2001 YAMAHA TDR 125 brake

EAU00009
TABLE OF CONTENTS
GIVE SAFETY THE RIGHT OF WAY.................1-1
DESCRIPTION....................................................2-1
Left view...........................................................2-1
Right view.........................................................2-2
Controls and instruments..................................2-3
INSTRUMENT AND CONTROL FUNCTIONS....3-1
Main switch/steering lock..................................3-1
Indicator and warning lights..............................3-2
Speedometer unit.............................................3-3
Tachometer......................................................3-3
Coolant temperature gauge..............................3-4
Handlebar switches..........................................3-4
Clutch lever.......................................................3-6
Shift pedal.........................................................3-6
Brake lever.......................................................3-7
Brake pedal......................................................3-7
Fuel tank cap....................................................3-7
Fuel (except for Switzerland and Austria).........3-8
Fuel (for Switzerland and Austria)....................3-8
Catalytic converter
(for Switzerland and Austria)..........................3-9
2-stroke engine oil..........................................3-10
Fuel cock........................................................3-11
Starter (choke) lever ......................................3-12
Seat................................................................3-12Helmet holder.................................................3-13
Adjusting the shock absorber assembly.........3-13
YEIS handling precautions.............................3-14
YPVS..............................................................3-14
Sidestand........................................................3-15
Ignition circuit cut-off system..........................3-16
PRE-OPERATION CHECKS...............................4-1
Pre-operation check list....................................4-1
OPERATION AND IMPORTANT RIDING
POINTS...............................................................5-1
Starting a cold engine.......................................5-1
Starting a warm engine.....................................5-2
Shifting..............................................................5-3
Recommended shift points
(for Switzerland only)......................................5-3
Tips for reducing fuel consumption...................5-4
Engine break-in................................................5-4
Parking.............................................................5-5
PERIODIC MAINTENANCE AND MINOR
REPAIR...............................................................6-1
OwnerÕs tool kit.................................................6-1
Periodic maintenance and lubrication chart......6-2
Removing and installing cowlings and panel....6-5
Checking the spark plug...................................6-7
123
456
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Transmission oil................................................6-8
Coolant...........................................................6-10
Cleaning the air filter element.........................6-13
Adjusting the carburetor.................................6-15
Adjusting the engine idling speed...................6-16
Adjusting the throttle cable free play..............6-17
Tires................................................................6-17
Wheels............................................................6-20
Adjusting the clutch lever free play.................6-20
Adjusting the brake lever free play.................6-21
Adjusting the brake pedal position..................6-22
Adjusting the rear brake light switch...............6-22
Checking the front and rear brake pads.........6-23
Checking the brake fluid level.........................6-24
Changing the brake fluid.................................6-25
Drive chain slack............................................6-25
Lubricating the drive chain..............................6-26
Checking and lubricating the cables...............6-27
Checking and lubricating the throttle grip
and cable......................................................6-28
Adjusting the Autolube pump..........................6-28
Checking and lubricating the brake and shift
pedals...........................................................6-29
Checking and lubricating the brake and
clutch levers..................................................6-29
Checking and lubricating the sidestand..........6-29Lubricating the rear suspension.....................6-30
Checking the front fork...................................6-30
Checking the steering.....................................6-31
Checking the wheel bearings.........................6-32
Battery............................................................6-32
Replacing the fuse..........................................6-33
Replacing a headlight bulb.............................6-34
Replacing the tail/brake light bulb...................6-35
Replacing a turn signal light bulb....................6-36
Supporting the motorcycle..............................6-37
Front wheel.....................................................6-37
Rear wheel.....................................................6-39
Troubleshooting..............................................6-41
Troubleshooting charts...................................6-42
MOTORCYCLE CARE AND STORAGE.............7-1
Care..................................................................7-1
Storage.............................................................7-4
SPECIFICATIONS...............................................8-1
Conversion table...............................................8-5
CONSUMER INFORMATION.............................9-1
Identification numbers......................................9-1
Key identification number.................................9-1
Vehicle identification number............................9-1
Model label.......................................................9-2
TABLE OF CONTENTS
789
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2-2
DESCRIPTION
12
3
4
5
6
7
8
9 8.OwnerÕs tool kit (page 6-1)
9.Fuse (page 6-33)
10.Air filter element(page 6-13)
11.Radiator cap (page 6-11)
12.Brake pedal (page 3-7, 6-22)
13.Coolant reservoir tank (page 6-10)14.Shock absorber spring preload
adjusting ring (page 3-13)
89
1011
12
13 14
Right view
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DESCRIPTION
12
3
4
5
6
7
8
9
2-3
1.Clutch lever (page 3-6, 6-20)
2.Left handlebar switches (page 3-4)
3.Speedometer unit(page 3-3)
4.Coolant temperature gauge (page 3-4)
5.Tachometer (page 3-3)6.Right handlebar switches (page 3-6)
7.Brake lever (page 3-7, 6-21)
8.Throttle grip (page 6-17, 6-28)
9.Fuel tank cap (page 3-7)
10.Main switch/steering lock (page 3-1)
1
2345
67
8 9
10
Controls and instruments
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3-7
1
EAU00158
Brake leverThe brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the han-
dlebar grip.1.Brake lever
INSTRUMENT AND CONTROL FUNCTIONS
1
23
4
5
6
7
8
9
1
1.Brake pedal
EAU00162
Brake pedalThe brake pedal is on the right side
of the motorcycle. To apply the rear
brake, press down on the brake
pedal.
