1D01-AE1 SERVICE MANUAL DT125RE DT125X 2005

DT125RE/X 1D01-1D02/2C81 SERVICE MANUAL 2005 Yamaha Motor Espaa, S.A. 1st Edition, January 2005 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Espaa, S.A. is expressly prohibited. Printed in Spain.

EAS00002 NOTICE This manual was produced by the Yamaha Motor Espaa S.A. primarily for use by Yamaha dealersand their qualified mechanics. It is not possible to include all the knowledge of a mechanic in onemanual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamahavehicles should have a basic understanding of mechanics and the techniques to repair these typesof vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely torender the vehicle unsafe and unfit for use. Yamaha Motor Espaa S.A is continually striving to improve all of its models. Modifications and sig-nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealersand will appear in future editions of this manual where applicable. NOTE: Designs and specifications are subject to change without notice. TECHNICAL PUBLICATIONS YAMAHA MOTOR ESPAA, S.A. EAS00004 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injuryor death to the motorcycle operator, a bystander or a person chec-king or repairing the motorcycle. A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. A NOTE provides key information to make procedures easier or cleArer

EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensiveexplanations of all installation, removal, disassembly, assembly, repair and check procedures arelaid out with the individual steps in sequential order. The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to SYMBOLS. Each chapter is divided into sections. The current section title is shown at the top of eachpage, except in Chapter 3 (PERIODIC CHECKS AND ADJUSTMENTS), where the sub-section title(s) appears. Sub-section titles appear in smaller print than the section title. To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step. Symbols indicate parts to be lubricated or replaced. Refer to SYMBOLS. A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. Jobs requiring more information (such as special tools and technical data) are described Sequentially

GEN INFO CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION1-1 FRAME SERIAL NUMBER1-1 ENGINE SERIAL NUMBER1-1 IMPORTANT INFORMATION1-2 PREPARATION FOR REMOVAL1-2ALL REPLACEMENT PARTS1-2GASKETS, OIL SEALS AND ORINGS1-2LOCK WASHERS/PLATES AND COTTER PINS1-

2BEARINGS AND OIL SEALS13CIRCLIP1-3CHECKING THE CONNECTIONS1-4 SPECIAL TOOLS1-5

GEN INFO MOTORCYCLE IDENTIFICATIONS 1-1 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 themotorcycle and therefore it can be used for theenrollment in the face of the competent autho- rity. ENGINE SERIAL NUMBER The engine serial number is stamped onto the left side of the crankcase NOTE: The first three digits of this number identifies the model; the other digits indicate the number of production of the unit. NOTE: Design and specifications may change without notice

GEN INFO IMPORTANT INFORMATION 1-2 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 matedparts together. This includes gears, cylin-ders, pistons and other parts that havebeen mated through normal wear. Matedparts must always be reused or replaced asan assembly. 4. During disassembly, clean all of the partsand place them in trays in the order ofdisassembly. This will speed up assemblyand allow for the correct installation of allparts. 5.Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace-ments. Use oil and grease recommended byYamaha for all lubrication jobs. Other brandsmay be similar in function and appearance, butinferior in quality. EAS00022 GASKETS, OIL SEALS AND O-RINGs

1.When overhauling the engine, replace allgaskets, seals and O-rings. All gasket sur-faces, oil seal lips and O-rings must be cle-aned. 2. During reassembly, properly oil all matingparts and bearings and lubricate the oil seallips with grease

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GEN INFO IMPORTANT INFORMATION 1-3 EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu-facturers marks or numbers are visible. Wheninstalling oil seals, lubricate the oil seal lipswith a light coat of lithium-soap-based grease.Oil bearings liberally when installing, if appropriate. Oil seal CAUTION Do not spin the bearing with compressedair because this will damage the bearingsurfaces. Bearing EAS00025 CIRCLIPS Before reassembly, check all circlips carefullyand replace damaged or distorted circlips.Always replace piston pin clips after one use.When installing a circlip , make sure thesharp-edged corner is positioned oppositethe thrust that the circlip receives. Shaft GEN INFO CHECKING THE CONNECTIONS 1-4

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. Connect: lead coupler connector NOTE: Make sure all connections are tight. 5. Check: continuity (with the pocket tester) NOTE: If there is no continuity, clean the terminals. When checking the wire harness, perform steps (1) to (3). As a quick remedy, use a contact revitalizer available at most part stores

SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS2-1 ENGINE SPECIFICATIONS2-4CHASSIS SPECIFICATIONS2-6ELECTRICAL SPECIFICATIONS2-8

CONVERSION TABLE2-10 GENERAL TIGHTENING TORQUE SPECIFICATIONS2-10 ENGINE2-11 CHASSIS2-11 COOLANT FLOW CHART2-13 LUBRICATION POINTS AND LUBRICANT TYPE2-14 ENGINE2-14 CHASSIS2-15 CABLE ROUTING2-16

SPEC GENERAL SPECIFICATIONS 2-1 SPECIFICATIONS GENERAL SPECIFICATIONS model Model code Dimensions Overall length Overall width Overall height Seatheight Wheelbase Minimum ground clearance Minimum turning radius Basic weight With oil and full tank Engine Engine type Induction system Cylinder arrangement Displacement Borex stroke Compression ratio Maximum power Maximum torque Idle speed Starting system Lubrication system Oil type or grade Engine oil Total amount Transmission type Periodic oil change Total amount Radiator capacity Total amount ( including all DT 125 RE 1D01/1D02 2210mm 795mm 1200mm 900mm 1415mm 300mm 2100mm 126kg DT 125 X 2C81 2139mm 1121mm 1200mm 886mm 1396mm 271mm 2016mm 134kg

2 stroke, liquid cooled Reed valve Forward-inclined single cylinder 124 cubic cm 56.0 x 50.7 6.7: 1 111kw/ 8000rpm 13Nm/8000rpm 1250-1450r/min Electric starter Yamaha autolube

2T motor (Jaso grade fc) 1.3 L Type SE motor oil 0.75 L 0.8 L

0.92 L

routes) Coolant reservoir capacity

0.30 L

Air filter Fuel type Fuel tank capacity reserve Carburetor: Type/quantity manufacturer

Wet type element Regular unleaded gasoline 10.7 L 1.8 L Tm 28-92/ 1 mikuni

Model code SPARK PLUG : TYPE Manufacturer Spark plug gap Clutch type Transmission: Primary reductuion system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation :

1D01/1D02 BR8ES NKG 0.7-0.8 mm (0.0276-0.03315 in) Wet, multi disk Helical gear 71/22 (3,227) Chain drive 57/16 (3,563) Constant mesh, 6 speed Left foot operation

2C81

Gear ratio: st 1 nd 2 rd 3 th 4 th 5 th 6 Chasis Frame type: Castor angle trail Tire Type Size Front Rear manufacturer Cold tire pressure Front 0-90kg Rear 0-90kg

34/ 12(2.833) 30/16 (1.875) 24/17(1.412) 24/21(1.143) 22/23(0.957) 18/22 (0.818)

Semi double cradle 27 deg 107mm

semi double cradle 24.5 deg 73.1mm

With tube 80/90-21 48 P 110/80-18 58 P Michelin/T63

With tube 120/70-17 58 H 140/70-17 66 H Pirelli

150kpa(1.5kgf/cm2) 175kpa (1.75kgf/cm2)

180kpa (1.8kgf/cm2) 200kpa(2.0kgf/cm2)

Front 90-178 kg Rear 90-178kg Off road riding: Front Rear Brakes Front brake type Front brake operation Rear brake operation Suspensions: Front Rear Shock absorber: Front Rear Wheel travel Front wheel travel Rear wheel travel Electrical Ignition system Charging system Battery type Capacity

175kpa (1.75 kgf/ cm2) 200kpa (2.0kgf/cm2)

180kpa (1.8kgf/cm2) 200kpa (2.0kgf/cm2)

150kpa (1.5kgf/cm2) 175kpa (1.75kgf/cm2) Single disk 230mm diameter Right hand operation Right foot operation Single disk 298 mm diameter Right hand operation Right foot operation

Telescopic fork Swingarm (monocross suspension)

Coil air spring/ oil damper Coil and gas spring/ oil damper 270mm(10.63 in) 260 mm( 10.24 in) CDI AC MAGNETO GT6B-3 12V6Ah 200mm (7.87 inch 230mm ( 9.05 in)

headlight Bulb wattage x quantity Headlight Tail/ brake light Turn signal indicator Front Rear Meter control lights oil turn neutral high beam Low beam Amperages Principal fuse

Bulb type 12V60W/ 55W X1 12V21W/5W x1 12V10W X 1 12V10W X 1 LED

12V3W X 1 12 V3W X1 12V 3W X1 12V3W X 1 12V3W X 1 15A