Yamaha DT230 4TP3-AE1 Manuals

Manuals and User Guides for Yamaha DT230 4TP3-AE1. We have 1 Yamaha DT230 4TP3-AE1 manual available for free PDF download: Service Manual

Yamaha DT230 4TP3-AE1 Service Manual (315 pages)

Brand: Yamaha | Category: Motorcycle | Size: 7.63 MB

Important Manual Information
3
How to Use this Manual
4
Symbols
5
Table of Contents
6
Contents
7
General Information
7
Motorcycle Identification
9
Vehicle Identification Number
9
Model Code
9
Features
10
3-Dimensional Traction Control System
10
Traction Control System
11
Important Information
13
Preparation for Removal and Disassembly
13
Replacement Parts
13
Gaskets, Oil Seals and O-Rings
13
Lock Washers/Plates and Cotter Pins
14
Bearings and Oil Seals
14
Circlips
14
Checking the Connections
15
Special Tools
16
Specifications
19
General Specifications
21
Engine Specifications
22
Chassis Specifications
26
Electrical Specifications
30
Conversion Table/Tightening Torques
32
General Tightening Torques
32
Engine Tightening Torques
33
Chassis Tightening Torques
35
Lubrication Points and Lubricant Types
36
Engine Lubrication Points and Lubricant Types
36
Chassis Lubrication Points and Lubricant Types
37
Cable Routing
38
Periodic Checks and Adjustments
47
Introduction/Periodic Maintenance and Lubrication Intervals
49
Air Scoop, Side Covers, Seat, Fuel Tank and Muffler
51
Adjusting the Engine Idling Speed
52
Engine
52
Adjusting the Engine Idling Speed/Adjusting the Throttle Cable Free Play
53
Carburetor Side
53
Adjusting the Throttle Cable Free Play/Adjusting the Oil Pump Cable
54
Handlebar Side
54
Bleeding the Oil Pump/Checking the Spark Plug
55
Checking the Spark Plug/Checking the Transmission Oil Level
56
Checking the Transmission Oil Level/Changing the Transmission Oil
57
Recommended Oil
57
Changing the Transmission Oil/Adjusting the Clutch Cable Free Play
58
Adjusting the Clutch Cable Free Play/Cleaning the Air Filter Element
59
Cleaning the Air Filter Element
60
Checking the Carburetor Joint and Intake Manifold/Checking the Fuel Hoses/Checking the Crankcase Breather Hose/Checking the Exhaust System
61
Checking the Exhaust System/Checking the Coolant Level
62
Checking the Coolant Level/Changing the Coolant
63
Changing the Coolant
64
Recommended Antifreeze
64
Handling Notes for Coolant
65
Adjusting the Front Brake/Adjusting the Rear Brake
66
Chassis
66
Adjusting the Rear Brake
67
Checking the Brake Fluid Level
68
Checking the Brake Pads/Adjusting the Rear Brake Light Switch
69
Checking the Brake Hoses/Bleeding the Hydraulic Brake System
70
Bleeding the Hydraulic Brake System
71
Adjusting the Drive Chain Slack
72
Adjusting the Drive Chain Slack/Lubricating the Drive Chain
73
Lubricating the Drive Chain/Checking and Adjusting the Steering Head
74
Checking and Adjusting the Steering Head
75
Lower Ring Nut
75
Checking the Front Fork/Adjusting the Front Fork Legs
76
Adjusting the Front Fork Legs/Adjusting the Rear Shock Absorber Assembly
77
Adjusting Positions
77
Spring Preload
77
Adjusting the Rear Shock Absorber Assembly
78
Rebound Damping
78
Compression Damping
79
Checking the Tires
80
Front Tire
81
Checking the Tires/Checking and Tightening the Spokes
82
Rear Tire
82
Checking and Tightening the Spokes/Checking and Lubricating the Cables
83
Lubricating the Levers and Pedals/Lubricating the Sidestand/Lubricating the Rear Suspension
84
Checking and Charging the Battery
85
Electrical System
85
First Aid in Case of Bodily Contact
85
External
85
Caution
87
Charging Method Using a Variable Voltage Charger
88
Charging Method Using a Constant Voltage Charger
89
Checking and Charging the Battery/Checking the Fuses
90
Checking the Fuses
91
Replacing the Headlight Bulb/Adjusting the Headlight Beam
92
Overhauling the Engine
93
