Yamaha DT125R 1989 User manual

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•YAMAHA
2YY-AE1
SUPPLEMENTARY
SERVICE MANUAL
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FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
DT200R{W) '
89 . Forcomplete information on service procedures, it is necessary to usethis Supplemen-
tary Service Manual together with following manual:
DT125R Service Manual {3BN-ME1)
DT200R(W)
SUPPLEMENTARY
SERVICE MANUAL
TECHNICAL PUBLICATIONS
SERVICE DIVISION
MOTORCYCLE GROUP
YAMAHA MOTOR CO., LTD.
1988 by Yamaha Motor Co ., Ltd .
1st Edition, September 1988
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
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NOTICE
This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and
their qualified mechanics.
It is not possible to put an entire mechanic's education into one manual,
so
it is assumed that persons using this book to perform maintenance and repairs on Yamaha motor-
cycles have a basic understanding
of the mechanical conceptsand procedures inherent in motorcycle
repair technology.
Without such knowledge, attempted repairs or service to this model may render
it unfit to use and/or unsafe.
• Yamaha
Motor Company, Ltd. is continuallystriving to improve all models manufactured by Yamaha.
Modificationsand significantchanges in specifications
or procedureswillbeforwarded to all Authorized
Yamaha dealers and will, where applicable, appear in future editions
of this manual.
HOW TO USE THIS MANUAL
PARTICULARLY IMPORTANT INFORMATION
This material is distinguished by the following notation.
NOTE: A NOTE provides key information
to make procedures easier or clearer.
A CAUTION indicates special procedures
that must be followed to avoid damage
to the motorcycle.
•
__;__ WARNING : A WARNING indicates special procedures
that must be followed to avoid injury to -
a motorcycle operator or person inspecting
or repairing the motorcycle.
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The informa-
tion has been compiled to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations
of all disassembly, repair, assembly, and inspection operations.
In this revised format, thecondition
of a faulty componentwill precede an arrowsymbol and thecourse
of action required will follow the symbol, e.g.,
• Bearings
Pitting/ Damage-+Replace.
EXPLODED DIAGRAM
Each chapterprovide.sexploded diagrams before each disassembly section for ease in identifying cor-
rect disassembly and assembly procedures.
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ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols (D to @ are designed as
thumb tabs to indicate thechapter's numberand
content.
1 General information
Specifications
Periodic inspection and adjustment
Engine
Cooling system
Carburetion
Chassis
Electrical
Troubles
hoot ing
Illustrated symbols ® to ® are used to identify
the specifications appearing in the text.
Filling fluid
Lubricant
Special tool
Tightening
Wear limit, clearance
Engine speed
0, V,A
Illustrated symbols@ to @ in the exploded dia-
gram indicate grade
of lubricant and location of
lubrication point.
I
Apply engine oil
Apply gear oil
Apply molybdenum disulfide oil
Apply wheel
bea ring grease
Apply lightweight lithium-soap
base gr ease
@ Apply molybdenum disulfide grease
@ Ap ply locking agent (LOCTIT~ I
IJ

CONTENTS
GENERAL INFORMATION .......... ... .... . ................. M-4
MOTORCYCLE IDENTIFICATION
.. . . . . . . ........ . ..... . ......... M-4
FRAME SERIAL NUMBER . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-4
ENGINE SER IAL NUMBER . . . . . .. . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . M-4
SPECIFICATIONS . . .. . . .. .. . . . . . . . . . . . . . . . . . . . . . . . . . M-4·
GENERAL SPECIFICATIONS .......... .. ......... . ............... M-4
MAINTENANCE SPECIFICATIONS .... . ... .. ... .................. M-6
GENERAL TORQUE SPECIFICATIONS ..... . ........ . . . . .. .. . .... M-11
DEFINITION OF
UNITS ................... .. . . .. .. .. . .. . ...... .. . M-11
COOLANT FLOW CHART ............... . ...... . ................. M-12
LUBRICATION POINTS AND
LUBRICANT TYPE ...... .. .... . ........... . .................. . .. M- 12
CABLE ROUTING .................. . . ... .. . ... . ......... . .... .. . M- 13
PERIODIC INSPECTION AND ADJUSTMENT ...... ..... .M-16
CHASSIS ... .. ... ......... . . ... . . . . .. ........... . ..... .. ........ M-16
FRONT FORK ADJUSTMENT
..... ..... .. . .... . ......... . ..... .M-16
REAR SHOCK ABSORBER ADJUSTMENT . . . . . .. . . .. .. . .. . . . . . . A-1
RECOMMENDED COMBINATIONS OF FRONT FORK
AND REAR SHOCK ABSORBER SETTING . . . .. .. . . . . . .. .. . . . . . . A-2
COOLING SYSTEM. ... .. ...... .. ...... .... . .......... ......... A-2
THERMOSTATIC VALVE AND RADIATOR ... .. . ...... . ......... . A-2
REMOVAL . .
