2000 YAMAHA TDR 125 coolant

DESCRIPTION
1
2
3
4
5
6
7
8
9
2-2
8. Tool kit (page 6-1)
9. Fuse (page 6-32)
10. Air filter (page 6-15)
11. Radiator cap (page 6-11)
12. Rear brake pedal (page 3-9, 6-22)
13. Coolant reservoir tank (page 6-10)14. Rear shock absorber spring
preload adjusting ring (page 3-14)
8 9 10 11
12
13 14
Right view
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 11

3-5
01
140 120 100
3456 CH
1
2
1. Engine temperature gauge
2. Red zone
EAU00114
Engine temperature gauge
This gauge indicates the coolant tem-
perature when the main switch is on.
The engine operating temperature
will vary with changes in weather and
engine load. If the needle points to
the red zone or higher, stop your
motorcycle and let the engine cool.
(See page 6-10 for details.)
EC000002
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When the engine is overheated, do
not continue riding.
INSTRUMENT AND CONTROL FUNCTIONS
1
2
3
4
5
6
7
8
9
1
2
3
4
EAU00118Handlebar switches
EAU00134Lights switch
Turning the light switch to “
'”,
turns on the auxiliary light, meter
lights and taillight. Turning the light
switch to “:”, turns the headlight on
also.
EAU00121Dimmer switch
Turn the switch to “&” for the high
beam and to “%” for the low beam.
EAU00127Turn signal switch
To signal a right-hand turn, push the
switch to “6”. To signal a left-hand
turn, push the switch to “4”. Once
the switch is released it will return to
the center position. To cancel the sig-
nal, push the switch in after it has
returned to the center position.
EAU00129Horn switch “* *
”
Press the switch to sound the horn.
1. Lights switch
2. Dimmer switch
3. Turn signal switch
4. Horn switch “*”
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4-1
PRE-OPERATION CHECKS
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2
3
4
5
6
7
8
9Owners are personally responsible for their vehicle’s condition. Your motorcycle/scooter’s vital functions can start to
deteriorate quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any dam-
age, fluid leak or loss of tire pressure could have serious consequences. Therefore, it is very important that, in addition
to a thorough visual inspection, you check the following points before each ride.
EAU00340PRE-OPERATION CHECK LIST
ITEM CHECKS PAGE
Front brake9Check operation, free play, fluid level and vehicle for fluid leakage.
9Fill with DOT 4 (or DOT 3) brake fluid if necessary.
3-8~3-9, 6-21 ~ 6-24
Rear brake9Check operation, free play, fluid level and vehicle for fluid leakage.
9Fill with DOT 4 brake fluid if necessary.
Clutch9Check operation, condition and free play.
3-8, 6-20 ~ 6-21
9Adjust if necessary.
9Check for smooth operation.
Throttle grip and housing9Lubricate.6-17 ~ 6-18, 6-27
9Adjust throttle cable free play if necessary.
Engine oil9Check oil level.
3-12
9Fill with oil if necessary.
Transmission oil9Check oil level.
6-9 ~ 6-10
9Fill with oil if necessary.
Coolant9Check coolant level.
6-10 ~ 6-11
9Fill with coolant if necessary.
Drive chain9Check chain slack and condition.
6-25 ~ 6-26
9Adjust if necessary.
Wheels and tires9Check tire pressure, wear, damage. 6-18 ~ 6-20
Control and meter cable9Check for smooth operation.
6-27
9Lubricate if necessary.
EAU01114
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PERIODIC MAINTENANCE AND MINOR REPAIR
Tool kit ...................................................................6-1
Periodic maintenance and lubrication ....................6-3
Cowling and panel removal and installation...........6-6
Cowling A, B ..........................................................6-7
Panel A ..................................................................6-7
Spark plug inspection.............................................6-8
Transmission oil .....................................................6-9
Cooling system ....................................................6-10
Changing the coolant ...........................................6-11
Air filter .................................................................6-13
Carburetor adjustment .........................................6-15
Idle speed adjustment ..........................................6-15
Throttle cable free play adjustment ......................6-16
Tires .....................................................................6-17
Wheels .................................................................6-19
Clutch lever free play adjustment.........................6-19
Front brake lever free play adjustment ................6-20
Rear brake pedal height adjustment ....................6-20
Brake light switch adjustment ..............................6-21
Checking the front and rear brake pads...............6-21
Inspecting the brake fluid level.............................6-22
Brake fluid replacement .......................................6-23
Drive chain slack check .......................................6-23
Drive chain slack adjustment ...............................6-24Drive chain lubrication............................................6-25
Cable inspection and lubrication ............................6-25
Throttle cable and grip lubrication ..........................6-26
Autolube pump adjustment ....................................6-26
Brake and shift pedal lubrication ............................6-26
Brake and clutch lever lubrication ..........................6-27
Sidestand lubrication..............................................6-27
Rear suspension lubrication...................................6-27
Front fork inspection ..............................................6-28
Steering inspection ................................................6-28
Wheel bearings ......................................................6-29
Battery....................................................................6-29
Fuse replacement ..................................................6-30
Headlight bulb replacement ...................................6-31
Taillight bulb replacement ......................................6-32
Turn signal light bulb replacement .........................6-32
Front wheel removal ..............................................6-33
Front wheel installation ..........................................6-34
Rear wheel removal ...............................................6-34
Rear wheel installation ...........................................6-35
Troubleshooting .....................................................6-36
Troubleshooting chart ............................................6-37
6
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6-5
PERIODIC MAINTENANCE AND MINOR REPAIR
6
7
8
9
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 operation.
20 * Autolube pump9Correct if necessary.ÖÖÖ
9Bleed if necessary.
9Check oil level and vehicle for oil leakage.
21 Transmission oil9Correct accordingly.
ÖÖÖ
9Change oil at initial 1,000 km and thereafter every
24,000 km or 24 months (whichever comes first).
9Check coolant level and vehicle for coolant leakage.
22 * Cooling system9Correct if necessary.
ÖÖ
9Change coolant every 24,000 km or 24 months (whichever
comes first).
* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.EAU02970
NOTE
8The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8Hydraulic brake system
9When disassembling the master cylinder or caliper, always replace the brake fluid. Check the brake fluid level
regularly and fill as required.
9Replace the oil seals on the inner parts of the master cylinder and caliper every two years.
9Replace the brake hoses every four years or if cracked or damaged.
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6-10
1
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
PERIODIC MAINTENANCE AND MINOR REPAIR
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2
3
4
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6
7
8
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
PERIODIC MAINTENANCE AND MINOR REPAIR
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2
3
4
5
6
7
8
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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6-12
PERIODIC MAINTENANCE AND MINOR REPAIR
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2
3
4
5
6
7
8
9
1
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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