2005

DT125RE 1D01-AE1

DT125X
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. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.
Yamaha Motor España 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 dealers
and will appear in future editions of this manual where applicable.

NOTE:
Designs and specifications are subject to change without notice.

TECHNICAL PUBLICATIONS
YAMAHA MOTOR ESPAÑA, S.A.

EAS00004

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.
t The Safety Alert Symbol means ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!

s WARNING Failure to follow WARNING instructions could result in severe injury

or death to the motorcycle operator, a bystander or a person chec-
king or repairing the motorcycle.

CAUTION A CAUTION indicates special precautions that must be taken to

avoid damage to the motorcycle.

NOTE : A NOTE provides key information to make procedures easier or cle-

arer.
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 cor-
ner 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 each
page, 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 indi-
cates 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.
 EAS00008
 
SYMBOLS
GEN SPEC The following symbols are not relevant to
INFO every vehicle.

  Symbols  to indicate the subject of each

chapter.
CHK
CHAS 
ADJ General information
 Specifications
   Periodic checks and adjustments
 Chassis
ENG COOL  Engine
 Cooling system
 Carburetor(s)
 Electrical system
Troubleshooting
CARB ELEC


10
Symbols 
10 to 
17 indicate the following.
TRBL
SHTG 
10 Serviceable with engine mounted

11 Filling fluid

11 
12 
12 Lubricant

13 Special tool

14 Tightening torque

15 Wear limit, clearance

16 Engine speed

13 
14 
17 Electrical data

Symbols  18 to 
23 in the exploded diagrams

15 
16 
17
indicate the types of lubricants and lubrica-
tion points.


18 Engine oil


18 
19 
20

19 Gear oil

20 Molybdenum-disulfide oil

21 Wheel-bearing grease

22 Lithium-soap- based grease

23 Molybdenum-disulfide grease

21 
22 
23

Symbols  24 to 25 in the exploded diagrams

indicate the following.

24 
25

24 Apply locking agent (LOCTITE®)
New 
25 Replace the part
EAS00010

TABLE OF CONTENTS
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC
2
PERIODIC CHECKS AND
ADJUSTMENTS CHK
ADJ 3
CHASSIS CHAS
4
ENGINE ENG
5
COOLING SYSTEM COOL
6
CARBURETOR CARB
7
ELECTRICAL SYSTEM ELEC
8
TROUBLESHOOTING TRBL
SHTG 9
 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 CONNECTIONS……………………………………………1-4

SPECIAL TOOLS …………………………………………………………………1-5

 GEN
MOTORCYCLE IDENTIFICATIONS 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 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 num-
ber” of production of the unit.

NOTE:
Design and specifications may change without
notice.

1-1
 GEN
IMPORTANT INFORMATION 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, cylin-
ders, pistons and other parts that have
been “mated” through normal wear. Mated
parts must always be reused or replaced as
an assembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of
disassembly. This will speed up assembly
and allow for the correct installation of all
parts.
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 by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.

EAS00022

GASKETS, OIL SEALS AND O-RINGS

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

1-2
 GEN
IMPORTANT INFORMATION INFO
EAS00024

BEARINGS AND OIL SEALS

Install bearings and oil seals so that the manu-
facturer’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 appro-
priate.
 Oil seal

CAUTION
Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.

 Bearing

EAS00025

CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip , make sure the
sharp-edged corner  is positioned opposite
the thrust  that the circlip receives.
 Shaft

1-3
 GEN
CHECKING THE CONNECTIONS 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. Connect:
• lead
• coupler
• connector

NOTE:
Make sure all connections are tight.

5. Check:
• continuity
(with the pocket tester)
Pocket tester
90890-03112, YU-3112

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.

1-4
 GEN
SPECIAL TOOLS 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 inappro-
priate 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. Tool name / Usage Illustration

90890-01312 Fuel level gauge

This gauge is used to measure the fuel level in

the float chamber.
90890-03113 Engine tachometer

This tool is needed for detecting engine rpm.

90890-04086 Universal tool of subjection of the clutch

This tool is used to immobilize the clutch

during the assembly or disassembly of the
blockade nut of the clutch.
90890-01701 Sheave holder

This tool is used for holding the secondary

sheave.
90890-01362 Flywheel puller

For removing the flywheel.

90890-01304 Piston pin puller

This tool is used to remove the piston pin.

90890-01325 Radiator cap tester
90890-01352 Adaptor

These tools are used for checking the

cooling system.

1-5
 GEN
SPECIAL TOOLS INFO

Tool No. Tool name / Usage Illustration

90890-01135 Crankcase separation tool

This tool is used to remove the crankshaft

or separate the crankcase.
90890-01274 (1) Cranckshaft intalling tool
-01275 (2) Crankshaft pin
-01278 (3) 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 Fork seal driver weight
-01381 Fork seal driver attachment

This tool is used when installing the fork seal.

90890-01403 Ring nut wrench

This tool is used to loosen and tighten

the steering ring nut.
90890-03112 Pocket tester

These instruments are invaluable for

checking the electrical system.

1-6
 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 ………………………………………………………………………2-14
CHASSIS ………………………………………………………………………2-15

CABLE ROUTING ………………………………………………………………2-16

 GENERAL SPECIFICATIONS SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS

Model DT125RE DT125X

Model code 1D01/1D02 2C81
Dimensions:
Overall lenght 2210mm 2139mm
Overall width 795mm 1121mm
Overall height 1200mm 1200mm
Seatheight 900mm 886mm
Wheelbase 1415mm 1396mm
Minimum ground clearance 300mm 271 mm
Minimum turning radius 2100mm 2016mm
Basic weight:
With oil and full fuel tank 126kg 134 kg
Engine:
Engine type: 2 strokes, liquid cooled
Induction system Reed valve
Cylinder arrangement Forward-inclined single cylinder
Displacement 124cm3
BorexStroke 56,0x50,7
Compression ratio 6,7:1
Maximum power 11kW /8000rpm
Maximum torque 13Nm/8000rpm
Idle speed 1250~1450r/min
Starting system Electric starter
Lubrication system Yamaha Autolube
Oil type or grade:
Engine oil 2T motor oil (JASO grade FC)
Total amount 1,3L
Transmission oil Type SE motor oil
Periodic oil change 0,75L (0,79 us. qt.)
Total amount 0,8L (0,85 us.qt.)
Radiator capacity:
Total amount (including all routes) 0,92L
Coolant reservoir capacity 0,30L
Air filter: Wet type element
Fuel
Type Regular unleaded gasoline
Fuel tank capacity: 10,7L
Reserve 1,8L
Carburetor:
Type/quantity TM28-92 / 1
Manufacturer: MIKUNI

2-1
 GENERAL SPECIFICATIONS SPEC

Model code 1D01/1D02 2C81

Spark plug:
Type BR8ES
Manufacturer NGK
Spark plug gap 0,7~0,8mm (0,0276~0,03315in)
Clutch type Wet, multiple disc
Transmission:
Primary reduction system Helical gear
Primary reduction ratio 71/22(3,227)
Secondary reduction system chain drive
Secondary reduction ratio 57/16(3,563)
Transmission type Constant mesh, 6 speed
Operation Left foot operation
Gear ratio:
1ª 34/12(2.833)
2ª 30/16(1.875)
3ª 24/17(1.412)
4ª 24/21(1.143)
5ª 22/23(0.957)
6ª 18/22(0.818)
Chassis:
Frame type: Semi double cradle Semi double cradle
Castor angle 27º 24,5°
Trail 107mm 73,1 mm
Tire:
Type With tube With tube
Size
Front 80/90-21 48P 120/70-17 58H
Rear 110/80-18 58P 140/70-17 66H
Manufacturer Michelin /T63 Pirelli/ Sport Demon
Cold tire pressure:
Front 0~90kg 150kPa (1.5kgf/cm2) 180kPa (1.8kgf/cm2)
Rear 0~90kg 175kPa (1.75kgf/cm2) 200kPa (2.0kgf/cm2)
Front 90~178kg 175kPa (1.75kgf/cm2) 180kPa (1.8kgf/cm2)
Rear 90~178kg 200kPa (2.0kgf/cm2) 200kPa (2.0kgf/cm2)
Off road riding:
Front 150kPa (1.5kgf/cm2)
Rear 175kPa(1.75kgf/cm2)
Brakes:
Front brake type Single disc brake Single disc brake
230mm diameter 298 mm diameter
Front brake operation Right hand operation Right hand operation
Rear brake type Single disc brake Single disc brake
220mm diameter 220 mm diameter
Rear brake operation Right foot operation Right foot operation
Suspensions:
Front Telescopic fork
Rear Swingarm (monocross suspension)
Shock absorber:
Front Coil-air spring/Oil damper
Rear Coil and gas spring/Oil damper

2-2
 GENERAL SPECIFICATIONS SPEC

Model code 1D01/1D02 2C81

Wheel travel:
Front wheel travel 270mm(10.63in) 200mm (7,87in)
Rear wheel travel 260mm(10.24in) 230mm (9.05in)
Electrical:
Ignition system CDI
Charging system AC Magneto
Battery type GT6B-3
Capacity 12V 6Ah
Headlight: bulb type
Bulb wattage x quantity:
Headlight 12V60W/55W x 1
Tail/Brake light 12V21W/5W x 1
Turn signal indicator light

Front 12V10W x 1
Rear 12V10W x 1
Meter LED
Control lights:
“OIL” 12V3W X 1
“TURN” 12V3W X 1
“NEUTRAL” 12V3W X 1
“HIGH BEAM” 12V3W X 1
“LOW BEAM” 12V3W X 1
Amperages:
Principal fuse 15A

2-3
 GENERAL SPECIFICATIONS SPEC
ENGINE

Item Standard Limit

Cylinder head:
Warpage limit * Lines indicate 0,03mm
straightedge
measurement.

Cylinder:
Bore size 56.00~56.02mm ***
Taper limit 0.05mm ***
Out of round limit 0.01mm ***

Piston:
Piston size “D” 55.950~55.955 ***
Measurement point* 10mm ***
Piston to cylinder
clearance 0.045~0.050mm 0.10mm
Piston Offset 0.5mm ***

Piston ring:
Type Keystone ***
Dimensions(BxT): * *
Top ring 1.2x2.4mm ***
2nd ring 1.20x1.89mm ***
End gap (installed): * *
Top ring 0.30~0.45mm ***
2nd ring 0.30~0.45mm ***
Side clearance: * *
Top ring 0.02~0.06mm ***
2nd ring 0.035~0.070mm ***

Cooling system:
Radiator capacity (including all routes) 0.92L ***
Reservoir tank capacity 0.3L *
Radiator cap opening pressure 75~105kPa ***
(0.75~1.05kgf/cm2)
Radiator core width 110mm ***
Radiator core height 280mm ***
Radiator core thickness 32mm ***
Water pump type Single-suction centrifugal
pump

2-4
 GENERAL SPECIFICATIONS SPEC

Item Standard Limit

Crankshaft:

Crank width “A” 57.90~57.95mm ***

Runout limit “C” *** 0.03mm
Big end side clearance “D” 0.2~0.7mm ***
Small end free play “E” 0.026~0.040mm ***
Clutch:
Friction plate thickness 2.9~3.1mm 2.7mm
Quantity 7pcs ***
Clutch plate thickness 1.05~1.35mm 0.05mm
Quantity 6pcs ***
Clutch spring Free lenght 34.5mm ***
Quantity 5pcs ***
Minimum free lenght 32mm ***
Push rod bending limit 0.15mm ***
Transmission:
Main axle runout limit *** 0.08mm
Drive axle runout limit *** 0.08mm
Carburetor:
Type TM28-92/1 ***
ID Mark 1DO ***
Main jet #210 ***
Air jet 0.7 ***
Jet Needle position 5J40-2 ***
Needle jet Q2M (#939) ***
Pilot outlet 0.6 ***
Pilot jet #17.5 ***
Bypass1 1.6 ***
Air screw turns 1/4 ***
Valve seat size 2.8 ***
Starter jet 1 #40 ***
Power jet #60 ***
Float height 15.5~16.5mm ***
Fuel level 1.5~2.5mm
Idling speed 1250~1450r.p.m
Air filter:
Type Wet element ***
Oil type/grade Foam air filter oil or ***
SAE10W30SE
Reed valve:
Valve thickness 0.5mm ***
Valve stopper height 8.8mm ***
Valve bending limit 0.5mm ***
Lubrication system:
Autolube pump * *
Color code Dark blue ***
Minimum stroke 0.15~0.20mm ***
Maximum stroke 1.85~2.05mm ***
Minimum output 0.38~0.50cm3 ***
Maximum output 4.65~5.15cm3 ***
Pulley adjusting mark autoadjustable ***

2-5
 GENERAL SPECIFICATIONS SPEC
CHASSIS

Item Standard Limit

Model code 1D0 2C81 1D0 2C81
Front wheel:
Type Spoke wheels Spoke wheels
Rim Size 21x1.60 17 x 3.00
Rim Material Steel Steel
Front wheel travel: 270mm 270mm
Max. Radial wheel runout 1mm 1mm
Max. Lateral wheel runout 0.5mm 0.5mm

Rear wheel:
Type Spoke wheels Spoke wheels
Rim size 18x1.85 17x3.50
Rim material Steel Steel
Rear wheel travel 260mm(10.24in) 260mm(10.24in)
Max. Radial wheel runout 1mm(0.04in) 1mm(0.04in)
Max. Lateral wheel runout 0.5mm(0.02in) 0.5mm(0.02in)

Front disc brake:

Thickness 230.0x3.5mm 230.0x3.5mm
Brake pad lining thickness-inner 6mm 4.1mm 0.8mm 0.5mm
Brake pad lining thickness-outer 6 mm 6 mm 0.8mm 0.8mm
Master cylinder inside diameter 11mm 11mm
Caliper cylinder inside diameter 34.93mm 34.93mm
Recommended fluid DOT 4 DOT 4

Rear disc brake:

Thickness 220.0x4.5mm
Brake pad lining thickness-inner 5.6mm 1.0mm
Brake pad lining thickness-outer 5.6mm 1.0mm
Master cylinder inside diameter 12.7mm
Caliper cylinder inside diameter 30.16mm
Recommended fluid DOT 4

Steering system:
Steering type Ball and taper roller
bearing
Bearing size (quantity)
Upper 22pcs (0.1875in)

Front suspension:
Front fork travel 270mm 200 mm
Fork free lenght 503mm 503mm
Spring rate K1 3.1N/mm 3.1N/mm
Spring stroke K1 0~270mm 0~270mm
Optional spring available No No
Recommended oil Fork oil 10W Fork oil 10W
Quantity 495cm3 495cm3
Level 165.5mm 165.5mm

2-6
 GENERAL SPECIFICATIONS SPEC

Item Standard Limit

Model code 1D0 2C81 1D0 2C81
Rear suspension:
Type Swingarm Swingarm
(link suspension) (link suspension)
Rear shock absorber assemby travel 93mm 87 mm
Spring free lenght 245mm 250mm
Installed lenght 230mm 244mm
Spring preload (spring lenght) Hard/Soft Hard/Soft
(220/235mm) (234/249mm)
Spring rate K1 68.6N/mm 117.80N/mm
Spring stroke K1 0~93mm 0~87mm
Optional spring available No No
Enclosed gas/air pressure (STD) 150kPa 150kPa
(15kgf/cm2) (15kgf/cm2)
Tightening torque spring preload 20~25Nm 20~25Nm

Drive chain:
Type/Manufacturer 428V2/DAIDO 428V2/DAIDO
Link quantity 134 134
Drive chain slack 45~55mm 25~40mm
(1.77~2.16in) (0.98~1.57in)

Front lever brake/Rear brake pedal:

Free play front lever brake 2~5mm
Brake pedal free play 15mm

2-7
 GEN
GENERAL SPECIFICATIONS INFO
ELECTRICAL

Model 1D01/1D02 2C81

System voltage 12 V

Ignition system:
Ignition system type C.D.I.
Ignition timing (B.T.D.C.) ((º)) 17 /1500r/min
Advancer type Digital

C.D.I.:
Magneto model/manufacturer F4FU/YAMAHA
Pick up coil resistance((ohm)) 310±20%W/R-W/L
Source coil resistance ((ohm)) 730±20%B/R-G/W
Source coil resistance ((ohm)) 600±20%G/L-G/W
CDI unit model/manufacturer 1D0 /YAMAHA

Ignition coil:
Model/Manufacturer 3RW/YAMAHA
Primary coil resistance ((ohm)) 0.23±20%
Secondary coil resistance ((ohm)) 7.9±20%

Spark plug cap:

Material Resin
Resistance ((k ohm)) 5

A.C. Magneto:
Model/Manufacturer F4FU/YAMAHA
Standard output 14V170W5000r/min
Coil resistance ((ohm)) 0.6±20%W-W

Regulator:
Regulator type Semi conductor-short circuit
Model/Manufacturer SH629B-11/SHINDENGEN
No load regulated voltage 14.1~14.9V

Rectifier:
Rectifier capacity 25A
Withstand voltage 200V

Battery:
Battery type GT6B-3
Battery voltage/Capacity 12V6Ah

Bulbs (voltage/wattage x quantity)

Headlight type Bulb type
Headlight bulb type Halogen H4
Headlight 12V60W/55Wx1
Auxiliary light 12V5Wx1
Brake/tail light 12V21W/5Wx1
Front flasher light 12V10Wx2
Rear flasher light 12V10Wx2
Meter light LED

2-8
 GEN
GENERAL SPECIFICATIONS INFO
Indicator light
Neutral indicator light 12V3Wx1
Turn indicator light 12V3Wx1
Oil level indicator light 12V3Wx1
High beam indicator light 12V3Wx1
Starting system:
System type Electric starter
Starter motor:
Model/Manufacturer 3MB / Moric
Power output 0.2kW
Armature coil resistance 0.0315~0.0385<ohm> 20ºC
Brush overal lenght 5X7X7
<Limit> 3,5
Brush spring force 4.9N ±20%
<Limit> 3.92N
Commutator diameter 17.6mm
<Limit> 16.6mm
Mica undercut (depth) 1.35mm
Starter relay:
Model/Manufacturer 1D0/JIDECO
Amperage 180A
Coil resistance 4.2 - 4.6<ohm> 20ºC
Horn:
Horn type Plane
Quantity 1
Model/Manufacturer YF-12/NIKKO
Max. Amperage 3A
Performance 105~113db/2m
Turn signal relay:
Relay type Full transistor
Model/Manufacturer FE218BH/DENSO
Turn signal blinking frequency 75~95cyl/min
Wattage 10Wx2+3.4W
Oil level gauge:
Model/Manufacturer 3XP/ASTI
Starting citcuit cutt-off relay:
Model/Manufacturer 25G/OMRON
Coil resistance 100<ohm>±10%
Headlight relay:
Model/Manufacturer 25G/OMRON
Coil resistance 100<ohm>±10%
Side stand relay: BUILT IN CUT OFF RELAY
Thermostat switch:
Model/Manufacturer 4BA/DENSO
Temperature setting 120±3<degree>
Servo motor:
Model/Manufacturer 3XP/MATSUSHITA
Amperage for fuses:
Main fuse 15A
Spare fuse 15A

2-9
 CONVERSION TABLE /
GENERAL TIGHTENING TORQUES SPECIFICATIONS SPEC
EAS00028 EAS00029

CONVERSION TABLE GENERAL TIGHTENING TORQUE

All specification data in this manual are listed
SPECIFICATIONS
in SI and METRIC UNITS. This chart specifies tightening torques for
Use this table to convert METRIC unit data to standard fasteners with a standard ISO thread
IMPERIAL unit data. pitch. Tightening torque specifications for
special components or assemblies are provi-
Ex. ded for each chapter of this manual. To avoid
METRIC MULTIPLIER IMPERIAL warpage, tighten multi-fastener assemblies in
** mm x 0.03937 = ** in a crisscross pattern and progressive stages
2 mm x 0.03937 = 0.08 in until the specified tightening torque is rea-
ched. Unless otherwise specified, tightening
torque specifications require clean, dry thre-
CONVERSION TABLE ads. Components should be at room tempera-
ture.
METRIC TO IMPERIAL
Metric unit Multiplier Imperial unit
m•kg 7.233 ft•lb
Tightening m•kg 86.794 in•lb
Torque cm•kg 0.0723 ft•lb
cm•kg 0.8679 in•lb

Weight kg 2.205 lb
g 0.03527 oz

Speed km/hr 0.6214 mph

km 0.6214 mi
m 3.281 ft
Distance m 1.094 yd A: Width across flats
cm 0.3937 in B: Thread diameter
mm 0.03937 in

cc (cm3) 0.03527 oz (IMP liq.)

Volume, cc (cm3) 0.06102 cu•in
Capacity lt (liter) 0.8799 qt (IMP liq.) General tightening
lt (liter) 0.2199 gal (IMP liq.) A B torques
kg/mm 55.997 lb/in (nut) (bolt)
Nm m • kg
Misc. kg/cm2 14.2234 psi (lb/in2)
Centigrade 9/5 + 32 Fahrenheit (°F) 10 mm 6 mm 6 0.6
(°C)
12 mm 8 mm 15 1.5
14 mm 10 mm 30 3.0
17 mm 12 mm 55 5.5
19 mm 14 mm 85 8.5
22 mm 16 mm 130 13.0

2-10
 DEFINITION OF UNITS SPEC
TIGHTENING TORQUES
ENGINE

Tightening
Thread torque
Part to be tightened Q’ty size Nm m•kg Remarks
Spark plug 1 M14x1.25 20 2,0
Cylinder head Nut 5 M8x1.25 22 2,2
Cylinder Stud bolt 9 M8X1.25 13 1,3 LOCTITE
screw glue

Nut 4 M8x1.25 28 2,8

Power valve holder, Valve cover Cap seal
Bolt 6 M5x0.8 7 0,7
Power valve pully Bolt M6x1.0 10 1,0
Thermostat valve cover Screw 3 M6x1.0 8 0,8
Housing cover Screw 2 M6x1.0 8 0,8
Drain bolt (Housing cover) 1 M6x1.0 10 1
Radiator Bolt 2 M6x1.0 8 0,8
Radiator cap stopper Screw 1 M5x0.8 5 0,5
Oil pump Screw 2 M5x0.8 5 0,5
Carburetor joint Bolt 4 M6x1.0 8 0,8
Air filter Screw 2 M6x1.0 5 0,5
Exhaust pipe Nut 2 M8x1.25 18 1,8
Stud bolt 2 M8x1.25 10 1 LOCTITE
screw glue

Bolt 3 M6x1.0 8 0,8

Transmission Oil Drain Bolt 1 M8x1.25 15 1,5
Crankcase cover (left) Screw 6 M6x1.0 5 0,5
Crankcase cover (right) Screw 6 M6x1.0 8 0,8
Oil pump cover Screw 3 M6x1.0 5 0,5
Crankcase Screw 12 M6x1.0 8 0,8
Oil Seal Holder Screw 1 M8x1.25 16 1,6
Cover Screw 2 M6x1.0 8 0,8
Kick Crank Bass Nut 1 M12X1.0 70 7
Clutch Spring Bolt 5 M5x0.8 6 0,6
Plate cover Screw 2 M6x1.0 10 1
Drive Sprocket Nut 1 M16X1.0 60 6
Tachometer housing Bolt 1 M6x1.0 5 0,5
Stopper lever Bolt 1 M6x1.0 14 1,4 LOCTITE
screw glue

Shift pedal Bolt 1 M6x1.0 15 1,5

Thermo unit
Rotor 1 ~ 15 1,5
Nut 1 M12x1.25 80 8

2-11
 DEFINITION OF UNITS SPEC
CHASSIS

Tightened
Thread torque
Parts to be tightened size Nm m•kg Remarks
Engine stay (Top) and frame M10 30-35 3,0-3,5
Cylinder head stay (Top) and frame M10 30-35 3,0-3,5
Bottom screw (front) engine and frame M10 60-78 6,0-7,8
Bottom screw (front) engine to swingarm M10 30-35 3,0-3,5
Steering nut M25 120-155 12,0-15,5 Steering must turn
smoothly and
without free play
Fuel cock lever M6 5~8 0,5~0,8
Upper bracket and meter holder M6 5~8 0,5~0,8
Rear bolt fuel tank to frame M6 7,5-12 0,75-1,2
Footrest security pins — Completely bend
Front brake holder M10 2~3 0,2~0,3
Front brake pipe M10 23-37 2,3-3,7
Handlebar holder bolts to handlebars M8 5~8 0,5~0,8
Main switch M6 7~12 0,7~1,2 Security allen bolt
(with central pin)
Top holder bolts to suspension tubes M8 12~28 1,2~2,8
Sidestand nut M8 20-32 2,0-3,2
Rear brake lever M8 7,5-12 0,75-1,2
Rear master cylinder to holder M6 7,5-12 0,75-1,2
Brake pipe bolt M10 23-37 2,3-3,7
Security pin rear brake lever to pump — Completely bend
Pivot shaft M15 80-100 8,0-10,0
Swingarm to connecting arm M13 45-70 4,5-7,0
Connecting arm relay arm M13 45-70 4,5-7,0
Relay arm to frame M13 45-70 4,5-7,0
Damper to frame M10 30-35 3,0-3,5
Damper to relay arm M10 30-35 3,0-3,5
Swingarm end bolts — 2~4 0,2-0,4
Driven sprocket M8 32-37 3,2-3,7
Rear wheel axle nut M17 80-100 8,0-10,0 Check that the pin is
bent
Front brake caliper to outer tube M10 31-49 3,1-4,9
Front wheel axle M15 45-70 4,5-7,0
Exhaust to cylinder head M8 15-20 1,5-2,0
Exhaust assy 1 to central exhaust pipe M8 8~12 0,8-1,2
Central exhaust pipe to muffler M8 8~12 0,8-1,2
Muffler and central pipe to frame holder M8 38-42 3,8-4,2
Clutch lever pivot nut M6 5~8 0,5-0,8
Front brake pivot lever nut M6 5~8 0,5-0,8
Front brake lever adjusting nut M6 5~8 0,5-0,8
Security nuts M6 7,5-12 0,75-1,2
Chain puller M6 18-28 1,8-2,8
shift shaft nut M6 8~12 0,8-1,2
Rear footrest holder M8 17-22 1,7-2,2
Bottom bolts inner holder to tube M8 20-25 2,0-2,5

2-12
 COOLANT FLOW CHART SPEC
COOLANT FLOW CHART

Water pump Crankcase cover Crankcase Cylinder

Cylinder head

Bypass hose Thermostatic valve

(Thermostatic valve)

Outlet hose Radiator 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 rings - piston pins and pistons Apply engine oil

Power valve holder Apply lightweight lithium-soap base grease

Impeller shaft (water pump) Apply gear oil

Warm shaft (Autolube pump) Apply engine oil

Kick idle gear Apply gear oil

Kick axle Apply gear oil

Primary driven gear (clutch housing) Apply gear oil

Push rod Apply gear oil

Push lever axle Apply gear oil

Sliding gear (Transmission) Apply molybdenum disulfide grease

Free movement gear (Transmission) Apply molybdenum disulfide grease

Guide bar (Shift forks) Apply gear oil

Crankcase mating surfaces Yamaha bond no.4

2-14
 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 lightweight lithium-soap base grease

Front brake lever axle free play Apply lightweight lithium-soap base grease

Footrests free play Apply lightweight lithium-soap base grease

Rear footrests free play (ball and axle) Apply lightweight lithium-soap base grease

Swingarm axle to frame Apply lightweight lithium-soap base grease

Relay arm to swingarm Apply lightweight lithium-soap base grease

Connecting rods Apply lightweight lithium-soap base grease

Engine holder to cylinder head Apply lightweight lithium-soap base grease

Rear brake lever pivot Apply lightweight lithium-soap base grease

Sidestand pivot Apply lightweight lithium-soap base grease

Oil seal lip (front wheel) Apply lightweight lithium-soap base grease

Front wheel axle outer surface Apply lightweight lithium-soap base grease

Oil seal lip (rear wheel) Apply lightweight lithium-soap base grease

Rear wheel axle outer surface Apply lightweight lithium-soap base grease

2-15
 CABLE ROUTING SPEC
CABLE ROUTING

 Clutch wire 
A Cover with cap after connecting wires.
 Right turn signal lead 
B Route the installation between lower brac-
 Left turn signal lead ket and headlight bottom holder.
 Throttle cable 
C Clamp connection wire.
 Indicator light wire lead
 Meter wire lead
 Headlight bulb wire
Handle wire lead (right)


C



A


B 

2-16
 CABLE ROUTING SPEC
CABLE ROUTING

 Master cylinder 
A Turn the hose to obtain the desired angle.
 Front brake hose 
B Route clutch wire first for the inside, after
 Wire throttle route the throttle wire.
 Clutch sw wire lead 
C Clamp handle wire lead (L).
 SW handle wire lead (left) 
D Clamp handle wire lead (R).
 Clip 
E Clamp pipe overflow to the frame clamp.
 A.I.S.
Pipe overflow

F Hold hoses on chassis clamp.
Pipe to air filter 
G Cover with cap after connecting wires.
Pipe I 
H Route brake/tail light wire through rear
License light wire lead mudguard hole.
 Oil gauge 
I Clamp rear turning light wire (R) and
tail/brake lights wire to frame clamp.

