wheel YAMAHA TDR 125 2001 Owners Manual

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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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
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3
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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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6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
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2
3
4
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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
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6-19
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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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6-20
PERIODIC MAINTENANCE AND MINOR REPAIR
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9
EAU03773
Cast wheelsTo maximize the performance, dura-
bility, and safe operation of your
motorcycle, note the following points
regarding the specified wheels.
8The wheel rims should be
checked for cracks, bends or
warpage before each ride. If any
damage is found, have a
Yamaha dealer replace the
wheel. Do not attempt even the
smallest repair to the wheel. A
deformed or cracked wheel must
be replaced.
8The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced.
An unbalanced wheel can result
in poor performance, adverse
handling characteristics, and a
shortened tire life.
8Ride at moderate speeds after
changing a tire since the tire sur-
face must first be Òbroken inÓ for
it to develop its optimal charac-
teristics.
ab
12 c
EAU00694
Adjusting the clutch lever
free playThe clutch lever free play should
measure 10Ð15 mm as shown.
Periodically check the clutch lever
free play and, if necessary, adjust it
as follows.
1.Loosen the locknut at the clutch
lever.
2.To increase the clutch lever free
play, turn the adjusting bolt in
direction a. To decrease the
clutch lever free play, turn the
adjusting bolt in direction b.1.Locknut (clutch lever)
2.Adjusting bolt
c.Free play
ba
1
2
3.If the specified clutch lever free
play could be obtained as
described above, tighten the
locknut and skip the rest of the
procedure, otherwise proceed as
follows.
4.Fully turn the adjusting bolt at the
clutch lever in direction ato
loosen the clutch cable.
5.Loosen the locknut at the
crankcase.
6.To increase the clutch lever free
play, turn the adjusting nut in
direction a. To decrease the
clutch lever free play, turn the
adjusting nut in direction b.1.Locknut (crankcase)
2.Adjusting nut
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6-25
PERIODIC MAINTENANCE AND MINOR REPAIR
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9
EAU03073
Changing the brake fluidHave a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrica-
tion chart. In addition, have the oil
seals of the master cylinder and
caliper as well as the brake hoses
replaced at the intervals listed below
or whenever they are damaged or
leaking.
8Oil seals: Replace every two
years.
8Brake hoses: Replace every four
years.
EAU00744
Drive chain slackThe drive chain slack should be
checked before each ride and adjust-
ed if necessary.
To check the drive chain slack
1.Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:
When checking and adjusting the
drive chain slack, the motorcycle
should be positioned straight up and
there should be no weight on it.
a
a.Drive chain slack2.Shift the transmission into the
neutral position.
3.Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain,
and then measure the drive
chain slack as shown.
4.If the drive chain slack is incor-
rect, adjust it as follows. Drive chain slack:
25Ð40 mm
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PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU03752
To adjust the drive chain slack
1.Loosen the axle nut, then loosen
the locknut at each end of the
swingarm.
2.To tighten the drive chain, turn
the adjusting nut at each end of
the swingarm in direction a. To
loosen the drive chain, turn the
adjusting nut at each end of the
swingarm in direction b, and
then push the rear wheel for-
ward.
1
4
2
3
a
b1.Axle nut
2.Lock nut
3.Adjusting nut
4.Alignment marks
EAU03006
Lubricating the drive chainThe drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly
wear out, especially when riding in
dusty or wet areas. Service the drive
chain as follows.
EC000097
cCThe drive chain must be lubricated
after washing the motorcycle or
riding in the rain.1.Clean the drive chain with
kerosene and a small soft brush.
ECA00053
cCTo prevent damaging the O-rings,
do not clean the drive chain with
steam cleaners, high-pressure
washers or inappropriate solvents.
NOTE:
Using the alignment marks on each
side of the swingarm, make sure that
both adjusting nuts are in the same
position for proper wheel alignment.
EC000096
cCImproper drive chain slack will
overload the engine as well as
other vital parts of the motorcycle
and can lead to chain slippage or
breakage. To prevent this from
occurring, keep the drive chain
slack within the specified limits.3.Tighten the locknuts, and then
tighten the axle nut to the speci-
fied torque.
Tightening torque:
Axle nut:
104 Nm (10.4 m0kg)
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9To check the operation
1.Place the motorcycle on a level
surface and hold it in an upright
position.
2.While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and
rebounds smoothly.
EC000098
cCIf any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
EAU00794
Checking the steeringWorn or loose steering bearings may
cause danger. Therefore, the opera-
tion of the steering must be checked
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
1.Place a stand under the engine
to raise the front wheel off the
ground.
EW000115
wSecurely support the motorcycle
so that there is no danger of it
falling over.
2.Hold the lower ends of the front
fork legs and try to move them
forward and backward. If any
free play can be felt, have a
Yamaha dealer check or repair
the steering.
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EAU01144
Checking the wheel bearingsThe front and rear wheel bearings
must be checked at the intervals
specified in the periodic maintenance
and lubrication chart. If there is play
in the wheel hub or if the wheel does
not turn smoothly, have a Yamaha
dealer check the wheel bearings.
EAU00800
BatteryThis motorcycle is equipped with a
sealed-type (MF) battery, which does
not require any maintenance. There
is no need to check the electrolyte or
to add distilled water.
EC000101
cCNever attempt to remove the bat-
tery cell seals, as this would per-
manently damage the battery.
EW000116
w8Electrolyte is poisonous and
dangerous since it contains
sulfuric acid, which causes
severe burns. Avoid any con-
tact with skin, eyes or clothing
and always shield your eyes
when working near batteries.
In case of contact, administer
the following FIRST AID.
9EXTERNAL: Flush with
plenty of water.9INTERNAL: Drink large
quantities of water or milk
and immediately call a
physician.
9EYES: Flush with water for
15 minutes and seek prompt
medical attention.
8Batteries produce explosive
hydrogen gas. Therefore, keep
sparks, flames, cigarettes,
etc., away from the battery and
provide sufficient ventilation
when charging it in an
enclosed space.
8KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
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