TDR125(5AE-E3)Hyoshi 4/11/0 11:09 AM Page 1 (2,1) (Magenta plate) OWNER’S MANUAL TDR125 5AE-28199-E3
siro page 4/6/0 3:58 AM Page 1
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 1 INTRODUCTION EAU00001 Welcome to the Yamaha world of motorcycling! 1 As the owner of a TDR125, you are benefiting from Yamaha’s vast experience in and newest technology for the design and the manufacture of high-quality products, which have earned Yamaha a reputation for dependability. 2 Please take the time to read this manual thoroughly, so as to enjoy all your TDR125’s advantages.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 2 EAU00005 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations: 1 2 The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Q w 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.
AE-9-E3 (ENG) 4/11/0 11:06 AM Page 3 IMPORTANT MANUAL INFORMATION w EW000002 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 4 1 2 3 4 5 6 7 8 9 EAU00008 TDR125 OWNER’S MANUAL ©1999 by Yamaha Motor Co., Ltd. 1st Edition, August 1999 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 5 TABLE OF CONTENTS EAU00009 1 GIVE SAFETY THE RIGHT OF WAY 1 2 DESCRIPTION 2 3 INSTRUMENT AND CONTROL FUNCTIONS 3 4 PRE-OPERATION CHECKS 4 5 OPERATION AND IMPORTANT RIDING POINTS 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 7 MOTORCYCLE CARE AND STORAGE 7 8 SPECIFICATIONS 8 9 CONSUMER INFORMATION 9 INDEX
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 6
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 7 GIVE SAFETY THE RIGHT OF GIVE SAFETY THE RIGHT OF WAY ................................................
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 8 Q GIVE SAFETY THE RIGHT OF WAY 1 2 3 4 EAU00021 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 your motorcycle’s value and operating condition.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 9 DESCRIPTION Left view .............................................................................................2-1 Right view ...........................................................................................2-2 Controls/Instruments ..........................................................................
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 10 EAU00026 DESCRIPTION Left view 1 2 3 4 1 2 3 4 5 6 7 7 8 9 1. 2. 3. 4. 5. Dual headlight Fuel cock Engine oil tank Helmet holder Starter “1” 6 5 (page 3-6) (page 3-12) (page 3-12) (page 3-12) (page 3-13) 2-1 6. Y.E.I.S. 7. Y.P.V.S.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 11 DESCRIPTION Right view 8 9 10 11 1 2 3 4 5 6 7 8 14 13 12 8. 9. 10. 11. 12. 13. Tool kit Fuse Air filter Radiator cap Rear brake pedal Coolant reservoir tank (page 6-1) 14.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 12 DESCRIPTION Controls/Instruments 15 16 1 17 18 19 20 21 2 3 4 5 6 7 24 8 9 15. 16. 17. 18. 19. Clutch lever Left handlebar switches Speedometer Engine temperature gauge Tachometer 23 (page 3-8, 6-20) (page 3-5) (page 3-4) (page 3-5) (page 3-5) 22 20. 21. 22. 23. 24.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 13 INSTRUMENT AND CONTROL FUNCTIONS Main switch/steering lock........................................3-1 Indicator lights ........................................................3-2 Oil level indicator circuit check ...............................3-3 Speedometer ..........................................................3-4 Tachometer ............................................................3-4 Engine temperature gauge .....................................
