2000 YAMAHA TDR 125 engine

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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EVERY
6,000 km 12,000 km
No.
ITEM CHECKS AND MAINTENANCE JOBS
Initialor or
(1,000 km)6 months 12 months
(Whichever (Whichever
comes first) comes first)
9Check swingarm pivoting point for play.
10 * Swingarm9Correct if necessary.
ÖÖ
9Lubricate with lithium soap base grease every
24,000 km or 24 months (whichever comes first).
9Check chain slack.
11 Drive chain9
Adjust if necessary. Make sure that the rear wheel is properly aligned.Every 1,000 km and after washing
9Clean and lubricate.the motorcycle or riding in the rain
9Check bearing play and steering for roughness.
12 * Steering bearings9Correct accordingly.
ÖÖ
9Lubricate with lithium soap base grease every 24,000 km or
24 months (whichever comes first).
13 * Chassis fasteners9
Make sure that all nuts, bolts and screws are properly tightened.ÖÖ9Tighten if necessary.
14 Sidestand9Check operation.
ÖÖ
9Lubricate and repair if necessary.
15 * Sidestand switch9Check operation.
ÖÖÖ
9Replace if necessary.
16 * Front fork9Check operation and for oil leakage.
ÖÖ
9Correct accordingly.
17 *Rear shock absorber9Check operation and shock absorber for oil leakage.
ÖÖ
assembly9Replace shock absorber assembly if necessary.
Rear shock absorber9Check operation.
18 * assembly pivoting9Lubricate with lithium grease every 24,000 km ÖÖ
pointsor 24 months (whichever comes first).
19 * Carburetor9Check engine idling speed and starter operation.
ÖÖÖ
9Adjust if necessary.
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EAU01651
Spark plug inspection
The spark plug is an important
engine component and should be
inspected periodically, preferably by
a Yamaha dealer. The condition of
the spark plug can indicate the condi-
tion of the engine. The ideal color on
the white insulator around the center
electrode is a medium-to-light tan
color for a motorcycle that is being
ridden normally. Do not attempt to
diagnose any problems yourself.
Instead, take the motorcycle to a
Yamaha dealer. The spark plug
should be periodically removed and
inspected because heat and depositswill cause the spark plug to slowly
break down and erode. If electrode
erosion becomes excessive, or if car-
bon and other deposits are exces-
sive, the spark plug should be
replaced with the specified plug.
Before installing the spark plug, mea-
sure the electrode gap with a wire
thickness gauge and adjust it to
specification.When installing the plug, the gasket
surface should always be cleaned
and a new gasket used. Any grime
should be wiped off from the threads
and the spark plug tightened to the
specified torque.NOTE:
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is 1/4
to 1/2 turn past finger tight. The spark
plug should be tightened to the speci-
fied torque as soon as possible.
1. Spark plug wrench
PERIODIC MAINTENANCE AND MINOR REPAIR
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9 Specified spark plug:
BR9ES (NGK)
Spark plug gap:
0.7 ~ 0.8 mm
Tightening torque:
Spark plug:
20 Nm (2.0 m0kg)
1
1. Spark plug gap
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6-9
1
1. Transmission oil filler cap
2. With the engine stopped, check
the oil level through the level
window located at the right side
crankcase cover.
NOTE:
Wait a few minutes until the oil level
settles before checking.
3. The oil level should be above the
minimum level mark on the level
window. If the level is low, add
sufficient oil to raise it to the
proper level.Transmission oil replacement
1. Warm up the engine for several
minutes.
2. Stop the engine. Place an oil pan
under the engine and remove the
oil filler cap.
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EAU01080Transmission oil
Oil level measurement
1. Place the motorcycle on a level
place and hold it an upright posi-
tion. Warm up the engine for
several minutes.
NOTE:
Be sure the motorcycle is positioned
straight up when checking the oil
level. A slight tilt toward the side can
result in false readings.
1. Level window
2. Minimum level
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6-10
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3. Remove the drain bolt and drain
the oil.
4. Reinstall the drain bolt and tight-
en it to the specified torque.
5. Fill the engine with oil. Install the
oil filler cap and tighten it.
EC000078
cC
8
8
Do not put in any chemical
additives. Transmission oil
also lubricates the clutch and
additives could cause clutch
slippage.
