brake YAMAHA TDR 125 2002 User Guide

6-21
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00696
Adjusting the brake lever
free playThe brake lever free play should
measure 2–5 mm as shown.
Periodically check the brake lever
free play and, if necessary, adjust it
as follows.
1. Loosen the locknut at the brake
lever.
2. To increase the brake lever free
play, turn the adjusting bolt in
direction a. To decrease the
brake lever free play, turn the
adjusting bolt in direction b.
3. Tighten the locknut.
EW000099
w8After adjusting the brake lever
free play, check the free play
and make sure that the brake
is working properly.
8A soft or spongy feeling in the
brake lever can indicate the
presence of air in the
hydraulic system. If there is air
in the hydraulic system, have
a Yamaha dealer bleed the
system before operating the
motorcycle. Air in the
hydraulic system will diminish
the braking performance,
which may result in loss of
control and an accident.
1
2b
c
a
1. Locknut
2. Adjusting bolt
c. Free play
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6-22
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00712
Adjusting the brake pedal
positionThe top of the brake pedal should be
positioned approximately 23 mm
below the top of the footrest as
shown. Periodically check the brake
pedal position and, if necessary,
have a Yamaha dealer adjust it.
EW000109
wA soft or spongy feeling in the
brake pedal can indicate the pres-
ence of air in the hydraulic system.
If there is air in the hydraulic sys-
tem, have a Yamaha dealer bleed
the system before operating the
motorcycle. Air in the hydraulic
system will diminish the braking
performance, which may result in
loss of control and an accident.
EAU00713
Adjusting the rear brake light
switchThe rear brake light switch, which is
activated by the brake pedal, is prop-
erly adjusted when the brake light
comes on just before braking takes
effect. If necessary, adjust the brake
light switch as follows.
Turn the adjusting nut while holding
the rear brake light switch in place.
To make the brake light come on ear-
lier, turn the adjusting nut in direction
a. To make the brake light come on
later, turn the adjusting nut in direc-
tion b.
a
1
b
a12
1. Footrest
a. Brake pedal position1. Rear brake light switch
2. Adjusting nut
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6-23
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00721
Checking the front and rear
brake padsThe front and rear brake pads must
be checked for wear at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU00725
Front brake pads
Each front brake pad is provided with
a wear indicator groove, which allows
you to check the brake pad wear
without having to disassemble the
brake. To check the brake pad wear,
check the wear indicator groove. If a
brake pad has worn to the point that
the wear indicator groove has almost
disappeared, have a Yamaha dealer
replace the brake pads as a set.
EAU00728
Rear brake pads
Each rear brake pad is provided with
a wear indicator, which allows you to
check the brake pad wear without
having to disassemble the brake. To
check the brake pad wear, check the
position of the wear indicator while
applying the brake. If a brake pad
has worn to the point that the wear
indicator almost touches the brake
disc, have a Yamaha dealer replace
the brake pads as a set.
1
1
1. Wear indicator groove 1. Wear indicatorREARFRONT
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6-24
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03776
Checking the brake fluid
levelInsufficient brake fluid may allow air
to enter the brake system, possibly
causing it to become ineffective.
Before riding, check that the brake
fluid is above the minimum level mark
and replenish if necessary. A low
brake fluid level may indicate worn
brake pads and/or brake system
leakage. If the brake level is low, be
sure to check the brake pads for
wear and the brake system for leak-
age.Observe these precautions:
8When checking the fluid level,
make sure that the top of the
brake fluid reservoir is level.
8Use only the recommended qual-
ity brake fluid, otherwise the rub-
ber seals may deteriorate, caus-
ing leakage and poor braking
performance.8Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking perfor-
mance.
8Be careful that water does not
enter the brake fluid reservoir
when refilling. Water will signifi-
cantly lower the boiling point of
the fluid and may result in vapor
lock.
8Brake fluid may deteriorate paint-
ed surfaces or plastic parts.
Always clean up spilled fluid
immediately.
