FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the DT125R
’99. For complete information on service procedures, it is necessary to use this Supplementary Service
Manual together with following manual:

DT125R SERVICE MANUAL: 3BN-ME1

DT125R /DT125R ELECTRIC SUPPLEMENTARY SERVICE MANUAL: 3MB-AE1
DT125R /DT125RE SUPPLEMENTARY SERVICE MANUAL: 3BN-AE2
DT125R /DT125RE SUPPLEMENTARY SERVICE MANUAL: 3BN-AE3

DT125R
SUPPLEMENTARY
SERVICE MANUAL
1998 by Yamaha Motor Co., Ltd.
1st Edition, October 1998
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
 NOTICE
This manual was written by Yamaha Motor Company Ltd. primarily for use by Yamaha dealers and qualified
mechanics. It is not possible to put an entire mechanic’s education into one manual, so persons using this
book to perform maintenance and repairs on Yamaha motorcycles should have a basic understanding of
the mechanical concepts and procedures inherent in motorcycle repair technology. Without such knowl-
edge, attempted repairs or service to the motorcycle may render it unfit to use and/or unsafe.
Yamaha Motor Company Ltd. is continually striving to improve all models manufactured by Yamaha. Modifi-
cations and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha
dealers and will, where applicable, appear in future editions of this manual.

PARTICULARLY IMPORTANT INFORMATION

This material is distinguished by the following notation.

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 inspecting or repairing the motor-
cycle.

CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to
the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or cleaer.

 HOW TO USE THIS MANUAL
CONSTRACTION OF THIS MANUAL
This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)

1st title 1 : This is a chapter with its symbol on the upper right of each page.

2nd title 2 : This title appears on the upper of each page on the left of the chapter symbol. (For
the chapter “Periodic inspection and adjustment” the 3rd title appears.)

3rd title 3 : This is a final title.

MANUAL FORMAT
All of the procedures 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 inspections.
A set of particularly important procedure 4 is placed between a line of asterisks “ ” with each procedure
preceded by “
”.

IMPORTANT FEATURES
 Data and a special tool are framed in a box preceded by a relevant symbol 5 .
 An encircled numeral 6 indicates a part name, and an encircled alphabetical letter data or an alignment
mark 7 , the others being indicated by an alphabetical letter in a box 8 .
 A condition of a faulty component will precede an arrow symbol and the course of action required the
symbol 9 .

EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct
disassembly and assembly procedures.
ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols 1 to 9 are designed as
thumb tabs to indicate the chapter’s number and
content.
1 General information
2 Specifications
3 Periodic inspection and adjustment
4 Engine
5 Cooling system
6 Carburetion
7 Chassis
8 Electrical
9 Troubleshooting

Illustrated symbols 10 to 16 are used to identify

the specifications appearing in the text.
10 Filling fluid
11 Lubricant
12 Special tool
13 Tightening
14 Wear limit, clearance
15 Engine speed
16 Ω, V, A

Illustrated symbols 17 to 23 in the exploded dia-

gram indicate grade of lubricant and location of lu-
brication point.
17 Apply engine oil
18 Apply gear oil
19 Apply molybdenum disulfide oil
20 Apply wheel bearing grease
21 Apply lightweight lithium-soap base grease
22 Apply molybdenum disulfide grease
23 Apply locking agent (LOCTITE)
 CONTENTS

GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
FRAME SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5

SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5

MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6

PERIODIC INSPECTION AND ADJUSTMENT

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7

PERIODIC MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . E-7

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8
AUTOLUBE PUMP AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8

ELECTRICAL
DT125R CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8
COLOR CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9

IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9

DT125R ’99 WIRING DIAGRAM

 GEN
MOTORCYCLE IDENTIFICATION INFO
GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION
FRAME SERIAL NUMBER
The frame serial number 1 is stamped into the
right side of the steering head pipe.

MODEL LABEL
The model label 1 is affixed to the frame.
This information will be needed to order spare
parts.

