FOREWORD

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 SERVICE MANUAL: 3BN-ME1 DT125R /DT125R ELECTRIC SUPPLEMENTARY SERVICE MANUAL: 3MB-AE1 DT125R /DT125RE SUPPLEMENTARY SERVICE MANUAL: 3BN-AE2 DT125R /DT125RE SUPPLEMENTARY SERVICE MANUAL: 3BN-AE3

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 mechanics 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 knowledge, 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. Modifications 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.

PARTICULARLY IMPORTANT INFORMATION

This material is distinguished by the following notation. 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 motorcycle.

CAUTION:
NOTE:

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 cleaer.

HOW TO USE THIS MANUAL

CONSTRACTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See Illustrated symbols) 1st title 1 : 2nd title 2 : This is a chapter with its symbol on the upper right of each page. 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.) This is a final title.

3rd title 3 :

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 D. IMPORTANT FEATURES S Data and a special tool are framed in a box preceded by a relevant symbol 5 . S 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 . S 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 chapters number and content. 1 2 3 4 5 6 7 8 9
General information Specifications Periodic inspection and adjustment Engine Cooling system Carburetion Chassis Electrical Troubleshooting

Illustrated symbols 10 to 16 are used to identify the specifications appearing in the text.
10 Filling fluid 11 Lubricant 12 Special tool 13 Tightening 14 Wear limit, clearance 15 Engine speed 16 , V, A

Illustrated symbols 17 to 23 in the exploded diagram indicate grade of lubricant and location of lubrication point.
17 Apply engine oil 18 Apply gear oil 19 Apply molybdenum disulfide oil 20 Apply wheel bearing grease 21 Apply lightweight lithium-soap base grease 22 Apply molybdenum disulfide grease 23 Apply locking agent (LOCTITE)

CONTENTS GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5 FRAME SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5 MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5

SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5 MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6

PERIODIC INSPECTION AND ADJUSTMENT

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7 PERIODIC MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . E-7 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8 AUTOLUBE PUMP AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8

ELECTRICAL
DT125R CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8 COLOR CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9 IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9 DT125R 99 WIRING DIAGRAM

MOTORCYCLE IDENTIFICATION

GEN INFO

GENERAL INFORMATION
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.

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS
Model Model Code Number DT125R 3RMF (F) 3RMD (G) 3RME (GB) (N) (S) (SF) (G) (B) (SP) (P) (I) (GR) 4DJ9 (H) (A) 2170 mm (3RMD) (3RME) (3RMF) 2235 mm (4DJ9) 127 kg (3RMD) (3RME) (3RMF) 129 kg (4DJ9) Liquid cooled 2-stroke, gasoline Reed valve Single cylinder, Forward inclined 124 cm3 56.0 50.7 mm 6.7 : 1 (4DJ9) 6.5 : 1 (3RMD) (3RME) (3RMF) Kick starter Separate lubrication (Yamaha Autolube) TM28SS/1 pc. MIKUNI BR8ES/1 pc. (4DJ9) BR9ES/1 pc. (3RMD) (3RME) (3RMF) NGK 0.7 X 0.8 mm

Dimensions Overall length Basic Weight: With Oil and Full Fuel Tank Engine: Engine Type Induction System Cylinder Arrangement Displacement Bore Stroke Compression Ratio Starting System Lubrication System Carburetor: Type/Quantity Manufacturer Spark Plug: Type/Quantity Manufacturer Plug Gap

MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS

ENGINE

SPEC

Carburetor: I.D. Mark Main Jet Air Jet Jet Needle-Position Needle Jet Cutaway Pilot Outlet Pilot Jet Air Screw Bypass 1 Valve Seat Size Starter Jet Power Jet Fuel Level Float Height Idling Speed Lubrication System: Autolube Pump: Color Code Minimum Stroke Maximum Stroke Minimum Output Maximum Output Pulley Adjusting Mark

(M.J.) (A.J.) (J.N.) (N.J.) (C.A.) (P.O.) (P.J.) (A.S.) (B.P.1) (V.S.) (G.S.) (PW.J.) (F.L.) (F.H.)