... ....... . . .... . ......... . ... . .. .. ..... . ....... . A-3
INSTALLATION . .
..... . .. . ..... ... .......... .. ......... . .... . A-4
CARBURETION ........ . ................ .. .. .. ... . .... ... ..... . A-5
CARBURETOR .. .. .... .. . . . . .................... . .... ..... . . . . . . A-5
REMOVAL
............. .... .. . .. . .... .. ......... . . ... .... ... . A-5
DISASSEMBLY
.... . .. . .. . . ... .... ............. . ............ . . A-6
INSPECTION
............. . ·.· . . ... .... ............... ... .. . .. . A-6
ASSEMBLY . .
... ............. . ... . .. . ... . . .. ... ... .. . ....... . A-7
INSTALLATION
..... ... . ........... . .... . ........... ... ..... . A-8
ADJUSTMENT
.... .. .. . .... . ............ . . .... ...... ... ... .. . A-9
CHASSIS.. ........ .. ... . ... . ........... ... ............. . ..... ... A-9
FRONT FORK . .. . .... . ......... .... ...... . ..... . .. .. .......... .. A-9
REAR SHOCK ABSORBER .... . ....... . .. . ..... . .... . ....... . ... A-10
HANDLING NOTE
....... . ..... . ...... . .. .... . ........ .. ...... A-10
NOTES
ON DISPOSAL ........ ... .................... . ........ A-10
REMOVAL . . . .
......... . . .. ...... .......... . ........ . ........ A-11
INSPECTION
........ . ........ . .. . ... ... .... ....... ... . ..... . . A-11
INSTALLATION . .
.. ... . ............... .. .. . .. ................ A- 11
ELECTRICAL ........ . ...... . ......... ...... ............. . ...... A-13
DT200R(W) CIRCUIT DIAGRAM . .. . . . .. . . ... .............. .. . ... A-13
DT200RW WIRING DIAGRAM
DT200R WIRING DIAGRAM
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GNEFON I ~1
MOTORCYCLE IDENTIFICATION C9'~
--------------------------
GENERAL INFORMATION
- 1-
MOTORCYCLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
(FOR OCEANIA)
The vehicle identification number G) is stamped
on the right
of the steering head pipe.
Starting Serial Number:
JV A3CJT0* KA002101
FRAME SERIAL NUMBER (EXCEPT FOR
OCEANIA)
The frame serial number G) is stamped on the
right
of the steering head pipe.
Starting Serial Number:
2YY-020101
ENGINE SERIAL
NUMBER
Theengine serial number CD isstamped into the
elevated part of theleftrear section of theengine.
NOTE: -------------
The first three digits of these numbers are for
model identifications; the remaining digitsarethe
unit production number.
Starting serial number:
FOR OCEANIA: 3CJ-002101
EXCEPT FOR
OCEANIA : 3ET-020101
NOTE:
-------------
Designs and specifications are subject to change
without notice.