8 8
Be sure no foreign material
enters the crankcase.
6. Start the engine and warm up for
a few minutes. While warming
up, check for oil leakage. If oil
leakage is found, stop the engine
immediately and check for
cause.
1. Drain bolt
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9 Tightening torque:
Drain bolt:
15 Nm (1.5 m0kg)
Recommended oil:
See page 8-1
Oil quantity:
Total amount: 0.8 L
Periodic oil change: 0.75 L
1
2
1. Maximum level mark
2. Minimum level mark
EAU01621*Cooling system
1. Check the coolant level in the
reservoir tank when the engine is
cold as the coolant level will vary
with engine temperature. The
coolant level should be between
the minimum and maximum
marks on the tank.
2. If the coolant level is at or below
the minimum mark, fill with tap
water (soft water) to bring the
level up to the specified level.
Change the coolant every two
years.
3. If your motorcycle overheats, see
page 6-38 for details.
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EAU01622*Changing the coolant
1. Put the motorcycle on a level
place.
2. Remove the seat (See page
3-13 for seat removal proce-
dures.)
3. Remove cowling B and radiator
cover. (See page 6-7 for removal
and installation procedures.)
6-11
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94. Remove the radiator cap.
EW000067
w
Do not remove the radiator cap
when the engine is hot.
EC000080
cC
Hard water or salt water is harmful
to the engine. You may use dis-
tilled water if you can’t get soft
water.
1
1. Radiator cap
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5. Place a container under the
engine and remove the coolant
drain bolt.
1. Drain bolt
1
6. Disconnect the reservoir tank
hose on the reservoir tank side
and drain the coolant from the
reservoir tank.
7. After draining the coolant, thor-
oughly flush the cooling system
with clean tap water.
8. Replace the coolant drain bolt
washer if it is damaged and tight-
en the coolant drain bolt to the
specified torque.
1. Reservoir tank hose
Tightening torque:
Coolant drain bolt:
8 Nm (0.8 m0kg)
9. Install the reservoir tank hose.
10. Pour the recommended coolant
into the radiator until it is full.
EC000080
cC
Hard water or salt water is harmful
to the engine. You may use dis-
tilled water if you can’t get soft
water.
Recommended antifreeze:
High quality ethylene glycol
antifreeze containing
corrosion inhibitors for
aluminum engines
Antifreeze and water mixing ratio:
1:1
Total amount:
1.05 L
Reservoir tank capacity:
0.35 L
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1. Reservoir tank cap
2. Stopper
3. Stopper bolt
4. Maximum level mark
5. Minimum level mark
11. Install the radiator cap.
12. Run the engine several minutes.
Stop the engine and recheck the
coolant level in the radiator. If it
is low, add more coolant until it
reaches the top of the radiator.
13. Fill the reservoir tank with
coolant up to specified level.
14. Install the reservoir tank cap and
check for coolant leakage.
NOTE:
If any leakage is found, ask a
Yamaha dealer to inspect the cooling
sytem.
15. Install the cowling, radiator cover
and the seat.
1
EAU01476*Air filter
The air filter should be cleaned at the
specified intervals. It should be
cleaned more frequently if you are
riding in unusually wet or dusty
areas.
1. Remove the seat.
2. Remove cowling A and B. (See
page 6-7 for cowling removal
and installation steps.)
3. Remove the fuel tank bolt.
4. Lift the front of the fuel tank
upward and position it away from
the air filter case. (Do not
remove the fuel hoses.)
1. Bolt
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EW000071
w
8 8
Support the fuel tank carefully
during this procedure.
8 8
Do not tilt the fuel tank too
much or pull it too hard
because the fuel hose connec-
tions may become loose caus-
ing fuel leakage.
1
2
2
1. Relay (´2)
2. Screw (´7)
5. Remove the relays and the
screws holding the air filter case
cover.
1
1. Air filter
6. Remove the air filter element
from its case and clean it with
solvent. After cleaning, remove
the remaining solvent by squeez-
ing the air filter.
7. Apply recommended oil to the
entire surface of the air filter and
squeeze out the excess oil. The
air filter should be wet but not
dripping.
8. Install the air filter element in its
case.
9. Reinstall the parts removed for
access. Recommended oil:
2-stroke engine oil
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