J Route the following cables through the
frame bracket:
rear turning signal wire (R), rear turning sig-
nal wire (L), tail/brake wire, license light
wire.


A



B  
F

D 
E



 
C  
H

G  J

I


2-17
 CABLE ROUTING SPEC
CABLE ROUTING

 Main switch wire lead 

A Route speedometer cable to frame guide.
 Pipe overflow 
B Route pipe overflow behind engine holder.
 Ignition coil 
C Screw ground wire and rectifier with the
 Horn same bolt.
 Flasher relay 
D Pipe overflow pass behind oil hose.
 Air vent hose 
E Route carburetor breather hose between
 Fuel pipe
rear shock absorber and swingarm.
Oil pipe

F Route pipe overflow between rear shock
absorber and swingarm.


B


F 
E

D

 
A


C




2-18
 CABLE ROUTING SPEC
CABLE ROUTING

 Front brake hose 

A Route brake hose through the guide.
 Clutch wire 
B Clamp clutch wire.
 Ignition coil 
C Guide wire (chassis): SW handle wire lead
 Throttle wire (R), SW handle wire lead (L), clutch SW
 Therm switch wire lead, front stop SW wire lead, wire
 Sidestand switch wire lead throttle, wire clutch.
 Oil hose 
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).

I Install clamp with open part to the upper
side. Route pipe overflow and pipe I
through clamp.

J Route sidestand switch through brackets.
The lead must have no slack at distance
“X”.

K Route oil hose through clamp under the
battery.

L Route sidestand switch through the lower
part of the air filter.



C  
I


A


F

B

H


K

D

E x 
J


G

L


2-19
 CHK
ADJ
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION/PERIODIC MAINTENANCE/LUBRICATION …………………3-1

ENGINE ……………………………………………………………………………3-2
Y.P.V.S. CABLE ADJUSTMENT ………………………………………………3-2
IDLE SPEED ADJUSTMENT …………………………………………………3-3
THROTTLE CABLE FREE PLAY ADJUSTMENT……………………………3-4
CARBURETOR CABLE FREE PLAY ADJUSTMENT ………………………3-5
AUTOLUBE PUMP STROKE ADJUSTMENT ………………………………3-6
AUTOLUBE PUMP AIR BLEEDING …………………………………………3-6
SPARK PLUG INSPECTION …………………………………………………3-7
IGNITION TIMING CHECK ……………………………………………………3-8
ENGINE OIL LEVEL INSPECTION …………………………………………3-9
TRANSMISSION OIL LEVEL INSPECTION ………………………………3-11
TRANSMISSION OIL REPLACEMENT ……………………………………3-11
CLUTCH ADJUSTMENT ……………………………………………………3-12
AIR FILTER CLEANING………………………………………………………3-16
CARBURETOR JOINT INSPECTION ………………………………………3-18
FUEL LINE INSPECTION ……………………………………………………3-18
CHECKING THE CRANKCASE BREATHER HOSE ………………………3-18
EXHAUST SYSTEM INSPECTION …………………………………………3-19
ENGINE OIL LINE INSPECTION ……………………………………………3-19
COOLANT LEVEL INSPECTION ……………………………………………3-19
COOLANT REPLACEMENT …………………………………………………3-20
COOLING SYSTEM INSPECTION …………………………………………3-23

CHASSIS …………………………………………………………………………3-24
FRONT BRAKE ADJUSTMENT ……………………………………………3-24
REAR BRAKE ADJUSTMENT ………………………………………………3-24
BRAKE FLUID INSPECTION ………………………………………………3-25
BRAKE PAD INSPECTION …………………………………………………3-27
BRAKE LIGHT SWITCH ADJUSTMENT …………………………………3-27
BRAKE HOSE INSPECTION ………………………………………………3-28
DRIVE CHAIN SLACK ADJUSTMENT ……………………………………3-28
DRIVE CHAIN LUBRICATION ………………………………………………3-30
STEERING HEAD ADJUSTMENT …………………………………………3-30
FRONT FORK INSPECTION ………………………………………………3-32
REAR SHOCK ABSORBER ADJUSTMENT ………………………………3-33
TIRE INSPECTION……………………………………………………………3-34
WHEEL INSPECTION ………………………………………………………3-36
CABLE INSPECTION AND LUBRICATION ………………………………3-37

ELECTRICAL ……………………………………………………………………3-39
BATTERY INSPECTION ……………………………………………………3-39
FUSE INSPECTION …………………………………………………………3-42
HEADLIGHT BULB REPLACEMENT ………………………………………3-43
HEADLIGHT BEAM ADJUSTMENT ………………………………………3-44
 INTRODUCTION/PERIODIC MAINTENANCE/ CHK
LUBRICATION INTERVALS 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 tech-
nical skills.

ODOMETER READING ANUAL

( x 1.000 km)
CHECK
No ITEM CHECK OR MAINTENANCE JOB 1 6 12 18 24

1 * Fue line Check fuel hoses and vacuum hose for cracks or damage. √ √ √ √ √
2 Spark plug • Check condition.
• Clean and regap. √ √
• Replace. √ √
3 Air filter element • Clean. √ √
• Replace. √ √
4 Clutch • Check operation.
• Adjust. √ √ √ √ √

5 * Front brake • Check operation and adjust brake lever

free play. √ √ √ √ √ √
• Replace brake shoes. Whenever worn to the limit
6 * Rear brake • Check operation, fluid level and vehicle
for fluid leakage. √ √ √ √ √ √
• Replace brake pads. Whenever worn to the limit
7 * Brake hoses • Check for cracks or damage. √ √ √ √ √
• Replace. Every 4 years
8 * Wheels • Check runout, spoke tightness and
for damage. √ √ √ √
• Tighten spokes if necessary.
9 * Tires • Check tread depth and for damage.
• Replace if necessary. √ √ √ √ √
• Check air pressure.
• Correct if necessary.
10 * Wheel • Check bearing for looseness or damage.
√ √ √ √
bearings
11 * Swingarm • Check operation and for excessive play. √ √ √ √
• Lubricate with lithium-soap-based grease. Every 24,000 km
12 Drive chain • Check chain slack.
• Make sure that the rear wheel is properly aligned. Every 500 km and after washing
• Clean and lubricate. the motorcycle or riding in the rain
13 * Steering • Check bearing play and steering for roughness. √ √ √ √ √
bearings • Lubricate with lithium-soap-based grease. Every 24,000 km
14 * Chassis • Make sure that all nuts, bolts and screws
√ √ √ √ √
fasteners are properly tightened.
15 Sidestand • Check operation.
√ √ √ √ √
• Lubricate.
16 * Sidestand • Check operation.
√ √ √ √ √ √
switch
17 * Front fork • Check operation and for oil leakage. √ √ √ √
18 * Shock absorber • Check operation and shock absorber
√ √ √ √
assembly for oil leakage.
19 * Rear suspension • Check operation. √ √ √ √
relay arm and • Lubricate with lithium-soap-based grease. √ √
connecting arm
pivoting points
20 * Carburetor • Check starter (choke) operation.
√ √ √ √ √ √
• Adjust engine idling speed.
21 Engine oil • Change. √ When the oil change indicator light comes on
(every 3,000 km)
• Check oil level and vehicle for oil leakage. Every 3,000 km √
22 * Autolube pump • Check operation.
√ √ √ √
• Bleed if necessary.
23 Transmission oil • Check oil level. √ √ √ √ √ √
• Change. √ √
24 * Cooling system • Check coolant level and vehicle for coolant √ √ √ √ √
leakage.
• Change. Every 3 years
25 * Throttle grip • Check operation and free play.
housing and • Adjust the throttle cable free play if necessary. √ √ √ √ √
cable • Lubricate the throttle grip housing and cable.

3-1
 CHK
Y.P.V.S. CABLE ADJUSTMENT ADJ
ENGINE
Y.P.V.S. CABLE ADJUSTMENT
1 1. Remove
• pulley cover (power valve) 
2. Turn on the main switch

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 
2 Not aligned  Adjust the Y.P.V.S. Cables
1 3
2 4. Adjust
• Y.P.V.S. Cables

1 Adjustments steps:
• Loosen both locknuts  and turn in both
adjusters  .
• Insert a pin [fl 0,16 in.)] through the aligning
indent in the pulley and into the hole to lock
the pulley.
• Turn both adjusters, counterclockwise so
that the cable free play becomes zero mm
(zero in.) with fingers.
• Turn both adjusters 1/4 turn clockwise.
• Tighten the locknuts.

Locknuts:
8 Nm (0,8 m•kg, 5,8 ft•lb)

• Turn on the main switch and check taht the

alignment mark is aligned.
If not, rpeat the above steps.


5. Install
• pulley cover (Power valve) 

1 Locknuts:
7 Nm (0,7 m•kg, 5,1 ft•lb)

3-2
 CHK
IDLE SPEED ADJUSTMENT ADJ
IDLE SPEED ADJUSTMENT
(a)
1. Adjust:
2 • engine idle speed
EAS00054
(b) 1 ADJUSTING THE ENGINE IDLING SPEED

NOTE:
Prior to adjusting the engine idling speed, the
air filter element should be clean, and the engi-
ne should have adequate compression.

1. Start the engine and let it warm up for seve-

ral 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.

Engine idling speed

1250 ~ 1450 r/min

4. Adjust:
• engine idling speed

a. Turn the pilot screw  in or out until it is
lightly seated.
b. Turn the pilot screw out the specified num-
ber of turns.
Pilot screw setting
1/4 turns out
c. Turn the throttle stop screw  in direction
a or b until the specified engine idling
speed is obtained.
Direction 
a Engine idling speed is
increased.
Direction 
b Engine idling speed is
decreased.

5. Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play (at the
flange of the throttle grip)
3 ~ 5 mm (0,11 ~ 0,18 in)

3-3
 CHK
ADJUSTING THE THROTTLE CABLE FREE PLAY ADJ
EAS00058

ADJUSTING THE THROTTLE CABLE FREE

PLAY

NOTE:
Prior to adjusting the throttle cable free play,
the engine idling speed and carburetor synch-
ronization 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)

1 2. Adjust:
2 • throttle cable free play

Handlebar side
a. Loosen the locknut .
b. Turn the adjusting nut  in direction  a or
b until the specified throttle cable free play
is obtained.

Direction 
a Throttle cable free play
is increased.
Direction 
b Throttle cable free play
is decreased.

c. Tighten the locknut.

s WARNING
After adjusting the throttle cable free play,
start the engine and turn the handlebar to
the right or left to ensure that this does not
cause the engine idling speed to change.



3-4
ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHK
CARBURETOR CABLE FREE PLAY ADJUSTMEN 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
2 Out of specification  adjust

Carburetor Cable Free Play:

1,0 mm (0,04 in)

3. Adjust:
• Caburetor free play

Adjustment steps:
• Loosen the locknut 
• Turn the adjuster  in or out until the
correct free play obtained.

Turn in Free play is increased.

Turn out Free play is decreased.

• Tighten the locknuts



4. Push in the adjuster cover.

3-5
 AUTOLUBE PUMP STROKE ADJUSTMEN/ CHK
AUTOLUBE PUMP AIR BLEEDING ADJ
AUTOLUBE PUMP STROKE ADJUSTMENT
1. Remove:
1 • Autolube pump cover 
2. Adjusting mark
Not aligned  Adjust the Autolube Pump

3. Adjust
• Autolube pump

The adjusting marks  a and  b has to match
when the throttle cable free play ends.

Adjustment steps:
(a) (b) a. Loosen the locknut 
b. Turn the adjuster  until the correct adjust-
ment is obtained
c. Tighten the locknut.


AUTOLUBE PUMP AIR BLEEDING

NOTE:
The Autolube pump and delivery lines must be
bleed on the following ocasions:
• Setting up a new motorcycle out of the
crate.
• Whenever the oil tank has run dry.
• Whenever any portion of the engine oil sys-
tem is disconnected.

1. Remove:
• autolube pump cover
2. Fill:
• oil tank 
1
Yamaha il 2T or Air-Cooled
2 Stroke Engine Oil

3-6
 AUTOLUBE PUMP AIR BLEEDING/ CHK
CHECKING THE SPARK PLUG 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.
1 • Keep the engine running at about
2.000r/min for two minutes or so
• When air bubbles are expelled completely,
install the bleed cap.

NOTE:
Place a rag or oil pan under the autolube pump
to catch the oil.



EAS00060

CHECKING THE SPARK PLUG

1. Disconnect:
• spark plug cap
2. Remove:
• spark plug

CAUTION
Before removing the spark plug, blow away
any dirt accumulated in the spark plug well
with compressed air to prevent it from
falling into the cylinder.

3. Check:
• spark plug type
Incorrect  Change.

Spark plug type (manufacturer)

BR8ES (NGK)

4. Check:
• electrode 
Damage/wear  Replace the spark plug.
• insulator 
Abnormal color  Replace the spark plug.
Normal color is medium-to-light tan.
5. Clean:
• spark plug
(with a spark plug cleaner or wire brush)

3-7
 CHECKING THE SPARK PLUG/ CHK
CHECKING THE IGNITION TIMING 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. Connect:
• spark plug cap

EAS00064

CHECKING THE IGNITION TIMING

NOTE:
Prior to checking the ignition timing, check the
wiring connections of the entire ignition sys-
tem. Make sure all connections are tight and
free of corrosion.

1. Remove:
• crankcase cover (left)
2. Connect:
• timing light
• engine tachometer
(onto the spark plug lead of cylinder #1)
Timing light
90890-03141
Engine Tachometer
90890-03113

3-8
CHECKING THE IGNITION TIMING/ CHK
ENGINE OIL LEVEL INSPECTION 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. Install:
• Crankcase cover (left)

ENGINE OIL LEVEL INSPECTION

1. Check
• oil level
oil level low  Adjust sufficient oil

Recommended oil:
Yamaha Oil 2T or Air Cooled 2
stroke Engine Oil

Oil Tank Capacity:

1,3 L

3-9
 CHK
ENGINE OIL LEVEL INSPECTION ADJ
OIL WARNING LIGHT CHECKING METHOD
Main Switch “ON”

Gears in “NEUTRAL”

Oil warning indicator Oil warning indicator

light does not come on light come on

Shift into gear

Oil warning indicator Oil warning indicator

light does not come on light come on

Refeer to CHAPTER 8
“SIGNAL SYSTEM” Engine oil level and Supply engine oil
electrical circuit are OK

y
CAUTION
80 b j
40
60
100 Always use the same type of engine oil;
000015 z N mixing oils may result in a harmful chemical
20 km/h
120

0 130 reaction and lead to poor performance.

0008 1
 “OIL” Indicator light

3-10
 TRANSMISSION OIL LEVEL INSPECTION/ CHK
TRANSMISSION OIL REPLACEMENT 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
2
stopping the engine.
• The oil should e confirmed between maxi-
mum  and minimum  marks.
• If the oil level is lower, add sufficient oil to
raise it to the proper level.
3 1
Recommended oil:
SAE10W30 Type SE Motor Oil

• Do not add any chemical additives.

Transmission oil also lubricates the clutch
and additives could cause clutch slippage.
• Be sure no foreign material enters the
crankcase.


TRANSMISSION OIL REPLACEMENT

1. Warm up the engine for several minutes.
1 2. Place a container under the engine.
3. Remove:
• oil filler cap 
• drain pulg 
drain transmission oil.
2
NOTE:
Drain the transmission oil with the motorcycle
slightly inclined to the right.

4. Inspect:
2 • gasket (Drain plug)
• O-Ring (oil filter cap)
Damage  Replace

3-11
 TRANSMISSION OIL REPLACEMENT/ CHK
ADJUSTING THE CLUTCH CABLE FREE PLAY 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. Inspect:
• Oil leaks
• Oil level

NOTE:
Wipe off any oil spilled on the crankcase.

EAS00078

3 ADJUSTING THE CLUTCH CABLE FREE

PLAY
1. Check:
• clutch cable free play 
Out of specification  Adjust.
Clutch cable free play (at the end
of the clutch lever)
1 2 10-15mm (0,34-0,59in.)

2. Adjust:
• clutch cable free play 

Handlebar side
a. Loosen the locknut .
b. Turn the adjusting bolt  in direction a or
b until the specified clutch cable free play
is obtained.

3-12
 CHK
ADJUSTING THE CLUTCH CABLE FREE PLAY ADJ
Direction 
a Clutch cable free play is
increased.
Direction 
b Clutch cable free play is
decreased.

c. Tighten the locknut.

NOTE:
If the specified clutch cable free play cannot
be obtained on the handlebar side of the
cable, use the adjusting nut on the engine
1 1
side.

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.
2
Direction 
a Clutch cable free play is
increased.
Direction 
b Clutch cable free play is
decreased.
c. Tighten the locknuts.


Mechanism adjustment
1. Remove:
• Brush guard
2. Loosen:
• Locknuts 
3. Turn the adjusters .

1 2

4. Drain:
1 • Coolant
Refeer to the “COOLANT REPLACEMENT”
section.
5. Disconnect:
• Outlet hose (radiator)
6. Remove:
• Screw (Water outlet pipe) 

3-13
 CHK
ADJUSTING THE CLUTCH CABLE FREE PLAY ADJ
7. Disconnect:
• Autolube pump cable 
1 • Autolube pump hose 
Refer to the “AUTOLUBE PUMP CABLE
AND HOSE” section in the CHAPTER 4.

8. Drain:
2 • Transmission oil
Refer to the ”TRANSMISSION OIL REPLA-
CEMENT” section.
4 9. Remove:
• Return spring 
• Bolt (master cylinder) 
1 3 • Brake pedal 
• Crankcase cover (Right) 

10. Adjust:
• Adjuster (push rod=1) 

Adjustments steps:
• Loosen the locknut 
1
• Move the push lever  toward the front
2 with you finger until it stops.
• With the push lever in this position turn the
adjuster  to align the mark  on the end
of the push lever with the mark  (protube-
rance) on the crankcase.
• Tighten the locknut .

3 Locknut
8 Nm (0,8 m • kg, 5,8 ft • lb)
4

5

11. Install:
• crankcase cover (right)
• brake pedal
• return spring
Screw (crankcase cover):
8 Nm (0,8 m • kg, 5,8 ft • lb)

Drain plug (Oil):

15 Nm (1,5 m • kg, 11 ft • lb)

Drain plug (coolant):

10 Nm (1,0 m • kg, 7,2 ft • lb)

Screw (brake pedal):

20 Nm (2,0 m • kg, 14 ft • lb)

3-14
 CHK
ADJUSTING THE CLUTCH CABLE FREE PLAY ADJ
NOTE:
3 • When installing the crankcase cover, engage
1
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.
2 • Before installing the brake pedal apply the
lithium soap base grease to the brake pedal
pivot shaft.

12. Install:
• Gasket (Autolube pump cover) 
13. Connect:
1 • Autolube pump hoses 
• Autolube pump cable 
14. Install:
• Screw (Water outlet pipe) 

Screw (Water outlet Pipe)

8 Nm (0,8 m • kg, 5,8 ft • lb)

15. Connect:
• Outlet hose (Radiator)
16. Adjust:
• Clutch cable free play
Refer to the “Cable free play adjustment”
section.”

17. Install:
1 • Brush guard 

18. Fill:
• Crankcase
Refer to the “TRANSMISSION OIL REPLA-
CEMENT” section.
Recommended oil:
SAE10W30 Type SE Motor Oil
Periodic Oil Change
0,75 L

19. Fill:
• Radiator
• Reservoir tank (radiator)
Refer to the “COOLANT REPLACEMENT”
section.

Total amount:
0,92 L

3-15
 ADJUSTING THE CLUTCH CABLE FREE PLAY/ CHK
CLEANING THE AIR FILTER ELEMENT ADJ
20. Air bleeding:
• Autolube pump
1
Refer to the “AUTOLUBE PUMP AIR BLEE-
DING section.
21. Install:
• Autolube pump cover 

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
1 case.

1 1. Remove:
• Side cover (left)

2. Remove:
• air filter case cover screws 
• air filter assembly 
Slide out guide together with element
1
3. Clean:
• air filter element
(with solvent)

s WARNING
Never use low flash point solvents, such as
gasoline, to clean the air filter element.
Such solvents may cause a fire or an explo-
sion.

NOTE:
After cleaning, gently squeeze the air filter ele-
ment to remove the excess solvent.

3-16
 CHK
CLEANING THE AIR FILTER ELEMENT ADJ
CAUTION
1 2 Do not twist the air filter element when
squeezing it.

4. Check:
• air filter element
Damage  Replace.

1 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.

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.

2 • Air filter assembly.

Slide in guide to air case.

1
CAUTION
Be sure to insert the element guide into the
filter case with its handle  located close
to you, and also pay attention to the seal
sponge for damage.

7. Install:
• Side cover (left)

3-17
 CARBURETOR JOINT INSPECTIONS /FUEL LINE CHK
INSPECTION/CHECKING THE CRANKCASE BREATHER HOSE ADJ
CARBURETOR JOINT INSPECTION
1. Inspect:
• Carburetor joint 
1 Crack-damage  Replace
Refer to the “REED VALVE” section in chap-
ter 7 for replacement

2. Check the tightening torque of the carbure-

tor joint securing bolts.

Bolt (Carburetor joint)

8 Nm (0,8 m • kg, 5,8 ft • lb)

FUEL LINE INSPECTION

1 1. Inspect:
• Fuel hose 
Cracks-damage  replace
Loose connection  Connect properly

EAS00098

CHECKING THE CRANKCASE BREATHER

HOSE
1. Check:
• crankcase breather hose
Cracks/damage  Replace.
Loose connection  Connect properly.

CAUTION
Make sure the crankcase breather hose is
routed correctly.

3-18
 EXHAUST SYSTEM INSPECTION/ENGINE OIL LINE CHK
INSPECTION/ COOLANT LEVEL INSPECTION ADJ
EXHAUST SYSTEM INSPECTION
1 .Inspect:
• Gasket (exhaust pipe) 
• Joint (Silencer) 
Damage  Replace
4 Exhaust gas leakage  Repair
• Exhaust pipe 
• Silencer 
7 Cracked/Dent/Damage  Repair or
replace
2. Tighten:
• Exhaust pipe
2
• Muffler
Nut  (Exhaust pipe)
18 Nm (1,9 m • kg, 13 ft• lb)
1
Screw  (Muffler Joint)
10 Nm (1,0 m • kg, 7,2 lb • ft)

5 Bolts 
3 10 Nm (1,0 m • kg, 7,2 lb • ft)

ENGINE OIL LINE INSPECTION

1. Remove:
• Autolube pump cover
2. Inspect:
• Oil hose 
1 • Oil delivery hose 
Cracks-damage  replace
Loose connection  Connect properly
2 3. Install:
• Autolube pump cover
Screw (autolube pump cover)
7 Nm (0,7 m • kg, 5,1 ft • lb)

COOLANT LEVEL INSPECTION

1. Place the machine in a level surface.
1 2. Remove:
• Side cover (left)
2 3. Inspect:
FULL • Coolant level
LOW Coolant level is under “Low” level line
  Add soft water (tap water).
 Coolant reservoir tank.

3-19
 COOLANT LEVEL INSPECTION/ CHK
CHANGING THE COOLANT 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. Remove:
• side covers (left and right)
• exhaust pipe.
2. Disconnect:
1 • coolant reservoir hose 
FULL

LOW

3. Drain:
• coolant
(from the coolant reservoir)
4. Remove:
• radiator cap

s WARNING
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the
engine is hot. Scalding hot fluid and steam
may be blown out, which could cause
serious injury. When the engine has cooled,
open the radiator cap as follows:
Place a thick rag or a towel over the radia-

3-20
 CHK
CHANGING THE COOLANT ADJ
tor cap and slowly turn the radiator cap
counterclockwise toward the detent to
allow any residual pressure to escape.
2 When the hissing sound has stopped, press
down on the radiator cap and turn it coun-
terclockwise to remove.