Cables and Brake Pedal
95
Servomotor, Drive Sprocket, Leads and Engine
97
Removing the Pivot Shaft
99
Installing the Engine
99
Cylinder Head, Cylinder, Piston and YPVS Valve
100
YPVS Valve
102
Removing the Cylinder Head
103
Removing the Cylinder and Piston
103
Removing the YPVS Valve
104
Checking the Cylinder Head
104
Checking the Cylinder and Piston
105
Checking the Piston Rings
107
Piston Ring Side Clearance
107
Piston Ring End Gap
107
Checking the Piston Pin
108
Installing the YPVS Valve
108
Installing the Piston and Cylinder
109
Clutch
111
Clutch Cover
111
Pull Lever
113
Removing the Clutch and Primary Drive Gear
114
Checking the Friction Plates
114
Friction Plate Thickness
114
Checking the Clutch Plates
115
Checking the Clutch Springs
115
Checking the Clutch Housing and Clutch Boss
115
Checking the Pressure Plate
116
Checking the Pull Lever Shaft and Pull Rod
116
Checking the Primary Drive
116
Installing the Clutch
117
Shift Shaft
120
Checking the Shift Shaft
121
Checking the Stopper Lever
121
Installing the Shift Shaft
121
Installing the Shift Pedal
122
Oil Pump and Oil Pump Drive Gear
123
Checking the Oil Pump Drive Gear
124
Checking the Worm Shaft
124
Installing the Oil Pump
124
Starter Clutch and CDI Magneto
126
Stator
126
Rotor and Starter Clutch
127
Removing the Rotor
128
Checking the Starter Clutch
128
Installing the Starter Clutch
129
Installing the Rotor
129
Balancer Weight Gears
131
Removing the Balancer Weight Gears
132
Checking the Balancer Weight Gears
132
Installing the Balancer Weight Gears
132
Crankcase and Crankshaft
133
Balancer Weight and Crankshaft Assembly
135
Disassembling the Crankcase
136
Removing the Crankshaft Assembly
137
Checking the Crankshaft and Connecting Rod
137
Checking the Crankcase
138
Assembling the Crankcase
139
Crankcase Bolts
140
Checking the Reed Valve
141
Checking the Bearings and Oil Seals
141
Installing the Crankshaft
141
Transmission, Shift Cam and Shift Fork
142
Drive Axle and Main Axle Assembly
143
Removing the Transmission
145
Checking the Shift Forks
145
Checking the Shift Drum Assembly
145
Checking the Transmission
146
Installing the Transmission
147
Cooling System
149
Radiators
151
Checking the Radiator
152
Installing the Radiator
153
Thermostat Assembly
154
Checking the Thermostat
155
Installing the Thermostat Assembly
155
Water Pump
157
Checking the Water Pump
158
Installing the Water Pump
158
Carburetor
161
Carburetor Parts View
163
Checking the Carburetor
166
Assembling the Carburetor
168
Float Height
169
Installing the Carburetor
170
Engine Idling Speed
170
Measuring and Adjusting the Fuel Level
171
Chassis
173
Front Wheel and Brake Disc
175
Removing the Front Wheel
177
Disassembling the Front Wheel
177
Checking the Front Wheel
177
Checking the Brake Discs
179
Assembling the Front Wheel
181
Installing the Front Wheel
181
Adjusting the Front Wheel Static Balance
182
Rear Wheel, Brake Disc, and Rear Wheel Sprocket
184
Removing the Rear Wheel
186
Checking the Rear Wheel
186
Checking and Replacing the Rear Wheel Sprocket
187
Installing the Rear Wheel
187
Adjusting the Rear Wheel Static Balance
188
Drive Chain Slack
188
Front and Rear Brakes
189
Front Brake Pads
189
Rear Brake Pads
190
Replacing the Front Brake Pads
191
Replacing the Rear Brake Pads
193
Bleed Screw
194
Front Brake Master Cylinder
196
Rear Brake Master Cylinder
198
Removing the Front Brake Master Cylinder
200
Removing the Rear Brake Master Cylinder
200
Checking the Front and Rear Brake Master Cylinder
201
Assembling and Installing the Front Brake Master Cylinder
202
Recommended Brake Fluid
202
Assembling the Rear Brake Master Cylinder
204
Front Brake Caliper
206
Rear Brake Caliper
208
Disassembling the Front Brake Caliper
210
Disassembling the Rear Brake Caliper
