2000 YAMAHA TDR 125 coolant level

4-1
PRE-OPERATION CHECKS
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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.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 48

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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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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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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6-13
PERIODIC MAINTENANCE AND MINOR REPAIR
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3
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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6-38
PERIODIC MAINTENANCE AND MINOR REPAIR
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5. Engine overheating
w
Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Open the radiator cap as follows. Wait until the
engine has cooled. Remove the radiator cap stopper by removing the screw. Place a thick rag like a towel over
the radiator cap and slowly rotate the cap counterclockwise to the detent. This procedure allows any residual
pressure to escape. When the hissing sound has stopped, press down on the cap while turning counterclock-
wise and remove it.
NOTE:
If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the rec-
ommended coolant as soon as possible.
Level is OK.
Wait until the engine
has cooled.
Restart the engine. If the engine overheats again, ask a
Yamaha dealer to inspect and repair the cooling system. Check the coolant level in the
reservoir tank and/or radiator.
Add coolant (See NOTE.)
Level is low, check thecooling system for leakage.Leakage.No
leakage.Ask a Yamaha dealer to inspect
and repair the cooling system.
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