 kg (396 lb) Cold tire pressure Up to 90 Kg (198 bf) load* DT125RE A Tire Size: 80/90-21 48P B Rim Size: 150kPa (1,5kgf/cm2)(21,8psi) 180Kpa (1,8kgf/cm2)(26,1psi) 90kg (198lbf)~Maximum load 175kPa (1,75kgf/cm2)(25,4psi) 180Kpa
REMOVING THE FRONT WHEEL CHAS EAS00519 REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface. s WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 1 2. Remove: • Cable holder (speedometer) 3. Disconnect: • Speedometer cable 4. Loosen: • Nuts (Axle holder) 3 2 5.
CHECKING THE FRONT WHEEL CHAS EAS00526 CHECKING THE FRONT WHEEL 1. Check: • wheel axle Roll the wheel axle on a flat surface. Bends Replace. s WARNING Do not attempt to straighten a bent wheel axle. 2. Check: • tire • front wheel Damage/wear Replace. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in chapter 3. 3. Check: • spokes Bends/damage Replace. Loose Tighten. Tap the spokes with a screwdriver.
CHECKING THE FRONT WHEEL 6. Check: • collars Damage/wear CHAS Replace. s WARNING • After mounting a new tire, ride conservatively for a while to become accustomed to the “feel” of the new tire and to allow the tire to seat itself properly in the rim. Failure to do so could lead to an accident with possible injury to the rider or damage to the motorcycle. • After a tire has been repaired or replaced, be sure to tighten the tire air valve stem locknut to specification. Tire air valve stem locknut 1.
CHECKING THE FRONT WHEEL/ INSTALLING THE FRONT WHEEL CHAS CAUTION 7 Do not contact the wheel bearing inner race or balls. Contact should be made only with the outer race. NOTE: Use a socket that matches the diameter of the wheel bearing outer race and oil seal. EAS00542 INSTALLING THE FRONT WHEEL 1. Lubricate: • wheel axle • wheel bearings • oil seal lips • speedometer drive gear • speedometer driven gear 1 Recommended lubricant Lithium-soap-based grease 2.
INSTALLING THE FRONT WHEEL CHAS 4. Tighten: • wheel axle 45~70 Nm (4.5~7.0 m•kg, 33~51.3 ft•lb) • Nut (Axle holder): 7.5~12 Nm (0.75~1.2 m•kg, 5.5~8.8 ft•lb) s WARNING Make sure the brake cable is routed properly. CAUTION Before tightening the wheel axle nut, push down hard on the handlebar several times and check if the front fork rebounds smoothly.
REAR WHEEL CHAS REAR WHEEL Hub Collar Bearing Oil Seal Rim Spoke Cap Basic weight: With oil and full fuel tank Maximum load* 15 Chain puller 16 Chain puller 17 Wheel axle 18 Washer 19 Nut 20 Drive chain Driven Sprocket Bolt 10 Nut 11 Collar 12 Dust Cover 13 Collar 14 Oil Seal DT125RE 126 kg DT125X 134 kg 178 kg (392 lb) 180 kg (396 lb) Cold tire pressure DT125RE A Tire Size: 110/80-18 58P B Rim Size: Up to 90 Kg (198 bf) load* 175kPa (1,75kgf/cm2)(25,4psi) 200
REMOVING THE REAR WHEEL CHAS EAS00561 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface. s WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 1 2. Remove: • rear brake caliper protection 1 NOTE: Do not depress the brake pedal when removing the brake caliper. 3. Loosen: • bolts (swingarm end). 4.
INSPECTING THE REAR WHEEL/ INSTALLING THE REAR WHEEL 2 CHAS INSPECTING THE REAR WHEEL 1. Inspect: • Rear wheel axle Refer to the “FRONT WHEEL - INSPECTION” section. 2. Inspect: • Wheel hub • Dust covers (Bearings) • Wheel Refer to the “FRONT WHEEL - INSPECTION” section. 3. Measure: • Wheel runout Refer to the “FRONT WHEEL - INSPECTION” section. 4. Check: • Wheel bearings Refer to the “FRONT WHEEL - INSPECTION” section. 5. Check: • Wheel balance Refer to the “FRONT WHEEL - INSPECTION” section.
INSTALLING THE REAR WHEEL CHAS 2. Adjust: • Drive chain slack a Drive chain slack: DT125RE 40~55mm (1,77~2,16in.) DT125X 25~40mm (0,98~1,58 in.) • Refer to the “DRIVE CHAIN SLACK ADJUSTMENT” section in CHAPTER 3. Recommended lubricant Lithium-soap-based grease 3. Tighten: • wheel axle nut • bolts (swingarm end) 30 Nm (3 m•kg, 22 ft•lb) 80~100Nm (8.0~10.0 m•kg, 58.7~73.
CHAS FRONT AND REAR BRAKE FRONT AND REAR BRAKE Brake hose Brake caliper Pad spring Piston Master cylinder cap Diaphragm Master cylinder kit Master cylinder A Brake Fluid Type: DOT 4 or DOT 3 B Brake pad Wear Limit: 0,8 m (0.03 in.) C Brake Disc Wear Limit: 3mm (0.12 in.
CHAS FRONT AND REAR BRAKE Reservoir tank cap protector Reservoir tank cap Inner cap Diaphragm Reservoir tank Reservoir hose A Brake Fluid Type: DOT 4 or DOT 3 B Brake pad Wear Limit: 0,8 m (0.03 in.) C Brake Disc Wear Limit: 4mm (0.16 in.
REPLACING THE FRONT BRAKE PADS CHAS EAS00579 CAUTION Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly. • Never use solvents on internal brake components.
REPLACING THE FRONT BRAKE PADS CHAS 3. Remove: • brake pads • brake pad springs 4. Measure: • brake pad wear limit a Out of specification Replace the brake pads as a set. Brake pad wear limit 0.8 mm (0.03 in) 5. Install: • brake pad springs • brake pads 1 NOTE: Always install new brake pads and a new brake pad spring as a set. a. Connect a clear plastic hose tightly to the bleed screw . Put the other end of the hose into an open container. b.
REPLACING THE FRONT BRAKE PADS/ REPLACING THE REAR BRAKE PADS CHAS 6. Lubricate: • retaining bolt Recommended lubricant Lithium-soap-based grease CAUTION 1 • Do not allow grease to contact the brake pads. • Remove any excess grease. 7. Install: • retaining bolt 18 Nm (1,8 m•kg, 13ft•lb) 8. Check: • brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. FRONT a 9.
REPLACING THE REAR BRAKE PADS CHAS 1. Remove: • Protector (caliper body) • Retaining bolt • Turn the caliper body counterclockwise 2. Remove: • brake pads • brake pad springs • Shim (brake pad) 2 1 3. Measure: • brake pad wear limit a Out of specification Replace the brake pads as a set. 2 Brake pad wear limit 0.8 mm (0.03 in) 1 4.
REPLACING THE REAR BRAKE PADS CHAS 5. Lubricate: • Retaining bolt (Caliper body) 1 6. Tighten: • Retaining bolt (Caliper body) 18 Nm (1,8 m•kg, 13ft•lb) 7. Check: • brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 1 8. Check: • brake pedal operation Soft or spongy feeling Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.
DISASSEMBLING THE FRONT BRAKE CALIPER CHAS EAS00618 DISASSEMBLING THE FRONT BRAKE CALIPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • union bolt • copper washers • brake hose 2 1 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 2. Remove: • Retaining bolt (caliper body) • Brake pads • Pad springs Refer to the “BRAKE PAD REPLACEMENT” section. 2 1 2 3.
DISASSEMBLING THE FRONT BRAKE CALIPER/ DISASSEMBLING THE REAR BRAKE CALIPER CHAS a Blow compressed air into the brake hose joint opening a to force out the piston from the brake caliper. s WARNING • Cover the brake caliper piston with a rag. Be careful not to get injured when the piston is expelled from the brake caliper. • Never try to pry out the brake caliper piston. (a) b.
DISASSEMBLING THE REAR BRAKE CALIPER CHAS 3. Disconnect the dust boot and then pull out the caliper body from the guide shaft on te caliper bracket . 3 1 2 4. Remove: • Rear wheel Refer to the “REAR WHEEL” section. • Caliper bracket 5. Remove: • Caliper piston • Dust seal • Piston seal a. Blow compressed air into the brake hose joint opening a to force out the piston from the brake caliper. (a) s WARNING • Cover the brake caliper piston with a rag.
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER CHAS EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: • Brake switch • Brake lever • Return spring (brake lever) 1 NOTE: When removing the brake switch push the switch hook using a suitable rod, then pull it out. 3 2 2. Pull back the brake hose cover from the master cylinder. 3 2 1 3.
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER/DISASSEMBLING THE REAR BRAKE MASTER CYLINDER CHAS 5. Remove: • Cap (master cylinder) • Diaphragm • Dust boot • Circlip • Master cylinder kit NOTE: To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose. DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 1. Remove: • Brake hose guides 2. Loosen: • Union bolt 3.
DISASSEMBLING THE REAR BRAKE MASTER CYLINDER/CHECKING THE FRONT AND REAR BRAKE CALIPER CHAS 4. Remove: • Brake hoses • Reservoir tank • Circlip • Push rod • Master cylinder kit 2 1 5 3 5. Remove: • Cap (reservoir tank) • Inner cap (reservoir tank) • Diaphragm NOTE: To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose.
CHECKING THE FRONT AND REAR BRAKE CALIPER CHAS 1. Check: • brake caliper piston Rust/scratches/wear Replace the brake caliper piston. • brake caliper cylinder Scratches/wear Replace the brake caliper assembly. • brake caliper body Cracks/damage Replace the brake caliper assembly. • brake fluid delivery passage (brake caliper body) Obstruction Blow out with compressed air. s WARNING Whenever a brake caliper is disassembled, replace the piston seals. A 2.
CHAS CHECKING THE FRONT AND REAR BRAKE CALIPER 1 3. Check: • Master cylinder Wear/scratches Replace the caliper assembly. • Master cylinder body Cracks/damage Replace. • Oil delivery passage (caliper body) Blow out with compressed air. A Front B Rear 1 4. Check: • Master cylinder kit Scratches/Wear/Damage A Front B Rear Replace. 5. Check: • Reservoir tank Cracks/damage Replace. • Diaphragm (Front) Wear/damage Replace. 2 6.
CHECKING THE FRONT AND REAR BRAKE CALIPER CHAS NOTE: • Replace the pad spring as a set if pad replacement is required. • Replace the pads as a set if either if found to be worn to the wear limit. 8. Inspect: • Brake disc Galling/damage Replace. 1 9. Measure: • Brake disc deflection Out of specification Inspect wheel runout. If wheel runout is in good condition, replace. Maximum deflection: 0.15mm (0.006in.) • Brake disc thickness Out of specification Replace. Minimum thickness: Front: 3.
ASSEMBLING AND INSTALLING THE FRONT AND REAR BRAKE CALIPER CHAS ASSEMBLING AND INSTALLING FRONT AND REAR BRAKE CALIPER THE s WARNING • Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components as they will cause the piston seals to swell and distort. • Whenever a brake caliper is disassembled, replace the brake caliper piston seals. Recommended brake fluid DOT 4 Front brake 1.
ASSEMBLING AND INSTALLING THE FRONT AND REAR BRAKE CALIPER CHAS 4. Install: • Piston seal • Dust seal • Clip • Caliper piston s WARNING Always use new piston seal and dust seal. CAUTION Install the clip into the slot on the caliper body correctly. 5. Install: • Caliper bracket Caliper bracket: 35 Nm (3.5 m•kg, 25ft•lb) 2 1 6. Install: • Pad springs • Brake pads Refer to the “BRAKE PAD REPLACEMENT” section. 7.
