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Yamaha DT230 Owner's Manual

Summary of DT230

  • Page 1

    Printed on recycled paper printed in japan 2000·7– 0.1 × 1(e) ! Owner’s manual 4tp-28199-21 dt230(n) yamaha motor co., ltd..

  • Page 2: Introduction

    Eau00000 introduction 1 2 4 5 6 7 8 9 congratulations on your purchase of the yamaha dt230. This model is the result of yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made...

  • Page 3: Important Manual Information

    Eau00005 important manual information 1 2 3 4 5 6 7 8 9 particularly important information is distinguished in this manual by the following notations: the safety alert symbol means attention! Become alert! Your safety is involved! Failure to follow warning instructions could result in severe injury ...

  • Page 4: Important Manual Information

    Important manual information 1 2 4 5 6 7 8 9 ew000002 w please read this manual carefully and completely before operating this motorcycle. 4tp-9-21 7/25/00 3:46 pm page 3.

  • Page 5: Dt230 (N)

    1 2 3 4 5 6 7 8 9 dt230 (n) owner’s manual ©2000 by yamaha motor co., ltd. 1st edition, july 2000 all rights reserved. Any reprinting or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited. Printed in japan. Eau03337 4tp-9-21 7/25/00 3:46 pm page 4.

  • Page 6: Table of Contents

    Eau00009 table of contents 1 2 3 4 5 6 7 8 9 safety information.....................................1-1 safe riding.........................................................1-1 protective apparel .............................................1-3 modification...............................................

  • Page 7: Table of Contents

    7 8 removing and installing panels ........................6-6 checking the spark plug ...................................6-7 transmission oil ................................................6-9 coolant ...........................................................6-10 changing the coolant ...............

  • Page 8: Table of Contents

    Table of contents 1 2 3 4 5 6 7 8 9 consumer information..............................9-1 identification numbers record ...........................9-1 key identification number .................................9-1 vehicle identification number ............................9-1 model label ...............

  • Page 9: Safe Riding

    1-1 motorcycles are single track vehicles. Their safe use and operation are dependent upon the use of proper riding techniques as well as the exper- tise of the operator. Every operator should know the following require- ments before riding this motorcycle. He or she should: 1. Obtain thorough instr...

  • Page 10: Safety Information

    1-2 q safety information 1 2 3 4 5 6 7 8 9 4. Many accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license. A. Make sure that you are qualified and that you only lend your motorcycle to other qualified oper-...

  • Page 11: Safety Information

    1-3 q safety information 1 2 3 4 5 6 7 8 9 protective apparel the majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries. 1. Always wear an approved helmet. 2. Wea...

  • Page 12: Safety Information

    1-4 q safety information 1 2 3 4 5 6 7 8 9 loading the total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of 180 kg. When loading within this weight limit, keep the following in mind: 1. Cargo and accessory weight should be kept as low and close to ...

  • Page 13: Safety Information

    1-5 q safety information 1 2 3 4 5 6 7 8 9 1. Never install accessories or carry cargo that would impair the performance of your motorcycle. Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance, limit suspension trave...

  • Page 14: Safety Information

    1-6 q safety information 1 2 3 4 5 6 7 8 9 2. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your motorcycle in an area that has adequate ventilation. 3. A...

  • Page 15: Safety Information

    1-7 q safety information 1 2 3 4 5 6 7 8 9 eau02977 location of important labels please read the following important labels carefully before operating this motorcycle. 1 2 warning before you operate this vehicle, read the owner’s manual. English 3hp-21568-00 4aa-22259-40 2 1 4tp-9-21 7/25/00 3:46 pm...

  • Page 16

    1-8 1 2 3 4 5 6 7 8 9 4tp-9-21 7/25/00 3:46 pm page 15.

  • Page 17: Description

    Eau00026 description 1 2 3 4 5 6 7 8 9 2-1 1 2 3 4 5 6 7 8 9 10 11 12 left view 1. Headlight (page 6-34) 2. Rear shock absorber compression damping adjusting knob (page 3-14) 3. Fuel cock (page 3-9) 4. Starter (choke) lever “ 1 ” (page 3-10) 5. Air filter element (page 6-14) 6. 2-stroke engine oil t...

