Professional Documents
Culture Documents
This Supplementary Service Manual has been prepared to introduce new service and data for the DT125R
’99. For complete information on service procedures, it is necessary to use this Supplementary Service
Manual together with following manual:
DT125R
SUPPLEMENTARY
SERVICE MANUAL
1998 by Yamaha Motor Co., Ltd.
1st Edition, October 1998
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
NOTICE
This manual was written by Yamaha Motor Company Ltd. primarily for use by Yamaha dealers and qualified
mechanics. It is not possible to put an entire mechanic’s education into one manual, so persons using this
book to perform maintenance and repairs on Yamaha motorcycles should have a basic understanding of
the mechanical concepts and procedures inherent in motorcycle repair technology. Without such knowl-
edge, attempted repairs or service to the motorcycle may render it unfit to use and/or unsafe.
Yamaha Motor Company Ltd. is continually striving to improve all models manufactured by Yamaha. Modifi-
cations and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha
dealers and will, where applicable, appear in future editions of this manual.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY
IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to the
motorcycle operator, a bystander, or a person inspecting or repairing the motor-
cycle.
CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to
the motorcycle.
1st title 1 : This is a chapter with its symbol on the upper right of each page.
2nd title 2 : This title appears on the upper of each page on the left of the chapter symbol. (For
the chapter “Periodic inspection and adjustment” the 3rd title appears.)
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The information has
been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive
explanations of all disassembly, repair assembly, and inspections.
A set of particularly important procedure 4 is placed between a line of asterisks “ ” with each procedure
preceded by “”.
IMPORTANT FEATURES
Data and a special tool are framed in a box preceded by a relevant symbol 5 .
An encircled numeral 6 indicates a part name, and an encircled alphabetical letter data or an alignment
mark 7 , the others being indicated by an alphabetical letter in a box 8 .
A condition of a faulty component will precede an arrow symbol and the course of action required the
symbol 9 .
EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct
disassembly and assembly procedures.
ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols 1 to 9 are designed as
thumb tabs to indicate the chapter’s number and
content.
1 General information
2 Specifications
3 Periodic inspection and adjustment
4 Engine
5 Cooling system
6 Carburetion
7 Chassis
8 Electrical
9 Troubleshooting
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
FRAME SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8
AUTOLUBE PUMP AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8
ELECTRICAL
DT125R CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8
COLOR CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9
MOTORCYCLE IDENTIFICATION
FRAME SERIAL NUMBER
The frame serial number 1 is stamped into the
right side of the steering head pipe.
MODEL LABEL
The model label 1 is affixed to the frame.
This information will be needed to order spare
parts.
–1–
GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model DT125R
Model Code Number 3RMF (F)
3RMD (G)
3RME (GB) (N) (S) (SF) (G) (B)
(SP) (P) (I) (GR)
4DJ9 (H) (A)
Dimensions
Overall length 2170 mm (3RMD) (3RME) (3RMF)
2235 mm (4DJ9)
Basic Weight:
With Oil and Full Fuel Tank 127 kg (3RMD) (3RME) (3RMF)
129 kg (4DJ9)
Engine:
Engine Type Liquid cooled 2-stroke, gasoline
Induction System Reed valve
Cylinder Arrangement Single cylinder, Forward inclined
Displacement 124 cm3
Bore Stroke 56.0 50.7 mm
Compression Ratio 6.7 : 1 (4DJ9)
6.5 : 1 (3RMD) (3RME) (3RMF)
Starting System Kick starter
Lubrication System Separate lubrication (Yamaha Autolube)
Carburetor:
Type/Quantity TM28SS/1 pc.