ASSEMBLING AND INSTALLING THE FRONT AND REAR BRAKE CALIPER CHAS 8. Install: • Copper washers • Brake hose • Union bolt 2 Union bolt: 26 Nm (2.6m•kg, 19ft•lb) 3 1 CAUTION When installing the brake hoses to the caliper and master cylinder lightly touch the brake pipe with the projections on them. s WARNING • Proper hose routing is essential to insure safe machine operation. Refer to “CABLE ROUTING” • Always use new copper washers. 9.
ASSEMBLING AND INSTALLING THE FRONT AND REAR BRAKE CALIPER CHAS 10. Bleed: • brake system Refer to “AIR BLEEDING” section. 11. Check: • brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level. Refer to “BRAKE FLUID INSPECTION” in chapter 3. ”Lower” level line. 12. Install: • Diaphragm • Cap (Master cylinder) Screw (Master cylinder): 2 Nm (0.2m•kg, 1.4ft•lb) (a) 13. Adjust: • Front brake lever free play 2 1 Free play: 2~5mm (0.08~0.
ASSEMBLING AND INSTALLING THE FRONT AND REAR BRAKE CALIPER CHAS ASSEMBLING AND INSTALLING FRONT AND REAR BRAKE CALIPER 1. Install: • Master cylinder kit • Push rod • Circlip • Dust boot • Brake hoses • Cooper washers • Union bolt • Reservoir tank 7 8 6 5 THE NOTE: At this time, teporarily tighten the union bolt 1 2 3 4 s WARNING Always use a new cooper washer 2.
ASSEMBLING AND INSTALLING THE FRONT AND REAR BRAKE CALIPER CHAS NOTE: When installing the caliper piston , be sure to have it’s open end facing the caliper cylinder 4. Install: • Caliper bracket • Rear wheel Refer to the “REAR WHEEL INSTALLATION” section. NOTE: Be sure the boss on the swingarm correctly engages with the locating slot on the caliper bracket. 1 1 5. Install: • Pad springs • Brake pads • Shim Refer to the “BRAKE PAD REPLACEMENT” section. 23 6.
ASSEMBLING AND INSTALLING THE FRONT AND REAR BRAKE CALIPER CHAS 7. Install: • Cooper washers • Brake hose • Union bolt • Protector (Caliper body) Union Bolt: 26 Nm (2.6 m•kg, 19 ft•lb) CAUTION When installing the brake hoses to the caliper and master cylinder , lightly touch the brake pipe with the projections on them. 3 4 s WARNING 2 • Proper hose routing is essential to insure safe machine operation. Refer to “CABLE ROUTING” section. • Always use new cooper washers.
ASSEMBLING AND INSTALLING THE FRONT AND REAR BRAKE CALIPER CHAS 9. Bleed: • brake system Refer to “AIR BLEEDING” section. 10. Check: • brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level. Refer to “BRAKE FLUID INSPECTION” in chapter 3. REAR 1 ”Lower” level line. 11. Install: • Diaphragm • Inner cap (Reservoir tank) • Cap (Master cylinder) 12. Adjust: • Rear brake pedal height (a) Pedal height: 15mm (0.95in) Below top of footrest.
BLEEDING THE HYDRAULIC BRAKE SYSTEM CHAS EAS00134 BLEEDING THE HYDRAULIC BRAKE SYSTEM s WARNING Bleed the hydraulic brake system whenever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. • brake operation is faulty. NOTE: • Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow.
BLEEDING THE HYDRAULIC BRAKE SYSTEM CHAS NOTE: Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend. h. Tighten the bleed screw and then release the brake lever or brake pedal. i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose. j. Tighten the bleed screw to specification. Bleed screw 6 Nm (0.6 m•kg, 4.3 ft•lb) k.
CHAS FRONT FORKS FRONT FORKS Damper rod Oil lock pieces Circlip 10 Dust seal 11 Oil seal Cap bolt O-ring Spacer Spring seat Fork spring Inner fork tube A FOR OIL (EACH): CAPACITY: 495 cm3 GRADE: FOR OIL 10W OR EQUIVALENT OIL LEVEL: 165.
REMOVAL/DISASSEMBLY CHAS REMOVAL s WARNING Support the motorcycle securely so there is no danger of it falling over. 1 Elevate the front wheel by placing a suitable stand under the engine. 2. Remove: • Brake caliper assembly 2 3. Loosen: • upper bracket pinch bolt • cap bolt • lower bracket pinch bolt 1 s WARNING 3 Before loosening the upper and lower bracket pinch bolts, support the front fork leg. 4. Remove: • front fork leg DISASSEMBLY 1.
REMOVAL/DISASSEMBLY CHAS 3. Drain: • Fork oil 1 2 4. Remove: • Retaining clip Use a thin slotted head screwdriver • Washer CAUTION Take care not to scratch the inner tube 1 2 5. Remove: • Bolt (Damper rod) • Cooper washer NOTE: Hold the damper rod to loosen the bolt (Damper rod) by the T-handle and the Holder Damper rod holder 90890-01388 T-handle 90890-01326 2 1 3 6.
DISASSEMBLY/CHECKING THE FRONT FORK LEGS CHAS 7. Remove: • Inner fork tube a. Hold the front fork leg horizontally. b. Securely clamp the brake caliper bracket in a vise with soft jaws. c. Separate the inner tube from the outer tube by pulling the inner tube forcefully but carefully. CAUTION • Excessive force will damage the oil seal and bushing. A damaged oil seal or bushing must be replaced.
CHECKING THE FRONT FORK LEGS/ASSEMBLING THE FRONT FORK LEGS CHAS 3. Check: • damper rod • piston ring Damage/wear Replace. Obstruction Blow out all of the oil passages with compressed air. • rebound spring Damage Replace. 2 3 1 4. Check: • cap bolt O-ring Damage/wear Replace. EAS00659 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. s WARNING • Make sure the oil levels in both front fork legs are equal.
ASSEMBLING THE FRONT FORK LEGS CHAS 2. Lubricate: • inner tube’s outer surface Recommended lubricant Fork oil 10W or equivalent 3. Tighten: • damper rod assembly bolt 62 Nm (6.2 m•kg, 45 ft•lb) LOCTITE® NOTE: While holding the damper rod assembly with the damper rod holder and T-handle, tighten the damper rod assembly bolt. Damper rod holder 90890-01388 T-handle 90890-01326 4.
ASSEMBLING THE FRONT FORK LEGS CHAS NOTE: • Before installing the oil seal, lubricate its lips with lithium-soap-based grease. • Lubricate the outer surface of the inner tube with fork oil. • Before installing the oil seal, cover the top of the front fork leg with a plastic bag 2 to protect the oil seal during installation. 6. Install: • oil seal clip NOTE: Adjust the oil seal clip so that it fits into the outer tube’s groove. 7.
ASSEMBLING THE FRONT FORK LEGS CHAS NOTE: • While filling the front fork leg, keep it upright. • After filling, slowly pump the front fork leg up and down to distribute the fork oil. 9. Install: • spring • spring seat • spacer • cap bolt 4 3 NOTE: 2 • Install the spring with the smaller pitch facing up. • Before installing the cap bolt, lubricate its O-ring with grease. • Temporarily tighten the cap bolt.
STEERING HEAD AND HANDLEBARS CHAS STERING HEAD AND HADLEBARS Handlebar Handlebar Handlebar Handlebar Handlebar Ring nut 10 Cover 11 Bearing race 12 Headlight stay grip (Right) grip (Left) holder (Upper) crown A TIGHTENING STEPS •Tightening ring nut 35Nm to 40Nm (3.5 to 4.0 m•kg, 25.6 to 29.3 ft•lb) •Loosen it fully •Retighten it 3Nm to 5Nm (0.3 to 0.5 m•kg, 2.2 to 3.
REMOVAL CHAS REMOVAL 1. Elevate the front wheel by placing a suitable stand under the engine. s WARNING Securely support the motorcycle so there is no danger of falling over 2. Remove: • Front wheel Refer to the “FRONT WHEEL REMOVAL” section. • Front fork Refer to the “FRONT FORK REMOVAL” section. 3. Remove: • Bolts (front fender) • Front fender • Washers 1 2 1 4. Remove: • Headlight cover • Headlightn lens unit 2 3 5. Disconnect: • Headlight lead • Auxiliary light lead 6.
REMOVAL CHAS 7. Remove: • Flasher lights (left and right) • Brake hose guide (From left side only) 8. Disconnect: • Speedometer cable 4 1 1 2 3 9. Remove: • Bands 10. Disconnect: • Meter leads • Handlebar switch leads • Main switch leads • Flasher relay leads 11. Remove: • Bands • Master cylinder assembly y 60 80 100 40 0 0 0 0 1 5 120 20 km/h 130 0 0008 12. Remove: • Brush guard 13. Disconnect: • Clutch cable (from clutch cable pivot) 14.
REMOVAL CHAS 15. Loosen: • Screws (throttle cable housing) 1 16. Remove: • Handlebar holders • Handlebars 1 NOTE: 2 For completely removal of the handlebar, be sure to clear the throttle cable housing 17. Remove: • Flange nut • Handlebar crown 1 2 18.
CHAS REMOVAL/INSPECTION 19. Remove: • Bearing cover • Ball race (Top-Upper) • Ball bearing (22pcs) INSPECTION 1. Wash the bearing in solvent. 2. Inspect: • Bearings • Bearing races Pitting/Damage Replace • Dust seal Wear/Damage Replace 2 1 2 Bearing race replacement steps: • Remove the bearing races on the head pipe using a long rod and the hammer as shown. • Remove the bearing race on the steering stern using the floor chinsel and the hammer as shown.
INSPECTION/INSTALLATION 4. Inspect: • Handlebar Cracks/Bend/Damage CHAS Replace s WARNING Do not attempt to straighten a bent handlebar as this may dangerously weaken the handlebar. Handlebar replacement steps: • Remove the hadlebar grip and handlebar switch (Left) and lever holder. • Install the lever holder and handlebar switch (Left) to a new handlebar. • Apply a light coat of an adhesive for rubber on the left handlebar end. • Install the handlebar grip.
INSTALLATION CHAS 3. Install: • Ball race (Upper-Lower) • Bearing cover • Under bracket • Ring nut 2 s WARNING 1 Hold the under bracket until its secured 4. Tighten: • Ring nut Tightening steps: • Tighten the ring nut using the Ring Nut Wrench Ring Nut Wrench: 90890-01403 NOTE: Set the torque wrench to the right nut wrench so that they form a right angle Ring Nut (Initial tightening): 35Nm to 40Nm (3.5 to 4.0 m·kg, 25.6 to 29.
INSTALLATION CHAS 6. Install: • Meter assembly Bolt (Meter assembly): 5Nm to 8Nm (0.5 to 0.8 m·kg, 3.6 to 5.8 ft·lb) 1 7. Install: • Front fork Refer to the “FRONT FORK INSTALLATION” section. Pinch Bolt (Under Bracket): 20 to 25Nm (2.0 to 2.5 m·kg, 14.6 to 18.3 ft·lb) NOTE: In this stage, temporarily tighten the pinch bolts (Handlebar crown). 8. Tighten: • Flange nut (Steering stem) • Pinch bolts (Handlebar crown) 2 Flange nut (Steering stem): 120 to 155 Nm (12 a 15.
INSTALLATION CHAS 9. Install: • Handlebar • Handlebar holders Bolt (Handlebar holder): 12 to 28 Nm (1.2 a 2.8 m·kg, 8.80 to 20.5ft·lb) NOTE: The handlebar should be installed in the position assigned by the position mark CAUTION First tighten the bolts on the front side of the handlebar holder, and then tighten the bolts on the rear side.
INSTALLATION CHAS 12. Install: • Headlight lens unit 13. Install: • Front wheel Refer to the “FRONT WHEEL INSTALLATION” section. Front wheel axle: 80 to 100 Nm (8.0 a 10.0 m·kg,58.6 to 73.3ft·lb) Axle security bolts: 7.5 to 12 Nm (0.75 to 1.2 m·kg, 5.5 to 8.8.5ft·lb) 14. Adjust: • Clutch cable free play Refer to the “CLUTCH ADJUSTMENT” section in chapter 3. 3 Free play: 2~3mm (0.08~0.
REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM Rear shock absorber assembly Spring Bush A SPRING PRELOAD (INSTALLED): FOR DT125RE STANDARD LENGTH: 230 mm MINIMUM LENGTH: 220 mm MAXIMUM LENGTH: 235 mm A SPRING PRELOAD (INSTALLED): FOR DT125X STANDARD LENGTH: 244 mm MINIMUM LENGTH: 234 mm MAXIMUM LENGTH: 249 mm 30 to 35 Nm (3,0 to 3,5 m • kg, 22 to 25,6 ft•lb) 4-55 CHAS
REAR SHOCK ABSORBER AND SWINGARM CHAS Bearing Oil seal 10 Bush 11 Plain washer 12 Shim 13 Thrust cover Swingarm Relay arm Connecting arm Chain case Chain guard Chain guide Collar 3 to 5 Nm (0,3 to 0,5 m • kg, 2,2 to 3,6 ft•lb) 2 to 4 Nm (0,2 to 0,4 m • kg, 1,46 to 2,9 ft•lb) 3 to 5 Nm (0,3 to 0,5 m • kg, 2,2 to 3,6 ft•lb) 80 to 100 Nm (8 to 10 m • kg, 58,6 to 73,3 ft•lb) 45 to 70 Nm (4,5 to 7 m • kg, 33 to 51,3 ft•lb) 45 to 70 Nm (4,5 to 7 m • kg, 33 to 51,3 ft•lb) 4-56
HANDLING THE REAR SHOCK ABSORBER/DISPOSING OF A REAR SHOCK ABSORBER/REMOVING CHAS EAS00686 HANDLING THE REAR SHOCK ABSORBER s WARNING This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber.
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY CHAS NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: • Bolt (Connecting arm swingarm) (from swingarm side) 1 3. Remove: • Bolt (Shock absorber Lower) s WARNING When removing the lower bolt hold the swingarm so that it does not drop downwards when the lower bolt is removed. 1 2 4. Remove: • Bolt (Shock absorber Upper) 1 5.
REMOVING THE SWINGARM ASSEMBLY CHAS REMOVING THE SWINGARM ASSEMBLY s WARNING Securely support the motorcycle so there is no danger of falling it over 1. Elevate the rear wheel by placing a suitable stand under the engine. 2. Remove: • Rear shock absorber Refer to the “REAR SHOCK ABSORBER” section. 3. Remove: • Rear wheel Refer to the “REAR WHEEL REMOVAL” section. 1 4. Remove: • Brake hose guides • Mud guard 5. Remove: • Protector (Brake caliper) • Brake caliper assembly 1 2 6.
REMOVING THE SWINGARM ASSEMBLY CHAS 7. Check: • Swingarm free play Inspection steps • Check the tightening torque of the pivot shaft (swingarm) securing nut Nut (Swingarm-Pivot shaft): 80 to 100Nm (8 to 10 m·kg; 58.6 to 73.3lb·ft) • Check the swingarm side play by moving it from side to side. If side play noticeable, check the inner collar, bearing, bushing and thrust over, or adjust the shim. Side play (At the end of the swingarm): 1mm (0.
REMOVING THE SWINGARM ASSEMBLY CHAS 10. Remove: • Relay arm 11. Remove: • Chain protector 1 12.
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY CHAS EAS00695 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: • rear shock absorber rod Bends/damage Replace the rear shock absorber assembly. • rear shock absorber Gas leaks/oil leaks Replace the rear shock absorber assembly. • spring Damage/wear Replace the rear shock absorber assembly. • bushings Damage/wear Replace. • dust seals Damage/wear Replace. • bolts Bends/damage/wear Replace. EAS00707 CHECKING THE SWINGARM 1.
CHECKING THE SWINGARM 1 3 4 CHAS 4. Check: • dust covers • spacer • washers • oil seals Damage/wear Replace. • bearings Damage/pitting Replace. 2 2 4 3 1 5. Check: • connecting arms • relay arm Damage/wear Replace. 1 1 9 8 2 6. Check: • bearings • oil seals Damage/pitting 2 1 1 2 4-63 Replace.
CHECKING THE SWINGARM/INSTALLING THE SWINGARM 7. Check: • spacers Damage/scratches CHAS Replace. EAS00711 INSTALLING THE SWINGARM 1. Lubricate: • bearings • spacers • dust covers • pivot shaft Recommended lubricant Molybdenum disulfide grease 2. Install: • relay arm 45 to 70 Nm (4.5 to 7.0m•kg, 33 to 95.5ft•lb) • connecting arms 45 to 70 Nm (4.5 to 7.0m•kg, 33 to 95.5ft•lb) NOTE: Install the connecting arm front bolt from the right. 3.
INSTALLING THE SWINGARM CHAS 4. Adjust: • drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” in chapter 3. Drive chain slack DT125RE 40~55mm (1,77~2,16in.) DT125X 25~40mm (0,98~1,58 in.
DRIVE CHAIN AND SPROCKETS CHAS DRIVE CHAIN AND SPROCKETS Drive sprocket Chain joint Drive chain A B C D E DRIVE CHAIN TYPE 428V2 No.
REMOVING THE DRIVE CHAIN CHAS REMOVING THE DRIVE CHAIN 1. Stand the motorcycle on a level surface. s WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: • Crankcase cover (left) 1 3. Straighten: • Lock washer tab 4. Loosen: • Nut (drive sprocket) 1 2 NOTE: When loosening the drive sprocket nut, apply the rear brake pedal and transmission gear to the 6th position. 5.
REMOVING THE DRIVE CHAIN/CHECKING THE DRIVE CHAIN CHAS 8. Remove: • Chain guide rollers (Upper and lower) EAS00709 CHECKING THE DRIVE CHAIN 1. Measure: • ten-link section a of the drive chain Out of specification Replace the drive chain. Ten-link drive chain section limit (maximum) 120 mm (4.72 in) 2. Check: • drive chain Stiffness Clean and lubricate or replace. 3. Clean: • drive chain a. Wipe the drive chain with a clean cloth. b.
CHECKING THE DRIVE CHAIN CHAS CAUTION This motorcycle has a drive chain with small rubber O-rings between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain. High-pressure methods could force dirt or water into the drive chain’s internals, and solvents will deteriorate the O-rings. A coarse brush can also damage the O-rings. Therefore, use only kerosene to clean the drive chain.
INSTALLING THE DRIVE CHAIN CHAS EAS00713 INSTALLING THE DRIVE CHAIN 1. Lubricate: • drive chain • master link Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains 2 2. Install: • drive chain • drive sprocket • washer • drive sprocket nut 3 4 60 Nm (6.0 m•kg, 43 ft•lb) NOTE: While applying the rear brake, tighten the drive sprocket nut. 3.
INSTALLING THE DRIVE CHAIN CHAS CAUTION A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident. Therefore, keep the drive chain slack within the specified limits.
ENG
5
ENG CHAPTER 5 ENGINE ENGINE REMOVAL……………………………………………………………………5-1 SIDE COVERS …………………………………………………………………5-1 COOLANT ………………………………………………………………………5-1 TRANSMISSION OIL …………………………………………………………5-1 EXHAUST PIPE ………………………………………………………………5-2 CARBURETOR …………………………………………………………………5-2 AUTOLUBE PUMP CABLE AND HOSE ……………………………………5-2 CLUTCH CABLE ………………………………………………………………5-3 Y.P.V.S.
ENGINE REMOVAL ENG ENGINE OVERHAUL ENGINE REMOVAL NOTE: It’s not necessary to remove the engine in order to remove the following components: • Cylinder head • Cylinder • Piston and piston ring • Power valve • Clutch • Primary drive gear • Kick axle • Shift shaft • Magneto rotor • Stator • Autolube pump SIDE COVERS 1. Remove: • Side cover (right) • Side cover (left) • Seat COOLANT 1. Drain: • Coolant Refer to the “COOLANT REPLACEMENT” section in chapter 3. TRANSMISSION OIL 1.
ENGINE REMOVAL ENG EXHAUST PIPE 1. Loosen: • Bolts (Exhaust holder) • Screw (muffler joint) 2. Remove: • A.I.S. hose • Bolts (Exhaust pipe) • Exhaust pipe 1 CARBURETOR 1. Remove: • Fuel tank • Carburetor Refer to the “CARBURETOR REMOVAL” section in chapter 6. 2 1 3 AUTOLUBE PUMP CABLE AND HOSE 1. Remove: • Autolube pump cover 1 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 of the oil tank.
ENGINE REMOVAL ENG CLUTCH CABLE 1. Loosen: • Adjuster (Clutch cable) 2 2. Loosen: • Adjuster lock nuts (Clutch cable) 4 3. Disconnect: • Clutch cable (from clutch push lever and cable guide ). 2 1 3 Y.P.V.S. CABLES 1. Remove: • Pulley cover (Power valve) 1 2. Remove: • Pulley (Power valve) 3 1 2 Removal steps • Loosen both locknuts and turn in both adjusters . • Insert a pin (Ø4mm.(Ø0.
ENGINE REMOVAL ENG 3. Disconnect: • Servomotor unit leads 4. Remove: • Servomotor unit • Adjuster (Y.P.V.S. cable) • Pulley housing 3 2 RADIATOR HOSES 1. Disconnect: • Radiator hose (Inlet) 1 2. Disconnect: • Radiator hose (Outlet) 1 LEADS 1. Disconnect: • Battery lead (Negative) 1 2.
ENGINE REMOVAL ENG 3. Disconnect: • CDI magneto leads 1 4. Remove: • Bands DRIVE CHAIN 1. Remove: • Change pedal • Crankcase cover (Left) • Gasket (Crankcase cover) 1 2 2. Straighten: • Lock washer tab 3. Loosen: • Nut (Drive sprocket) 1 2 1 NOTE: When loosening the nut (Drive sprocket) apply the rear brake pedal and transmission gear to the 6th position 4. Remove: • Drive chain • Nut (Drive sprocket) • Lock washer • Drive sprocket • Spacer collar 4 2 5 3 ENGINE REMOVAL 1.
ENGINE REMOVAL/ ENGINE DISASSEMBLY 2. Remove: • Bolt (Engine mount • Pivot shaft ENG Rear lower) NOTE: The engine and swingarm are installed using the same pivot shaft. Therefore, take care so that the pivot shaft is pulled, not entirely, out, but for enough to set the engine free. 2 1 3.
ENGINE DISASSEMBLY ENG 2. Remove: • Spark plug • Thermo unit 2 1 s WARNING Handle the thermo unit with special care. Never subject it to strong or allow it to be dropped. In case of being dropped, it must be replaced. 3. Remove: • Cover (thermostatic valve) 4. Remove: • Gasket • Thermostatic valve • O-ring 3 2 5 1 5. Remove: • Cylinder head • Gasket (Cylinder head) 2 NOTE: 3 • Loosen the nuts starting with the highest numbered one.
ENGINE DISASSEMBLY ENG EAS00253 3 REMOVING THE CYLINDER AND PISTON 1. Remove: • piston pin clip • piston pin • piston 2 1 CAUTION Do not use a hammer to drive the piston pin out. NOTE: • Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase. • Before removing the piston pin, deburr the piston pin clip’s groove and the piston’s pin bore area.
ENGINE DISASSEMBLY 1. Remove: • Water outlet pipe • O-Ring (from water outlet pipe) Right side Left side 2 1 2. Remove: • Crankcase cover (Right) • Dowel pins • Gasket (Crankcase cover) 1 2 3.
ENGINE DISASSEMBLY ENG NOTE: 1 • 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 holder 2 Universal Clutch Holder 90890-04086 4. Straighten: • Lock washer tab 5.
ENGINE DISASSEMBLY 1 2 ENG 8. Remove: • Spacer collar • Oil seal retainer 2 CLUTCH PUSH LEVER 1. Unhook: • Return spring (Push lever) 3 4 2. Remove: • Push lever (Clutch) • Return spring • Washer 1 SHIFT SHAFT AND STOPPER LEVER NOTE: With the engine mounted, the shift shaft can be maintained by removing the following parts. • Brake pedal • Radiator hose (Outlet) • Autolube pump cable and hoses • Crankcase cover (Right) • Clutch 1.
