YAMAHA TDR 125 2000 Service Manual

5-4
EAU01258Starting a warm engine
The starter (choke) is not required
when the engine is warm.
EC000046
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See the “Engine break-in” section
prior to operating the motorcycle
for the first time.
EAU00423Shifting
The transmission lets you control the
amount of power you have available
at a given speed for starting, acceler-
ating, climbing hills, etc. The use of
the shift pedal is shown in the illustra-
tion.
To shift into neutral, depress the shift
pedal repeatedly until it reaches the
end of its travel, then raise the pedal
slightly.
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8
8
Do not coast for long periods
with the engine off, and do not
tow the motorcycle a long dis-
tance. Even with gears in neu-
tral, the transmission is only
properly lubricated when the
engine is running. Inadequate
lubrication may damage the
transmission.
8 8
Always use the clutch when
changing gears. The engine,
transmission, and driveline are
not designed to withstand the
shock of forced shifting and
can be damaged by shifting
without using the clutch.
OPERATION AND IMPORTANT RIDING POINTS
1
2
3
4
5
6
7
8
9
6
5
4
3
2
1 N1
1. Shift pedal
N. Neutral
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5-5
EAU00424
Tips for reducing fuel
consumption
Your motorcycle’s fuel consumption
depends to a large extent on your rid-
ing style. The following tips can help
reduce fuel consumption:
8Warm up the engine before rid-
ing.
8Turn off the starter (choke) as
soon as possible.
8Shift up swiftly and avoid high
engine speeds during accelera-
tion.
8Do not double-clutch or rev the
engine while shifting down and
avoid high engine speeds with
no load on the engine.
8Turn off the engine instead of let-
ting it idle for an extended length
of time, i.e. in traffic jams, at traf-
fic lights or railroad crossings.
EAU00436Engine break-in
There is never a more important peri-
od in the life of your motorcycle than
the period between zero and 1,000
km. For this reason we ask that you
carefully read the following material.
Because the engine is brand new,
you must not put an excessive load
on it for the first 1,000 km. The vari-
ous parts in the engine wear and pol-
ish themselves to the correct operat-
ing clearances. During this period,
prolonged full throttle operation, or
any condition which might result in
excessive heating of the engine,
must be avoided.
OPERATION AND IMPORTANT RIDING POINTS
1
2
3
4
5
6
7
8
9
EAU02937
Recommended shift points
(for Switzerland only)
The recommended shift points are
shown in the table below.
Acceleration shift point
km/h
1st ®2nd 20
2nd ®3rd 30
3rd ®4th 40
4th ®5th 50
5th ®6th 60
NOTE:
When shifting two gears down from
5th to 3rd, bring your motorcycle to a
speed of 35 km/h.
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5-6
EAU00453
0 ~ 500 km
Avoid operation above 6,000 r/min.
Stop the engine and let it cool for 5 to
10 minutes after every hour of opera-
tion. Vary the speed of the motorcy-
cle from time to time. Do not operate
it at one set throttle position.
500 ~ 1,000 km
Avoid prolonged operation above
7,000 r/min. Rev the motorcycle
freely through the gears, but do not
use full throttle at any time.
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After 1,000 km of operation, be
sure to replace the transmission
oil.
1,000 km and beyond
Full throttle can be used.
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8
8
Never let engine speeds enter
the red zone.
8 8
If any engine trouble should
occur during the break-in peri-
od, consult a Yamaha dealer
immediately.
EAU00458
Parking
When parking the motorcycle, stop
the engine and remove the ignition
key. Turn the fuel cock to “OFF”
whenever stopping the engine.
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w
The exhaust system is hot. Park
the motorcycle in a place where
pedestrians or children are not
likely to touch the motorcycle. Do
not park the motorcycle on a slope
or soft ground; the motorcycle
may overturn.
EC000062
cC
Never park this motorcycle in an
area that would cause a fire hazard
such as grass or other materials
that may easily burn.
