oil YAMAHA TDR 125 2000 User Guide

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PERIODIC MAINTENANCE AND MINOR REPAIR
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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)
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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6-9
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1. Transmission oil filler cap
2. With the engine stopped, check
the oil level through the level
window located at the right side
crankcase cover.
NOTE:
Wait a few minutes until the oil level
settles before checking.
3. The oil level should be above the
minimum level mark on the level
window. If the level is low, add
sufficient oil to raise it to the
proper level.Transmission oil replacement
1. Warm up the engine for several
minutes.
2. Stop the engine. Place an oil pan
under the engine and remove the
oil filler cap.
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EAU01080Transmission oil
Oil level measurement
1. Place the motorcycle on a level
place and hold it an upright posi-
tion. Warm up the engine for
several minutes.
NOTE:
Be sure the motorcycle is positioned
straight up when checking the oil
level. A slight tilt toward the side can
result in false readings.
1. Level window
2. Minimum level
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3. Remove the drain bolt and drain
the oil.
4. Reinstall the drain bolt and tight-
en it to the specified torque.
5. Fill the engine with oil. Install the
oil filler cap and tighten it.
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8
8
Do not put in any chemical
additives. Transmission oil
also lubricates the clutch and
additives could cause clutch
slippage.
8 8
Be sure no foreign material
enters the crankcase.
6. Start the engine and warm up for
a few minutes. While warming
up, check for oil leakage. If oil
leakage is found, stop the engine
immediately and check for
cause.
1. Drain bolt
PERIODIC MAINTENANCE AND MINOR REPAIR
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9 Tightening torque:
Drain bolt:
15 Nm (1.5 m0kg)
Recommended oil:
See page 8-1
Oil quantity:
Total amount: 0.8 L
Periodic oil change: 0.75 L
1
2
1. Maximum level mark
2. Minimum level mark
EAU01621*Cooling system
1. Check the coolant level in the
reservoir tank when the engine is
cold as the coolant level will vary
with engine temperature. The
coolant level should be between
the minimum and maximum
marks on the tank.
2. If the coolant level is at or below
the minimum mark, fill with tap
water (soft water) to bring the
level up to the specified level.
Change the coolant every two
years.
3. If your motorcycle overheats, see
page 6-38 for details.
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EW000071
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8 8
Support the fuel tank carefully
during this procedure.
8 8
Do not tilt the fuel tank too
much or pull it too hard
because the fuel hose connec-
tions may become loose caus-
ing fuel leakage.
1
2
2
1. Relay (´2)
2. Screw (´7)
5. Remove the relays and the
screws holding the air filter case
cover.
1
1. Air filter
6. Remove the air filter element
from its case and clean it with
solvent. After cleaning, remove
the remaining solvent by squeez-
ing the air filter.
7. Apply recommended oil to the
entire surface of the air filter and
squeeze out the excess oil. The
air filter should be wet but not
dripping.
8. Install the air filter element in its
case.
9. Reinstall the parts removed for
access. Recommended oil:
2-stroke engine oil
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98Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor brake performance.
8Be careful that water does not
enter the master cylinder when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.
8Brake fluid may deteriorate paint-
ed surfaces or plastic parts.
Always clean up spilled fluid
immediately.
8Have a Yamaha dealer check
the cause if the brake fluid level
goes down.
EAU00742Brake fluid replacement
The brake fluid should be replaced
only by trained Yamaha service per-
sonnel. Have the Yamaha dealer
replace the following components
during periodic maintenance or when
they are damaged or leaking:
8oil seals (every two years)
8brake hoses (every four years)
EAU00744Drive chain slack check
NOTE:
Spin the wheel several times and find
the tightest position of the chain.
Check and/or adjust the chain slack
while it’s in this tightest position.
a
a. Chain slack
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EAU03006
Drive chain lubrication
The chain consists of many parts
which work with each other. If the
chain is not maintained properly, it
will wear out quickly. Therefore, the
chain must be serviced regularly.
This service is especially necessary
when riding in dusty areas. This
motorcycle is equipped with a sealed
type chain. Steam cleaning, high-
pressure washers, and solvents can
damage the drive chain, so do not
use these for cleaning it. Use only
kerosene to clean the drive chain.
Wipe it dry, and thoroughly lubricate it
with SAE 30 ~ 50W motor oil. Do not
use any other lubricants on the drive
chain. They may contain solvents
that could damage the sealed chain.
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Be sure to oil the chain after wash-
ing the motorcycle or riding in the
rain.
