Table Of Contents - Yamaha DT230 4TP3-AE1 Service Manual

Table of Contents

Important Manual Information3
How To Use This Manual4
Symbols5
Table Of Contents6
Contents7
General Information7
Motorcycle Identification9
Vehicle Identification Number9
Model Code9
Features10
3-Dimensional Traction Control System10
Traction Control System11
Important Information13
Preparation For Removal And Disassembly13
Replacement Parts13
Gaskets, Oil Seals And O-Rings13
Lock Washers/Plates And Cotter Pins14
Bearings And Oil Seals14
Circlips14
Checking The Connections15
Special Tools16
Specifications19
General Specifications21
Engine Specifications22
Chassis Specifications26
Electrical Specifications30
Conversion Table/Tightening Torques32
General Tightening Torques32
Engine Tightening Torques33
Chassis Tightening Torques35
Lubrication Points And Lubricant Types36
Engine Lubrication Points And Lubricant Types36
Chassis Lubrication Points And Lubricant Types37
Cable Routing38
Periodic Checks And Adjustments47
Introduction/Periodic Maintenance And Lubrication Intervals49
Air Scoop, Side Covers, Seat, Fuel Tank And Muffler51
Adjusting The Engine Idling Speed52
Engine52
Adjusting The Engine Idling Speed/Adjusting The Throttle Cable Free Play53
Carburetor Side53
Adjusting The Throttle Cable Free Play/Adjusting The Oil Pump Cable54
Handlebar Side54
Bleeding The Oil Pump/Checking The Spark Plug55
Checking The Spark Plug/Checking The Transmission Oil Level56
Checking The Transmission Oil Level/Changing The Transmission Oil57
Recommended Oil57
Changing The Transmission Oil/Adjusting The Clutch Cable Free Play58
Adjusting The Clutch Cable Free Play/Cleaning The Air Filter Element59
Cleaning The Air Filter Element60
Checking The Carburetor Joint And Intake Manifold/Checking The Fuel Hoses/Checking The Crankcase Breather Hose/Checking The Exhaust System61
Checking The Exhaust System/Checking The Coolant Level62
Checking The Coolant Level/Changing The Coolant63
Changing The Coolant64
Recommended Antifreeze64
Handling Notes For Coolant65
Adjusting The Front Brake/Adjusting The Rear Brake66
Chassis66
Adjusting The Rear Brake67
Checking The Brake Fluid Level68
Checking The Brake Pads/Adjusting The Rear Brake Light Switch69
Checking The Brake Hoses/Bleeding The Hydraulic Brake System70
Bleeding The Hydraulic Brake System71
Adjusting The Drive Chain Slack72
Adjusting The Drive Chain Slack/Lubricating The Drive Chain73
Lubricating The Drive Chain/Checking And Adjusting The Steering Head74
Checking And Adjusting The Steering Head75
Lower Ring Nut75
Checking The Front Fork/Adjusting The Front Fork Legs76
Adjusting The Front Fork Legs/Adjusting The Rear Shock Absorber Assembly77
Adjusting Positions77
Spring Preload77
Adjusting The Rear Shock Absorber Assembly78
Rebound Damping78
Compression Damping79
Checking The Tires80
Front Tire81
Checking The Tires/Checking And Tightening The Spokes82
Rear Tire82
Checking And Tightening The Spokes/Checking And Lubricating The Cables83
Lubricating The Levers And Pedals/Lubricating The Sidestand/Lubricating The Rear Suspension84
Checking And Charging The Battery85
Electrical System85
First Aid In Case Of Bodily Contact85
External85
Caution87
Charging Method Using A Variable Voltage Charger88
Charging Method Using A Constant Voltage Charger89
Checking And Charging The Battery/Checking The Fuses90
Checking The Fuses91
Replacing The Headlight Bulb/Adjusting The Headlight Beam92
Overhauling The Engine93
Cables And Brake Pedal95
Servomotor, Drive Sprocket, Leads And Engine97
Removing The Pivot Shaft99