3RM02 (3RMD) (3RME) (3RMF) 4DJ02 (4DJ9) #210 (4DJ9) #240 (3RMD) (3RME) (3RMF) 0.7 5J25-4 (3RMD-E-F) 5J25-3 (4DJ9) Q-2 2.5 0.6 #17.5 (4DJ9) #25 (3RMD-E-F) 1-1/4 (3RMD-E-F) 1-5/8 (4DJ9) 1.6 2.8 #40 #60 (4DJ9) #95 (3RMD-E-F) 0.5 X +1.5 mm 15.5 X 16.5 mm 1,300 X 1,400 r/min

Green (3RME-D) (4DJ9) Red (3RMF) 0.20 X 0.24 0.20 X 0.24 1.35 X 1.49 2.72 X 2.86 0.38 X 0.46 cm3 /200 stroke 0.38 X 0.46 cm3 /200 stroke 2.59 X 2.86 cm3 /200 stroke 5.23 X 5.5 cm3 /200 stroke Auto adjuster

MAINTENANCE SPECIFICATIONS
ELECTRICAL

SPEC

Model CDI: Magneto Model/Manufacturer C.B.I. Unit Model/Manufacturer

DT125R F3RM/YAMAHA 3RM-10/YAMAHA (3RMD) 3RM-20/YAMAHA (3RME) 3RM-30/YAMAHA (4DJ9) (3RMF) 688 X 1,032 at 20_C (Blank/Red Green/White) Resin type 5 k C.D.I. magneto F3RM/YAMAHA Semi-conductor-Short circuit type SH671-12/SHINDENGEN 8A Full transistor type FE246BH/DENSO 2YK/NIPPON SEKI

Source Coil Resistance Spark Plug Cap: Type Resistance Charging System: C.D.I. magneto: Model/Manufacturer Rectifier/Regulator Type Model/manufacturer Capacity Flasher Relay: Type Model/Manufacturer Thermo Unit: Model/Manufacturer

INTRODUCTION/ PERIODIC MAINTENANCE AND LUBRICATION

INTRODUCTION

INSP ADJ

PERIODIC INSPECTION AND ADJUSTMENT

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.

PERIODIC MAINTENANCE AND LUBRICATION

EVERY Initial (1,000 km) 6,000 km or 6 months (Whichever comes first) 12,000 km or 12 months (Whichever comes first)

No.

ITEM

CHECKS AND MAINTENANCE JOBS

1 2 3 4

Fuel line Spark plug Air filter

S Check fuel hoses for cracks or damage. S Replace if necessary. S Check condition. S Clean, regap or replace if necessary. S Clean or replace if necessary. S Check electrolyte level and specific gravity. S Correct or recharge if necessary. S Make sure that the breather hose is properly routed. S Check operation. S Adjust or replace cable. S Check operation, fluid level and vehicle for fluid leakage. (See NOTE) S Correct accordingly. S Replace brake pads if necessary. S Check operation, fluid level and vehicle for fluid leakage. (See NOTE) S Correct accordingly. S Replace brake pads if necessary. S Check balance, runout, spoke tightness and for damage. S Tighten spokes and rebalance, replace if necessary. S S S S Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary.

Battery

Clutch

Front brake

Rear brake

Wheels

Tires

10 11

* *

Wheel bearings Swingarm

S Check bearing for looseness or damage. S Replace if necessary. S Check swingarm pivoting point for play. S Correct if necessary. S Check chain slack. S Adjust if necessary. Make sure that the rear wheel is properly aligned S Clean and lubricate. S Check bearing play and steering for roughness. S Correct accordingly. S Lubricate with lithium soap base grease every 24,000 km or 24 months (whichever comes first). S Make sure that all nuts, bolts and screws are properly tightened. S Tighten if necessary. S Check operation. S Lubricate and repair if necessary. Every 500 km and after washing the motorcycle or riding in the rain

12

Drive chain

13

Steering bearings

14

Chassis fasteners

15

Sidestand

PERIODIC MAINTENANCE AND LUBRICATION

INSP ADJ
EVERY 6,000 km or 6 months (Whichever comes first) 12,000 km or 12 months (Whichever comes first)

No.

ITEM

CHECKS AND MAINTENANCE JOBS

Initial (1,000 km)

16 17 18

* * *

Sidestand switch Front fork Rear shock absorber assembly Rear suspension relay arm and connecting arm pivoting points Carburetor

S Check operation. S Replace if necessary. S Check operation and for oil leakage. S Correct accordingly. S Check operation and shock absorber for oil leakage. S Replace shock absorber assembly if necessary. S Check operation. S Correct if necessary. S Check engine idling speed and starter operation. S Adjust if necessary. S Check operation. S Correct if necessary. S Bleed if necessary. S Check oil level and vehicle for oil leakage. S Correct accordingly. S Change oil at initial 1,000 km and thereafter every 24,000 km or 24 months (whichever comes first). S Check coolant level and vehicle for coolant leakage. S Correct if necessary. S Change coolant every 24,000 km or 24 months (whichever comes first).

19

20

21

Autolube pump

22

Transmission oil

23

Cooling system

* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.

NOTE: S The air filter needs more frequent service if you are riding in unusually wet or dusty areas. S Hydraulic brake system S When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid level regularly and fill as required. S Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years. S Replace the brake hoses every four years or if cracked or damaged.