ENGINE DISASSEMBLY ENG ROTOR NOTE: With the engine mounted, the rotor can be maintained by removing the following parts: • Crankcase cover (Left). 1. Remove: • Nut (Rotor) • Plain washer NOTE: Hold the rotor to loosen the nut (Rotor) by the Universal Rotor Holder Universal Rotor Holder 90890-01235 2. Remove: • Rotor • Woodruff key Rotor Puller 90890-01189 3. Disconnect: • Neutral switch lead 4.
ENGINE DISASSEMBLY ENG 1. Remove: • Carburetor joint • Reed valve assemby • Gasket 1 3 2 CRANKCASE RIGHT 1. Remove: • Crankcase (Right) NOTE: • Loosen the bolts starting with the highest numbered one. • Loosen each bolt 1/4 turn and remove them after all bolts are loosened.
ENGINE DISASSEMBLY ENG CAUTION • • • • • Use soft hammer to tap on the case half. Tap only on reinforced portions of case. Don’t tap on gasket mating surface. Work slowly and carefully. Make sure the case halves separate evenly. If one end “hangs up”, take pressure off the push screw, realign, and start over. If the cases don’t separate, check for a remaining case screw or fitting. • Don’t force. 2. Remove: • Dowel pins • Damper collar 1 3.
ENGINE DISASSEMBLY 3. Remove: • Balancer weight 1 2 ENG CRANKSHAFT 1. Remove: • Crankshaft 1 NOTE: • Remove the crankshaft with the Crankcase Separating Tool • Fully tighten the tool holding bolts, but make sure the tool body is parallel with the case. If necessary, one screw may be backed out slightly to level tool body.
ENGINE DISASSEMBLY ENG 1. Remove: • Hose guide • Power valve holder (Right) 2 2. Remove: • Bolt (Power valve) NOTE: When loosening the power valve connecting bolt , lock the valve by inserting a wooden pice into the exhaust port. 1 2 3.
ENGINE DISASSEMBLY/ INSPECTION AND REPAIR ENG 1. Remove:(ref. oilpump) • Circlip • Drive gear (autolube pump) • Circlip • Oil seal • Collar • Pin • Drive shaft (autolube pump) • O-Ring • Autolube pump 8 5 7 6 4 3 1 2 1 EAS00227 CHECKING THE CYLINDER HEAD 1. Eliminate: • combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damaging or scratching: • spark plug bore threads • valve seats 2.
INSPECTION AND REPAIR ENG a. Place a straightedge and a thickness gauge across the cylinder head. b. Measure the warpage. c. If the limit is exceeded, resurface the cylinder head as follows. d. Place a 400 ~ 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern. NOTE: To ensure an even surface, rotate the cylinder head several times.
INSPECTION AND REPAIR ENG Standard Cylinder Bore “C” Taper “T” 56.00 ~ 56.02 mm (2.204 ~ 2.205 in) — Limit 0.05 mm (0.001968 in) 0.01 mm (0.00039 in) Out of — round “R” C = maximum of D1 ~ D2 T = maximum of D1 or D2 - maximum of D5 or D6 R = maximum of D1, D3 or D5 - minimum of D2, D4 or D6 b. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. c. Measure piston skirt diameter “P” with the micrometer.
ENG INSPECTION AND REPAIR NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. Piston ring side clearance Top ring 0.02 ~ 0.060 mm (0.0008 ~ 0.0024 in) 2nd ring 0.035 ~ 0.070 mm (0.0014 ~ 0.0028 in) 2. Install: • piston ring (into the cylinder) NOTE: Level the piston ring into the cylinder with the piston crown. 3. Measure: • piston ring end gap Out of specification ring.
INSPECTION AND REPAIR ENG Piston ring oversize • Top and 2nd piston rings The size of the top and 2nd oversize piston rings is stamped on the top of each ring. Oversize 25 mm Oversize 50 mm PISTON PIN AND BEARING 1. Lubricate: • Small end bearing • Piston pin (Lightly) 2. Install: • Small end bearing • Piston pin (into small end of connecting rod) 2 1 3 3. Check: • Free play There should be no noticeable play.
INSPECTION AND REPAIR ENG 2. Measure: • friction plate thickness Out of specification Replace the friction plates as a set. NOTE: Measure the friction plate at four places. Friction plate thickness 2.9 ~ 3.1 mm (0.11 ~ 0.12 in) : 2.7 mm EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: • clutch plate Damage Replace the clutch plates as a set. 2.
INSPECTION AND REPAIR ENG 2. Measure: • clutch spring free length Out of specification Replace the clutch springs as a set. Clutch spring free length 34,5mm (1.36 in) EAS00284 CHECKING THE CLUTCH HOUSING 1. Check: • clutch housing dogs Damage/pitting/wear Deburr the clutch housing dogs or replace the clutch housing. NOTE: Pitting on the clutch housing dogs will cause erratic clutch operation. 2. Check: • bearing Damage/wear Replace the bearing and clutch housing.
INSPECTION AND REPAIR ENG EAS00288 1 CHECKING THE CLUTCH PUSH RODS 1. Check: • O-ring • short clutch push rod • long clutch push rod • ball Cracks/damage/wear Replace the defective part(s). 2 4 3 2. Measure: • long clutch push rod bending limit Out of specification Replace the long clutch push rod. Long clutch push rod bending limit 0.15 mm (0.0059 in) EAS00292 CHECKING THE PRIMARY DRIVE 1.
INSPECTION AND REPAIR ENG EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. 1. Check: • shift fork cam follower • shift fork pawl Bends/damage/scoring/wear Replace the shift fork. 2 1 2. Check: • shift fork guide bar Roll the shift fork guide bar on a flat surface. Bends Replace. s WARNING Do not attempt to straighten a bent shift fork guide bar. 3.
INSPECTION AND REPAIR ENG EAS00423 CHECKING THE TRANSMISSION 1. Measure: • main axle runout (with a centering device and dial gauge ) Out of specification Replace the main axle. Main axle runout limit 0.08 mm (0.0031 in) 2. Measure: • drive axle runout (with a centering device and dial gauge ) Out of specification Replace the drive axle. Drive axle runout limit 0.08 mm (0.0031 in) 3. Check: • transmission gears Blue discoloration/pitting/wear Replace the defective gear(s).
INSPECTION AND REPAIR ENG EAS00328 CHECKING THE SHIFT SHAFT 1. Check: • shift shaft • shift pawls Bends/damage/wear Replace. 2. Check: • stopper lever Roller turns roughly Replace Bend/damage Replace 3. Check: • Return spring (shift shaft) • Return spring (Shift pawls) • Return spring (Stopper lever) Wear/damage Replace. 5 2 1 4 3 6 EAS00394 CHECKING THE CRANKSHAFT AND CONNECTING ROD 1.
ENG INSPECTION AND REPAIR 3. Measure: • crankshaft width Out of specification crankshaft. Replace the Crankshaft width 57.9~57.95 mm (2.279~2.281 in) 4. Check: • crankshaft sprocket Damage/wear Replace the crankshaft. • bearing Cracks/damage/wear Replace the crankshaft. 1 2 2 AUTOLUBE PUMP Wear or an internal malfunction may cause pump output to vary from the factory settings. This situation is, however extremely dangerous.If improper output is suspected, inspect the following: 1.
ENG INSPECTION AND REPAIR 3. Check: • Pump output. Out of specification Adjust. Minimum output/200 stroke: 0.38 ~ 0.50cm3 (0.02 ~ 0.03cu.in) Maximum output/200stroke: 4.65 ~ 5.15cm3 (0.28 ~ 0.31cu.in) 4. Check: • Drive gear (Autolube pump) • Drive shaft (Autolube pump) • Pivot collar (Drive shaft) Wear/damage Replace. 8 5 7 6 4 3 1 2 1 POWER VALVE 1. Eliminate: • Score marks and lacquer deposits. • Carbon deposits.
INSPECTION AND REPAIR ENG EAS00399 CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: • crankcase Cracks/damage Replace. • oil delivery passages Obstruction Blow out with compressed air.
ENGINE ASSEMBLY AND ADJUSTMENTS AUTOLUBE PUMP Collar O-Ring 10 Screw 11 Oil seal 12 Autolube pump gear 13 Pin 14 Circlip Autolube pump End cap Hose Clip Adjusting bolt Washer Drive shaft 5 Nm (0.5 m • kg, 3.
ENGINE ASSEMBLY AND ADJUSTMENTS ENG AUTOLUBE PUMP 1. Lubricate: • Oil seal lips 8 Lightweight Lithium-soap base grease 5 2. Install: • Drive shaft (autolube pump) • Circlip • Pin • Drive gear (autolube pump) • Circlip • O-ring • Autolube pump 7 6 4 3 1 2 Screw (Autolube pump): 5 Nm (0.5m•kg; 3.
ENGINE ASSEMBLY AND ADJUSTMENTS ENG POWER VALVE Pulley housing Pulley Pulley cover Y.P.V.S. Cable Power valve Power valve holder (right) O-ring Power valve holder (left) Gasket seal 7 Nm (0.7 m • kg, 5.1ft•lb) A USE NEW ONE 10 Nm (1.0 m • kg, 7.2ft•lb) A USE NEW ONE 7 Nm (0.7 m • kg, 5.1ft•lb) 7 Nm (0.7 m • kg, 5.
ENGINE ASSEMBLY AND ADJUSTMENTS 2 ENG POWER VALVE 1. Lubricate: • Power valve connecting rod 2 Molybdenum Disulfide Grease 3 1 4 • O-rings • Gasket seal • Bushes (Power valve shaft contact surface) • Power valve surface 3 Lightweight Lithium-soap base grease 3 2 2. Install: • Power valve holder (Left) • Gasket seal (to left power valve) • Dowel pins • Power valve (Left and right ) (to cylinder block) • Bolt (Power valve) 5 4 3.
ENGINE ASSEMBLY AND ADJUSTMENTS ENG CRANKSHAFT/PISTON/BALANCER A B D Balancer gear Bearing Straight key Balancer weight Bearing Drive gear Oil seal Collar Bearing 10 Piston ring set 11 Piston 12 Piston pin 13 Piston pin clip 14 Small end bearing 15 Staight key 16 Crank (Right) PISTON TO CYLINDER CLEARANCE: 0.045~0.050 mm(0.0018~0.0020in) EN GAP (INSTALLED): Top ring 0.30~0.45mm(0.012~0.018in) 2rd ring 0.30~0.45mm(0.012~0.
ENGINE ASSEMBLY AND ADJUSTMENTS ENG TRANSMISSION A 19 Special washer 20 Oil seal 21 Drive sprocket 22 Lock washer Cylindrical bearing Main axle 2nd pignion gear 3rd 4th pignion gear 5th pignion gear 6th pignion gear Plain washer Circlip Bearing 10 Drive axle 11 1st wheel gear 12 2nd wheel gear 13 3rd wheel gear 14 4th wheel gear 15 5th wheel gear 16 6th wheel gear RUNOUT LIMIT 008mm(0.003in) B USE NEW ONE B A USE NEW ONE RUNOUT LIMIT 0.08mm(0.
ENGINE ASSEMBLY AND ADJUSTMENTS SHIFTER Shift fork Shift fork Shift fork Shift fork Shift cam Stopper lever Return spring Securing bolt Shift fork #1 14 Nm (1.
ENGINE ASSEMBLY AND ADJUSTMENTS ENG EAS00408 INSTALLING THE CRANKSHAFT 1. Install: • crankshaft assembly NOTE: • Install the crankshaft assembly with the crankshaft installer pot, crankshaft installer bolt, adapter (M12) and spacer. Crankshaft installer pot 90890-01274 Crankshaft installer bolt 90890-01275 Adapter (M12) 90890-01278 Spacer 90890-01288 2.