OPERATION AND IMPORTANT RIDING POINTS
1
2
3
4
5
6
7
8
9
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1
2
3
4
5
6
7
8
9
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PERIODIC MAINTENANCE AND MINOR REPAIR
Tool kit ...................................................................6-1
Periodic maintenance and lubrication ....................6-3
Cowling and panel removal and installation...........6-6
Cowling A, B ..........................................................6-7
Panel A ..................................................................6-7
Spark plug inspection.............................................6-8
Transmission oil .....................................................6-9
Cooling system ....................................................6-10
Changing the coolant ...........................................6-11
Air filter .................................................................6-13
Carburetor adjustment .........................................6-15
Idle speed adjustment ..........................................6-15
Throttle cable free play adjustment ......................6-16
Tires .....................................................................6-17
Wheels .................................................................6-19
Clutch lever free play adjustment.........................6-19
Front brake lever free play adjustment ................6-20
Rear brake pedal height adjustment ....................6-20
Brake light switch adjustment ..............................6-21
Checking the front and rear brake pads...............6-21
Inspecting the brake fluid level.............................6-22
Brake fluid replacement .......................................6-23
Drive chain slack check .......................................6-23
Drive chain slack adjustment ...............................6-24Drive chain lubrication............................................6-25
Cable inspection and lubrication ............................6-25
Throttle cable and grip lubrication ..........................6-26
Autolube pump adjustment ....................................6-26
Brake and shift pedal lubrication ............................6-26
Brake and clutch lever lubrication ..........................6-27
Sidestand lubrication..............................................6-27
Rear suspension lubrication...................................6-27
Front fork inspection ..............................................6-28
Steering inspection ................................................6-28
Wheel bearings ......................................................6-29
Battery....................................................................6-29
Fuse replacement ..................................................6-30
Headlight bulb replacement ...................................6-31
Taillight bulb replacement ......................................6-32
Turn signal light bulb replacement .........................6-32
Front wheel removal ..............................................6-33
Front wheel installation ..........................................6-34
Rear wheel removal ...............................................6-34
Rear wheel installation ...........................................6-35
Troubleshooting .....................................................6-36
Troubleshooting chart ............................................6-37
6
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6-1
EAU00464
Periodic inspection, adjustment and
lubrication will keep your motorcycle
in the safest and most efficient condi-
tion possible. Safety is an obligation
of the motorcycle owner. The mainte-
nance and lubrication schedule chart
should be considered strictly as a
guide to general maintenance and
lubrication intervals.
YOU MUST TAKE INTO CONSIDER-
ATION THAT WEATHER, TERRAIN,
GEOGRAPHICAL LOCATIONS, AND
A VARIETY OF INDIVIDUAL USES
ALL TEND TO DEMAND THAT
EACH OWNER ALTER THIS TIME
SCHEDULE TO SHORTER INTER-
VALS TO MATCH THE ENVIRON-
MENT. The most important points of
motorcycle inspection, adjustment,
and lubrication are explained in the
following pages.
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If you are not familiar with motor-
cycle service, this work should be
done by a Yamaha dealer.
EAU00462
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
1
EAU00469Tool kit
The service information included in
this manual is intended to provide
you, the owner, with the necessary
information for completing some of
your own preventive maintenance
and minor repairs.
The tools provided in the owner’s tool
kit are to assist you in the perfor-
mance of periodic maintenance.
However, some other tools such as a
torque wrench are also necessary to
perform the maintenance correctly.
1. Tool kit
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6-2
NOTE:
If you do not have necessary tools
required during a service operation,
take your motorcycle to a Yamaha
dealer for service.
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w
Modifications to this motorcycle
not approved by Yamaha may
cause loss of performance, and
render it unsafe for use. Consult a
Yamaha dealer before attempting
any changes.
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
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EVERY
6,000 km 12,000 km
No.