ENGINE
ENGINE

INSP ADJ

AUTOLUBE PUMP AIR BLEEDING

NOTE: The Autolube pump and delivery lines must be bled on the following occasions: S Setting up a new motorcycle out of the create. S Whenever the oil tank has run dry. S Whenever any portion of the engine oil system is disconnected.
1. Remove: S Autolube pump cover 2. Fill: S Oil tank 1 Yamaha Oil 2T or Air-Cooled 2-Stroke Engine Oil 2 Oil tank filler cap

3. Air bleed: S Pump case and/or oil pipe Air bleeding steps: S Remove the bleed screw 1 . S Keep the oil running out until a bubbles disappear. S When air bubbles are expelled completely, tighten the bleed screw.

NOTE: S Check the bleed screw gasket, and if damaged, replace with a new one. S Place a rag or oil pan under the autolube pump to catch oil.

DT125R CIRCUIT DIAGRAM

ELEC

ELECTRICAL
DT125R CIRCUIT DIAGRAM

DT125R CIRCUIT DIAGRAM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

ELEC

CDI magneto Neutral switch Rectifier / regulator Fuse Battery Main switch ENGINE STOP switch Servomotor CDI unit Ignition coil Read switch Meter light Meter light Neutral indicator light Oil level indicator light High beam indicator light Engine temperature gauge Thermo unit

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

Turn indicator light Neutral relay Sidestand switch Oil level switch Rear brake switch Front brake switch Tail / brake light Flasher relay Horn Flasher light Turn switch Horn switch Lights (Dimmer) switch Lights switch Handlebar switches (left) Auxiliary light Headlight

COLOR CODE

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

W/R W/L Y/R G/R G/Y G/W Br/W L/R

White/Red White/Blue Yellow/Red Green/Red Green/Yellow Green/White Brown/White Blue/Red

IGNITION SYSTEM
IGNITION SYSTEM
TROUBLESHOOTING Check: 1. Sidestand switch 2. Neutral switch 3. Wiring connection (Ignition system) 1. Sidestand switch S Disconnect the sidestand switch leads from the wireharness. S Connect the Pocket Tester ( 1) to the sidestand switch. Tester (+) Lead ! Black 1 Terminal Tester () Lead ! Black 2 Terminal

ELEC

S Move the sidestand to up position and down position. S Check the sidestand switch for continuity. Sidestand position Up Down f: Continuity Good condition f f : No continuity GOOD CONDITION Bad condition BAD CONDITION f f Replace Sidestand switch.

10

IGNITION SYSTEM

ELEC

2. Neutral switch S Disconnect the Neutral relay coupler 1 from the wireharness. S Connect the Pocket Tester ( 1) to the neutral switch lead. Tester (+) Lead ! Sky blue 2 lead Tester () Lead ! Frame Ground

S Shift the transmission in neutral and gear. S Check the neutral switch for continuity.
Transmission position

Good condition f

Bad condition BAD CONDITION f f f Replace neutral switch.

Neutral Gear f: Continuity

: No continuity GOOD CONDITION

11

IGNITION SYSTEM

ELEC

3. Neutral relay S Disconnect the neutral relay from the wireharness. S Connect the pocket tester ( 1) and battery (12 V) to the neutral relay.

NO CONTINUITY

S Check the neutral relay for continuity. CONTINUITY 4. Wiring connection S Check the entire ignition system for connections. Refer to the WIRING DIAGRAM section. CORRECT Replace ignition control unit.

Neutral relay is faulty, replace it.

POOR CONNECTION

Correct.

12

DT125R 99 WIRING DIAGRAM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

CDI magneto Neutral switch Rectifier/ regulator Fuse Battery Main switch ENGINE STOP switch Servomotor CDI unit Ignition coil Read switch Meter light Meter light Neutral indicator light Oil level indicator light High beam indicator light Engine temperature gauge Thermo unit Turn indicator light Neutral relay Sidestand switch Oil level switch Rear brake switch Front brake switch Tail/ brake light Flasher relay Horn Flasher light Turn switch Horn switch Lights (Dimmer) switch Lights switch Handlebar switches (left) Auxiliary light Headlight

COLOR CODE
B ...... R...... O ..... L ...... Black Red Orange Blue P ...... Y ...... G ..... W ..... Pink Yellow Green White Ch . . . . Dg . . . . Sb . . . . . Br . . . . . Chocolate Dark green Sky blue Brown L/Y . . . . B/Y . . . . B/W . . . B/R. . . . Blue / Yellow Black / Yellow Black / White Black / Red W/R . . . W/L . . . Y/R. . . . G/R . . . White / Red White / Blue Yellow / Red Green / Red G/Y . . . G/W . . . Br / W . . L/R . . . . Green / Yellow Green / White Brown / White Blue / Red