8As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if
the brake fluid level goes down
suddenly, have a Yamaha dealer
check the cause.
1
LOWER
1
LOWERUPPER
1. Minimum level mark 1. Minimum level mark
Recommended brake fluid:
DOT 4
FRONT
REAR
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6-25
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03976
Changing the brake fluidHave a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addi-
tion, have the oil seals of the master
cylinders and calipers 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.
2. 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.
a
a. Drive chain slack
Drive chain slack:
25–40 mm
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6-29
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03370
Checking and lubricating the
brake and shift pedalsThe operation of the brake and shift
pedals should be checked before
each ride, and the pedal pivots
should be lubricated if necessary.
EAU03164
Checking and lubricating the
brake and clutch leversThe operation of the brake and clutch
levers should be checked before
each ride, and the lever pivots should
be lubricated if necessary.
EAU03165
Checking and lubricating the
sidestandThe operation of the sidestand
should be checked before each ride,
and the sidestand pivot and metal-to-
metal contact surfaces should be
lubricated if necessary.
EW000113
wIf the sidestand does not move up
and down smoothly, have a
Yamaha dealer check or repair it.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
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6-31
PERIODIC MAINTENANCE AND MINOR REPAIR
6To 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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6-35
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EC000105
cCDo not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the
bulb, and the bulb life will be
adversely affected. Thoroughly
clean off any dirt and fingerprints
on the headlight bulb using a cloth
moistened with alcohol or thinner.5. Install the bulb cover, and then
connect the coupler.
6. Install the cowling.7. Have a Yamaha dealer adjust
the headlight beam if necessary.
EAU01078
Replacing the tail/brake light
bulb1. Remove the seat. (See page
3-12 for seat removal and instal-
lation procedures.)
2. Remove panel A. (See page
6-6 for panel removal and instal-
lation procedures.)
a
a. Do not touch this area.
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6-38
PERIODIC MAINTENANCE AND MINOR REPAIR
6 2. Loosen the front wheel axle
pinch bolt, then the wheel axle.
3. Lift the front wheel off the ground
according to the procedure on
page 6-37.
4. Pull the wheel axle out, and then
remove the wheel.
ECA00048
cCDo not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
EAU04273
To install the front wheel
Installing
1. Install the speedometer gear unit
into the wheel hub so that the
projections mesh with the slots.
2. Lift the wheel up between the
fork legs.NOTE:
Make sure that there is enough
space between the brake pads
before inserting the brake disc and
that the slot in the speedometer gear
unit fits over the retainer on the fork
leg.
3. Insert the wheel axle.
4. Lower the front wheel so that it is
on the ground.
5. Tighten the wheel axle to the
specified torque.
6. Tighten the front wheel axle
pinch bolt to the specified torque.
7. Push down hard on the handle-
bar several times to check for
proper fork operation.
2
1
1
1
1. Pinch bolt
2. Wheel axle1. Speedometer gear unit 1. Retainer
Tightening torque:
Wheel axle:
59 Nm (5.9 m0kgf)
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6-40
PERIODIC MAINTENANCE AND MINOR REPAIR
6 6. While supporting the brake
caliper, pull the wheel axle out.
7. Remove the wheel.
ECA00048
cCDo not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
EAU01620
To install the rear wheel
1. Install the brake caliper onto the
swingarm as shown.NOTE:
Make sure that the slot in the brake
caliper bracket fits over the retainer
on the swingarm.2. Install the drive chain onto the
rear sprocket.
3. Insert the wheel axle from the
left-hand side, install the axle
nut, and then lower the rear
wheel so that it is on the ground.
NOTE:
Make sure that there is enough
space between the brake pads
before inserting the brake disc
between the brake pads.4. Adjust the drive chain slack.
(See page 6-26 for drive chain
slack adjustment procedures.)
5. Tighten the axle nut to the speci-
fied torque.
1
1. Retainer
Tightening torque:
Axle nut:
104 Nm (10.4 m0kgf)
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