ENGINE ASSEMBLY AND ADJUSTMENTS ENG NOTE: • The embossed marks mqRA.anq on the shift forks should face towards the left side of the engine and be in the following sequence: “3”, “2”, “1”. • The grooved side of the shift fork guide bar should face towards the right side of the engine. CRANKCASE (RIGHT) 1. Install: • Bearing retainer 1 Screw (Bearing retainer): 7 Nm (0.7 m•kg; 5.1 ft•lb) Use Loctite® 2.
ENGINE ASSEMBLY AND ADJUSTMENTS ENG CAUTION Before installing and torquing the bolts (Crankcase) be sure to check wheter the transmission is functioning properly by manually rotating the shift cam either way. NOTE: Tighten the bolts (Crankcase) in stage, using a crisscross pattern. Bolts(Crankcase): 8 Nm (0.8 m•kg; 5.8 ft•lb) 5. Apply: • 2 stroke oil (to crank pin, bearing and oil delivery hole). 6. Check: • Crankshaft and transmission operation Unsmooth operation Repair. REED VALVE 1.
ENGINE ASSEMBLY AND ADJUSTMENTS MAGNETO ROTOR Stator assembly Rotor Washer 80 Nm (8.
ENGINE ASSEMBLY AND ADJUSTMENTS ENG MAGNETO ROTOR 1. Install: • Stator Screw(Stator): 8 Nm (0.8 m•kg; 5.8 ft•lb) Use Loctite® 1 2. Connect: • Neutral switch lead 1 3. Install: • Woodruf key • Rotor • Plain washer • Nut (Rotor) 1 NOTE: 2 3 • Clean the tapered portions of the crankshaft and rotor. • When installing the rotor, make sure the key is properly seated in the key way of the crankshaft.
ENGINE ASSEMBLY AND ADJUSTMENTS ENG SHIFT SHAFT Shift tank Spring Circlip Oil seal Change pedal 15 Nm (1.
ENGINE ASSEMBLY AND ADJUSTMENTS ENG STOPPER LEVER AND SHIFT SHAFT 1. Install: • Return spring • Stopper lever 2 14Nm (1.4m•kg, 10 ft•lb) 1 NOTE: • Mesh the stopper lever with the shift cam. 2. Install: • shift shaft 1 NOTE: • Lubricate the oil seal lips with lithiumsoap-based grease. 1 3. Check: • shift pawl position Gaps a and b are not equal Replace the defective part(s). 1 (a) (b) Shift cam CLUTCH PUSH LEVER 1.
ENGINE ASSEMBLY AND ADJUSTMENTS 2. Install: • Washer • Return spring • Push lever 3. Set the return spring to the spring hook .
ENGINE ASSEMBLY AND ADJUSTMENTS ENG CLUTCH AND PRIMARY DRIVE GEAR 10 Thrust plate 11 Conical spring washer 12 Push rod #1 13 Ball 14 Push rod #2 15 Push lever axle 16 Return spring 17 Bearing 18 primary drive gear Clutch spring Pressure plate Push plate Clutch plate Friction plate Clutch damper Clutch boss Thrust washer Clutch housing A CLUTCH SPRING FREE LENGHT LIMIT: 34.5 mm(1.26in) B FRICTION PLATE WEAR LIMIT 2.7 mm(0.106in) C CLUTCH PLATE WEAR LIMIT: 0.05 mm(0.
ENGINE ASSEMBLY AND ADJUSTMENTS ENG BALANCER GEAR, PRIMARY DRIVE GEAR AND CLUTCH 1. Install: • Oil seal retainer • Spacer collar 3 1 2 Oil Seal Retainer: 16 Nm (1.6 m•kg; 11 ft•lb) NOTE: Before installing the spacer collar greae the oil seal lip . 2. Install: • Straight key • Drive gear (Balancer weight) • Baffle plate 2 1 Screw (Baffle Plate): 8 Nm (0.8 m•kg; 5.8 ft•lb) Use Loctite® 3 3.
ENGINE ASSEMBLY AND ADJUSTMENTS ENG s WARNING Always use a new lock washer 5. Tighten: • Nut (Primary drive gear) • Nut (Balancer driven gear) 3 2 Nut (Primary drive gear): 80 Nm (8.0 m•kg; 58 ft•lb) Nut (Balancer driven gear): 55 Nm (5.5 m•kg; 40 ft•lb) 1 NOTE: Hold the rotor to tighten the nut (Primary drive gear) and nut (Balancer driven gear) by the Universal Rotor Holder Universal Rotor Holder: 90890-01235 6. Bend the lock washer tab along the nuts flats. 98 8 7.
ENGINE ASSEMBLY AND ADJUSTMENTS 98 8 5 4 8. Install: • Push rod #2 • Ball • Conical spring washer • Thrust plate • Clutch housing • Thrust washer • Clutch boss • Lock washer • Nut (Clutch boss) 7 3 2 ENG 1 s WARNING Always use a new lock washer NOTE: • Be careful to install the conical spring washer in proper position as shown. • Install the lock washer tab onto the indentation of the clutch boss. 9. Tighten: • Nut (Clutch boss) 2 Nut (Clutch boss): 70 Nm (7.
ENGINE ASSEMBLY AND ADJUSTMENTS 3 ENG 11. Install: • Friction plates • Clutch plates • Clutch damper 2 1 Installation steps • Install the friction plate onto the clutch boss. • Install the clutch plate so as to locate the projection at #1. • Install the friction plate with the larger inside diameter onto the clutch boss. • Install the clutch damper onto the clutch plate. • Install the remaining clutch plates and friction plates alternately on the clutch boss.
ENGINE ASSEMBLY AND ADJUSTMENTS ENG NOTE: Tighten the bolts (pressure plate) in stage, using a crisscross pattern 14. Adjust: • Clutch mechanism free play Refer to the “CLUTCH MECHANISM ADJUSTMENT” section in chapter 3. 15.
ENG ENGINE ASSEMBLY AND ADJUSTMENTS CYLINDER HEAD AND CYLINDER Spark plug Cylinder head Cylinder head gasket Cylinder Cylinder gasket A SPARK PLUG B MANUFACTURER NGK C TYPE: BR9ES 20 Nm (2.0m • kg, 14ft•lb) 22 Nm (2.2m • kg, 16ft•lb) F D PLUG GAP: 0.7~0.8mm (0.028~0.0012in) E CYLINDER HEAD WARRAGE LIMIT: 0.03mm(0.0012in) USE NEW ONE G The “UP” mark on the gasket musb be facing up 28 Nm (2.8m • kg, 20ft•lb) 13 Nm (1.3m • kg, 9.4ft•lb) F USE NEW ONE 13 Nm (1.3m • kg, 9.
ENGINE ASSEMBLY AND ADJUSTMENTS PISTON, CYLINDER AND CYLINDER HEAD 1. Install: • Bearing • Piston • Piston pin • Piston pin clips 2 4 ENG NOTE: 3 • Apply engineoil tothe piston pin, bearings and piston skirts areas. • Make sure the arrow mark on the piston points towards the exhaust side of the cylinder. • Before installing the piston pin clip, cover the crankcase opening with a clean rag to prevent the clip from falling into the crankcase.
ENGINE ASSEMBLY AND ADJUSTMENTS ENG 3. Install: • Dowel pins NEW (Cylinder) • Gasket 1 s WARNING Always use a new gasket 2 4. Install: • Cylinder • Clutch cable guide 1 NOTE: Install the cylinder with one hand while compressing the piston rings with the other hand 5. Tighten: • Nuts (cylinder) Nut (Cylinder): 28 Nm (2.8 m•kg, 20 ft•lb) NOTE: Tighten the nuts ins stage using a crisscross pattern. 6.
ENGINE ASSEMBLY AND ADJUSTMENTS ENG 8. Install: • O-ring • Thermostatic valve • Gasket NOTE: Apply the lithium soap base grease to the Oring 1 s WARNING • Always use a new O-ring. • Always use a new gasket. 3 2 9. Install: • Cover (Thermostatic valve) Screw (Thermostatic Valve Cover): 8 Nm (0.8 m•kg, 5.8 ft•lb) 1 10. Install: • Spark plug • Thermo unit 2 Spark plug: 20 Nm (2.0 m•kg, 14 ft•lb) Thermo unit: 15 Nm (1.
ENGINE ASSEMBLY AND ADJUSTMENTS ENG 11. Install: • Hoses (Inlet and outlet ) Union bolt: 8 Nm (0.8 m•kg, 5.8 ft•lb) REMOUNTING THE ENGINE Reverse the “ENGINE REMOVAL” procedure. Note the following points: 1. Install: • Engine assemb (to right side) • Mounting bolts Pivot shaft : 90 Nm (9.0 m•kg, 65 ft•lb) Bolt (Rear Lower): 33 Nm (3.3 m•kg, 24 ft•lb) Bolt (Front): 58 Nm (6.8 m•kg, 42 ft•lb) Bolt (Engine stay Upper): 33 Nm (3.
ENGINE ASSEMBLY AND ADJUSTMENTS ENG 3. Bend the lock washer tab along the nut flats 4. Install: • Gasket (Crankcase cover) • Crankcase cover (Left) • Change pedal NOTE: Tighten the screws (Crankcase cover) in stage, using a crisscross pattern. 2 1 Screw (Crankcase cover): 8 Nm (0.8 m•kg, 5.8 ft•lb) Bolt (Change pedal): 15 Nm (1.5 m•kg, 11 ft•lb) 5. Adjust: • Drive chain slack Refer to the “DRIVE CHAIN SLACK ADJUSTMENT” section in chapter 3. 2 6.
ENGINE ASSEMBLY AND ADJUSTMENTS ENG 8. Connect: • Servomotor unit lead • Cables (Y.P.V.S.) (to power valve pulley) 9. Install: • Pulley (power valve) 1 1 Bolt (Power valve pulley): 10Nm (1.0 m•kg, 7.2 ft•lb) 2 10. Adjust: • Y.P.V.S. cables Refer to the “Y.P.V.S. CABLE ADJUSTMENT” section in chapter 3. 1 NOTE: Before adjusting the Y.P.V.S. cables, turn the main switch “ON” and operate the Y.P.V.S. motor. 11. Install: • Pulley cover (Power valve) Bolt (Pulley Cover): 7 Nm (0.7 m•kg, 5.
ENGINE ASSEMBLY AND ADJUSTMENTS ENG 13. Air bleeding: • Autolube pump Refer to the “AUTOLUBE PUMP AIR BLEEDING” section in chapter 3. 14. Install: • Autolube pump cover Bolt (Autolube pump cover): 5 Nm (0.5 m•kg, 3.6 ft•lb) 1 15. Install: • Gasket (Exhaust pipe) • Exhaust pipe 3 2 Nut (Exhaust pipe): 18 Nm (1.8 m•kg, 13 ft•lb) Bolt (Stay): 10 Nm (1.0 m•kg, 7.2 ft•lb) Bolt (Frame mount): 10 Nm (1.0 m•kg, 7.2 ft•lb) Screw (Muffler joint): 10 Nm (1.0 m•kg, 7.
ENGINE ASSEMBLY AND ADJUSTMENTS ENG 17. Fill: • Crankcase Refer to the “TRANSMISSION OIL REPLACEMENT” section in chapter 3.
COOL
6
COOL CHAPTER 6 COOLING SYSTEM WATER PUMP ……………………………………………………………………6-1 REMOVAL ………………………………………………………………………6-2 INSPECTION……………………………………………………………………6-4 INSTALLATION …………………………………………………………………6-4 THERMOSTATIC VALVE AND RADIATOR ……………………………………6-7 REMOVAL ………………………………………………………………………6-8 INSPECTION …………………………………………………………………6-10 INSTALLATION ………………………………………………………………6-11
COOL WATER PUMP COOLING SYSTEM WATER PUMP Water pump housing cover Gasket Dowel pin 10 Drain bolt 11 Gasket Impeller shaft Oil Seal Pin Impeller shaft gear Plain washer Circlip 8 Nm (0.8 m • kg, 5.