–1–
 GENERAL SPECIFICATIONS SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS
Model DT125R
Model Code Number 3RMF (F)
3RMD (G)
3RME (GB) (N) (S) (SF) (G) (B)
(SP) (P) (I) (GR)
4DJ9 (H) (A)
Dimensions
Overall length 2170 mm (3RMD) (3RME) (3RMF)
2235 mm (4DJ9)
Basic Weight:
With Oil and Full Fuel Tank 127 kg (3RMD) (3RME) (3RMF)
129 kg (4DJ9)
Engine:
Engine Type Liquid cooled 2-stroke, gasoline
Induction System Reed valve
Cylinder Arrangement Single cylinder, Forward inclined
Displacement 124 cm3
Bore
Stroke 56.0
50.7 mm
Compression Ratio 6.7 : 1 (4DJ9)
6.5 : 1 (3RMD) (3RME) (3RMF)
Starting System Kick starter
Lubrication System Separate lubrication (Yamaha Autolube)
Carburetor:
Type/Quantity TM28SS/1 pc.
Manufacturer MIKUNI
Spark Plug:
Type/Quantity BR8ES/1 pc. (4DJ9)
BR9ES/1 pc. (3RMD) (3RME) (3RMF)
Manufacturer NGK
Plug Gap 0.7  0.8 mm

–2–
 MAINTENANCE SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONS
ENGINE
Carburetor:
I.D. Mark 3RM02 (3RMD) (3RME) (3RMF) 4DJ02 (4DJ9)
Main Jet (M.J.) #210 (4DJ9) #240 (3RMD) (3RME) (3RMF)
Air Jet (A.J.) ø0.7
Jet Needle-Position (J.N.) 5J25-4 (3RMD-E-F) 5J25-3 (4DJ9)
Needle Jet (N.J.) Q-2
Cutaway (C.A.) 2.5
Pilot Outlet (P.O.) 0.6
Pilot Jet (P.J.) #17.5 (4DJ9) #25 (3RMD-E-F)
Air Screw (A.S.) 1-1/4 (3RMD-E-F) 1-5/8 (4DJ9)
Bypass 1 (B.P.1) ø1.6
Valve Seat Size (V.S.) ø2.8
Starter Jet (G.S.) #40
Power Jet (PW.J.) #60 (4DJ9) #95 (3RMD-E-F)
Fuel Level (F.L.) –0.5
+1.5 mm
Float Height (F.H.) 15.5
16.5 mm
Idling Speed 1,300
1,400 r/min
Lubrication System:
Autolube Pump:
Color Code Green (3RME-D) (4DJ9) Red (3RMF)
Minimum Stroke 0.20
0.24 0.20
0.24
Maximum Stroke 1.35
1.49 2.72
2.86
Minimum Output 0.38
0.46 cm3 /200 stroke 0.38
0.46 cm3 /200 stroke
Maximum Output 2.59
2.86 cm3 /200 stroke 5.23
5.5 cm3 /200 stroke
Pulley Adjusting Mark Auto adjuster

–3–
 MAINTENANCE SPECIFICATIONS SPEC
ELECTRICAL

Model DT125R
CDI:
Magneto Model/Manufacturer F3RM/YAMAHA
C.B.I. Unit Model/Manufacturer 3RM-10/YAMAHA (3RMD)
3RM-20/YAMAHA (3RME)
3RM-30/YAMAHA (4DJ9) (3RMF)
Source Coil Resistance 688
1,032 Ω at 20
C
(Blank/Red – Green/White)
Spark Plug Cap:
Type Resin type
Resistance 5 kΩ
Charging System: C.D.I. magneto
C.D.I. magneto:
Model/Manufacturer F3RM/YAMAHA
Rectifier/Regulator
Type Semi-conductor-Short circuit type
Model/manufacturer SH671-12/SHINDENGEN
Capacity 8A
Flasher Relay:
Type Full transistor type
Model/Manufacturer FE246BH/DENSO
Thermo Unit: 2YK/NIPPON SEKI
Model/Manufacturer

–4–
 INTRODUCTION/ INSP
PERIODIC MAINTENANCE AND LUBRICATION ADJ
PERIODIC INSPECTION AND ADJUSTMENT
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 serviced technicians
should be familiar with this entire chapter.

PERIODIC MAINTENANCE AND LUBRICATION

EVERY
6,000 km 12,000 km
Initial or or
No. ITEM CHECKS AND MAINTENANCE JOBS
(1,000 km) 6 months 12 months
(Whichever (Whichever
comes first) comes first)

Check fuel hoses for cracks or damage.
1 * Fuel line



Replace if necessary.

Check condition.
2 Spark plug




Clean, regap or replace if necessary.
3 Air filter
Clean or replace if necessary.



