brake YAMAHA TDR 125 2001 Owners Manual

EAU00009
TABLE OF CONTENTS
GIVE SAFETY THE RIGHT OF WAY.................1-1
DESCRIPTION....................................................2-1
Left view...........................................................2-1
Right view.........................................................2-2
Controls and instruments..................................2-3
INSTRUMENT AND CONTROL FUNCTIONS....3-1
Main switch/steering lock..................................3-1
Indicator and warning lights..............................3-2
Speedometer unit.............................................3-3
Tachometer......................................................3-3
Coolant temperature gauge..............................3-4
Handlebar switches..........................................3-4
Clutch lever.......................................................3-6
Shift pedal.........................................................3-6
Brake lever.......................................................3-7
Brake pedal......................................................3-7
Fuel tank cap....................................................3-7
Fuel (except for Switzerland and Austria).........3-8
Fuel (for Switzerland and Austria)....................3-8
Catalytic converter
(for Switzerland and Austria)..........................3-9
2-stroke engine oil..........................................3-10
Fuel cock........................................................3-11
Starter (choke) lever ......................................3-12
Seat................................................................3-12Helmet holder.................................................3-13
Adjusting the shock absorber assembly.........3-13
YEIS handling precautions.............................3-14
YPVS..............................................................3-14
Sidestand........................................................3-15
Ignition circuit cut-off system..........................3-16
PRE-OPERATION CHECKS...............................4-1
Pre-operation check list....................................4-1
OPERATION AND IMPORTANT RIDING
POINTS...............................................................5-1
Starting a cold engine.......................................5-1
Starting a warm engine.....................................5-2
Shifting..............................................................5-3
Recommended shift points
(for Switzerland only)......................................5-3
Tips for reducing fuel consumption...................5-4
Engine break-in................................................5-4
Parking.............................................................5-5
PERIODIC MAINTENANCE AND MINOR
REPAIR...............................................................6-1
OwnerÕs tool kit.................................................6-1
Periodic maintenance and lubrication chart......6-2
Removing and installing cowlings and panel....6-5
Checking the spark plug...................................6-7
123
456
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Transmission oil................................................6-8
Coolant...........................................................6-10
Cleaning the air filter element.........................6-13
Adjusting the carburetor.................................6-15
Adjusting the engine idling speed...................6-16
Adjusting the throttle cable free play..............6-17
Tires................................................................6-17
Wheels............................................................6-20
Adjusting the clutch lever free play.................6-20
Adjusting the brake lever free play.................6-21
Adjusting the brake pedal position..................6-22
Adjusting the rear brake light switch...............6-22
Checking the front and rear brake pads.........6-23
Checking the brake fluid level.........................6-24
Changing the brake fluid.................................6-25
Drive chain slack............................................6-25
Lubricating the drive chain..............................6-26
Checking and lubricating the cables...............6-27
Checking and lubricating the throttle grip
and cable......................................................6-28
Adjusting the Autolube pump..........................6-28
Checking and lubricating the brake and shift
pedals...........................................................6-29
Checking and lubricating the brake and
clutch levers..................................................6-29
Checking and lubricating the sidestand..........6-29Lubricating the rear suspension.....................6-30
Checking the front fork...................................6-30
Checking the steering.....................................6-31
Checking the wheel bearings.........................6-32