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 14 EAU00027 INSTRUMENT AND CONTROL FUNCTIONS ON FF 1 O N PUSH P I G NI TI 1. Push 6 7 8 2. Turn EAU00029 The main switch controls the ignition and lighting systems. Its operation is described below. EAU00036 ON Electrical circuits are switched on. The engine can be started. The key cannot be removed in this position. 9 EAU00038 OFF All electrical circuits are switched off. The key can be removed in this position.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 15 INSTRUMENT AND CONTROL FUNCTIONS EAU00063 C 80 100 0 0 0 0 0 1120 1 H 2 4 3 2 1 0 140 180 0001 9 10 11 12 ~1000r/min km/h 4 1. 2. 3. 4. 5 6 7 8 3 Turn indicator light “5” High beam indicator light “&” Neutral indicator light “N” Oil level indicator light “7” &” High beam indicator light “& This indicator comes on when the headlight high beam is used. EAU01313 Oil level indicator light “7” This indicator comes on when the oil level is low.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 16 INSTRUMENT AND CONTROL FUNCTIONS EAU00071 Oil level indicator circuit check 1 Turn the main switch to “ON” and the engine stop switch to “#”. 2 3 4 5 Oil level indicator light does not come on. Oil level indicator light comes on. Put the transmission in neutral or apply the clutch lever, then push the start switch. Check engine oil level. 6 7 Oil level indicator light comes on. Oil level indicator light does not come on. Oil level is OK. Oil level is low.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 17 INSTRUMENT AND CONTROL FUNCTIONS 2 C 1 40 H 80 100 60 0 0 0 0 0 1120 140 20 0 180 0001 km/h 4 1. 2. 3. 4. NOTE: (for German model equipped with speed limiter only) This motorcycle is equipped with a speed limiter which prevents it from exceeding a top speed of 80 km/h. C 1 H 5 6 7 8 4 3 2 1 0 9 10 11 12 ~1000r/min 1 2 3 2 3 Speedometer Odometer Trip odometer Reset knob 1. Tachometer 2.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 18 INSTRUMENT AND CONTROL FUNCTIONS EAU00127 1 2 1 1 C 2 3 H 100 0 1120 140 4 4 6 7 8 9 3 4 3 1. Engine temperature gauge 2. Red zone Engine temperature gauge This gauge indicates the coolant temperature when the main switch is on. The engine operating temperature will vary with changes in weather and engine load. If the needle points to the red zone or higher, stop your motorcycle and let the engine cool. (See page 6-10 for details.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 19 INSTRUMENT AND CONTROL FUNCTIONS EAU00136 Headlight beam variation 3 : High beam light on , : Auxiliary light on 2 : Low beam light on ' Left 1 2 Bulb to be used Right & 3 ' % ' 2 & 3 3 % 2 2 Halogen bulb Halogen bulb 12V 60/55W 12V 35/35W Destination 12V 60/55W France Sweden Portugal Spain Greece Belgium Germany Switzerland Finland Austria 12V 35/35W England Ireland NOTE: Right and left directions are those assumed from the position of a p
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 20 INSTRUMENT AND CONTROL FUNCTIONS EAU00143 1 ,” Start switch “, The starter motor cranks the engine when pushing the start switch. 2 cC 1 3 4 EC000005 See starting instructions prior to starting the engine. 2 1. Engine stop switch 2. Start switch “,” EAU00138 5 6 7 8 Engine stop switch The engine stop switch is a safety device for use in an emergency such as when the motorcycle overturns or if trouble occurs in the throttle system.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 21 INSTRUMENT AND CONTROL FUNCTIONS 1 1 6 5 4 3 2 N 1 1 1 2 3 1. Clutch lever EAU00152 Clutch lever The clutch lever is located on the left handlebar, and the ignition circuit cutoff system is incorporated in the clutch lever holder. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth clutch operation.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 22 INSTRUMENT AND CONTROL FUNCTIONS NOTE: This tank cap cannot be closed unless the key is in the lock. The key cannot be removed if the cap is not locked properly. 2 1 1 2 4 w 1 3 1. Rear brake pedal EAU00162 Rear brake pedal 5 6 7 8 9 The rear brake pedal is on the right side of the motorcycle. Press down on the brake pedal to apply the rear brake. 1. Open 2. Unlock EAU02935 Fuel tank cap To open Open the lock cover.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 23 INSTRUMENT AND CONTROL FUNCTIONS w 2 2 4 1. Filler tube 2. Filling nozzle 3. Fuel level EAU01183 1. 2. 3. 4. 3 1 Filler tube Filling nozzle Leaf valve Fuel level cC EAU01184* Fuel (except for Switzerland and Austria) Make sure there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown in the illustration. w Do not overfill the fuel tank. Avoid spilling fuel on the hot engine.