OWNER'S MANUAL TDR125 5AE-28199-E5 EAU03338 INTRODUCTION Welcome to the Yamaha world of motorcycling! As the owner of a TDR125, you are benefiting from Yamaha's vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your TDR125. The owner's manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself and others from trouble and injury. In addition, the many tips given in this manual will help keep your motorcycle in the best possible condition. If you have any further questions, do not hesitate to contact your Yamaha dealer. The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first! 1 EAU00005 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations: 1 Q w 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 inspecting or repairing the motorcycle. A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. A NOTE provides key information to make procedures easier or clearer. cC NOTE: NOTE: 8 This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. 8 Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer. IMPORTANT MANUAL INFORMATION w EW000002 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. 1 1 EAU03337 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. EAU00009 TABLE OF CONTENTS 1 2 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 .............................................................. 3-12 Helmet 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 3 4 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 5 6 TABLE OF CONTENTS 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 ....... 6-29 Lubricating 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 7 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 8 9 EAU00021 QGIVE SAFETY THE RIGHT OF WAY Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. 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 operating condition of your motorcycle. Moreover, what is true for the motorcycle is also true for the rider: good performance depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of course, out of the question. Motorcycle riders--more than car drivers--must always be at their mental and physical best. Under the influence of even small amounts of alcohol, there is a tendency to take dangerous risks. Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passengers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant synthetic materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet. Optimum protective wear, however, should not encourage carelessness. Although full-coverage helmets and suits, in particular, create an illusion of total safety and protection, motorcyclists will always be vulnerable. Riders who lack critical self-control run the risk of going too fast and are apt to take chances. This is even more dangerous in wet weather. The good motorcyclist rides safely, predictably and defensively--avoiding all dangers, including those caused by others. Enjoy your ride! 1 1-1 EAU00026 DESCRIPTION Left view 1 2 3 4 2 7 1. 2. 3. 4. 5. Headlight Fuel cock 2-stroke engine oil tank Helmet holder Starter (choke) lever 6 5 6. YEIS 7. YPVS (page 3-14) (page 3-15) (page 6-34) (page 3-11) (page 3-10) (page 3-13) (page 3-12) 2-1 DESCRIPTION Right view 89 10 11 2 14 13 12 8. 9. 10. 11. 12. 13. Owner's tool kit Fuse Air filter element Radiator cap Brake pedal Coolant reservoir tank (page 6-1) 14. Shock absorber spring preload (page 6-33) adjusting ring (page 6-13) (page 6-11) (page 3-7, 6-22) (page 6-10) 2-2 (page 3-13) DESCRIPTION Controls and instruments 1 2 3 4 5 6 7 2 10 9 8 1. 2. 3. 4. 5. Clutch lever Left handlebar switches Speedometer unit Coolant temperature gauge Tachometer (page 3-6, 6-20) (page 3-4) (page 3-3) (page 3-4) (page 3-3) 6. 7. 8. 9. 10. 2-3 Right handlebar switches Brake lever Throttle grip Fuel tank cap Main switch/steering lock (page 3-6) (page 3-7, 6-21) (page 6-17, 6-28) (page 3-7) (page 3-1) EAU00027 INSTRUMENT AND CONTROL FUNCTIONS OFF O PUSH ON ON FF YM -8 a b w EW000016 LOCK PARKING P IG N I TI EAU00029 a. Push. b. Turn. EAU00040 Never turn the key to "OFF" or "LOCK" while the motorcycle is moving, otherwise the electrical systems will be switched off, which may result in loss of control or an accident. Make sure that the motorcycle is stopped before turning the key to "OFF" or "LOCK". EAU01574 O Main switch/steering lock The main switch/steering lock controls 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 removed. EAU00038 OFF All electrical systems are off. The key can be removed. LO C N K 3 LOCK The steering is locked, and all electrical systems are off. The key can be removed. To lock the steering 1. Turn the handlebars all the way to the left. 2. Push the key in from the "OFF" position, and then turn it to "LOCK" while still pushing it. 3. Remove the key. To unlock the steering Push the key in, and then turn it to "OFF" while still pushing it. 3-1 . (Parking) The steering is locked, and the taillights and auxiliary lights are on, but all other electrical systems are off. The key can be removed. The steering must be locked before the key can be turned to ".". cC ECA00043 Do not use the parking position for an extended length of time, otherwise the battery may discharge. INSTRUMENT AND CONTROL FUNCTIONS EAU04304 EAU00061 1 2 3 1. 2. 3. 4. 4 3 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 ...