DT125 3BN0-ME5 repair manual
Short Description
Download DT125 3BN0-ME5 repair manual...
Description
FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the DT125R ’99. For complete information on service procedures, it is necessary to use this Supplementary Service Manual together with following manual: DT125R SERVICE MANUAL: 3BN-ME1 DT125R /DT125R ELECTRIC SUPPLEMENTARY SERVICE MANUAL: 3MB-AE1 DT125R /DT125RE SUPPLEMENTARY SERVICE MANUAL: 3BN-AE2 DT125R /DT125RE SUPPLEMENTARY SERVICE MANUAL: 3BN-AE3
DT125R SUPPLEMENTARY SERVICE MANUAL 1998 by Yamaha Motor Co., Ltd. 1st Edition, October 1998 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
NOTICE This manual was written by Yamaha Motor Company Ltd. primarily for use by Yamaha dealers and qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so persons using this book to perform maintenance and repairs on Yamaha motorcycles should have a basic understanding of the mechanical concepts and procedures inherent in motorcycle repair technology. Without such knowledge, attempted repairs or service to the motorcycle may render it unfit to use and/or unsafe. Yamaha Motor Company Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual.
PARTICULARLY IMPORTANT INFORMATION This material is distinguished by the following notation. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander, or a person inspecting or repairing the motorcycle.
CAUTION: NOTE:
A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. A NOTE provides key information to make procedures easier or cleaer.
HOW TO USE THIS MANUAL CONSTRACTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1 :
This is a chapter with its symbol on the upper right of each page.
2nd title 2 :
This title appears on the upper of each page on the left of the chapter symbol. (For the chapter “Periodic inspection and adjustment” the 3rd title appears.)
3rd title 3 :
This is a final title.
MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair assembly, and inspections. A set of particularly important procedure 4 is placed between a line of asterisks “ ” with each procedure preceded by “”. IMPORTANT FEATURES Data and a special tool are framed in a box preceded by a relevant symbol 5 . An encircled numeral 6 indicates a part name, and an encircled alphabetical letter data or an alignment mark 7 , the others being indicated by an alphabetical letter in a box 8 . A condition of a faulty component will precede an arrow symbol and the course of action required the symbol 9 . EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures.
ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols 1 to 9 are designed as thumb tabs to indicate the chapter’s number and content. 1 2 3 4 5 6 7 8 9
General information Specifications Periodic inspection and adjustment Engine Cooling system Carburetion Chassis Electrical Troubleshooting
Illustrated symbols 10 to 16 are used to identify the specifications appearing in the text. 10 Filling fluid 11 Lubricant 12 Special tool 13 Tightening 14 Wear limit, clearance 15 Engine speed 16 Ω, V, A
Illustrated symbols 17 to 23 in the exploded diagram indicate grade of lubricant and location of lubrication point. 17 Apply engine oil 18 Apply gear oil 19 Apply molybdenum disulfide oil 20 Apply wheel bearing grease 21 Apply lightweight lithium-soap base grease 22 Apply molybdenum disulfide grease 23 Apply locking agent (LOCTITE)
CONTENTS GENERAL INFORMATION MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5 FRAME SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5 MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
SPECIFICATIONS GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5 MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6
PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7 PERIODIC MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . E-7 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8 AUTOLUBE PUMP AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8
ELECTRICAL DT125R CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8 COLOR CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9 IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9 DT125R ’99 WIRING DIAGRAM
MOTORCYCLE IDENTIFICATION
GEN INFO
GENERAL INFORMATION MOTORCYCLE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number 1 is stamped into the right side of the steering head pipe.
MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.
