2001 YAMAHA TDR 125 check engine light

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
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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
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0
001
0001
00
140
180 120 100 80
1 23456
7
8
9
10
11
12
X1000r/min
km/h
CH
1
2
4
3
EAU03034
Indicator and warning lights
EAU03201
Oil level warning light Ò
7
Ó
This warning light comes on when
the engine oil level is low.
The electrical circuit of the warning
light can be checked according to the
following procedure.
1.Set the engine stop switch to Ò#Ó
and turn the key to ÒONÓ.
2.Shift the transmission into the
neutral position or pull the clutch
lever.3.Push the start switch. If the
warning light does not come on
while pushing the start switch,
have a Yamaha dealer check the
electrical circuit.
NOTE:
Even if the oil level is sufficient, the
warning light may flicker when riding
on a slope or during sudden acceler-
ation or deceleration, but this is not a
malfunction.
EAU00057
Turn signal indicator light Ò5Ó
This indicator light flashes when the
turn signal switch is pushed to the left
or right.
EAU00061
Neutral indicator light ÒNÓ
This indicator light comes on when
the transmission is in the neutral
position.
EAU00063
High beam indicator light Ò&Ó
This indicator light comes on when
the high beam of the headlight is
switched on.
1.Turn signal indicator light Ò5Ó
2.High beam indicator light Ò&Ó
3.Oil level warning light Ò
7
Ó
4.Neutral indicator light ÒNÓ
3-2
INSTRUMENT AND CONTROL FUNCTIONS
1
23
4
5
6
7
8
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5-1
EAU00373
w8Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer
regarding any control or func-
tion that you do not thorough-
ly understand.
8Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
8Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
EAU00381
Starting a cold engineIn order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
8The transmission is in the neutral
position.
8The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EW000054
w8Before starting the engine,
check the function of the igni-
tion circuit cut-off system
according to the procedure
described on page 3-17.
8Never ride with the sidestand
down.1.Turn the fuel cock lever to ÒONÓ.
2.Turn the key to ÒONÓ and make
sure that the engine stop switch
is set to Ò#Ó.3.Shift the transmission into the
neutral position.
NOTE:
When the transmission is in the neu-
tral position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical
circuit.4.Turn the starter (choke) on and
completely close the throttle.
(See page 3-12 for starter
(choke) operation.)
5.Start the engine by pushing the
start switch.NOTE:
If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the
engine more than 10 seconds on any
one attempt.
EAU00372
OPERATION AND IMPORTANT RIDING POINTS
1
2
3
45
6
7
8
9
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5-2
EC000034
cCThe oil level warning light should
come on when the start switch is
pushed, and it should go off when
the start switch is released. If the
oil level warning light flickers or
remains on after starting, immedi-
ately stop the engine, and then
check the engine oil level and the
vehicle for oil leakage. If neces-
sary, add engine oil, and then
check the warning light again. If
the warning light does not come
on when pushing the start switch,
or if it does not go off after starting
with sufficient engine oil, have a
Yamaha dealer check the electrical
circuit.6.After starting the engine, move
the starter (choke) lever back
halfway.
ECA00045
cCFor maximum engine life, never
accelerate hard when the engine is
cold!7.When the engine is warm, turn
the starter (choke) off.NOTE:
The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off.
EAU01258
Starting a warm engineFollow the same procedure as for
starting a cold engine with the excep-
tion that the starter (choke) is not
required when the engine is warm.
OPERATION AND IMPORTANT RIDING POINTS
1
2
3
45
6
7
8
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1
2.Remove the spark plug as
shown, with the spark plug
wrench included in the ownerÕs
tool kit.To check the spark plug
1.Check that the porcelain insula-
tor around the center electrode
of the spark plug is a medium-to-
light tan (the ideal color when the
motorcycle is ridden normally).
NOTE:
If the spark plug shows a distinctly
different color, the engine could be
defective. Do not attempt to diagnose
such problems yourself. Instead,
have a Yamaha dealer check the
motorcycle.2.Check the spark plug for elec-
trode erosion and excessive car-
bon or other deposits, and
replace it if necessary.
1.Spark plug wrench
6-7
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9Specified spark plug:
BR9ES (NGK)
1
EAU01833
Checking the spark plugThe spark plug is an important
engine component, which is easy to
check. Since heat and deposits will
cause any spark plug to slowly erode,
the spark plug should be removed
and checked in accordance with the
periodic maintenance and lubrication
chart. In addition, the condition of the
spark plug can reveal the condition of
the engine.
To remove the spark plug
1.Remove the spark plug cap.1.Spark plug cap
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6-8
NOTE:
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is
1/4Ð1/2 turn past finger tight.
However, the spark plug should be
tightened to the specified torque as
soon as possible.4.Install the spark plug cap.
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9 Spark plug gap:
0.7Ð0.8 mm
Tightening torque:
Spark plug:
20 Nm (2.0 m0kg)
a
a.Spark plug gapTo install the spark plug
1.Measure the spark plug gap with
a wire thickness gauge and, if
necessary, adjust the gap to
specification.
2.Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3.Install the spark plug with the
spark plug wrench, and then
tighten it to the specified torque.
EAU03751
Transmission oilThe transmission oil level should be
checked before each ride. In addition,
the transmission oil must be changed
at the intervals specified in the peri-
odic maintenance and lubrication
chart.
To check the transmission oil level
1.Place the motorcycle on a level
surface and hold it in an upright
position. NOTE:
Make sure that the motorcycle is
positioned straight up when checking
the oil level. A slight tilt to the side
can result in a false reading.2.Start the engine, warm it up for
several minutes, and then turn it
off.
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6-10
EC000077
cC8In order to prevent clutch slip-
page (since the transmission
oil also lubricates the clutch),
do not mix any chemical addi-
tives with the oil.
8Make sure that no foreign
material enters the transmis-
sion.6.Start the engine, and then let it
idle for several minutes while
checking the transmission for oil
leakage. If oil is leaking, immedi-
ately turn off the engine and
check for the cause.
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9 Recommended transmission oil:
See page 8-1
Oil quantity:
Periodic oil change:
0.75 L
Total amount (dry transmission):
0.8 L
1
2
1.Maximum level mark
2.Minimum level mark2.Check the coolant level in the
coolant reservoir.NOTE:
The coolant should be between the
minimum and maximum level marks.3.If the coolant is at or below the
minimum level mark, open the
reservoir cap, add coolant to the
maximum level mark, and then
close the reservoir cap.
EAU03761
CoolantTo check the coolant level
1.Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:
8The coolant level must be
checked on a cold engine since
the level varies with engine tem-
perature.
8Make sure that the motorcycle is
positioned straight up when
checking the coolant level. A
slight tilt to the side can result in
a false reading.
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