Yamaha TDR125 manual

TDR125 5AE-28199-E5 OWNER ’ S MANUAL[...]

EAU03338 INTRODUCTION 1 Welcome to the Yamaha world of motorcycling! As the owner of a TDR125, you are benefiting from Yamaha’s vast experience and newest technolo- gy regarding the design and manufacture of high-quality products, which have earned Yamaha a rep- utation for dependability. Please take the time to read this manual thoroughly, so as[...]

EAU00005 IMPORT ANT MANUAL INFORMA TION 1 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander, or a person in[...]

IMPORT ANT MANUAL INFORMA TION 1 EW000002 w PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. 5AE-28199-E5 honbun 7/6/01 10:18 AM Page 3[...]

1 TDR125 OWNER’S MANUAL ©2001 by Yamaha Motor Co., Ltd. 1st Edition, May 2001 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan. EAU03337 5AE-28199-E5 honbun 7/6/01 10:18 AM Page 4[...]

EAU00009 T ABLE 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 INS[...]

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 sp[...]

1-1 EAU00021 Q GIVE SAFETY THE RIGHT OF W A Y 1 Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and free- dom. However, they also impose certain limits, which you must accept; even the best motorcycle does not ignore the laws of physics. Regular care and maintenance are essential for preserving value and ope[...]

2-1 EAU00026 DESCRIPTION 2 1. Headlight (page 6-34) 2. Fuel cock (page 3-11) 3. 2-stroke engine oil tank (page 3-10) 4. Helmet holder (page 3-13) 5. Starter (choke) lever (page 3-12) 6. YEIS (page 3-14) 7. YPVS (page 3-15) 12 34 5 6 7 Left view 5AE-28199-E5 honbun 7/6/01 10:18 AM Page 8[...]

2-2 DESCRIPTION 2 8. Owner’s 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 10 11 12 13 14 Right view 5AE-28199-E5 honbun 7/6/01 10:18 AM Page 9[...]

2-3 DESCRIPTION 2 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 ([...]

3-1 EAU00027 INSTRUMENT AND CONTROL FUNCTIONS 3 EAU00029 Main switch/steering lock The main switch/steering lock con- trols the ignition and lighting systems, and is used to lock the steering. The various positions are described below. EAU00036 ON All electrical systems are supplied with power, and the engine can be started. The key cannot be remov[...]

3-2 EAU03034 Indicator and warning lights EAU00057 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. EAU04304 2-stroke engine oil level warnin[...]

3-3 INSTRUMENT AND CONTROL FUNCTIONS 3 EAU01087 Speedometer unit The speedometer unit is equipped with a speedometer, an odometer and a tripmeter. The speedometer shows riding speed. The odometer shows the total distance traveled. The tripmeter shows the distance traveled since it was last set to zero with the reset knob. The tripmeter can be used [...]

3-4 EAU01652 Coolant temperature gauge With the key in the “ ON ” position, the coolant temperature gauge indicates the temperature of the coolant. The coolant temperature varies with changes in the weather and engine load. If the needle reaches or enters the red zone, stop the motorcycle and let the engine cool. (See page 6-43 for further inst[...]

3-5 INSTRUMENT AND CONTROL FUNCTIONS 3 EAU00136 Headlight variations NOTE: Right and left are defined as seen when standing in front of the motorcycle. 3 : High beam light on , 2 : Low beam light on ' : Auxiliary light on 1 2 & & % % Left Right Bulb to be used Destination 3 ' 3 2 ' 2 3 2 Halogen bulb Halogen bulb France Swede[...]

3-6 EAU03890 Engine stop switch “ # / $ ” Set this switch to “ # ” before starting the engine. Set this switch to “ $ ” to stop the engine in case of an emer- gency, such as when the motorcycle overturns or when the throttle cable is stuck. EAU00143 Start switch “ , ” Push this switch to crank the engine with the starter. EC000005 c[...]

3-7 INSTRUMENT AND CONTROL FUNCTIONS 3 EAU00158 Brake lever The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the han- dlebar grip. EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal. EAU02935 Fuel tank cap To open [...]

3-8 NOTE: The fuel tank cap cannot be closed unless the key is in the lock. In addi- tion, the key cannot be removed if the cap is not properly closed and locked. EWA00025 w Make sure that the fuel tank cap is properly closed before riding. EAU03753 Fuel (except for Switzerland and Austria) Make sure that there is sufficient fuel in the tank. Fill [...]