Battery............................................................6-32
Replacing the fuse..........................................6-33
Replacing a headlight bulb.............................6-34
Replacing the tail/brake light bulb...................6-35
Replacing a turn signal light bulb....................6-36
Supporting the motorcycle..............................6-37
Front wheel.....................................................6-37
Rear wheel.....................................................6-39
Troubleshooting..............................................6-41
Troubleshooting charts...................................6-42
MOTORCYCLE CARE AND STORAGE.............7-1
Care..................................................................7-1
Storage.............................................................7-4
SPECIFICATIONS...............................................8-1
Conversion table...............................................8-5
CONSUMER INFORMATION.............................9-1
Identification numbers......................................9-1
Key identification number.................................9-1
Vehicle identification number............................9-1
Model label.......................................................9-2
TABLE OF CONTENTS
789
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2-2
DESCRIPTION
12
3
4
5
6
7
8
9 8.OwnerÕs tool kit (page 6-1)
9.Fuse (page 6-33)
10.Air filter element(page 6-13)
11.Radiator cap (page 6-11)
12.Brake pedal (page 3-7, 6-22)
13.Coolant reservoir tank (page 6-10)14.Shock absorber spring preload
adjusting ring (page 3-13)
89
1011
12
13 14
Right view
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DESCRIPTION
12
3
4
5
6
7
8
9
2-3
1.Clutch lever (page 3-6, 6-20)
2.Left handlebar switches (page 3-4)
3.Speedometer unit(page 3-3)
4.Coolant temperature gauge (page 3-4)
5.Tachometer (page 3-3)6.Right handlebar switches (page 3-6)
7.Brake lever (page 3-7, 6-21)
8.Throttle grip (page 6-17, 6-28)
9.Fuel tank cap (page 3-7)
10.Main switch/steering lock (page 3-1)
1
2345
67
8 9
10
Controls and instruments
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3-7
1
EAU00158
Brake leverThe brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the han-
dlebar grip.1.Brake lever
INSTRUMENT AND CONTROL FUNCTIONS
1
23
4
5
6
7
8
9
1
1.Brake pedal
EAU00162
Brake pedalThe brake pedal is on the right side
of the motorcycle. To apply the rear
brake, press down on the brake
pedal.
1
a
b
EAU02935
Fuel tank capTo open the fuel tank cap
Open the fuel tank cap lock cover,
insert the key into the lock, and then
turn it 1/4 turn clockwise. The lock will
be released and the fuel tank cap can
be opened.
To close the fuel tank cap
1.Push the fuel tank cap into posi-
tion with the key inserted in the
lock.
2.Turn the key counterclockwise to
the original position, remove it,
and then close the lock cover.1.Fuel tank cap lock cover
a.Open.
b.Unlock.
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4-1
EAU01114
PRE-OPERATION CHECKS
1
2
34
5
6
7
8
9The condition of a vehicle is the ownerÕs responsibility. Vital components can start to deteriorate quickly and unexpect-
edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak-
age or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thor-
ough visual inspection, to check the following points before each ride.
EAU03439
Pre-operation check list
ITEMCHECKSPAGE
Fuel¥Check fuel level in fuel tank.
¥Refuel if necessary.
¥Check fuel line for leakage.3-7Ð3-9
Two-stroke engine oil¥Check oil level in oil tank.
¥If necessary, add recommended oil to specified level.
¥Check vehicle for oil leakage.3-10
Transmission oil¥Check oil level in transmission case.
¥If necessary, add recommended oil to specified level.6-8Ð6-10
Coolant¥Check coolant level in reservoir.
¥If necessary, add recommended coolant to specified level.
¥Check cooling system for leakage.6-10Ð6-13
Front brake¥Check operation.
¥If soft or spongy, have Yamaha dealer bleed hydraulic system.
¥Check lever free play.
¥Adjust if necessary.
¥Check fluid level in reservoir.
¥If necessary, add recommended brake fluid to specified level.
¥Check hydraulic system for leakage.3-7, 6-21, 6-23Ð6-24
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4-2
PRE-OPERATION CHECKS
1
2
34
5
6
7
8
9
Rear brake¥Check operation.
¥If soft or spongy, have Yamaha dealer bleed hydraulic system.
¥Check fluid level in reservoir.
¥If necessary, add recommended brake fluid to specified level.
¥Check hydraulic system for leakage.3-7, 6-22Ð6-24
Clutch¥Check operation.
¥Lubricate cable if necessary.
¥Check lever free play.
¥Adjust if necessary.3-6, 6-20Ð6-21
Throttle grip¥Make sure that operation is smooth.
¥Lubricate throttle grip, housing and cable if necessary.
¥Check free play.
¥Adjust if necessary.6-17, 6-28
Control cables¥Make sure that operation is smooth.
