key YAMAHA TDR 125 2002 Owners Manual

EAU00005
IMPORTANT MANUAL INFORMATION
1Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander, or a person inspecting or repairing the
motorcycle.A CAUTION indicates special precautions that must be taken to avoid damage to
the motorcycle.A NOTE provides key information to make procedures easier or clearer.
Qw
cCNOTE:
NOTE:
8This manual should be considered a permanent part of this motorcycle and should remain
with it even if the motorcycle is subsequently sold.
8Yamaha continually seeks advancements in product design and quality. Therefore, while this
manual contains the most current product information available at the time of printing, there
may be minor discrepancies between your motorcycle and this manual. If you have any ques-
tions concerning this manual, please consult your Yamaha dealer.
5AE-28199-E5 honbun 7/6/01 10:18 AM Page 2

Checking the spark plug ................................ 6-7
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
Cast wheels ................................................. 6-19
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-28199-E5 honbun 7/6/01 10:18 AM Page 6

3-1
EAU00027
INSTRUMENT AND CONTROL FUNCTIONS
3
EAU00029
Main switch/steering lockThe main switch/steering lock con-
trols the ignition and lighting systems,
and is used to lock the steering. The
various positions are described
below.
EAU00036
ON
All electrical systems are supplied
with power, and the engine can be
started. The key cannot be removed.
EAU00038
OFF
All electrical systems are off. The key
can be removed.
EAU00040
LOCK
The steering is locked, and all electri-
cal systems are off. The key can be
removed.
To lock the steering1. Turn the handlebars all the way
to the left.
2. Push the key in from the “OFF”
position, and then turn it to
“LOCK” while still pushing it.
3. Remove the key.
To unlock the steeringPush the key in, and then turn it to
“OFF” while still pushing it.
EW000016
wNever turn the key to “OFF” or
“LOCK” while the motorcycle is
moving, otherwise the electrical
systems will be switched off,
which may result in loss of control
or an accident. Make sure that the
motorcycle is stopped before turn-
ing the key to “OFF” or “LOCK”.
EAU01574
.
.
(Parking)
The steering is locked, and the tail-
lights and auxiliary lights are on, but
all other electrical systems are off.
The key can be removed.
The steering must be locked before
the key can be turned to “
.
”.
ECA00043
cCDo not use the parking position for
an extended length of time, other-
wise the battery may discharge.
OFFON
LOCKPPUSH
YM-8
IGNITION
ON
OFF
LOCK
PARKING
a
b
a. Push.
b. Turn.
5AE-28199-E5 honbun 7/6/01 10:18 AM Page 11

3-2
EAU03034
Indicator and warning lights
EAU00057
Turn signal indicator light “5”
This indicator light flashes when the
turn signal switch is pushed to the left
or right.
EAU00063
High beam indicator light “&”
This indicator light comes on when
the high beam of the headlight is
switched on.
EAU04304
2-stroke engine oil level warning
light “
7
”
This warning light comes on when
the 2-stroke 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
"#" and turn the key to "ON".
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 2-stroke engine oil level is
sufficient, the warning light may flick-
er when riding on a slope or during
sudden acceleration or deceleration,
but this is not a malfunction.
EAU00061
Neutral indicator light “N”
This indicator light comes on when
the transmission is in the neutral
position.
INSTRUMENT AND CONTROL FUNCTIONS
3
1
2
3
4
1. Turn signal indicator light “5”
2. High beam indicator light “&”
3. 2-stroke enjine oil level warning light “
7
”
4. Neutral indicator light “N”
5AE-28199-E5 honbun 7/6/01 10:18 AM Page 12

3-4
EAU01652
Coolant temperature gaugeWith the key in the “ON” position, the
coolant temperature gauge indicates
the temperature of the coolant. The
coolant temperature varies with
changes in the weather and engine
load. If the needle reaches or enters
the red zone, stop the motorcycle
and let the engine cool. (See page
6-43 for further instructions.)
EC000002
cCDo not operate the engine if it is
overheated.
EAU00118
Handlebar switches
EAU03898
Light switch “
9/
'
/:”
Set this switch to “'
” to turn on
the auxiliary light, meter lighting and
taillight. Set the switch to “:” to turn
on the headlight also. Set the switch
to “
9” to turn off all the lights.
EAU03888
Dimmer switch “&/%”
Set this switch to “&” for the high
beam and to “%” for the low beam.
EAU03889
Turn signal switch “4/6”
To signal a right-hand turn, push this
switch to “6”. To signal a left-hand
turn, push this switch to “4”. When
released, the switch returns to the
center position. To cancel the turn
signal lights, push the switch in after
it has returned to the center position.
EAU00129
Horn switch “*”
Press this switch to sound the horn.
INSTRUMENT AND CONTROL FUNCTIONS
3
2 1
1
2
3
4
1. Coolant temperature gauge
2. Red zone1. Light switch “
9/
'
/:”
2. Dimmer switch “&/%”
3. Turn signal switch “4/6”
4. Horn switch “*”
5AE-28199-E5 honbun 7/6/01 10:18 AM Page 14

