clutch YAMAHA TDR 125 2002 User Guide

6-2
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03686
Periodic maintenance and lubrication chart
NOTE:
8
The 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. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 6 12 18 24
1
*Fuel line•Check fuel hoses for cracks or damage.√√√√ √
2 Spark plug•Replace.√√√√ √
3 Air filter element•Clean.√√
•Replace.√√
4 Clutch•Check operation.
•Adjust.√√√√√
5*Front brake•Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√√√√ √
•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.)√√√√√ √
•Replace brake pads.Whenever worn to the limit
7*Brake hoses•Check for cracks or damage.√√√√ √
•Replace. (See NOTE on page 6-4.)Every 4 years
8*Wheels•Check runout and for damage.√√√√
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6-10
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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.
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.
2. 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.
1
2
1. Maximum level mark
2. Minimum level mark
Recommended transmission oil:
See page 8-1.
Oil quantity:
Periodic oil change:
0.75 L
Total amount (dry transmission):
0.8 L
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6-20
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00694
Adjusting the clutch lever
free playThe clutch lever free play should
measure 10–15 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.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.
ab
12 c
ba
1
2
1. Locknut (clutch lever)
2. Adjusting bolt
c. Free play1. Locknut (crankcase)
2. Adjusting nut
7. Tighten the locknut at the clutch
lever and the crankcase.
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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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8-2
SPECIFICATIONS
8
Spark plug
Manufacturer/model NGK/BR9ES
Spark plug gap 0.7–0.8 mm
Clutch typeWet, multiple-disc
Transmission
Primary reduction system Helical gear
Primary reduction ratio 71/22 (3.227)
Secondary reduction system Chain drive
Secondary reduction ratio 3.563
Number of drive chain
sprocket teeth (rear/front) 57/16
Transmission type Constant mesh 6-speed
Operation Left foot
Gear ratio 1st 2.833
2nd 1.875
3rd 1.412
4th 1.143
5th 0.957
6th 0.818
Chassis
Frame type Semi double cradle
Caster angle 26°
Trail 116 mmTires
Front
Type Tubeless
Size 100/90-18 56P or
100/90-18 M/C 56P
Manufacturer/ BRIDGESTONE / TW53
model DUNLOP / D602F
Rear
Type Tubeless
Size 130/80-17 65P or
130/80-17 M/C 65P
Manufacturer/ BRIDGESTONE / TW54
model DUNLOP / D602
Maximum load* 180 kg
179 kg (CH, A)
Air pressure (cold tire)
up to 90 kg load*
Front
175 kPa (1.75 kgf/cm
2, 1.75 bar)
Rear
200 kPa (2.00 kgf/cm
2, 2.00 bar)
90 kg load–Maximum
load*
Front
175 kPa (1.75 kgf/cm
2, 1.75 bar)
Rear
225 kPa (2.25 kgf/cm
2, 2.25 bar)
* Total weight of rider, passenger, cargo and accessories
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