EAU02962
Cable inspection and
lubrication
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Damage to the outer housing of
cables may lead to internal rusting
and interfere with the cable move-
ment. Replace damaged cables as
soon as possible to prevent unsafe
conditions.
Lubricate the cables and cable ends.
If a cable does not operate smoothly,
ask a Yamaha dealer to replace it.
Recommended lubricant:
Engine oil
EAU00773
Throttle cable and grip
lubrication
The throttle twist grip assembly
should be greased at the time that
the cable is lubricated, since the grip
must be removed to get at the end of
the throttle cable. After removing the
screws, hold the end of the cable up
in the air and put in several drops of
lubricant. With the throttle grip disas-
sembled, coat the metal surface of
the grip assembly with a suitable all-
purpose grease.
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EAU00774
Autolube pump adjustment
The autolube pump is a vital part of
the engine and requires very sophisti-
cated adjustment.
Adjusting should be left to a Yamaha
dealer who has the professional
knowledge and experience to do so.
EAU02984
Brake and shift pedal
lubrication
Lubricate the pivoting parts.
Recommended lubricant:
Engine oil
EAU02985
Brake and clutch lever
lubrication
Lubricate the pivoting parts.
Recommended lubricant:
Engine oil
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EAU02986
Sidestand lubrication
Lubricate the sidestand pivoting point
and metal-to-metal contact surfaces.
Check that the sidestand moves up
and down smoothly.
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If the sidestand does not move
smoothly, consult a Yamaha deal-
er.
Recommended lubricant:
Engine oil
EAU00791
Rear suspension lubrication
Lubricate the pivoting parts.
Recommended lubricant:
Lithium soap base grease
EAU02939
Front fork inspection
Visual checkEW000115
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Securely support the motorcycle
so there is no danger of it falling
over.
Check for scratches or damage on
the inner tube and excessive oil leak-
age from the front fork.
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EAU01144Wheel bearings
If there is play in the front or rear
wheel hub or if the wheel does not
turn smoothly, have a Yamaha dealer
inspect the wheel bearings.
EAU00800Battery
This motorcycle is equipped with a
sealed-type battery. Therefore it is
not necessary to check the elec-
trolyte or fill the battery with distilled
water.
8 8
If the battery seems to have dis-
charged, consult a Yamaha deal-
er.
8 8
If the motorcycle is equipped
with optional electrical acces-
sories, the battery tends to dis-
charge more quickly, so be sure
to recharge it periodically.
EC000101
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Never try to remove the sealing
caps of the battery cells. The bat-
tery will be damaged.
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Battery electrolyte is poisonous
and dangerous, causing severe
burns, etc. It contains sulfuric
acid. Avoid contact with skin, eyes
or clothing.
ANTIDOTE:
8 8
EXTERNAL: Flush with water.
8 8
INTERNAL: Drink large quanti-
ties of water or milk. Follow
with milk of magnesia, beaten
egg, or vegetable oil. Call a
physician immediately.
8 8
EYES: Flush with water for 15
minutes and get prompt med-
ical attention.
Batteries produce explosive
gases. Keep sparks, flame, ciga-
rettes etc., away. Ventilate when
charging or using in an enclosed
space. Always shield your eyes
when working near batteries.
KEEP OUT OF REACH OF CHIL-
DREN.
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1. Headlight connector
2. Bulb holder cover
EAU01079*
Headlight bulb replacement
If the headlight bulb burns out,
replace the bulb as follows:
1. Remove cowling A and B. (See
page 6-7 for removal and instal-
lation procedures.)
2. Disconnect the headlight con-
nector and remove the bulb hold-
er cover.
3. Remove the bulb holder.
NOTE:
Removal procedure is different
depending on the bulb holder type.
Remove your bulb holder by referring
to the above illustration.
4. Remove the defective bulb.EW000119
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Keep flammable products and your
hands away from a bulb while it is
on, as it is hot. Do not touch a
bulb until it cools down.
Type 1Type 2
Type 3Type 4 Turn
Unhook
UnhockTurn5. Put a new bulb into position and
secure it in place with the bulb
holder.
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Avoid touching the glass part of a
bulb. Keep it free from oil; other-
wise, the transparency of the
glass, life of the bulb, and lumi-
nous flux will be adversely affect-
ed. If oil gets on a bulb, thoroughly
clean it with a cloth moistened
with alcohol or lacquer thinner.
6. Install the bulb holder cover.
7. Install the headlight connector
and the cowling.
If the headlight beam adjustment
is necessary, ask a Yamaha
dealer to make adjustment.
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