Installing The Engine99
Cylinder Head, Cylinder, Piston And Ypvs Valve100
Ypvs Valve102
Removing The Cylinder Head103
Removing The Cylinder And Piston103
Removing The Ypvs Valve104
Checking The Cylinder Head104
Checking The Cylinder And Piston105
Checking The Piston Rings107
Piston Ring Side Clearance107
Piston Ring End Gap107
Checking The Piston Pin108
Installing The Ypvs Valve108
Installing The Piston And Cylinder109
Clutch111
Clutch Cover111
Pull Lever113
Removing The Clutch And Primary Drive Gear114
Checking The Friction Plates114
Friction Plate Thickness114
Checking The Clutch Plates115
Checking The Clutch Springs115
Checking The Clutch Housing And Clutch Boss115
Checking The Pressure Plate116
Checking The Pull Lever Shaft And Pull Rod116
Checking The Primary Drive116
Installing The Clutch117
Shift Shaft120
Checking The Shift Shaft121
Checking The Stopper Lever121
Installing The Shift Shaft121
Installing The Shift Pedal122
Oil Pump And Oil Pump Drive Gear123
Checking The Oil Pump Drive Gear124
Checking The Worm Shaft124
Installing The Oil Pump124
Starter Clutch And Cdi Magneto126
Stator126
Rotor And Starter Clutch127
Removing The Rotor128
Checking The Starter Clutch128
Installing The Starter Clutch129
Installing The Rotor129
Balancer Weight Gears131
Removing The Balancer Weight Gears132
Checking The Balancer Weight Gears132
Installing The Balancer Weight Gears132
Crankcase And Crankshaft133
Balancer Weight And Crankshaft Assembly135
Disassembling The Crankcase136
Removing The Crankshaft Assembly137
Checking The Crankshaft And Connecting Rod137
Checking The Crankcase138
Assembling The Crankcase139
Crankcase Bolts140
Checking The Reed Valve141
Checking The Bearings And Oil Seals141
Installing The Crankshaft141
Transmission, Shift Cam And Shift Fork142
Drive Axle And Main Axle Assembly143
Removing The Transmission145
Checking The Shift Forks145
Checking The Shift Drum Assembly145
Checking The Transmission146
Installing The Transmission147
Cooling System149
Radiators151
Checking The Radiator152
Installing The Radiator153
Thermostat Assembly154
Checking The Thermostat155
Installing The Thermostat Assembly155
Water Pump157
Checking The Water Pump158
Installing The Water Pump158
Carburetor161
Carburetor Parts View163
Checking The Carburetor166
Assembling The Carburetor168
Float Height169
Installing The Carburetor170
Engine Idling Speed170
Measuring And Adjusting The Fuel Level171
Front Wheel And Brake Disc175
Removing The Front Wheel177
Disassembling The Front Wheel177
Checking The Front Wheel177
Checking The Brake Discs179
Assembling The Front Wheel181
Installing The Front Wheel181
Adjusting The Front Wheel Static Balance182
Rear Wheel, Brake Disc, And Rear Wheel Sprocket184
Removing The Rear Wheel186
Checking The Rear Wheel186
Checking And Replacing The Rear Wheel Sprocket187
Installing The Rear Wheel187
Adjusting The Rear Wheel Static Balance188
Drive Chain Slack188
Front And Rear Brakes189
Front Brake Pads189
Rear Brake Pads190
Replacing The Front Brake Pads191
Replacing The Rear Brake Pads193
Bleed Screw194
Front Brake Master Cylinder196
Rear Brake Master Cylinder198
Removing The Front Brake Master Cylinder200
Removing The Rear Brake Master Cylinder200
Checking The Front And Rear Brake Master Cylinder201
Assembling And Installing The Front Brake Master Cylinder202
Recommended Brake Fluid202
Assembling The Rear Brake Master Cylinder204
Front Brake Caliper206
Rear Brake Caliper208
Disassembling The Front Brake Caliper210
Disassembling The Rear Brake Caliper210