WATER PUMP COOL REMOVAL NOTE: It is necessay to disassemble the water pump unless there is no abnormality such as excessive change in coolant temperature and/or discoloration of coolant or milky transmission oil. 1. Drain: • Transmission oil Refer to the “TRANSMISSION OIL REPLACEMENT” section in chapter 3. • Coolant Refer to the “COOLANT REPLACEMENT” section in chapter 3. 2.Disconnect: • Outlet hose (Radiator) 3.Remove: • Screw (Water outlet pipe) 2 1 4. Remove: • Autolube pump cover 5.
WATER PUMP 2 7. Remove: • Return spring • Bolt (Master cylinder) • Brake pedal • Crankcase cover 4 3 COOL 1 8. Remove: • Water outlet pipe • Housing cover (Water pump) • Gasket • Dowel pins 2 1 1 2 9. Remove: • Circlip • Plain washer • Impeller shaft gear 3 10. Remove: • Pin • Plain washer 1 2 11. Remove: • Impeller shaft 12. Eliminate deposits from the impeller and water pump housing.
WATER PUMP COOL EAS00472 CHECKING THE WATER PUMP 1. Check: • O-ring Damage/wear Replace. • oil seal Damage/wear Replace the water pump housing assembly. 2. Check: • impeller Cracks/damage/wear Replace the water pump housing assembly. • bearing Rough movement Replace the water pump housing assembly. Oil seal replacement steps: • Remove the oil seal from the crankcase cover by tapping it towards the outside.
WATER PUMP COOL 3. Install: • Housing cover (Water pump) • Water outlet pipe Screw (Crankcase cover): 8 Nm (0.8 m•kg, 5.8 ft•lb) Screw (Water Outlet Pipe): 8 Nm (0.8 m•kg, 5.8 ft•lb) 2 CAUTION 1 • Always use new gaskets • Always use a new O-ring 3 2 4. Install: • Crankcase cover (Right) • Brake pedal • Return spring • Drain plug (Transmission oil) • Drain plug (Coolant) 1 5 Screw (Crankcase cover): 8 Nm (0.8 m•kg, 5.8 ft•lb) Screw (Brake pedal): 20 Nm (2.
WATER PUMP COOL 6. Fill: • Crankcase Refer to the “TRANSMISSION OIL REPLACEMENT” section in chapter 3. Recommended Oil: SAE 10W30 type SE Motor Oil Periodic Oil Change: 0,75L 7. Fill: • Radiator Refer to the “COOLANT REPLACEMENT” section. Total amount: 0,92L 8. Air bleeding: • Autolube pump Refer to the “AUTOLUBE PUMP AIR BLEEDING” section. 9. Install: • Autolube pump cover Screw (Autolube pump cover): 5 Nm (0.5 m•kg, 3.
COOL THERMOSTATIC VALVE AND RADIATOR THERMOSTATIC VALVE AND RADIATOR A Hose (Carburetor warmer Hose (Carburetor warmer Thermostatic valve cover 10 Gasket 11 Thermostatic valve 12 O-ring Radiator assembly Radiator cap Inlet hose Coolant breather hose Outlet hose Gasket RADIATOR CAP OPENING PRESSURE: 75~105kPA (0.75~1.05kg/cm2, 10~14psi) Inlet) Inlet) B COOLANT CAPACITY: 0.92L Including all routes C THERMOSTATIC VALVE OPENING TEMPERATURE: 63~67°C (146~153°C) 8 Nm (0.
THERMOSTATIC VALVE AND RADIATOR COOL REMOVAL 1. Remove: • Side covers (Left and Right) • Seat • Exhaust pipe 1 1 2. Remove: • Radiator cover • Oil tank cover • Fuel tank Refer to the “CARBURETOR REMOVAL” section in chapter 7. 3. Drain: • Cooling system Refer to the “COOLANT REPLACEMENT” section in chapter 3. NOTE: Thoroughly flush the cooling system with clean tap water. CAUTION Take care so that coolant doesn’t splash painted surfaces. If splashes, wash it away with water.
THERMOSTATIC VALVE AND RADIATOR 1 COOL 4. Remove: • Radiator cap 5. Disconnect: • Breather hose (Radiator ) 6. Remove: • Inlet hose (Radiator) • Outlet hose (Radiator) 3 2 4 7. Remove: • Water outlet pipe • O-ring 2 8. Remove: • Radiator fin 1 9.
THERMOSTATIC VALVE AND RADIATOR COOL 10. Remove: • Thermostatic valve cover • Gasket • Thermostatic valve • O-ring 3 EAS00455 CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction Clean. Apply compressed air to the rear of the radiator. Damage Repair or replace. NOTE: Straighten any flattened fins with a thin, flathead screwdriver. 2. Check: • radiator hoses • radiator pipes Cracks/damage Replace. 3.
THERMOSTATIC VALVE AND RADIATOR COOL a. Install the radiator cap tester and radiator cap tester adapter to the radiator cap. Radiator cap tester 90890-01325 Radiator cap tester adapter 90890-01352 1 b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure. 2 4. Inspect: • Thermostatic valve Valve doesn’t open at 63~67ºC (146~153ºF) Replace. INSTALLATION Reverse the “REMOVAL” procedure.
THERMOSTATIC VALVE AND RADIATOR COOL 2. Install: • Radiator Bolt(Radiator): 8 Nm (0.8 m·kg; 5.8 ft·lb) 1 3. Apply grease to the O-ring 4. Install: • O-ring • Water outlet pipe s WARNING 1 Always use a new O-ring 2 Screw (Water Outlet Pipe): 8 Nm (0.8 m·kg; 5.8 ft·lb) 5. Fill: • Radiator • Reservoir tank (Radiator) Refer to the “COOLANT REPLACEMENT” section in chapter 3. 6.
THERMOSTATIC VALVE AND RADIATOR COOL Inspection steps • Attach the Cooling System Tester to the radiator Radiator cap tester 90890-01325 • Apply 100kPa (1.0 kg/cm2, 14psi) pressure. • Measure the indicated pressure with the gauge.
CARB
7
CARB CHAPTER 7 CARBURETOR CARBURETOR ……………………………………………………………………7-1 REMOVAL ………………………………………………………………………7-2 DISASSEMBLY …………………………………………………………………7-3 INSPECTION……………………………………………………………………7-4 ASSEMBLY ……………………………………………………………………7-6 INSTALLATION …………………………………………………………………7-8 ADJUSTMENT …………………………………………………………………7-9 REED VALVE ……………………………………………………………………7-10 REMOVAL ……………………………………………………………………7-11 DISASSEMBLY ………………………………………………………………7-11 INSPECTION …………………………………………………………………7-12 ASSEMBLY ……………………………………………………………………7-12
CARBURETION CARB CARBURETION CARBURETOR Pilot jet Needle jet 10 Gasket 11 Main jet 12 Needle valve assembly 13 Float 14 Drain screw Cap Throttle valve spring Starter plunger Throttle stop screw Pilot air screw Throttle valve Needle set Main Jet (M.J.) Main Air Jet (M.A.J.) Jet Needle (J.N.) Needle Jet (N.J.) Pilot Jet (P.J.) Power Jet (PW.J.) Pilot Air Screw (P.A.S.) Float Height (F.H.) Engine Idling Speed 7-1 #210 ø 0.8 5J40-2 Q2-M (#939) #17.5 #60 15.5~16.5mm(0.61~0.
CARBURETOR CARB REMOVAL NOTE: The following parts can be cleaned and inspected without disassembly • Throttle valve • Starter plunger • Throttle stop screw 1 1. Remove: • Side cover (Left and Right) • Seat • Radiator cover 2 2. Turn the fuel cock to “OFF” position. 3. Disconnect: • Fuel hose (from carburetor side) 1 4. Remove: • Fuel tank s WARNING Gasoline is highly flammable. Avoid spilling fuel over the engine when it’s hot 5. Disconnect: • Reservoir tank (Rear brake) • Y.E.I.S.
CARBURETOR CARB 6. Disconnect: • Hoses • Oil delivery hose • Cooling hoses 7. Loosen: • Screw (carburetor joint) • Screw (air box) 8. Remove: • Carburetor top • Carburetor 2 1 9. Remove: • Cable holder • Throttle valve • Return spring DISASSEMBLY 1. Remove: • Hoses 1 1 1 1 2.
CARBURETOR CARB 4. Remove: • Float pin • Float • Needle valve 2 1 3 5. Remove: • Valve seat • Main jet • Jet needle holder 1 2 6. Remove: • Throttle stop screw • Pilot air screw 1 INSPECTION 1. Inspect: • Carburetor mixing chamber body Contamination Clean NOTE: Use petroleum based solvent for cleaning. Blow out all passages and jets with compressed air. 2.
CARBURETOR CARB 3. Inspect: • Valve seat • Gasket • Needle valve NOTE: 1 Always replace the needle valve and valve seat as a set. 4. Inspect: • Starter plunger Wear/Contamination Replace 5. Check: • Free movement Stick Replace Insert the throttle valve into the carburetor body and check for free movement. 6. Inspect: • Throttle stop screw • Pilot air screw • O-ring Wear/Damage Replace 7. Inspect: • Jet needle Bends/Wear Replace 8. Inspect: • Throttle valve Wear/Damage Replace 9.
CARB CARBURETOR 10. Inspect: • Float Damage Replace 1 11. Inspect: • Main jet • Needle jet • Pilot jet Contamination Clean NOTE: Blow out the jets with compressed air ASSEMBLY Reverse the “DISASSEMBLY” procedures. Note the following points. CAUTION Before reassembling, wash all parts with clean gasoline 1. Tighten: • Jet needle holder 2. Install: • Valve seat • Main jet • Pilot jet • Needle jet 1 NOTE: 2 4 Align the knock pin with the pin slot in the needle jet 3.
CARBURETOR CARB Measurement and adjustment steps: • Hold the carburetor in an upside down position. • Measure the distance from the mating surface on the float chamber (gasket removed) to the top of the float. CAUTION The float arm should be resting on the needle valve, but not compressing the needle valve. • If the float height is not within specification, inspect the valve seat and needle valve. • If either is worn, replace them both.
CARBURETOR CARB 7. Intall: • Throttle valve NOTE: Align the groove of the throttle valve with the projection of the carburetor body. INSTALLATION Reverse the “REMOVAL” procedures. Note the following points. 1. Install: • Carburetor assembly NOTE: Align the groove of the carburetor joint with the projection of the carburetor body. 2. Adjust: • Idle speed Refer to the “IDLE SPEED ADJUSTMENT” section in chapter 3. Engine idle speed 1250~1450 rev/min 3. Adjust: • Carburetor cable free play.
CARBURETOR CARB ADJUSTMENT Fuel level adjustment 1. Measure: • Fuel level Out of specification adjust Fuel level: 1.5~2.5mm (0.05~0.09in.) In the middle of the Float Chamber. Below the carburetor Body edge. Fuel level measurement and adjustment steps: • Place the motorcycle on a level surface. • Use a garage jack under the engine to ensure that the carburetor is positioned vertically. • Connect the fuel level gauge to the drain pipe .
REED VALVE CARB REED VALVE Reed valve assembly Reed valve Stopper plate Gasket Carburetor joint Y.E.I.S. Chamber 10 Nm (1.0 m • kg, 7.2 ft•lb) 1 Nm (0.1 m • kg, 0.
REED VALVE CARB REMOVAL 1. Remove: • Carburetor Refer to the “CARBURETOR REMOVAL” section. 2. Remove: • Carburetor joint 1 3. Remove: • Reed valve assembly • Gasket 2 1 DISASSEMBLY 1. Remove: • Y.E.I.S. chamber 1 2.
