2000 YAMAHA TDR 125 maintenance

TABLE OF CONTENTS
1 GIVE SAFETY THE RIGHT OF WAY
2 DESCRIPTION
3 INSTRUMENT AND CONTROL FUNCTIONS
4 PRE-OPERATION CHECKS
5 OPERATION AND IMPORTANT RIDING POINTS
6 PERIODIC MAINTENANCE AND MINOR REPAIR
7 MOTORCYCLE CARE AND STORAGE
8 SPECIFICATIONS
9 CONSUMER INFORMATION
INDEX
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Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and free-
dom. However, they also impose certain limits, which you must accept; even the best motorcycle
does not ignore the laws of physics.
Regular care and maintenance are essential for preserving your motorcycle’s value and operating
condition. Moreover, what is true for the motorcycle is also true for the rider: good performance
depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of
course, out of the question. Motorcycle riders more than car drivers must always be at their mental
and physical best. Under the influence of even small amounts of alcohol, there is a tendency to take
dangerous risks.
Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passen-
gers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant synthetic
materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet. Optimum pro-
tective wear, however, should not encourage carelessness. Though full-coverage helmets and suits,
in particular, create an illusion of total safety and protection, motorcyclists will always be vulnerable.
Riders who lack critical self-control run the risk of going too fast and are apt to take chances. This is
even more dangerous in wet weather. The good motorcyclist rides safely, predictably and defensively
avoiding all dangers, including those caused by others.
Enjoy your ride!
EAU00021
QGIVE SAFETY THE RIGHT OF WAY
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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
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6-1
EAU00464
Periodic inspection, adjustment and
lubrication will keep your motorcycle
in the safest and most efficient condi-
tion possible. Safety is an obligation
of the motorcycle owner. The mainte-
nance and lubrication schedule chart
should be considered strictly as a
guide to general maintenance and
lubrication intervals.
YOU MUST TAKE INTO CONSIDER-
ATION THAT WEATHER, TERRAIN,
GEOGRAPHICAL LOCATIONS, AND
A VARIETY OF INDIVIDUAL USES
ALL TEND TO DEMAND THAT
EACH OWNER ALTER THIS TIME
SCHEDULE TO SHORTER INTER-
VALS TO MATCH THE ENVIRON-
MENT. The most important points of
motorcycle inspection, adjustment,
and lubrication are explained in the
following pages.
EW000060
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If you are not familiar with motor-
cycle service, this work should be
done by a Yamaha dealer.
EAU00462
PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU00469Tool kit
The service information included in
this manual is intended to provide
you, the owner, with the necessary
information for completing some of
your own preventive maintenance
and minor repairs.
The tools provided in the owner’s tool
kit are to assist you in the perfor-
mance of periodic maintenance.
However, some other tools such as a
torque wrench are also necessary to
perform the maintenance correctly.
1. Tool kit
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NOTE:
If you do not have necessary tools
required during a service operation,
take your motorcycle to a Yamaha
dealer for service.
EW000063
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Modifications to this motorcycle
not approved by Yamaha may
cause loss of performance, and
render it unsafe for use. Consult a
Yamaha dealer before attempting
any changes.
PERIODIC MAINTENANCE AND MINOR REPAIR
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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)
1 * Fuel line 9Check fuel hoses for cracks or damage.
ÖÖ
9Replace if necessary.
2 Spark plug9Check condition.
ÖÖÖ
9Clean, regap or replace if necessary.
3 Air filter9Clean or replace if necessary.ÖÖ
4 Clutch9Check operation.
ÖÖÖ
9Adjust or replace cable.
9Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)
Ö
5 * Front brake
9Correct accordingly.ÖÖ
9Replace brake pads if necessary.
9Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)
6 * Rear brake
9Correct accordingly.ÖÖÖ
9Replace brake pads if necessary.
7 * Wheels9Check balance, runout and for damage.
ÖÖ
9Rebalance or replace if necessary.
9Check tread depth and for damage.
8 * Tires9Replace if necessary.
ÖÖ
9Check air pressure.
9Correct if necessary.
9 * Wheel bearings9Check bearing for looseness or damage.
ÖÖ
9Replace if necessary.
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PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU00473
PERIODIC MAINTENANCE AND LUBRICATION
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PERIODIC MAINTENANCE AND MINOR REPAIR
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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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PERIODIC MAINTENANCE AND MINOR REPAIR
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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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