GENERAL SPECIFICATIONS I SPEC I f>f I
SPECIFICATIONS
GENERAL SPECIFICATIONS (Oc): For Ocean
ia
Model
DT200R (W)
Model Code Number 2YY1,
3CJ1 (Oc)
Eng ine Starting Number
3ET -020101, 3CJ-002101 (Oc)
Frame Seri
al Number, Vehicle Identification 2YY-000101,
JYA3CJTO*KA002 1 01 (O c)
Number (Oc)
Dimensions:
Overall Length 2,
165 mm (85 .2 in)
Overall Width
830 mm (32.7 in)
Overall
He i ght
1, 255 mm (49 .4 in)
Seat Height
885 mm (34.8 in)
Wheel
Base
1,415 mm (55.7 in)
Minimum Ground Clearance
315 mm (12.4 in)
Basic Weight:
With
Oil and Full Fuel Tank
122 kg (269 lb), 121 kg (267 l b) (Oc)
Minimum Turning Radius: 2,100 mm (82.7 in)
Engine:
Engine Type Liquid cooled 2-stroke, gasoline
Induction System
Reed valve
Cylinder Arrangement Single cylinder, Forward inclined
Displacement
195 cm3
Borex Stroke 66x 57 mm
(2 . 598 x 2.244 in)
Compression Ratio
6.4: 1
Starting System Kick starter
Lubrication System Separate lubrication (Yamaha Autolube)
Engine
Oil :
Type Yamaha oil 2T or air-cooled 2-stroke engine oil
Capacity 1.2 L
(1.1 Imp qt , 1.3 US qt)
Transmission
Oil :
Type SAE 10W30 type
SE motor oil
Capacity:
Periodic Oil Change 0.75 L (0.66 Imp
qt , 0.79 US qt )
Total Amount 0.80 L (0.70 Imp qt, 0.84
US qt )
Coolant Capacity:
Including All Routes 1.20 L (1.06 Imp
qt , 1.27 US qt )
Air Filter:
Type
Wet element
Fuel:
Type Regular gasoline
Fuel Tank Capacity:
Full Amount
10 .0 L (2 .2 Imp ga l, 2.6 US gal)
Reserve Amount 1.8 L (0.
40 Imp gal, 0. 48 US ga ll
-2-
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GENERAL SPECIFICAJ]ONS I SPEC I f>f I
IJ
Model DT200R(W)
Carburetor:
Type/Quantity TM28/ 1 pc.
Manufacturer MIKUNI
Spark Plug:
Type/Quantity BR9ES/ 1 pc.
Manufacturer NGK
Plug Gap
0.7~0.8 mm (0 . 028-0 .032 i n)
Clutch:
Type
Wet, multiple disc
Transmission:
Type Constant mesh 6-speed
• Primary Reduction System Helical gear
Primary Reduction Ratio 52/
17 (3.059)
Secondary Reduction System Chain drive
Secondary Reduction Ratio 43/
13 (3.308)
Operation Left
foot operation
Gear Ratio: 1st 33/
12 (2.750)
2nd 30/ 16 (1.875)
3rd 24/
17 (1.412)
4th 24/21 (1.143)
5th 22/23 (0.957)
6th 18/22 (0.818)
Chassis:
Frame Type Semi double cradle
Caster Angle 27.
5°
Trail 113
mm (4.45 in)
-Tire:
Type With tube
Size:
Front 3.00-21 4PR
Rear 4.60-18 4PR
Maximum Load*
Front 47 kg (104 lb)
Rear 134 kg (295 lb)
Cold Tire Pressure: Front Rear
Up
to 90 kg (198 lb) Load* 130 k Pa 150 kPa
(1.3 kg/cm2, 18 psi)
(1 .5 kg/cm2, 22 psi)
90 kg (198 lb)-Maximum Load* 150
kPa 180 kPa
(1.5 kg/cm2, 22 psi) (1.8 kg/cm2, 26 psi)
Off-road
Rid ing
130 kPa
150 kPa
(1 .3 kg/cm2, 18 psi) (1.5 kg/cm2, 22 psi)
*Load is total weight
of cargo, rider, passenger, and accessories.
