transmission YAMAHA TDR 125 2000 User Guide

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
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 43

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.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 48

6-9
1
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.
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
12
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
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 52

6-10
1
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.
EC000078
cC
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
1
2
3
4
5
6
7
8
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.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 53

SPECIFICATIONS
1
2
3
4
5
6
7
8
9
Specifications
Model TDR125
Dimensions
Overall length 2,120 mm
(F, GB, IRL, B, P, GR, E)
2,185 mm (S, SF, D, CH, A)
Overall width 840 mm
Overall height 1,295 mm
Seat height 850 mm
Wheel base 1,405 mm
Ground clearance 270 mm
Minimum turning radius 2,200 mm
Basic weight (with oil and full
fuel tank)135 kg
136 kg (CH, A)
Engine
Engine type Liquid cooled 2-stroke,
gasoline
Cylinder arrangement Forward inclined single
cylinder
Displacement 125 cm
3
Bore ´Stroke 56.0 ´50.7 mm
Compression ratio 6.6:1
Starting system Electric starter
Lubrication system Separate lubrication
(Yamaha Autolube)Engine oil (2-cycle)
Type Yamaha oil 2T or equivalent
2-stroke engine oil
Capacity
Total amount 1.2 L
Transmission oil
Type SAE 10W30 SE motor oil
Capacity
Periodic oil change 0.75 L
Total amount 0.8 L
Radiator capacity
(Including all routes) 1.05 L
Air filterWet type element
Fuel
Type Regular unleaded gasoline
Fuel tank capacity 11 L
Reserve amount 2.2 L
Carburetor
Type/quantity TM28SS/1
Manufacturer MIKUNI
EAU01038
SPECIFICATIONS
8-1
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 90

SPECIFICATIONS
1
2
3
4
5
6
7
8
9
8-2 Spark plug
Type/Manufacturer BR9ES/NGK
Spark plug gap 0.7 ~ 0.8 mm
Clutch typeWet, multiple-disc
Transmission
Primary reduction system Helical gear
Primary reduction ratio 71/22 (3.227)
Secondary reduction system Chain drive
Secondary reduction ratio 57/16 (3.563)
Transmission type Constant mesh 6-speed
Operation Left foot operation
Gear ratio 1st 2.833
2nd 1.875
3rd 1.412
4th 1.143
5th 0.957
6th 0.818
Chassis
Frame type Semi double cradle
Caster angle 26°
Trail 116 mmTire
Type Tubeless
Front
Size 100/90-18 56P
Manufacturer/ BRIDGESTONE/TW53
model DUNLOP/D602F
Rear
Size 130/80-17 65P
Manufacturer/ BRIDGESTONE/TW54
model DUNLOP/D602
Maximum load* 180 kg
179 kg (CH, A)
Air pressure (cold tire)
up to 90 kg load*
Front 175 kPa (1.75 kg/cm
2, 1.75 bar)
Rear 200 kPa (2.00 kg/cm
2, 2.00 bar)
90 kg load ~ Maximum
load*
Front 175 kPa (1.75 kg/cm
2, 1.75 bar)
Rear 225 kPa (2.25 kg/cm
2, 2.25 bar)
* Load is total weight of cargo, rider, passenger and
accessories.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 91

INDEX
Recommended shift points
(for Switzerland only) ............................5-5
Right view ................................................2-2
S
Seat .......................................................3-13
Shift pedal ...............................................3-8
Shifting ....................................................5-4
Sidestand ..............................................3-16
Sidestand lubrication .............................6-27
Sidestand/clutch switch operation
check ..................................................3-17
Spark plug inspection ..............................6-8
Specifications ..........................................8-1
Speedometer ...........................................3-4
Start switch ..............................................3-7
Starter (choke) “1” ...............................3-13
Starting a warm engine ...........................5-4
Starting the engine ..................................5-1
Steering inspection ................................6-28
Storage ....................................................7-4
T
Tachometer .............................................3-4
Taillight bulb replacement .....................6-32
Throttle cable and grip lubrication .........6-25
Throttle cable free play adjustment .......6-16
Tips for reducing fuel consumption .........5-5
Tires ......................................................6-17
Tool kit .....................................................6-1
Transmission oil ......................................6-9
Troubleshooting.....................................6-36
Troubleshooting chart............................6-37
Turn indicator light ...................................3-2
Turn signal light bulb replacement ........6-32Turn signal switch....................................3-5
Two-stroke engine oil ............................3-12
V
Vehicle identification number ..................9-1
W
Wheel bearings .....................................6-29
Wheels ..................................................6-19
Y
Y.P.V.S.
(Yamaha Power Valve System) ..........3-16
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 99