–1–
GENERAL SPECIFICATIONS
SPECIFICATIONS GENERAL SPECIFICATIONS Model Model Code Number
Dimensions Overall length Basic Weight: With Oil and Full Fuel Tank Engine: Engine Type Induction System Cylinder Arrangement Displacement Bore Stroke Compression Ratio Starting System Lubrication System Carburetor: Type/Quantity Manufacturer Spark Plug: Type/Quantity Manufacturer Plug Gap
DT125R 3RMF (F) 3RMD (G) 3RME (GB) (N) (S) (SF) (G) (B) (SP) (P) (I) (GR) 4DJ9 (H) (A) 2170 mm (3RMD) (3RME) (3RMF) 2235 mm (4DJ9) 127 kg (3RMD) (3RME) (3RMF) 129 kg (4DJ9) Liquid cooled 2-stroke, gasoline Reed valve Single cylinder, Forward inclined 124 cm3 56.0 50.7 mm 6.7 : 1 (4DJ9) 6.5 : 1 (3RMD) (3RME) (3RMF) Kick starter Separate lubrication (Yamaha Autolube) TM28SS/1 pc. MIKUNI BR8ES/1 pc. (4DJ9) BR9ES/1 pc. (3RMD) (3RME) (3RMF) NGK 0.7 0.8 mm
–2–
SPEC
MAINTENANCE SPECIFICATIONS
SPEC
MAINTENANCE SPECIFICATIONS ENGINE
Carburetor: I.D. Mark Main Jet Air Jet Jet Needle-Position Needle Jet Cutaway Pilot Outlet Pilot Jet Air Screw Bypass 1 Valve Seat Size Starter Jet Power Jet Fuel Level Float Height Idling Speed
(M.J.) (A.J.) (J.N.) (N.J.) (C.A.) (P.O.) (P.J.) (A.S.) (B.P.1) (V.S.) (G.S.) (PW.J.) (F.L.) (F.H.)
3RM02 (3RMD) (3RME) (3RMF) 4DJ02 (4DJ9) #210 (4DJ9) #240 (3RMD) (3RME) (3RMF) ø0.7 5J25-4 (3RMD-E-F) 5J25-3 (4DJ9) Q-2 2.5 0.6 #17.5 (4DJ9) #25 (3RMD-E-F) 1-1/4 (3RMD-E-F) 1-5/8 (4DJ9) ø1.6 ø2.8 #40 #60 (4DJ9) #95 (3RMD-E-F) –0.5 +1.5 mm 15.5 16.5 mm 1,300 1,400 r/min
Lubrication System: Autolube Pump: Color Code Minimum Stroke Maximum Stroke Minimum Output Maximum Output
Green (3RME-D) (4DJ9) Red (3RMF) 0.20 0.24 0.20 0.24 1.35 1.49 2.72 2.86 0.38 0.46 cm3 /200 stroke 0.38 0.46 cm3 /200 stroke 2.59 2.86 cm3 /200 stroke 5.23 5.5 cm3 /200 stroke
Pulley Adjusting Mark
Auto adjuster
–3–
MAINTENANCE SPECIFICATIONS
SPEC
ELECTRICAL
Model CDI: Magneto Model/Manufacturer C.B.I. Unit Model/Manufacturer
Source Coil Resistance
DT125R F3RM/YAMAHA 3RM-10/YAMAHA (3RMD) 3RM-20/YAMAHA (3RME) 3RM-30/YAMAHA (4DJ9) (3RMF) 688 1,032 Ω at 20C (Blank/Red – Green/White)
Spark Plug Cap: Type Resistance
Resin type 5 kΩ
Charging System:
C.D.I. magneto
C.D.I. magneto: Model/Manufacturer
F3RM/YAMAHA
Rectifier/Regulator Type Model/manufacturer Capacity
Semi-conductor-Short circuit type SH671-12/SHINDENGEN 8A
Flasher Relay: Type Model/Manufacturer
Full transistor type FE246BH/DENSO
Thermo Unit: Model/Manufacturer
2YK/NIPPON SEKI
–4–
INTRODUCTION/ PERIODIC MAINTENANCE AND LUBRICATION
INSP ADJ
PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as new vehicles that are being prepared for sale. All serviced technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE AND LUBRICATION EVERY
No.