-3-

GENERAL SPECIFICATIONS I SPEC I Pf I
Model DT200R(Wl
Brake:
Front Brake Type Single disc brake
Front Brake Operation Right hand operation
Rear Brake Type Single disc brake
Rear Brake Operation Right foot operation
Suspension:
Front Suspension Type Telescopic fork
Rear Suspension Type Swingarm (Monocross suspension)
Shock Absorber:
Front Shock Absorber Coil and air spri
ng /Oil damper
Rear Shock Absorber Coil and
gas spring/ Oil damper
Wheel Travel: •
Front Wheel Travel 270 mm (10.6 in)
Rear Wheel Travel 270 mm (10.6 in)
Electrical:
Ignition System
CDI
Generator System Flywheel magneto
Battery:
Type GM3-3B/FB3L-B
Capacity 12V 3AH
Headlight:
Type Bulb type
Bulb Wattage (Quantity):
Headlight 12V 00W/55W, 12V 35W/36.5W (Ocl
Tail/Brake Light 12V 5W/21W
Flasher Light 12V 21W
(4 pcs.), 12V 10W (4 pcs.) (Oc)
Auxiliary Light 12V
4W (1 pc.) Except for Oceania -
Meter Light 12V 3.4W (2 pcs.)
"NEUTRAL" Indicator Light 12V 3.4W (1 pc.)
"HIGH
BEAM" Indicator Light 12V
3.4W (1 pc.)
"OIL" Indicator Light 12V 3.4W (1 pc.)
"TURN" Indicator Light 12V 3.4W
(1 pc.)
-4 -

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MAINTENANCE SPECIFICATIONS I SPEC I Pf I I]
MAINTENANCE SPECIFICATIONS
ENGINE
Cylinder Head :
Warpage Limit
Cylinder:
Bore Size
Taper Limit
Out
of Round Limit
Piston:
Model
@
Piston Size "D"
Measuring Point "a"
7~=f
Piston Off-Set - D -,
Piston-to Cylinder Clearance
<Limit>
Over Size: 1st
2nd
Piston Ring:
Sectional Sketch
End Gap (Installed)
Side Clearance
Top Ring
cJ]a
I• •I
T
2nd Ring
cJ]a
I• •I
T
Top Ring
2nd Ring
Top Ring
2nd
Ring
DT200R(W)
0.
03 mm (0.0012 in)
*Lines indicate straightedge measurement.
66.00-66.02 mm (2.598-2.599 in)
0.
05 mm (0 . 002 in)
0.01 mm (0.0004 in)
65.94-66.00 mm
(2 . 596-2 . 598 in)
10 mm (0.4 in)
0 mm (0 in)
0.055-0 . 060 mm (0.0022-0.0024 in)
<
0.1 mm (0.004 in)>
66.25 mm (2.61 in)
66.50 mm (2.62 in)
Keystone type
B=1.2 mm (0.047 in)
T=2.8 mm (0.110 in)
Plain type
B=1.2 mm (0.047 in)
T=2.4 mm (0.095 in)
0.30-0.45 mm (0.012-0.018 in)
0.
30-0.45 mm (0.012-0.018 in)
0.020-0.060 mm (0.0008-0.0024 in)
0.030-0.065 mm (0.0012-0.0026 in)
-5 -

MAINTENANCE SPECIFICATIQ.!IIS ISPEC\ 1>f I
Model DT200R(W)
Crankshaft:
Crank
Width "A" 57.90~57.95 mm (2 . 280~2 . 282 in)
Runout
limit " B" 0.02 mm (0.0008 in)
Big
End Side Clearance "C " 0. 20~0.70 mm (0.008~0.028 in)
<Limit>
D < 1.0 mm (0.040
in)>
Small End Free Play " D" -- 0.8~ 1.0 mm (0.031 ~0.040 in)
fl
B B
9 -
---
~
a:,
D
A A
-,
--
I C •
A
Clutch:
Friction Plate:
Thickness 2.
9~3 .1 mm (0 . 114-0 . 122 in)
Quantity 7 pcs.
Wear
limit 2.7 mm (0.106 in)
Clutch Plate:
Thickness
1.05~ 1.35 mm (0.041 ~0 .053 in)
Quantity 6 pcs.
Warpage
limit 0.05 mm (0.002 in)
Clutch Spring:
Free Length 34.5 mm (1.358 in)
Quantity 5 pcs.
