2000 YAMAHA TDR 125 brake

6-28
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9 Operation check
1. Place the motorcycle on a level
place.
2. Hold the motorcycle in an upright
position and apply the front
brake.
3. Push down hard on the handle-
bars several times and check if
the fork rebounds smoothly.
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If any damage or unsmooth move-
ment is found with the front fork,
consult a Yamaha dealer.
EAU00794Steering inspection
Periodically inspect the condition of
the steering. Worn out or loose steer-
ing bearings may be dangerous.
Place a stand under the engine to
raise the front wheel off the ground.
Hold the lower end of the front forks
and try to move them forward and
backward. If any free play can be felt,
ask a Yamaha dealer to inspect and
adjust the steering. Inspection is eas-
ier if the front wheel is removed.
EW000115
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Securely support the motorcycle
so there is no danger of it falling
over.
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6-33
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
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7
8
9
1
1. Speedometer cable
EAU00894Front wheel removalEW000122
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8 8
It is advisable to have a
Yamaha dealer service the
wheel.
8 8
Securely support the motorcy-
cle so there is no danger of it
falling over.
1. Remove the speedometer cable
from the front wheel side.
2
1
1. Pinch bolt
2. Wheel axle
2. Loosen the pinch bolt and wheel
axle.
3. Elevate the front wheel by plac-
ing a suitable stand under the
engine.
4. Remove the wheel axle and the
front wheel.
NOTE:
Do not depress the brake lever when
the disc and caliper are separated.
1
1. Bulb
3. Install a new bulb by pushing it
inward and turning it clockwise.
4. Install the lens and tighten the
screw.
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6-34
PERIODIC MAINTENANCE AND MINOR REPAIR
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2
3
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8
9
3. Install the wheel axle and let the
motorcycle down.
4. Push down hard on the handle-
bars several times to check for
proper fork operation.
5. Tighten the wheel axle to the
specified torque.
6. Install the pinch bolt and tighten
it to the specified torque.
7. Install the speedometer cable.Tightening torque:
Wheel axle:
59 Nm (5.9 m0kg)
Pinch bolt:
20 Nm (2.0 m0kg)
312
EAU01618Rear wheel removalEW000122
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8 8
It is advisable to have a
Yamaha dealer service the
wheel.
8 8
Securely support the motorcy-
cle so there is no danger of it
falling over.
1. Loosen the axle nut.
1. Locknut
2. Adjusting nut
3. Axle nut
EAU01394Front wheel installation
1. Install the speedometer gear unit
into the wheel hub. Make sure
the wheel hub and the
speedometer gear unit are
installed with the projections
meshed into the slots.
2. Lift up the wheel between the
front fork legs and guide the
brake disc between the brake
pads. Make sure the slot in the
speedometer gear unit fits over
the stopper on the front fork
outer tube.
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6-35
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
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7
8
9
2. Elevate the rear wheel by placing
a suitable stand under the
engine.
3. Remove the axle nut.
4. Loosen the locknuts and chain
adjusting nuts on each side.
5. Push the wheel forward and
remove the drive chain.
6. While supporting the brake
caliper, pull out the wheel axle.
7. Remove the wheel assembly.
NOTE:
8Do not depress the brake pedal
when the disc and caliper are
separated.
8You do not have to disassemble
the chain in order to remove or
install the rear wheel.
EAU01620
Rear wheel installation
1. Install the rear brake caliper.
Make sure the slot in the caliper
bracket is fit over the stopper on
the swingarm.
2. Install the rear wheel and chain.
Guide the brake disc between
the brake pads. Make sure there
is enough gap between the
brake pads before inserting the
brake disc.
3. Install the wheel axle and axle
nut, and let the motorcycle down.
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1
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9
7-2
8 8
Improper 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.
8 8
Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abra-
sive cleaning products, sol-
vent or thinner, fuel (gasoline),
rust removers or inhibitors,
brake fluid, antifreeze or elec-
trolyte.8 8
Do not use high-pressure
washers or steam-jet cleaners
since they cause water seep-
age and deterioration in the
following areas: seals (of
wheel bearings, swingarm
bearings, forks and brakes),
electric components (cou-
plers, connectors, instru-
ments, switches and lights),
breather hoses and vents.
8 8
For motorcycles equipped
with a windshield: Do not use
strong cleaners or hard
sponges as they will cause
dulling or scratching. Some
cleaning compounds for plas-
tic may leave scratches on the
windshield. Test the product
on a small hidden part of the
windshield to make sure they
do not leave any marks. If the
windshield is scratched, use a
quality plastic polishing com-
pound after washing.After riding in the rain, near the sea
or on salt-sprayed roads
Since sea salt or salt sprayed on the
roads in the winter are extremely cor-
rosive in combination with water,
carry out the following steps after
each ride in the rain, near the sea or
on salt-sprayed roads. (Salt sprayed
in the winter may remain on the roads
well into spring.)
1. Clean your motorcycle with cold
water and soap after the engine
has cooled down.
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Do not use warm water since it
increases the corrosive action of
the salt.
2. Be sure to apply a corrosion pro-
tection spray on all (even
chrome- and nickel-plated) metal
surfaces to prevent corrosion.