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. Check:
• copper washer  (coolant drain bolt-engi-
ne )
1 8. Install:
• coolant drain bolt (engine)
Coolant drain bolt (engine):
10Nm (1.0 m·kg, 7,2lb·ft)

9. Connect:
• coolant reservoir hose
10. Fill:
• cooling system
(with the specified amount of the recom-
mended coolant)
Recommended antifreeze
High-quality ethylene glycol anti-
freeze containing corrosion inhi-
bitors for aluminum engines
Mixing ratio
1:1 (antifreeze:water)
Quantity
Total amount
0,92 L (0,81 Imp qt, 0,97 US qt)
Coolant reservoir capacity
0,30 L (0,26 Imp qt, 0,32 US qt)
From minimum to maximum level
mark
0,24 L (0,21 Imp qt, 0,25 US qt)

Handling notes for coolant

Coolant is potentially harmful and should be
handled with special care.

s WARNING
• If coolant splashes in your eyes, tho-
roughly wash them with water and con-
sult a doctor.
• If coolant splashes on your clothes,
quickly wash it away with water and then
3-21
 CHK
CHANGING THE COOLANT 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 disti-
lled water is not available, soft water
may be used.
• If coolant comes into contact with pain-
ted surfaces, immediately wash them
with water.
• Do not mix different types of antifreeze.

11. Install:
• radiator cap
12. Fill:
• coolant reservoir
(with the recommended coolant to the
maximum level mark  a)
13. Install:
• coolant reservoir cap
14. Start the engine, warm it up for several
(a) FULL minutes, and then stop it.
LOW
15. Check:
• coolant level
Refer to “CHECKING THE COOLANT
LEVEL”.

NOTE:
Before checking the coolant level, wait a few
minutes until the coolant has settled.
1
3

16. Install:
• Exhaust pipe
• Side covers (left and right)

Nut  (Exhaust pipe):

18 Nm (1,8 m • kg, 13 ft • lb)
Bolt  (Stay):
10 Nm (1,0 m • kg, 7,2 ft • lb)
Screw  (Muffler Joint):
10 Nm (1,0 m • kg, 7,2 ft • lb)

3-22
 CHK
COOLING SYSTEM INSPECTION 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.

3-23
 ADJUSTING THE FRONT BRAKE/ CHK
ADJUSTING THE REAR BRAKE ADJ
EAS00108

3 CHASSIS
ADJUSTING THE FRONT BRAKE
1. Check:
• brake lever free play 
Out of specification  Adjust.
2 Brake lever free play (at the end of
1
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.

Direction 
a Brake lever free play is
increased.
Direction 
b Brake lever free play is
decreased.
c. Tighten the locknut.

s WARNING
A soft or spongy feeling in the brake lever
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will consi-
derably reduce braking performance and
could result in loss of control and possibly
an accident. Therefore, check and, if neces-
sary, bleed the brake system.

CAUTION
After adjusting the brake lever free play,
make sure there is no brake drag.



EAS00111

ADJUSTING THE REAR BRAKE

1. Check:
• brake pedal position
(distance  a from the top of the rider foo-
(a) trest to the top of the brake pedal)
(b) Out of specification  Adjust.

Brake pedal position (below the

1 top of the rider footrest)
15 mm (0,6 in)
3-24
 ADJUSTING THE REAR BRAKE/ CHK
CHECKING THE BRAKE FLUID LEVEL 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 Brake pedal is raised.
1
Direction 
b Brake pedal is lowered.

s WARNING
After adjusting the brake pedal position,
check that the end of the adjusting bolt pro-
trudes 2 mm (0,08 in) from the bottom of the
set nut.

c. Tighten the locknut.

s WARNING
A soft or spongy feeling in the brake pedal
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will consi-
derably reduce braking performance and
could result in loss of control and possibly
an accident. Therefore, check and, if neces-
sary, bleed the brake system.

CAUTION
After adjusting the brake pedal position,
make sure there is no brake drag.



3. Adjust:
• rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH”.

EAS00115

FRONT A CHECKING THE BRAKE FLUID LEVEL

1. Stand the motorcycle on a level surface.

NOTE:
• Place the motorcycle on a suitable stand.
1 • Make sure the motorcycle is upright.

3-25
 CHK
CHECKING THE BRAKE FLUID LEVEL ADJ
B 2. Check:
REAR • brake fluid level
Below the minimum level mark   Add
the recommended brake fluid to the proper
level.
1 Recommended brake fluid
DOT 4


A Front brake

B 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. Mixing
brake fluids may result in a harmful che-
mical reaction, leading to poor brake
performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point
of the brake fluid and could cause vapor
lock.

CAUTION
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.

NOTE:
In order to ensure a correct reading of the
brake fluid level, make sure the top of the
brake fluid reservoir is horizontal.

3-26
 CHECKING THE FRONT AND REAR BRAKE PADS/ CHK
ADJUSTING THE REAR BRAKE LIGHT SWITCH ADJ
EAS00119
A
FRONT CHECKING THE FRONT AND REAR BRAKE
PADS
The following procedure applies to all of the
brake pads.
1. Remove:
1 • Rubber plug
2. Operate the brake.
3. Check:
• front brake pad
• rear brake pad
Wear indicators  almost touch the brake
B disc  Replace the brake pads as a set.
REAR
Refer to “REPLACING THE FRONT BRAKE
PADS” and “REPLACING THE REAR
1 BRAKE PADS” in chapter 4.


A Front brake

B Rear brake
4. Install:
• Rubber plug.

EAS00128

ADJUSTING THE REAR BRAKE LIGHT

SWITCH

1 NOTE:
The rear brake light switch is operated by
2 movement of the brake pedal.
The rear brake light switch is properly adjusted
when the brake light comes on just before the
braking effect starts.

1. Check:
• rear brake light operation timing
Incorrect  Adjust.
2. Adjust:
• rear brake light operation timing


a. Hold the main body  of the rear brake

light switch so that it does not rotate and
turn the adjusting nut  in direction a or
b until the rear brake light comes on at the
proper time.

Direction 
a Brake light comes on
sooner.
Direction 
b Brake light comes on
later.



3-27
CHECKING THE FRONT AND REAR BRAKE HOSES/ CHK
ADJUSTING THE DRIVE CHAIN SLACK 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 dama-
ged hose.
Refer to “FRONT AND REAR BRAKES” in
chapter 4.

EAS00139

ADJUSTING THE DRIVE CHAIN SLACK

NOTE:
The drive chain slack must be checked at the
tightest point on the chain.

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 speci-
fied limits.

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:
Both wheels should be on the ground without
a rider on the motorcycle.

2. Move the rear wheel several times and find

the tightest position of drive chain.

3-28
 CHK
ADJUSTING THE DRIVE CHAIN SLACK ADJ
3. Check:
• drive chain slack a
Out of specification  Adjust.
Drive chain slack
25 ~ 40 mm DT125X
(0,9842 ~ 1,5748 in)
45 ~ 55 mm DT125RE
(1,7716 ~ 2,1653 in)
4. Remove:
• cotter pin
5. Loosen:
• wheel axle nut 
2 6. Adjust:
• drive chain slack


a. Loosen both locknuts.

1 b. Turn both adjusters  in direction  a or b
until the specified drive chain slack is obtai-
ned.

Direction 
a Drive chain is tightened.
Direction 
b Drive chain is loosened.

NOTE:
• To maintain the proper wheel alignment,
adjust both sides evenly.
• Push the rear wheel forward to make sure
there is no clearance between the swin-
garm end plates and the ends of the swin-
garm.

c. Tighten the wheel axle nut to specification.

Wheel axle nut

90 Nm (9.0 m • kg, 65 ft • lb)

d. Tighten the locknuts to specification.



7. Install:
• cotter pin

s WARNING
Always use a new cotter pin.

CAUTION
Do not loosen the wheel axle nut after tigh-
tening it to the specified torque. If the groo-
ve in the wheel axle nut is not aligned with
the cotter pin hole in the wheel axle, tighten
the nut further until they are aligned.

3-29
 LUBRICATING THE DRIVE CHAIN/ CHK
CHEEKING AND ADJUSTING THE STEERING HEAD ADJ
EAS00142

LUBRICATING THE DRIVE CHAIN

The drive chain consists of many interacting
parts. If the drive chain is not maintained pro-
perly, 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.
Steam cleaning, high-pressure washing, cer-
tain solvents, and the use of a coarse brush
can damage these O-rings. Therefore, use
only kerosene to clean the drive chain. Wipe
the drive chain dry and thoroughly lubricate it
with engine oil or chain lubricant that is suita-
ble for O-ring chains. Do not use any other
lubricants on the drive chain since they may
contain solvents that could damage the O-
rings.
Recommended lubricant
Engine oil or chain lubricant sui-
table for O-ring chains

EAS00146

CHECKING AND ADJUSTING THE

STEERING HEAD
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.

2. Check:
• steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness  Adjust the steering
head.

3. Remove:
• side covers, seat, fuel tank, main switch
protector.
Remove handlebar from its position.
Remove handle crown.
4. Adjust:
83 dB
V TL
09 *9 61 00 00 m in
D E0 ) - 40

• steering head
(A

2/ 61 00 00
*0 13 00 5 1
9
-

3-30
 CHK
CHEEKING AND ADJUSTING THE STEERING HEAD ADJ


a. Remove the lock washer , the upper ring

nut , and the rubber washer .
b. Loosen the lower ring nut  and then tigh-
ten 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)
1
2
3 c. Loosen the lower ring nut  completely,
4 then tighten it to specification.

s WARNING
Do not overtighten the lower ring nut.

Lower ring nut (final tightening tor-

que)
4 Nm (0.4 m • kg, 2.8 ft • lb)

d. Check the steering head for looseness or

binding by turning the front fork all the way
in both directions. If any binding is felt,
remove the lower bracket and check the
upper and lower bearings.
Refer to “STEERING HEAD” in chapter 4.
e. Install the rubber washer .
f. Install the upper ring nut .
g. Finger tighten the upper ring nut , then
align the slots of both ring nuts. If neces-
sary, hold the lower ring nut and tighten the
upper ring nut until their slots are aligned.
h. Install the lock washer .

NOTE:
Make sure the lock washer tabs sit correctly in
the ring nut slots.



5. Install:
• Install handle crown
• Install Handlebars
• Install side covers, seat, fuel tank, main
switch protector.
Nut Cap
120 ~ 155 Nm (12.0 ~ 15.5m•kg,
85.3 ~ 110.1 ft•lb)

3-31
CHEEKING AND ADJUSTING THE STEERING HEAD/ CHK
CHECKING THE FRONT FORK ADJ
6. Measure:
• steering head tension


NOTE:
Make sure all of the cables and wires are pro-
perly 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 loc-
king tie.
d. Hold the spring gauge at a 90° angle from
the handlebar, pull the spring gauge, and
then record the measurement when the
handlebar starts to run.
Steering head tension
200 ~ 250 g

e. Repeat the above procedure on the opposi-

te handlebar.
f. If the steering head tension is out of speci-
fication (both handlebars should be within
specification), remove the upper bracket
and loosen or tighten the upper ring nut.
g. Reinstall the upper bracket and measure
the steering head tension again as descri-
bed above.
h. Repeat the above procedure until the stee-
ring head tension is within specification.
i. Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness  Adjust the steering
head.


EAS00149

CHECKING THE FRONT FORK

1. Stand the motorcycle on a level surface.

s WARNING
Securely support the motorcycle so that
there is no danger of it falling over.

3-32
CHECKING THE FRONT FORK/ADJUSTING THE REAR CHK
SHOCK ABSORBER ASSEMBLY 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.

EAS00156

ADJUSTING THE REAR SHOCK

ABSORBER ASSEMBLY

s WARNING
Securely support the motorcycle so that
there is no danger of it falling over.

Spring preload

CAUTION
Never go beyond the maximum or minimum
adjustment positions.

1. Adjust:
• loosen the locknut 
• adjust the spring preload
(b) (a) 

a. Adjust the spring preload with a ring nut

1 2 wrench.
Ring nut wrench
90890-01268
b. Turn the adjusting ring  in direction 
a or 
b.
Direction 
a Spring preload is increa-
sed (suspension is harder)
Direction 
b Spring preload is decrea-
sed (suspension is softer).

Adjusting positions
Minimum Standard Maximum
220 mm 230 mm 235 mm


3-33
ADJUSTING THE REAR SHOCK ABSORBER CHK
ASSEMBLY/CHECKING THE TIRES 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.
• The tire pressure and the suspension
must be adjusted according to the total
weight (including cargo, rider, passenger
and accessories) and the anticipated
riding speed.
• Operation of an overloaded motorcycle
could cause tire damage, an accident or
an injury.
NEVER OVERLOAD THE MOTORCYCLE.

Tire air pressure (measured on cold tires):

DT125R
Up to 90 kg (198 lb):
Front:
150 kPa (21,8 psi) (1,5 kgf/cm2)
Rear:
175 kPa (25,4 psi) (1,75 kgf/cm2)
90 kg (198 lb) to maximum load:
Front:
175 kPa (25,4 psi) (1,75 kgf/cm2)
Rear:
200 kPa (28,9 psi) (2 kgf/cm2)
Maximum load*:
178 kg (392 lb)
DT125X
Up to 90 kg (198 lb):
Front:
180 kPa (26,1 psi) (1,8 kgf/cm2)
Rear:
200 kPa (28,9 psi) (2 kgf/cm2)
90 kg (198 lb) to maximum load:
Front:
180 kPa (26,1 psi) (1,8 kgf/cm2)
Rear:
200 kPa (28,9 psi) (2 kgf/cm2)
Maximum load*:
180 kg (396 lb)
* Total weight of rider, passenger, cargo and
accessories

3-34
 CHK
CHECKING THE TIRES 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:
1 • tire surfaces
Damage/wear  Replace the tire.
Minimum tire tread depth
2
1.6 mm (0.04 in)

 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.
• Always replace a new tube tire and a new
tube as a set.
• To avoid pinching the tube, make sure
the wheel rim band and tube are cente-
red in the wheel groove.
• Patching a punctured tube is not recom-
mended. If it is absolutely necessary to
do so, use great care and replace the
tube as soon as possible with a good
quality replacement.

Tube wheel Tube tire only

Tubeless wheel Tube or tubeless tire

s WARNING
• After extensive tests, the tires listed below
have been approved by Yamaha Motor
España, S.A. for this model. The front and
rear tires should always be by the same
manufacturer and of the same design. No
guarantee concerning handling characteris-
tics can be given if a tire combination other
than one approved by Yamaha is used on
this motorcycle.

3-35
 CHECKING THE TIRES/ CHK
CHECKING AND TIGHTENING THE SPOKES 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.
• After a tire has been repaired or repla-
ced, be sure to tighten the tire air valve
stem nut  and locknut  to specifica-
tion.

Tire air valve stem (front wheel

only)
Valve stem lock nut
1.5 Nm (0.15 m•kg, 1.1 ft•lb)

EAS00169

1 CHECKING AND TIGHTENING THE

SPOKES
The following procedure applies to all of the
spokes.
1. Check:
• spoke 
Bends/damage  Replace.
Loose  Tighten.
Tap the spokes with a screwdriver.

NOTE:
A tight spoke will emit a clear, ringing tone; a
loose spoke will sound flat.

3-36
CHECKING AND TIGHTENING THE SPOKES/ CHK
CHECKING AND LUBRICATING THE CABLES 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. Check:
• outer cable
Damage  Replace.
2. Check:
• cable operation
Rough movement  Lubricate.

Recommended lubricant
SAE 10W30 Motor Oil

NOTE:
Hold the cable end upright and pour a few
drops of lubricant into the cable sheath or use
a suitable lubricating device.

3-37
LUBRICATING THE LEVERS AND PEDALS/LUBRICATING THE CHK
SIDESTAND/LUBRICANTING THE REAR SUSPENSION ADJ
EAS00171

LUBRICATING THE LEVERS AND PEDALS

Lubricate the pivoting point and metal-to-
metal moving parts of the levers and pedals.

Recommended lubricant
SAE 10W30 Motor Oil

EAS00172

LUBRICATING THE SIDESTAND

Lubricate the pivoting point and metal-to-
metal moving parts of the sidestand.

Recommended lubricant
SAE 10W30 Motor Oil

EAS00174

LUBRICATING THE REAR SUSPENSION

Lubricate the pivoting point and metal-to-
metal moving parts of the rear suspension.

Recommended lubricant
Molybdenum disulfide grease

3-38
 CHK
ELECTRICAL SYSTEM 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).
• DO NOT SMOKE when charging or hand-
ling batteries.
• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent
eye injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
• Skin <—> Wash with water.
• Eyes <—> Flush with water for 15 minu-
tes and get immediate medical attention.
INTERNAL
• Drink large quantities of water or milk
followed with milk of magnesia, beaten
egg or vegetable oil. Get immediate
medical attention.

CAUTION
• This is a sealed battery. Never remove
the sealing caps because the balance
between cells will not be maintained and
battery performance will deteriorate.
• Charging time, charging amperage and
charging voltage for an MF battery are
different from those of conventional bat-
teries. The MF battery should be charged
as explained in the charging method
illustrations. If the battery is overchar-
ged, the electrolyte level will drop consi-
derably. Therefore, take special care
when charging the battery.

3-39
 CHK
CHECKING AND CHARGING THE BATTERY ADJ
NOTE:
Since MF batteries are sealed, it is not possi-
ble to check the charge state of the battery by
measuring the specific gravity of the electroly-
te. 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. Remove:
• battery

4. Check:
1 2 • battery charge


a. Connect a pocket tester to the battery ter-

minals.
Positive tester probe  positive battery
terminal.
Negative tester probe  negative battery
terminal.

NOTE:
• The charge state of an MF battery can be
checked by measuring its open-circuit vol-
tage (i.e., the voltage when the positive bat-
tery terminal is disconnected).
• No charging is necessary when the open-
circuit voltage equals or exceeds 12.8 V.

b. Check the charge of the battery, as shown

in the charts and the following example.
Example
c. Open-circuit voltage = 12.0 V
d. Charging time = 6.5 hours
e. Charge of the battery = 20 ~ 30%


5. Charge:
• battery

3-40
 CHK
CHECKING AND CHARGING THE BATTERY 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 char-
ging current on the battery charger, be
careful not to overcharge the battery.
• When charging a battery, be sure to
remove it from the motorcycle. (If char-
ging has to be done with the battery
mounted on the motorcycle, disconnect
the negative battery lead from the bat-
tery terminal.)
• To reduce the chance of sparks, do not
plug in the battery charger until the bat-
tery charger leads are connected to the
battery.
• Before removing the battery charger lead
clips from the battery terminals, be sure
to turn off the battery charger.
• Make sure the battery charger lead clips
are in full contact with the battery termi-
nal and that they are not shorted. A
corroded battery charger lead clip may
generate heat in the contact area and a
weak clip spring may cause sparks.
• If the battery becomes hot to the touch
at any time during the charging process,
disconnect the battery charger and let
the battery cool before reconnecting it.
Hot batteries can explode!
• As shown in the following illustration, the
open-circuit voltage of an MF battery
stabilizes about 30 minutes after char-
ging has been completed. Therefore,
wait 30 minutes after charging is com-
pleted before measuring the open-circuit
voltage.

Charging method using a variable-current

(voltage) charger
Charging method using a constant voltage
charger
6. Install:
• battery
7. Connect:
• battery leads
(to the battery terminals)

3-41
CHECKING AND CHARGING THE BATTERY/ CHK
CHECKING THE FUSES ADJ
CAUTION
1 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.

CAUTION
To avoid a short circuit, always set the main
switch to “OFF” when checking or repla-
cing a fuse.

1. Remove:
• Rear side cover (right)
2. Check:
• fuse


a. Connect the pocket tester to the fuse and

check the continuity.

NOTE:
Set the pocket tester selector to “<OHM>
<MLT> 1”.

Pocket tester
90890-03112

b. If the pocket tester indicates “<INF>”,

replace the fuse.


3-42
 CHECKING THE FUSES/ CHK
REPLACING THE HEADLIGHT BULB 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.
1 d. If the fuse immediately blows again, check
the electrical circuit.

Fuses Amperage rating Q'ty

Main 15A 1
Reserve 15A 1

s WARNING
Never use a fuse with an amperage rating
other than that specified. Improvising or
using a fuse with the wrong amperage
rating may cause extensive damage to the
electrical system, cause the lighting and
ignition systems to malfunction and could
possibly cause a fire.



4. Install:
• Rear side cover (right).

EAS00182

REPLACING THE HEADLIGHT BULB

1. Remove front cowling
2. Disconnect:
• Couplers
3. Remove headlight bulb cover 
4. Remove the headlight bulb holder accor-
1 ding to the drawing, then remove the defec-
tive bulb 
2

s WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled
down.

3-43
 REPLACING THE HEADLIGHT BULB/ CHK
ADJUSTING THE HEADLIGHT BEAM ADJ
5. Install:
• headlight bulbNew
Secure the new headlight bulb with the
headlight bulb holder.

CAUTION
Avoid touching the glass part of the head-
light 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. Install:
• headlight bulb cover
8. Connect:
• Front cowling

EAS00184

ADJUSTING THE HEADLIGHT BEAM

1. Adjust:
• headlight beam (vertically)
a. Loosen screws  and 
2 b. Adjust the headlight vertically
c. Tighten screw  and 
1

3-44
 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………………………………………4-19
INSPECTION AND REPAIR …………………………………………………4-23
ASSEMBLY ……………………………………………………………………4-27
AIR BLEEDING ………………………………………………………………4-35

FRONT FORK ……………………………………………………………………4-37

REMOVAL ……………………………………………………………………4-38
DISASSEMBLY ………………………………………………………………4-38
INSPECTION …………………………………………………………………4-40
ASSEMBLY ……………………………………………………………………4-41

STEERING HEAD AND HANDLEBAR ………………………………………4-45

REMOVAL ……………………………………………………………………4-46
INSPECTION …………………………………………………………………4-49
INSTALLATION ………………………………………………………………4-50

REAR SHOCK ABSORBER AND SWINGARM ……………………………4-55

HANDLING NOTES …………………………………………………………4-57
NOTES ON DISPOSAL ………………………………………………………4-57
REMOVAL ……………………………………………………………………4-57
INSPECTION …………………………………………………………………4-62
SIDE CLEARANCE ADJUSTMENT…………………………………………4-62
INSTALLATION ………………………………………………………………4-64

DRIVE CHAIN AND SPROCKETS ……………………………………………4-66

REMOVAL ……………………………………………………………………4-67
INSPECTION …………………………………………………………………4-68
INSTALLATION ………………………………………………………………4-70
 FRONT WHEEL CHAS

CHASSIS
FRONT WHEEL

 Hub  Cap
 Bearing Collar
 Collar Dust cover
 Oil Seal 
10 Wheel axle
 Rim 
11 Cap
 Spoke 
12 Gear unit (speedometer)

Basic weight: DT125RE DT125X DT125RE

With oil and full fuel tank 126 kg 134 kg
A Tire Size:
Maximum load* 178 kg (392 lb) 180 kg (396 lb) 80/90-21 48P
Cold tire pressure B Rim Size:
Up to 90 Kg (198 bf) load* 150kPa 180Kpa 21x1.60
(1,5kgf/cm2)(21,8psi) (1,8kgf/cm2)(26,1psi) C Rim Runout Limit:
90kg (198lbf)~Maximum load 175kPa 180Kpa Vertical:
(1,75kgf/cm2)(25,4psi) (1,8kgf/cm2)(26,1psi) 1,0 mm (0,08 in)
Off-road riding 150kPa — Lateral:
(1,5kgf/cm2)(21,8psi) 0,5 mm (0,02 in)

DT125X
A Tire Size:
120/70/17 58H
B Rim Size:
17x3.00
58 Nm (5,8 m • kg, 42ft•lb) C Rim Runout Limit:
Vertical:
1,0 mm (0,08 in)
Lateral:
0,5 mm (0,02 in)

4-1
 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.

2. Remove:
1 3 • Cable holder (speedometer) 
3. Disconnect:
• Speedometer cable
4. Loosen:
• Nuts (Axle holder)

5. Remove:
2 • Front wheel axle
• Front wheel 
1
• Gear unit (speedometer) 
• Spacer collar 

NOTE:
Do not apply the brake lever when removing
the brake caliper.
3

4-2
 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.
1 Loose  Tighten.
Tap the spokes with a screwdriver.

NOTE:
A tight spoke will emit a clear, ringing tone, a
loose spoke will sound flat.

4. Tighten:
• spokes

2~3.5 Nm (0.2~0.35 m•kg,

1.42~2.49 ft•lb)

NOTE:
After tightening the spokes, measure the front
wheel runout.

5. Measure:
• front wheel radial runout
• front wheel lateral runout
Over the specified limits  Replace.

Front wheel radial runout limit

1 mm (0.04 in)
Front wheel lateral runout limit
0.5 mm (0.02 in)

4-3
CHECKING THE FRONT WHEEL CHAS
6. Check:
• collars
Damage/wear  Replace.

s WARNING
• After mounting a new tire, ride conserva-
tively 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 dama-
ge to the motorcycle.
• After a tire has been repaired or repla-
ced, be sure to tighten the tire air valve
stem locknut  to specification.

Tire air valve stem locknut

1.5 Nm (0.15 m•kg, 1.1 ft•lb)

7. Check:
• wheel bearings
Front wheel turns roughly or is loose 

Replace the wheel bearings.

• oil seals
Damage/wear  Replace.

8. Replace:
• wheel bearings New
• oil seals New



a. Clean the outside of the front wheel hub.

b. Remove the oil seals with a flat-head
screwdriver.

NOTE:
To prevent damaging the wheel, place a rag
between the screwdriver and the wheel surfa-
ce.

c. Remove the wheel bearings with a general

bearing puller.
d. Install the new wheel bearings and oil seals
in the reverse order of disassembly.

4-4
 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
1 • wheel bearings
• oil seal lips
• speedometer drive gear
• speedometer driven gear
Recommended lubricant
Lithium-soap-based grease

2. Install:
• speedometer gear unit 

NOTE:
Make sure the speedometer gear unit and the
wheel hub are installed with the two projec-
1 tions meshed into the two slots respectively.

3. Install:
• front wheel

NOTE:
Make sure the slot in the speedometer gear
unit fits over the stopper on the outer tube.

4-5
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 pro-
perly.

CAUTION
Before tightening the wheel axle nut, push
down hard on the handlebar several times
and check if the front fork rebounds smo-
othly.

4-6
 REAR WHEEL CHAS
REAR WHEEL

 Hub Driven Sprocket 

15 Chain puller
 Collar Bolt 
16 Chain puller
 Bearing 
10 Nut 
17 Wheel axle
 Oil Seal 
11 Collar 
18 Washer
 Rim 
12 Dust Cover 
19 Nut
 Spoke 
13 Collar 
20 Drive chain
 Cap 
14 Oil Seal

Basic weight: DT125RE DT125X DT125RE

With oil and full fuel tank 126 kg 134 kg
A Tire Size:
Maximum load* 178 kg (392 lb) 180 kg (396 lb) 110/80-18 58P
Cold tire pressure B Rim Size:
Up to 90 Kg (198 bf) load* 175kPa 200Kpa 18 x 1,85
(1,75kgf/cm2)(25,4psi) (2,0kgf/cm2)(28,9psi) C Rim Runout:
90kg (198lbf)~Maximum load 200kPa 200Kpa Vertical:
(2,0kgf/cm2)(28,9psi) (2,0kgf/cm2)(28,9psi) 1,0 mm (0,08 in)
Off-road riding 175kPa — Lateral:
(1,75kgf/cm2)(25,4psi) 0,5 mm (0,02 in)

DT125X
A Tire Size:
140/70-17 66H
B Rim Size:
17x3.50
C Rim Runout Limit:
Vertical:
1,0 mm (0,08 in)
Lateral:
0,5 mm (0,02 in)

90 Nm (9,0 m • kg,
65ft•lb)

4-7
 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.

