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Yamaha DT125 DT125RE DT125X 2002-2008 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Yamaha Model: DT125RE, DT125X Model Variant Codes: DT125RE, DT125X Model Years Covered: 2002, 2003, 2004, 2005, 2006, 2007, 2008 👋 Introduction Market Position Segment: Lightweight Dual-Sport / Motocross Competitive Analysis Competitors: KTM EXC series, Honda CR/XR series, Kawasaki KDX series, Suzuki RM series. Key Features Model Focus: The DT125 series represents Yamaha's enduring commitment to the 125cc class, offering robust performance and off-road capability in a user-friendly package. The RE and X variants likely cater to slightly different street-legal and off-road focused configurations. 📋 Manual Details Coverage Areas Primary Coverage: Workshop Service and Repair Page Count Estimated Pages: 300+ Manual Type Type: Comprehensive Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine overhaul, top-end (cylinder, piston, rings), bottom-end (crankshaft, connecting rod, bearings), lubrication system, cooling system (if applicable), fuel system (carburetor, intake), exhaust system. Transmission: Gearbox operation, clutch, shift mechanism, lubrication, troubleshooting. Chassis: Frame, swingarm, suspension (forks, shock absorber), steering system, wheels, bearings. Brakes: Front and rear brake systems (disc brakes likely), hydraulic components, fluid replacement, bleeding, pad/shoe replacement. Electrical System: Ignition system, lighting, charging system (stator, rectifier/regulator), battery, starting system, wiring diagrams, component testing. Fuel System: Carburetor tuning, cleaning, jetting, fuel lines, fuel tank maintenance. Bodywork: Fairings, fenders, seat, handlebars, controls, fasteners. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, chain adjustment, lubrication points, spark plug replacement, air filter cleaning/replacement. Troubleshooting: Diagnostic charts for common problems, symptom-based troubleshooting for engine, electrical, and mechanical issues. Repair: Step-by-step repair instructions for all major components, including disassembly, reassembly, and torquing specifications. Diagnostics: Basic diagnostic procedures, component testing methods. Technical Depth Depth: Comprehensive, from basic owner maintenance to complete engine and chassis rebuilds. 📊 Manual Specifications File Format File Type: PDF Print Quality Quality: High-resolution, clear diagrams and text. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Type: 2-stroke, liquid-cooled, reed valve induction Displacement: 124 cc (approximate, specific variants may differ slightly) Bore X Stroke: 56.5 mm x 50.2 mm (typical for this era DT125) Compression Ratio: Approximately 7.2:1 to 8.0:1 (varies by specific model variant) Performance Horsepower: Approximately 15-18 HP (street-legal variants), higher for off-road focused models. Torque: Approximately 12-15 Nm (varies by model variant) Fuel System Carburetor: Mikuni VM28 (typical for DT125RE/X) Fuel Type: Unleaded gasoline (91 octane or higher recommended) Lubrication System: Autolube (premix system for 2-stroke oil) Ignition Type: CDI (Capacitor Discharge Ignition) 🔧 Transmission Standard Type: 6-speed constant mesh Features Clutch: Wet, multi-disc Drive Type: Chain drive 📐 Dimensions Exterior Overall Length: Approx. 2150 mm (varies by model) Overall Width: Approx. 800 mm (varies by model) Overall Height: Approx. 1200 mm (varies by model) Weights Dry Weight: Approx. 115-125 kg (varies by model) Wet Weight: Approx. 125-135 kg (varies by model) Capacity Fuel Tank Capacity: 10.0 Liters (approx.) Oil Tank Capacity: 1.0 Liters (approx.) for Autolube system 🛡️ Safety Features Ratings Crash Tests: N/A (Motorcycle - manufacturer-specific safety design) Active Features Braking System: Front disc brake, Rear disc brake (common for RE/X variants). ABS not standard. Passive Features Lighting: Headlight, taillight, brake light, turn signals (street-legal variants). 💡 Technology Features Infotainment Features: Basic analog instrumentation (speedometer, tachometer, odometer, trip meter, engine warning light, turn signal indicators). Driver Assistance Features: N/A (Focus on core mechanical and electrical systems). Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change: Every 3,000-5,000 km or annually (transmission oil). Check owner's manual for specifics. Spark Plug Replacement: Every 5,000-8,000 km or as needed based on inspection. Air Filter Cleaning: Every 2,000-3,000 km or more frequently in dusty conditions. Chain Lubrication: Every 500-1,000 km or after riding in wet conditions. Fluid Specifications Engine Oil: Yamalube 2-stroke oil or equivalent API TC, JASO FD approved oil. Transmission Oil: Yamalube Gear Oil 10W-40 or equivalent SAE 80 hypoid gear oil. Brake Fluid: DOT 4 hydraulic brake fluid. Coolant: Yamaha's recommended permanent type coolant or equivalent ethylene glycol-based coolant with anti-rust inhibitors. Known Issues Common Problems: Carburetor gumming if not run regularly, exhaust power valve sticking (on some earlier models, but may be present), clutch wear, fork seal leaks, electrical connector corrosion in wet environments. Preventative Maintenance: Regular cleaning of the carburetor, use of quality 2-stroke oil, proper chain maintenance, and ensuring electrical connections are clean and sealed. 📚 Vehicle History Brand Heritage Heritage: Yamaha has a long and storied history in off-road and dual-sport motorcycles, with the DT lineage dating back decades, known for their reliability and versatility. Model Evolution Evolution: The DT125 platform has seen continuous updates, with the 2002-2008 models representing a more modern iteration, likely incorporating improvements in engine emissions, suspension, and braking compared to earlier generations. The RE and X suffixes typically indicate variations for road legality and off-road focus respectively. Production Manufacturing Locations: Primarily Japan, with potential assembly in other...
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Yamaha DT125 DT125RE DT125X 2002-2008 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
DT125RE, DT125X
Model Variant Codes:
DT125RE, DT125X
Model Years Covered:
2002, 2003, 2004, 2005, 2006, 2007, 2008
👋 Introduction
Market Position
Segment:
Lightweight Dual-Sport / Motocross
Competitive Analysis
Competitors:
KTM EXC series, Honda CR/XR series, Kawasaki KDX series, Suzuki RM series.
Key Features
Model Focus:
The DT125 series represents Yamaha's enduring commitment to the 125cc class, offering robust performance and off-road capability in a user-friendly package. The RE and X variants likely cater to slightly different street-legal and off-road focused configurations.
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop Service and Repair
Page Count
Estimated Pages:
300+
Manual Type
Type:
Comprehensive Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Engine overhaul, top-end (cylinder, piston, rings), bottom-end (crankshaft, connecting rod, bearings), lubrication system, cooling system (if applicable), fuel system (carburetor, intake), exhaust system.
Transmission:
Gearbox operation, clutch, shift mechanism, lubrication, troubleshooting.
Chassis:
Frame, swingarm, suspension (forks, shock absorber), steering system, wheels, bearings.
Brakes:
Front and rear brake systems (disc brakes likely), hydraulic components, fluid replacement, bleeding, pad/shoe replacement.
Electrical System:
Ignition system, lighting, charging system (stator, rectifier/regulator), battery, starting system, wiring diagrams, component testing.
Fuel System:
Carburetor tuning, cleaning, jetting, fuel lines, fuel tank maintenance.
Bodywork:
Fairings, fenders, seat, handlebars, controls, fasteners.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustment, lubrication points, spark plug replacement, air filter cleaning/replacement.
Troubleshooting:
Diagnostic charts for common problems, symptom-based troubleshooting for engine, electrical, and mechanical issues.
Repair:
Step-by-step repair instructions for all major components, including disassembly, reassembly, and torquing specifications.
Diagnostics:
Basic diagnostic procedures, component testing methods.
