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
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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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MOTORCYCLE IDENTIFICATION C9'~
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GENERAL INFORMATION
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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:
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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
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GENERAL SPECIFICAJ]ONS I SPEC I f>f I
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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.
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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.)
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