Yamaha DT200L 1984-1988 User manual

'••^
.
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•^- ••-....
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

SPECIAL TOOLS
GEN
INFO
^s
SPECIAL TOOLS
The proper special tools are necessary for com-
plete and accurate tune-up and assembly. Using
the correct special tool will help prevent damage
caused by the use of improper tools or improvis-
ed techniques.
FOR TUNE UP
1. Inductive Tachometer
P. /N 90890-03082
This tool is needed for detecting engine rpm.
2. Inductive Timing Light
P/N 90890-03109
This tool is necessary for adjusting timing.
3. Fuel Level Gauge
P/N 90890-01312
This gauge is used to measure the fuel level in the float
chamber.
1-4

GEN
INFO
SPECIAL TOOLS
4. Cooling System Tester
P/N 90890-01325
This tester is needed for checking the cooling system.
FOR ENGINE SERVICE
1. Universal Clutch Holder
P/N 90890-04086
This tool is used to hold the clutch when removing
or installing the clutch boss locknut.
2. Rotor Holding Tool
P/N 90890-01235
0
This tool is used to hold the rotor when removing or
installing the flywheel magneto securing nut.
3. Rotor Fuller
P/N 90890-01189
This tool is needed to remove the flywheel magneto.
4. Crank Installer Pot
P/N 90890-01274
This tool is used to install the crankshaft.
1-5

CD
GEN
SPECIAL TOOLS INFO
5. Crank Installer Bolt
P/N 90890-01275 -
Crank Installer Adapter
P/N 90890-01278 -
This tool is used to install the crankshaft.
6. Crankcase Separating Tool
P/N 90890-01135
This tool is needed to separate the crankcases.
7. Piston Pin Fuller
P/N YU-01304
CD
5^
This tool is used to remove the piston pin.
FOR CHASSIS SERVICE
1. T-Handle
P/N 90890-01326 -
Damper Rod Holder
P/N 90890-01294 -
This tool is used to loosen and tighten the front fork
cylinder holding bolt.
2. Front Fork Seal Driver (Weight)
P/N 90890-01367 -
Adapter
P/N 90890-01370 -
These tools are used when installing the fork seal.
1-6

GEN
INFO
SPECIAL TOOLS
.
3. Ring Nut Wrench
P/N 90890-01268
This tool is used to loosen and tighten the steering ring
nut.
FOR ELECTRICAL COMPONENTS
1. Electro Tester
P/N 90890-03021
2D! BA
es
^
This instrument is necessary for checking the ignition
system components.
^
^
^
2. Pocket Tester
P/N 90890-03104
^
This instrument is invaluable for checking the electrical
system.
1-7