  • Page 18: Description

    Description 1 2 3 4 5 6 7 8 9 2-2 13 14 15 16 17 18 right view 13. Coolant reservoir (page 6-11) 14. Owner’s tool kit (page 6-1) 15. Battery (page 6-32) 16. Fuse (page 6-33) 17. Radiator cap (page 6-12) 18. Brake pedal (page 3-7, 6-22) 4tp-9-21 7/25/00 3:46 pm page 17.

  • Page 19: Description

    1 2 3 4 5 6 7 8 9 description 2-3 1. Clutch lever (page 3-6, 6-20) 2. Left handlebar switches (page 3-5) 3. Speedometer unit (page 3-3) 4. Main switch/steering lock (page 3-1) 5. Right handlebar switches (page 3-5) 6. Brake lever (page 3-6, 6-21) 7. Throttle grip (page 6-16, 6-28) 8. Fuel tank cap (...

  • Page 20: Main Switch/steering Lock

    3-1 p u s h off on lock o ff on l o c k igni ti o n eau00029 main switch/steering lock the main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The vari- ous positions are described below. Eau00031 on all electrical systems are supplied with power, ...

  • Page 21: 2 3

    3-2 1 2 3 4 5 6 eau03034 indicator and warning lights eau03587 oil level/coolant temperature warning light “warning” this warning light has the following three functions. 8 when the engine oil level is low, the warning light comes on and symbol “ 7 ” flashes. If this occurs, stop the engine immedi- ...

  • Page 22: 2 3

    3-3 1 2 3 4 5 6 eau00063 high beam indicator light “ & ” this indicator light comes on when the high beam of the headlight is switched on. Eau00061 neutral indicator light “n” this indicator light comes on when the transmission is in the neutral position. Eau00100 speedometer unit the speedometer un...

  • Page 23: Note:

    3-4 note: when the key is turned to “on”, the speedometer displays “188 km/h” for a few seconds, during which time the electrical circuit is being checked. 2. Push the mode select button to display a mode. Mode “b” to set the lower tripmeter to zero, push the reset button for at least one second. To...

  • Page 24: Handlebar Switches

    3-5 1 2 3 2 1 eau00118 handlebar switches eau00121 dimmer switch set this switch to “ & ” for the high beam and to “ % ” for the low beam. Eau00127 turn signal switch to signal a right-hand turn, push this switch to “ 6 ”. To signal a left-hand turn, push this switch to “ 4 ”. When released, the swi...

  • Page 25: Brake Lever

    1 eau00158 brake lever the brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the han- dlebar grip. 1. Brake lever 3-6 1 5 4 3 2 1 n 6 1 1. Clutch lever 1. Shift pedal n. Neutral eau00152 clutch lever the clutch lever is located at the left handlebar ...

  • Page 26: Brake Pedal

    3-7 1 1 b a eau00162 brake pedal the brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal. Eau00177 fuel tank cap to remove the fuel tank cap 1. Insert the key into the lock and turn it 1/4 turn counterclockwise. 2. Turn the fuel tank cap 1/3 tur...

  • Page 27: 2-Stroke Engine Oil

    2 1 eau01413 2-stroke engine oil make sure that there is sufficient oil in the 2-stroke engine oil tank. If neces- sary, add oil as follows. 1. Remove panel a. (see page 6-6 for panel removal and installation procedures.) 2. Remove the 2-stroke engine oil tank cap and add the recom- mended oil. 3. I...

  • Page 28: Note:

    3-9 note: make sure that the 2-stroke engine oil tank cap is properly closed. Instrument and control functions 1 2 3 4 5 6 7 8 9 recommended oil: yamalube 2 or equivalent 2-stroke engine oil (jaso grade “fc”) oil quantity: 1.3 l eau03050 fuel cock the fuel cock supplies fuel from the tank to the car...

