engine YAMAHA TDR 125 2001 Owner's Manual

EAU00453
0Ð500 km
8Avoid prolonged operation above
6,000 r/min.
8After every hour of operation,
stop the engine, and then let it
cool for five to ten minutes.
8Vary the engine speed from time
to time. Do not operate the
engine at one set throttle posi-
tion.
500Ð1,000 km
8Avoid prolonged operation above
7,000 r/min.
8Rev the engine freely through
the gears, but do not use full
throttle at any time.
EC000060
cCAfter 1,000 km of operation, the
transmission oil must be changed.
5-4
EAU00424
Tips for reducing fuel
consumptionFuel consumption depends largely on
your riding style. Consider the follow-
ing tips to reduce fuel consumption:
8Thoroughly warm up the engine.
8Turn the starter (choke) off as
soon as possible.
8Shift up swiftly, and avoid high
engine speeds during accelera-
tion.
8Do not rev the engine while shift-
ing down, and avoid high engine
speeds with no load on the
engine.
8Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at
traffic lights or at railroad cross-
ings).
EAU00436
Engine break-inThere is never a more important peri-
od in the life of your engine than the
period between 0 and 1,000 km. For
this reason, you should read the fol-
lowing material carefully.
Since the engine is brand new, do
not put an excessive load on it for the
first 1,000 km. The various parts in
the engine wear and polish them-
selves to the correct operating clear-
ances. During this period, prolonged
full-throttle operation or any condition
that might result in engine overheat-
ing must be avoided.
OPERATION AND IMPORTANT RIDING POINTS
1
2
3
45
6
7
8
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5-5
1,000 km and beyond
The vehicle can now be operated
normally.
EC000053
cC8Keep the engine speed out of
the tachometer red zone.
8If any engine trouble should
occur during the engine break-
in period, immediately have a
Yamaha dealer check the vehi-
cle.
EAU00458
ParkingWhen parking, stop the engine,
remove the key from the main switch,
and then turn the fuel cock lever to
ÒOFFÓ.
EW000058
w8Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely
to touch them.
8Do not park on a slope or on
soft ground, otherwise the
motorcycle may overturn.
EC000062
cCNever park in an area where there
are fire hazards such as grass or
other flammable materials.OPERATION AND IMPORTANT RIDING POINTS
1
2
3
45
6
7
8
9
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PERIODIC MAINTENANCE AND MINOR REPAIR
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9
*Tires¥Check tread depth and for damage.
¥Replace if necessary.
¥Check air pressure.
¥Correct if necessary.ÖÖÖÖ
10*Wheel bearings¥Check bearing for looseness or damage.ÖÖÖÖ
11*Swingarm¥Check swingarm pivoting point for play.ÖÖÖÖ
¥Lubricate with lithium-soap-based grease.Every 24,000km
12Drive chain¥Check chain slack.
¥Make sure that the rear wheel is properly aligned.
¥Clean and lubricate.Every 1,000 km and after washing the motorcycle
or riding in the rain.
13*Steering bearings¥Check bearing play and steering for roughness.ÖÖÖÖÖ
¥Lubricate with lithium-soap-based greaseEvery 24,000km
14*Chassis fasteners¥Make sure that all nuts, bolts and screws are properly tightened.ÖÖÖÖÖ
15Sidestand¥Check operation.
¥Lubricate.ÖÖÖÖÖ
16*Sidestand switch¥Check operation.ÖÖÖÖÖÖ
17*Front fork¥Check operation and for oil leakage.ÖÖÖÖ
18*Rear shock absorber
assembly¥Check operation and shock absorber for oil leakage.ÖÖÖÖ
¥Lubricate the pivoting points with molybdenum disulfide
grease.ÖÖ
19*Carburetor¥Check starter (choke) operation.
¥Adjust engine idling speed.ÖÖÖÖÖÖ NO.ITEMCHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
16121824
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1
2.Remove the spark plug as
shown, with the spark plug
wrench included in the ownerÕs
tool kit.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
different color, the engine could be
defective. Do not attempt to diagnose
such problems yourself. Instead,
have a Yamaha dealer check the
motorcycle.2.Check the spark plug for elec-
trode erosion and excessive car-
bon or other deposits, and
replace it if necessary.
1.Spark plug wrench
6-7
PERIODIC MAINTENANCE AND MINOR REPAIR
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9Specified spark plug:
BR9ES (NGK)
1
EAU01833
Checking the spark plugThe spark plug is an important
engine component, which is easy to
check. Since heat and deposits will
cause any spark plug to slowly erode,
the spark plug should be removed
and checked in accordance with the
periodic maintenance and lubrication
chart. In addition, the condition of the
spark plug can reveal the condition of
the engine.
To remove the spark plug
1.Remove the spark plug cap.1.Spark plug cap
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6-8
NOTE:
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is
1/4Ð1/2 turn past finger tight.
However, the spark plug should be
tightened to the specified torque as
soon as possible.4.Install the spark plug cap.
PERIODIC MAINTENANCE AND MINOR REPAIR
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9 Spark plug gap:
0.7Ð0.8 mm
Tightening torque:
Spark plug:
20 Nm (2.0 m0kg)
a
a.Spark plug gapTo install the spark plug
1.Measure the spark plug gap with
a wire thickness gauge and, if
necessary, adjust the gap to
specification.
2.Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3.Install the spark plug with the
spark plug wrench, and then
tighten it to the specified torque.