ITEM
CHECKS AND MAINTENANCE JOBS
Initial (1,000 km)
6,000 km or 6 months (Whichever comes first)
12,000 km or 12 months (Whichever comes first)
Fuel line
Check fuel hoses for cracks or damage. Replace if necessary.
2
Spark plug
Check condition. Clean, regap or replace if necessary.
3
Air filter
Clean or replace if necessary.
Battery
Check electrolyte level and specific gravity. Correct or recharge if necessary. Make sure that the breather hose is properly routed.
Clutch
Check operation. Adjust or replace cable.
1
4
*
*
5
6
*
Front brake
Check operation, fluid level and vehicle for fluid leakage. (See NOTE) Correct accordingly. Replace brake pads if necessary.
7
*
Rear brake
Check operation, fluid level and vehicle for fluid leakage. (See NOTE) Correct accordingly. Replace brake pads if necessary.
8
*
Wheels
Check balance, runout, spoke tightness and for damage. Tighten spokes and rebalance, replace if necessary.
9
*
Tires
10
*
Wheel bearings
Check bearing for looseness or damage. Replace if necessary.
11
*
Swingarm
Check swingarm pivoting point for play. Correct if necessary.
Drive chain
Check chain slack. Adjust if necessary. Make sure that the rear wheel is properly aligned Clean and lubricate.
Every 500 km and after washing the motorcycle or riding in the rain
12
Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary.
13
*
Steering bearings
Check bearing play and steering for roughness. Correct accordingly. Lubricate with lithium soap base grease every 24,000 km or 24 months (whichever comes first).
14
*
Chassis fasteners
Make sure that all nuts, bolts and screws are properly tightened. Tighten if necessary.
Sidestand
Check operation. Lubricate and repair if necessary.
15
–5–
PERIODIC MAINTENANCE AND LUBRICATION
INSP ADJ EVERY
No.
ITEM
CHECKS AND MAINTENANCE JOBS
Initial (1,000 km)
6,000 km or 6 months (Whichever comes first)
12,000 km or 12 months (Whichever comes first)
16
*
Sidestand switch
Check operation. Replace if necessary.
17
*
Front fork
Check operation and for oil leakage. Correct accordingly.
18
*
Rear shock absorber assembly
Check operation and shock absorber for oil leakage. Replace shock absorber assembly if necessary.
19
*
Rear suspension relay arm and connecting arm pivoting points
Check operation. Correct if necessary.
20
*
Carburetor
Check engine idling speed and starter operation. Adjust if necessary.
21
*
Autolube pump
Check operation. Correct if necessary. Bleed if necessary.
Transmission oil
Check oil level and vehicle for oil leakage. Correct accordingly. Change oil at initial 1,000 km and thereafter every 24,000 km or 24 months (whichever comes first).
Cooling system
Check coolant level and vehicle for coolant leakage. Correct if necessary. Change coolant every 24,000 km or 24 months (whichever comes first).
22
23
*
* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.
NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake system When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid level regularly and fill as required. Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years. Replace the brake hoses every four years or if cracked or damaged.
–6–
ENGINE
INSP ADJ
ENGINE AUTOLUBE PUMP AIR BLEEDING
NOTE: The Autolube pump and delivery lines must be bled on the following occasions: Setting up a new motorcycle out of the create. Whenever the oil tank has run dry. Whenever any portion of the engine oil system is disconnected. 1. Remove: Autolube pump cover 2. Fill: Oil tank 1 Yamaha Oil 2T or Air-Cooled 2-Stroke Engine Oil 2 Oil tank filler cap
3. Air bleed: Pump case and/or oil pipe Air bleeding steps: Remove the bleed screw 1 . Keep the oil running out until a bubbles disappear. When air bubbles are expelled completely, tighten the bleed screw.
NOTE: Check the bleed screw gasket, and if damaged, replace with a new one. Place a rag or oil pan under the autolube pump to catch oil.