3-9 INSTRUMENT AND CONTROL FUNCTIONS 3 EW000130 w 8 Do not overfill the fuel tank, otherwise it may overflow when the fuel warms up and expands. 8 Avoid spilling fuel on the hot engine. EAU00185 c C Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted sur- faces or plastic parts. EAU04206 Your Yamaha e[...]

3-10 EC000114 c C The following precautions must be observed to prevent a fire hazard or other damages. 8 Use only unleaded gasoline. The use of leaded gasoline will cause unrepairable damage to the catalytic converter. 8 Never park the motorcycle near possible fire hazards such as grass or other materi- als that easily burn. 8 Do not allow the eng[...]

3-11 INSTRUMENT AND CONTROL FUNCTIONS 3 EAU03050 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it also. The fuel cock has three positions: OFF With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running. ON With the lever in this position, fuel [...]

3-12 EAU03839 Starter (choke) lever “ 1 ” Starting a cold engine requires a rich- er air-fuel mixture, which is supplied by the starter (choke). Move the lever in direction a to turn on the starter (choke). Move the lever in direction b to turn off the starter (choke). EAU01619 Seat To remove the seat 1. Insert the key into the seat lock, and t[...]

3-13 INSTRUMENT AND CONTROL FUNCTIONS 3 EAU00260 Helmet holder To open the helmet holder, insert the key into the lock, and then turn the key as shown. To lock the helmet holder, place it in the original position, and then remove the key. EW000030 w Never ride with a helmet attached to the helmet holder, since the hel- met may hit objects, causing [...]

3-14 EAU00315 w This shock absorber contains highly pressurized nitrogen gas. For proper handling, read and understand the following informa- tion before handling the shock absorber. The manufacturer can- not be held responsible for proper- ty damage or personal injury that may result from improper han- dling. 8 Do not tamper with or attempt to ope[...]

3-15 INSTRUMENT AND CONTROL FUNCTIONS 3 EAU00326 YPVS This 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[...]

3-16 EW000044 w The 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[...]

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 shoul[...]

4-1 EAU01114 PRE-OPERA TION CHECKS 4 The 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. [...]

4-2 PRE-OPERA TION CHECKS 4 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, 6-22 – 6-24 Clutch • Check operation. • Lubricate cable if necessary. ?[...]

4-3 PRE-OPERA TION CHECKS 4 NOTE: Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very short time; and the added safety it assures is more than worth the time involved. EWA00033 w If any item in the Pre-operation check list is not working properly, have it inspected and repaired befo[...]

5-1 EAU00372 OPERA TION AND IMPORT ANT RIDING POINTS 5 EAU00373 w 8 Become 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. 8 Never start the engine or oper- ate it in a closed area for any length of time. Exhaust f[...]

5-2 OPERA TION AND IMPORT ANT RIDING POINTS 5 ECA00106 c C The 2-stroke engine oil level warn- ing light should come on when the start switch is pushed, and it should go off when the start switch is released. If the warning light flickers or remains on after starting, immediately stop the engine, and then check the 2-stroke engine oil level and the[...]

5-3 OPERA TION AND IMPORT ANT RIDING POINTS 5 EAU00423 Shifting Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc. The gear positions are shown in the illustration. NOTE: To shift the transmission into the neu- tral position, press the shift pedal down repeatedly until it reache[...]

5-4 OPERA TION AND IMPORT ANT RIDING POINTS 5 EAU00424 Tips for reducing fuel consumption Fuel consumption depends largely on your riding style. Consider the follow- ing tips to reduce fuel consumption: 8 Thoroughly warm up the engine. 8 Turn the starter (choke) off as soon as possible. 8 Shift up swiftly, and avoid high engine speeds during accele[...]

5-5 OPERA TION AND IMPORT ANT RIDING POINTS 5 1,000 km and beyond The vehicle can now be operated normally. EC000053 c C 8 Keep the engine speed out of the tachometer red zone. 8 If any engine trouble should occur during the engine break- in period, immediately have a Yamaha dealer check the vehi- cle. EAU00458 Parking When parking, stop the engine[...]

6-1 EAU00462 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU00464 Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condi- tion possible. The most important points of inspection, adjustment, and lubrication are explained on the fol- lowing pages. The intervals [...]

