2000 YAMAHA TDR 125 maintenance

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1. Wear limit: 0.8 mmREAR
EAU00733
Inspecting the brake fluid
level
Insufficient brake fluid may let air
enter the brake system, possibly
causing the brakes to become inef-
fective.
Before riding, check that the brake
fluid is above the minimum level and
replenish when necessary.
Observe these precautions:
8When checking the fluid level,
make sure the top of the master
cylinder is level by turning the
handlebars.
1
1. Minimum level markFRONT
1
1. Minimum level mark
8Use only the designated quality
brake fluid. Otherwise, the rub-
ber seals may deteriorate, caus-
ing leakage and poor brake per-
formance.
NOTE:
If DOT 4 is not available, DOT 3 can
be used for the front brake only.
REAR
Recommended fluid:
DOT 4
EAU00730
Rear brake
Inspect the pads through the window
as shown.
If the thickness is less than the speci-
fied value, have a Yamaha dealer
replace the pads.
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98Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor brake performance.
8Be careful that water does not
enter the master cylinder when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.
8Brake fluid may deteriorate paint-
ed surfaces or plastic parts.
Always clean up spilled fluid
immediately.
8Have a Yamaha dealer check
the cause if the brake fluid level
goes down.
EAU00742Brake fluid replacement
The brake fluid should be replaced
only by trained Yamaha service per-
sonnel. Have the Yamaha dealer
replace the following components
during periodic maintenance or when
they are damaged or leaking:
8oil seals (every two years)
8brake hoses (every four years)
EAU00744Drive chain slack check
NOTE:
Spin the wheel several times and find
the tightest position of the chain.
Check and/or adjust the chain slack
while it’s in this tightest position.
a
a. Chain slack
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9 To check the chain slack the motor-
cycle must be held straight up with
both wheels on the ground and with-
out rider. Check the slack at the posi-
tion shown in the illustration. Normal
slack is approximately 25 ~ 40 mm. If
the slack exceeds 40 mm, adjust.
EAU00762Drive chain slack adjustment
1. Loosen the axle nut.
2. Loosen the locknuts on each
side. To tighten the chain, turn
the chain adjusting nuts in direc-
tiona. To loosen the chain, turn
the adjusting nuts in directionb
and push the wheel forward.
3
412
a
b
1. Locknut
2. Adjusting nut
3. Axle nut
4. Alignment marks
Turn each adjusting nut exactly
the same amount to maintain
correct axle alignment. There are
marks on each side of the
swingarm. Use these marks to
align the rear wheel.
EC000096
cC
Too little chain slack will overload
the engine and other vital parts.
Keep the slack within the specified
limits.
3. After adjusting, tighten the lock-
nuts. Then tighten the axle nut to
the specified torque.
Tightening torque:
Axle nut:
104 Nm (10.4 m0kg)
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EAU03006
Drive chain lubrication
The chain consists of many parts
which work with each other. If the
chain is not maintained properly, it
will wear out quickly. Therefore, the
chain must be serviced regularly.
This service is especially necessary
when riding in dusty areas. This
motorcycle is equipped with a sealed
type chain. Steam cleaning, high-
pressure washers, and solvents can
damage the drive chain, so do not
use these for cleaning it. Use only
kerosene to clean the drive chain.
Wipe it dry, and thoroughly lubricate it
with SAE 30 ~ 50W motor oil. Do not
use any other lubricants on the drive
chain. They may contain solvents
that could damage the sealed chain.
EC000097
cC
Be sure to oil the chain after wash-
ing the motorcycle or riding in the
rain.
EAU02962
Cable inspection and
lubrication
EW000112
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Damage to the outer housing of
cables may lead to internal rusting
and interfere with the cable move-
ment. Replace damaged cables as
soon as possible to prevent unsafe
conditions.
Lubricate the cables and cable ends.
If a cable does not operate smoothly,
ask a Yamaha dealer to replace it.
Recommended lubricant:
Engine oil
EAU00773
Throttle cable and grip
lubrication
The throttle twist grip assembly
should be greased at the time that
the cable is lubricated, since the grip
must be removed to get at the end of
the throttle cable. After removing the
screws, hold the end of the cable up
in the air and put in several drops of
lubricant. With the throttle grip disas-
sembled, coat the metal surface of
the grip assembly with a suitable all-
purpose grease.
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EAU00774
Autolube pump adjustment
The autolube pump is a vital part of
the engine and requires very sophisti-
cated adjustment.
Adjusting should be left to a Yamaha
dealer who has the professional
knowledge and experience to do so.
EAU02984
Brake and shift pedal
lubrication
Lubricate the pivoting parts.
Recommended lubricant:
Engine oil
EAU02985
Brake and clutch lever
lubrication
Lubricate the pivoting parts.
Recommended lubricant:
Engine oil
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EAU02986
Sidestand lubrication
Lubricate the sidestand pivoting point
and metal-to-metal contact surfaces.
Check that the sidestand moves up
and down smoothly.
EW000113
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If the sidestand does not move
smoothly, consult a Yamaha deal-
er.
Recommended lubricant:
Engine oil
EAU00791
Rear suspension lubrication
Lubricate the pivoting parts.
Recommended lubricant:
Lithium soap base grease
EAU02939
Front fork inspection
Visual checkEW000115
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Securely support the motorcycle
so there is no danger of it falling
over.
Check for scratches or damage on
the inner tube and excessive oil leak-
age from the front fork.
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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.
EC000098
cC
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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EAU01144Wheel bearings
If there is play in the front or rear
wheel hub or if the wheel does not
turn smoothly, have a Yamaha dealer
inspect the wheel bearings.
EAU00800Battery
This motorcycle is equipped with a
sealed-type battery. Therefore it is
not necessary to check the elec-
trolyte or fill the battery with distilled
water.
8 8
If the battery seems to have dis-
charged, consult a Yamaha deal-
er.
8 8
If the motorcycle is equipped
with optional electrical acces-
sories, the battery tends to dis-
charge more quickly, so be sure
to recharge it periodically.
EC000101
cC
Never try to remove the sealing
caps of the battery cells. The bat-
tery will be damaged.
EW000116
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Battery electrolyte is poisonous
and dangerous, causing severe
burns, etc. It contains sulfuric
acid. Avoid contact with skin, eyes
or clothing.
ANTIDOTE:
8 8
EXTERNAL: Flush with water.
8 8
INTERNAL: Drink large quanti-
ties of water or milk. Follow
with milk of magnesia, beaten
egg, or vegetable oil. Call a
physician immediately.
8 8
EYES: Flush with water for 15
minutes and get prompt med-
ical attention.
Batteries produce explosive
gases. Keep sparks, flame, ciga-
rettes etc., away. Ventilate when
charging or using in an enclosed
space. Always shield your eyes
when working near batteries.
KEEP OUT OF REACH OF CHIL-
DREN.
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