Minimum
Free Length 32.0 mm (1.260 in)
Clutch
Release Method Inner push,
Cam push
Push
Rod Bending limit 0. 15 mm (0.006 in) •
Transmission:
Main Axle Runout Limit 0.08 mm (0.003 in)
Drive Axle Runout Limit 0.08 mm (0.003 in)
Shifter:
Type
Cam drum and guide bar
Guide Bar Bending Limit 0.03 mm (0.0012 in)
Kick Starter:
Type Kick and mesh type
Air Filter:
Oil Grade Foam-Air-Filter oil or SAE 10W30 SE
- 6-

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MAINTENANCE SPECIFICATU1111S I SPEC I f'f I
Carburetor:
I.D . Mark
Main
Jet
Air Jet
Jet
Needle-Position
Needle
Jet
Cutaway
Pilot Outlet
Pilot
Jet
Bypass 1
Valve Seat Size
Starter
Jet
Power Jet
Fuel Level
Float Height
Idling Speed
Reed Valve:
Model
Valve Thickness
Valve Stopper Height
Valve Bending Limit
Lubrication System:
Autolube Pump:
Color Code
Minimum Stroke
Maximum Stroke
Minimum Output
Maximum Output
Pulley Adjusting Mark
Cooling System:
Radiator Core
Width
Radiator Core Height
(M .J.)
(A.J.)
(J.N.)
(N.J.)
(C.A.)
(P.
O. )
(P.J.)
(B.P. 1)
(V.S.)
(G.S.)
(PW.
J.)
(F.L.)
(F.H.)
Radiator Core Thickness
Radiator Cap Opening Pressure
Reservoir Tank Capacity
Water Pump Type
Thermostatic Valve:
Opening Temperature
Full Open Temperature/Lift
2YYOO
#150
c/>0.5
5J10-4
P-2
2.5
c/>0.6
#25
c/>1.6
c/>2.8
#25
#65
DT200R(W)
-2.5- -4.5 mm (-0 . 10- -0.18 in)
20-21 mm (0.79-0.83 in)
1,300-1 ,400 r/min
0.4 mm (0.02 in)
6.8
mm (0 .27 in)
0.5
mm (0.02 in)
White
0.
20-0.25 mm (0. 008-0.010 in)
1.85-2.05 mm (0.073-0 .080 in)
0.
50-0.63 cm3 per 200 strokes
4.65-5.15 cm3 per 200 strokes
Auto adjuster
110
mm (4.3 in)
280 mm (11.0 in)
32 .0 mm (1.26 in)
75-105 kPa (0.75- 1.05 kg/cm
2,
10-14 psi)
0.3 L
(0 .32 Imp qt, 0.26 US qt)
Single-suction centrifugal pump
63-67 °C (146-153°F)
80°C (176°F)/7 mm (0.28 in) or more
-7-

MAINTENANCE SPECIFICATIONS I SPEC I :Pf I
Tightening Torque:
Thread Ti
ght ening torque
Part
to be ti gh tened Q'
ty
size Remarks
Nm m•kg
ft•lb
Spark Pl ug 1
M14 x 1.25 20 2.0 14
Cylinder Head
Nut 5 M a x 1.25 22 2.2 16
Cylinder a
Stud bolt 9 M 8 x 1.25 13 1.3
9.4
Nut
4 M 8 x 1.25
28
2.8
20
Power Valve Holder, Valve, Cover,
Cap Seal
Bolt 6 M 5 x 0.8 7 0.7 5.1
Power Valve Pully
Bolt 1 M 6 x 1.0 10 1.0
7.2
•
Balancer Gear
Nut
2
M12 x1.0 55 5.5 40
Thermostat Va lve Cover
Screw 3 M 6 x 1.0 8 0.8 5.8
Housing Cover
Screw 2 M 6 x 1.0 8 0.8 5.8
Drain Bolt (Housing Cover) 1 M 6 x 1.0
