Yamaha DT200L 1984-1988 User manual

'••^
.
^'
•^- ••-....
39L-28197-20

DT200L
SERVICE MANUAL
©1984 by Yamaha Motor Co., Ltd.
1st Edition, April 1984
All rights reserved. Any reprinting
or unauthorized use without the
written permission of Yamaha Motor
Co.. Ltd. is expressly prohibited.
Printed in Japan

NOTICE
This manual was written by th. Y'. ""haMO:"r, com. p:", y, pr^. a;, ^ ^e.
b;'^'mah:dea-l.,
s .
nd
their
^al'<'ed_me':ha;:".
K,
^nlpls
^teh^ppel,
t.
^ enatir°e'mechanic's education into ^anua^s^ asns^^rr-
^o'ns"u'smg"thisbook'to perform maintenance and •:ePa", son, Yam^";°;0;:
sc^eus°haave"a'basic u'nderstanding of the mechanjcal. co, nclp;s. ^^0;
^uMesTn
vhVe
n°.
"ncrnZr°oy°^7epa"i«eohnology:Wi<h^ts^k^^^^^^^^^
^tueum'Pate'dI
7epal
irs"orservice'to
this
model
may
render
it
unfit
to
use
and/or
unsafe.
Yamaha Motor Company, Ltd. is continu. lly stminlu, ;?1^°"^d^
maan;factu'red by Yamaha. Modifications ^are ^ica"t^c^g^^
s'p:cm:a;ro
n;o7proceduresw,
llbeforw^d. d^.
^^o^^d^.
^^
Zsl
aanl
dw"ill"whe;'e
applicable,
appear
in
future
editions
of
this
manual.
OVERSEAS SERVICE
OVERSEAS OPERATIONS
YAMAHA MOTOR CO., LTD.
HOW TO USE THIS MANUAL
PARTICULARLY IMPORTANT INFORMATION
This material is distinguished by the following notation.
NOTE:
WARNING
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.
A WARNING indicates special procedures that must be follow-
ed to avoid injury to a motorcycle operator or person inspecting
or repairing the motorcycle.

MANUAL FORMAT
All of the pr6cedures 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 inspection operations.
In this revised format, the condition of a faulty component will precede an arrow
symbol and the course of action required will follow the symbol, e. g.,
• Bearings;
Pitting/ Damage-^ Replace.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section for ease
in identifying correct disassembly and assembly procedures.

CD
TSEN
INFO
ARB
INSP
ADJ
(4)
ENG ^, COOL
HAS (^
SYMBOL MARKS
(Refer to the illustration)
Symbol marks W to
tabs to indicate the
content.
;1) General information
(2) Periodic inspection and adjustment
C3) Engine
@ Cooling system
(5) Carburetion
(6) Chassis
(7) Electrical
(§) Appendices
are designed as thumb
chapter's number and
(7)
ELEC
PPX <\
@
<?
c\
Q)
£@3
© . (Q) , @
t^E—
Symbol marks (9) to Q4> indicate specific data as
the following items:
@ Recommended liquid
Recommended grease
Tightening torque
Wear limit
Engine speed
n, v,A
Symbol marks Q^) to l^) in the exploded diagram
indicate grade of lubricant and location of lubrica-
tion point.
Apply engine oil
Apply gear oil
Apply molybdenum disulfide oil
Apply wheel bearing grease
Apply lightweight lithium soap base grease
Apply molybdenum disulfide grease
Apply locking agent (LOCTITE®)
1
[LT]

INDEX
GENERAL INFORMATION
PERIODIC INSPECTIONS
AND ADJUSTMENTS
ENGINE OVERHAUL
COOLING SYSTEM
CARBURETION
CHASSIS
ELECTRICAL
APPENDICES
0
GEN
JlMFO
INSP
ADJ
ENG 3
COOL 4
CARS 5
CHAS Q
ELEC 7
s
APPX 3

GEN
INFO
CHAPTER 1.
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION . .
FRAME SERIAL NUMBER ....
ENGINE SERIAL NUMBER ....
IMPORTANT INFORMATION ...
ALL REPLACEMENT PARTS ...
GASKET, OIL SEALS, AND 0-RINGS .
LOCK WASHER/PLATES AND COTTER PINS
BEARINGS AND OIL SEALS.
CIRCLIPS
1-1
1-1
1-1
1-2
1-2
1-2
1-2
1-3
1-3
SPECIAL TOOLS ..... ... . ... ... ... ... ... 1.4
FOR TUNE UP.................. ....... .... .... .... ... 1.4
FOR ENGINE SERVICE ........... .... .... .... .... ..... 1.5
FOR CHASSIS SERVICE......... . .... ... ... ... ..... 1-6
FOR ELECTRICAL COMPONENTS . ... ... ... ... ... 1-7
1

GEN
INFO
MOTORCYCLE IDENTIFICATION
GENERAL
INFORMATION
MOTORCYCLE IDENTIFICATION
FRAME SERIAL NUMBER
The frame serial number (1) is stamped into the
right side of the steering head pipe.
ENGINE SERIAL NUMBER
The engine serial number (D is stamped into the
elevated part of the left rear section of the engine.
NOTE:
The first three digits of these numbers are for
model identifications; the remaining digits are the
unit production number.
!)
Starting Serial Number:
39L-000101
NOTE:
Designs and specifications are subject to change
without notice.
1-1

IMPORTANT INFORMATION
GEN
INFO
^^
IMPORTANT INFORMATION
ALL REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all
replacements. Use oil and/or grease recom-
mended by Yamaha for assembly and ad-
justment. Other brands may be similar in
function and appearance, but inferior in
quality.
CASKETS, OIL SEALS, AND 0-RINGS
1. All gaskets, seals, and 0-rings should be
replaced when an engine is overhauled. All
gasket surfaces, oil seal lips and 0-rings
must be cleaned.
2. Properly oil all mating parts and bearings dur-
ing reassembly. Apply grease to the oil seal
lips.
OR
ou
ODER
([)
LOCK WASHERS/PLATES AND COTTER
PINS
1. All lock washers/Plates (D and cotter pins
must be replaced when they are removed.
Lock tab(s) should be bent along the bolt or
nut flat(s) after the bolt or nut has been pro-
perly tightened.
1-2

GEN
INFO
IMPORTANT INFORMATION
CD
BEARINGS AND OIL SEALS
1. Install the bearing(s) and oil seal(s) with their
manufacturer's marks or numbers facing
outward. (In other words, the stamped let-
ters must be on the side exposed to view.)
When installing oil seal(s), apply a light
(D Oil seal
coating of light-weight lithium base grease
to the seal lip(s). Oil the bearings liberally
when installing.
(D
Do not use compressed air to spin the bear-
ings dry. This causes damage to the bearing
surfaces.
^>
(D
(S)
(D Bearing
CIRCLIPS
1. All circlips should be inspected carefully
before reassembly. Always replace piston pin
clips after one use. Replace distorted circlips.
When installing a circlip (D, make sure that
the sharp edged corner (2) is positioned op-
posite to the thrust (3) it receives. See the
sectional view.
(4) Shaft
1-3