EAU03751
Transmission oilThe transmission oil level should be
checked before each ride. In addition,
the transmission oil must be changed
at the intervals specified in the peri-
odic maintenance and lubrication
chart.
To check the transmission oil level
1.Place the motorcycle on a level
surface and hold it in an upright
position. NOTE:
Make sure that the motorcycle is
positioned straight up when checking
the oil level. A slight tilt to the side
can result in a false reading.2.Start the engine, warm it up for
several minutes, and then turn it
off.
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1
4.Install the transmission oil drain
bolt, and then tighten it to the
specified torque.
5.Add the specified amount of the
recommended transmission oil,
and then install and tighten the
oil filler cap.1.Transmission oil drain bolt
6-9
1
1.Oil filler capTo change the transmission oil
1.Start the engine, warm it up for
several minutes, and then turn it
off.
2.Place an oil pan under the trans-
mission to collect the used oil.
3.Remove the oil filler cap and
drain bolt to drain the oil from the
transmission.
PERIODIC MAINTENANCE AND MINOR REPAIR
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8
9Tightening torque:
Transmission oil drain bolt:
15 Nm (1.5 m0kg)
1
2
1.Check window
2.Minimum level mark3.Wait a few minutes until the oil
settles, and then check the oil
level through the check window
located at the right side of the
crankcase.NOTE:
The transmission oil should be above
the minimum level mark.4.If the oil is below the minimum
level mark, remove the oil filler
cap, add sufficient oil of the rec-
ommended type to raise it to the
correct level, and then install and
tighten the cap.
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6-10
EC000077
cC8In order to prevent clutch slip-
page (since the transmission
oil also lubricates the clutch),
do not mix any chemical addi-
tives with the oil.
8Make sure that no foreign
material enters the transmis-
sion.6.Start the engine, and then let it
idle for several minutes while
checking the transmission for oil
leakage. If oil is leaking, immedi-
ately turn off the engine and
check for the cause.
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9 Recommended transmission oil:
See page 8-1
Oil quantity:
Periodic oil change:
0.75 L
Total amount (dry transmission):
0.8 L
1
2
1.Maximum level mark
2.Minimum level mark2.Check the coolant level in the
coolant reservoir.NOTE:
The coolant should be between the
minimum and maximum level marks.3.If the coolant is at or below the
minimum level mark, open the
reservoir cap, add coolant to the
maximum level mark, and then
close the reservoir cap.
EAU03761
CoolantTo check the coolant level
1.Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:
8The coolant level must be
checked on a cold engine since
the level varies with engine tem-
perature.
8Make sure that the motorcycle is
positioned straight up when
checking the coolant level. A
slight tilt to the side can result in
a false reading.
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EW000067
wNever attempt to remove the radia-
tor cap when the engine is hot.NOTE:
If the engine overheats, see page
6-43 for further instructions.
6-11
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EAU03746
To change the coolant
1.Place the motorcycle on a level
surface and let the engine cool if
necessary.
2.Remove the seat. (See page
3-12 for seat removal and instal-
lation procedures.)
3.Remove the radiator cover and
cowling B. (See pages 6-6 for
cowling removal and installation
procedures.)
4.Remove the radiator cap .
EW000067
wNever attempt to remove the radia-
tor cap when the engine is hot.
1
1.Radiator cap
1
5.Place a container under the
engine to collect the used
coolant.
6.Remove the coolant drain bolt
and disconnect the hose on the
side of the reservoir to drain the
reservoir.
7.After the coolant is completely
drained, thoroughly flush the
cooling system with clean tap
water.
8.Install the coolant drain bolt, and
then tighten it to the specified
torque.1.Coolant drain bolt
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1
NOTE:
Check the washer for damage and
replace it if necessary.9.Install the reservoir tank hose.1.Hose
Tightening torque:
Coolant drain bolt:
8 Nm (0.8 m0kg)
10.Pour the recommended coolant
into the radiator until it is full.
Antifreeze/water mixture ratio:
1:1
Recommended antifreeze:
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Coolant quantity:
Total amount:
1.05 L
Coolant reservoir capacity:
0.35 L
EC000080
cC8If 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.
8If water has been used instead
of coolant, replace it with
coolant as soon as possible,
otherwise the engine may not
be sufficiently cooled and the
cooling system will not be pro-
tected against frost and corro-
sion.
8If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possi-
ble, otherwise the effective-
ness of the coolant will be
reduced. 11.Install the radiator cap, start the
engine, let it idle for several min-
utes, and then turn it off.
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1.Coolant reservoir tank cap
2.Stopper
3.Screw
4.Maximum level mark
5.Minimum level mark12.Remove the radiator cap to
check the coolant level in the
radiator. If necessary, add suffi-
cient coolant until it reaches the
top of the radiator, and then
install the radiator cap.
13.Check the coolant level in the
reservoir. If necessary, remove
the coolant reservoir cap by
removing the screw and stopper,
add coolant to the maximum
level mark, and then install the
cap, stopper and screw.14.Start the engine, and then check
the vehicle for coolant leakage. If
coolant is leaking, have a
Yamaha dealer check the cool-
ing system.
15.Install the cowling, radiator cover
and seat.
1
EAU03747
Cleaning the air filter
elementThe 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 wet or dusty areas.
1.Remove the seat. (See page
3-12 for seat removal and instal-
lation procedures.)
2.Remove cowlings A and B. (See
page 6-6 for cowling removal
and installation procedures.)
3.Remove the fuel tank bolt.1.Bolt
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