  • Page 29: Res

    3-10 instrument and control functions 1 2 3 4 5 6 7 8 9 res this indicates reserve. If you run out of fuel while riding, move the lever to this position. Fill the tank at the first opportunity. Be sure to set the lever back to “on” after refueling! Off on fuel res 1 res 1. Arrow mark positioned over...

  • Page 30: To Install The Seat

    3-11 instrument and control functions 1 2 3 4 5 6 7 8 9 1 2 1. Projection ( × 2) 2. Seat holder ( × 2) to install the seat 1. Insert the projections on the front of the seat into the seat holders as shown. 2. Place the seat in the original position, and then tighten the bolts. Note: make sure that t...

  • Page 31: The Fork Legs.

    3-12 instrument and control functions 1 2 3 4 5 6 7 8 9 3. Install the rubber caps. Eca00034 c c be sure to install the rubber caps to prevent dust, etc. From entering the fork legs. Eau03672 adjusting the shock absorber assembly this shock absorber assembly is equipped with a spring preload adjusti...

  • Page 32: Spring Preload

    3. Tighten the locknut to the speci- fied torque. Eca00076 c c always tighten the locknut against the adjusting nut, and then tighten the locknut to the specified torque. 3-13 instrument and control functions 1 2 3 4 5 6 7 8 9 1 a b 1. Special wrench spring preload: minimum (soft): distance a = 252 ...

  • Page 33: Note:

    3-14 instrument and control functions 1 2 3 4 5 6 7 8 9 note: although the total number of clicks of a damping force adjusting mecha- nism may not exactly match the above specifications due to small dif- ferences in production, the actual number of clicks always represents the entire adjusting range...

  • Page 34: Ypvs

    3-15 instrument and control functions 1 2 3 4 5 6 7 8 9 1 eau00326 ypvs this model is equipped with the ypvs (yamaha power valve system). This system boosts engine performance and efficiency by means of a variable valve in the exhaust port. The ypvs valve is constantly adjusted in accordance with th...

  • Page 35: Sidestand

    3-16 eau00330 sidestand the sidestand is located on the left side of the frame. Raise the side- stand or lower it with your foot while holding the motorcycle upright. Note: the built-in sidestand switch is part of the ignition circuit cut-off system, which cuts the ignition in certain situ- ations. ...

  • Page 36: Note:

    3-17 instrument and control functions 1 2 3 4 5 6 7 8 9 with the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is set to “ # ”. 3. Turn the key to “on”. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? The...

  • Page 37: Pre-Operation Checks

    4-1 eau01114 pre-operation checks 1 2 3 4 5 6 7 8 9 the condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpect- edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak- age o...

  • Page 38: Pre-Operation Checks

    4-2 pre-operation checks 1 2 3 4 5 6 7 8 9 clutch • check operation. • lubricate cable if necessary. • check lever free play. • adjust if necessary. 3-6, 6-20–6-21 throttle grip • make sure that operation is smooth. • lubricate throttle grip, housing and cable if necessary. • check free play. • adju...

  • Page 39: Pre-Operation Checks

    4-3 pre-operation checks 1 2 3 4 5 6 7 8 9 note: pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very short time; and the added safety it assures is more than worth the time involved. Ewa00033 w if any item in the pre-operation check ...

  • Page 40: Become Thoroughly Familiar

    5-1 eau00372 operation and important riding points 1 2 3 4 5 6 7 8 9 eau00373 w 8 become thoroughly familiar with all operating controls and their functions before riding. Consult a yamaha dealer regarding any control or func- tion that you do not thorough- ly understand. 8 never start the engine or...

  • Page 41: Note:

    5-2 operation and important riding points 1 2 3 4 5 6 7 8 9 note: if the engine fails to start, release the start switch, wait a few seconds, and then try again. Each starting attempt should be as short as possible to pre- serve the battery. Do not crank the engine more than 10 seconds on any one at...