6-2 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU03686 Periodic maintenance and lubrication chart NOTE: 8 The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. 8 From 30,000 km, repeat the maintenance intervals starting from 6,000 km. 8 Items marked with an asterisk should be performed by a Yam[...]

6-3 PERIODIC MAINTENANCE AND MINOR REP AIR 6 9 * Tires • Check tread depth and for damage. • Replace if necessary. • Check air pressure. • Correct if necessary. √√√√ √ 10 * Wheel bearings • Check bearing for looseness or damage. √√√√ 11 * Swingarm • Check operation and for excessive play. √√√√ • Lubricate wit[...]

6-4 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU03884 NOTE: 8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 8 Hydraulic brake service 9 Regularly check and, if necessary, correct the brake fluid level. 9 Every two years replace the internal components of the brake master cylinders and calipers, and ch[...]

6-5 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU03624 Removing and installing the cowlings and panel The cowlings and panel shown above need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a cowling or the panel needs to be removed and installed. 1 1 1 1. Cowling A 1. Cowling B 1. Pan[...]

6-6 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU03745 Cowlings A and B To remove one of the cowlings: 1. Remove the seat. (See page 3-12 for seat removal and instal- lation procedures.) 2. Remove the radiator cover by removing the screws. 3. Remove the screws, and then pull the cowling off as shown. To install the cowling 1. Place the cowling in th[...]

6-7 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU01833 Checking the spark plug The 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 con[...]

6-8 PERIODIC MAINTENANCE AND MINOR REP AIR 6 To 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[...]

6-9 PERIODIC MAINTENANCE AND MINOR REP AIR 6 3. Wait a few minutes until the oil settles, and then check the oil level through the check window located at the right side of the crankcase. NOTE: The transmission oil should be at or above the minimum level mark. 4. If the oil is below the minimum level mark, remove the oil filler cap, add sufficient [...]

6-10 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EC000077 c C 8 In order to prevent clutch slip- page (since the transmission oil also lubricates the clutch), do not mix any chemical addi- tives with the oil. 8 Make sure that no foreign material enters the transmis- sion. 6. Start the engine, and then let it idle for several minutes while checking the[...]

6-11 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EW000067 w Never 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[...]

6-12 PERIODIC MAINTENANCE AND MINOR REP AIR 6 NOTE: Check the washer for damage and replace it if necessary. 9. Connect the hose to the coolant reservoir. 10. Pour the recommended coolant into the radiator until it is full. EC000080 c C 8 If coolant is not available, use distilled water or soft tap water instead. Do not use hard water or salt water[...]

6-13 PERIODIC MAINTENANCE AND MINOR REP AIR 6 12. 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 a[...]

6-14 PERIODIC MAINTENANCE AND MINOR REP AIR 6 4. Lift the front of the fuel tank to position the fuel tank away from the air filter case. (Do not discon- nect the fuel hoses!) EW000071 w 8 Make sure that the fuel tank is well supported. 8 Do not tilt or pull the fuel tank too much, otherwise the fuel hoses may come loose, which could cause fuel lea[...]

6-15 PERIODIC MAINTENANCE AND MINOR REP AIR 6 8. Insert the sponge material into the air filter case. EC000082 c C 8 Make sure that the air filter ele- ment is properly seated in the air filter case. 8 The engine should never be operated without the air filter element installed, otherwise the piston and/or cylinder may become excessively worn. 9. I[...]

6-16 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU00632 Adjusting the engine idling speed The engine idling speed must be checked and, if necessary, adjusted as follows at the intervals specified in the periodic maintenance and lubrica- tion chart. 1. Start the engine and warm it up for several minutes at 1,000 – 2,000 r/min while occa- sionally r[...]

6-17 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU00634 Adjusting the throttle cable free play The throttle cable free play should measure 3 – 5 mm at the throttle grip. Periodically check the throttle cable free play and, if necessary, adjust it as follows. NOTE: The engine idling speed must be cor- rectly adjusted before checking and adjusting t[...]

6-18 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EWA00012 w Because loading has an enormous impact on the handling, braking, performance and safety character- istics of your motorcycle, you should keep the following precau- tions in mind. 8 NEVER OVERLOAD THE MOTORCYCLE! Operation of an overloaded motorcycle may result in tire damage, loss of control,[...]

