YAMAHA TDR 125 2002 Manual PDF

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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6-36
PERIODIC MAINTENANCE AND MINOR REPAIR
6 3. Remove the socket (together
with the bulb) by turning it coun-
terclockwise.
4. Remove the defective bulb by
pushing it in and turning it coun-
terclockwise.
5. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
6. Install the socket (together with
the bulb) by turning it clockwise.
7. Install the panel and the seat.
EAU03497
Replacing a turn signal light
bulb1. Remove the turn signal light lens
by removing the screw.2. Remove the defective bulb by
pushing it in and turning it coun-
terclockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screw.
ECA00065
cCDo not overtighten the screw, oth-
erwise the lens may break.
1
12
1
1. Socket 1. Lens
2. Screw1. Bulb
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6-37
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU01579
Supporting the motorcycleSince this model is not equipped with
a centerstand, follow these precau-
tions when removing the front and
rear wheel or performing other main-
tenance requiring the motorcycle to
stand upright. Check that the motor-
cycle is in a stable and level position
before starting any maintenance. A
strong wooden box can be placed
under the engine for added stability.
To service the front wheel
1. Stabilize the rear of the motorcy-
cle by using a motorcycle stand
or, if an additional motorcycle
stand is not available, by placing
a jack under the frame in front of
the rear wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.To service the rear wheel
Raise the rear wheel off the ground
by using a motorcycle stand or, if a
motorcycle stand is not available, by
placing a jack either under each side
of the frame in front of the rear wheel
or under each side of the swingarm.
EAU03239
Front wheelTo remove the front wheel
EW000122
w8It is advisable to have a
Yamaha dealer service the
wheel.
8Securely support the motorcy-
cle so that there is no danger
of it falling over.1. Disconnect the speedometer
cable from the front wheel.
1
1. Speedometer cable
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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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6-39
PERIODIC MAINTENANCE AND MINOR REPAIR
68. Connect the speedometer cable.
EAU03755
Rear wheelTo remove the rear wheel
EW000122
w8It is advisable to have a
Yamaha dealer service the
wheel.
8Securely support the motorcy-
cle so that there is no danger
of it falling over.1. Loosen the axle nut.2. Lift the rear wheel off the ground
according to the procedure on
page 6-37.
3. Remove the axle nut.
4. Loosen the locknut and the drive
chain slack adjusting nut on each
end of the swingarm.
5. Push the wheel forward, and
then remove the drive chain from
the rear sprocket.
NOTE:
The drive chain does not need to be
disassembled in order to remove and
install the wheel.
1
2
3
1. Axle nut
2. Locknut
3. Adjusting nut
Tightening torque:
Front wheel axle pinch bolt:
20 Nm (2.0 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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6-41
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03087
TroubleshootingAlthough Yamaha motorcycles
receive a thorough inspection before
shipment from the factory, trouble
may occur during operation. Any
problem in the fuel, compression, or
ignition systems, for example, can
cause poor starting and loss of
power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcy-
cle require any repair, take it to a
Yamaha dealer, whose skilled techni-
cians have the necessary tools,
experience, and know-how to service
the motorcycle properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life
and can lead to expensive repair
bills.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU01581
Troubleshooting chartsStarting problems or poor engine performance
EW000125
wKeep away open flames and do not smoke while checking or working on the fuel system.Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plug
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.
The battery is good.Check the battery lead connections,
and charge the battery if necessary.
DryWet
Open the throttle halfway and operate
the electric starter.
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6-43
PERIODIC MAINTENANCE AND MINOR REPAIR
6
NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended
coolant as soon as possible.Engine overheating
EW000070
w8Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
8After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the
hissing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the
cap.Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.Add coolant. (See NOTE.)
Start the engine. If the engine overheats again,
have a
Yamaha dealer check
and repair the cooling system.
There is
leakage.
There is
no leakage.
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7-1
EAU03521
MOTORCYCLE CARE AND STORAGE
7
CareWhile the open design of a motorcy-
cle reveals the attractiveness of the
technology, it also makes it more vul-
nerable. Rust and corrosion can
develop even if high-quality compo-
nents are used. A rusty exhaust pipe
may go unnoticed on a car, however,
it detracts from the overall appear-
ance of a motorcycle. Frequent and
proper care does not only comply
with the terms of the warranty, but it
will also keep your motorcycle looking
good, extend its life and optimize its
performance.Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and cov-
ers as well as all electrical cou-
plers and connectors, including
the spark plug cap, are tightly
installed.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such
products onto seals, gaskets,
sprockets, the drive chain and
wheel axles. Always rinse the dirt
and degreaser off with water.Cleaning
ECA00010
cC8Avoid using strong acidic
wheel cleaners, especially on
spoked wheels. If such prod-
ucts are used on hard-to-
remove dirt, do not leave the
cleaner on the affected area
any longer than instructed.
Also, thoroughly rinse the area
off with water, immediately dry
it, and then apply a corrosion
protection spray.
8Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent
and water to clean plastic.
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