  • Page 42: The Neutral Position, Do Not

    5-3 operation and important riding points 1 2 3 4 5 6 7 8 9 ec000048 c c 8 even with the transmission in the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long distances. The transmission is properly lubricated only when the engine is ...

  • Page 43: 0–150 Km

    5-4 operation and important riding points 1 2 3 4 5 6 7 8 9 eau00455 0–150 km 8 avoid prolonged operation above 1/3 throttle. 8 after every hour of operation, stop the engine, and then let it cool for five to ten minutes. 8 vary the engine speed from time to time. Do not operate the engine at one se...

  • Page 44: Note:

    6-1 eau00462 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 note: if you do not have the tools or experi- ence required for a particular job, have a yamaha dealer perform it for you. Ew000063 w modifications not approved by yamaha may cause loss of perfor- mance and render the vehicle unsaf...

  • Page 45: Note:

    6-2 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 eau03540 periodic maintenance and lubrication chart note: 8 the annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. 8 from 30,000 km, repeat the maintenance intervals starting from 6,000...

  • Page 46

    6-3 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 9 * tires • check tread depth and for damage. • replace if necessary. • check air pressure. • correct if necessary. √ √ √ √ 10 * wheel bearings • check bearing for looseness or damage. √ √ √ √ 11 * swingarm • check operation and for excessi...

  • Page 47: Note:

    6-4 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 eau03541 note: 8 the air filter needs more frequent service if you are riding in unusually wet or dusty areas. 8 hydraulic brake service 8 regularly check and, if necessary, correct the brake fluid level. 8 every two years replace the inter...

  • Page 48: Removing and Installing

    6-5 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 1 2 1 eau01065 removing and installing cowlings the cowlings shown above need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a cowling needs to be removed and installed. 1. C...

  • Page 49: Panel A

    6-6 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 1 1. Panel b refer to this section each time a panel needs to be removed and installed. 1 1. Screw eau00488 panel a to remove the panel remove the screw, and then pull the panel off as shown. To install the panel place the panel in the orig...

  • Page 50: Panel B

    6-7 periodic maintenance and minor repair 6 1 1 1 eau00488 panel b to remove the panel remove the screw, and then pull the panel off as shown. To install the panel place the panel in the original posi- tion, and then install the screw. 1. Screw 1. Spark plug cap 1. Spark plug wrench eau01833 checkin...

  • Page 51: To Check The Spark Plug

    6-8 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 a to check the spark plug 1. Check that the porcelain insula- tor around the center electrode of the spark plug is a medium-to- light tan (the ideal color when the motorcycle is ridden normally). Note: if the spark plug shows a distinctly d...

  • Page 52: Transmission Oil

    6-9 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 1 2 3 eau03109 transmission oil oil level inspection 1. Place the motorcycle on a level place and hold it in an upright position. Warm up the engine for several minutes. Note: be sure the motorcycle is positioned straight up when checking t...

  • Page 53: Coolant

    6-10 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 3. Remove the drain bolt and drain the oil. 4. Install the drain bolt and tighten it to the specified torque. 5. Fill the engine with sufficient oil to reach the specified level. Install the oil filler cap and tight- en it. Ec000079 c c in...

  • Page 54: To The Engine.

    6-11 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 ec000080 c c 8 if coolant is not available, use distilled water or soft tap water instead. Do not use hard water or salt water since it is harmful to the engine. 8 if water has been used instead of coolant, replace it with coolant as soon ...

  • Page 55: Changing The Coolant

    4. Place a container under the engine and remove the coolant drain bolt. 5. Disconnect the reservoir tank hose on the reservoir tank side and drain the coolant from the reservoir tank. 6. After draining the coolant, thor- oughly flush the cooling system with clean tap water. 7. Replace the coolant d...

  • Page 56: To The Engine.

    6-13 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 ec000080 c c 8 if coolant is not available, use distilled water or soft tap water instead. Do not use hard water or salt water since it is harmful to the engine. 8 if water has been used instead of coolant, replace it with coolant as soon ...