6-19 PERIODIC MAINTENANCE AND MINOR REP AIR 6 Tire information This motorcycle is equipped with cast wheel and tubeless tires. EW000078 w 8 The front and rear tires should be of the same make and design, otherwise the handling characteristics of the motorcy- cle cannot be guaranteed. 8 After extensive tests, only the tires listed below have been ap[...]

6-20 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU00694 Adjusting the clutch lever free play The clutch lever free play should measure 10 – 15 mm as shown. Periodically check the clutch lever free play and, if necessary, adjust it as follows. 1. Loosen the locknut at the clutch lever. 2. To increase the clutch lever free play, turn the adjusting b[...]

6-21 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU00696 Adjusting the brake lever free play The brake lever free play should measure 2 – 5 mm as shown. Periodically check the brake lever free play and, if necessary, adjust it as follows. 1. Loosen the locknut at the brake lever. 2. To increase the brake lever free play, turn the adjusting bolt in [...]

6-22 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU00712 Adjusting the brake pedal position The top of the brake pedal should be positioned approximately 23 mm below the top of the footrest as shown. Periodically check the brake pedal position and, if necessary, have a Yamaha dealer adjust it. EW000109 w A soft or spongy feeling in the brake pedal ca[...]

6-23 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU00721 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. EAU00725 Front brake pads Each front brake pad is provided with a wear indicator groove, which allows you to check the brak[...]

6-24 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU03776 Checking the brake fluid level Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become ineffective. Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn brake pads [...]

6-25 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU03976 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the NOTE after the periodic mainte- nance and lubrication chart. In addi- tion, have the oil seals of the master cylinders and calipers as well as the brake hoses replaced at the intervals listed [...]

6-26 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU03752 To adjust the drive chain slack 1. Loosen the axle nut, then loosen the locknut at each end of the swingarm. 2. To tighten the drive chain, turn the adjusting nut at each end of the swingarm in direction a . To loosen the drive chain, turn the adjusting nut at each end of the swingarm in direct[...]

6-27 PERIODIC MAINTENANCE AND MINOR REP AIR 6 2. Wipe the drive chain dry. 3. Thoroughly lubricate the drive chain with a special O-ring chain lubricant. ECA00052 c C Do not use engine oil or any other lubricants for the drive chain, as they may contain substances that could damage the O-rings. EAU02962 Checking and lubricating the cables The opera[...]

6-28 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU04034 Checking and lubricating the throttle grip and cable Throttle grip and cable, checking and lubricating The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubri- cated or replaced at the intervals specified in the periodic maintenance chart. E[...]

6-29 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU03370 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary. EAU03164 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers [...]

6-30 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU03166 Lubricating the rear suspension Rear suspension, lubricating The pivoting points of the rear sus- pension must be lubricated at the intervals specified in the periodic maintenance and lubrication chart. EAU02939 Checking the front fork The condition and operation of the front fork must be check[...]

6-31 PERIODIC MAINTENANCE AND MINOR REP AIR 6 To 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 c C If any damage is found or the front fork doe[...]

6-32 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU01144 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. EAU00800 Battery T[...]

6-33 PERIODIC MAINTENANCE AND MINOR REP AIR 6 To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to dis- charge more quickly if the motorcycle is equipped with optional electrical accessories. To store the battery 1. If the motorcycle will not be used[...]

6-34 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EC000103 c C Do not use a fuse of a higher amperage rating than recommend- ed to avoid causing extensive damage to the electrical system and possibly a fire. 3. Turn the key to “ ON ” and turn on the electrical circuits to check if the devices operate. 4. If the fuse immediately blows again, have a [...]

6-35 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EC000105 c C Do 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 al[...]

6-36 PERIODIC MAINTENANCE AND MINOR REP AIR 6 3. Remove the socket (together with the bulb) by turning it coun- terclockwise. 4. Remove the defective bulb by pushing it in and turning it coun- terclockwise. 5. Insert a new bulb into the socket, push it in, and then turn it clock- wise until it stops. 6. Install the socket (together with the bulb) b[...]

6-37 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU01579 Supporting the motorcycle Since this model is not equipped with a centerstand, follow these precau- tions when removing the front and rear wheel or performing other main- tenance requiring the motorcycle to stand upright. Check that the motor- cycle is in a stable and level position before star[...]

