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Yamaha Manuals
Motorcycle
DT230 4TP3-AE1
Service manual
Yamaha DT230 4TP3-AE1 Service Manual
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Important Manual Information
How to Use this Manual
Symbols
Table of Contents
Contents
General Information
Motorcycle Identification
Vehicle Identification Number
Model Code
Features
3-Dimensional Traction Control System
Traction Control System
Important Information
Preparation for Removal and Disassembly
Replacement Parts
Gaskets, Oil Seals and O-Rings
Lock Washers/Plates and Cotter Pins
Bearings and Oil Seals
Circlips
Checking the Connections
Special Tools
Specifications
General Specifications
Engine Specifications
Chassis Specifications
Electrical Specifications
Conversion Table/Tightening Torques
General Tightening Torques
Engine Tightening Torques
Chassis Tightening Torques
Lubrication Points and Lubricant Types
Engine Lubrication Points and Lubricant Types
Chassis Lubrication Points and Lubricant Types
Cable Routing
Periodic Checks and Adjustments
Introduction/Periodic Maintenance and Lubrication Intervals
Air Scoop, Side Covers, Seat, Fuel Tank and Muffler
Adjusting the Engine Idling Speed
Engine
Adjusting the Engine Idling Speed/Adjusting the Throttle Cable Free Play
Carburetor Side
Adjusting the Throttle Cable Free Play/Adjusting the Oil Pump Cable
Handlebar Side
Bleeding the Oil Pump/Checking the Spark Plug
Checking the Spark Plug/Checking the Transmission Oil Level
Checking the Transmission Oil Level/Changing the Transmission Oil
Recommended Oil
Changing the Transmission Oil/Adjusting the Clutch Cable Free Play
Adjusting the Clutch Cable Free Play/Cleaning the Air Filter Element
Cleaning the Air Filter Element
Checking the Carburetor Joint and Intake Manifold/Checking the Fuel Hoses/Checking the Crankcase Breather Hose/Checking the Exhaust System
Checking the Exhaust System/Checking the Coolant Level
Checking the Coolant Level/Changing the Coolant
Changing the Coolant
Recommended Antifreeze
Handling Notes for Coolant
Adjusting the Front Brake/Adjusting the Rear Brake
Chassis
Adjusting the Rear Brake
Checking the Brake Fluid Level
Checking the Brake Pads/Adjusting the Rear Brake Light Switch
Checking the Brake Hoses/Bleeding the Hydraulic Brake System
Bleeding the Hydraulic Brake System
Adjusting the Drive Chain Slack
Adjusting the Drive Chain Slack/Lubricating the Drive Chain
Lubricating the Drive Chain/Checking and Adjusting the Steering Head
Checking and Adjusting the Steering Head
Lower Ring Nut
Checking the Front Fork/Adjusting the Front Fork Legs
Adjusting the Front Fork Legs/Adjusting the Rear Shock Absorber Assembly
Adjusting Positions
Spring Preload
Adjusting the Rear Shock Absorber Assembly
Rebound Damping
Compression Damping
Checking the Tires
Front Tire
Checking the Tires/Checking and Tightening the Spokes
Rear Tire
Checking and Tightening the Spokes/Checking and Lubricating the Cables
Lubricating the Levers and Pedals/Lubricating the Sidestand/Lubricating the Rear Suspension
Checking and Charging the Battery
Electrical System
First Aid in Case of Bodily Contact
External
Caution
Charging Method Using a Variable Voltage Charger
Charging Method Using a Constant Voltage Charger
Checking and Charging the Battery/Checking the Fuses
Checking the Fuses
Replacing the Headlight Bulb/Adjusting the Headlight Beam
Overhauling the Engine
Cables and Brake Pedal
Servomotor, Drive Sprocket, Leads and Engine
Removing the Pivot Shaft
Installing the Engine
Cylinder Head, Cylinder, Piston and YPVS Valve
YPVS Valve
Removing the Cylinder Head
Removing the Cylinder and Piston
Removing the YPVS Valve
Checking the Cylinder Head
Checking the Cylinder and Piston
Checking the Piston Rings
Piston Ring Side Clearance
Piston Ring End Gap
Checking the Piston Pin
Installing the YPVS Valve
Installing the Piston and Cylinder
Clutch
Clutch Cover
Pull Lever
Removing the Clutch and Primary Drive Gear
Checking the Friction Plates
Friction Plate Thickness
Checking the Clutch Plates
Checking the Clutch Springs
Checking the Clutch Housing and Clutch Boss
Checking the Pressure Plate
Checking the Pull Lever Shaft and Pull Rod
Checking the Primary Drive
Installing the Clutch
Shift Shaft
Checking the Shift Shaft
Checking the Stopper Lever
Installing the Shift Shaft
Installing the Shift Pedal
Oil Pump and Oil Pump Drive Gear
Checking the Oil Pump Drive Gear
Checking the Worm Shaft
Installing the Oil Pump
Starter Clutch and CDI Magneto
Stator