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 24 INSTRUMENT AND CONTROL FUNCTIONS EAU00191 1 2 3 4 5 6 Recommended fuel: Regular unleaded gasoline with a research octane number of 91 or higher. Fuel tank capacity: Total: 11.0 L Reserve: 2.2 L NOTE: If knocking or pinging occurs, use a different brand of gasoline or higher octane grade. EAU01084 EC000114 Catalyzer cC (for Switzerland and Austria) This motorcycle is equipped with a catalytic converter in the exhaust chamber.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 25 INSTRUMENT AND CONTROL FUNCTIONS OFF: closed position 1 ON: normal position 1 OFF 2 1 1. Filler cap ON 1. Arrow mark pointing to “OFF” EAU02956 1. Arrow mark pointing to “ON” EAU03050 Two-stroke engine oil Fuel cock Make sure the two-stroke engine oil is at the specified level. Fill with oil as necessary. The fuel cock supplies fuel from the tank to the carburetor while filtering it also.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 26 INSTRUMENT AND CONTROL FUNCTIONS RES: reserve position RES a 1 2 1 1 1 b 3 4 5 6 7 8 1. Arrow mark pointing to “RES” RES This indicates reserve. If you run out of fuel while riding, move the lever to this position. Fill the tank at the first opportunity. Be sure to set the lever back to “ON” after refueling! 1. Starter(choke) “1” 1. Unlock EAU02976 EAU01619 Starter (choke) “1” Seat Starting a cold engine requires a richer air-fuel mixture.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 27 INSTRUMENT AND CONTROL FUNCTIONS 1 1 1 1 b a 2 2 3 1. Projection 2. Seat holder To install Insert the projection on the front of the seat into the seat holder. Push down on the seat and remove the key. NOTE: Make sure that the seat is securely fitted. 1. Open 1. Adjusting ring EAU00260 Helmet holder To open the helmet holder, insert the key in the lock and turn it as shown. To lock the helmet holder, replace the holder in its original position.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 28 INSTRUMENT AND CONTROL FUNCTIONS 1 2 1 3 4 1. Position indicator Hard 5 6 7 8 9 Adjusting Position 9 8 7 6 EAU00315 w 1 2 3 4 5 6 7 8 9 5 Standard Soft 4 3 2 1 This shock absorber contains highly pressurized nitrogen gas. Read and understand the following information before handling the shock absorber. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 29 INSTRUMENT AND CONTROL FUNCTIONS EAU00326 Y.P.V.S. (Yamaha Power Valve System) The Y.P.V.S. is a vital part of the engine and requires very sophisticated adjustment. Adjustment should be left to a Yamaha dealer who has the professional knowledge and experience to do so. cC EC000024 cC EAU00330 Sidestand If the Y.P.V.S. does not operate, ask a Yamaha dealer to inspect the vehicle. This model is equipped with an ignition circuit cut-off system.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 30 INSTRUMENT AND CONTROL FUNCTIONS w 1 2 3 4 5 6 7 8 EW000044 This motorcycle must not be operated with the sidestand in the down position. If the stand is not properly retracted, it could contact the ground and distract the operator, resulting in a possible loss of control. Yamaha has designed into this motorcycle a lockout system to assist the operator in fulfilling the responsibility of retracting the sidestand.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 31 PRE-OPERATION CHECKS Pre-operation check list ......................................................................
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 32 EAU01114 PRE-OPERATION CHECKS 1 Owners are personally responsible for their vehicle’s condition. Your motorcycle/scooter’s vital functions can start to deteriorate quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid leak or loss of tire pressure could have serious consequences.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 33 PRE-OPERATION CHECKS ITEM 9 Brake and shift pedal shafts 9 9 Brake and clutch lever pivots 9 9 Sidestand pivot 9 9 Chassis fasteners 9 9 Fuel tank 9 Lights, signals and 9 switches CHECKS Check for smooth operation. Lubricate if necessary. Check for smooth operation. Lubricate if necessary. Check for smooth operation. Lubricate if necessary. Make sure that all nuts, bolts, and screws are properly tightened. Tighten if necessary. Check fuel level.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 34 1 2 3 4 5 6 7 8 9
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 35 OPERATION AND IMPORTANT RIDING POINTS Starting the engine .............................................................................5-1 Starting a warm engine.......................................................................5-4 Shifting................................................................................................5-4 Recommended shift points (for Switzerland only) ..............................5-5 Tips for reducing fuel consumption...........