2. Remove:
• rear brake caliper protection 
1
NOTE:
Do not depress the brake pedal when remo-
ving the brake caliper.

3. Loosen:
• bolts (swingarm end).

4. Remove:
• wheel axle nut 
2 • wheel axle
• rear wheel

NOTE:
1 Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.

4-8
 INSPECTING THE REAR WHEEL/
INSTALLING THE REAR WHEEL CHAS
INSPECTING THE REAR WHEEL
1. Inspect:
• Rear wheel axle
Refer to the “FRONT WHEEL - INSPEC-
TION” section.
2. Inspect:
• Wheel hub 
• Dust covers (Bearings) 
2 4 • Wheel 
1
Refer to the “FRONT WHEEL - INSPEC-
3 TION” section.
3. Measure:
• Wheel runout
Refer to the “FRONT WHEEL - INSPEC-
TION” section.
4. Check:
• Wheel bearings 
Refer to the “FRONT WHEEL - INSPEC-
TION” section.
4
5. Check:
2 • Wheel balance
Refer to the “FRONT WHEEL - INSPEC-
TION” section.

EAS00572

INSTALLING THE REAR WHEEL

When installing the rear wheel, reverse the
removal procedure. Note the following points:
1. Lubricate:
3 2 • wheel axle 
• wheel bearings
• oil seal lips 

2
3
1

4-9
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,

58.7~73.3 ft•lb)

4-10
 FRONT AND REAR BRAKE CHAS
FRONT AND REAR BRAKE

 Master cylinder cap  Brake hose Piston seal

 Diaphragm  Brake caliper 
10 Dust seal
 Master cylinder kit  Pad spring 
11 Brake pad
 Master cylinder Piston 
12 Brake disc

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.)

D USE NEW ONE

26 Nm (2,6 m • kg, 19ft•lb)

6 Nm (0,6 m • kg,
4,3ft•lb)

18 Nm (1,8 m • kg, 13ft•lb)

D USE NEW ONE

D USE NEW ONE

35 Nm (3,5 m • kg, 25ft•lb)

20 Nm (2,0m•kg,
14ft•lb)

4-11
 FRONT AND REAR BRAKE CHAS
 Reservoir tank cap protec-  Master cylinder 
13 Dust seal
tor Master cylinder kit 
14 Shim
 Reservoir tank cap Brake hose 
15 Pad spring
 Inner cap 
10 Brake caliper 
16 Brake pads
 Diaphragm 
11 Piston 
17 Brake disc
 Reservoir tank 
12 Piston seal
 Reservoir hose

18 Nm (1,8 m • kg, 13ft•lb)

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: 6 Nm (0,6 m • kg, D USE NEW ONE
4mm (0.16 in.) 4,3ft•lb)

10 Nm (1,0 m • kg, 7,2ft•lb)

26 Nm (2,6 m • kg,
19ft•lb) D USE NEW ONE

4 Nm (0,4 m • kg,
2,9ft•lb)

D USE NEW ONE

4-12
 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.
• Use only clean or new brake fluid for cle-
aning brake components.
• Brake fluid may damage painted surfa-
ces and plastic parts. Therefore, always
clean up any spilt brake fluid immedia-
tely.
• Avoid brake fluid coming into contact
with the eyes as it can cause serious
injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get
immediate medical attention.

EAS00581

REPLACING THE FRONT BRAKE PADS

NOTE:
When replacing the brake pads, it is not
necessary to disconnect the brake hose or
disassemble the brake caliper.

1. Loosen:
• retaining bolt (caliper body)

2. Turn:
• brake caliper counterclockwise
2
1
2

4-13
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. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.

Bleed screw
6 Nm (0.6 m•kg, 4.3 ft•lb)

d. Install new brake pads and a new brake pad

spring.

1

4-14
 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:
FRONT • brake fluid level
Below the minimum level mark a  Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
a
LEVEL” in chapter 3.

9. Check:
• brake lever operation
Soft or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.

EAS00583

REPLACING THE REAR BRAKE PADS

NOTE:
When replacing the brake pads, it is not
necessary to disconnect the brake hose or
disassemble the brake caliper.

4-15
 REPLACING THE REAR BRAKE PADS CHAS
1. Remove:
2 • Protector (caliper body) 
• Retaining bolt 
• Turn the caliper body counterclockwise
2. Remove:
• brake pads 
• brake pad springs 
• Shim (brake pad)
1

3. Measure:
• brake pad wear limit a
Out of specification  Replace the brake
2 pads as a set.

Brake pad wear limit

0.8 mm (0.03 in)

1
4. Install:
• brake pad shims
(onto the brake pads)
• brake pad springs
• brake pads

NOTE:
Always install new brake pads, brake pad
shims, and a 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. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.

Bleed screw
6 Nm (0.6 m•kg, 4.3 ft•lb)

4-16
 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
1
LEVEL” in chapter 3.

8. Check:
• brake pedal operation
Soft or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.

4-17
 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:
2 1 • union bolt 
• copper washers 
• brake hose

NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.

2. Remove:
• Retaining bolt (caliper body)
2
• Brake pads 
1 • Pad springs 
Refer to the “BRAKE PAD REPLACE-
MENT” section.

3. Remove:
• Caliper body 
• Caliper bracket

4. Remove:
• Caliper piston 
• Clip
• Dust seal
• Piston seal

4-18
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
(a) piston is expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
ton.

b. Remove the clip using a thin screwdriver

CAUTION
• When removing the clip, take care not to
damage the dust seal and caliper body.

c. Remove the brake caliper piston seals.



EAS00626

DISASSEMBLING THE REAR BRAKE

4
CALIPER

NOTE:
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
3
1 2 1. Remove:
• Protector (Caliper body) 
• Union bolts 
• Copper washers
• Retaining bolt (Caliper body)

NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.

3 2. Remove:
• Brake pads 
• Shim (brake pads) 
• Pad springs
Refer to the “BRAKE PAD REPLACE-
MENT” section.

1 2

4-19
 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

2
1

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
(a) 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 pis-
ton.

b. Remove the brake caliper piston seals.



4-20
 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. Remove:
• Union bolt 
• Cooper washers 

4. Remove:
• Bracket (master cylinder)
• Master cylinder

4-21
 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
6 1. Remove:
• Brake hose guides 
2. Loosen:
7 • Union bolt 
3. Remove:
7 • Cotter pin 
8 • Washer 
• Cotter pin 
• Screw (Reservoir tank 
1 • Bolts (master cylinder) 
• Master cylinder
(with brake hose and reservoir tank)
1

4-22
 DISASSEMBLING THE REAR BRAKE MASTER
CYLINDER/CHECKING THE FRONT AND REAR BRAKE
CALIPER CHAS
4. Remove:
• Brake hoses 
• Reservoir tank 
• Circlip 
2 • Push rod
• Master cylinder kit 
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.

EAS00630

CHECKING THE FRONT AND REAR BRAKE

CALIPER
Recommended brake component
replacement schedule

Brake pads If necessary

Piston seals Every two years
Brake hose Every four years
Brake fluid Every two years and
whenever the brake is
disassembled

4-23
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.

2. Check:
• Caliper body 
• Caliper bracket 
Cracks/damage  Replace.
• Oil delivery passage (caliper body)
Blow out with compressed air.
• Slide collar (caliper body) 
• Guide shaft (caliper bracket) 
Rust/wear/damage  Replace.
• Slider boot caliper body) 
• Dust boot (Guide pin - bracket)
Cracks/damage  Replace.
B 
A Front

B Rear

4-24
CHECKING THE FRONT AND REAR BRAKE CALIPER CHAS
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
1 1 
B Rear

4. Check:
• Master cylinder kit 
Scratches/Wear/Damage  Replace.


A Front

B Rear

5. Check:
• Reservoir tank 
Cracks/damage  Replace.
• Diaphragm (Front) 
Wear/damage  Replace.

6. Check:
• Brake hoses
Cracks/wear/damage  Replace.
1

7. Measure:
• Brake pads (thickness) a
Out of specification  Replace.

Brake pad wear limit

0.8 mm (0.03 in)

 Wear indicator

4-25
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.

9. Measure:
• Brake disc deflection
Out of specification  Inspect wheel
runout.
If wheel runout is in good condition, repla-
ce.

Maximum deflection:
0.15mm (0.006in.)

• Brake disc thickness

Out of specification  Replace.

Minimum thickness:
Front: 3.0mm (0.12in.)
Rear: 4.0mm (0.16in.)

 Dial gauge

A Front

B Rear

Bolt (brake disc):

20 Nm (2.0 m•kg, 14ft•lb)
Use LOCTITE®

4-26
 ASSEMBLING AND INSTALLING THE FRONT AND
REAR BRAKE CALIPER CHAS
ASSEMBLING AND INSTALLING THE
FRONT AND REAR BRAKE CALIPER

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 pis-
ton seals to swell and distort.
• Whenever a brake caliper is disassem-
bled, replace the brake caliper piston
seals.

Recommended brake fluid

DOT 4

Front brake
1. Install:
• Master cylinder kit 
3 • Circlip 
2 1 • Dust boot 

2. Install:
FRONT
• Master cylinder 
1 NOTE:
• Install the master cylinder bracket with the
“UP” mark facing upward.
• Tighten first the upper bolt, then the lower
bolt.
Bolts (Master cylinder bracket):
9 Nm (0.9 m•kg, 6.5ft•lb)

3. Install:
• Return spring (brake lever) 
• Brake lever 
• Brake switch 

NOTE:
Apply lithium soap base grease to the brake
lever pivot.
2 3 1

4-27
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 

2 Caliper bracket:
35 Nm (3.5 m•kg, 25ft•lb)

6. Install:
• Pad springs
• Brake pads
Refer to the “BRAKE PAD REPLACE-
MENT” section.
7. Install:
• Caliper body 

NOTE:
Apply the lithium soap-base grease onto the
caliper guide shaft and retaining bolt.

CAUTION
• Take care no to allow the brake pads to
be smeared by grease.
• Wipe off any unnecessary grease that
comes out of place.

Retaining bolt (Caliper body):

18 Nm (1.8m•kg, 13ft•lb)

4-28
ASSEMBLING AND INSTALLING THE FRONT AND
REAR BRAKE CALIPER CHAS
8. Install:
• Copper washers 
• Brake hose 
• Union bolt 
2

Union bolt:
3 26 Nm (2.6m•kg, 19ft•lb)

1
CAUTION
When installing the brake hoses to the cali-
per  and master cylinder  lightly touch
the brake pipe with the projections  on
them.

s WARNING
• Proper hose routing is essential to insu-
re safe machine operation. Refer to
“CABLE ROUTING”
• Always use new copper washers.

9. Fill:
• Master cylinder tank

Recommended brake fluid:

DOT 4

3
CAUTION
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.

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. Mixing
brake fluids may result in a harmful che-
mical reaction, leading to poor brake
performance.
• When refilling, be careful that water does
not enter the brake master cylinder
reservoir. Water will significantly lower
the boiling point of the brake fluid and
could cause vapor lock.

4-29
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:
2 • Front brake lever free play 
1
Free play:
2~5mm (0.08~0.20in)
Refer to the “FRONT BRAKE ADJUST-
MENT” section in chapter 3.

2
1

4-30
ASSEMBLING AND INSTALLING THE FRONT AND
REAR BRAKE CALIPER CHAS

7
ASSEMBLING AND INSTALLING THE
FRONT AND REAR BRAKE CALIPER
8 1. Install:
• Master cylinder kit 
• Push rod 
6
• Circlip 
• Dust boot 
5 • Brake hoses 
• Cooper washers 
• Union bolt 
• Reservoir tank

NOTE:
1 At this time, teporarily tighten the union bolt

2
s WARNING
3
4 Always use a new cooper washer

2. Install:
• Master cylinder 
• Reservoir tank 
2
• Pin 
• Washer 
• Cotter pin 
• Brake hose guides 

NOTE:
Apply the lithium-soap base grease to the pin.

6 1
s WARNING
6
Always use a new cotter pin.

Bolt (Master cylinder):

10 Nm (1.0 m•kg, 7.2 ft•lb)
Screw (Reservoir tank):
4 Nm (0.4 m•kg, 2.9 ft•lb)

3. Install:
• Piston seal 
• Dust seal 
• Caliper piston 

s WARNING
Always use new piston seal and dust seal

4-31
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 INSTALLA-
TION” section.

NOTE:
Be sure the boss on the swingarm correctly
1 engages with the locating slot on the caliper
bracket.

5. Install:
1
23 • Pad springs 
• Brake pads 
• Shim 
Refer to the “BRAKE PAD REPLACE-
MENT” section.

6. Install:
• Caliper body 
Retaining Bolt (Caliper body):
18 Nm (1.8 m•kg, 13 ft•lb)

1 NOTE:
Apply the lithium-soap base grease onto the
caliper guide shaft and retaining bolt

CAUTION
• Take care not to allow the brake pads to
be smeared by grease.
• Wipe off any unnecessary grease that
comes out of place.

4-32
 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 cali-
3 per  and master cylinder , lightly touch
4 the brake pipe with the projections  on
them.

2 s WARNING
• Proper hose routing is essential to insu-
re safe machine operation. Refer to
1 “CABLE ROUTING” section.
• Always use new cooper washers.

Recommended brake fluid:

DOT 4
If DOT 4 is not avaliable DOT 3
can be used.

CAUTION
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.

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. Mixing
brake fluids may result in a harmful che-
mical reaction, leading to poor brake
performance.
• When refilling, be careful that water does
not enter the brake master cylinder
reservoir. Water will significantly lower
the boiling point of the brake fluid and
could cause vapor lock.

4-33
 ASSEMBLING AND INSTALLING THE FRONT AND
REAR BRAKE CALIPER CHAS
9. Bleed:
• brake system
Refer to “AIR BLEEDING” section.

REAR 10. Check:

• brake fluid level
Below the minimum level mark   Add
the recommended brake fluid to the proper
level.
1 Refer to “BRAKE FLUID INSPECTION” in
chapter 3.

”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.
Refer to the “REAR BRAKE ADJUST-
MENT” section.
1

13. Adjust:
• Drive chain slack (a)
Refer to the “DRIVE CHAIN SLACK
ADJUSTMENT” section in chapter 3.

Drive chain slack:

DT125RE 40~55mm (1,77~2,16in.)
DT125X 25~40mm (0,98~1,58 in.)

4-34
BLEEDING THE HYDRAULIC BRAKE SYSTEM CHAS
EAS00134

BLEEDING THE HYDRAULIC BRAKE

SYSTEM

s WARNING
Bleed the hydraulic brake system whene-
ver:
• 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.
• When bleeding the hydraulic brake system,
make sure there is always enough brake
fluid before applying the brake. Ignoring this
precaution could allow air to enter the
hydraulic brake system, considerably lengt-
hening the bleeding procedure.
• If bleeding is difficult, it may be necessary
to let the brake fluid settle for a few hours.
Repeat the bleeding procedure when the
tiny bubbles in the hose have disappeared.

1. Bleed:
• hydraulic brake system


A a. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid.
b. Install the diaphragm (brake master cylinder
1
reservoir or brake fluid reservoir).
c. Connect a clear plastic hose  tightly to the
bleed screw .

2 
A Front

B Rear

B d. Place the other end of the hose into a con-

tainer.
e. Slowly apply the brake several times.
f. Fully pull the brake lever or fully press down
the brake pedal and hold it in position.
g. Loosen the bleed screw.

4-35
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 bub-
bles 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. Fill the brake fluid reservoir to the proper

level with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL”.

s WARNING
After bleeding the hydraulic brake system,
check the brake operation.



4-36
 FRONT FORKS CHAS
FRONT FORKS

 Cap bolt  Damper rod 

12 Washer
 O-ring Oil lock pieces 
13 Slide bush
 Spacer Circlip 
14 Outer fork tube
 Spring seat 
10 Dust seal 
15 Axle holder
 Fork spring 
11 Oil seal 
16 Fork boot
 Inner fork tube

A FOR OIL (EACH): B FOR SPRING:

CAPACITY: MINIMUM FREE
495 cm3 LENGTH:
GRADE: 503mm
FOR OIL 10W OR
EQUIVALENT 30 Nm (3,0 m • kg, 22ft•lb)
OIL LEVEL:
165.5mm
Below the top of inner tube
fully rebounded without
fork spring

23 Nm (2,3m•kg,
17ft•lb)

C USE NEW ONE

LT

10 Nm (1,0 m • kg, 7,2ft•lb)

C USE NEW ONE

62 Nm (6,2 m • kg, 45ft•lb)

4-37
 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 

3. Loosen:
2 • upper bracket pinch bolt 
1 • cap bolt 
• lower bracket pinch bolt 

s WARNING
3
Before loosening the upper and lower brac-
ket pinch bolts, support the front fork leg.

4. Remove:
• front fork leg

1 DISASSEMBLY
1. Remove:
• Clamps (Upper  and lower )
• Fork boot 
3

1 2.Remove:
2 • Cap bolt 
3 • Spacer 
4 • Spring seat 
• Fork spring 

4-38
 REMOVAL/DISASSEMBLY CHAS
3. Drain:
1
• Fork oil

4. Remove:
• Retaining clip 
Use a thin slotted head screwdriver
• Washer 

CAUTION
Take care not to scratch the inner tube
2
1

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

2 90890-01388
1 T-handle
90890-01326

6. Remove:
• Damper rod 
• Rebound spring
(Out of inner fork tube )

4-39
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 care-
fully.

CAUTION
• Excessive force will damage the oil seal
and bushing. A damaged oil seal or bus-
hing must be replaced.
• Avoid bottoming the inner tube into the
outer tube during the above procedure,
as the oil flow stopper will be damaged.



EAS00656

CHECKING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.

1. Check:
• inner tube 
1
• outer tube 
Bends/damage/scratches  Replace.

s WARNING
2 Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.

2. Measure:
• spring free length 
a
Out of specification  Replace.
Spring free length
DT125RE 503mm (19.8 in)
DT125X 501mm (19.7 in)

4-40
CHECKING THE FRONT FORK LEGS/ASSEMBLING
THE FRONT FORK LEGS CHAS

2 3. Check:
3 • damper rod 
• piston ring 
Damage/wear  Replace.
1 Obstruction  Blow out all of the oil pas-
sages with compressed air.
• rebound spring 
Damage  Replace.

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.
• Uneven oil levels can result in poor hand-
ling and a loss of stability.

NOTE:
• When assembling the front fork leg, be
sure to replace the following parts:
- inner tube bushing
- outer tube bushing
- oil seal
- dust seal
• Before assembling the front fork leg, make
sure all of the components are clean.

2 1. Install:
• damper rod assembly 
1
CAUTION
Allow the damper rod assembly to slide
slowly down the inner tube  until it pro-
trudes from the bottom of the inner tube. Be
careful not to damage the inner tube.

4-41
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. Install:
• outer tube bushing 
(with the fork seal driver weight and fork
seal driver attachment)

Fork seal driver weight

90890-01367
Fork seal driver attachment
90890-01381

5. Install:
• washer
• oil seal 
(with the fork seal driver weight and fork
seal driver attachment)

CAUTION
Make sure the numbered side of the oil seal
faces up.

4-42
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. Install:
• dust seal 
(with the fork seal driver weight)

Fork seal driver weight

90890-01367

8. Fill:
• front fork leg
(with the specified amount of the recom-
mended fork oil)
Quantity (each front fork leg)
DT125RE 0.495 L
DT125X 0.6 L
Recommended oil
Yamaha fork and shock oil 10W
or equivalent

Front fork leg oil level (from the

top of the inner tube, with the
inner tube fully compressed and
without the fork spring)
DT125RE 165.5 mm (6.52 in)
DT125X 140mm (5.52 in)

4-43
 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:
4 • spring 
• spring seat 
• spacer 
3 • cap bolt 

NOTE:
2
1 • 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.

4-44
 STEERING HEAD AND HANDLEBARS CHAS
STERING HEAD AND HADLEBARS

 Handlebar 
10 Cover
 Handlebar grip (Right) 
11 Bearing race
 Handlebar grip (Left) 
12 Headlight stay
 Handlebar holder (Upper)
 Handlebar crown
Ring nut

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 3.6 ft•lb)

120 to 155 Nm (12 to 15,5 m • kg,

88 to 110 ft•lb)

120 to 155 Nm
(12 to 15,5 m • kg,
88 to 110 ft•lb)
12 to 28 Nm (1,2 to 2,8 m • kg,
8,8 to 20,5 ft•lb)

4-45
 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 
1
• Washers

1 4. Remove:
2
• Headlight cover 
• Headlightn lens unit 

5. Disconnect:
• Headlight lead
• Auxiliary light lead 
6. Disconnect:
• Flasher light leads

4-46
 REMOVAL CHAS
7. Remove:
• Flasher lights (left and right) 
• Brake hose guide 
(From left side only)
4 8. Disconnect:
1 • Speedometer cable 
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

60 80
40 100
0 0 0 0 1 5 120
20 km/h

0 130

0008

12. Remove:
• Brush guard

13. Disconnect:
• Clutch cable
(from clutch cable pivot)
1 14. Remove:
• Meter assembly 

4-47
 REMOVAL CHAS
15. Loosen:
• Screws (throttle cable housing) 

16. Remove:
1 • Handlebar holders 
• Handlebars 

NOTE:
2
For completely removal of the handlebar, be
sure to clear the throttle cable housing

17. Remove:
• Flange nut 
• Handlebar crown 

2
1

18. Remove:
• Lock washer 
• Ring nut 1 
• Ring nut 2 
1 • Cover 
2
3 NOTE:
4
Remove the ring nut using the Ring Nut
wrench

Ring Nut Wrench:

90890-01403

s WARNING
Support the lower bracket so that it may
not fall down

4-48
 REMOVAL/INSPECTION CHAS
19. Remove:
• Bearing cover 
• Ball race (Top-Upper) 
• Ball bearing  (22pcs)

INSPECTION
2 1. Wash the bearing in solvent.
1
2. Inspect:
• Bearings
2 • Bearing races 
Pitting/Damage  Replace
• Dust seal
Wear/Damage  Replace



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.
• Install the new dust seal and races.


NOTE:
• Always replace bearings and races as a set
• Replace the dust seat whenever the stee-
ring head is disassembled.

CAUTION
If the bearing race is fitted not squarly, the
head pipe could be damaged

3. Inspect:
1
• Handlebar crown 
• Under bracket 
with steering stem
Cracks/Bend/Damage  Replace

4-49
 INSPECTION/INSTALLATION CHAS
4. Inspect:
• Handlebar
Cracks/Bend/Damage  Replace

s WARNING
Do not attempt to straighten a bent handle-
bar 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 rub-
ber on the left handlebar end.
• Install the handlebar grip.

NOTE:
Wipe off any excess adhesive with a clear rag

s WARNING
Leave the handlebar intact until the adhesi-
ve becomes dry enough to make the grip
and handlebar stuck securely.



INSTALLATION
Reverse the “REMOVAL” procedures.
Note the following points

2 1. Lubricate:
• Bearing races 
1 • Bearings 
1

Lithium Soap Base Grease

2. Install:
• Ball bearings

NOTE:
Be sure the balls has the same size and the
quantity is correct (22pcs)

4-50
 INSTALLATION CHAS
3. Install:
• Ball race (Upper-Lower)
• Bearing cover 
• Under bracket
• Ring nut 
2
1 s WARNING
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 29.3 ft·lb)

• Loosen the ring nut fully

• Retighten the ring nut using the Ring Nut
Wrench

s WARNING
Avoid over tightening

Ring Nut (Final tightening):

3Nm to 5Nm (0.3 to 0.5 m·kg, 2.2
to 3.6 ft·lb)



5. Install:
• Handlebar crown 
• Flange nut (Steering stem) 

2
NOTE:
Temporarily tighten the flange bol.
1

4-51
 INSTALLATION CHAS
6. Install:
• Meter assembly 

1 Bolt (Meter assembly):

5Nm to 8Nm (0.5 to 0.8 m·kg, 3.6
to 5.8 ft·lb)

7. Install:
• Front fork
Refer to the “FRONT FORK INSTALLA-
TION” 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

1 Flange nut (Steering stem):

120 to 155 Nm (12 a 15.5 m·kg,88
to 110ft·lb)
Pinch bolt (Handlebar crown):
12 to 28 Nm (1.2 to 2.8 m·kg, 8.80
to 20.5ft·lb)
NOTE:
• Install the brake hose guide to the left side
only.
• On the left side, install the flasher light
having a chocolate color lead. Next, install
the other flasher light with a dark green
color lead.

4-52
 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 posi-
tion 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.

NOTE:
Before installing the handlebar onto the hand-
lebar crown, apply a light coat of lithium soap
base grease onto the handlebar end and install
the throttle housing to the handlebar.

10. Install:
• Brake master cylinder

NOTE:
• Install the master cylinder bracket with the
“UP” mark facing upward.
• Tighten first the upper bolt, then the lower
bolt.
Bolts (Master cylinder bracket):
5 to 8 Nm (0.5 a 0.8 m·kg, 3.6 to
5,8ft·lb)
11. Install:
• Clutch cable

NOTE:
Apply a light coat of lithium soap base grease
onto the clutch cable end

4-53
 INSTALLATION CHAS
12. Install:
• Headlight lens unit

13. Install:
• Front wheel
Refer to the “FRONT WHEEL INSTALLA-
TION” 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:
3 • Clutch cable free play 
Refer to the “CLUTCH ADJUSTMENT”
section in chapter 3.