  • Page 57: Cleaning The Air Filter

    6-14 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 eau03671 cleaning the air filter element the air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrica- tion chart. Clean the air filter element more frequently if you are riding in unusually w...

  • Page 58: Air Filter Case.

    6-15 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 8. Install the sponge material onto the frame, place the air filter ele- ment in the original position on the guide, and then tighten the wing nut. 9. Insert the air filter element into the air filter case. Ec000082 c c 8 make sure that th...

  • Page 59: Adjusting The Engine Idling

    6-16 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 eau01168 adjusting the engine idling speed the engine idling speed must be checked and, if necessary, adjusted as follows at the intervals specified in the periodic maintenance and lubrica- tion chart. Note: a diagnostic tachometer is need...

  • Page 60: Tires

    6-17 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 eau03593 tires to maximize the performance, dura- bility, and safe operation of your motorcycle, note the following points regarding the specified tires. Tire air pressure the tire air pressure should be checked and, if necessary, adjusted...

  • Page 61: Tions In Mind.

    6-18 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 ewa00012 w because loading has an enormous impact on the handling, braking, performance and safety character- istics of your motorcycle, you should keep the following precau- tions in mind. 8 never overload the motorcycle! Operation of an ...

  • Page 62: Worn-Out Tire. When A Tire

    6-19 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 eau00680 w 8 it is dangerous to ride with a worn-out tire. When a tire tread begins to show cross- wise lines, have a yamaha dealer replace the tire immedi- ately. 8 the replacement of all wheel- and brake-related parts, including the tire...

  • Page 63: Spoke Wheels

    6-20 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 eau00685 spoke wheels to maximize the performance, dura- bility, and safe operation of your motorcycle, note the following points regarding the specified wheels. 8 the wheel rims should be checked for cracks, bends or warpage, and the spok...

  • Page 64: Adjusting The Brake Lever

    6-21 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 4. Fully turn the adjusting bolt in direction a to loosen the clutch cable. 5. Loosen the locknut further down the clutch cable. 6. To increase the clutch lever free play, turn the adjusting nut in direction a . To decrease the clutch leve...

  • Page 65: And Make Sure That The Brake

    6-22 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 ew000099 w 8 after adjusting the brake lever free play, check the free play and make sure that the brake is working properly. 8 a soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system. If there ...

  • Page 66: Checking The Front and Rear

    6-23 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 eau01314 checking the front and rear brake pads the front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. Each brake pad is provided with a wear indicator groove, w...

  • Page 67: Checking The Brake Fluid

    6-24 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 observe these precautions: 8 when checking the fluid level, make sure that the top of the master cylinder or brake fluid reservoir is level. 8 use only the recommended qual- ity brake fluid, otherwise the rub- ber seals may deteriorate, ca...

  • Page 68: Drive Chain Slack

    6-25 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 eau00744 drive chain slack the drive chain slack should be checked before each ride and adjust- ed if necessary. To check the drive chain slack 1. Place the motorcycle on a level surface and hold it in an upright position. Note: when check...

  • Page 69: Note:

    6-26 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 ec000096 c c improper drive chain slack will overload the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage. To prevent this from occurring, keep the drive chain slack within the specified lim...

  • Page 70: Unsafe Conditions.

    6-27 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 ew000112 w damage to the outer sheath may interfere with proper cable opera- tion and will cause the inner cable to rust. Replace a damaged cable as soon as possible to prevent unsafe conditions. Eau02962 checking and lubricating the cable...

  • Page 71: Checking and Lubricating The

    6-28 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 eau03209 checking and lubricating the throttle grip and cable the operation of the throttle grip and the condition of the throttle cable should be checked before each ride, and the cable should be lubricated or replaced if necessary. Note:...

  • Page 72: Checking and Lubricating The

    6-29 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 eau03165 checking and lubricating the sidestand the operation of the sidestand should be checked before each ride, and the sidestand pivot and metal-to-metal contact surfaces should be lubricated if necessary. Ew000113 w if the sidestand d...

