Yamaha DT125RE 2005 Manuel utilisateur

SERVICE MANUAL

DT125RE

1D01-AE1

DT125X

2005

DT125RE/X

1D01-1D02/2C81

SERVICE MANUAL

1st Edition, January 2005

unauthorized use without the written

permission of Yamaha Motor España, S.A.

is expressly prohibited.

Printed in Spain.

EAS00001

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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.

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IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT!

YOUR SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury

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

king or repairing the motorcycle.

A CAUTION indicates special precautions that must be taken to

avoid damage to the motorcycle.

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

arer.

ssWARNING

CAUTION

NOTE :

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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.

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SYMBOLS

The following symbols are not relevant to

every vehicle.

Symbols to indicate the subject of each

chapter.

General information

Specifications

Periodic checks and adjustments

Chassis

Engine

Cooling system

Carburetor(s)

Electrical system

Troubleshooting

Symbols 10 to 17 indicate the following.

10 Serviceable with engine mounted

11 Filling fluid

12 Lubricant

13 Special tool

14 Tightening torque

15 Wear limit, clearance

16 Engine speed

17 Electrical data

Symbols 18 to 23 in the exploded diagrams

indicate the types of lubricants and lubrica-

tion points.

18 Engine oil

19 Gear oil

20 Molybdenum-disulfide oil

21 Wheel-bearing grease

22 Lithium-soap- based grease

23 Molybdenum-disulfide grease

Symbols 24 to 25 in the exploded diagrams

indicate the following.

24 Apply locking agent (LOCTITE®)

25 Replace the part

CHK

ADJ

ENG

CARB

TRBL

SHTG

SPEC

CHAS

COOL

ELEC

GEN

INFO

New











11

13

16

18

21

24









10

12

15 17

25

20

23

19

22

14

SPEC 2

SPECIFICATIONS

CHK

ADJ 3

PERIODIC CHECKS AND

ADJUSTMENTS

CHAS 4

CHASSIS

ENG 5

ENGINE

COOL 6

COOLING SYSTEM

CARB 7

CARBURETOR

ELEC 8

ELECTRICAL SYSTEM

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TABLE OF CONTENTS

TRBL

SHTG 9

TROUBLESHOOTING

GENERAL INFORMATION GEN

INFO 1

GEN

INFO

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

INFO

MOTORCYCLE IDENTIFICATIONS

1-1

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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.



Ce manuel convient aux modèles suivants

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