¥Lubricate if necessary.6-27
Drive chain¥Check chain slack.
¥Adjust if necessary.
¥Check chain condition.
¥Lubricate if necessary.6-25Ð6-27
Wheels and tires¥Check for damage.
¥Check tire condition and tread depth.
¥Check air pressure.
¥Correct if necessary.6-17Ð6-20
Brake and shift pedals¥Make sure that operation is smooth.
¥Lubricate pedal pivoting points if necessary.6-29
Brake and clutch levers¥Make sure that operation is smooth.
¥Lubricate lever pivoting points if necessary.6-29
Sidestand¥Make sure that operation is smooth.
¥Lubricate pivot if necessary.6-29Ð6-30 ITEMCHECKSPAGE
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6-2
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU03686
Periodic maintenance and lubrication chart
NOTE:
8The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
8From 30,000 km, repeat the maintenance intervals starting from 6,000 km.
8Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.NO.ITEMCHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
16121824
1
*Fuel line¥Check fuel hoses for cracks or damage.ÖÖÖÖÖ
2Spark plug¥Replace.ÖÖÖÖÖ
3Air filter element¥Clean.ÖÖ
¥Replace.ÖÖ
4Clutch¥Check operation.
¥Adjust.ÖÖÖÖÖ
5*Front brake¥Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)ÖÖÖÖÖÖ
¥Replace brake pads.Whenever worn to the limit
6*Rear brake¥Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)ÖÖÖÖÖÖ
¥Replace brake pads.Whenever worn to the limit
7*Brake hoses¥Check for cracks or damage.ÖÖÖÖÖ
¥Replace. (See NOTE on page 6-4.)Every 4 years
8*Wheels¥Check runout and for damage.ÖÖÖÖ
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6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
6
20
*Autolube pump¥Check operation.
¥Bleed if necessary.ÖÖÖÖ
21Transmission oil¥Check.ÖÖÖÖÖÖ
¥Change.ÖÖ
22*Cooling system¥Check coolant level and vehicle for coolant leakage.ÖÖÖÖÖ
¥Change.Every 3 years
23*Front and rear brake
switches¥Check operation.ÖÖÖÖÖÖ
24Moving parts and cables¥Lubricate.ÖÖÖÖÖ
25*Lights, signals and
switches¥Check operation.
¥Adjust headlight beam.ÖÖÖÖÖÖ NO.ITEMCHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
16121824
EAU03541
NOTE:
8The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8Hydraulic brake service
9Regularly check and, if necessary, correct the brake fluid level.
9Every two years replace the internal components of the brake master cylinder and caliper, and change the brake
fluid.
9Replace the brake hoses every four years and if cracked or damaged.
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6-19
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9Tire information
This motorcycle is equipped with cast
wheels and tubeless tires.
EW000078
w8The front and rear tires should
be of the same make and
design, otherwise the handling
characteristics of the motorcy-
cle cannot be guaranteed.
8After extensive tests, only the
tires listed below have been
approved for this model by
Yamaha Motor Co., Ltd.
EAU00683
w8Have a Yamaha dealer replace
excessively worn tires. Be-
sides being illegal, operating
the motorcycle with excessive-
ly worn tires decreases riding
stability and can lead to loss
of control.
8The replacement of all wheel-
and brake-related parts, inclu-
ding the tires, should be left to
a Yamaha dealer, who has the
necessary professional knowl-
edge and experience.
FRONT
ManufacturerSizeTypeBRIDGESTONE
100/90-18 56PTW53
DUNLOP
100/90-18 56PD602F
REAR
ManufacturerSizeType
BRIDGESTONE
130/80-17 65PTW54
DUNLOP130/80-17 65PD602
EW000079
w8Have a Yamaha dealer replace
excessively worn tires.
Besides being illegal, operat-
ing the motorcycle with exces-
sively worn tires decreases
riding stability and can lead to
loss of control.
8The replacement of all wheel-
and brake-related parts,
including the tires, should be
left to a Yamaha dealer, who
has the necessary profession-
al knowledge and experience.
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