Check electrolyte level and specific gravity.
4 * Battery
Correct or recharge if necessary.



Make sure that the breather hose is properly routed.

Check operation.
5 Clutch




Adjust or replace cable.

Check operation, fluid level and vehicle for fluid
leakage. (See NOTE)
6 * Front brake




Correct accordingly.

Replace brake pads if necessary.

Check operation, fluid level and vehicle for fluid
leakage. (See NOTE)
7 * Rear brake




Correct accordingly.

Replace brake pads if necessary.

Check balance, runout, spoke tightness and for
8 * Wheels damage.



Tighten spokes and rebalance, replace if necessary.

Check tread depth and for damage.

Replace if necessary.
9 * Tires



Check air pressure.

Correct if necessary.

Check bearing for looseness or damage.
10 * Wheel bearings



Replace if necessary.

Check swingarm pivoting point for play.
11 * Swingarm



Correct if necessary.

Check chain slack.

Adjust if necessary. Make sure that the rear wheel is Every 500 km and after washing
12 Drive chain
properly aligned the motorcycle or riding in the rain

Clean and lubricate.

Check bearing play and steering for roughness.

Correct accordingly.
13 * Steering bearings



Lubricate with lithium soap base grease every 24,000
km or 24 months (whichever comes first).

Make sure that all nuts, bolts and screws are properly
14 * Chassis fasteners tightened.



Tighten if necessary.

Check operation.
15 Sidestand



Lubricate and repair if necessary.

–5–
 INSP
PERIODIC MAINTENANCE AND LUBRICATION ADJ
EVERY
6,000 km 12,000 km
Initial or or
No. ITEM CHECKS AND MAINTENANCE JOBS
(1,000 km) 6 months 12 months
(Whichever (Whichever
comes first) comes first)

Check operation.
16 * Sidestand switch




Replace if necessary.

Check operation and for oil leakage.
17 * Front fork



Correct accordingly.
Rear shock absorber
Check operation and shock absorber for oil leakage.
18 *


assembly
Replace shock absorber assembly if necessary.
Rear suspension
relay arm and
Check operation.
19 *


connecting arm
Correct if necessary.
pivoting points

Check engine idling speed and starter operation.
20 * Carburetor




Adjust if necessary.

Check operation.
21 * Autolube pump
Correct if necessary.




Bleed if necessary.

Check oil level and vehicle for oil leakage.

Correct accordingly.
22 Transmission oil




Change oil at initial 1,000 km and thereafter every
24,000 km or 24 months (whichever comes first).

Check coolant level and vehicle for coolant leakage.

Correct if necessary.
23 * Cooling system



Change coolant every 24,000 km or 24 months
(whichever comes first).

* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.
NOTE:

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

Hydraulic brake system

When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the
brake fluid level regularly and fill as required.

Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.

Replace the brake hoses every four years or if cracked or damaged.

–6–
 INSP
ENGINE ADJ
ENGINE
AUTOLUBE PUMP AIR BLEEDING
NOTE:
The Autolube pump and delivery lines must be
bled on the following occasions:

Setting up a new motorcycle out of the create.

Whenever the oil tank has run dry.

Whenever any portion of the engine oil system is
disconnected.

1. Remove:

Autolube pump cover
2. Fill:

Oil tank 1

Yamaha Oil 2T or Air-Cooled

2-Stroke Engine Oil

2 Oil tank filler cap

3. Air bleed:

Pump case and/or oil pipe

Air bleeding steps:

Remove the bleed screw 1 .

Keep the oil running out until a bubbles disap-
pear.

When air bubbles are expelled completely,
tighten the bleed screw.
NOTE:

Check the bleed screw gasket, and if dam-
aged, replace with a new one.

Place a rag or oil pan under the autolube
pump to catch oil.