Free play:
2~3mm (0.08~0.12in)

1 2

4-54
 REAR SHOCK ABSORBER AND SWINGARM CHAS
REAR SHOCK ABSORBER AND SWINGARM

 Rear shock absorber assembly

 Spring
 Bush

A SPRING PRELOAD (INSTALLED): A SPRING PRELOAD (INSTALLED):

FOR DT125RE FOR DT125X
STANDARD LENGTH: STANDARD LENGTH:
230 mm 244 mm
MINIMUM LENGTH: MINIMUM LENGTH:
220 mm 234 mm
MAXIMUM LENGTH: MAXIMUM LENGTH:
235 mm 249 mm

30 to 35 Nm (3,0 to 3,5 m • kg,

22 to 25,6 ft•lb)

4-55
 REAR SHOCK ABSORBER AND SWINGARM CHAS
 Swingarm Bearing
 Relay arm Oil seal
 Connecting arm 
10 Bush
 Chain case 
11 Plain washer
 Chain guard 
12 Shim
 Chain guide 
13 Thrust cover
 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/DISPO-
SING 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 informa-
tion. The manufacturer cannot be held res-
ponsible for property damage or personal
injury that may result from improper hand-
ling of the rear shock absorber.
• Do not tamper or attempt to open the
rear shock absorber.
• Do not subject the rear shock absorber
to an open flame or any other source of
high heat. High heat can cause an explo-
sion due to excessive gas pressure.
• Do not deform or damage the rear shock
absorber in any way. Rear shock absor-
ber damage will result in poor damping
performance.

EAS00688

DISPOSING OF A REAR SHOCK

ABSORBER
Gas pressure must be released before dispo-
sing of a rear shock absorber. To release the
gas pressure, drill a 2 ~ 3-mm hole through the
rear shock absorber at a point 15 ~ 20 mm
from its end as shown.

s WARNING
Wear eye protection to prevent eye damage
from released gas or metal chips.

EAS00690

REMOVING THE REAR SHOCK ABSORBER

ASSEMBLY
1. Stand the motorcycle on a level surface.

s WARNING
Securely support the motorcycle so that
there is no danger of it falling over.

4-57
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)

3. Remove:
• Bolt (Shock absorber  Lower)

s WARNING
When removing the lower bolt  hold the
swingarm  so that it does not drop down-
wards when the lower bolt is removed.
1 2

4. Remove:
• Bolt (Shock absorber  Upper) 

5. Remove:
• Rear shock absorber

NOTE:
Pull up the swingarm, then remove the rear
shock absorber, through between the swin-
garm and relay arm

4-58
 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
1 Refer to the “REAR SHOCK ABSORBER”
section.
3. Remove:
• Rear wheel
Refer to the “REAR WHEEL REMOVAL”
section.

4. Remove:
• Brake hose guides 
• Mud guard

5. Remove:
• Protector (Brake caliper) 
• Brake caliper assembly 

1 2

3 6. Remove:
• Chain case 
• Chain guide 
• Chain guard 
1

4-59
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 swin-
1 garm):
1mm (0.04in)

• Check the swingarm vertical movement

by moving it up and down.
If vertical movement is tight, binding or
rough, check the inner collar, bearing, bus-
hing and thrust cover or adjust the shim.


8. Remove:
• Pivot shaft 
• Swingarm

9. Remove:
• Connecting arm 

4-60
 REMOVING THE SWINGARM ASSEMBLY CHAS
10. Remove:
• Relay arm

1 11. Remove:
• Chain protector 

12. Remove:
• Thrust covers 
• Inner collars (Swingarm) 
• Inner collars (Connecting arm) 
• Inner collar (Relay arm) 

1
2

3
2
4 2 1

4-61
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. Check:
• swingarm
Bends/cracks/damage  Replace.

2. Check:
• pivot shaft
Roll the pivot shaft on a flat surface.
Bends  Replace.

s WARNING
Do not attempt to straighten a bent pivot
shaft.

3. Wash:
• pivot shaft
• dust covers
• spacer
• washers
• bearings

Recommended cleaning solvent

Kerosene

4-62
 CHECKING THE SWINGARM CHAS
4. Check:
• dust covers 
1 3 • spacer 
4 • washers 
2 • oil seals 
Damage/wear  Replace.
• bearings
Damage/pitting  Replace.
2
4
3
1

5. Check:
• connecting arms 
• relay arm 
Damage/wear  Replace.
1

9
8
2

6. Check:
• bearings 
• oil seals 
Damage/pitting  Replace.

2
1

4-63
CHECKING THE SWINGARM/INSTALLING THE
SWINGARM CHAS
7. Check:
• spacers
Damage/scratches  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. Install:
• rear shock absorber assembly
• rear wheel
Refer to “INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY” and “INSTA-
LLING THE REAR WHEEL”.

4-64
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.)

4-65
 DRIVE CHAIN AND SPROCKETS CHAS
DRIVE CHAIN AND SPROCKETS

 Drive sprocket
 Chain joint
 Drive chain

A DRIVE CHAIN
B TYPE
428V2
C No. OF LINKS
134
D DRIVE CHAIN SLACK DT125RE
45~55mm
(1,77~2,16in)
E DRIVE CHAIN SLACK DT125X
25~40mm
(0,984~1,575in)

32 to 37 Nm (3,2 to 3,7 m • kg,

23,5 to 27,1 ft•lb)

4-66
 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) 

3. Straighten:
• Lock washer tab 
1 4. Loosen:
2 • Nut (drive sprocket) 

NOTE:
When loosening the drive sprocket nut, apply
the rear brake pedal and transmission gear to
the 6th position.

5. Remove:
4 • Clip (master link) 
• Plate (master link) 
• master link 
• O-rings 
• Drive chain

3 4 2 1

6. Remove:
1 • Chain guide 
• Drive sprocket
7. Remove:
• Rear wheel
Refer to the “REAR WHEEL REMOVAL”
section.

4-67
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 repla-
ce.

3. Clean:
• drive chain


a. Wipe the drive chain with a clean cloth.

b. Put the drive chain in kerosene and remove
any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.

4-68
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 sol-
vents (e.g., benzine), or a coarse brush to
clean the drive chain. High-pressure met-
hods could force dirt or water into the drive
chain’s internals, and solvents will deterio-
rate the O-rings. A coarse brush can also
damage the O-rings. Therefore, use only
kerosene to clean the drive chain. Don’t
soak drive chain in kerosine more them ten
minutes. O-ring is damage by kerosine.



4. Check:
• O-rings 
Damage  Replace the drive chain.
• drive chain rollers 
Damage/wear  Replace the drive chain.
• drive chain side plates 
Damage/wear  Replace the drive chain.
Cracks  Replace the drive chain and
make sure the battery breather hose is
properly routed away from the drive chain
and below the swingarm.

5. Lubricate:
• drive chain

Recommended lubricant
Engine oil or chain lubricant sui-
table for O-ring chains

6. Check:
• drive sprocket
• rear wheel sprocket
More than 1/4 tooth a wear  Replace
the drive chain sprockets as a set.
Bent teeth  Replace the drive chain
sprockets as a set.


b Correct
 Drive chain roller
 Drive chain sprocket

4-69
 INSTALLING THE DRIVE CHAIN CHAS
EAS00713

INSTALLING THE DRIVE CHAIN

1. Lubricate:
• drive chain
• master link <NEW>

Recommended lubricant
Engine oil or chain lubricant sui-
table for O-ring chains

2 2. Install:
4 3 • drive chain
• drive sprocket 
• washer 
• drive sprocket nut 

60 Nm (6.0 m•kg, 43 ft•lb)

NOTE:
While applying the rear brake, tighten the drive
sprocket nut.

3. Install:
2 • master link 
• O-ring 
• master link plate 
(with a drive chain cutter)
1 3
CAUTION
Never install a new drive chain onto worn
drive chain sprockets; this will dramatically
shorten the drive chain’s life.

4. Adjust:
• drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” in chapter 3.

Drive chain slack DT125RE

45 ~ 55 mm (1.77 ~ 2.16 in)
Drive chain slack DT125X
25 ~ 40 mm (0.984 ~ 1.575 in)

4-70
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 speci-
fied limits.

4-71
 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. CABLES ………………………………………………………………5-3
RADIATOR HOSE………………………………………………………………5-4
LEADS …………………………………………………………………………5-4
DRIVE CHAIN …………………………………………………………………5-5

ENGINE DISASSEMBLY…………………………………………………………5-6
CYLINDER HEAD, CYLINDER AND PISTON ………………………………5-8
CLUTCH, PRIMARY DRIVE GEAR AND BALANCER GEAR ……………5-8
CLUTCH PUSH LEVER………………………………………………………5-11
SHIFT SAHFT AND STOPPER LEVER ……………………………………5-11
MAGNETO ROTOR …………………………………………………………5-12
REED VALVE …………………………………………………………………5-12
CRANKCASE (RIGHT) ………………………………………………………5-13
SHIFTER, TRANSMISSION AND BALANCER WEIGHT …………………5-14
CRANKSHFT …………………………………………………………………5-15
POWER VALVE ………………………………………………………………5-15
AUTOLUBE PUMP ASSEMBLY ……………………………………………5-16

INSPECTION AND REPAIR ……………………………………………………5-17

CYLINDER HEAD ……………………………………………………………5-17
CYLINDER AND PISTON ……………………………………………………5-18
PISTON RINGS ………………………………………………………………5-19
PISTON PIN AND BEARING ………………………………………………5-21
CLUTCH ………………………………………………………………………5-21
PRIMARY DRIVE ……………………………………………………………5-24
TRANSMISSION AND SHIFTER ……………………………………………5-25
SHIFT SHAFT AND STOPPER LEVER ……………………………………5-27
CRANKSHAFT ………………………………………………………………5-27
AUTOLUBE PUMP …………………………………………………………5-28
POWER VALVE ………………………………………………………………5-29
CRANKCASE …………………………………………………………………5-30

ENGINE ASSEMBLY AND ADJUSTMENTS ………………………………5-31

AUTOLUBE PUMP …………………………………………………………5-31
POWER VALVE ………………………………………………………………5-33
CRANKSHAFT AND BALANCER …………………………………………5-35
TRANSMISSION AND SHIFTER ……………………………………………5-36
CRANKCASE (RIGHT) ………………………………………………………5-39
REED VALVE …………………………………………………………………5-40
MAGNETO ROTOR …………………………………………………………5-41
STOPPER LEVER AND SHIFT SHAFT ……………………………………5-43
CLUTCH PUSH LEVER………………………………………………………5-46
BALANCER GEAR, PRIMARY DRIVE GEAR AND CLUTCH ……………5-47
PISTON CYLINDER AND CYLINDER HEAD………………………………5-52
REMOUNTING ENGINE ……………………………………………………5-56
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. Drain:
• Transmission oil
Refer to the “TRANSMISSION OIL REPLA-
CEMENT” section in chapter 3.

5-1
 ENGINE REMOVAL ENG
EXHAUST PIPE
1. Loosen:
• Bolts (Exhaust holder)
• Screw (muffler joint) 

2. Remove:
• A.I.S. hose 
1 • Bolts (Exhaust pipe) 
• Exhaust pipe

CARBURETOR
1. Remove:
• Fuel tank
2
• Carburetor
1 Refer to the “CARBURETOR REMOVAL”
section in chapter 6.

AUTOLUBE PUMP CABLE AND HOSE

1 1. Remove:
• Autolube pump cover 

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
2 the oil tank.
1

3. Remove:
• Pump cable 
1 NOTE:
Turn the pump pulley clockwise by finger to
make the pump cable loose enough for its end
to be removed from the pulley.

5-2
 ENGINE REMOVAL ENG
CLUTCH CABLE
2 1. Loosen:
• Adjuster (Clutch cable) 

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:
3 • Pulley (Power valve) 
2 
1
4 Removal steps
2 • Loosen both locknuts  and turn in both
adjusters .
1 • Insert a pin (Ø4mm.(Ø0.16in)) through the
5 aligning indent in the pulley  and into the
5 hole to lock the pulley.
• Remove the pulley  from the power valve
and then disconnect the Y.P.V.S. cables 
from the pulley.
• Remove the pin


5-3
 ENGINE REMOVAL ENG
3. Disconnect:
• Servomotor unit leads
4. Remove:
• Servomotor unit 
• Adjuster (Y.P.V.S. cable) 
• Pulley housing

2
3

RADIATOR HOSES
1 1. Disconnect:
• Radiator hose (Inlet) 

2. Disconnect:
• Radiator hose (Outlet) 

LEADS
1 1. Disconnect:
• Battery lead (Negative) 

1
2. Disconnect:
• Spark plug lead 
2 • Thermo unit lead 

5-4
 ENGINE REMOVAL ENG
3. Disconnect:
1 • CDI magneto leads 

4. Remove:
• Bands

DRIVE CHAIN
1. Remove:
• Change pedal 
• Crankcase cover (Left) 
• Gasket (Crankcase cover)

2 1

2. Straighten:
• Lock washer tab 
1
2 3. Loosen:
1 • Nut (Drive sprocket) 

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) 
4 • Lock washer 
• Drive sprocket 
• Spacer collar 
5 2
3

ENGINE REMOVAL
1 1. Remove:
• Bolts (Engine stay  Upper) 
• Bolts (Engine mount  Front) 

5-5
 ENGINE REMOVAL/
ENGINE DISASSEMBLY ENG
2. Remove:
• Bolt (Engine mount  Rear lower)
• Pivot shaft 

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. Remove:
• Engine assembly
(from right side)

ENGINE DISASSEMBLY
CYLINDER HEAD, CYLINDER AND PISTON

NOTE:
With the engine mounted, the cylinder head,
cylinder and piston can be maintained by
removing the following parts.
• Side covers (Right and left)
• Seat
• Radiator cover
• Oil tank cover
• Fuel tank
• Radiator hose (inlet)
• Servomotor unit (Y.P.V.S.)
• Engine stay (Upper)
• Exhaust pipe

1. Remove:
1 • Hoses (Inlet  and Outlet )

5-6
 ENGINE DISASSEMBLY ENG
2. Remove:
2 • Spark plug 
• Thermo unit 
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 1

5. Remove:
5 2 • Cylinder head
• Gasket (Cylinder head)

NOTE:
• Loosen the nuts starting with the highest
3 numbered one.
4 • Loosen each nut 1/4 turn, and remove them
after all nuts are loosened.
1

6. Remove:
• Clutch cable guide
• Cylinder 
• Gasket (Cylinder)
• Dowel pins
1
NOTE:
Loosen each nut 1/4 turn, and remove them
after all nuts are loosened.

5-7
 ENGINE DISASSEMBLY ENG
EAS00253
3
REMOVING THE CYLINDER AND PISTON
2 1. Remove:
• piston pin clip 
1 • piston pin 
• piston 

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. If both areas are deburred
and the piston pin is still difficult to remo-
ve, remove it with the piston pin puller set.

Piston pin puller set

90890-01304

2. Remove:
• top ring
• 2nd ring
• oil ring

NOTE:
When removing a piston ring, open the end
gap with your fingers and lift the other side of
the ring over the piston crown.

CLUTCH, PRIMARY DRIVE GEAR AND

BALANCER GEAR

NOTE:
With the engine mounted, the clutch, primary
drive gear and balancer gear can be maintai-
ned by removing the following parts:

• Brake pedal
• Radiator hose (Outlet)
• Autolube pump cable and hoses
• Crankcase cover (Right)

5-8
 ENGINE DISASSEMBLY ENG
1. Remove:
• Water outlet pipe 
• O-Ring 
(from water outlet pipe)

2  Right side
 Left side
1

2. Remove:
• Crankcase cover (Right)
• Dowel pins
• Gasket (Crankcase cover)

3. Remove:
1 • Bolts 
2 3 • Clutch springs 
8 • Pressure plate 
9 • Push rod #1 
• Friction plates 
7
6 • Clutch plates 
5 • Clutch dumper 
10 • Nut (Clutch boss)
11 • Lock washer
• Clutch boss  10
• Thrust washer  11
• Clutch housing  12
• Thrust plate 13
• Conical spring washer 
14
• Boll 15
12 13 • Push rod #2  16
14
4
15
16

5-9
 ENGINE DISASSEMBLY ENG
NOTE:
1
• Before loosening the nut (Clutch boss) 
straighten the lock washer tab.
2 • Hold the clutch boss to loosen the nut
(Clutch boss) by the universal Clutch hol-
der 

Universal Clutch Holder

90890-04086

1 4. Straighten:
3 • Lock washer tab 
2 5. Loosen:
• Nut (Primary drive gear) 
• Nut (Balancer gear) 

NOTE:
Hold the magneto rotor to loosen the nut (pri-
mary drive gear) and nut (Balancer driven
gear) by the universal rotor holder

Universal Rotor Holder

90890-01235

3 2 6. Remove:
1 • Nut (Balancer driven gear) 
• Lock washer 
6 • Driven gear (Balancer weight) 
5
• Straight key
• Nut (Primary drive gear) 
• Plain washer 
• Primary drive gear 
7 • Baffle plate
8

7. Remove:
• Drive gear (Balancer weight) 
• Straight key 

5-10
 ENGINE DISASSEMBLY ENG
8. Remove:
1
2 • Spacer collar 
• Oil seal retainer 

2 3 CLUTCH PUSH LEVER

1. Unhook:
• Return spring (Push lever) 
4
2. Remove:
1 • Push lever (Clutch) 
• Return spring 
• Washer 

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. Remove:
• Shift shaft 
1

CAUTION
When removing the shift shaft, hold the
guide bar (shift fork) 2 in place. Otherwise,
the guide bar will come loose with the shift
shaft, leaving the shift fork out of order in
the crankcase.

2. Remove:
• Stopper lever 
• Return spring 

1
2

5-11
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. Remove:
• Stator

REED VALVE

NOTE:
With the engine mounted, the reed valve can
be maintained by removing the following parts:
• Side covers (Right and Left)
• Seat
• Radiator cover
• Oil tank cover
• Fuel tank
• Carburetor

5-12
 ENGINE DISASSEMBLY ENG
1. Remove:
1 • Carburetor joint 
• Reed valve assemby 
• Gasket 

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.


1 Removal steps:
• Attach the Crankcase Separating Tool 

Crankcase Separating Tool:

90890-01135

NOTE:
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 evel tool body.

• As pressure is applied alternately tap on

the front engine mounting boss, transmis-
sion shafts and shift cam.
Then remove the crankcase (Right).

NOTE:
1 Turn the shift cam  to the position shown in
the figure so that it doesn’t contact the crank-
case when separating the crankcase.

5-13
 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 pres-
sure off the push screw, realign, and
start over. If the cases don’t separate,
check for a remaining case screw or fit-
ting.
• Don’t force.



2. Remove:
• Dowel pins 
1
• Damper collar 

3. Remove:
2
1 • Bearing retainer 

SHIFTER, TRANSMISSION AND BALANCER

1 WEIGHT
3
1. Remove:
• Guide bars 
• Shift cam 
• Shift forks 

NOTE:
Note the position of each part. Pay particular
2 attention to the location and direction of shift
forks.

2. Remove:
• Transmission assembly
Tap lightly on the transmission drive axle
with a soft hammer.

5-14
 ENGINE DISASSEMBLY ENG
3. Remove:
1 • Balancer weight 

CRANKSHAFT
1
2 1. Remove:
• Crankshaft 

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 bac-
ked out slightly to level tool body.

Crankcase Separating Tool:

90890-01135

POWER VALVE

NOTE:
With the engine mounted, the power valve can
be maintained by removing the following parts:
• Side covers
• Seat
• Radiator cover
• Cover (engine oil tank)
• Fuel tank
• Servomotor unit

5-15
 ENGINE DISASSEMBLY ENG
1. Remove:
• Hose guide
• Power valve holder (Right)

2. Remove:
• Bolt (Power valve) 

NOTE:
When loosening the power valve connecting
bolt , lock the valve by inserting a wooden
1 pice  into the exhaust port.
2

3. Remove:
• Power valve (Right) 
• Power valve (Left) 
• Dowel pins 
• Holder (Power valve)
• Gasket seal

1
3 2

AUTOLUBE PUMP ASSEMBLY

NOTE:
With the engine mounted, the autolube pump
assembly can be maintained by removing the
following parts:
• Brake pedal
• Radiator hose (Outlet)
• Autolube pump cable and hoses
• Kick crank
• Crankcase cover (Right)

5-16
 ENGINE DISASSEMBLY/
INSPECTION AND REPAIR ENG
1. Remove:(ref. oilpump)
•  Circlip
•  Drive gear (autolube pump)
8 •  Circlip
•  Oil seal
•  Collar
•  Pin
•  Drive shaft (autolube pump)
•  O-Ring
5 • Autolube pump

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 dama-
ging or scratching:
• spark plug bore threads
• valve seats

2. Check:
• cylinder head
Damage/scratches  Replace.

3. Measure:
• cylinder head warpage
Out of specification  Resurface the cylin-
der head.

Maximum cylinder head warpage

0.03 mm (0,0012 in)

5-17
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 cylin-
der 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.



EAS00255

CHECKING THE CYLINDER AND PISTON

1. Check:
• piston wall
• cylinder wall
Vertical scratches  Rebore or replace the
cylinder, and replace the piston and piston
rings as a set.

2. Measure:
• piston-to-cylinder clearance


a. Measure cylinder bore “C” with the cylinder

bore gauge.

NOTE:
Measure cylinder bore “C” by taking side-to-
side and front-to-back measurements of the
cylinder. Then, find the average of the measu-
rements.

Cylinder bore gauge

56.00 ~ 56.02 mm (2.2047 ~
2.2055 in)

5-18
INSPECTION AND REPAIR ENG
Standard Limit
Cylinder
Bore “C” 56.00 ~ 56.02 mm
(2.204 ~ 2.205 in)
Taper “T” — 0.05 mm
(0.001968 in)
Out of — 0.01 mm
round “R” (0.00039 in)
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.
Micrometer
90890 - 03008

Piston size “P”

Standard 56.34 ~ 56.40 mm
(2.218 ~ 2.220 in)
Oversize  56.65 mm (2.23 in)
Oversize  56.90 mm (2.24 in)
d. If out of specification, replace the piston
and piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” -
Piston skirt diameter “P”

Piston-to-cylinder clearance
0.045 ~ 0.050 mm (0.0018 ~
0.0020 in)
Limit: 0.1 mm (0.004 in)

f. If out of specification, rebore or replace the

cylinder, and replace the piston and piston
rings as a set.


EAS00264

CHECKING THE PISTON RINGS

1. Measure:
• piston ring side clearance
Out of specification a  Replace the pis-
ton and piston rings as a set.

5-19
INSPECTION AND REPAIR ENG
NOTE:
Before measuring the piston ring side clearan-
ce, 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  Replace the piston
ring.

NOTE:
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is exces-
sive, replace all three piston rings.

Piston ring end gap

Top ring
0.3 ~ 0.45 mm
(0.012 ~ 0.018 in)
2nd ring
0.30 ~ 0.45 mm
(0.012 ~ 0.018 in)

5-20
 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:
2
• Small end bearing 
• Piston pin 
1 (Lightly)
2. Install:
• Small end bearing 
3 • Piston pin 
(into small end  of connecting rod)

3 3. Check:
• Free play
There should be no noticeable play. Free
play exists  Inspect the connecting rod
for wear/Replace the pin and/or connec-
ting rod as required.
4. Install:
• Piston pin
(into piston pin hole)

5. Check:
• Free play (when the piston pin is in place
in the piston).
There should be no noticeable play. Free
play exists  Inspect the connecting rod
for wear/Replace the pin and/or connec-
ting rod as required.
6. Inspect:
• Piston pin and bearing
Signs of heat discoloration  Replace

EAS00280

CHECKING THE FRICTION PLATES

The following procedure applies to all of the
friction plates.
1. Check:
• friction plate
Damage/wear  Replace the friction
plates as a set.

5-21
INSPECTION AND REPAIR ENG
2. Measure:
• friction plate thickness
Out of specification  Replace the fric-
tion 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)
<Limit>: 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. Measure:
• clutch plate warpage
(with a surface plate and thickness gauge
)
Out of specification  Replace the
clutch plates as a set.

Clutch plate warpage limit

0.05 mm (0.001 in)

EAS00282

CHECKING THE CLUTCH SPRINGS

The following procedure applies to all of the
clutch springs.

1. Check:
• clutch spring
Damage  Replace the clutch springs
as a set.

5-22
 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.

EAS00285

CHECKING THE CLUTCH BOSS

1. Check:
• clutch boss splines
Damage/pitting/wear  Replace the clutch
boss.

NOTE:
Pitting on the clutch boss splines will cause
erratic clutch operation.

EAS00286

1 CHECKING THE PRESSURE PLATE

1. Check:
• pressure plate 
Cracks/damage  Replace.
• bearing
Damage/wear  Replace.

5-23
 INSPECTION AND REPAIR ENG
EAS00288

CHECKING THE CLUTCH PUSH RODS

1. Check:
• O-ring 
• short clutch push rod 
1
2 • long clutch push rod 
• ball 
Cracks/damage/wear  Replace the
4 defective part(s).
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. Check:
• primary drive gear
• primary driven gear
Damage/wear  Replace the primary
drive and primary driven gears as a set.
Excessive noise during operation 
Replace the primary drive and primary dri-
ven gears as a set.

2. Check:
• primary-drive-gear-to-primary-driven-gear
free play
Free play exists  Replace the primary
drive and primary driven gears as a set.

5-24
 INSPECTION AND REPAIR ENG
EAS00421

CHECKING THE SHIFT FORKS

The following procedure applies to all of the
shift forks.
2 1. Check:
• shift fork cam follower 
• shift fork pawl 
Bends/damage/scoring/wear  Replace
1 the shift fork.

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. Check:
• shift fork movement
(along the shift fork guide bar)
Rough movement  Replace the shift
forks and shift fork guide bar as a set.

EAS00422

CHECKING THE SHIFT DRUM ASSEMBLY

1. Check:
• shift drum grooves
Damage/scratches/wear  Replace the
shift drum assembly.
• shift drum segment 
Damage/wear  Replace the shift drum
assembly.
• shift drum bearing 
Damage/pitting  Replace the shift drum
assembly.

5-25
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).
• transmission gear dogs
Cracks/damage/rounded edges 
Replace the defective gear(s).

4. Check:
• transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect  Reassemble the transmis-
sion axle assemblies.

5. Check:
• transmission gear movement
Rough movement  Replace the defec-
tive part(s).
6. Check:
• circlips
Bends/damage/looseness  Replace.

5-26
 INSPECTION AND REPAIR ENG
EAS00328

CHECKING THE SHIFT SHAFT

1. Check:
• shift shaft 
• shift pawls 
Bends/damage/wear  Replace.
2. Check:
5 • stopper lever 
Roller turns roughly  Replace
2 Bend/damage  Replace
3. Check:
• Return spring (shift shaft) 
1 • Return spring (Shift pawls) 
• Return spring (Stopper lever) 
Wear/damage  Replace.
4
3
6

EAS00394

CHECKING THE CRANKSHAFT AND

CONNECTING ROD
1. Measure:
• crankshaft runout
Out of specification  Replace the
crankshaft, bearing or both.

NOTE:
Turn the crankshaft slowly.

Maximum crankshaft runout

0.03 mm (0.0012 in)

2. Measure:
• big end side clearance
Out of specification  Replace the big
end bearing, crankshaft pin, or connecting
rod.