INSP
ADJ
CHAPTER 2.
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION
PERIODIC MAINTENANCE/LUBRICATION
2-1
2-1
ENGINE.
IDLING SPEED ADJUSTMENT...
THROTTLE CABLE ADJUSTMENT
AIR FILTER CLEANING
2-2
.
2-2
2-2
.
2-3
MINIMUM PUMP STROKE ADJUSTMENT ... ... ... .... .. 2-4
AUTOLUBE PUMP AIR BLEEDING .......... ... ... ... .. 2-5
ENGINE OIL LEVEL INSPECTION .................................... 2-6
TRANSMISSION OIL LEVEL INSPECTION ............................. 2-8
TRANSMISSION OIL REPLACEMENT................................. 2-9
HANDLING NOTES OF COOLANT.......... ........... ......... 2-10
COOLANT LEVEL INSPECTION . . .... ....... .... ... 2-10
CHASSIS ...................... ... .......... ... .... 2-11
FUEL COCK CLEANING ....... .... ... ... ........ . 2-11
FRONT BRAKE ADJUSTMENT . . .... ... ... ... ... . 2-12
FRONT BRAKE PAD INSPECTION ... ......... ... .... .. 2-13
BRAKE FLUID LEVEL INSPECTION ... ... ... .... ... .. 2-13
REAR BRAKE ADJUSTMENT........ .... ... .... ... .. 2-14
REAR BRAKE LINING INSPECTION .. ... ... ... ... ... 2-14
CLUTCH ADJUSTMENT............. ... ... .... ... .... 2-15
DRIVE CHAIN TENSION CHECK ..... ... ... ... .... .... 2-17
DRIVE CHAIN TENSION ADJUSTMENT ... ... ... ... .... 2-17
DRIVE CHAIN LUBRICATION ...... .... ... ... ... ... 2-18
FRONT FORK OIL CHANGE ....... ..... ... ... ... ..... 2-19
STEERING HEAD INSPECTION .... .... ... ... .... ... 2-21
STEERING HEAD ADJUSTMENT.
REAR SHOCK ABSORBER ADJUSTMENT
WHEEL BEARINGS CHECK
CABLE INSPECTION AND LUBRICATION
TIRES CHECK ....
WHEELS CHECK
ELECTRICAL
IGNITION TIMING CHECK ...
BATTERY INSPECTION
SPARK PLUG INSPECTION
BRAKE LIGHT SWITCH ADJUSTMENT
HEADLIGHT BULB REPLACEMENT .
HEADLIGHT BEAM ADJUSTMENT.
FUSE INSPECTION
2-22
2-23
2-25
2-25
.
2-26
2-28
2-30
.
2-30
2-30
.
2-32
.
2-34
.
2-34
.
2-35
2-35
2

INSP • INTRODUCTION
ADJ ^\ /PERIODIC MAINTENANCE/LUBRICATION
PERIODIJC INSPECTIONS AND ADJUSTMENTS
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 service technicians
should be familiar with this entire chapter.
PERIODIC MAINTENANCE/LUBRICATION
ITEM
Spark plug(s)
Air filter
Carburetor*
Fuel line*
Transmission oil
Autolube pump*
Brake*
Clutch*
Rear arm pivot shaft*
Rear suspension
link pivots*
Wheels*
Wheel bearings*
Steering bearing*
Front forks*
Rear shock absorber*
Cooling system*
Drive chain
Fittings/Fasteners*
Battery*
REMARKS
Check/Clean or replace.
Clean. Replace if necessary.
Check/Adjust/idle speed, starter operation.
Check fuel hose for cracks or damage.
Replace (Warm engine before draining) every, 24, 000
(16, 000) or 24 months.
Check/Adjust*/Air bleeding.*
Check operation/fluid leakage/See NOTE/Adjust if
necessary.
Check operation. /Adjust if necessary.
Check rear arm assembly for looseness.
Moderately repack. ***
Check operation. Moderatery repack. ***
Check balance/damage/runout/spoke tightnes.
Check bearings assembly for looseness/damage.
Replace if damaged.
Check bearings assembly for looseness. Moderately
repack every 24, 000 (16, 000) or 24 months. **
Check operation/oil leakage.
Check operation/oil leakage.
Check/Repair as required/Replace coolant every 24, 000
(16, 000) or 24 months.
Check tension/alignment/clean/lube.
Check all chassis fittings and fasteners.
Check specific gravity. Check breather pipe for proper
operation.
It is recommended that these items be serviced by a Yamaha dealer.
Medium weight wheel bearing grease.
Lithium soap base grease.
Unit: km (mi)
EVERY
BRnEAKR^ 6, 000(4, 000) 12, 000(8, 000)
or 6 months or 12 months
0
0
REPLACE
0
0
CHECK
CHECK
CHECK
0
0
0
0
0
CHECK
0
0
0
0
0
0
0
0
0
CHECK
EVERY 500 (300)
0
0
0
0
0
0
CHECK
0
0
0
0
0
0
0
CHECK
0
0
CHECK
0
0
NOTE:
B1rakeW'^n
r<SSg
the
master
cylinder
or
caliper
cylinde,,
replace
the
brake
fluid.
Normally
check
the brake fuild level and add the fluid as required.
2. On the inner"parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.
2-1