–7–
 DT125R CIRCUIT DIAGRAM ELEC

ELECTRICAL
DT125R CIRCUIT DIAGRAM

–8–
 DT125R CIRCUIT DIAGRAM ELEC
1 CDI magneto 19 Turn indicator light
2 Neutral switch 20 Neutral relay
3 Rectifier / regulator 21 Sidestand switch
4 Fuse 22 Oil level switch
5 Battery 23 Rear brake switch
6 Main switch 24 Front brake switch
7 “ENGINE STOP” switch 25 Tail / brake light
8 Servomotor 26 Flasher relay
9 CDI unit 27 Horn
10 Ignition coil 28 Flasher light
11 Read switch 29 “Turn” switch
12 Meter light 30 “Horn” switch
13 Meter light 31 “Lights” (Dimmer) switch
14 Neutral indicator light 32 “Lights” switch
15 Oil level indicator light 33 Handlebar switches (left)
16 High beam indicator light 34 Auxiliary light
17 Engine temperature gauge 35 Headlight
18 Thermo unit

COLOR CODE

B Black Ch Chocolate W/R White/Red

R Red Dg Dark green W/L White/Blue
O Orange Sb Sky blue Y/R Yellow/Red
L Blue Br Brown G/R Green/Red
P Pink L/Y Blue/Yellow G/Y Green/Yellow
Y Yellow B/Y Black/Yellow G/W Green/White
G Green B/W Black/White Br/W Brown/White
W White B/R Black/Red L/R Blue/Red

–9–
 IGNITION SYSTEM ELEC
IGNITION SYSTEM
TROUBLESHOOTING
Check:
1. Sidestand switch
2. Neutral switch
3. Wiring connection (Ignition system)

1. Sidestand switch

Disconnect the sidestand switch leads from
the wireharness.

Connect the Pocket Tester (Ω
1) to the side-
stand switch.
Tester (+) Lead
Black 1 Terminal
Tester (–) Lead
Black 2 Terminal

Move the sidestand to up position and down

position.

Check the sidestand switch for continuity.
Sidestand Good
Bad condition
position condition BAD CONDITION
Up 


Down


: Continuity
: No continuity Replace “Sidestand” switch.

GOOD
CONDITION

–10–
 IGNITION SYSTEM ELEC

2. Neutral switch

Disconnect the Neutral relay coupler 1 from
the wireharness.

Connect the Pocket Tester (Ω
1) to the neu-
tral switch lead.
Tester (+) Lead
Sky blue 2 lead
Tester (–) Lead
Frame Ground

Shift the transmission in neutral and gear.

Check the neutral switch for continuity.
Transmission Good
position
Bad condition
condition BAD CONDITION
Neutral 


Gear


: Continuity
: No continuity Replace neutral switch.

GOOD
CONDITION

–11–
 IGNITION SYSTEM ELEC

3. Neutral relay
S Disconnect the neutral relay from the wirehar-
ness.
S Connect the pocket tester (Ω
1) and battery
(12 V) to the neutral relay.

NO CONTINUITY

S Check the neutral relay for continuity. Neutral relay is faulty, replace it.

CONTINUITY

4. Wiring connection POOR CONNECTION

S Check the entire ignition system for connec-

tions.
Refer to the “WIRING DIAGRAM” section. Correct.

CORRECT

Replace ignition control unit.

–12–
DT125R ’99 WIRING DIAGRAM
1 CDI magneto
2 Neutral switch
3 Rectifier/ regulator
4 Fuse
5 Battery
6 Main switch
7 “ENGINE STOP” switch
8 Servomotor
9 CDI unit
10 Ignition coil
11 Read switch
12 Meter light
13 Meter light
14 Neutral indicator light
15 Oil level indicator light
16 High beam indicator light
17 Engine temperature gauge
18 Thermo unit
19 Turn indicator light
20 Neutral relay
21 Sidestand switch
22 Oil level switch
23 Rear brake switch
24 Front brake switch
25 Tail/ brake light
26 Flasher relay
27 Horn
28 Flasher light
29 “Turn” switch
30 “Horn” switch
31 “Lights” (Dimmer) switch
32 “Lights” switch
33 Handlebar switches (left)
34 Auxiliary light
35 Headlight

COLOR CODE
B ...... Black P ...... Pink Ch . . . . Chocolate L/Y . . . . Blue / Yellow W/R . . . White / Red G/Y . . . Green / Yellow
R...... Red Y ...... Yellow Dg . . . . Dark green B/Y . . . . Black / Yellow W/L . . . White / Blue G/W . . . Green / White
O ..... Orange G ..... Green Sb . . . . . Sky blue B/W . . . Black / White Y/R. . . . Yellow / Red Br / W . . Brown / White
L ...... Blue W ..... White Br . . . . . Brown B/R. . . . Black / Red G/R . . . Green / Red L/R . . . . Blue / Red