Big end side clearance

0.2~0.7mm (0.0079~0.0276in)

5-27
 INSPECTION AND REPAIR ENG
3. Measure:
• crankshaft width
Out of specification  Replace the
crankshaft.

Crankshaft width
57.9~57.95 mm (2.279~2.281 in)

4. Check:
• crankshaft sprocket 
Damage/wear  Replace the cranks-
haft.
1 • bearing 
Cracks/damage/wear  Replace the
crankshaft.

AUTOLUBE PUMP
Wear or an internal malfunction may cause
1 pump output to vary from the factory settings.
This situation is, however extremely dange-
rous.If improper output is suspected, inspect
2 4 the following:
3
1. Inspect:
• Delivery line
6 5 Obstructions  Blow out.
• Pump body seal/crankcase cover seal
Wear/damage  Replace.
2. Inspect:
10 • Allowing air
13 Air exists  Air bleed.
Refer to the “AUTOLUBE PUMP AIR BLE-
EDING” section in chapter 3.
9
7
8
11
14
12
14

5-28
 INSPECTION AND REPAIR ENG
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) 
8 • Pivot collar (Drive shaft) 
Wear/damage  Replace.

7
6
4
3
1
2
1

POWER VALVE
1. Eliminate:
1 • Score marks and lacquer deposits.
• Carbon deposits.
(from power valve , specially in cleaning
groove  surface, and its contact surface
of cylinder block).

2. Check:
• O-rings 
• Bushes 
• Gsket seals 
Wear/damage  Replace

1
2
3

5-29
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.

5-30
 ENGINE ASSEMBLY AND ADJUSTMENTS ENG
AUTOLUBE PUMP

 Autolube pump Collar

 End cap O-Ring
 Hose 
10 Screw
 Clip 
11 Oil seal
 Adjusting bolt 
12 Autolube pump gear
 Washer 
13 Pin
 Drive shaft 
14 Circlip

5 Nm (0.5 m • kg, 3.6ft•lb)

5-31
 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 
7 • Pin 
6 • Drive gear (autolube pump) 
• Circlip 
4
• O-ring 
3
• Autolube pump
1
2
Screw (Autolube pump):
1
5 Nm (0.5m•kg; 3.6ft·lb)

s WARNING
• Always use a new circlip
• Always use a new O-ring

5-32
 ENGINE ASSEMBLY AND ADJUSTMENTS ENG
POWER VALVE

 Power valve  Pulley housing

 Power valve holder (right)  Pulley
 O-ring Pulley cover
 Power valve holder (left) Y.P.V.S. Cable
 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, 5.1ft•lb)

5-33
 ENGINE ASSEMBLY AND ADJUSTMENTS ENG
POWER VALVE
2
1. Lubricate:
2 • Power valve connecting rod 

Molybdenum Disulfide Grease

• O-rings 
3 4 3 • Gasket seal 
• Bushes
(Power valve shaft contact surface)
• Power valve surface 
1 Lightweight Lithium-soap base
2 3
grease

2. Install:
• Power valve holder (Left) 
• Gasket seal 
(to left power valve)
4 5 • Dowel pins 
• Power valve (Left  and right )
(to cylinder block)
• Bolt (Power valve)

3. Tighten:
• Bolt (Power valve) 

Bolt (Power Valve):

7 Nm (0.7 m•kg; 5.1 ft•lb)
1
2 NOTE:
When tightening the power valve connecting
bolt , lock the valve by insterting a wooden
pice  into the exhaust port.

1 4. Install:
• Power valve holder 
2

Bolt (Power Valve Holder):

1 7 Nm (0.7 m•kg; 5.1 ft•lb)

5. Check:
• Power valve operation
Unsmooth operation  Repair.

5-34
 ENGINE ASSEMBLY AND ADJUSTMENTS ENG
CRANKSHAFT/PISTON/BALANCER

 Balancer gear Bearing 

17 Thrust bearing
 Bearing 
10 Piston ring set 
18 Connecting rod
 Straight key 
11 Piston 
19 Crank pin
 Balancer weight 
12 Piston pin 
20 Big end bearing
 Bearing 
13 Piston pin clip 
21 Crank (Left)
 Drive gear 
14 Small end bearing 
22 Wodruff key
 Oil seal 
15 Staight key 
23 Bearing
Collar 
16 Crank (Right) 
24 Oil seal

A PISTON TO CYLINDER CLEARANCE: C CRANKSHAFT

0.045~0.050 mm(0.0018~0.0020in) Width 57.90~57.95mm
B EN GAP (INSTALLED): (2.279~2.271in)
Top ring Max Runout 0.03mm (0.012in)
0.30~0.45mm(0.012~0.018in) Big end side clearance 0.2~0.7mm(0.0079~0.0276in)
2rd ring
Big end radial clearance 0.026~0.040mm(0in)
0.30~0.45mm(0.012~0.018in)

D BALANCER GEAR INSTALLATION

5-35
 ENGINE ASSEMBLY AND ADJUSTMENTS ENG
TRANSMISSION

 Main axle Cylindrical bearing 

19 Special washer
 2nd pignion gear 
10 Drive axle 
20 Oil seal
 3rd 4th pignion gear 
11 1st wheel gear 
21 Drive sprocket
 5th pignion gear 
12 2nd wheel gear 
22 Lock washer
 6th pignion gear 
13 3rd wheel gear
 Plain washer 
14 4th wheel gear
 Circlip 
15 5th wheel gear
Bearing 
16 6th wheel gear

A RUNOUT LIMIT
008mm(0.003in)

B USE NEW ONE

B USE NEW ONE

A RUNOUT LIMIT
0.08mm(0.003in)

B USE NEW ONE

B USE NEW ONE

5-36
 ENGINE ASSEMBLY AND ADJUSTMENTS ENG
SHIFTER

 Shift cam  Shift fork #2

 Stopper lever  Shift fork #3
 Return spring Shift fork #1
 Securing bolt Shift fork #2
 Shift fork #1

14 Nm (1.4 m • kg,10ft•lb)

5-37
 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. Install:
• crankshaft assembly

CAUTION
To avoid scratching the crankshaft and to
ease the installation procedure, lubricate
the oil seal lips with lithium-soap-based
grease and each bearing with engine oil.

NOTE:
Hold the connecting rod at top dead center
(TDC) with one hand while turning the nut of
the crankshaft installer bolt with the other. Turn
the crankshaft installer bolt until the crankshaft
assembly bottoms against the bearing.

EAS00427

1 INSTALLING THE SHIFT FORKS AND

SHIFT DRUM ASSEMBLY
3 1. Install:
• shift fork guide bars 
2 • shift fork “3” 
• shift fork “2” 
• shift fork “1” 

5-38
 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.

1 CRANKCASE (RIGHT)
1. Install:
• Bearing retainer 
Screw (Bearing retainer):
7 Nm (0.7 m•kg; 5.1 ft•lb)
Use Loctite®

2. Apply:
1 • yamaha Bond nº4 
(to mating surface of both crankcase hal-
ves)

Yamaha Bond nº4:

90890-05143
3
2
3

3. Install:
• Damper collar 
• Dowel pins 

4. Install:
• Crankcase (Right)

Installation steps:
• Apply the lithium soap base grease to the
oil seal lips.
• Fit the right crankcase onto the left case.
Tap lightly on the case with a soft hammer.

NOTE:
Turn the shift cam to the position shown in the
figure so that it doesn’t contact the crankcase
when installing the crankcase.

• Install the water outlet pipe stay

• Tighten the bolts (Crankcase)

5-39
 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. Install:
3 • Breather hose (Crankcase)
• Gasket 
• Reed valve assembly 
• Carburetor joint 

1 s WARNING
2
• Always use a new gasket.
• A damaged gasket may cause the engine
revs to accelerate.

2. Tighten:
• Bolts (Carburetor joint)

Bolts(Carburator joint):
8 Nm (0.8 m•kg; 5.8 ft•lb)

5-40
 ENGINE ASSEMBLY AND ADJUSTMENTS ENG
MAGNETO ROTOR

 Stator assembly
 Rotor
 Washer

80 Nm (8.0 m • kg, 58ft•lb)

5-41
 ENGINE ASSEMBLY AND ADJUSTMENTS ENG
MAGNETO ROTOR
1. Install:
• Stator 

Screw(Stator):
8 Nm (0.8 m•kg; 5.8 ft•lb)
Use Loctite®

2. Connect:
• Neutral switch lead 
1

1 3. Install:
• Woodruf key 
• Rotor 
• Plain washer 
• Nut (Rotor) 

NOTE:
• Clean the tapered portions of the cranks-
haft and rotor.
2 3 4 • When installing the rotor, make sure the
key is properly seated in the key way of
the crankshaft.
• Hold the rotor by the Rotor Holder to tigh-
ten the nut

Universal Rotor Holder:

90890-01235

Nut (Rotor):
80 Nm (8.0 m•kg; 58 ft•lb)

5-42
 ENGINE ASSEMBLY AND ADJUSTMENTS ENG
SHIFT SHAFT

 Shift tank
 Spring
 Circlip
 Oil seal
 Change pedal

15 Nm (1.5 m • kg, 11ft•lb)

5-43
 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:
1 • shift shaft 

NOTE:
• Lubricate the oil seal lips with lithium-
soap-based grease.

3. Check:
• shift pawl  position
1 Gaps  a and b are not equal 

Replace the defective part(s).

(a)

(b)

 Shift cam

CLUTCH PUSH LEVER

1. Lubricate:
• Bearing 
4 • Oil seal lip 
• Washer 
• Push lever axle 
3 Lithium Soap Base Grease
2
1

5-44
ENGINE ASSEMBLY AND ADJUSTMENTS ENG
2. Install:
3
• Washer 
• Return spring 
1
2 • Push lever 
3. Set the return spring  to the spring hook
.

5-45
 ENGINE ASSEMBLY AND ADJUSTMENTS ENG
CLUTCH AND PRIMARY DRIVE GEAR

 Clutch spring 
10 Thrust plate
 Pressure plate 
11 Conical spring washer
 Push plate 
12 Push rod #1
 Clutch plate 
13 Ball
 Friction plate 
14 Push rod #2
 Clutch damper 
15 Push lever axle
 Clutch boss 
16 Return spring
Thrust washer 
17 Bearing
Clutch housing 
18 primary drive gear

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(0.002in)

70 Nm (7.0m • kg, 50ft•lb)

80 Nm (8.0 m • kg, 58ft•lb)

5-46
 ENGINE ASSEMBLY AND ADJUSTMENTS ENG
BALANCER GEAR, PRIMARY DRIVE GEAR
AND CLUTCH

1. Install:
• Oil seal retainer 
3 • Spacer collar 
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 
2 • Drive gear (Balancer weight) 
1 • Baffle plate 

Screw (Baffle Plate):

8 Nm (0.8 m•kg; 5.8 ft•lb)
Use Loctite®

2 3. Install:
• Driven gear (Balancer weight) 
1 • Straight key 

CAUTION
Align the balancer drive gear mark 3 with
the balancer driven gear mark 4

4. Install:
1 • Lock washer 
• Nut (Balancer driven gear) 
• Plain washer 
• Nut (Primary drive gear) 
2
3 NOTE:
4
Install the lock washer tab  into the key way
of the balancer driven gear .

5-47
 ENGINE ASSEMBLY AND ADJUSTMENTS ENG

s WARNING
Always use a new lock washer

5. Tighten:
3 • Nut (Primary drive gear) 
2
• Nut (Balancer driven gear) 

Nut (Primary drive gear):

80 Nm (8.0 m•kg; 58 ft•lb)
Nut (Balancer driven gear):
1 55 Nm (5.5 m•kg; 40 ft•lb)

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 7. Lubricate:
7 • Push rod #2
8
• Ball 

Lithium Soap Base Grease

5 4
3
2 1

5-48
 ENGINE ASSEMBLY AND ADJUSTMENTS ENG
98 8. Install:
7 • Push rod #2
8 • Ball 
• Conical spring washer 
• Thrust plate 
• Clutch housing 
• Thrust washer 
5 4 • Clutch boss 
3 • Lock washer
2 • Nut (Clutch boss)
1

s WARNING
Always use a new lock washer

NOTE:
• Be careful to install the conical spring was-
her  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 (7.0 m•kg; 50 ft•lb)

NOTE:
Hold the clutch boss to tighten the nut 
(clutch boss) by the Universal Clutch Holder 

Universal Clutch Holder:

90890-04086

10. Bend the lock washer tab along the nut

flats.

5-49
 ENGINE ASSEMBLY AND ADJUSTMENTS ENG
11. Install:
3 • Friction plates 
2 • Clutch plates 
1 • Clutch damper 


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 insi-
de diameter onto the clutch boss.
• Install the clutch damper onto the clutch
plate.
• Install the remaining clutch plates and fric-
tion plates alternately on the clutch boss.
• Be sure to install a clutch plate with pro-
jection offset aproximately 60º from pre-
vious plate projection.
Continue this procedure in a clockwise
direction until all clutch plates are installed.

NOTE:
Before installing friction and clutch plates, sink
them into transmission oil almost 3 hours
before mounting

4 12. Install:
3 2
• Push rod #1 
• Pressure plate 
• Clutch springs 
• Bolts (Pressure plate) 

NOTE:
Align the punched mark  on the clutch boss
with the punched mark  on the clutch pres-
1 sure plate.

13. Tighten:
• Bolts (Pressure plate)

Bolt (Pressure plate):

6 Nm (0.6 m•kg; 4.8 ft•lb)

5-50
 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. Install:
• Gasket (Crankcase cover)
• Dowel pins
• Crankcase cover (Right) 
• Drain plug (Transmission oil) 
• Drain plug (Coolant) 

NOTE:
3 Tighten the screws (Crankcase cover) in stage
1 using a crisscross pattern

s WARNING
Always use a new gasket

Screw (Crankcase cover):

8 Nm (0.8 m•kg; 5.8 ft•lb)
Drain plug (Transmission Oil):
15Nm (1.5 m•kg; 11 ft•lb)
Drain plug (Coolant):
10Nm (1.0 m•kg; 7.2 ft•lb)

16. Apply the grease to the O-ring

17. Install:
• O-ring 
(to water outlet pipe )
2 • Water outlet pipe 

s WARNING
1
Always use a new O-ring

Screw (Water Outlet Pipe):

8 Nm (0.8 m•kg; 5.8 ft•lb)

5-51
 ENGINE ASSEMBLY AND ADJUSTMENTS ENG
CYLINDER HEAD AND CYLINDER

 Spark plug
 Cylinder head
 Cylinder head gasket
 Cylinder
 Cylinder gasket

A SPARK PLUG
B MANUFACTURER
NGK
C TYPE:
20 Nm (2.0m • kg, 14ft•lb) BR9ES
D PLUG GAP:
0.7~0.8mm
(0.028~0.0012in)
22 Nm (2.2m • kg, 16ft•lb) E CYLINDER HEAD
WARRAGE LIMIT:
0.03mm(0.0012in)

F 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, 9.4ft•lb)

5-52
 ENGINE ASSEMBLY AND ADJUSTMENTS ENG
PISTON, CYLINDER AND CYLINDER HEAD
1. Install:
2 • Bearing
• Piston 
• Piston pin 
• Piston pin clips 

3 NOTE:
4
• Apply engineoil tothe piston pin, bearings
4 and piston skirts areas.
1 • 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 crank-
case.

s WARNING
Always use a new piston pin clip

CAUTION
Do not allow the clip open ends to meet the
piston pin slot

2. Check:
• Piston ring position

CAUTION
• Make sure ring ends are properly fitted
around ring locating pins in piston groo-
ves.
• Be sure to check te manufacture’s marks
or numbers stamped on the rings are on
the top side of the rings.

5-53
 ENGINE ASSEMBLY AND ADJUSTMENTS ENG
3. Install:
• Dowel pins 
NEW (Cylinder) 
• Gasket <NEW>
1
s WARNING
Always use a new gasket
2

4. Install:
1 • Cylinder 
• Clutch cable guide

NOTE:
Install the cylinder with one hand while com-
pressing 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. Install:
• Gasket (Cylinder head)
• Cylinder head

s WARNING
Always use a new gasket

NOTE:
The “UP” mark on the gasket must be facing
up

7. Tighten:
5 • Nuts (Cylinder head)
2
Nut (Cylinder Head):
22 Nm (2.2 m•kg, 16 ft•lb)

3 4 NOTE:
1 Tighten the nuts in stage, using a crisscross
pattern

5-54
ENGINE ASSEMBLY AND ADJUSTMENTS ENG
8. Install:
• O-ring 
• Thermostatic valve 
• Gasket 

NOTE:
Apply the lithium soap base grease to the O-
1
ring

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)

10. Install:
• Spark plug 
• Thermo unit 

Spark plug:
20 Nm (2.0 m•kg, 14 ft•lb)
Thermo unit:
2 1 15 Nm (1.5 m•kg, 11 ft•lb)

s WARNING
Handle the thermo unit with special care.
Never subject it too strong or allow it to be
dropped. In case of being hited, replace it.

5-55
 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 (3.3 m•kg, 24 ft•lb)

NOTE:
• Apply lithium soap base grease to the
pivot shaft.
• Temporary tighten the bolts before tighte-
ning them to specification.

2 2. Install:
3 • Spacer collar 
4 • Drive sprocket 
• Lock washer 
• Nut (Drive sprocket) 
1 • Drive chain

NOTE:
Before installing the spacer collar  apply
grease to the oil seal lip.

Nut (Drive sprocket):

60 Nm (6.0 m•kg, 43 ft•lb)

5-56
 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.
1 2

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. Connect:
• Radiator hose (Outlet) 
• Radiator hose (Inlet) 

7. Install:
• Pulley housing
• Adjusters (Y.P.V.S. cables) 
• Servomotor unit 

Bolt (Pulley housing):

8 Nm (0.8 m•kg, 5.8 ft•lb)
2 Screw (Servomoto unit):
7 Nm (0.7 m•kg, 5.1 ft•lb)
1

5-57
 ENGINE ASSEMBLY AND ADJUSTMENTS ENG
8. Connect:
• Servomotor unit lead
• Cables (Y.P.V.S.)
(to power valve pulley)

9. Install:
1 • Pulley (power valve) 
1
Bolt (Power valve pulley):
2 10Nm (1.0 m•kg, 7.2 ft•lb)

10. Adjust:
• Y.P.V.S. cables
Refer to the “Y.P.V.S. CABLE ADJUST-
1 MENT” section in chapter 3.

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, 5.1 ft•lb)

1 12. Adjust:
• Clutch cable free play 
Refer to the “CLUTCH ADJUSTMENT”
section in chapter 3.

5-58
ENGINE ASSEMBLY AND ADJUSTMENTS ENG
13. Air bleeding:
• Autolube pump
Refer to the “AUTOLUBE PUMP AIR BLE-
EDING” section in chapter 3.

14. Install:
• Autolube pump cover 

1 Bolt (Autolube pump cover):

5 Nm (0.5 m•kg, 3.6 ft•lb)

15. Install:
• Gasket (Exhaust pipe)
• Exhaust pipe
3
2 1 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, 7.2 ft•lb)

s WARNING
Always use a new gasket

16. Fill:
• Radiator
• Reservoir tank (Radiator)
Refer to the “COOLANT REPLACEMENT”
section in chapter 3.

Total amount:
0,92L

5-59
ENGINE ASSEMBLY AND ADJUSTMENTS ENG
17. Fill:
• Crankcase
Refer to the “TRANSMISSION OIL REPLA-
CEMENT” section in chapter 3.

Total amount:
0,92L

5-60
 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
 WATER PUMP COOL

COOLING SYSTEM
WATER PUMP

 Impeller shaft  Water pump housing cover

 Oil Seal Gasket
 Pin Dowel pin
 Impeller shaft gear 
10 Drain bolt
 Plain washer 
11 Gasket
 Circlip

8 Nm (0.8 m • kg, 5.8 ft•lb)

A USE NEW ONE

A USE NEW ONE

6-1
 WATER PUMP COOL
REMOVAL

NOTE:
It is necessay to disassemble the water pump
unless there is no abnormality such as exces-
sive change in coolant temperature and/or dis-
coloration of coolant or milky transmission oil.

1. Drain:
• Transmission oil
Refer to the “TRANSMISSION OIL REPLA-
CEMENT” section in chapter 3.
• Coolant
Refer to the “COOLANT REPLACEMENT”
section in chapter 3.

2.Disconnect:
• Outlet hose (Radiator) 
3.Remove:
2 • Screw (Water outlet pipe) 

4. Remove:
• Autolube pump cover
5. Disconnect:
3 • Oil delivery hose 
6. Remove:
• Gasket (Autolube pump cover) 
2 • Stopper clip (Pump cable)
• Clip (Pump cable outer)
1 • Autolube pump cable 

NOTE:
• Plug the oil hose so that oil will not run out
of the oil tank.
• Turn the pump pulley counterclockwise by
finger to make the pump calbe loose
enough for its end to be removed from the
pulley.

6-2
 WATER PUMP COOL
7. Remove:
4
2 3 • Return spring 
• Bolt (Master cylinder) 
• Brake pedal 
• Crankcase cover 

8. Remove:
• Water outlet pipe 
• Housing cover (Water pump) 
• Gasket
• Dowel pins
2

1 9. Remove:
2 3 • Circlip 
• Plain washer 
• Impeller shaft gear 

1 10. Remove:
• Pin 
• Plain washer 
2

11. Remove:
• Impeller shaft 
12. Eliminate deposits from the impeller and
water pump housing.

6-3
 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.
• Install the new oil seal with the “WATER
SIDE” mark on the outside.

NOTE:
• Apply the lightweight lithium base grease to
oil seal outside.
• Press fit the oil seal until it contacts the bot-
tom.



INSTALL
Reverse the “REMOVAL” procedure. Note the
following points.
1. Apply:
• Lightweight lithium base grease
(to oil seal lips and impeller shaft)

2. Install:
1 • Impeller shaft 
Install the shaft while turning it.

NOTE:
Take care so that the oil seal lip is not dama-
ged or the spring doesn’t slip off its position.

6-4
 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):
2 8 Nm (0.8 m•kg, 5.8 ft•lb)

1 CAUTION
• Always use new gaskets
• Always use a new O-ring

4. Install:
3 • Crankcase cover (Right) 
2
1 • Brake pedal 
• Return spring 
• Drain plug (Transmission oil) 
• Drain plug (Coolant) 
5
Screw (Crankcase cover):
8 Nm (0.8 m•kg, 5.8 ft•lb)
Screw (Brake pedal):
4 20 Nm (2.0 m•kg, 14 ft•lb)
Drain plug (Transmission Oil):
15 Nm (1.5 m•kg, 11 ft•lb)
Drain plug (Coolant):
10 Nm (1.0 m•kg, 7.2 ft•lb)

NOTE:
Before installing the brake pedal apply lithium
soap base grease to the brake pedal pivot
shaft.

s WARNING
Always use new cotter pin and gasket.

5. Install:
1 • Screw (Water outlet pipe) 

Screw (Water Outlet pipe):

8 Nm (0.8 m•kg, 5.8 ft•lb)

6-5
 WATER PUMP COOL
6. Fill:
• Crankcase
Refer to the “TRANSMISSION OIL REPLA-
CEMENT” 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 BLEE-
DING” section.
9. Install:
• Autolube pump cover

Screw (Autolube pump cover):

5 Nm (0.5 m•kg, 3.6 ft•lb)

6-6
 THERMOSTATIC VALVE AND RADIATOR COOL
THERMOSTATIC VALVE AND RADIATOR

 Radiator assembly  Hose (Carburetor warmer Inlet)

 Radiator cap Hose (Carburetor warmer  Inlet)

 Inlet hose Thermostatic valve cover

 Coolant breather hose 
10 Gasket
 Outlet hose 
11 Thermostatic valve
 Gasket 
12 O-ring

A RADIATOR CAP OPENING PRESSURE: B COOLANT CAPACITY:

75~105kPA 0.92L Including all routes
(0.75~1.05kg/cm2, 10~14psi)
C THERMOSTATIC VALVE OPENING
TEMPERATURE:
8 Nm (0.8 m • kg, 5.8 ft•lb) 63~67°C (146~153°C)

D USE NEW ONE

8 Nm (0.8 m • kg,
5.8 ft•lb)

D USE NEW ONE

8 Nm (0.8 m • kg, 5.8 ft•lb)

D USE NEW ONE

D USE NEW ONE

8 Nm (0.8 m • kg, 5.8 ft•lb)

6-7
THERMOSTATIC VALVE AND RADIATOR COOL
REMOVAL
1. Remove:
• Side covers (Left and Right)
• Seat
• Exhaust pipe 

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.

s WARNING
Do not remove the radiator cap, drain bolts
and hoses specially when the engine and
the radiator are hot. Scalding hot fluid and
steam may be blown out under pressure,
wich could cause serious injury. When the
engine has cooled, place a thick rag like a
towel over the radiator cap, slowly rotate
the cap counterclockwise to detent. This
proceduce allows any residual pressure to
escape. When the hissing sound stops,
press down the cap while turning counter-
clockwise to remove it.

6-8
 THERMOSTATIC VALVE AND RADIATOR COOL
4. Remove:
1 3 • Radiator cap 
2 5. Disconnect:
• Breather hose (Radiator  )
6. Remove:
• Inlet hose (Radiator) 
• Outlet hose (Radiator) 

2 7. Remove:
• Water outlet pipe 
• O-ring 

8. Remove:
• Radiator fin 

9. Remove:
• Radiator

6-9
THERMOSTATIC VALVE AND RADIATOR COOL

3 10. Remove:
• Thermostatic valve cover
• Gasket 
• Thermostatic valve 
• O-ring 

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, flat-
head screwdriver.

2. Check:
• radiator hoses
• radiator pipes
Cracks/damage  Replace.

3. Measure:
• radiator cap opening pressure
Below the specified pressure  Replace
the radiator cap.

Radiator cap opening pressure

75~ 105 kPa
(0.75 ~ 1.05 kg/cm2, 10 ~ 14 psi)

6-10
 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
2 seconds and make sure there is no drop in
pressure.


4. Inspect:
• Thermostatic valve
Valve doesn’t open at 63~67ºC (146~153ºF)
 Replace.

INSTALLATION
Reverse the “REMOVAL” procedure. Note the
following points.
3 1. Install:
• O-ring 
• Thermostatic valve 
2 • Gasket 
1 • Thermostatic valve cover

s WARNING
Always use new O-ring and gasket

Screw (Thermostatic Valve Cover):

8 Nm (0.8 m·kg; 5.8 ft·lb)

6-11
 THERMOSTATIC VALVE AND RADIATOR COOL
2. Install:
• Radiator 

Bolt(Radiator):
8 Nm (0.8 m·kg; 5.8 ft·lb)

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. Inspect:
• Cooling system
Decrease of pressure (leaks)Repair as
required

FULL

LOW

6-12
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.