Checking The Front And Rear Brake Calipers211
Assembling And Installing The Front Brake Caliper212
Assembling And Installing The Rear Brake Caliper214
Front Fork216
Removing The Front Fork Legs219
Disassembling The Front Fork Legs219
Checking The Front Fork Legs220
Assembling The Front Fork Legs221
Spring Free Length Limit221
Installing The Front Fork Legs224
Handlebar225
Removing The Handlebar227
Checking The Handlebar227
Installing The Handlebar227
Steering Head230
Front Fender, Headlight And Meter230
Lower Bracket231
Removing The Lower Bracket232
Checking The Steering Head232
Installing The Steering Head233
Rear Shock Absorber Assembly235
Handling The Rear Shock Absorber And Gas Cylinder236
Disposing Of A Rear Shock Absorber And Gas Cylinder236
Removing The Rear Shock Absorber Assembly237
Checking The Rear Shock Absorber Assembly And Gas Cylinder237
Installing The Rear Shock Absorber Assembly238
Swingarm239
Removing The Swingarm242
Pivot Shaft Nut242
Checking The Swingarm243
Adjusting The Side Clearance244
Installing The Swingarm245
Swingarm Side Clearance245
Shim Thickness245
Drive Chain247
Removing The Drive Chain248
Checking The Drive Chain248
Installing The Drive Chain250
Electrical253
Electrical Components255
Instrument Functions256
Indicator Lights256
Oil Level/Coolant Temperature Indicator Light "Warning"256
Digital Speedometer257
Mode "A"257
Mode "B"258
Switches259
Checking Switch Continuity259
Checking The Switches260
Checking The Bulbs And Bulb Sockets262
Types Of Bulbs262
Checking The Condition Of The Bulbs262
Checking The Condition Of The Bulb Sockets264
Checking The Leds264
Ignition System266
Circuit Diagram266
Troubleshooting267
Spark Plug267
Ignition Spark Gap267
Spark Plug Cap Resistance268
Ignition Coil Resistance268
Pickup Coil Resistance268
Main Switch269
Source Coil Resistance269
Engine Stop Switch269
Neutral Switch269
Starting Circuit Cutoff Relay270
Diode270
Wiring270
Electric Starting System Circuit Diagram271
Starting Circuit Cutoff System Operation272
The Starter Motor Fails To Turn273
Battery273
Main Fuse273
Starter Motor273
Starter Relay275
Sidestand Switch275
Clutch Switch276
Start Switch276
Checking The Starter Motor279
Assembling The Starter Motor280
Minimum Brush Length280
Charging System Circuit Diagram281
The Battery Is Not Being Charged282
Charging Voltage282
Lighting Coil Resistance283
Lighting System Circuit Diagram284
Dimmer Switch285
Checking The Lighting System286
Headlight Bulb And Socket286
Voltage286
Headlight286
The Tail/Brake Light Fails To Light287
The Licence Plate Light Fails To Light287
Signaling System Circuit Diagram289
Signaling System290
Checking The Signaling System292
Horn Switch292
Horn292
Turn Signal Switch293
The Oil Level Warning Light Led295
Oil Level Switch (Diode)296
The Speedometer Does Not Operate297
Meter Assembly297
Speed Sensor298
Cooling System Circuit Diagram299
The Oil Level Water/Coolant Temperature Warning Light Led Fails To Light When The Engine Is Warm300
Oil Level/Coolant Temperature Warning Light Led300
Thermo Unit301
Yamaha Power Valve System (Ypvs) Circuit Diagram302
When The Engine Speed Changes, The Ypvs Servomotor Does Not Operate303
Troubleshooting Contents305
Starting Problems308
Fuel System308
Electrical Systems308
Starting Problems/Incorrect Engine Idling Speed/Poor Medium-And-High-Speed Performance309
Faulty Gear Shifting/Faulty Clutch/Overheating310
Overheating/Overcooling/Poor Braking Performance/Faulty Front Fork Legs311
Unstable Handling/Faulty Lighting Or Signaling System312
Dt230L Wiring Diagram314