REED VALVE CARB INSPECTION 1. Inspect: • Reed valve • Reed valve stopper Cracks/Damage Replace 1 2 2. Measure: • Reed valve bending limit Out of specification Replace. Reed valve Bending Limit: 0.5mm (0.02in) Surface plate 3. Measure: • Reed valve stopper height Out of specification Replace. Reed valve Stopper Height: 6.8mm (0.27in) Surface plate 4. Inspect: • Carburetor joint • Y.E.I.S. chamber Cracks/Damage Replace. 2 1 ASSEMBLY Reverse the “DISASSEMBLY” precedure.
REED VALVE CARB • Fit the reed valve stopper out with the corresponding cut on the reed valve. 2. Tighten: • Screws (Reed valve) Screws (Reed valve): 1 Nm (0.1 m·kg; 0.7 ft·lb) Use LOCTITE® NOTE: Tighten each screw gradually to avoid warping. 3. Install: • Y.E.I.S. chamber NOTE: 1 The arrow on the Y.E.I.S. chamber must point forward. INSTALLATION Reverse the “REMOVAL” procedure. Note the following points. 1.
ELEC
8
ELEC CHAPTER 8 ELECTRICAL SYSTEM DT125RE CIRCUIT DIAGRAM …………………………………………………8-1 COLOR CODE …………………………………………………………………8-1 ELECTRICAL COMPONENTS …………………………………………………8-2 CHECKING SWITCH CONTINUITY …………………………………………8-4 CHECKING THE SWITCHES …………………………………………………8-5 IGNITION SYSTEM ………………………………………………………………8-6 CIRCUIT DIAGRAM ……………………………………………………………8-6 IGNITION CONTROL CIRCUIT OPERATION ………………………………8-6 TROUBLESHOOTING …………………………………………………………8-8 CHARGING SYSTEM …………………………………………………………8-14 CIRCUIT DIAGRAM …………………………………
DT125RE CIRCUIT DIAGRAM ELEC ELECTRICAL DT125RE CIRCUIT DIAGRAM B R O L P Y G W Black Red Orange Blue Pink Yellow Green White Ch Dg Sb Br L/Y B/Y B/W B/R Chocolate Dark green Sky blue Brown Blue/Yellow Black/Yellow Black/White black/Red 8-1 W/R W/L Y/R G/R G/Y G/W Br/W L7R White/Red White/Blue Yellow/Red Green/Red Green/Yellow Green/White Brown/White Blue/Red
ELECTRICAL COMPONENTS ELEC ELECTRICAL COMPONENTS(1) Thermo unit Rectifier/Regulator Ignition coil Main switch CDI Unit Servomotor Battery Fuse Neutral switch Ignition coil: Primary coil resistance: 0.23 Ω at 20 °C Secondary coil resistance: 7.
ELECTRICAL COMPONENTS ELEC ELECTRICAL COMPONENTS(2) Sidestand switch Brake switch Relay Horn Flasher relay Conductor wire Rectifier 2 Oil gauge Battery: Capacity: 12V 6Ah No maintenance 8-3
CHECKING SWITCH CONTINUTY ELEC EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. CAUTION: Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
ELEC CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear Repair or replace. Improperly connected Properly connect. Incorrect continuity reading Replace the switch.
IGNITION SYSTEM IGNITION SYSTEM The circuit diagram showns the ignition system.
IGNITION SYSTEM NOTE: For the color codes see the electric diagram Magneto CDI Battery Fuse Starter relay Starting engine Main switch C.D.I.
IGNITION SYSTEM EAS00736 ELEC EAS00740 TROUBLESHOOTING 1. Spark plug • Check the condition of the spark plug. • Check the spark plug type. • Measure the spark plug gap. Refer to “CHECKING THE SPARK PLUG” in chapter 3. The ignition system fails to operate (no spark or intermittent spark). Check: 1. Main and ignition fuses 2. Battery 3. Spark plug 4. Ignition spark gap 5. Spark plug cap resistance 6. Ignition coil resistance 7. Main switch 8. Engine stop switch 9. Neutral switch 10. Sidestand switch 11.
IGNITION SYSTEM ELEC EAS00744 • Connect the pocket tester (Ω x 1k) to the ignition coil as shown. 3. Spark plug cap resistance • Remove the spark plug cap from the spark plug lead. • Connect the pocket tester (“Ω x 1k” range) to the spark plug cap as shown. • Measure the spark plug cap resistance. Negative tester probe Ignition coil base Positive tester probe spark plug lead • Measure the secondary coil resistance. Secondary coil resistance 7.
ELEC IGNITION SYSTEM EAS00749 EAS00750 5. Main switch 6. “ENGINE STOP” switch • Disconnect the main switch coupler and lead from the wireharness (red). • Connect the pocket tester (Ω 100) to the main switch. • Disconnect the “ENGINE STOP” switch leads from the wireharness. • Connect the pocket tester (Ω 100) to the “ENGINE STOP” switch.
ELEC IGNITION SYSTEM EAS00748 7. source coil resistance 8. Pickup coil resistance • Disconnect the CDI magneto coupler from the wireharness. • Connect the pocket tester (Ω 100) to the source coil. • Disconnect the CDI magneto coupler from the wire harness. • Connect the pocket tester (Ω 100) to the pickup coil.
ELEC IGNITION SYSTEM EAS00752 EAS00751 Procedure (2) 2. Neutral switch 1. Sidestand switch • Disconnect the CDI magneto coupler from the wireharness. • Connect the pocket tester (Ω 100) to the neutral switch lead. • Disconnect the sidestand switch leads from the wireharness. • Connect the pocket tester (Ω100) to the sidestand switch.
CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM Generator Rectifier/regulator Battery Main fuse 8-14 ELEC
CHARGING SYSTEM EAS00774 EAS00775 TROUBLESHOOTING 3. Charging voltage • Connect the engine tachometer to the spark plug lead. • Connect the pocket tester (DC 20 V) to the battery. The battery is not being charged. 1. 2. 3. 4. 5.
LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM 29 Headlight 34 Tail light 36 Meter lights Magento-CDI Rectifier/regulator Main switch 21 “LIGHTS” switch 8-16 ELEC
LIGHTING SYSTEM ELEC EAS00781 TROUBLESHOOTING 1. Bulb • Remove the bulb. Refer to the “HEADLIGHT BULB REPLACEMENT” section in the chapter 3. • Connect the pocket tester (Ω 100) to the bulbs terminals. Any of the following fail to light: headlight, high beam indicator light, taillight, auxiliary light or meter light. Check: 1. Headlight bulb/”HI BEAM” indicator light bulb 2. Headlight bulb socket/”HI BEAM” 3. “LIGHTS” (dimmer) switch 4. “Lights” switch 5. Lighting voltage 6. Lighting coil resistance 7.
LIGHTING SYSTEM ELEC 2. Bulb socket 3. “LIGHTS” (Dimmer) switch • Disconnect the bulb socket leads from the wire harness. • Install the bulb to the bulb socket. • Connect the pocket tester (Ω 100) to the bulbs terminals. • Connect the pocket tester (Ω 100) to the bulbs terminals. Yellow Positive tester probe Negative tester probe Black When turning “LIGHTS” (Dimmer) switch to “HI”.
LIGHTING SYSTEM ELEC EAS00787 4. Lighting voltage. 5. Wiring • Turn (Dimmer) switch to “LO”. • Connect the pocket tester (DC 20 V) to the battery. • Check the entire lighting system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the lighting system’s wiring properly connected and without defects? Positive tester probe Green terminal Negative tester probe Black terminal YES Check the condition of each of the lighting system’s circuits. Refer to “CHECKING THE LIGHTING SYSTEM”.
LIGHTING SYSTEM ELEC TROUBLESHOOTING 1. Bulb Meter light does not come on • Remove the bulb. Refer to the “METER ASSEMBLY” section. • Connect the pocket tester (Ω 1) to the bulbs terminals. Check: 1. Meter light bulb 2. Meter light bulb socket 3. Wiring connection (of the entire lighting system) Positive tester probe terminal Negative tester probe terminal NOTE: • Before troubleshooting, remove the following part(s): 1. Sidecovers (left and right) 2. Seat 3. Fuel tank 4. Headlight cover 5.
LIGHTING SYSTEM 2. Bulb socket • Disconnect the bulb socket lead and coupler from the wire harness. • Install the bulb to the bulb socket. • Connect the pocket tester (Ω 1) to the bulbs socket lead end and coupler. Positive tester probe Blue lead Negative tester probe Black Terminal • Check the bulb socket for continuity. • Is the bulb socket OK? YES NO Replace the bulb socket. EAS00787 3. Wiring • Check the entire lighting system’s wiring. Refer to “CIRCUIT DIAGRAM”.
LIGHTING SYSTEM ELEC TROUBLESHOOTING 1. Bulb Tail light/Auxiliary light do not come on • Remove the bulb. • Connect the pocket tester (Ω 1) to the bulb terminals. Check: 1. Tail/Brake light bulb/Auxiliary light bulb 2. Tail light bulb socket/Auxiliary light 3. Main switch 4.
LIGHTING SYSTEM ELEC 2. Bulb socket 3. Main switch • Disconnect the bulb socket and leads from the wire harness. • Install the bulb to the bulb socket. • Connect the pocket tester (Ω 1) to the bulbs socket lead end and coupler. • Disconnect the main switch coupler from the wire harness.
LIGHTING SYSTEM EAS00787 4. Wiring • Check the entire lighting system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the lighting system’s wiring properly connected and without defects? YES Check the condition of each of the lighting system’s circuits. Refer to “CHECKING THE LIGHTING SYSTEM”. NO Properly connect or repair the lighting system’s wiring.
SIGNAL SYSTEM ELEC EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM Main switch Main fuse Battery 15 Neutral switch 35 Engine oil level switch 37 Diode 20 Horn switch 25 Horn 22 Turn switch 26 Turn signal relay 8-26 34 Tail/brake light 28 Rear brake light switch 27 Front brake light switch
ELEC SIGNAL SYSTEM EAS00794 TROUBLESHOOTING 3. Main switch • Disconnect the main switch coupler from the wire harness. • Connect the pocket tester (Ω 1) to the main switch. Any of the following fail to light: flasher light, brake light or an indicator light do not come on and the horn fails to sound. Tester (+) Lead Red Lead Teter (-) Lead Brown-Blue Lead Check: 1. Fuse 2. battery 3. main switch 4.
SIGNAL SYSTEM ELEC 2. Bulb socket FLASHER LIGHT DOES NOT BRINK • Install the bulb to the sockets. • Disconnect the flahser light leads from the wire harness. • Connect the pocket tester (Ω 1) to the flasher light leads. 1. Bulb • Remove the bulb. • Connect the pocket tester (Ω 1) to the bulb terminals.
ELEC SIGNAL SYSTEM 3. “TURN” switch 4. Voltage • Disconnect the “TURN” switch (Left handlebar switch) coupler from the wire harness. • Connect the pocket tester (Ω 1) to the “TURN” switch. • Disconnect the flasher relay coupler from the wire harness. • Turn the main switch to “ON”. • Turn the “TURN” switch to the “R” or “L”. • Connect the pocket tester (DC20V) to the flasher relay coupler.
SIGNAL SYSTEM ELEC 2. Bulb socket BRAKE LIGH DOES NOT COME ON • Disconnect the bulb socket coupler from the wire harness. • Connect the pocket tester (Ω 1) to the bulb socket leads. 1. Bulb • Remove the bulb. • Connect the pocket tester (Ω 1) to the bulb terminals. Positive tester probe Yellow Terminal Negative tester probe Black Terminal Positive tester probe terminal Negative tester probe terminal • Check the bulb socket for continuity.
ELEC SIGNAL SYSTEM 3. Front brake switch 4. Rear brake switch • Disconnect the front brake switch coupler from the wire harness. • Connect the pocket tester (Ω 1) to the brake switch coupler. • Disconnect the front brake switch coupler from the wire harness. • Connect the pocket tester (Ω 1) to the brake switch coupler.