3-7
INSTRUMENT AND CONTROL FUNCTIONS
3
EAU00158
Brake leverThe brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the han-
dlebar grip.
EAU00162
Brake pedalThe brake pedal is on the right side
of the motorcycle. To apply the rear
brake, press down on the brake
pedal.
EAU02935
Fuel tank capTo open the fuel tank cap
Open the fuel tank cap lock cover,
insert the key into the lock, and then
turn it 1/4 turn clockwise. The lock will
be released and the fuel tank cap can
be opened.
To close the fuel tank cap
1. Push the fuel tank cap into posi-
tion with the key inserted in the
lock.
2. Turn the key counterclockwise to
the original position, remove it,
and then close the lock cover.
1
1
1
a
b
1. Brake lever 1. Brake pedal 1. Fuel tank cap lock cover
a. Open.
b. Unlock.
5AE-28199-E5 honbun 7/6/01 10:18 AM Page 17

3-8
NOTE:
The fuel tank cap cannot be closed
unless the key is in the lock. In addi-
tion, the key cannot be removed if the
cap is not properly closed and
locked.
EWA00025
wMake sure that the fuel tank cap is
properly closed before riding.
EAU03753
Fuel(except for Switzerland and
Austria)
Make sure that there is sufficient fuel
in the tank. Fill the fuel tank to the
bottom of the filler tube as shown.
EW000130
w8Do not overfill the fuel tank,
otherwise it may overflow
when the fuel warms up and
expands.
8Avoid spilling fuel on the hot
engine.
EAU03754
Fuel(for Switzerland and Austria)
Make sure that there is sufficient fuel
in the tank. When refueling, be sure
to insert the pump nozzle into the fuel
tank filler hole and to fill the tank to
the bottom of the filler tube as shown.
INSTRUMENT AND CONTROL FUNCTIONS
3
2
1
1
3 5 42
1. Filler tube
2. Fuel level1. Pump nozzle
2. Fuel tank filler hole
3. Filler tube
4. Fuel level
5. Leaf valve
5AE-28199-E5 honbun 7/6/01 10:18 AM Page 18

3-12
EAU03839
Starter (choke) lever “1”Starting a cold engine requires a rich-
er air-fuel mixture, which is supplied
by the starter (choke).
Move the lever in direction ato turn
on the starter (choke).
Move the lever in direction bto turn
off the starter (choke).
EAU01619
SeatTo remove the seat
1. Insert the key into the seat lock,
and then turn it clockwise.
2. Pull the seat off.To install the seat
1. Insert the projection on the front
of the seat into the seat holder
as shown.
2. Push the rear of the seat down to
lock it in place.
3. Turn the key counterclockwise,
and then remove it.
NOTE:
Make sure that the seat is properly
secured before riding.
INSTRUMENT AND CONTROL FUNCTIONS
3
1
a
b
a
1
2
1. Starter (choke) lever “1”a. Unlock. 1. Projection
2. Seat holder
5AE-28199-E5 honbun 7/6/01 10:18 AM Page 22

3-13
INSTRUMENT AND CONTROL FUNCTIONS
3
EAU00260
Helmet holderTo open the helmet holder, insert the
key into the lock, and then turn the
key as shown.
To lock the helmet holder, place it in
the original position, and then remove
the key.
EW000030
wNever ride with a helmet attached
to the helmet holder, since the hel-
met may hit objects, causing loss
of control and possibly an acci-
dent.
EAU00295
Adjusting the shock
absorber assemblyThis shock absorber assembly is
equipped with a spring preload
adjusting ring.
EC000015
cCNever attempt to turn an adjusting
mechanism beyond the maximum
or minimum settings.
Adjust the spring preload as follows.
To increase the spring preload and
thereby harden the suspension, turn
the adjusting ring in direction a. To
decrease the spring preload and
thereby soften the suspension, turn
the adjusting ring in direction b.NOTE:
Align the appropriate notch in the
adjusting ring with the position indica-
tor on the shock absorber.
a
a
b1
a. Open.1. Spring preload adjusting ring
5AE-28199-E5 honbun 7/6/01 10:18 AM Page 23

3-15
INSTRUMENT AND CONTROL FUNCTIONS
3
EAU00326
YPVSThis model is equipped with the
YPVS (Yamaha Power Valve
System). This system boosts engine
performance and efficiency by means
of a variable valve in the exhaust
port. The YPVS valve is constantly
adjusted in accordance with the
engine speed by a computer-con-
trolled servomotor.
Since the YPVS is an important part
of the engine and requires very
sophisticated adjustment, have a
Yamaha dealer, who has the neces-
sary professional knowledge and
experience, make this adjustment.
EC000023
cCThe YPVS has been set and exten-
sively tested at the Yamaha facto-
ry. Changing these settings with-
out sufficient technical knowledge
may result in poor performance of
or damage to the engine.YPVS operation noises can be heard
in the following instances:
8When the key is turned to “ON”
and the engine is started.
8When the engine stalls with the
key in the “ON” position.
EC000024
cCIf the YPVS does not operate, have
a Yamaha dealer check it.
EAU00330
SidestandThe sidestand is located on the left
side of the frame. Raise the side-
stand or lower it with your foot while
holding the motorcycle upright.NOTE:
The built-in sidestand switch is part of
the ignition circuit cut-off system,
which cuts the ignition in certain situ-
ations. (See further down for an
explanation of the ignition circuit cut-
off system.)
1
1. YPVS
5AE-28199-E5 honbun 7/6/01 10:18 AM Page 25