6-13
 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
INSTALLATION ………………………………………………………………7-13
 CARBURETION CARB

CARBURETION
CARBURETOR

 Cap Pilot jet

 Throttle valve spring Needle jet
 Starter plunger 
10 Gasket
 Throttle stop screw 
11 Main jet
 Pilot air screw 
12 Needle valve assembly
 Throttle valve 
13 Float
 Needle set 
14 Drain screw

Main Jet (M.J.) #210

Main Air Jet (M.A.J.) ø 0.8
Jet Needle (J.N.) 5J40-2
Needle Jet (N.J.) Q2-M (#939)
Pilot Jet (P.J.) #17.5
Power Jet (PW.J.) #60
Pilot Air Screw (P.A.S.)
Float Height (F.H.) 15.5~16.5mm(0.61~0.65in)
Engine Idling Speed 1250~1450 rev/min.speed:

7-1
 CARBURETOR CARB
REMOVAL

NOTE:
The following parts can be cleaned and ins-
pected without disassembly
• Throttle valve
• Starter plunger
• Throttle stop screw

1 1. Remove:
2 • Side cover (Left and Right) 
• Seat
• Radiator cover 

2. Turn the fuel cock to “OFF” position.

1 3. Disconnect:
• Fuel hose 
(from carburetor side)

4. Remove:
• Fuel tank

s WARNING
Gasoline is highly flammable. Avoid spilling
fuel over the engine when it’s hot

5. Disconnect:
REAR • Reservoir tank (Rear brake) 
• Y.E.I.S. system

7-2
 CARBURETOR CARB
6. Disconnect:
• Hoses
• Oil delivery hose
• Cooling hoses
2 7. Loosen:
• Screw (carburetor joint) 
• Screw (air box) 
8. Remove:
• Carburetor top
1 • Carburetor

9. Remove:
• Cable holder
• Throttle valve
• Return spring

DISASSEMBLY
1
1. Remove:
• Hoses 
1

2. Remove:
• Starter plunger assembly 

3 Remove:
• Float chamber 
• Gasket float chamber 

7-3
 CARBURETOR CARB
4. Remove:
• Float pin 
• Float 
2
• Needle valve 

1
3

5. Remove:
• Valve seat 
• Main jet 
• Jet needle holder

6. Remove:
• Throttle stop screw 
• Pilot air screw

INSPECTION
1. Inspect:
• Carburetor mixing chamber body
Contamination  Clean

NOTE:
Use petroleum based solvent for cleaning.
Blow out all passages and jets with compres-
sed air.

2. Inspect:
• Carburetor float chamber body
Contamination  Clean

NOTE:
Starter jet and all air jets are fixed type

7-4
 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. Check:
• Free movement
Stick  Replace
Insert the throttle valve into the carburetor
body, and check for free movement.

7-5
 CARBURETOR CARB
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 
1 • Needle jet 

NOTE:
2 4 Align the knock pin with the pin slot in the
needle jet

3. Measure:
• Float height 
a
Out of specification  Adjust

Float height (F.H.):

15.5~16.5mm (0.61~0.65in)

7-6
 CARBURETOR CARB

Measurement and adjustment steps:
• Hold the carburetor in an upside down
position.
• Measure the distance from the mating sur-
face 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.
1 • If either is worn, replace them both.
• If both are fine, adjust the float height by
bending the float tang  on the float.
• Recheck the float height.


4. Install:
• Float chamber 
• Hose 
• Gasket (float chamber) 

s WARNING
1
Always use a new gasket

5. Tighten:
3 2 • Screws (Float chamber)
Screw (Float chamber)
2 Nm (0.2 m·kg; 1.4 ft·lb)

6. Install:
• Starter plunger 

7-7
 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.
Refer to the “THROTTLE CABLE FREE
PLAY ADJUSTMENT” section in chapter 3.
Throttle cable free play:
3-5mm 0’11-0,19in.

4. Adjust:
• Carburetor cable free play
Refer to the “CARBURETOR CABLE FREE
PLAY ADJUSTMENT” section in chapter 3.

Carburetor cable free play:

1mm (0.04in.)

7-8
 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 ver-
tically.
• Connect the fuel level gauge  to the drain
pipe  .

Fuel level gauge:

90890-01312

• Loosen the drain screw and warm up the

engine for several minutes.
• Measure the fuel level with tha gauge.
• If the level is incorrect, adjust the fuel level.
• Remove the carburetor.
• Inspect the valve seat and needle valve.
• If either is worn, replace them both.
• If both are fine, adjust the float level by ben-
ding the float tang slightly.
• Install the carburetor.
• Recheck the fuel level.


7-9
 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, 0.7 ft•lb)

B USE NEW ONE

7-10
 REED VALVE CARB
REMOVAL
1. Remove:
• Carburetor
Refer to the “CARBURETOR REMOVAL”
section.

2. Remove:
• Carburetor joint 

3. Remove:
• Reed valve assembly 
• Gasket 
2

DISASSEMBLY
1. Remove:
1
• Y.E.I.S. chamber 

2. Remove:
• Reed valve stopper 
• Reed valve 

7-11
 REED VALVE CARB
INSPECTION
1. Inspect:
• Reed valve 
• Reed valve stopper 
Cracks/Damage  Replace

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 
2
• Y.E.I.S. chamber 
Cracks/Damage  Replace.

ASSEMBLY
Reverse the “DISASSEMBLY” precedure. Note
the following points.
1. Install:
• Reed valves
• Reed valve stoppers

NOTE:
• Place the reed valve with its concave side
facing the reed valve seat.

7-12
 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 war-
ping.

3. Install:
• Y.E.I.S. chamber 

1 NOTE:
The arrow on the Y.E.I.S. chamber must point
forward.

INSTALLATION
Reverse the “REMOVAL” procedure. Note the
following points.
1 1. Install:
• Gasket (New) 
• Reed valve assembly 
2
s WARNING
A damaged gasket may cause the engine
revs to accelerate. Always use a new gas-
ket.

2. Install:
1 • Carburetor joint 

Bolt (Carburetor joint):

10 Nm (1.0 m·kg; 7.2 ft·lb)

7-13
 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 …………………………………………………………8-14
TROUBLESHOOTING ………………………………………………………8-15

LIGHTING SYSTEM ……………………………………………………………8-16

CIRCUIT DIAGRAM …………………………………………………………8-16
TROUBLESHOOTING ………………………………………………………8-17

SIGNALING SYSTEM …………………………………………………………8-26

CIRCUIT DIAGRAM …………………………………………………………8-26
TROUBLESHOOTING ………………………………………………………8-27

COOLING SYSTEM ……………………………………………………………8-38

CIRCUIT DIAGRAM …………………………………………………………8-38
TROUBLESHOOTING ………………………………………………………8-39

YAMAHA POER VALVE SYSTEM ……………………………………………8-42

CIRCUIT DIAGRAM …………………………………………………………8-42
TROUBLESHOOTING ………………………………………………………8-43

METER ASSEMBLY ……………………………………………………………8-46

REMOVAL ……………………………………………………………………8-47
INSTALLATION ………………………………………………………………8-48
 DT125RE CIRCUIT DIAGRAM ELEC

ELECTRICAL
DT125RE CIRCUIT DIAGRAM

B Black Ch Chocolate W/R White/Red

R Red Dg Dark green W/L White/Blue
O Orange Sb Sky blue Y/R Yellow/Red
L Blue Br Brown G/R Green/Red
P Pink L/Y Blue/Yellow G/Y Green/Yellow
Y Yellow B/Y Black/Yellow G/W Green/White
G Green B/W Black/White Br/W Brown/White
W White B/R black/Red L7R Blue/Red

8-1
 ELECTRICAL COMPONENTS ELEC
ELECTRICAL COMPONENTS(1)

 CDI Unit  Thermo unit

 Servomotor  Rectifier/Regulator
 Battery Ignition coil
 Fuse Main switch
 Neutral switch

Ignition coil:
Primary coil resistance:
0.23 Ω at 20 °C
Secondary coil resistance:
7.9 kΩ at 20 °C

8-2
 ELECTRICAL COMPONENTS ELEC
ELECTRICAL COMPONENTS(2)

 Flasher relay  Sidestand switch

 Conductor wire  Brake switch
 Rectifier 2  Relay
 Oil gauge Horn

Battery:
Capacity:
12V 6Ah
No maintenance

8-3
 CHECKING SWITCH CONTINUTY ELEC
EAS00730

CHECKING SWITCH CONTINUITY

Check each switch for continuity with the poc-
ket 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 cou-
pler terminal slots. Always insert the probes
from the opposite end of the coupler, taking
care not to loosen or damage the leads.

Pocket tester
90890-03112

NOTE:
• Before checking for continuity, set the poc-
ket tester to “0” and to the “Ωx1” range.
• When checking for continuity, switch back
and forth between the switch positions a
b few times.
GY Br R B B/W
LOCK The terminal connections for switches (e.g.,
OPEN main switch, engine stop switch) are shown in
a an illustration similar to the one on the left.
OFF The switch positions  a are shown in the far
CHECK left column and the switch lead colors  b are
ON shown in the top row in the switch illustration.

NOTE:
“—” indicates a continuity of electricity
between switch terminals (i.e., a closed circuit
at the respective switch position).

The example illustration on the left shows

that:
There is continuity between black and
black/white when the switch is set to “ON”.
There is continuity between red and brown
when the switch is set to “ON”.

8-4
 CHECKING THE SWITCHES ELEC
EAS00731

CHECKING THE SWITCHES

Check each switch for damage or wear, proper Damage/wear  Repair or replace.
connections, and also for continuity between the Improperly connected  Properly connect.
terminals. Refer to “CHECKING SWITCH CON- Incorrect continuity reading  Replace the
TINUITY”. switch.


7 
9


10


20


35

20


22


28 
15


23


12

 Main swich 
35 Oil Level gauge

24 Left handle swicht 
15 Neutral swicht

12 Side stand swicht 
28 Rear stop swicht
 Right handle swicht  Fuse

8-5
 IGNITION SYSTEM ELEC

IGNITION SYSTEM
The circuit diagram showns the ignition system.

8-6
 IGNITION SYSTEM ELEC
NOTE:
For the color codes see the electric diagram

 Magneto CDI
 Battery
 Fuse
 Starter relay
 Starting engine
 Main switch
C.D.I.
Ignition coil

7 1 4 2

·
·

5 8
9 6

8-7
 IGNITION SYSTEM ELEC
EAS00736 EAS00740

TROUBLESHOOTING
1. Spark plug
• Check the condition of the spark plug.
The ignition system fails to operate • Check the spark plug type.
(no spark or intermittent spark). • Measure the spark plug gap.
Refer to “CHECKING THE SPARK PLUG”
Check: in chapter 3.
1. Main and ignition fuses Standard spark plug
2. Battery BR8HS (NGK)
3. Spark plug Spark plug gap
4. Ignition spark gap 0.6 ~ 0.7 mm
5. Spark plug cap resistance • Is the spark plug in good condition, is it of
6. Ignition coil resistance the correct type, and is its gap within spe-
cification?
7. Main switch
8. Engine stop switch
9. Neutral switch YES NO
10. Sidestand switch
Re-gap or replace
11. Pickup coil resistance the spark plug.
12. Wiring connections (of the entire ignition EAS00742

system)
2. Ignition spark gap
NOTE: • Disconnect the spark plug cap from the
• Before troubleshooting, remove the follo- spark plug.
wing part(s): • Connect the ignition checker  as shown.
1. Side covers (right and left)
2. Seat
3. Fuel tank
4. Headlight cover
5. Headlight unit
• Troubleshoot with the following special
tool(s).

Ignition checker
90890-06754  Spark plug cap
Pocket tester • Set the main switch to “ON”.
90890-03112 • Measure the ignition spark gap 
a.
• Crank the engine by pushing the starter
switch and gradually increase the spark
gap until a misfire occurs.
Minimum ignition spark gap
6 mm (0.24 in)

• Is there a spark and is the spark gap within

specification?

YES NO

The ignition system

is OK.

8-8
 IGNITION SYSTEM ELEC
EAS00744
• Connect the pocket tester (Ω x 1k) to the
3. Spark plug cap resistance ignition coil as shown.
• 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

Spark plug cap resistance 7.9 +/- kΩ 20°C (68 °C)
5KΩ at 20°C (68 °C)
• Is the ignition coil OK?
• Is the spark plug cap OK?
YES NO
YES NO
Replace the ignition
Replace the spark coil.
plug cap.
EAS00746

4. Ignition coil resistance (Orange) from the

wireharness
• Disconnect the ignition coil connectors
from the ignition coil terminals.
• Connect the pocket tester (Ω x 1) to the
ignition coil as shown.

Positive tester probe  Orange terminal

Negative tester probe  Ignition coil
base

• Measure the primary coil resistance.

Primary coil resistance
0.23 +/- 20°C (68 °C)

8-9
 IGNITION SYSTEM ELEC
EAS00749 EAS00750

5. Main switch 6. “ENGINE STOP” switch

• Disconnect the main switch coupler and • Disconnect the “ENGINE STOP” switch
lead from the wireharness (red). leads from the wireharness.
• Connect the pocket tester (Ω 100) to the • Connect the pocket tester (Ω 100) to the
main switch. “ENGINE STOP” switch.

Positive tester probe  red Lead Positive tester probe  black/white Lead

Negative tester probe  brown-blue Negative tester probe  Black Lead

Terminal

• Turn the “ENGINE STOP” switch to “OFF”

• Turn the main switch to “ON” and “OFF”. and “RUN”.
• Check the main switch for continuity. • Check the “ENGINE STOP” switch for con-
tinuity.
Switch Good Bad
position condition condition Switch Good Bad
position condition condition
OFF  X X 
ON X  X  OFF X  X 
PARK X  X  ON  X X 

:Continuity X: No continuity :Continuity X: No continuity

• Is the engine stop switch OK?

YES NO

Replace the main YES NO

switch.
Replace the hand-
lebar switch.

8-10
 IGNITION SYSTEM ELEC
EAS00748

7. source coil resistance 8. Pickup coil resistance

• Disconnect the CDI magneto coupler  • Disconnect the CDI magneto coupler from
from the wireharness. the wire harness.
• Connect the pocket tester (Ω 100) to the • Connect the pocket tester (Ω 100) to the
source coil. pickup coil.

Positive tester probe  Green/white  Positive tester probe  white/blue

Terminal Negative tester probe  white/red
Negative tester probe  Black/red 
Teminal
1
1

3 2
2
3

• Measure the pickup coil resistance.

• Measure the source coil resistance. Pickup coil resistance

280 ~ 420 Ω at 20°C (68°F)
Source coil resistance (between white/red and
192~288 Ω at 20°C (68°F) white/blue)

• Is the source coil resistance OK? • Is the pickup coil OK?

YES NO YES NO

Replace the source Replace the pickup

coil. coil.

EAS00754

9. Wiring
• Check the entire ignition system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the ignition system’s wiring properly con-
nected and without defects?

YES NO

Replace the DC- Properly connect or

CDI unit. repair the ignition
system’s wiring.

8-11
 IGNITION SYSTEM ELEC
EAS00752 EAS00751

Procedure (2)
2. Neutral switch
1. Sidestand switch
• Disconnect the CDI magneto coupler from
• Disconnect the sidestand switch leads the wireharness.
from the wireharness. • Connect the pocket tester (Ω 100) to the
• Connect the pocket tester (Ω100) to the neutral switch lead.
sidestand switch.
Positive tester probe  sky blue lead
Positive tester probe  blue/white Negative tester probe  Frame ground
Terminal
Negative tester probe  blue/black
1
Terminal

• Shift the transmission in neutral and gear.

• Check the neutral switch for continuity.
• Move the sidestand to up position and
down position. Switch Good Bad
• Check the sidestand switch for continuity. position condition condition
NEUTRAL  X X 
Switch Good Bad
GEAR X  X 
position condition condition
UP  X X  :Continuity X: No continuity
DOWN X  X 
• Is the sidestand switch OK?
:Continuity X: No continuity
YES NO
• Is the sidestand switch OK?

Replace the sides-

YES NO tand switch.
EAS00754
Replace the sides-
tand switch. 3. Wiring
• Check the entire ignition system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the ignition system’s wiring properly con-
nected and without defects?

YES NO

Replace the DC- Properly connect or

CDI unit. repair the ignition
system’s wiring.

8-12
 CHARGING SYSTEM ELEC
EAS00773

CHARGING SYSTEM
CIRCUIT DIAGRAM

 Generator  Battery
 Rectifier/regulator  Main fuse

8-14
 CHARGING SYSTEM ELEC
EAS00774 EAS00775

TROUBLESHOOTING
3. Charging voltage
• Connect the engine tachometer to the
The battery is not being charged. spark plug lead.
• Connect the pocket tester (DC 20 V) to the
1. main fuse battery.
2. battery
Positive tester probe  positive battery
3. charging voltage
terminal
4. charging coil resistance Negative tester probe  negative battery
5. wiring connections terminal
(of the entire charging system)

NOTE:
• Before troubleshooting, remove the follo-
wing part(s):
1. Side covers (Left and right)
2. Seat
3. Fuel tank
4. Radiator cover
• Troubleshoot with the following special
tool(s).
• Start the engine and let it run at approxi-
Engine tachometer mately 3000 r/min.
90890-03113 • Measure the charging voltage.
Pocket tester
90890-03112 Charging voltage
14 V at 5000 r/min

NOTE:
1. Fuse Make sure the battery is fully charged.
• Remove the fuse.
• Connect the pocket tester (Ω 100) to the • Is the charging voltage within specification?
fuse.
• Check the fuse for continuity.
• Is the fuse OK? YES NO

YES NO The charging circuit

is OK.

Replace the fuse. EAS00779

4. Wiring
2. Battery • Check the wiring connections of the entire
• Check the battery condition. charging system.
Refer to the “BATTERY INSPECTION” sec- Refer to “CIRCUIT DIAGRAM”.
tion in CHAPTER 3. • Is the charging system’s wiring properly
• Is the battery OK? connected and without defects?

YES YES NO
NO

Replace the recti- Properly connect or

Replace the battery. fier/regulator. repair the charging
system’s wiring.
8-15
 LIGHTING SYSTEM ELEC
EAS00780

LIGHTING SYSTEM
CIRCUIT DIAGRAM

 Magento-CDI 
29 Headlight
 Rectifier/regulator 
34 Tail light
 Main switch 
36 Meter lights

21 “LIGHTS” switch

8-16
 LIGHTING SYSTEM ELEC
EAS00781

TROUBLESHOOTING
1. Bulb
• Remove the bulb.
Any of the following fail to light: head- Refer to the “HEADLIGHT BULB REPLA-
light, high beam indicator light, taillight, CEMENT” section in the chapter 3.
auxiliary light or meter light. • Connect the pocket tester (Ω 100) to the
bulbs terminals.
Check:
1. Headlight bulb/”HI BEAM” indicator light Positive tester probe  terminal 
bulb Negative tester probe  terminal 
2. Headlight bulb socket/”HI BEAM”
3. “LIGHTS” (dimmer) switch Positive tester probe  terminal 
4. “Lights” switch Negative tester probe  terminal 
5. Lighting voltage
6. Lighting coil resistance A
7. wiring connection
(of the entire lighting system)

NOTE:
• Before troubleshooting, remove the follo-
wing part(s):
1. Sidecovers (left and right)
2. Seat
3. Fuel tank
4. Headlight cover B
5. Headlight unit
• Troubleshoot with the following special
tool(s).

Pocket tester
90890-03112
Inductive Tachometer:
90890-03113

A. Headlight bulb
B. “HI BEAM” indicator light bulb
• Check the bulb for continuity.
• Is the bulb OK?

YES NO

Replace the bulb.

8-17
 LIGHTING SYSTEM ELEC

2. Bulb socket 3. “LIGHTS” (Dimmer) switch

• Disconnect the bulb socket leads from the • Connect the pocket tester (Ω 100) to the
wire harness. bulbs terminals.
• Install the bulb to the bulb socket. When turning “LIGHTS” (Dimmer) switch to
• Connect the pocket tester (Ω 100) to the “HI”.
bulbs terminals.
Positive tester probe  Yellow lead
Positive tester probe  Yellow lead Negative tester probe  Black lead
Negative tester probe  Black lead When turning “LIGHTS” (Dimmer) switch to
“LO”.
Positive tester probe  Green lead
Negative tester probe  Black lead Positive tester probe  Green lead
Negative tester probe  Black lead

A. Headlight bulb socket

B. “HI BEAM” indicator light bulb socket • Turn the “LIGHTS” (Dimmer) switch to the
“HI” and “LO”.
• Check the bulb socket for continuity. • Check the “LIGHTS” (Dimmer) for conti-
• Is the bulb socket OK? nuity.

YES NO Switch Good Bad

position condition condition
Replace the bulb “HI”  X  X
socket. “LO”   X X

:Continuity X: No continuity
• Is the “LIGHTS” (Dimmer) OK?

YES NO

Replace handlebar
switch (left).

8-18
 LIGHTING SYSTEM ELEC
EAS00787

4. Lighting voltage. 5. Wiring

• Turn (Dimmer) switch to “LO”. • Check the entire lighting system’s wiring.
• Connect the pocket tester (DC 20 V) to the Refer to “CIRCUIT DIAGRAM”.
battery. • Is the lighting system’s wiring properly con-
nected and without defects?
Positive tester probe  Green  terminal
Negative tester probe  Black  terminal
YES NO

Check the condition Properly connect or

of each of the ligh- repair the lighting
ting system’s cir- system’s wiring.
cuits.
Refer to “CHEC-
KING THE LIGH-
TING SYSTEM”.

• Connect the inductive tachometer to the

spark plug lead.
• Start the engine and check the lightning
voltage.

• Is the “LIGHTS” switch OK?

YES NO

Replace handlebar
switch (left).

8-19
 LIGHTING SYSTEM ELEC
TROUBLESHOOTING
1. Bulb
Meter light does not come on
• Remove the bulb.
Refer to the “METER ASSEMBLY” section.
Check: • Connect the pocket tester (Ω 1) to the
1. Meter light bulb bulbs terminals.
2. Meter light bulb socket Positive tester probe  terminal 
3. Wiring connection Negative tester probe  terminal 
(of the entire lighting system)

NOTE:
• Before troubleshooting, remove the follo-
wing part(s):
1. Sidecovers (left and right)
2. Seat
3. Fuel tank
4. Headlight cover
5. Headlight unit
• Troubleshoot with the following special
tool(s).
• Check the bulb for continuity.
• Is the bulb OK?

Pocket tester
90890-03112 YES NO
Inductive Tachometer:
90890-03113
Replace the bulb.

8-20
 LIGHTING SYSTEM ELEC

2. Bulb socket
• Disconnect the bulb socket lead and cou-
pler 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”.
• Is the lighting system’s wiring properly con-
nected and without defects?

YES NO

Check the condition Properly connect or

of each of the ligh- repair the lighting
ting system’s cir- system’s wiring.
cuits.
Refer to “CHEC-
KING THE LIGH-
TING SYSTEM”.

8-21
 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
Check: terminals.
1. Tail/Brake light bulb/Auxiliary light bulb
Positive tester probe  terminal 
2. Tail light bulb socket/Auxiliary light Negative tester probe  terminal 
3. Main switch
4. Wiring connection Positive tester probe  terminal 
(of the entire lighting system) Negative tester probe  terminal 

NOTE:
• Before troubleshooting, remove the follo-
wing part(s):
1. Sidecovers (left and right)
2. Seat
3. Fuel tank
4. Headlight cover
5. Headlight unit
• Troubleshoot with the following special
tool(s).

Pocket tester
90890-03112
Inductive Tachometer:
90890-03113

A. Tail/Brake bulb
B. Auxiliary light bulb

• Check the bulb for continuity.

• Is the bulb OK?

YES NO

Replace the bulb.

8-22
 LIGHTING SYSTEM ELEC

2. Bulb socket 3. Main switch

• Disconnect the bulb socket and leads from • Disconnect the main switch coupler from
the wire harness. the wire harness.
• Install the bulb to the bulb socket.
• Connect the pocket tester (Ω 1) to the
bulbs socket lead end and coupler.

A
Positive tester probe  Blue  Terminal
Negative tester probe  Black  Terminal

B
Positive tester probe  Blue/Red 
Lead
Negative tester probe  Black  Lead • Connect the pocket tester (Ω 1) to the main
switch.
A • Check the main switch for continuity.

A
Positive tester probe  Red Lead
Negative tester probe  Brown-blue
Lead

Switch Good Bad

position condition condition
ON  X X 
OFF X  X 
B
B
Positive tester probe  Yellow-blue Lead
Negative tester probe  Blue-Black
Lead

Switch Good Bad

position condition condition
ON  X X 
OFF X  X 
• Check the bulb socket for continuity.
• Is the bulb socket OK? C
Positive tester probe  Red Lead
Negative tester probe  Blue-Black
YES NO Lead

Replace the bulb Switch Good Bad

socket. position condition condition
P  X X 
OFF X  X 

:Continuity X: No continuity

8-23
 LIGHTING SYSTEM ELEC
EAS00787

4. Wiring
• Check the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the lighting system’s wiring properly con-
nected and without defects?

YES NO

Check the condition Properly connect or

of each of the ligh- repair the lighting
ting system’s cir- system’s wiring.
cuits.
Refer to “CHEC-
KING THE LIGH-
TING SYSTEM”.

8-24
 SIGNAL SYSTEM ELEC
EAS00793

SIGNALING SYSTEM
CIRCUIT DIAGRAM

 Main switch 
37 Diode 
34 Tail/brake light
 Main fuse 
20 Horn switch 
28 Rear brake light switch
 Battery 
25 Horn 
27 Front brake light switch

15 Neutral switch 
22 Turn switch

35 Engine oil level switch 
26 Turn signal relay

8-26
 SIGNAL SYSTEM ELEC
EAS00794

TROUBLESHOOTING
3. Main switch
• Disconnect the main switch coupler from
Any of the following fail to light: flasher the wire harness.
light, brake light or an indicator light do • Connect the pocket tester (Ω 1) to the main
not come on and the horn fails to sound. switch.
Check: Tester (+) Lead  Red  Lead
1. Fuse Teter (-) Lead  Brown-Blue  Lead
2. battery
3. main switch
4. wiring connections
(of the entire signaling system)

NOTE:
• Before troubleshooting, remove the follo-
wing part(s):
1. Side covers (left and right)
2. Seat • Turn the main switch to “ON”, “OFF” and
3. Fuel tank “PARK”.
4. Headlight cover • Check the main switch for continuity.
5. Headlight unit
• Troubleshoot with the following special Switch Good Bad
tool(s). position condition condition
ON  X X 
OFF X  X 
Pocket tester
PARK X  X 
90890-03112
:Continuity X: No continuity

1. Fuse
• Remove the fuse.
EAS00795
• Connect the pocket tester (Ω 1) to the fuse.
• Check the fuse for continuity. 4. Wiring
• Check the entire signal system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
2. Battery • Is the signaling system’s wiring properly
connected and without defects?
• Check the battery condition.
Refer to the “BATTERY INSPECTION” sec-
tion in chapter 3. YES NO

Check the condition Properly connect or

of each of the sig- repair the signaling
naling system’s cir- system’s wiring.
cuits.
Refer to “CHEC-
KING THE SIGNA-
LING SYSTEM”.