  • Page 73: Checking The Front Fork

    6-30 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 eau02939 checking the front fork the condition and operation of the front fork must be checked as follows at the intervals specified in the peri- odic maintenance and lubrication chart. To check the condition ew000115 w securely support th...

  • Page 74: Checking The Wheel Bearings

    6-31 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 eau01144 checking the wheel bearings the front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, ...

  • Page 75: Battery

    6-32 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 eau00800 battery this motorcycle is equipped with a sealed-type (mf) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water. Ec000101 c c never attempt to remove the bat- tery c...

  • Page 76: Replacing The Fuse

    6-33 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 eau00804 replacing the fuse if the fuse is blown, replace it as fol- lows. 1. Turn the key to “off” and turn off all electrical circuits. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. Specified fuse: 30a ...

  • Page 77: Replacing The Headlight Bulb

    6-34 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 eau03592 replacing the headlight bulb this motorcycle is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows: 1. Remove cowling a together with the headlight unit. (see page 6-5 for cowling removal...

  • Page 78: Has Cooled Down.

    6-35 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 3. Unhook the headlight bulb hold- er, and then remove the defec- tive bulb. Ew000119 w headlight bulbs get very hot. Therefore, keep flammable prod- ucts away from a lit headlight bulb, and do not touch the bulb until it has cooled down. ...

  • Page 79: Bulb

    6-36 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 1 2 1 1. Bulb 1. Screw 2. Lens eau03497 replacing a turn signal light bulb 1. Remove the turn signal light lens by removing the screw. 2. Remove the defective bulb by pushing it in and turning it coun- terclockwise. 3. Insert a new bulb in...

  • Page 80: Replacing The License Plate

    6-37 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 1 1. Bulb 2. Remove the defective bulb by pushing it in and turning it coun- terclockwise. 3. Insert a new bulb into the socket, push it in, and then turn it clock- wise until it stops. 4. Install the lens by installing the screws. Ec00010...

  • Page 81: Supporting The Motorcycle

    6-38 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 eau01579 supporting the motorcycle since this model is not equipped with a centerstand, follow these precau- tions when removing the front and rear wheel or performing other main- tenance requiring the motorcycle to stand upright. Check th...

  • Page 82: Front Wheel

    6-39 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 1 2 1. Axle holder nut ( × 4) 2. Wheel axle eau00879 front wheel to remove the front wheel ew000122 w 8 it is advisable to have a yamaha dealer service the wheel. 8 securely support the motorcy- cle so that there is no danger of it falling...

  • Page 83: Rear Wheel

    6-40 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 eau03588 rear wheel to remove the rear wheel ew000122 w 8 it is advisable to have a yamaha dealer service the wheel. 8 securely support the motorcy- cle so that there is no danger of it falling over. 1. Loosen the axle nut. 2. Lift the rea...

  • Page 84: Note:

    6-41 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 4. Push the wheel forward, and then remove the drive chain from the rear sprocket. Note: the drive chain does not need to be disassembled in order to remove and install the rear wheel. 5. Remove the wheel. Eca00048 c c do not apply the bra...

  • Page 85: Troubleshooting

    6-42 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 eau03087 troubleshooting although yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor...

  • Page 86: Troubleshooting Charts

    6-43 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 eau01581 troubleshooting charts starting problems or poor engine performance ew000125 w keep away open flames and do not smoke while checking or working on the fuel system. 1. Fuel 2. Compression 3. Ignition 4. Battery remove spark there i...

  • Page 87: Engine Overheating

    6-44 periodic maintenance and minor repair 1 2 3 4 5 6 7 8 9 engine overheating ew000070 w 8 do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. Be sure to wait until the engine has coole...

  • Page 88: Motorcycle Care and Storage

    7-1 eau03521 motorcycle care and storage 1 2 3 4 5 6 7 8 9 care while the open design of a motorcy- cle reveals the attractiveness of the technology, it also makes it more vul- nerable. Rust and corrosion can develop even if high-quality compo- nents are used. A rusty exhaust pipe may go unnoticed o...