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 36 OPERATION AND IMPORTANT RIDING POINTS w 1 2 3 4 5 6 7 8 9 EAU00373 8 Before riding this motorcycle, become thoroughly familiar with all operating controls and their functions. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. 8 Never start your engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and can cause loss of consciousness and death within a short time.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 37 OPERATION AND IMPORTANT RIDING POINTS TURN THE MAIN SWITCH TO “ON” AND THE ENGINE STOP SWITCH TO “#”. 1 IF TRANSMISSION IS IN NEUTRAL AND SIDESTAND IS DOWN, IF TRANSMISSION IS IN GEAR AND SIDESTAND IS UP, PUSH THE START SWITCH. ENGINE WILL START. PULL IN THE CLUTCH LEVER AND PUSH THE START SWITCH. ENGINE WILL START. RETRACT SIDESTAND AND PUT TRANSMISSION IN GEAR. 2 3 4 5 MOTORCYCLE CAN BE RIDDEN. MOTORCYCLE CAN BE RIDDEN.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 38 OPERATION AND IMPORTANT RIDING POINTS 1 2 3 4 5 6 7 8 9 1. Turn the fuel cock to “ON”. 2. Turn the main switch to “ON” and the engine stop switch to “#“. 3. Shift transmission into neutral. NOTE: When the transmission is in neutral, the neutral indicator light should be on. If the light does not come on, ask a Yamaha dealer to inspect it. 4. Turn on the starter (choke) and completely close the throttle grip. 5. Start the engine by pushing the start switch.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 39 OPERATION AND IMPORTANT RIDING POINTS EAU01258 cC Starting a warm engine The starter (choke) is not required when the engine is warm. cC 6 5 4 3 2 N 1 EC000046 See the “Engine break-in” section prior to operating the motorcycle for the first time. 1 1. Shift pedal N. Neutral EAU00423 Shifting The transmission lets you control the amount of power you have available at a given speed for starting, accelerating, climbing hills, etc.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 40 OPERATION AND IMPORTANT RIDING POINTS EAU02937 1 Tips for reducing fuel consumption The recommended shift points are shown in the table below. Your motorcycle’s fuel consumption depends to a large extent on your riding style. The following tips can help reduce fuel consumption: 8 Warm up the engine before riding. 8 Turn off the starter (choke) as soon as possible. 8 Shift up swiftly and avoid high engine speeds during acceleration.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 41 OPERATION AND IMPORTANT RIDING POINTS EAU00453 0 ~ 500 km Avoid operation above 6,000 r/min. Stop the engine and let it cool for 5 to 10 minutes after every hour of operation. Vary the speed of the motorcycle from time to time. Do not operate it at one set throttle position. 500 ~ 1,000 km Avoid prolonged operation above 7,000 r/min. Rev the motorcycle freely through the gears, but do not use full throttle at any time.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 42 1 2 3 4 5 6 7 8 9
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 43 PERIODIC MAINTENANCE AND MINOR REPAIR Tool kit ...................................................................6-1 Periodic maintenance and lubrication ....................6-3 Cowling and panel removal and installation...........6-6 Cowling A, B ..........................................................6-7 Panel A ..................................................................6-7 Spark plug inspection.............................................
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 44 EAU00462 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00464 1 2 3 4 5 6 7 8 9 Periodic inspection, adjustment and lubrication will keep your motorcycle in the safest and most efficient condition possible. Safety is an obligation of the motorcycle owner. The maintenance and lubrication schedule chart should be considered strictly as a guide to general maintenance and lubrication intervals.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 45 PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: If you do not have necessary tools required during a service operation, take your motorcycle to a Yamaha dealer for service. w 1 2 EW000063 3 Modifications to this motorcycle not approved by Yamaha may cause loss of performance, and render it unsafe for use. Consult a Yamaha dealer before attempting any changes.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 46 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00473 PERIODIC MAINTENANCE AND LUBRICATION EVERY 1 No. ITEM CHECKS AND MAINTENANCE JOBS 2 Initial (1,000 km) 6,000 km or 6 months (Whichever comes first) 12,000 km or 12 months (Whichever comes first) √ √ √ √ √ √ 1 * Fuel line 9 Check fuel hoses for cracks or damage. 9 Replace if necessary. 2 Spark plug 9 Check condition. 9 Clean, regap or replace if necessary. 3 Air filter 9 Clean or replace if necessary.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 47 PERIODIC MAINTENANCE AND MINOR REPAIR EVERY No. ITEM CHECKS AND MAINTENANCE JOBS 10 * Swingarm 9 Check swingarm pivoting point for play. 9 Correct if necessary. 9 Lubricate with lithium soap base grease every 24,000 km or 24 months (whichever comes first). 11 9 Check chain slack. 9 Adjust if necessary. Make sure that the rear wheel is properly aligned. 9 Clean and lubricate.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 48 PERIODIC MAINTENANCE AND MINOR REPAIR EVERY No. ITEM CHECKS AND MAINTENANCE JOBS Initial (1,000 km) 6,000 km or 6 months (Whichever comes first) 12,000 km or 12 months (Whichever comes first) 20 * Autolube pump 9 Check operation. 9 Correct if necessary. 9 Bleed if necessary. √ √ √ 21 9 Check oil level and vehicle for oil leakage. 9 Correct accordingly. 9 Change oil at initial 1,000 km and thereafter every 24,000 km or 24 months (whichever comes first).