10
1.0 7.2
Radiator
Bolt 2 M 6 x 1.0 8 0.8 5.8
Warm Water Hose (Carburetor)
Bolt 2 M 6 x 1.0 8 0.8
5.8
Radiator Cap Stopper
Screw 1 M 5 x 0.8 5 0.5 3.6
Oil Pump
Screw 2 M 5 x 0.8 5 0.5 3.6
Carburetor Joint
•
Bolt 4 M 6 x 1.0 8 0.8 5.8
Air Filter
Bolt 2 M 6 x 1.0 5 0.5 3.6
Exhaust Pipe
Nut
2 M 8 x 1.25
18
1.8 13 l
Stud Bolt 2 M 8 x 1.25
10
1.0 7.2 a
Bolt 3 M 6 x 1.0 8 0.8 5.8
Transmissi on Oil Dra in Bolt
1 M 8 x 1.25 15 1.5
11
Crankcase Cover (Left)
Screw 6 M 6 x 1.0 5 0.5 3.6
Crankcase Cover (Right)
Screw 6 M 6 x 1.0 8 0.8 5.8
Oil Pump Cover
Screw 3 M 6 x 1.0 5 0.5 3.6
Crankcase
Screw 12 M 6 x 1.0 8 0.8 5.6
Oil Seal Holder
Screw 1 M 8 x 1.25 16 1.6 11
-8 -

MAINTENANCE SPECIFICATIONS I SPEC I Pf I I]
Tightening Torque:
Part
to be tightened O'
ty
Thread Tightening torque
size Remarks
Nm
m•kg ft• lb
Cover
Screw 2 M 6 x 1.0 8 0.8 5.6
Kick Crank Boss
Nut 1 M12 x1.0 65 6.5 47
Primary Drive Gear
Nut 1 M12 x 1.0 80 8.0 58
Clutch Boss
Nut 1 M12 x 1.0 70 7.0 51
Clutch Spring
• Bolt 5 M 5 x 0.8 6 0.6 4.3
Plate Cover
Screw 2 M 6x 1.0 10 1.0 7.2
Drive Sprock et
Nut 1 M16 x 1.0 60 0.6 43
Tachometer Housing
Bolt 1 M 6x 1.0 5 0.5 3.6
Stopper Lever a
Bolt 1 M 6x 1.0
14
1.4 10
Change Pedal
Bolt 1 M 6x 1.0 15 1.5 11
Thermo Unit 1 -
15 1.5
11
Rotor
Nut 1
M12 x 1.25 80 8.0 58
- 9-

MAINTENANCE SPECIFICATIONS I SPEC I ,Vf I
CHASSIS
Model
Steering System:
Bearing Type Upper
lower
Bearing Size (Quantity):
Upper
Front Suspension:
Front Fork Travel
Fork Spring
Free length
<limit>
Spring Rate (Kil
Stroke (Kil
Optional Spring
Oil Capacity
Oil level
Oil Grade
Rear Suspension:
Shock Absorber Travel
Spring
Free length
<limit>
Fitting length
Spring Rate (Kil
Stroke (Kil
Optional Spring
Enclosed
Gas Pressure
Swingarm:
Free Play limit (Swingarm End)
Front Wheel:
Type
Rim Size
Rim Material
Rim Runout
limit
Vertical
Lateral
Rear Wheel:
Type
Rim Size
Rim Material
Rim Runout limit
Vertical
lateral
DT200R(W)
Ball bearing
Taper roller bearing
3/
16 in (22 pcs.)
270 mm (10.6 in)
548 mm (21.6 in)
< 543 mm (21.4
in)>
3.5 N/ mm (0.35 kg/mm, 20 lb/in)
0-270 mm (0- 10.6 in)
No.
512 cm3 (18.1 Imp oz, 17 .3 US oz)
140 mm (5.51 in)
From top
of inner tube fully compressed
without spring.
Fork oil 10W or equivalent
99 mm
(3 .90 in)
265 mm (10.40 in)
<263 mm (10.35 in)>
250 mm (9. 84 in)
66.7 N/mm (6.8 kg/mm,
381 lb /i n)
0-99 mm (0-3.90 in)
No.