Manufacturer MIKUNI
Spark Plug:
Type/Quantity BR8ES/1 pc. (4DJ9)
BR9ES/1 pc. (3RMD) (3RME) (3RMF)
Manufacturer NGK
Plug Gap 0.7 0.8 mm
–2–
MAINTENANCE SPECIFICATIONS SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Carburetor:
I.D. Mark 3RM02 (3RMD) (3RME) (3RMF) 4DJ02 (4DJ9)
Main Jet (M.J.) #210 (4DJ9) #240 (3RMD) (3RME) (3RMF)
Air Jet (A.J.) ø0.7
Jet Needle-Position (J.N.) 5J25-4 (3RMD-E-F) 5J25-3 (4DJ9)
Needle Jet (N.J.) Q-2
Cutaway (C.A.) 2.5
Pilot Outlet (P.O.) 0.6
Pilot Jet (P.J.) #17.5 (4DJ9) #25 (3RMD-E-F)
Air Screw (A.S.) 1-1/4 (3RMD-E-F) 1-5/8 (4DJ9)
Bypass 1 (B.P.1) ø1.6
Valve Seat Size (V.S.) ø2.8
Starter Jet (G.S.) #40
Power Jet (PW.J.) #60 (4DJ9) #95 (3RMD-E-F)
Fuel Level (F.L.) –0.5 +1.5 mm
Float Height (F.H.) 15.5 16.5 mm
Idling Speed 1,300 1,400 r/min
Lubrication System:
Autolube Pump:
Color Code Green (3RME-D) (4DJ9) Red (3RMF)
Minimum Stroke 0.20 0.24 0.20 0.24
Maximum Stroke 1.35 1.49 2.72 2.86
Minimum Output 0.38 0.46 cm3 /200 stroke 0.38 0.46 cm3 /200 stroke
Maximum Output 2.59 2.86 cm3 /200 stroke 5.23 5.5 cm3 /200 stroke
Pulley Adjusting Mark Auto adjuster
–3–
MAINTENANCE SPECIFICATIONS SPEC
ELECTRICAL
Model DT125R
CDI:
Magneto Model/Manufacturer F3RM/YAMAHA
C.B.I. Unit Model/Manufacturer 3RM-10/YAMAHA (3RMD)
3RM-20/YAMAHA (3RME)
3RM-30/YAMAHA (4DJ9) (3RMF)
Source Coil Resistance 688 1,032 Ω at 20C
(Blank/Red – Green/White)
Spark Plug Cap:
Type Resin type
Resistance 5 kΩ
Charging System: C.D.I. magneto
C.D.I. magneto:
Model/Manufacturer F3RM/YAMAHA
Rectifier/Regulator
Type Semi-conductor-Short circuit type
Model/manufacturer SH671-12/SHINDENGEN
Capacity 8A
Flasher Relay:
Type Full transistor type
Model/Manufacturer FE246BH/DENSO
Thermo Unit: 2YK/NIPPON SEKI
Model/Manufacturer
–4–
INTRODUCTION/ INSP
PERIODIC MAINTENANCE AND LUBRICATION ADJ
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjustments.
These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a
longer service life. The need for costly overhaul work will be greatly reduced. This information applies to
vehicles already in service as well as new vehicles that are being prepared for sale. All serviced technicians
should be familiar with this entire chapter.
–5–
INSP
PERIODIC MAINTENANCE AND LUBRICATION ADJ
EVERY
6,000 km 12,000 km
Initial or or
No. ITEM CHECKS AND MAINTENANCE JOBS
(1,000 km) 6 months 12 months
(Whichever (Whichever
comes first) comes first)
Check operation.
16 * Sidestand switch
Replace if necessary.
Check operation and for oil leakage.
17 * Front fork
Correct accordingly.
Rear shock absorber Check operation and shock absorber for oil leakage.
18 *
assembly Replace shock absorber assembly if necessary.
Rear suspension
relay arm and Check operation.
19 *
connecting arm Correct if necessary.
pivoting points
Check engine idling speed and starter operation.
20 * Carburetor
Adjust if necessary.
Check operation.
21 * Autolube pump Correct if necessary.
Bleed if necessary.
Check oil level and vehicle for oil leakage.
Correct accordingly.
22 Transmission oil
Change oil at initial 1,000 km and thereafter every
24,000 km or 24 months (whichever comes first).
Check coolant level and vehicle for coolant leakage.
Correct if necessary.
23 * Cooling system
Change coolant every 24,000 km or 24 months
(whichever comes first).
* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.
NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake system
When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the
brake fluid level regularly and fill as required.
Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
Replace the brake hoses every four years or if cracked or damaged.