1
a
b
EAU02935
Fuel tank capTo open the fuel tank cap
Open the fuel tank cap lock cover,
insert the key into the lock, and then
turn it 1/4 turn clockwise. The lock will
be released and the fuel tank cap can
be opened.
To close the fuel tank cap
1.Push the fuel tank cap into posi-
tion with the key inserted in the
lock.
2.Turn the key counterclockwise to
the original position, remove it,
and then close the lock cover.1.Fuel tank cap lock cover
a.Open.
b.Unlock.
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4-1
EAU01114
PRE-OPERATION CHECKS
1
2
34
5
6
7
8
9The condition of a vehicle is the ownerÕs responsibility. Vital components can start to deteriorate quickly and unexpect-
edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak-
age or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thor-
ough visual inspection, to check the following points before each ride.
EAU03439
Pre-operation check list
ITEMCHECKSPAGE
Fuel¥Check fuel level in fuel tank.
¥Refuel if necessary.
¥Check fuel line for leakage.3-7Ð3-9
Two-stroke engine oil¥Check oil level in oil tank.
¥If necessary, add recommended oil to specified level.
¥Check vehicle for oil leakage.3-10
Transmission oil¥Check oil level in transmission case.
¥If necessary, add recommended oil to specified level.6-8Ð6-10
Coolant¥Check coolant level in reservoir.
¥If necessary, add recommended coolant to specified level.
¥Check cooling system for leakage.6-10Ð6-13
Front brake¥Check operation.
¥If soft or spongy, have Yamaha dealer bleed hydraulic system.
¥Check lever free play.
¥Adjust if necessary.
¥Check fluid level in reservoir.
¥If necessary, add recommended brake fluid to specified level.
¥Check hydraulic system for leakage.3-7, 6-21, 6-23Ð6-24
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4-2
PRE-OPERATION CHECKS
1
2
34
5
6
7
8
9
Rear brake¥Check operation.
¥If soft or spongy, have Yamaha dealer bleed hydraulic system.
¥Check fluid level in reservoir.
¥If necessary, add recommended brake fluid to specified level.
¥Check hydraulic system for leakage.3-7, 6-22Ð6-24
Clutch¥Check operation.
¥Lubricate cable if necessary.
¥Check lever free play.
¥Adjust if necessary.3-6, 6-20Ð6-21
Throttle grip¥Make sure that operation is smooth.
¥Lubricate throttle grip, housing and cable if necessary.
¥Check free play.
¥Adjust if necessary.6-17, 6-28
Control cables¥Make sure that operation is smooth.
¥Lubricate if necessary.6-27
Drive chain¥Check chain slack.
¥Adjust if necessary.
¥Check chain condition.
¥Lubricate if necessary.6-25Ð6-27
Wheels and tires¥Check for damage.
¥Check tire condition and tread depth.
¥Check air pressure.
¥Correct if necessary.6-17Ð6-20
Brake and shift pedals¥Make sure that operation is smooth.
¥Lubricate pedal pivoting points if necessary.6-29
Brake and clutch levers¥Make sure that operation is smooth.
¥Lubricate lever pivoting points if necessary.6-29
Sidestand¥Make sure that operation is smooth.
¥Lubricate pivot if necessary.6-29Ð6-30 ITEMCHECKSPAGE
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6-2
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU03686
Periodic maintenance and lubrication chart
NOTE:
8The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
8From 30,000 km, repeat the maintenance intervals starting from 6,000 km.
8Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.NO.ITEMCHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
16121824
1
*Fuel line¥Check fuel hoses for cracks or damage.ÖÖÖÖÖ
2Spark plug¥Replace.ÖÖÖÖÖ
3Air filter element¥Clean.ÖÖ
¥Replace.ÖÖ
4Clutch¥Check operation.
¥Adjust.ÖÖÖÖÖ
5*Front brake¥Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)ÖÖÖÖÖÖ
¥Replace brake pads.Whenever worn to the limit
6*Rear brake¥Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)ÖÖÖÖÖÖ
¥Replace brake pads.Whenever worn to the limit
7*Brake hoses¥Check for cracks or damage.ÖÖÖÖÖ
¥Replace. (See NOTE on page 6-4.)Every 4 years
8*Wheels¥Check runout and for damage.ÖÖÖÖ
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