IDLING SPEED ADJUSTMENT INSP
/THROTTLE CABLE ADJUSTMET ADJ
ENGINE
Idling Speed Adjustment
1. Remove:
• Rear shock absorber gas chamber
2. Tighten:
• Pilot air screw (lightly) (D
3. Loosen:
• Pilot air screw
Back it out from its lightly seated
position.
CD Pilot air screw
(2) Throttle stop screw
Standard Turned Out: 1 and 1/2
4. Start the engine, and let it warm up.
5. Adjust:
• Idling speed
Turn the throttle stop screw (2) to adjust.
^
Idling speed: 1, 350 r/min
6. Install:
• Rear shock absorber gas chamber
NOTE:
Insert the projection on the gas chamber into the
hole on the gas chamber bracket.
Throttle Cable Adjustment
NOTE:
Before adjusting the throttle cable free play, the
engine idling speed should be adjusted.
'^) Locknut
Adjuster
(a) Free play
2-2

INSP
ADJ
AIR FILTER CLEANING
1
1. Loosen:
• Locknut
2. Adjust:
• Free play (aj
^ Free play. 2 ~5mmt0. 08~0. 20 in)
3. Tighten:
• Locknut®
Air Filter Cleaning
1. Remove:
• Seat
• Air filter case cover
2. Remove:
• Air filter element (D
The engineshould never be run without the
airdeaner element; excessive piston and/or
cylinder wear may result.
3. Clean:
• Air filter element
Clean it with solvent.
NOTE:
After cleaning, remove the remaining solvent by
squeezing the element.
4. Inspect:
• Element
Damage -^ Replace.
5. Apply:
• SAE 10W30 motor oil
6. Squeeze out the excess oil.
NOTE:
The element should be wet but not dripping.
2-3

INSP
MINIMUM PUMP STROKE ADJUSTMENT ADJ
7. Install:
» • Air filter element
NOTE:
Make saure its sealing surface matches the seal-
ing surface of the case so there is no air leak.
• Air filter case cover
• Seat
Minimum Pump Stroke Adjustment
1. Remove:
• Oil pump cover
2. While running the engine at idle, observe
the pump adjust plate carefully. Stop the
engine moment that the adjust plate moves
out to its limit.
3. Measure:
• Gap (Between the raised boss on the,
pump adjust pulley and adjust plate)
Minimum Pump Stroke:
0. 35-0. 40 mm (0. 014-0. 016 in)
NOTE:
When inserting the thickness gauge between the
adjust plate and the adjust pulley, be careful so
that neither the plate nor the pulley is moved. In
other words, do not force the thickness gauge
into the gap.
(1) Thickness gauge
4. Repeat steps "2" and "3" above a few times.
When the gap measured is the largest, the
pump stroke is considered to be at a
minimum.
5. If clearance is not correct, adjust as follows:
2-4

INSP
ADJ
AUTOLUBE PUMP AIR BLEEDING
a. Remove:
• LocknutQ)
• Spring Washer(2)
• Adjust plate (3)
b. Remove or add:
• Adjust shim (4)
c. Install:
• Components in above list (step "a'
d. Measure:
• Gap
Autolube Pump Airjileeding
The Autolube pump and delivery line must be bl-
ed on the following occasions:
• Setting up a new motorcycle out of the
crate.
• Whenever the Autolube tank has run
dry.
• Whenever any portion of the Autolube
system is disconnected.
1. Bleeding the pump case and/or oil pipe
a. Remove:
• Pump cover
• Bleed screw
b. Keep the oil running out until air bubbles
disappear.
c. Inspect:
• Bleed screw gasket
Damage - Replace
d. Install:
• Components in above list (step a
2-5