210
Checking the Front and Rear Brake Calipers
211
Assembling and Installing the Front Brake Caliper
212
Assembling and Installing the Rear Brake Caliper
214
Front Fork
216
Removing the Front Fork Legs
219
Disassembling the Front Fork Legs
219
Checking the Front Fork Legs
220
Assembling the Front Fork Legs
221
Spring Free Length Limit
221
Installing the Front Fork Legs
224
Handlebar
225
Removing the Handlebar
227
Checking the Handlebar
227
Installing the Handlebar
227
Steering Head
230
Front Fender, Headlight and Meter
230
Lower Bracket
231
Removing the Lower Bracket
232
Checking the Steering Head
232
Installing the Steering Head
233
Rear Shock Absorber Assembly
235
Handling the Rear Shock Absorber and Gas Cylinder
236
Disposing of a Rear Shock Absorber and Gas Cylinder
236
Removing the Rear Shock Absorber Assembly
237
Checking the Rear Shock Absorber Assembly and Gas Cylinder
237
Installing the Rear Shock Absorber Assembly
238
Swingarm
239
Removing the Swingarm
242
Pivot Shaft Nut
242
Checking the Swingarm
243
Adjusting the Side Clearance
244
Installing the Swingarm
245
Swingarm Side Clearance
245
Shim Thickness
245
Drive Chain
247
Removing the Drive Chain
248
Checking the Drive Chain
248
Installing the Drive Chain
250
Electrical
253
Electrical Components
255
Instrument Functions
256
Indicator Lights
256
Oil Level/Coolant Temperature Indicator Light "Warning"
256
Digital Speedometer
257
Mode "A"
257
Mode "B"
258
Switches
259
Checking Switch Continuity
259
Checking the Switches
260
Checking the Bulbs and Bulb Sockets
262
Types of Bulbs
262
Checking the Condition of the Bulbs
262
Checking the Condition of the Bulb Sockets
264
Checking the Leds
264
Ignition System
266
Circuit Diagram
266
Troubleshooting
267
Spark Plug
267
Ignition Spark Gap
267
Spark Plug Cap Resistance
268
Ignition Coil Resistance
268
Pickup Coil Resistance
268
Main Switch
269
Source Coil Resistance
269
Engine Stop Switch
269
Neutral Switch
269
Starting Circuit Cutoff Relay
270
Diode
270
Wiring
270
Electric Starting System Circuit Diagram
271
Starting Circuit Cutoff System Operation
272
The Starter Motor Fails to Turn
273
Battery
273
Main Fuse
273
Starter Motor
273
Starter Relay
275
Sidestand Switch
275
Clutch Switch
276
Start Switch
276
Checking the Starter Motor
279
Assembling the Starter Motor
280
Minimum Brush Length
280
Charging System Circuit Diagram
281
The Battery Is Not Being Charged
282
Charging Voltage
282
Lighting Coil Resistance
283
Lighting System Circuit Diagram
284
Dimmer Switch
285
Checking the Lighting System
286
Headlight Bulb and Socket
286
Voltage
286
Headlight
286
The Tail/Brake Light Fails to Light
287
The Licence Plate Light Fails to Light
287
Signaling System Circuit Diagram
289
Signaling System
290
Checking the Signaling System
292
Horn Switch
292
Horn
292
Turn Signal Switch
293
The Oil Level Warning Light LED
295
Oil Level Switch (Diode)
296
The Speedometer Does Not Operate
297
Meter Assembly
297
Speed Sensor
298
Cooling System Circuit Diagram
299
The Oil Level Water/Coolant Temperature Warning Light LED Fails to Light When the Engine Is Warm
300
Oil Level/Coolant Temperature Warning Light LED
300
Thermo Unit
301
YAMAHA Power Valve System (YPVS) Circuit Diagram
302
When the Engine Speed Changes, the YPVS Servomotor Does Not Operate
303
Troubleshooting Contents
305
Starting Problems
308
Engine
308
Fuel System
308
Electrical Systems
308
Starting Problems/Incorrect Engine Idling Speed/Poor Medium-And-High-Speed Performance
309
Faulty Gear Shifting/Faulty Clutch/Overheating
310
Overheating/Overcooling/Poor Braking Performance/Faulty Front Fork Legs
311
Unstable Handling/Faulty Lighting or Signaling System
312
DT230L Wiring Diagram
314

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