6-38 PERIODIC MAINTENANCE AND MINOR REP AIR 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 c C Do not apply the brake after the wheel has been removed together with the brake disc, otherw[...]

6-39 PERIODIC MAINTENANCE AND MINOR REP AIR 6 8. Connect the speedometer cable. EAU03755 Rear wheel To remove the rear wheel EW000122 w 8 It is advisable to have a Yamaha dealer service the wheel. 8 Securely support the motorcy- cle so that there is no danger of it falling over. 1. Loosen the axle nut. 2. Lift the rear wheel off the ground accordin[...]

6-40 PERIODIC MAINTENANCE AND MINOR REP AIR 6 6. While supporting the brake caliper, pull the wheel axle out. 7. Remove the wheel. ECA00048 c C Do 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 s[...]

6-41 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU03087 T roubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting chart[...]

6-42 PERIODIC MAINTENANCE AND MINOR REP AIR 6 EAU01581 T roubleshooting charts Starting problems or poor engine performance EW000125 w Keep away open flames and do not smoke while checking or working on the fuel system. Check the fuel level in the fuel tank. 1. Fuel There is enough fuel. There is no fuel. Check the compression. Supply fuel. The eng[...]

6-43 PERIODIC MAINTENANCE AND MINOR REP AIR 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 w 8 Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out und[...]

7-1 EAU03521 MOT ORCYCLE CARE AND STORAGE 7 Care While the open design of a motorcy- cle reveals the attractiveness of the technology, it also makes it more vul- nerable. Rust and corrosion can develop even if high-quality compo- nents are used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts from the overall appear- ance of a [...]

7-2 MOT ORCYCLE CARE AND STORAGE 7 8 Do 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. 8 Do not use high-pressure washer[...]

7-3 MOT ORCYCLE 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-[...]

7-4 MOT ORCYCLE CARE AND STORAGE 7 Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, pro- tect it against dust with a porous cover. ECA00014 c C 8 Storing the motorcycle in a poorly ventilated room or cov- ering it with a tarp, while it is still wet, will allow water and humidity to seep in and cause rust. 8 To[...]

7-5 MOT ORCYCLE CARE AND STORAGE 7 6. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/centerstand. 7. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the ground. Alternatively, turn the wheels a little every month in ord[...]

8-1 EAU01038 SPECIFICA TIONS 8 Model TDR125 Dimensions Overall length 2,120 mm (F, GB, IRL, B, P, GR, E) 2,185 mm (S, SF, D, CH, A) Overall width 840 mm Overall height 1,295 mm Seat height 850 mm Wheel base 1,405 mm Ground clearance 270 mm Minimum turning radius 2,200 mm Basic weight (with oil and full fuel tank) 135 kg 136 kg (CH, A) Engine Engine[...]

8-2 SPECIFICA TIONS 8 Spark plug Manufacturer/model NGK/BR9ES Spark plug gap 0.7 – 0.8 mm Clutch type Wet, multiple-disc Transmission Primary reduction system Helical gear Primary reduction ratio 71/22 (3.227) Secondary reduction system Chain drive Secondary reduction ratio 3.563 Number of drive chain sprocket teeth (rear/front) 57/16 Transmissio[...]

8-3 SPECIFICA TIONS 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 4 Suspension Front Type Telescopic fork Rear Type Swingarm (Monocross) Spring/shock ab[...]

8-4 SPECIFICA TIONS 8 Headlight type Quartz 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 Neu[...]

8-5 SPECIFICA TIONS 8 EAU03941 Conversion table All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. METRIC MULTIPLIER IMPERIAL ** mm × 0.03937 = ** in 2 mm × 0.03937 = 0.08 in CONVERSION TABLE METRIC TO IMPERIAL Metric unit Multiplier Imperial unit m • kg[...]

9-1 EAU01039 CONSUMER INFORMA TION 9 EAU02944 Identification numbers Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION NUMBER: 2. VEHICLE IDENT[...]

9-2 CONSUMER INFORMA TION 9 EAU01050 Model label The model label is affixed to the frame under the seat. (See page 3-12 for seat removal and installation procedures.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer. 1 1. Model label 5AE-28199-E5 honbun 7/6/01[...]

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5AE-28199-E5 honbun 7/6/01 10:18 AM Page 92[...]

PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2001 · 7 – 0.1 × 1(E) ! Y AMAHA MOT OR CO. , L TD.[...]