Yamaha DT125RE 2005 User manual

SERVICE MANUAL
DT125RE 1D01-AE1
DT125X
2005

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.
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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.
tt
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

1

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.