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 49 PERIODIC MAINTENANCE AND MINOR REPAIR 1 1 1 1 2 3 1. Cowling A 1. Cowling B 1. Panel A EAU01139 Cowling and panel removal and installation 4 5 The cowlings and panels illustrated need to be removed to perform some of the maintenance described in this chapter. Refer to this section each time a cowling or panel has to be removed or reinstalled.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 50 PERIODIC MAINTENANCE AND MINOR REPAIR 2 1 1 1 1 2 2 3 4 1. Radiator cover 2. Screw (×2) 1. Screw (×10) EAU01088 5 6 7 8 Cowling A, B To remove 1. Remove the seat. 2. Remove the radiator cover screws and the radiator cover. 3. Remove the screws and pull outward on the areas shown. To install 1. Place the cowling in the original position and install the screws. 2. Place the radiator cover in the original position and install the screws. 3. Install the seat.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 51 PERIODIC MAINTENANCE AND MINOR REPAIR When installing the plug, the gasket surface should always be cleaned and a new gasket used. Any grime should be wiped off from the threads and the spark plug tightened to the specified torque. 1 1 1. Spark plug wrench Tightening torque: Spark plug: 20 Nm (2.0 m0kg) 1.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 52 PERIODIC MAINTENANCE AND MINOR REPAIR 2. With the engine stopped, check the oil level through the level window located at the right side crankcase cover. 1 2 2 NOTE: Wait a few minutes until the oil level settles before checking. 1 3 4 1. Level window 2. Minimum level EAU01080 5 6 7 8 9 Transmission oil Oil level measurement 1. Place the motorcycle on a level place and hold it an upright position. Warm up the engine for several minutes. 3.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 53 PERIODIC MAINTENANCE AND MINOR REPAIR 1 Recommended oil: See page 8-1 Oil quantity: Total amount: 0.8 L Periodic oil change: 0.75 L 3. Remove the drain bolt and drain the oil. 4. Reinstall the drain bolt and tighten it to the specified torque. Tightening torque: Drain bolt: 15 Nm (1.5 m0kg) 5. Fill the engine with oil. Install the oil filler cap and tighten it. 2 2 EC000078 cC 1. Drain bolt 1 1 3 8 Do not put in any chemical additives.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 54 PERIODIC MAINTENANCE AND MINOR REPAIR w 1 2 3 4 EW000067 Do not remove the radiator cap when the engine is hot. cC EAU01622* Changing the coolant EC000080 Hard water or salt water is harmful to the engine. You may use distilled water if you can’t get soft water. 1. Put the motorcycle on a level place. 2. Remove the seat (See page 3-13 for seat removal procedures.) 3. Remove cowling B and radiator cover. (See page 6-7 for removal and installation procedures.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 55 PERIODIC MAINTENANCE AND MINOR REPAIR 1 1 1. Drain bolt 5. Place a container under the engine and remove the coolant drain bolt. 1. Reservoir tank hose 6. Disconnect the reservoir tank hose on the reservoir tank side and drain the coolant from the reservoir tank. 7. After draining the coolant, thoroughly flush the cooling system with clean tap water. 8.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 56 PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 11. Install the radiator cap. 12. Run the engine several minutes. Stop the engine and recheck the coolant level in the radiator. If it is low, add more coolant until it reaches the top of the radiator. 1 2 3 1 4 5 3 4 5 6 7 8 9 1. 2. 3. 4. 5. Reservoir tank cap Stopper Stopper bolt Maximum level mark Minimum level mark 13. Fill the reservoir tank with coolant up to specified level. 14.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 57 PERIODIC MAINTENANCE AND MINOR REPAIR w EW000071 8 Support the fuel tank carefully during this procedure. 8 Do not tilt the fuel tank too much or pull it too hard because the fuel hose connections may become loose causing fuel leakage. 2 1 2 1 1 2 3 1. Relay (×2) 2. Screw (×7) 1. Air filter 5. Remove the relays and the screws holding the air filter case cover. 6. Remove the air filter element from its case and clean it with solvent.