check oil 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
5AE-9-E4 (ENG) 8/30/00 5:04 PM Page 6

0
001
0001
00
140
180 120 100 80
1 23456
7
8
9
10
11
12
X1000r/min
km/h
CH
1
2
4
3
EAU03034
Indicator and warning lights
EAU03201
Oil level warning light Ò
7
Ó
This warning light comes on when
the engine oil level is low.
The electrical circuit of the warning
light can be checked according to the
following procedure.
1.Set the engine stop switch to Ò#Ó
and turn the key to ÒONÓ.
2.Shift the transmission into the
neutral position or pull the clutch
lever.3.Push the start switch. If the
warning light does not come on
while pushing the start switch,
have a Yamaha dealer check the
electrical circuit.
NOTE:
Even if the oil level is sufficient, the
warning light may flicker when riding
on a slope or during sudden acceler-
ation or deceleration, but this is not a
malfunction.
EAU00057
Turn signal indicator light Ò5Ó
This indicator light flashes when the
turn signal switch is pushed to the left
or right.
EAU00061
Neutral indicator light ÒNÓ
This indicator light comes on when
the transmission is in the neutral
position.
EAU00063
High beam indicator light Ò&Ó
This indicator light comes on when
the high beam of the headlight is
switched on.
1.Turn signal indicator light Ò5Ó
2.High beam indicator light Ò&Ó
3.Oil level warning light Ò
7
Ó
4.Neutral indicator light ÒNÓ
3-2
INSTRUMENT AND CONTROL FUNCTIONS
1
23
4
5
6
7
8
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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
5AE-9-E4 (ENG) 8/30/00 5:04 PM Page 28

5-2
EC000034
cCThe oil level warning light should
come on when the start switch is
pushed, and it should go off when
the start switch is released. If the
oil level warning light flickers or
remains on after starting, immedi-
ately stop the engine, and then
check the engine oil level and the
vehicle for oil leakage. If neces-
sary, add engine oil, and then
check the warning light again. If
the warning light does not come
on when pushing the start switch,
or if it does not go off after starting
with sufficient engine oil, have a
Yamaha dealer check the electrical
circuit.6.After starting the engine, move
the starter (choke) lever back
halfway.
ECA00045
cCFor maximum engine life, never
accelerate hard when the engine is
cold!7.When the engine is warm, turn
the starter (choke) off.NOTE:
The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off.
EAU01258
Starting a warm engineFollow the same procedure as for
starting a cold engine with the excep-
tion that the starter (choke) is not
required when the engine is warm.
OPERATION AND IMPORTANT RIDING POINTS
1
2
3
45
6
7
8
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6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
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
5AE-9-E4 (ENG) 8/30/00 5:04 PM Page 38

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.
5AE-9-E4 (ENG) 8/30/00 5:04 PM Page 39

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
1
2
3
4
56
7
8
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.
5AE-9-E4 (ENG) 8/30/00 5:04 PM Page 43

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
1
2
3
4
56
7
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.
5AE-9-E4 (ENG) 8/30/00 5:04 PM Page 44

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.
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
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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