1471.0
kPa (15 kg/cm2, 213 psi)
1.0 mm (0.04 in)
Move swingarm end side
to side
Spoke wheel
1.60x
21
Steel
2.0 mm (0.08 in)
2.0 mm (0.08 in)
Spoke wheel
2.
15 x 18
Steel
2.0 mm (0.08 in)
2.0 mm (0.08 in)
- 10 -
•
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MAINTENANCE SPECIFICATIONS I SPEC I fVf I 0
Model DT200R(W)
Drive Chain:
Type/Manufacturer 528V6/DAIDO
Number
of Links 105 Links+joint
Chain
Free Play 25-40 mm (0 . 98- 1. 57 in)
Front Disc Brake:
Type Single
Disc Outside Diameter
230 mm (9.06 in)
Disc Thickness 3.5 mm
(0 . 14 in)
Pad Thickness 6.0 mm (0.24 in)
<Wear Limit>
< 0.8 mm (0 .03 in)>
Master Cylinder Inside Diameter
12 .7 mm (0.5 in)
Caliper Cylinder Inside Diameter 34.9 mm
(1 . 38 in)
• Brake Fluid Type DOT No. 4
If DOT No. 4 is not available,
DOT No. 3 can be used.
Rear Disc Brake:
Type Single
Disc Outside Diameter
220 mm (8 . 66 in)
Disc Thickness 4.5 mm
(0 . 18 in)
Pad Thickness 6 mm
(0 .24 in)
<
Limit> <0.8 mm (0 . 03 in)>
Master Cylinder Inside Diameter 12.7 mm (0.5 in)
Caliper Cylinder Inside Diameter
30 .2 mm (1.19 in)
Brake Fluid Type DOT No. 4
If DOT No. 4 is not available,
DOT No. 3
can be used.
Brake Lever and Brake
Pedal :
-Brake Lever
Free Play 2-5 mm (0.08-0.20 in)
At end of brake lever
Brake
Pedal Position
15 mm (0.59 in)
Below top
of footrest
Brake
Pedal Free Play
Adjustment free
Clutch Lever and Throttle Grip:
Clutch Lever
Free Play
2-3 mm (0 . 08-0.12 in)
At the lever pivot
Throttle Cable
Free Play
2-5 mm (0.08-0 .20 in)
At grip flange
- 11 -

MAINTENANCE SPECIFICATIONS I SPEC I~f I
Tightening Torque:
Part
to be tight ened Tightening torque
Thread si
ze Remarks
Nm m•kg ft•lb
Front Fork, Steering:
Handle Crown and lnnter Tube M 8 x 1.25
23 2.3 17
Handle Crown and Steeri
ng Sh aft M22 x 1.0 90 9.0 65
Handlebar Holder M 8 x 1.25
23
2.3 17 Refer
to
Stee ri ng Shaft and Ring Nut
M25 x 1.0 6 0.6 4.3 "NOTE
".
Brake Hose Holder M 6 x 1.0 10 1.0 7.2
Master Cylinder Cap M 4 x 0.7 2 0.2 1.4
Handle Crown Pinch
Bolt M 8 x 1.25
23
2.3 17
Engine
Mount ing:
Engine
Stay (Front) and Frame M10x1.25
63 6.3 45
Engine
Stay (Top) and Frame M 8 x 1.25
33 3.3 24
Engine and Frame M Bx 1.25
33 3.3 24
Swingarm, Rear Shock Absorber:
Pivot
Shaft and Frame M16x 1.5 90 0.9 65
Swingarm and Connecting Rod
M14 x 1.5 58 5.8 42
Relay Arm and Connecting Rod M14 x 1.5
58 5.8 42
Relay Arm and Frame M10x 1.25
58
5.8
42
Rear Shock Absorber and Frame M10x 1.25 33 3.3 24
Rear Arm and Rear Shock Absorber M10x 1.25
33
3.3 24
Chain Cover M 6 x 1.0 4 0.4 2.9
Swingarm End
Bolt
M 6 x 1.0 3 0.3 2.2
Fuel Tank, Seat, Rear Fender:
License Bracket and
Stay
M 6 x 1.0 5 0.5 3.6
Wheels:
Front Wheel
Axle M14 x 1.5 58 5.8
42
Rear Wheel Axle and Nut
M18 x 1.5 90 9.0 65
Front Wheel Axle Holder M 6x 1.0 10 1.0 7.2
Front Brake Caliper M10 x 1.25 35 3.5 25
Union Bolt (Brake Hose)
M10 x 1. 25
26 2.6 19
Wheel Sprocket and
Hub M 8x 1.25 35 3.5 25
Footrest Brake Pedal:
Sidestand M10x 1.25 40 4.0 29
Sidestand Switch M 5x 0.8 4 0.4 29
Footrest (Rear and Frame) M Bx 1.25 20 2.0
14
Master Cylinder (Rear) M 6 x 1.0 10 1.0 7.2
Reservoir Tank M 6 x 1.0 4 0.4 2.9
NOTE : ------------------------------
1. First, tighten the ring nut approximately 38 Nm (3.8 m• kg, 27 ft•lb) by using the torque wrench,
then loosen
the ring nut one turn .
