2002 YAMAHA TDR 125 brake

6-31
PERIODIC MAINTENANCE AND MINOR REPAIR
6To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and
rebounds smoothly.
EC000098
cCIf any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
EAU00794
Checking the steeringWorn or loose steering bearings may
cause danger. Therefore, the opera-
tion of the steering must be checked
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
1. Place a stand under the engine
to raise the front wheel off the
ground.
EW000115
wSecurely support the motorcycle
so that there is no danger of it
falling over.
2. Hold the lower ends of the front
fork legs and try to move them
forward and backward. If any
free play can be felt, have a
Yamaha dealer check or repair
the steering.
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6-35
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EC000105
cCDo not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the
bulb, and the bulb life will be
adversely affected. Thoroughly
clean off any dirt and fingerprints
on the headlight bulb using a cloth
moistened with alcohol or thinner.5. Install the bulb cover, and then
connect the coupler.
6. Install the cowling.7. Have a Yamaha dealer adjust
the headlight beam if necessary.
EAU01078
Replacing the tail/brake light
bulb1. Remove the seat. (See page
3-12 for seat removal and instal-
lation procedures.)
2. Remove panel A. (See page
6-6 for panel removal and instal-
lation procedures.)
a
a. Do not touch this area.
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6-38
PERIODIC MAINTENANCE AND MINOR REPAIR
6 2. Loosen the front wheel axle
pinch bolt, then the wheel axle.
3. Lift the front wheel off the ground
according to the procedure on
page 6-37.
4. Pull the wheel axle out, and then
remove the wheel.
ECA00048
cCDo not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
EAU04273
To install the front wheel
Installing
1. Install the speedometer gear unit
into the wheel hub so that the
projections mesh with the slots.
2. Lift the wheel up between the
fork legs.NOTE:
Make sure that there is enough
space between the brake pads
before inserting the brake disc and
that the slot in the speedometer gear
unit fits over the retainer on the fork
leg.
3. Insert the wheel axle.
4. Lower the front wheel so that it is
on the ground.
5. Tighten the wheel axle to the
specified torque.
6. Tighten the front wheel axle
pinch bolt to the specified torque.
7. Push down hard on the handle-
bar several times to check for
proper fork operation.
2
1
1
1
1. Pinch bolt
2. Wheel axle1. Speedometer gear unit 1. Retainer
Tightening torque:
Wheel axle:
59 Nm (5.9 m0kgf)
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6-40
PERIODIC MAINTENANCE AND MINOR REPAIR
6 6. While supporting the brake
caliper, pull the wheel axle out.
7. Remove the wheel.
ECA00048
cCDo not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
EAU01620
To install the rear wheel
1. Install the brake caliper onto the
swingarm as shown.NOTE:
Make sure that the slot in the brake
caliper bracket fits over the retainer
on the swingarm.2. Install the drive chain onto the
rear sprocket.
3. Insert the wheel axle from the
left-hand side, install the axle
nut, and then lower the rear
wheel so that it is on the ground.
NOTE:
Make sure that there is enough
space between the brake pads
before inserting the brake disc
between the brake pads.4. Adjust the drive chain slack.
(See page 6-26 for drive chain
slack adjustment procedures.)
5. Tighten the axle nut to the speci-
fied torque.
1
1. Retainer
Tightening torque:
Axle nut:
104 Nm (10.4 m0kgf)
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7-2
MOTORCYCLE CARE AND STORAGE
78Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abra-
sive cleaning products, sol-
vent or thinner, fuel (gasoline),
rust removers or inhibitors,
brake fluid, antifreeze or elec-
trolyte.
8Do not use high-pressure
washers or steam-jet cleaners
since they cause water seep-
age and deterioration in the
following areas: seals (of
wheel and swingarm bearings,
fork and brakes), electric com-
ponents (couplers, connec-
tors, instruments, switches
and lights), breather hoses
and vents.8For motorcycles equipped
with a windshield: Do not use
strong cleaners or hard
sponges as they will cause
dulling or scratching. Some
cleaning compounds for plas-
tic may leave scratches on the
windshield. Test the product
on a small hidden part of the
windshield to make sure that it
does not leave any marks. If
the windshield is scratched,
use a quality plastic polishing
compound after washing.
After normal useRemove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottle-
brush for hard-to-reach areas.
Stubborn dirt and insects will come
off more easily if the area is covered
with a wet cloth for a few minutes
before cleaning.After riding in the rain, near the sea
or on salt-sprayed roadsSince sea salt or salt sprayed on
roads during winter are extremely
corrosive in combination with water,
carry out the following steps after
each ride in the rain, near the sea or
on salt-sprayed roads.NOTE:
Salt sprayed on roads in the winter
may remain well into spring.1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.
ECA00012
cCDo not use warm water since it
increases the corrosive action of
the salt.2. Apply a corrosion protection
spray on all metal, including
chrome- and nickel-plated, sur-
faces to prevent corrosion.
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7-3
MOTORCYCLE CARE AND STORAGE
7 After cleaning
1. Dry the motorcycle with a
chamois or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally
induced discoloring of stainless-
steel exhaust systems can be
removed through polishing.)
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal, includ-
ing chrome- and nickel-plated,
surfaces.
5. Use spray oil as a universal
cleaner to remove any remaining
dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.8. Let the motorcycle dry complete-
ly before storing or covering it.
EWA00001
w8Make sure that there is no oil
or wax on the brakes or tires.
If necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or
acetone, and wash the tires
with warm water and a mild
detergent.
8Before operating the motorcy-
cle test its braking perfor-
mance and cornering behav-
ior.
ECA00013
cC8Apply spray oil and wax spar-
ingly and make sure to wipe
off any excess.
8Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
8Avoid using abrasive polish-
ing compounds as they will
wear away the paint.NOTE:
Consult a Yamaha dealer for advice
on what products to use.
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8-3
SPECIFICATIONS
8
Wheels
Front
Type Cast
Size 18 ×MT2.15 or
18 M/C ×MT2.15
Rear
Type Cast
Size 17 ×MT2.50 or
17 M/C ×MT2.50
Brakes
Front
Type Single disc brake
Operation Right hand
Fluid DOT 4
Rear
Type Single disc brake
Operation Right foot
Fluid DOT 4Suspension
Front
Type Telescopic fork
Rear
Type Swingarm (Monocross)
Spring/shock absorber
Front
Type Coil spring/oil damper
Rear
Type Coil-gas spring/oil damper
Wheel travel
Front 180 mm
Rear 180 mm
Electrical
Ignition system C.D.I.
Charging system
Type A.C. magneto
Standard output 14 V, 12A @ 5,000 r/min
Battery
Type YTX5L-BS
Voltage, capacity 12 V, 4 Ah
5AE-28199-E5 honbun 7/6/01 10:18 AM Page 86

8-4
SPECIFICATIONS
8
Headlight typeQuartz bulb (halogen)
Bulb voltage, wattage ×quantity
Headlight 12 V, 60/55W ×2
12 V, 35/35W ×2 (GB, IRL)
Tail/brake light 12 V, 5/21W ×2
Front turn signal light 12 V, 21W ×2
Rear turn signal light 12 V, 21W ×2
Auxiliary light 12 V, 4W ×2
12 V, 3.4W ×2 (GB, IRL)
Meter lighting 12 V, 3.4W ×3
Neutral indicator light 12 V, 3.4W ×1
High beam indicator light 12 V, 3.4W ×1
Oil level warning light 12 V, 3.4W ×1
Turn indicator light 12 V, 3.4W ×1
Fuse20A
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