–6–
INSP
ENGINE ADJ
ENGINE
AUTOLUBE PUMP AIR BLEEDING
NOTE:
The Autolube pump and delivery lines must be
bled on the following occasions:
Setting up a new motorcycle out of the create.
Whenever the oil tank has run dry.
Whenever any portion of the engine oil system is
disconnected.
1. Remove:
Autolube pump cover
2. Fill:
Oil tank 1
3. Air bleed:
Pump case and/or oil pipe
–7–
DT125R CIRCUIT DIAGRAM ELEC
ELECTRICAL
DT125R CIRCUIT DIAGRAM
–8–
DT125R CIRCUIT DIAGRAM ELEC
1 CDI magneto 19 Turn indicator light
2 Neutral switch 20 Neutral relay
3 Rectifier / regulator 21 Sidestand switch
4 Fuse 22 Oil level switch
5 Battery 23 Rear brake switch
6 Main switch 24 Front brake switch
7 “ENGINE STOP” switch 25 Tail / brake light
8 Servomotor 26 Flasher relay
9 CDI unit 27 Horn
10 Ignition coil 28 Flasher light
11 Read switch 29 “Turn” switch
12 Meter light 30 “Horn” switch
13 Meter light 31 “Lights” (Dimmer) switch
14 Neutral indicator light 32 “Lights” switch
15 Oil level indicator light 33 Handlebar switches (left)
16 High beam indicator light 34 Auxiliary light
17 Engine temperature gauge 35 Headlight
18 Thermo unit
COLOR CODE
–9–
IGNITION SYSTEM ELEC
IGNITION SYSTEM
TROUBLESHOOTING
Check:
1. Sidestand switch
2. Neutral switch
3. Wiring connection (Ignition system)
1. Sidestand switch
Disconnect the sidestand switch leads from
the wireharness.
Connect the Pocket Tester (Ω 1) to the side-
stand switch.
Tester (+) Lead Black 1 Terminal
Tester (–) Lead Black 2 Terminal
GOOD
CONDITION
–10–
IGNITION SYSTEM ELEC
2. Neutral switch
Disconnect the Neutral relay coupler 1 from
the wireharness.
Connect the Pocket Tester (Ω 1) to the neu-
tral switch lead.
Tester (+) Lead Sky blue 2 lead
Tester (–) Lead Frame Ground
GOOD
CONDITION
–11–
IGNITION SYSTEM ELEC
3. Neutral relay
S Disconnect the neutral relay from the wirehar-
ness.
S Connect the pocket tester (Ω 1) and battery
(12 V) to the neutral relay.
NO CONTINUITY
S Check the neutral relay for continuity. Neutral relay is faulty, replace it.
CONTINUITY
CORRECT
–12–
DT125R ’99 WIRING DIAGRAM
1 CDI magneto
2 Neutral switch
3 Rectifier/ regulator
4 Fuse
5 Battery
6 Main switch
7 “ENGINE STOP” switch
8 Servomotor
9 CDI unit
10 Ignition coil
11 Read switch
12 Meter light
13 Meter light
14 Neutral indicator light
15 Oil level indicator light
16 High beam indicator light
17 Engine temperature gauge
18 Thermo unit
19 Turn indicator light
20 Neutral relay
21 Sidestand switch
22 Oil level switch
23 Rear brake switch
24 Front brake switch
25 Tail/ brake light
26 Flasher relay
27 Horn
28 Flasher light
29 “Turn” switch
30 “Horn” switch
31 “Lights” (Dimmer) switch
32 “Lights” switch
33 Handlebar switches (left)
34 Auxiliary light
35 Headlight
COLOR CODE
B ...... Black P ...... Pink Ch . . . . Chocolate L/Y . . . . Blue / Yellow W/R . . . White / Red G/Y . . . Green / Yellow
R...... Red Y ...... Yellow Dg . . . . Dark green B/Y . . . . Black / Yellow W/L . . . White / Blue G/W . . . Green / White
O ..... Orange G ..... Green Sb . . . . . Sky blue B/W . . . Black / White Y/R. . . . Yellow / Red Br / W . . Brown / White
L ...... Blue W ..... White Br . . . . . Brown B/R. . . . Black / Red G/R . . . Green / Red L/R . . . . Blue / Red