  • Page 89: Motorcycle Care and Storage

    7-2 motorcycle care and storage 1 2 3 4 5 6 7 8 9 8 do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abra- sive cleaning products, sol- vent or thinner, fuel (gasoline), rust removers or inhibitors, brake flui...

  • Page 90: Motorcycle Care and Storage

    7-3 motorcycle care and storage 1 2 3 4 5 6 7 8 9 after cleaning 1. Dry the motorcycle with a chamois or an absorbing cloth. 2. Immediately dry the drive chain and lubricate it to prevent it from rusting. 3. Use a chrome polish to shine chrome, aluminum and stainless- steel parts, including the exha...

  • Page 91: Motorcycle Care and Storage

    7-4 motorcycle care and storage 1 2 3 4 5 6 7 8 9 storage short-term always store your motorcycle in a cool, dry place and, if necessary, pro- tect it against dust with a porous cover. Eca00014 c c 8 storing the motorcycle in a poorly ventilated room or cov- ering it with a tarp, while it is still w...

  • Page 92: Motorcycle Care and Storage

    7-5 motorcycle care and storage 1 2 3 4 5 6 7 8 9 6. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/centerstand. 7. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the g...

  • Page 93: Specifications

    8-1 eau01038 specifications 1 2 3 4 5 6 7 8 9 specifications model dt230(n) dimensions overall length 2,225 mm overall width 800 mm overall height 1,200 mm seat height 865 mm wheel base 1,410 mm ground clearance 300 mm minimum turning radius 2,100 mm basic weight (with oil and full fuel tank) 133 kg...

  • Page 94: Specifications

    8-2 1 2 3 4 5 6 7 8 9 specifications spark plug manufacturer/model ngk/br9es gap 0.7–0.8 mm clutch type wet, multiple-disc transmission primary reduction system helical gear primary reduction ratio 54/21 (2.571) secondary reduction system chain drive secondary reduction ratio 3.437 number of drive c...

  • Page 95: Specifications

    Specifications 8-3 1 2 3 4 5 6 7 8 9 wheels front type spoke wheel size 1.60 × 21 rear type spoke wheel size 2.15 × 18 brakes front type single disc brake operation right hand fluid dot 4 rear type single disc brake operation right foot fluid dot 4 suspension front telescopic fork rear swingarm (new...

  • Page 96: Specifications

    8-4 1 2 3 4 5 6 7 8 9 specifications neutral indicator light 12 v, 3w × 1 high beam indicator light 12 v, 3w × 1 turn signal indicator light 12 v, 3w × 1 oil level/coolant temperature warning light led fuse 30a 4tp-9-21 7/25/00 3:46 pm page 95.

  • Page 97: Specifications

    Specifications 1 2 3 4 5 6 7 8 9 8-5 eau01064 conversion table all specification data in this manual are listed in si and metric units. Use this table to convert metric unit data to imperial unit data. Ex. Metric multiplier imperial ** mm × 0.03937 = ** in 2 mm × 0.03937 = 0.08 in metric to imperial...

  • Page 98: Consumer Information

    9-1 1 2 3 4 5 6 7 8 9 eau01039 consumer information 1 1 eau02944 identification numbers record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a yamaha dealer or for reference in case ...

  • Page 99: Consumer Information

    1 2 3 4 5 6 7 8 9 9-2 consumer information 1 eau01049 model label the model label is affixed to the loca- tion shown in the figure. Record the information on this label in the space provided. This information will be needed when ordering spare parts from a yamaha dealer. 1. Model label eau01388 moto...

  • Page 100

    1 2 3 4 5 6 7 8 9 4tp-9-21 7/25/00 3:46 pm page 99.

  • Page 101

    4tp-9-21 7/25/00 3:46 pm page 100

  • Page 102

    Printed on recycled paper printed in japan 2000·7– 0.1 × 1(e) ! Owner’s manual 4tp-28199-21 dt230(n) yamaha motor co., ltd..