Technical Depth
Depth:
Comprehensive, from basic owner maintenance to complete engine and chassis rebuilds.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Quality:
High-resolution, clear diagrams and text.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Type:
2-stroke, liquid-cooled, reed valve induction
Displacement:
124 cc (approximate, specific variants may differ slightly)
Bore X Stroke:
56.5 mm x 50.2 mm (typical for this era DT125)
Compression Ratio:
Approximately 7.2:1 to 8.0:1 (varies by specific model variant)
Performance
Horsepower:
Approximately 15-18 HP (street-legal variants), higher for off-road focused models.
Torque:
Approximately 12-15 Nm (varies by model variant)
Fuel System
Carburetor:
Mikuni VM28 (typical for DT125RE/X)
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Lubrication
System:
Autolube (premix system for 2-stroke oil)
Ignition
Type:
CDI (Capacitor Discharge Ignition)
🔧 Transmission
Standard
Type:
6-speed constant mesh
Features
Clutch:
Wet, multi-disc
Drive Type:
Chain drive
📐 Dimensions
Exterior
Overall Length:
Approx. 2150 mm (varies by model)
Overall Width:
Approx. 800 mm (varies by model)
Overall Height:
Approx. 1200 mm (varies by model)
Weights
Dry Weight:
Approx. 115-125 kg (varies by model)
Wet Weight:
Approx. 125-135 kg (varies by model)
Capacity
Fuel Tank Capacity:
10.0 Liters (approx.)
Oil Tank Capacity:
1.0 Liters (approx.) for Autolube system
🛡️ Safety Features
Ratings
Crash Tests:
N/A (Motorcycle - manufacturer-specific safety design)
Active Features
Braking System:
Front disc brake, Rear disc brake (common for RE/X variants). ABS not standard.
Passive Features
Lighting:
Headlight, taillight, brake light, turn signals (street-legal variants).
💡 Technology Features
Infotainment
Features:
Basic analog instrumentation (speedometer, tachometer, odometer, trip meter, engine warning light, turn signal indicators).
Driver Assistance
Features:
N/A (Focus on core mechanical and electrical systems).
Connectivity
Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000-5,000 km or annually (transmission oil). Check owner's manual for specifics.
Spark Plug Replacement:
Every 5,000-8,000 km or as needed based on inspection.
Air Filter Cleaning:
Every 2,000-3,000 km or more frequently in dusty conditions.
Chain Lubrication:
Every 500-1,000 km or after riding in wet conditions.
Fluid Specifications
Engine Oil:
Yamalube 2-stroke oil or equivalent API TC, JASO FD approved oil.
Transmission Oil:
Yamalube Gear Oil 10W-40 or equivalent SAE 80 hypoid gear oil.
Brake Fluid:
DOT 4 hydraulic brake fluid.
Coolant:
Yamaha's recommended permanent type coolant or equivalent ethylene glycol-based coolant with anti-rust inhibitors.
Known Issues
Common Problems:
Carburetor gumming if not run regularly, exhaust power valve sticking (on some earlier models, but may be present), clutch wear, fork seal leaks, electrical connector corrosion in wet environments.
Preventative Maintenance:
Regular cleaning of the carburetor, use of quality 2-stroke oil, proper chain maintenance, and ensuring electrical connections are clean and sealed.
📚 Vehicle History
Brand Heritage
Heritage:
Yamaha has a long and storied history in off-road and dual-sport motorcycles, with the DT lineage dating back decades, known for their reliability and versatility.
Model Evolution
Evolution:
The DT125 platform has seen continuous updates, with the 2002-2008 models representing a more modern iteration, likely incorporating improvements in engine emissions, suspension, and braking compared to earlier generations. The RE and X suffixes typically indicate variations for road legality and off-road focus respectively.
Production
Manufacturing Locations:
Primarily Japan, with potential assembly in other regions.
🏆 Awards & Recognition
Recognitions
Awards:
While specific awards for the 2002-2008 DT125RE/X are not widely publicized, the DT series has consistently been recognized for its reliability, value, and off-road prowess in its segment over its production lifespan.
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