–7–
DT125R CIRCUIT DIAGRAM
ELECTRICAL DT125R CIRCUIT DIAGRAM
–8–
ELEC
ELEC
DT125R CIRCUIT DIAGRAM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
CDI magneto Neutral switch Rectifier / regulator Fuse Battery Main switch “ENGINE STOP” switch Servomotor CDI unit Ignition coil Read switch Meter light Meter light Neutral indicator light Oil level indicator light High beam indicator light Engine temperature gauge Thermo unit
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
Turn indicator light Neutral relay Sidestand switch Oil level switch Rear brake switch Front brake switch Tail / brake light Flasher relay Horn Flasher light “Turn” switch “Horn” switch “Lights” (Dimmer) switch “Lights” switch Handlebar switches (left) Auxiliary light Headlight
COLOR CODE
B
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
–9–
L/R
Blue/Red
IGNITION SYSTEM
ELEC
IGNITION SYSTEM TROUBLESHOOTING Check: 1. Sidestand switch 2. Neutral switch 3. Wiring connection (Ignition system) 1. Sidestand switch Disconnect the sidestand switch leads from the wireharness. Connect the Pocket Tester (Ω 1) to the sidestand switch. Tester (+) Lead Black 1 Terminal Tester (–) Lead Black 2 Terminal
Move the sidestand to up position and down position. Check the sidestand switch for continuity. Sidestand position
Good condition
Up
Down
: Continuity
Bad condition BAD CONDITION
: No continuity
Replace “Sidestand” switch.
GOOD CONDITION
–10–
IGNITION SYSTEM
2. Neutral switch Disconnect the Neutral relay coupler 1 from the wireharness. Connect the Pocket Tester (Ω 1) to the neutral switch lead. Tester (+) Lead Sky blue 2 lead Tester (–) Lead Frame Ground
Shift the transmission in neutral and gear. Check the neutral switch for continuity. Transmission position
Good condition
Neutral
Gear
: Continuity
Bad condition BAD CONDITION
: No continuity
Replace neutral switch.
GOOD CONDITION
–11–
ELEC
IGNITION SYSTEM
ELEC
3. Neutral relay S Disconnect the neutral relay from the wireharness. S Connect the pocket tester (Ω 1) and battery (12 V) to the neutral relay.
NO CONTINUITY
S Check the neutral relay for continuity.
Neutral relay is faulty, replace it.
CONTINUITY POOR CONNECTION
4. Wiring connection S Check the entire ignition system for connections. Refer to the “WIRING DIAGRAM” section.
Correct.
CORRECT Replace ignition control unit.
–12–
DT125R ’99 WIRING DIAGRAM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
COLOR CODE B ...... R...... O ..... L ......
Black Red Orange Blue
P ...... Y ...... G ..... W .....
Pink Yellow Green White
Ch . . . . Dg . . . . Sb . . . . . Br . . . . .
Chocolate Dark green Sky blue Brown
L/Y . . . . B/Y . . . . B/W . . . B/R. . . .
Blue / Yellow Black / Yellow Black / White Black / Red
W/R . . . W/L . . . Y/R. . . . G/R . . .
White / Red White / Blue Yellow / Red Green / Red
G/Y . . . G/W . . . Br / W . . L/R . . . .
Green / Yellow Green / White Brown / White Blue / Red
CDI magneto Neutral switch Rectifier/ regulator Fuse Battery Main switch “ENGINE STOP” switch Servomotor CDI unit Ignition coil Read switch Meter light Meter light Neutral indicator light Oil level indicator light High beam indicator light Engine temperature gauge Thermo unit Turn indicator light Neutral relay Sidestand switch Oil level switch Rear brake switch Front brake switch Tail/ brake light Flasher relay Horn Flasher light “Turn” switch “Horn” switch “Lights” (Dimmer) switch “Lights” switch Handlebar switches (left) Auxiliary light Headlight
View more...
Comments
