brake pads YAMAHA TDR 125 2000 Owners Manual

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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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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6-21
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
EW000109
w
A soft or spongy feeling in the
brake pedal can indicate the pres-
ence of air in the brake system.
This air must be removed by
bleeding the brake system before
the motorcycle is operated. Air in
the system will cause greatly
diminished braking capability and
can result in loss of control and an
accident. Have a Yamaha dealer
inspect and bleed the system if
necessary.
EAU00713
Brake light switch
adjustment
The rear brake light switch is activat-
ed by the brake pedal and is properly
adjusted when the brake light comes
on just before braking takes effect.
To adjust the rear brake light switch,
hold the switch body so it does not
rotate while turning the adjusting nut.
Turn the adjusting nut in direction a
to make the brake light come on earli-
er.
Turn the adjusting nut in direction b
to make the brake light come on
later.
ba
1
2
1. Brake light switch
2. Adjusting nut
EAU00721
Checking the front and rear
brake pads
EAU00725
Front brake
A wear indicator groove is provided
on each brake pad. This indicator
allows checking of brake pad wear
without disassembling the brake.
Inspect the groove. If the groove has
almost disappeared, ask a Yamaha
dealer to replace the pads.
1
1. Wear indicator grooveFRONT
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6-22
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
1
1. Wear limit: 0.8 mmREAR
EAU00733
Inspecting the brake fluid
level
Insufficient brake fluid may let air
enter the brake system, possibly
causing the brakes to become inef-
fective.
Before riding, check that the brake
fluid is above the minimum level and
replenish when necessary.
Observe these precautions:
8When checking the fluid level,
make sure the top of the master
cylinder is level by turning the
handlebars.
1
1. Minimum level markFRONT
1
1. Minimum level mark
8Use only the designated quality
brake fluid. Otherwise, the rub-
ber seals may deteriorate, caus-
ing leakage and poor brake per-
formance.
NOTE:
If DOT 4 is not available, DOT 3 can
be used for the front brake only.
REAR
Recommended fluid:
DOT 4
EAU00730
Rear brake
Inspect the pads through the window
as shown.
If the thickness is less than the speci-
fied value, have a Yamaha dealer
replace the pads.
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6-34
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
3. Install the wheel axle and let the
motorcycle down.
4. Push down hard on the handle-
bars several times to check for
proper fork operation.
5. Tighten the wheel axle to the
specified torque.
6. Install the pinch bolt and tighten
it to the specified torque.
7. Install the speedometer cable.Tightening torque:
Wheel axle:
59 Nm (5.9 m0kg)
Pinch bolt:
20 Nm (2.0 m0kg)
312
EAU01618Rear wheel removalEW000122
w
8 8
It is advisable to have a
Yamaha dealer service the
wheel.
8 8
Securely support the motorcy-
cle so there is no danger of it
falling over.
1. Loosen the axle nut.
1. Locknut
2. Adjusting nut
3. Axle nut
EAU01394Front wheel installation
1. Install the speedometer gear unit
into the wheel hub. Make sure
the wheel hub and the
speedometer gear unit are
installed with the projections
meshed into the slots.
2. Lift up the wheel between the
front fork legs and guide the
brake disc between the brake
pads. Make sure the slot in the
speedometer gear unit fits over
the stopper on the front fork
outer tube.
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6-35
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
2. Elevate the rear wheel by placing
a suitable stand under the
engine.
3. Remove the axle nut.
4. Loosen the locknuts and chain
adjusting nuts on each side.
5. Push the wheel forward and
remove the drive chain.
6. While supporting the brake
caliper, pull out the wheel axle.
7. Remove the wheel assembly.
NOTE:
8Do not depress the brake pedal
when the disc and caliper are
separated.
8You do not have to disassemble
the chain in order to remove or
install the rear wheel.
EAU01620
Rear wheel installation
1. Install the rear brake caliper.
Make sure the slot in the caliper
bracket is fit over the stopper on
the swingarm.
2. Install the rear wheel and chain.
Guide the brake disc between
the brake pads. Make sure there
is enough gap between the
brake pads before inserting the
brake disc.
3. Install the wheel axle and axle
nut, and let the motorcycle down.
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INDEX
Engine stop switch ..................................3-7
Engine temperature gauge ......................3-5
F
Front brake lever .....................................3-8
Front brake lever free play
adjustment ..........................................6-20
Front fork inspection ..............................6-28
Front wheel installation..........................6-34
Front wheel removal ..............................6-33
Fuel .......................................................3-10
Fuel cock ...............................................3-12
Fuel tank cap ...........................................3-9
Fuse replacement..................................6-30
H
Handlebar switches .................................3-5
Dimmer switch ......................................3-5
Engine stop switch ................................3-7
Headlight beam variation ......................3-6
Horn switch ...........................................3-5
Lights switch .........................................3-5
Start switch ...........................................3-7
Turn signal switch .................................3-5
Headlight beam variation.........................3-6
Headlight bulb replacement...................6-31
Helmet holder ........................................3-14
High beam indicator light .........................3-2
Horn switch..............................................3-5
How to use the conversion table .............8-5
I
Identification number records ..................9-1
Idle speed adjustment ...........................6-15
Indicator lights .........................................3-2
High beam indicator light ......................3-2Neutral indicator light ............................3-2
Oil level indicator light ...........................3-2
Turn indicator light ................................3-2
Inspecting the brake fluid level ..............6-22
K
Key identification number ........................9-1
L
Lights switch ............................................3-5
Left view ..................................................2-1
M
Main switch/Steering lock ........................3-1
Model lavel ..............................................9-2
N
Neutral indicator light...............................3-2
Note on handling of the Yamaha
Energy Induction System (Y.E.I.S.) ....3-15
O
Oil level indicator circuit check ................3-3
Oil level indicator light .............................3-2
P
Panel A ....................................................6-7
Parking ....................................................5-6
Periodic maintenance and
lubrication .............................................6-3
Pre-operation check list ...........................4-1
R
Rear brake pedal .....................................3-9
Rear brake pedal height adjustment .....6-20
Rear shock absorber adjustment ..........3-14
Rear suspension lubrication ..................6-27
Rear wheel installation ..........................6-35
Rear wheel removal ..............................6-34A
Air filter ..................................................6-13
Autolube pump adjustment....................6-26
B
Battery ...................................................6-29
Brake and clutch lever lubrication .........6-27
Brake and shift pedal lubrication ...........6-26
Brake fluid replacement.........................6-23
Brake light switch adjustment ................6-21
C
Cable inspection and lubrication ...........6-25
Carburetor adjustment...........................6-15
Care.........................................................7-1
Catalyzer
(for Switzerland and Austria) ..............3-11
Checking the front and rear brake
pads ....................................................6-21
Clutch lever .............................................3-8
Clutch lever free play adjustment ..........6-19
Controls/Instruments ...............................2-3
Cooling system ......................................6-11
Cowling A, B ............................................6-7
Cowling and panel removal and
installation .............................................6-6
D
Description ..............................................2-1
Dimmer switch .........................................3-5
Drive chain lubrication ...........................6-25
Drive chain slack adjustment.................6-24
Drive chain slack check .........................6-23
E
Engine break-in .......................................5-5
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