Yamaha DT125RE, DT125X - Service Manual / Repair Manual

YAMAHA DT125RE, DT125X - SERVICE MANUAL

- English Service Manual, in PDF format, to motorcycles Yamaha model DT125RE and DT125X.



CONTENTS:


GENERAL INFORMATION

Motorcycle identification
- Frame serial number
- Engine serial number
Important information
- Preparation for removal
- All replacement parts
- Gaskets, oil seals and o-rings
- Lock washers/plates and cotter pins
- Bearings and oil seals
- Circlip
- Checking the connections
Special tools


SPECIFICATIONS

General specifications
- Engine specifications
- Chassis specifications
- Electrical specifications
Conversion table
General tightening torque specifications
- Engine
- Chassis
Coolant flow chart
Lubrication points and lubricant type
- Engine
- Chassis
Cable routing


PERIODIC CHECKS AND ADJUSTMENTS

Introduction/periodic maintenance/lubrication
Engine
- Y.p.v.s. Cable adjustment
- Idle speed adjustment
- Throttle cable free play adjustment
- Carburetor cable free play adjustment
- Autolube pump stroke adjustment
- Autolube pump air bleeding
- Spark plug inspection
- Ignition timing check
- Engine oil level inspection
- Transmission oil level inspection
- Transmission oil replacement
- Clutch adjustment
- Air filter cleaning
- Carburetor joint inspection
- Fuel line inspection
- Checking the crankcase breather hose
- Exhaust system inspection
- Engine oil line inspection
- Coolant level inspection
- Coolant replacement
- Cooling system inspection
Chassis
- Front brake adjustment
- Rear brake adjustment
- Brake fluid inspection
- Brake pad inspection
- Brake light switch adjustment
- Brake hose inspection
- Drive chain slack adjustment
- Drive chain lubrication
- Steering head adjustment
- Front fork inspection
- Rear shock absorber adjustment
- Tire inspection
- Wheel inspection
- Cable inspection and lubrication
Electrical
- Battery inspection
- Fuse inspection
- Headlight bulb replacement
- Headlight beam adjustment


CHASSIS

Front wheel
- Removal
- Inspection
- Installation
Rear wheel
- Removal
- Inspection
- Installation
Front and rear brake
- Brake pad replacement
- Caliper disassembly
- Master cylinder disassembly
- Inspection and repair
- Assembly
- Air bleeding
Front fork
- Removal
- Disassembly
- Inspection
- Assembly
Steering head and handlebar
- Removal
- Inspection
- Installation
Rear shock absorber and swingarm
- Handling notes
- Notes on disposal
- Removal
- Inspection
- Side clearance adjustment
- Installation
Drive chain and sprockets
- Removal
- Inspection
- Installation


ENGINE

Engine removal
- Side covers
- Coolant
- Transmission oil
- Exhaust pipe
- Carburetor
- Autolube pump cable and hose
- Clutch cable
- Y.p.v.s. Cables
- Radiator hose
- Leads
- Drive chain
Engine disassembly
- Cylinder head, cylinder and piston
- Clutch, primary drive gear and balancer gear
- Clutch push lever
- Shift sahft and stopper lever
- Magneto rotor
- Reed valve
- Crankcase (right)
- Shifter, transmission and balancer weight
- Crankshft
- Power valve
- Autolube pump assembly
Inspection and repair
- Cylinder head
- Cylinder and piston
- Piston rings
- Piston pin and bearing
- Clutch
- Primary drive
- Transmission and shifter
- Shift shaft and stopper lever
- Crankshaft
- Autolube pump
- Power valve
- Crankcase
Engine assembly and adjustments
- Autolube pump
- Power valve
- Crankshaft and balancer
- Transmission and shifter
- Crankcase (right)
- Reed valve
- Magneto rotor
- Stopper lever and shift shaft
- Clutch push lever
- Balancer gear, primary drive gear and clutch
- Piston cylinder and cylinder head
- Remounting engine


COOLING SYSTEM

Water pump
- Removal
- Inspection
- Installation
Thermostatic valve and radiator
- Removal
- Inspection
- Installation


CARBURETOR

Carburetor
- Removal
- Disassembly
- Inspection
- Assembly
- Installation
- Adjustment
Reed valve
- Removal
- Disassembly
- Inspection
- Assembly
- Installation


ELECTRICAL SYSTEM

Dt125re circuit diagram
- Color code
Electrical components
- Checking switch continuity
- Checking the switches
Ignition system
- Circuit diagram
- Ignition control circuit operation
- Troubleshooting
Charging system
- Circuit diagram
- Troubleshooting
Lighting system
- Circuit diagram
- Troubleshooting
Signaling system
- Circuit diagram
- Troubleshooting
Cooling system
- Circuit diagram
- Troubleshooting
Yamaha poer valve system
- Circuit diagram
- Troubleshooting
Meter assembly
- Removal
- Installation


TROUBLESHOOTING

Starting failure / hard starting
- Fuel system
- Electrical system
Poor idle speed performance
- Poor idle speed performance
Poor medium and high speed performance
- Fuel system
- Electrical system
- Compression system
- Y.p.v.s.
Faulty gear shifting
- Hard shifting
- Change pedal does not move
- Jump out gear
Clutch slipping/dragging
- Clutch slipping
- Clutch dragging
Faulty brake
- Poor braking effect
Front fork oil leakage and front fork malfunction
- Oil leakage
- Malfunction
Instable handling
- Instable handling
Faulty signal and lighting system
- Headlight dark
- Bulb burnt out
- Flasher does not light
- Flasher keeps on
- Flasher winks slower
- Flasher winks quicker
- Horn is inoperative
Faulty y.p.v.s.
- Faulty y.p.v.s
Overheating or overcooling
- Overheating
- Overcooling
Dt125 wiring diagram


WIRING DIAGRAM COMPONENTS

- CDI. Mag.
- Rect./Regu.
- Battery
- Fuse
- Starter Relay
- Starting Motor
- Main Sw.
- Handle Sw. R
- Starter Sw.
- E/G Stop Sw.
- Clutch Sw.
- Side Stand Sw.
- Thermo Sw.
- Side Stand Relay
- Neutral Sw.
- CDI. Unit
- Ign. Coil
- Servo. Motor
- Lightning Relay
- Horn Sw.
- Dimmer Sw.
- Flasher Sw.
- Hazard Sw.
- Handle Sw. L
- Horn
- Flasher Relay
- Fr. Stop Sw.
- Rr. Stop Sw.
- Head Light
- Fr. Lh Flasher
- Rr. Lh Flasher
- Fr. Rh Flasher
- Rr. Rh Flasher
- Tail/Stop Light
- Oil Level Gauge
- Meter
- Diode 1
- License Light
- Position Lamp
- Anti Theft Unit