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 58 PERIODIC MAINTENANCE AND MINOR REPAIR cC 1 2 3 4 5 6 7 EC000082 8 Make sure the air filter is properly seated in the air filter case. 8 The engine should never be run without the air filter installed. Excessive piston and/or cylinder wear may result. w EW000131 Make sure that the fuel hoses and vacuum hose are properly connected, in place and not pinched. If a hose is damaged, be sure to replace it.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 59 PERIODIC MAINTENANCE AND MINOR REPAIR Standard idle speed: 1,300 ~ 1,500 r/min 1,400 ~ 1,500 r/min (A, CH only) b a 1 2 a NOTE: If the specified idle speed cannot be obtained by performing the above adjustment, consult a Yamaha dealer. 1 2 3 a. Free play EAU00634 Throttle cable free play adjustment NOTE: Before checking the throttle cable free play, the engine idling speed should be adjusted.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 60 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00647 Tires 1 2 3 4 5 6 7 8 9 To ensure maximum performance, long service, and safe operation, note the following: Tire air pressure Always check and adjust the tire pressure before operating the motorcycle. w 180 kg Maximum load* EW000082 179 kg (CH, A) Cold tire pressure Front Rear Up to 90 kg load* 175 kPa 200 kPa (1.75 kg/cm2, (2.00 kg/cm2, 1.75 bar) 2.00 bar) 90 kg load ~ Maximum load* 175 kPa 225 kPa (1.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 61 PERIODIC MAINTENANCE AND MINOR REPAIR FRONT 1 2 1. Tread depth 2. Side wall Tire inspection Always check the tires before operating the motorcycle. If center tread depth reaches the limit as shown, if the tire has a nail or glass fragments in it, or if the side wall is cracked, contact a Yamaha dealer immediately and have the tire replaced.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 62 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00687 Wheels 1 2 3 4 5 6 7 8 9 To ensure maximum performance, long service, and safe operation, note the following: 8 Always inspect the wheels before a ride. Check for cracks, bends, or warpage of the wheels. If any abnormal condition exists in a wheel, consult a Yamaha dealer. Do not attempt even small repairs to the wheel. If a wheel is deformed or cracked, it must be replaced.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 63 PERIODIC MAINTENANCE AND MINOR REPAIR 1 3 b a 2 1. Locknut 2. Adjusting bolt 3. Free play EAU00696 Front brake lever free play adjustment The free play at the front brake lever should be 2 ~ 5 mm. 1. Loosen the locknut. 2. Turn the adjusting bolt in direction a to increase free play or in directionb to decrease free play. 3. After adjusting, tighten the locknut. EW000099 w 8 Check the brake lever free play. Be sure the brake is working properly.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 64 PERIODIC MAINTENANCE AND MINOR REPAIR w 1 2 3 4 5 6 7 8 9 EW000109 A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. This air must be removed by bleeding the brake system before the motorcycle is operated. Air in the system will cause greatly diminished braking capability and can result in loss of control and an accident. Have a Yamaha dealer inspect and bleed the system if necessary. FRONT 1 2 a b 1 1.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 65 PERIODIC MAINTENANCE AND MINOR REPAIR REAR FRONT REAR 1 1 1 1 2 3 1. Wear limit: 0.8 mm 1. Minimum level mark EAU00730 Rear brake Inspect the pads through the window as shown. If the thickness is less than the specified value, have a Yamaha dealer replace the pads. 1. Minimum level mark EAU00733 Inspecting the brake fluid level Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 66 PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 3 4 5 6 7 8 Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor brake performance. 8 Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. 8 Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 67 PERIODIC MAINTENANCE AND MINOR REPAIR To check the chain slack the motorcycle must be held straight up with both wheels on the ground and without rider. Check the slack at the position shown in the illustration. Normal slack is approximately 25 ~ 40 mm. If the slack exceeds 40 mm, adjust. 1 2 3 a b Turn each adjusting nut exactly the same amount to maintain correct axle alignment. There are marks on each side of the swingarm.