2002 YAMAHA TDR 125 check engine

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 ............................... 2-3INSTRUMENT 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 ........................................................... 3-15
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
Owner’s tool kit .............................................. 6-1
Periodic maintenance and lubrication chart ... 6-2
Removing and installing the cowlings and
panel ............................................................ 6-5
123
456
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Checking the spark plug ................................ 6-7
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
Cast wheels ................................................. 6-19
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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3-2
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Indicator and warning lights
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Turn signal indicator light “5”
This indicator light flashes when the
turn signal switch is pushed to the left
or right.
EAU00063
High beam indicator light “&”
This indicator light comes on when
the high beam of the headlight is
switched on.
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2-stroke engine oil level warning
light “
7
”
This warning light comes on when
the 2-stroke 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
"#" and turn the key to "ON".
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 2-stroke engine oil level is
sufficient, the warning light may flick-
er when riding on a slope or during
sudden acceleration or deceleration,
but this is not a malfunction.
EAU00061
Neutral indicator light “N”
This indicator light comes on when
the transmission is in the neutral
position.
INSTRUMENT AND CONTROL FUNCTIONS
3
1
2
3
4
1. Turn signal indicator light “5”
2. High beam indicator light “&”
3. 2-stroke enjine oil level warning light “
7
”
4. Neutral indicator light “N”
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3-15
INSTRUMENT AND CONTROL FUNCTIONS
3
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YPVSThis model is equipped with the
YPVS (Yamaha Power Valve
System). This system boosts engine
performance and efficiency by means
of a variable valve in the exhaust
port. The YPVS valve is constantly
adjusted in accordance with the
engine speed by a computer-con-
trolled servomotor.
Since the YPVS is an important part
of the engine and requires very
sophisticated adjustment, have a
Yamaha dealer, who has the neces-
sary professional knowledge and
experience, make this adjustment.
EC000023
cCThe YPVS has been set and exten-
sively tested at the Yamaha facto-
ry. Changing these settings with-
out sufficient technical knowledge
may result in poor performance of
or damage to the engine.YPVS operation noises can be heard
in the following instances:
8When the key is turned to “ON”
and the engine is started.
8When the engine stalls with the
key in the “ON” position.
EC000024
cCIf the YPVS does not operate, have
a Yamaha dealer check it.
EAU00330
SidestandThe sidestand is located on the left
side of the frame. Raise the side-
stand or lower it with your foot while
holding the motorcycle upright.NOTE:
The built-in sidestand switch is part of
the ignition circuit cut-off system,
which cuts the ignition in certain situ-
ations. (See further down for an
explanation of the ignition circuit cut-
off system.)
1
1. YPVS
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3-16
EW000044
wThe motorcycle must not be ridden
with the sidestand down, or if the
sidestand cannot be properly
moved up (or does not stay up),
otherwise the sidestand could con-
tact the ground and distract the
operator, resulting in a possible
loss of control. Yamaha’s ignition
circuit cut-off system has been
designed to assist the operator in
fulfilling the responsibility of rais-
ing the sidestand before starting
off. Therefore, check this system
regularly as described below and
have a Yamaha dealer repair it if it
does not function properly.
EAU03720
Ignition circuit cut-off
systemThe ignition circuit cut-off system
(comprising the sidestand switch,
clutch switch and neutral switch) has
the following functions.
8It prevents starting when the
transmission is in gear and the
sidestand is up, but the clutch
lever is not pulled.
8It prevents starting when the
transmission is in gear and the
clutch lever is pulled, but the
sidestand is still down.
8It cuts the running engine when
the transmission is in gear and
the sidestand is moved down.
Periodically check the operation of
the ignition circuit cut-off system
according to the following procedure.
EW000045
wIf a malfunction is noted, have a
Yamaha dealer check the system
before riding.
INSTRUMENT AND CONTROL FUNCTIONS
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3-17
INSTRUMENT AND CONTROL FUNCTIONS
3
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is set to “
#”.
3. Turn the key to “ON”.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
The sidestand switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.The clutch switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
NO
NOTE:This check is most reliable if performed with
a warmed-up engine.
YESYES NO
The system is OK. The motorcycle can be ridden.
YES NO
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4-1
EAU01114
PRE-OPERATION CHECKS
4The condition of a vehicle is the owner’s 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
ITEM CHECKS PAGE
Fuel•Check fuel level in fuel tank.
•Refuel if necessary.
•Check fuel line for leakage.3-7–3-9
2-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.6-8–6-10
Coolant•Check coolant level in reservoir.
•If necessary, add recommended coolant to specified level.
•Check cooling system for leakage.6-10–6-13
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, 6-23–6-24
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5-1
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OPERATION AND IMPORTANT RIDING POINTS
5
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.
EAU04271
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 “ON”.
2. Turn the key to “ON” and make
sure that the engine stop switch
is set to “#”.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.
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