MOTORCYCLE CARE AND STORAGE
7
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After cleaning
1. Dry the motorcycle with a
chamois or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally
induced discoloring of stainless-
steel exhaust systems can be
removed through polishing.)
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all (even
chrome- and nickel-plated) metal
surfaces.
5. Use spray oil as a universal
cleaner to remove any remaining
dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry complete-
ly before storing it or covering it.EWA00001
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Make sure that there is no oil or
wax on the brakes and tires. If
necessary, clean the brake discs
and linings with a regular brake
disc cleaner or acetone, and wash
the tires with warm water and mild
soap. Then, carefully test the
motorcycle for its braking perfor-
mance and cornering behavior.
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8
8
Apply spray oil and wax spar-
ingly and wipe off any excess.
8 8
Never apply oil or wax on rub-
ber and plastic parts, but treat
them with a suitable care
product.
8 8
Avoid using abrasive polish-
ing compounds as they wear
away the paint.
NOTE:
Consult a Yamaha dealer for advice
on what products to use.
MOTORCYCLE CARE AND STORAGE
7-3
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SPECIFICATIONS
1
2
3
4
5
6
7
8
9
Wheels
Front
Type Cast wheel
Size 18 ´MT2.15
Rear
Type Cast wheel
Size 17 ´MT2.50
Brakes
Front
Type Single disc brake
Operation Right hand operation
Fluid DOT 3 or DOT 4
Rear
Type Single disc brake
Operation Right foot operation
Fluid DOT 4
Suspension
Front
Type Telescopic fork
Rear
Type Swingarm (Monocross)Shock absorber
Front
Type Coil spring/oil damper
Rear
Type Coil-gas spring/oil damper
Wheel travel
Front 180 mm
Rear 180 mm
Electrical
Ignition system C.D.I.
Charging system
Type C.D.I. magneto
Standard output 14 V, 12A @5,000 r/min
Battery
Type YTX5L-BS
Voltage, capacity 12 V, 4 AH
Headlight bulb typeHalogen bulb
Bulb voltage, wattage ´quantity
Headlight 12 V, 60/55W ´2
12 V, 35/35W ´2 (GB, IRL only)
8-3
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INDEX
Engine stop switch ..................................3-7
Engine temperature gauge ......................3-5
F
Front brake lever .....................................3-8
Front brake lever free play
adjustment ..........................................6-20
Front fork inspection ..............................6-28
Front wheel installation..........................6-34
Front wheel removal ..............................6-33
Fuel .......................................................3-10
Fuel cock ...............................................3-12
Fuel tank cap ...........................................3-9
Fuse replacement..................................6-30
H
Handlebar switches .................................3-5
Dimmer switch ......................................3-5
Engine stop switch ................................3-7
Headlight beam variation ......................3-6
Horn switch ...........................................3-5
Lights switch .........................................3-5
Start switch ...........................................3-7
Turn signal switch .................................3-5
Headlight beam variation.........................3-6
Headlight bulb replacement...................6-31
Helmet holder ........................................3-14
High beam indicator light .........................3-2
Horn switch..............................................3-5
How to use the conversion table .............8-5
I
Identification number records ..................9-1
Idle speed adjustment ...........................6-15
Indicator lights .........................................3-2
High beam indicator light ......................3-2Neutral indicator light ............................3-2
Oil level indicator light ...........................3-2
Turn indicator light ................................3-2
Inspecting the brake fluid level ..............6-22
K
Key identification number ........................9-1
L
Lights switch ............................................3-5
Left view ..................................................2-1
M
Main switch/Steering lock ........................3-1
Model lavel ..............................................9-2
N
Neutral indicator light...............................3-2
Note on handling of the Yamaha
Energy Induction System (Y.E.I.S.) ....3-15
O
Oil level indicator circuit check ................3-3
Oil level indicator light .............................3-2
P
Panel A ....................................................6-7
Parking ....................................................5-6
Periodic maintenance and
lubrication .............................................6-3
Pre-operation check list ...........................4-1
R
Rear brake pedal .....................................3-9
Rear brake pedal height adjustment .....6-20
Rear shock absorber adjustment ..........3-14
Rear suspension lubrication ..................6-27
Rear wheel installation ..........................6-35
Rear wheel removal ..............................6-34A
Air filter ..................................................6-13
Autolube pump adjustment....................6-26
B
Battery ...................................................6-29
Brake and clutch lever lubrication .........6-27
Brake and shift pedal lubrication ...........6-26
Brake fluid replacement.........................6-23
Brake light switch adjustment ................6-21
C
Cable inspection and lubrication ...........6-25
Carburetor adjustment...........................6-15
Care.........................................................7-1
Catalyzer
(for Switzerland and Austria) ..............3-11
Checking the front and rear brake
pads ....................................................6-21
Clutch lever .............................................3-8
Clutch lever free play adjustment ..........6-19
Controls/Instruments ...............................2-3
Cooling system ......................................6-11
Cowling A, B ............................................6-7
Cowling and panel removal and
installation .............................................6-6
D
Description ..............................................2-1
Dimmer switch .........................................3-5
Drive chain lubrication ...........................6-25
Drive chain slack adjustment.................6-24
Drive chain slack check .........................6-23
E
Engine break-in .......................................5-5
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