SIGNAL SYSTEM ELEC 2. Bulb socket “NEUTRAL” INDICATOR LIGHT DOES NOT COME ON • Disconnect the bulb socket coupler from the wire harness. • Connect the pocket tester (Ω 1) to the bulb socket leads. 1. Bulb • Remove the bulb. Refer to the “METER ASSEMBLY” section. • Connect the pocket tester (Ω 1) to the bulb terminals.
SIGNAL SYSTEM ELEC EAS00795 3. Neutral switch 4. Wiring • Disconnect the CDI magneto coupler from the wire harness. • Connect the pocket tester (Ω 1) to the neutral switch coupler. • Check the entire signal system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the signaling system’s wiring properly connected and without defects? Positive tester probe Sky Blue Terminal Negative tester probe Frame ground • Shift the transmission in neutral and gear. • Check the neutral switch for continuity.
SIGNAL SYSTEM ELEC 2. Bulb socket “OIL” INDICATOR LIGHT DOES NOT COME ON • Disconnect the bulb socket coupler from the wire harness. • Connect the pocket tester (Ω 1) to the coupler. 1. Bulb • Remove the bulb. Refer to the “METER ASSEMBLY” section. • Connect the pocket tester (Ω 1) to the bulb terminals.
ELEC SIGNAL SYSTEM 3. Oil level switch (Diode) 4. Oil level switch • Disconnect the oil level switch from the wire harness. • Connect the pocket tester (Ω 1) to the neutral switch coupler. • Connect the pocket tester (Ω 1) to the oil level switch. Positive tester probe Black/Red Terminal Negative tester probe Black Terminal Positive tester probe Black/Red Terminal Negative tester probe Sky Blue Terminal • Check the oil level switch for continuity.
SIGNAL SYSTEM ELEC 2. Voltage HORN DOES NOT SOUND, WHEN PUSHING “HORN” SWITCH • Connect the pocket tester (DC20V) to the horn terminal. Positive tester probe Brown Terminal Negative tester probe Frame ground. 1. “HORN” switch • Disconnect the “HORN” switch (Left handlebar switch) couplers from the wire harness. • Connect the pocket tester (Ω 1) to the “HORN” switch. Positive tester probe Pink Terminal Negative tester probe Black Terminal • Turn the main switch to “ON”.
SIGNAL SYSTEM 4. Horn • Disconnect the “pink” lead at the horn terminal. • Connect a jumper lead to the horn terminal and ground the jumper lead. • Does the horn sounds OK? YES NO Replace the horn. 5. Voltage • Connect the pocket tester (DC20V) to the horn at the pink terminal. Positive tester probe Pink Terminal Negative tester probe Frame ground. • Check the “pink” terminal voltage. “Pink” terminal voltage 12.
COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM Battery Main switch Main fuse 13 Thermo switch 8-38 ELEC
COOLING SYSTEM ELEC EAS00808 TROUBLESHOOTING 1. Fuse • Remove the fuse. • Connect the pocket tester (Ω 1) to the fuse. • Check the fuse for continuity. • Is the fuse OK? • The radiator fan motor fails to turn. • The water temperature gauge needle fails to move when the engine is warm. YES Check: 1. main fuse 2. battery 3. main switch 4. thermo switch 5. wiring connections (the entire cooling system) NO Replace the fuse. 2. Battery • Check the battery condition.
ELEC COOLING SYSTEM 3. Main switch 4. Thermo unit • Disconnect the main switch coupler from the wire harness. • Connect the pocket tester (Ω 1) to the main switch. • Remove the thermo unit from the cylinder head. • Connect the pocket tester (Ω 1) to the thermo unit • Inmerse the thermo unit in the water • Measure the resistances.
COOLING SYSTEM EAS00795 5. Wiring • Check the entire signal system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the signaling system’s wiring properly connected and without defects? YES Check the condition of each of the signaling system’s circuits. Refer to “CHECKING THE SIGNALING SYSTEM”. NO Properly connect or repair the signaling system’s wiring.
YAMAHA POWER VALVE SYSTEM YAMAHA POWER VALVE SYSTEM CIRCUIT DIAGRAM 16 CDI Unit Main switch Main fuse Battery 18 Servomotor 8-42 ELEC
MOTOR ELEC TROUBLESHOOTING 1. Fuse Servomotor does not move • Remove the fuse. • Connect the pocket tester (Ω 1) to the fuse. • Check the fuse for continuity. • Is the fuse OK? Check: 1. fuse 2. battery 3. main switch 4. servomotor operation 5. wiring connections (Yamaha Power Valve System) 6. servomotor and tachometer operation YES NO Replace the fuse. 2. Battery NOTE: • Check the battery condition. Refer to the “BATTERY INSPECTION” section in chapter 3.
MOTOR ELEC 3. Main switch 4. Servomotor operation • Disconnect the main switch coupler from the wire harness. • Connect the pocket tester (Ω 1) to the main switch. • Disconnect servomotor coupler from the wire harness. • Connect the battery leads to the servomotor. Positive tester probe Red Lead Negative tester probe Brown-Blue Terminal Positive tester probe Brown Terminal Negative tester probe Black Terminal • Turn the main switch to “ON”, “OFF” and “PARK”.
MOTOR 6. Servomotor and tachometer operation • Start the engine and increase revolution to about 7000rev/min. • Check servomotor and tachometer for operation. Pocket tester 90890-03112 • Is the servomotor OK? YES NO Replace the servomotor.
METER ASSEMBLY METER ASSEMBLY Meter bracket Stopper clip Washer Damper collar Speedometer Bulb Bulb socket Speedometer cable Meter cushion 8-46 ELEC
METER ASSEMBLY REMOVAL 1. Remove: • Headlight cover 1 2. Disconnect: • Headlight leads • Auxiliary light leads 1 3. Remove: • Band 4. Disconnect: • Speedometer cable 5. Disconnect: • Meter leads 6.
METER ASSEMBLY ELEC 7. Remove: • Meter cushion • Meter lights • Leads 3 CAUTION Do not remove the indicator bulbs sockets by pulling the leads 1 2 INSTALLATION Reverse the “REMOVAL” procedure. Note the following points: 1. Install the meter lights, indicator lights and leads as shown. 4 ”OIL” indicator light ”NEUTRAL” indicator light ”HIGH BEAM” indicator light ”TURN” indicator light 3 2 1 2. Install: • Meter assembly Bolt (Meter Assembly) 7 Nm (0.7 m•kg, 5.
METER ASSEMBLY ELEC NOTE: 1 Install the headlight lens unit onto the headlight stay by fitting the guide rubber properly in the guide hole of the headlight unit. 3. Install: • Headlight cover 4. Adjust: • Headlight beam Refer to the “HEADLIGHT BEAM ADJUSTMENT” section.
? TRBL SHTG
? 9
TRBL SHTG CHAPTER 9 TROUBLESHOOTING STARTING FAILURE / HARD STARTING ……………………………………9-1 FUEL SYSTEM …………………………………………………………………9-1 ELECTRICAL SYSTEM ………………………………………………………9-2 POOR IDLE SPEED PERFORMANCE ………………………………………9-3 POOR IDLE SPEED PERFORMANCE ………………………………………9-3 POOR MEDIUM AND HIGH SPEED PERFORMANCE ……………………9-3 FUEL SYSTEM …………………………………………………………………9-3 ELECTRICAL SYSTEM ………………………………………………………9-3 COMPRESSION SYSTEM ……………………………………………………9-4 Y.P.V.S.
STARTING FAILURE/HARD STARTING TRBL SHTG TROUBLESHOOTING NOTE: The following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refeer to the relative procedure in this manual for inspection, adjustment and replacement of parts.
TROUBLESHOOTING ELECTRICAL SYSTEM TRBL SHTG PROBABLE CAUSE • Spark plug • • • • • • Ignition coil • Broken or shorted primary/secondary • Faulty spark plug lead • Broken body • C.D.I. Unit system • • • • Faulty C.D.I.
TROUBLESHOOTING TRBL SHTG POOR IDLE SPEED PERFORMANCE POOR IDLE SPEED PERFORMANCE • Carburetor PROBABLE CAUSE Improperly returned starter plunger Clogged or loose pilot jet Clogged pilot air passage Improperly adjusted idle speed (throttle stop screw) • Improper throttle cable play • Faulty pick up coil • • • • POOR MEDIUM AND HIGH SPEED PERFORMANCE FUEL SYSTEM PROBLABLE CAUSE • Fuel tank • Clogged fuel filter • Deteriorated fuel or fuel containing water or foreign material • Clogged fuel breather h
TROUBLESHOOTING COMPRESSION SYSTEM TRBL SHTG PROBABLE CAUSE • Cylinder and cylinder head • • • • • Loose spark plug Broken cylinder head gasket Broken cylinder gasket Loose cylinder head or cylinder Worn, damaged or seized cylinder • Piston and piston ring • • • • Improperly installed piston ring Worn, fatigued or broken piston ring Seized piston ring Seized or damaged piston • Crankcase and crankshaft • Improperly seated crankcase • Improperly sealed crankcase (Damaged oil seal) • Seized cranksha
TROUBLESHOOTING TRBL SHTG FAULTY GEAR SHIFTING HARD SHIFTING PROBABLE CAUSE • Clutch • Improperly adjusted clutch cable • Improperly adjusted push lever position • Improper engagement of push lever and push rod • Warped clutch plate • Swollen friction plate • Broken clutch plate • Transmission oil • High oil level • Improper quality (High viscosity) • Deterioration CHANGE PEDAL DOES NOT MOVE PROBABLE CAUSE • Shift shaft • Bent shift shaft • Shift cam and shift fork • Groove jammed with impuriti
TROUBLESHOOTING CLUTCH DRAGGING • Clutch TRBL SHTG PROBABLE CAUSE • Improperly adjusted clutch cable • Improperly adjusted push lever position • Improper engagement of push lever and push rod • Warped clutch plate • Swollen friction plate • Broken clutch boss • Transmission oil • High oil level • Improper quality (High viscosity) • Deterioration FAULTY BRAKE POOR BRAKING EFFECT PROBABLE CAUSE • Disc brake • • • • • • • • • • • Worn brake pad Worn brake disc Air in brake fluid Leaking brake fluid Fa
TROUBLESHOOTING INSTABLE HANDLING INSTABLE HANDLING TRBL SHTG PROBABLE CAUSE • Handlebars • Improperly installed or bent • Steering • Improperly installed handle crown • Bent steering shaft • Improperly installed steering shaft (Improperly tightened ringnut) • Damaged ball bearing (roller bearing or bearing race) • Front forks • Uneven oil levels on both sides • Uneven spring tension (Uneven damping adjuster position) • Broken spring • Twisted front forks • Tires • Uneven tire pressure on both sid
TROUBLESHOOTING TRBL SHTG FAULTY SIGNAL AND LIGHTING SYSTEM HEADLIGHT DARK PROBABLE CAUSE • Improper bulb • Too many electric accesories • Hard charging (Broken charging coil and/or faulty rectifier/regualtor) • Incorrect connection • Improperly grounded • Poor contacts (main or “LIGHTS” switch) • Bulb life expired BULB BURNT OUT • • • • • • PROBABLE CAUSE Improper bulb Faulty battery Faulty rectifier/regulator Improperly grounded Faulty main and/or light switch Bulb life expired • • • • • • • PROBAB
TROUBLESHOOTING FAULTY Y.P.V.S. • Power valve TRBL SHTG PROBABLE CAUSE • Seized or damaged power valve • Carbon build-up • Control cable • Improperly adjusted cable • Seized or discontinuous cable • Electrical parts • Insufficient battery capacity (improperly charged battery) • Faulty main switch • Faulty servomotor • Faulty CDI unit • Faulty Y.P.V.S.
DT125 WIRING DIAGRAM
COMPONENTS COLOR CODE B ..........................Balck R ..........................Red L...........................Blue G ..........................Green Or.........................Orange Y ..........................Yellow P ..........................Pink Br .........................Brown Ch ........................Chocolate Sb ........................Skip blue Dg ........................Dark green W .........................White Gy ........................Gray BG .......................Black-Green BY ..