8-27
 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.
1. Bulb • Connect the pocket tester (Ω 1) to the flas-
• Remove the bulb. her light leads.
• Connect the pocket tester (Ω 1) to the bulb
terminals. When checking right flasher light:
Positive tester probe  Dark Green 
Positive tester probe  terminal  Lead
Negative tester probe  terminal  Negative tester probe  Black  Lead

When checking left flasher light:

Positive tester probe  Chocolate 
Lead
Negative tester probe  Black  Lead

A FRONT

• Check the bulb for continuity.

YES NO
B REAR

Replace the bulb

• Check the bulb socket for continuity.

• Is the bulb socket OK?

YES NO

Replace the bulb

socket.

8-28
 SIGNAL SYSTEM ELEC

3. “TURN” switch 4. Voltage

• Disconnect the “TURN” switch (Left hand- • Disconnect the flasher relay  coupler
lebar switch) coupler  from the wire har- from the wire harness.
ness. • Turn the main switch to “ON”.
• Connect the pocket tester (Ω 1) to the • Turn the “TURN” switch to the “R” or “L”.
“TURN” switch. • Connect the pocket tester (DC20V) to the
flasher relay coupler.
When turning “TURN”” switch to “R”:
Positive tester probe  Brown/White  Positive tester probe  Brown 
Lead Terminal
Negative tester probe  Dark green  Negative tester probe  Frame ground.
Lead

When turning “TURN” switch to “L”:

Positive tester probe  Brown/White 
Lead
Negative tester probe  Chocolate 
Lead

• Check the flasher votage.

Flasher voltage
12.0 V

• Is the flasher relay OK?

• Turn the “TURN” switch to the “R” and “L”.

YES NO
• Check the “TURN” switch for continuity.

Switch Good Bad Replace the flasher

position condition condition relay.
R  X X  EAS00795
L   X X
:Continuity X: No continuity 5. Wiring
• Check the entire signal system’s wiring.
• Is the “TURN” switch OK? Refer to “CIRCUIT DIAGRAM”.
• Is the signaling system’s wiring properly
connected and without defects?
YES NO
YES NO
Replace the
“TURN” switch.
Check the condition Properly connect or
of each of the sig- repair the signaling
naling system’s cir- system’s wiring.
cuits.
Refer to “CHEC-
KING THE SIGNA-
LING SYSTEM”.

8-29
 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
1. Bulb socket leads.
• Remove the bulb.
• Connect the pocket tester (Ω 1) to the bulb Positive tester probe  Yellow 
terminals. Terminal
Negative tester probe  Black 
Positive tester probe  terminal  Terminal
Negative tester probe  terminal 

• Check the bulb socket for continuity.

• Check the bulb for continuity. • Is the bulb socket OK?
• Is the bulb OK?
YES NO
YES NO
Replace the bulb
Replace the bulb socket.

8-30
 SIGNAL SYSTEM ELEC

3. Front brake switch 4. Rear brake switch

• Disconnect the front brake switch coupler • Disconnect the front brake switch coupler
 from the wire harness.  from the wire harness.
• Connect the pocket tester (Ω 1) to the • Connect the pocket tester (Ω 1) to the
brake switch coupler. brake switch coupler.

Positive tester probe  Brown Terminal Positive tester probe  Brown 

Negative tester probe  Green/Yellow Terminal
Terminal Negative tester probe  Green/Yellow
 Terminal

• Check the brake switch for continuity.

• Check the brake switch for continuity.

Switch Good Bad Switch Good Bad

position condition condition position condition condition
Front brake  X X  Rear brake  X X 
applied applied
Front brake X  X  Rear brake X  X 
not applied not applied
:Continuity X: No continuity :Continuity X: No continuity

• Is the front brake switch OK? • Is the rear brake switch OK?

YES NO
YES NO
Replace the rear
Replace the front brake switch.
brake switch. 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 NO

Check the condition of Properly connect or

each of the signaling repair the signaling
system’s circuits. Refer system’s wiring.
to “CHECKING THE
SIGNALING SYSTEM”.
8-31
 SIGNAL SYSTEM ELEC

“NEUTRAL” INDICATOR LIGHT DOES 2. Bulb socket

NOT COME ON • Disconnect the bulb socket coupler from
the wire harness.
• Connect the pocket tester (Ω 1) to the bulb
1. Bulb socket leads.
• Remove the bulb.
Refer to the “METER ASSEMBLY” section. Positive tester probe  Brown 
• Connect the pocket tester (Ω 1) to the bulb Terminal
terminals. Negative tester probe  Sky Blue 
Terminal
Positive tester probe  terminal 
Negative tester probe  terminal 

• Check the bulb socket for continuity.

• Check the bulb for continuity. • Is the bulb socket OK?
• Is the bulb OK?
YES NO
YES NO
Replace the bulb
socket.
Replace the bulb.

8-32
 SIGNAL SYSTEM ELEC
EAS00795

3. Neutral switch 4. Wiring

• Disconnect the CDI magneto coupler from • Check the entire signal system’s wiring.
the wire harness. Refer to “CIRCUIT DIAGRAM”.
• Connect the pocket tester (Ω 1) to the neu- • Is the signaling system’s wiring properly
tral switch coupler. connected and without defects?

Positive tester probe  Sky Blue

Terminal YES NO
Negative tester probe  Frame ground
Check the condition of Properly connect or
each of the signaling repair the signaling
system’s circuits. Refer system’s wiring.
to “CHECKING THE
SIGNALING SYSTEM”.

• Shift the transmission in neutral and gear.

• Check the neutral switch for continuity.

Switch Good Bad

position condition condition
Neutral  X X 
Gear X  X 
:Continuity X: No continuity

• Is the neutral switch OK?

YES NO

Replace the neutral

switch.

8-33
 SIGNAL SYSTEM ELEC

“OIL” INDICATOR LIGHT DOES NOT 2. Bulb socket

COME ON • Disconnect the bulb socket coupler 
from the wire harness.
• Connect the pocket tester (Ω 1) to the cou-
1. Bulb pler.
• Remove the bulb.
Refer to the “METER ASSEMBLY” section. Positive tester probe  Brown 
• Connect the pocket tester (Ω 1) to the bulb Terminal
terminals. Negative tester probe  Black/Red 
Terminal
Positive tester probe  terminal 
Negative tester probe  terminal 

• Check the bulb socket for continuity.

• Is the bulb socket OK?
• Check the bulb for continuity.
• Is the bulb OK? YES NO

YES NO Replace the bulb

socket.

Replace the bulb.

8-34
 SIGNAL SYSTEM ELEC

3. Oil level switch (Diode) 4. Oil level switch

• Disconnect the oil level switch  from the • Connect the pocket tester (Ω 1) to the oil
wire harness. level switch.
• Connect the pocket tester (Ω 1) to the neu-
tral switch coupler. Positive tester probe  Black/Red 
Terminal
Positive tester probe  Black/Red  Negative tester probe  Black 
Terminal Terminal
Negative tester probe  Sky Blue 
Terminal

• Check the oil level switch for continuity.

• Hold the oil level switch in an upright and

upside down position.
• Check the oil level switch for continuity.

Switch Good Bad

position condition condition
• Is the oil level switch OK?
Upright  X X 
Upside X  X 
:Continuity X: No continuity
YES NO • Is the oil level switch OK?

Replace the oil level YES NO

switch.

Replace the oil level

switch.

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 NO

Check the condition of Properly connect or

each of the signaling repair the signaling
system’s circuits. Refer system’s wiring.
to “CHECKING THE
SIGNALING SYSTEM”.

8-35
 SIGNAL SYSTEM ELEC

HORN DOES NOT SOUND, WHEN PUS- 2. Voltage

HING “HORN” SWITCH • Connect the pocket tester (DC20V) to the
horn terminal.

1. “HORN” switch Positive tester probe  Brown 

• Disconnect the “HORN” switch (Left hand- Terminal
lebar switch) couplers from the wire har- Negative tester probe  Frame ground.
ness.
• 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”.

• Check the horn voltage.

Horn voltage
12.0 V

• Check the “HORN” switch for continuity.

Switch Good Bad

position condition condition EAS00795

“HORN” switch  X X  3. Wiring

is pushed
“HORN” switch X  X  • Check the entire signal system’s wiring.
is not pushed
Refer to “CIRCUIT DIAGRAM”.
• Is the signaling system’s wiring properly
:Continuity X: No continuity connected and without defects?
• Is the oil level switch OK?
YES NO
YES NO Check the condition of Properly connect or
each of the signaling repair the signaling
Replace the system’s circuits. Refer system’s wiring.
“HORN” switch. to “CHECKING THE
SIGNALING SYSTEM”.

8-36
 SIGNAL SYSTEM ELEC

4. Horn
• Disconnect the “pink” lead at the horn ter-
minal.
• Connect a jumper lead  to the horn ter-
minal 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

12.0 V

8-37
 COOLING SYSTEM ELEC
EAS00807

COOLING SYSTEM
CIRCUIT DIAGRAM

 Battery  Main fuse

 Main switch 
13 Thermo switch

8-38
 COOLING SYSTEM ELEC
EAS00808

TROUBLESHOOTING
1. Fuse
• Remove the fuse.
• The radiator fan motor fails to turn. • Connect the pocket tester (Ω 1) to the fuse.
• The water temperature gauge needle • Check the fuse for continuity.
fails to move when the engine is warm. • Is the fuse OK?

Check: YES NO
1. main fuse
2. battery
Replace the fuse.
3. main switch
4. thermo switch
5. wiring connections 2. Battery
(the entire cooling system) • Check the battery condition.
Refer to the “BATTERY INSPECTION” sec-
NOTE: tion in chapter 3.
• Before troubleshooting, remove the follo-
wing part(s):
1. side covers (left and right)
2. seat
3. fuel tank
4. headlight cover
5. headlight unit
• Troubleshoot with the following special
tool(s).

Pocket tester
90890-03112

8-39
 COOLING SYSTEM ELEC

3. Main switch 4. Thermo unit

• Disconnect the main switch coupler from • Remove the thermo unit from the cylinder
the wire harness. head.
• Connect the pocket tester (Ω 1) to the main • Connect the pocket tester (Ω 1) to the ther-
switch. mo unit 
• Inmerse the thermo unit in the water 
Positive tester probe  Red Lead • Measure the resistances.
Negative tester probe  Brown-Blue Note temperatures while heating the water
Terminal with the temperature gauge 

Positive tester probe  Terminal 

Negative tester probe  Body ground 

• Turn the main switch to “ON”, “OFF” and

“PARK”.
• Check the main switch for continuity.
Water 50ºC 80ºC 100ºC
temperature (122ºF) (176ºF) (212ºF)
Switch Good Bad
Resistance 153.9Ω 47.5~56.8Ω 26.2~29.3Ω
position condition condition
ON  X X  • Is the thermo unit OK?
OFF X  X 
PARK X  X 
:Continuity X: No continuity YES NO

Replace the thermo

YES NO unit.

Replace the main

switch.

8-40
 COOLING SYSTEM ELEC
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 NO

Check the condition Properly connect or

of each of the sig- repair the signaling
naling system’s cir- system’s wiring.
cuits.
Refer to “CHEC-
KING THE SIGNA-
LING SYSTEM”.

8-41
 YAMAHA POWER VALVE SYSTEM ELEC

YAMAHA POWER VALVE SYSTEM

CIRCUIT DIAGRAM


16 CDI Unit  Battery
 Main switch 
18 Servomotor
 Main fuse

8-42
 MOTOR ELEC
TROUBLESHOOTING
1. Fuse
Servomotor does not move • Remove the fuse.
• Connect the pocket tester (Ω 1) to the fuse.
Check: • Check the fuse for continuity.
1. fuse • Is the fuse OK?
2. battery
3. main switch YES NO
4. servomotor operation
5. wiring connections (Yamaha Power Valve
Replace the fuse.
System)
6. servomotor and tachometer operation
2. Battery
NOTE:
• Check the battery condition.
• Before troubleshooting, remove the follo- Refer to the “BATTERY INSPECTION” sec-
wing part(s): tion in chapter 3.
1. side covers (left and right)
2. seat
3. fuel tank
4. headlight cover
5. headlight unit
• Troubleshoot with the following special
tool(s).

Pocket tester
90890-03112

8-43
 MOTOR ELEC

3. Main switch 4. Servomotor operation

• Disconnect the main switch coupler  • Disconnect servomotor coupler  from the
from the wire harness. wire harness.
• Connect the pocket tester (Ω 1) to the main • Connect the battery leads to the servomo-
switch. tor.

Positive tester probe  Red  Lead Positive tester probe  Brown 

Negative tester probe  Brown-Blue  Terminal
Terminal Negative tester probe  Black 
Terminal

• Turn the main switch to “ON”, “OFF” and • Check the servomotor for operation.
“PARK”. • Is the servomotor OK?
• Check the main switch for continuity.

Switch Good Bad YES NO

position condition condition
ON  X X  Replace the servo-
OFF X  X  motor.
PARK X  X 
:Continuity X: No continuity
EAS00795

YES NO 5. Wiring
• Check the entire signal system’s wiring.
Replace the main Refer to “CIRCUIT DIAGRAM”.
switch. • Is the signaling system’s wiring properly
connected and without defects?

YES NO

Check the condition Properly connect or

of each of the sig- repair the signaling
naling system’s cir- system’s wiring.
cuits.
Refer to “CHEC-
KING THE SIGNA-
LING SYSTEM”.

8-44
 MOTOR ELEC

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 servo-

motor.

8-45
 METER ASSEMBLY ELEC

METER ASSEMBLY

 Speedometer  Meter bracket

 Bulb  Stopper clip
 Bulb socket Washer
 Speedometer cable Damper collar
 Meter cushion

8-46
 METER ASSEMBLY ELEC
1 REMOVAL
1. Remove:
• Headlight cover 

2. Disconnect:
• Headlight leads
• Auxiliary light leads

3. Remove:
• Band
4. Disconnect:
• Speedometer cable 

5. Disconnect:
• Meter leads 

6. Remove:
• Meter assembly

8-47
 METER ASSEMBLY ELEC
7. Remove:
3
• Meter cushion 
• Meter lights 
• Leads 

CAUTION
Do not remove the indicator bulbs sockets
1 by pulling the leads
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
3
 ”NEUTRAL” indicator light
 ”HIGH BEAM” indicator light
 ”TURN” indicator light
2

2. Install:
• Meter assembly 

Bolt (Meter Assembly)

7 Nm (0.7 m•kg, 5.1 ft•lb)

8-48
 METER ASSEMBLY ELEC
NOTE:
1
Install the headlight lens unit onto the head-
light stay by fitting the guide rubber  pro-
perly in the guide hole  of the headlight unit.

3. Install:
• Headlight cover 

4. Adjust:
• Headlight beam
Refer to the “HEADLIGHT BEAM ADJUST-
MENT” section.

8-49
 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. …………………………………………………………………………9-4

FAULTY GEAR SHIFTING ………………………………………………………9-5

HARD SHIFTING ………………………………………………………………9-5
CHANGE PEDAL DOES NOT MOVE ………………………………………9-5
JUMP OUT GEAR ……………………………………………………………9-5

CLUTCH SLIPPING/DRAGGING ………………………………………………9-5

CLUTCH SLIPPING ……………………………………………………………9-5
CLUTCH DRAGGING …………………………………………………………9-6

FAULTY BRAKE …………………………………………………………………9-6

POOR BRAKING EFFECT ……………………………………………………9-6

FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION ……9-6

OIL LEAKAGE …………………………………………………………………9-6
MALFUNCTION ………………………………………………………………9-6

INSTABLE HANDLING …………………………………………………………9-7

INSTABLE HANDLING ………………………………………………………9-7

FAULTY SIGNAL AND LIGHTING SYSTEM …………………………………9-8

HEADLIGHT DARK ……………………………………………………………9-8
BULB BURNT OUT ……………………………………………………………9-8
FLASHER DOES NOT LIGHT ………………………………………………9-8
FLASHER KEEPS ON …………………………………………………………9-8
FLASHER WINKS SLOWER …………………………………………………9-8
FLASHER WINKS QUICKER …………………………………………………9-8
HORN IS INOPERATIVE ………………………………………………………9-8

FAULTY Y.P.V.S. …………………………………………………………………9-9

FAULTY Y.P.V.S …………………………………………………………………9-9

OVERHEATING OR OVERCOOLING …………………………………………9-9

OVERHEATING …………………………………………………………………9-9
OVERCOOLING ………………………………………………………………9-9

DT125 WIRING DIAGRAM ……………………………………………………9-10

 TRBL
STARTING FAILURE/HARD STARTING SHTG
TROUBLESHOOTING
NOTE:
The following troubleshooting does not cover all the possible causes of trouble. It should be help-
ful, however, as a guide to troubleshooting. Refeer to the relative procedure in this manual for ins-
pection, adjustment and replacement of parts.

STARTING FAILURE/HARD STARTING

FUEL SYSTEM PROBABLE CAUSE

• Fuel tank • Empty

• Clogged fuel filter
• Clogged fuel tank cap
• Deteriorated fuel or fuel containing
or foreign material

• Fuel cock • Clogged fuel hose

• Carburetor • Deteriorated fuel, fuel containing

water or foreign material
• Clogged pilot jet
• Clogged pilot air passage
• Sucked-in air
• Deformed float
• Groove worm needle valve
• Improperly sealed valve seat
• Improperly adjustment fuel level
• Improperly set pilot jet
• Clogged starter jet
• Starter plunger malfunction
• Improperly adjusted starter cable

• Air cleaner • Clogged air filter

9-1
 TRBL
TROUBLESHOOTING SHTG
ELECTRICAL SYSTEM PROBABLE CAUSE

• Spark plug • Improper plug gap

• Worn electrodes
• Wire between terminals broken
• Improper heat range
• Faulty spark plug cap

• Ignition coil • Broken or shorted primary/secondary

• Faulty spark plug lead
• Broken body

• C.D.I. Unit system • Faulty C.D.I. unit

• Faulty source coil
• Faulty pick-up coil
• Broken woodruff key

• Switches and wiring • Faulty main switch

• Faulty engine stop switch
• Broken or shorted wiring
• Faulty neutral switch
• Faulty sidestand switch
• Faulty ignition control unit

COMPRESSION SYSTEM PROBABLE CAUSE

• Cylinder and cylinder head • Loose spark plug

• Loose cylinder head or cylinder
• Broken cylinder head gasket
• Broken cylinder gasket
• Worn, damaged or seized cylinder

• Piston and piston rings • 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 crankshaft

• Reed valve • Deformed reed valve stopper

• Improperly seated reed valve
• Loose intake manifold
• Broken gasket
• Broken reed valve

9-2
 TRBL
TROUBLESHOOTING SHTG
POOR IDLE SPEED PERFORMANCE

POOR IDLE SPEED PERFORMANCE PROBABLE CAUSE

• Carburetor • 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 hose

• Fuel cock • Clogged fuel hose

• Carburetor • Deteriorated fuel or fuel containing

water or foreign material
• Sucked-in air
• Deformed float
• Groove worn needle valve
• Improperly sealed valve seat
• Improperly set clip position of jet needle
• Improperly adjusted fuel level
• Clogged or loose main jet
• Clogged or loose needle jet

• Air cleaner • Clogged air filter

ELECTRICAL SYSTEM PROBLABLE CAUSE

• Spark plug • Improper plug gap

• Worn electrodes
• Wire between terminals broken
• Improper heat range
• Faulty spark plug cap

• CDI unit system • Faulty CDI unit

• Faulty source coil
• Faulty pickup coil

9-3
 TRBL
TROUBLESHOOTING SHTG
COMPRESSION SYSTEM 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 crankshaft

• Reed valve • Deformed reed valve stopper

• Improperly adjusted reed valve stopper
height
• Improperly seated reed valve
• Loose intake manifold
• Broken gasket
• Broken reed valve

Y.P.V.S. PROBABLE CAUSE

• Power valve • Seized or damaged power valve

• Carbon buid-up

• Control cable • Improperly adjustable cable

• Seized or discontinuous cable

• Electrical parts • Faulty battery

(Improperly charged battery)
• Faulty main switch
• Faulty servomotor
• Faulty GDI unit
• Faulty Y.P.V.S. control unit
• Broken or shorted wiring

9-4
 TRBL
TROUBLESHOOTING 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 impurities

• Seized shift fork
• Bent shift forks guide bar

• Transmission • Seized transmission gear

• Jammed impurities
• Incorrectly assembled transmission

JUMP OUT GEAR PROBABLE CAUSE

• Shift shaft • Improperly adjusted shift lever position

• Improperly returned stopper lever

•Shift fork • Worn shift fork

• Shift cam • Improper thrust play

• Worn shift cam groove

• Transmission • Worn gear dog

CLUTCH SLIPPING/DRAGGING

CLUTCH SLIPPING PROBABLE CAUSE

• Clutch • Improperly adjusted clutch cable
• Loose clutch spring
• Fatigued clutch sping
• Worn friction plate
• Worn clutch plate

• Transmission • Low oil level

• Improper quality (Low viscosity)
• Deterioration

9-5
 TRBL
TROUBLESHOOTING SHTG
CLUTCH DRAGGING 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 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
• Faulty cylinder kit cup
• Faulty caliper kit seal
• Loose union bolt
• Broken brake hose
• Oily or grasy brake disc
• Oily or greasy brake pad
• Improper brake fluid level

FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION

OIL LEAKAGE PROBABLE CAUSE

• Bent, damaged or rusty inner tube
• Damaged or cracked outer tube
• Damaged oil seal lip
• Improperly installed oil seal
• Improper oil level (too much)
• Loose damper rod holding bolt
• Broken

MALFUNCTION
• Bent, deformed or damaged inner tube
• Bent or deformed outer tube
• Damaged fork spring
• Worn or damaged slide metal
• Bent or damaged damper rod
• Improper oil viscosity
• Improper oil level

9-6
 TRBL
TROUBLESHOOTING SHTG
INSTABLE HANDLING
INSTABLE HANDLING 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 sides

• Incorrect tire pressure
• Unevenly worn tires

• Wheels • Incorrect wheel balance

• Deformed cast wheel
• Loose bearing
• Bent or loose wheel axle
• Excessive wheel run-out

• Frame • Twisted
• Damaged head pipe
• Improperly installed bearing race

• Swingarm • Worn bearing or bush

• Bent or damaged

• Rear shock absorber • Fatigued spring

• Improperly adjusted spring preload
• Oil leakage

• Drive chain • Improperly adjusted chain slack

9-7
 TRBL
TROUBLESHOOTING 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

FLASHER DOES NOT LIGHT PROBABLE CAUSE

• Improperly grounded
• Discharged battery
• Faulty “TURN” switch
• Faulty flasher relay
• Broken wireharness
• Loosely connected coupler
• Bulb burnt out

FLASHER KEEPS ON PROBABLE CAUSE

• Faulty flasher relay
• Insufficient battery capacity
(nearly discharged)
• Bulb burnt out

FLASHER WINKS SLOWER PROBABLE CAUSE

• Faulty flasher relay
• Insufficient battery capacity
(nearly discharged)
• Improper bulb
• Faulty main and/or “TURN” switch

FLASHER WINKS QUICKER PROBABLE CAUSE

• Improper bulb
• Faulty flasher relay

HORN IS INOPERATIVE PROBABLE CAUSE

• Faulty battery
• Faulty main and/or horn switch
• Improperly adjusted horn
• Faulty horn
• Broken wireharness
9-8
 TRBL
TROUBLESHOOTING SHTG
FAULTY Y.P.V.S. PROBABLE CAUSE
• Power valve • 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. control unit
• Broken or shorted wiring

OVERHEATING OR OVER-COOLING
OVERHEATING PROBABLE CAUSE

• Ignition system • Improper spark plug gap

• Improper spark plug heat range
• Faulty CDI unit

• Fuel system • Improper carburator main jet

(improper setting)
• Improperly adjusted fuel heigh
• Clogged air cleaner element
• Lean mixture (Faulty Autolube pump
settings)

• Compression system • Heavy carbon build-up

• Transmission oil • Incorrect oil level

• Improper oil viscosity
• Inferior oil quality

• Brake • Dragging bike

• Cooling system • Faulty water temperature gauge

• Faulty thermo-unit
• Incorrect coolant level
• Faulty thermostat valve
• Clogged or damaged radiator
• Faulty radiator cap
• Seized impeller shaft

OVER-COOLING PROBABLE CAUSE

• Cooling system • Faulty water temperature gauge
• Faulty thermo-unit
• Faulty thermostat valve

9-9
DT125 WIRING DIAGRAM
 COMPONENTS

1. CDI. Mag.
2. Rect./Regu.
3. Battery
4. Fuse
5. Starter Relay
6. Starting Motor
7. Main Sw.
8. Handle Sw. R
9. Starter Sw.
10. E/G Stop Sw.
COLOR CODE 11. Clutch Sw.
12. Side Stand Sw.
B ..........................Balck 13. Thermo Sw.
R ..........................Red 14. Side Stand Relay
L...........................Blue 15. Neutral Sw.
G ..........................Green 16. CDI. Unit
Or.........................Orange 17. Ign. Coil
Y ..........................Yellow 18. Servo. Motor
P ..........................Pink 19. Lightning Relay
Br .........................Brown 20. Horn Sw.
Ch ........................Chocolate 21. Dimmer Sw.
Sb ........................Skip blue 22. Flasher Sw.
Dg ........................Dark green 23. Hazard Sw.
W .........................White 24. Handle Sw. L
Gy ........................Gray 25. Horn
BG .......................Black-Green 26. Flasher Relay
BY ........................Black-Yellow 27. Fr. Stop Sw.
BW .......................Black-White 28. Rr. Stop Sw.
GR .......................Green-Red 29. Head Light
GY........................Green-Yellow 30. Fr. Lh Flasher
BrW......................Brown-White 31. Rr. Lh Flasher
YR ........................Yellow-Red 32. Fr. Rh Flasher
LR ........................Blue-Red 33. Rr. Rh Flasher
LY.........................Blue-Yellow 34. Tail/Stop Light
LG ........................Blue-Green 35. Oil Level Gauge
RY ........................Red-Yellow 36. Meter
PW .......................Pink-White 37. Diode 1
WG.......................White-Green 38. License Light
WL .......................White-Blue 39. Position Lamp
WR .......................White-Red 40. Anti Theft Unit