Rotor and Starter Clutch
Removing the Rotor
Checking the Starter Clutch
Installing the Starter Clutch
Installing the Rotor
Balancer Weight Gears
Removing the Balancer Weight Gears
Checking the Balancer Weight Gears
Installing the Balancer Weight Gears
Crankcase and Crankshaft
Balancer Weight and Crankshaft Assembly
Disassembling the Crankcase
Removing the Crankshaft Assembly
Checking the Crankshaft and Connecting Rod
Checking the Crankcase
Assembling the Crankcase
Crankcase Bolts
Checking the Reed Valve
Checking the Bearings and Oil Seals
Installing the Crankshaft
Transmission, Shift Cam and Shift Fork
Drive Axle and Main Axle Assembly
Removing the Transmission
Checking the Shift Forks
Checking the Shift Drum Assembly
Checking the Transmission
Installing the Transmission
Cooling System
Radiators
Checking the Radiator
Installing the Radiator
Thermostat Assembly
Checking the Thermostat
Installing the Thermostat Assembly
Water Pump
Checking the Water Pump
Installing the Water Pump
Carburetor
Carburetor Parts View
Checking the Carburetor
Assembling the Carburetor
Float Height
Installing the Carburetor
Engine Idling Speed
Measuring and Adjusting the Fuel Level
Chassis
Front Wheel and Brake Disc
Removing the Front Wheel
Disassembling the Front Wheel
Checking the Front Wheel
Checking the Brake Discs
Assembling the Front Wheel
Installing the Front Wheel
Adjusting the Front Wheel Static Balance
Rear Wheel, Brake Disc, and Rear Wheel Sprocket
Removing the Rear Wheel
Checking the Rear Wheel
Checking and Replacing the Rear Wheel Sprocket
Installing the Rear Wheel
Adjusting the Rear Wheel Static Balance
Drive Chain Slack
Front and Rear Brakes
Front Brake Pads
Rear Brake Pads
Replacing the Front Brake Pads
Replacing the Rear Brake Pads
Bleed Screw
Front Brake Master Cylinder
Rear Brake Master Cylinder
Removing the Front Brake Master Cylinder
Removing the Rear Brake Master Cylinder
Checking the Front and Rear Brake Master Cylinder
Assembling and Installing the Front Brake Master Cylinder
Recommended Brake Fluid
Assembling the Rear Brake Master Cylinder
Front Brake Caliper
Rear Brake Caliper
Disassembling the Front Brake Caliper
Disassembling the Rear Brake Caliper
Checking the Front and Rear Brake Calipers
Assembling and Installing the Front Brake Caliper
Assembling and Installing the Rear Brake Caliper
Front Fork
Removing the Front Fork Legs
Disassembling the Front Fork Legs
Checking the Front Fork Legs
Assembling the Front Fork Legs
Spring Free Length Limit
Installing the Front Fork Legs
Handlebar
Removing the Handlebar
Checking the Handlebar
Installing the Handlebar
Steering Head
Front Fender, Headlight and Meter
Lower Bracket
Removing the Lower Bracket
Checking the Steering Head
Installing the Steering Head
Rear Shock Absorber Assembly
Handling the Rear Shock Absorber and Gas Cylinder
Disposing of a Rear Shock Absorber and Gas Cylinder
Removing the Rear Shock Absorber Assembly
Checking the Rear Shock Absorber Assembly and Gas Cylinder
Installing the Rear Shock Absorber Assembly
Swingarm
Removing the Swingarm
Pivot Shaft Nut
Checking the Swingarm
Adjusting the Side Clearance
Installing the Swingarm
Swingarm Side Clearance
Shim Thickness
Drive Chain
Removing the Drive Chain
Checking the Drive Chain
Installing the Drive Chain
Electrical
Electrical Components
Instrument Functions
Indicator Lights
Oil Level/Coolant Temperature Indicator Light "Warning"
Digital Speedometer
Mode "A"
Mode "B"
Switches
Checking Switch Continuity
Checking the Switches
Checking the Bulbs and Bulb Sockets
Types of Bulbs
Checking the Condition of the Bulbs
Checking the Condition of the Bulb Sockets
Checking the Leds
Ignition System
Circuit Diagram
Troubleshooting
Spark Plug
Ignition Spark Gap
Spark Plug Cap Resistance
Ignition Coil Resistance
Pickup Coil Resistance
Main Switch
Source Coil Resistance
Engine Stop Switch
Neutral Switch
Starting Circuit Cutoff Relay
Diode
Wiring
Electric Starting System Circuit Diagram
Starting Circuit Cutoff System Operation
The Starter Motor Fails to Turn
Battery
Main Fuse
Starter Motor
Starter Relay
Sidestand Switch
Clutch Switch
Start Switch
Checking the Starter Motor
Assembling the Starter Motor
Minimum Brush Length
Charging System Circuit Diagram
The Battery Is Not Being Charged
Charging Voltage
Lighting Coil Resistance
Lighting System Circuit Diagram
Dimmer Switch
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Table of Contents
Troubleshooting
Troubleshooting
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