ITEM CHECKS AND MAINTENANCE JOBS
Initialor or
(1,000 km)6 months 12 months
(Whichever (Whichever
comes first) comes first)
1 * Fuel line 9Check fuel hoses for cracks or damage.
ÖÖ
9Replace if necessary.
2 Spark plug9Check condition.
ÖÖÖ
9Clean, regap or replace if necessary.
3 Air filter9Clean or replace if necessary.ÖÖ
4 Clutch9Check operation.
ÖÖÖ
9Adjust or replace cable.
9Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)
Ö
5 * Front brake
9Correct accordingly.ÖÖ
9Replace brake pads if necessary.
9Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)
6 * Rear brake
9Correct accordingly.ÖÖÖ
9Replace brake pads if necessary.
7 * Wheels9Check balance, runout and for damage.
ÖÖ
9Rebalance or replace if necessary.
9Check tread depth and for damage.
8 * Tires9Replace if necessary.
ÖÖ
9Check air pressure.
9Correct if necessary.
9 * Wheel bearings9Check bearing for looseness or damage.
ÖÖ
9Replace if necessary.
6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
EAU00473
PERIODIC MAINTENANCE AND LUBRICATION
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6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EVERY
6,000 km 12,000 km
No.
ITEM CHECKS AND MAINTENANCE JOBS
Initialor or
(1,000 km)6 months 12 months
(Whichever (Whichever
comes first) comes first)
9Check swingarm pivoting point for play.
10 * Swingarm9Correct if necessary.
ÖÖ
9Lubricate with lithium soap base grease every
24,000 km or 24 months (whichever comes first).
9Check chain slack.
11 Drive chain9
Adjust if necessary. Make sure that the rear wheel is properly aligned.Every 1,000 km and after washing
9Clean and lubricate.the motorcycle or riding in the rain
9Check bearing play and steering for roughness.
12 * Steering bearings9Correct accordingly.
ÖÖ
9Lubricate with lithium soap base grease every 24,000 km or
24 months (whichever comes first).
13 * Chassis fasteners9
Make sure that all nuts, bolts and screws are properly tightened.ÖÖ9Tighten if necessary.
14 Sidestand9Check operation.
ÖÖ
9Lubricate and repair if necessary.
15 * Sidestand switch9Check operation.
ÖÖÖ
9Replace if necessary.
16 * Front fork9Check operation and for oil leakage.
ÖÖ
9Correct accordingly.
17 *Rear shock absorber9Check operation and shock absorber for oil leakage.
ÖÖ
assembly9Replace shock absorber assembly if necessary.
Rear shock absorber9Check operation.
18 * assembly pivoting9Lubricate with lithium grease every 24,000 km ÖÖ
pointsor 24 months (whichever comes first).
19 * Carburetor9Check engine idling speed and starter operation.
ÖÖÖ
9Adjust if necessary.
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6-5
PERIODIC MAINTENANCE AND MINOR REPAIR
6
7
8
9
EVERY
6,000 km 12,000 km
No.
ITEM CHECKS AND MAINTENANCE JOBS
Initialor or
(1,000 km)6 months 12 months
(Whichever (Whichever
comes first) comes first)
9Check operation.
20 * Autolube pump9Correct if necessary.ÖÖÖ
9Bleed if necessary.
9Check oil level and vehicle for oil leakage.
21 Transmission oil9Correct accordingly.
ÖÖÖ
9Change oil at initial 1,000 km and thereafter every
24,000 km or 24 months (whichever comes first).
9Check coolant level and vehicle for coolant leakage.
22 * Cooling system9Correct if necessary.
ÖÖ
9Change coolant every 24,000 km or 24 months (whichever
comes first).
* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.EAU02970
NOTE
8The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8Hydraulic brake system
9When disassembling the master cylinder or caliper, always replace the brake fluid. Check the brake fluid level
regularly and fill as required.
9Replace the oil seals on the inner parts of the master cylinder and caliper every two years.
9Replace the brake hoses every four years or if cracked or damaged.
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