2. Retighten the ring
nut to specification.
- 1 2-
•
-

•
•
______ M_A_1_N_T_EN_A_N_c_e_s_P_e_c_1F_1c_A_T_1o_N_s_ I sPEC IPfI IM
ELECTRICAL
Model DT200R(Wl
Voltage: 12V
Ignition System:
Ignition Timing
(B.T . D.C.l
15° at 1,350 r/ min
Advancer Type Electrical
type
250
/±1 .5° at 1,350 r/ min
16.!
0±/ 5° at 7,450 r/
min
-
u
200
0
/v
I/
....:
•
---
t---.
t--f
r--
CD
L V •
-·
rJ:
---I"'-\
-
150
L t -\
-r--
\'·>
O>
I
C l
·e ,oo \ l'I.
i=
__ ...J
16 . 3° ± 1.5° at 4,250 r/min \\\
C I I I
l¼----
---
0
15 . 5°±1 . 5° at 2,850 r/ min
:~
50
70±
1.5°~ 19,250 ~/min
C
El
0 2 4 6 8
10 12
Engine Speed (x 1,000 r/min)
C.0 . 1.:
Magneto Model/ Manufacturer F3ET/
YAMAHA
C.0.1. Unit Model/Manufacturer
3ET/YAMAHA
Pickup Coil Resistance (Color)
280-4200 at 20°C (68°F)
(White / Red-White / Bluel
Source Coil Resistance (Color)
192-2880 at 20°c (68°Fl
(Black/
Red-Green / Wh ite)
Ignition Coil:
Model/Manufacturer
2JN / YAMAHA
Minimum Spark Gap 6
mm (0.24 in)
Primary Coil Resistance 0.7~
1.10 at 20°C (68° F)
Secondary Coil Resistance
5.7-8.5k0 at 20°C (68° F)
Spark Plug Cap:
Type Rubber
type
Plug Cap Resistance
4-6k0 at 20°C (68°F)
-13-

@l
MAINTENANCE SPECIFICATIONS I SPEC I 'f 'i I
Model DT200R(W)
Charging System: Flywheel magneto
Flywheel Magneto:
Model/Manufacturer
F3ET /YAMAHA
Charging Coil Resistance (Color) 0.
3-0.50 at 20°C (68°F) (White-Black)
Standard Output 12V 1.1A
at 2,500 r/min
When
"LIGHT" switch is turned to "OFF".
2.0
I;,,,-
<
-
C:
~
...
:::,
,.o I
u •
-I
:::,
C.
....
:::,
0
._
, 2 3 4 5 6 7 8 9
Engine Speed ( x 1,000 r/min)
Voltage Regulator: -
Type Semi conductor -Short circuit type
Rectifier:
Model/Manufacturer EHU01TR23/MATSUSHITA
Capacity 12A
Battery:
Specific Gravity 1
.280
Horn:
Type
Plane type
Quantity 1 pc.
Model/Manufacturer
YF-12/NIKKO
Maximum Amperage 2.5A
- 14-