2002 YAMAHA TDR 125 coolant level

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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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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6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03884
NOTE:
8The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8Hydraulic brake service
9Regularly check and, if necessary, correct the brake fluid level.
9Every two years replace the internal components of the brake master cylinders and calipers, and change the
brake fluid.
9Replace the brake hoses every four years and if cracked or damaged.21 Transmission oil•Check oil level.√√√√√ √
•Change.√√
22
*Cooling system•Check coolant level and vehicle for coolant leakage.√√√√ √
•Change.Every 3 years
23*Front and rear brake
switches•Check operation.√√√√√ √
24 Moving parts and cables•Lubricate.√√√√ √
25*Lights, signals and
switches•Check operation.
•Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 6 12 18 24
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6-10
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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.
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.
2. 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.
1
2
1. Maximum level mark
2. Minimum level mark
Recommended transmission oil:
See page 8-1.
Oil quantity:
Periodic oil change:
0.75 L
Total amount (dry transmission):
0.8 L
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6-11
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EW000067
wNever attempt to remove the radia-
tor cap when the engine is hot.NOTE:
If the engine overheats, see page
6-43 for further instructions.
EAU03746
To change the coolant
1. Place the motorcycle on a level
surface and let the engine cool if
necessary.
2. Remove the seat. (See page
3-12 for seat removal and instal-
lation procedures.)
3. Remove cowling B. (See page
6-6 for cowling removal and
installation procedures.)
4. Remove the radiator cap.
EW000067
wNever attempt to remove the radia-
tor cap when the engine is hot.
5. Place a container under the
engine to collect the used
coolant.
6. Remove the coolant drain bolt
and disconnect the hose on the
side of the reservoir to drain the
reservoir.
7. After the coolant is completely
drained, thoroughly flush the
cooling system with clean tap
water.
8. Install the coolant drain bolt, and
then tighten it to the specified
torque.
1
1
1. Radiator cap 1. Coolant drain bolt
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6-13
PERIODIC MAINTENANCE AND MINOR REPAIR
612. Remove the radiator cap to
check the coolant level in the
radiator. If necessary, add suffi-
cient coolant until it reaches the
top of the radiator, and then
install the radiator cap.
13. Check the coolant level in the
reservoir. If necessary, remove
the coolant reservoir cap by
removing the screw and retainer,
add coolant to the maximum
level mark, and then install the
coolant reservoir cap and retain-
er by installing the screw.14. Start the engine, and then check
the vehicle for coolant leakage. If
coolant is leaking, have a
Yamaha dealer check the cool-
ing system.
15. Install the cowling and the seat.
EAU03747
Cleaning the air filter
elementThe air filter element should be
cleaned at the intervals specified in
the periodic maintenance and lubrica-
tion chart. Clean the air filter element
more frequently if you are riding in
unusually wet or dusty areas.
1. Remove the seat. (See page
3-12 for seat removal and instal-
lation procedures.)
2. Remove cowlings A and B. (See
page 6-6 for cowling removal
and installation procedures.)
3. Remove the fuel tank bolt.
21
4
5
3
1
1. Coolant reservoir tank cap
2. Retainer
3. Screw
4. Maximum level mark
5. Minimum level mark1. Bolt
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6-43
PERIODIC MAINTENANCE AND MINOR REPAIR
6
NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended
coolant as soon as possible.Engine overheating
EW000070
w8Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
8After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the
hissing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the
cap.Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.Add coolant. (See NOTE.)
Start the engine. If the engine overheats again,
have a
Yamaha dealer check
and repair the cooling system.
There is
leakage.
There is
no leakage.
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