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 68 PERIODIC MAINTENANCE AND MINOR REPAIR EAU03006 Drive chain lubrication 1 2 3 4 5 6 7 8 9 The chain consists of many parts which work with each other. If the chain is not maintained properly, it will wear out quickly. Therefore, the chain must be serviced regularly. This service is especially necessary when riding in dusty areas. This motorcycle is equipped with a sealed type chain.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 69 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00774 Autolube pump adjustment The autolube pump is a vital part of the engine and requires very sophisticated adjustment. Adjusting should be left to a Yamaha dealer who has the professional knowledge and experience to do so. EAU02984 EAU02985 Brake and shift pedal lubrication Brake and clutch lever lubrication Lubricate the pivoting parts. Lubricate the pivoting parts.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 70 PERIODIC MAINTENANCE AND MINOR REPAIR EAU02986 1 2 3 EAU00791 Sidestand lubrication Rear suspension lubrication Lubricate the sidestand pivoting point and metal-to-metal contact surfaces. Check that the sidestand moves up and down smoothly. Lubricate the pivoting parts. Recommended lubricant: Lithium soap base grease Recommended lubricant: Engine oil EW000113 4 w 5 If the sidestand does not move smoothly, consult a Yamaha dealer.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 71 PERIODIC MAINTENANCE AND MINOR REPAIR Operation check 1. Place the motorcycle on a level place. 2. Hold the motorcycle in an upright position and apply the front brake. 3. Push down hard on the handlebars several times and check if the fork rebounds smoothly. cC w Securely support the motorcycle so there is no danger of it falling over. 1 2 3 EC000098 If any damage or unsmooth movement is found with the front fork, consult a Yamaha dealer.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 72 PERIODIC MAINTENANCE AND MINOR REPAIR EAU01144 1 2 3 4 5 6 7 8 EAU00800 Wheel bearings Battery If there is play in the front or rear wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer inspect the wheel bearings. This motorcycle is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or fill the battery with distilled water. 8 If the battery seems to have discharged, consult a Yamaha dealer.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 73 PERIODIC MAINTENANCE AND MINOR REPAIR Battery storage When the motorcycle is not used for a month or longer, remove the battery, fully charge it and store it in a cool, dry place. cC cC 1 EC000102 8 Completely recharge the battery before storing. Storing a discharged battery can cause permanent battery damage. 8 Use a battery charger designed for a sealed-type (MF) battery. Using a conventional battery charger will cause battery damage.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 74 PERIODIC MAINTENANCE AND MINOR REPAIR Type 1 2 2 1 1 1 3 4 6 7 8 9 Unhook Type 4 Unhock Turn 1. Headlight connector 2. Bulb holder cover EAU01079* 5 Turn Type 3 2 5. Put a new bulb into position and secure it in place with the bulb holder. Type 2 Headlight bulb replacement If the headlight bulb burns out, replace the bulb as follows: 1. Remove cowling A and B. (See page 6-7 for removal and installation procedures.) 2.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 75 PERIODIC MAINTENANCE AND MINOR REPAIR 2 1 1 2 1 1 2 3 1. Screw (×2) 2. Panel A 1. Socket EAU01078 Taillight bulb replacement 1. Remove the seat. 2. Remove panel A. (See page 6-7 for panel removal and installation procedures.) 3. To remove the socket, turn it counterclockwise. 4. To remove the defective bulb, turn it counterclockwise. 5. Push a new bulb into the socket and turn it clockwise. 6. Install the socket and turn it clockwise. 7.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 76 PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 1 2 1 3 4 5 6 7 8 9 1. Bulb 3. Install a new bulb by pushing it inward and turning it clockwise. 4. Install the lens and tighten the screw. 1 1. Speedometer cable EAU00894 Front wheel removal EW000122 w 8 It is advisable to have a Yamaha dealer service the wheel. 8 Securely support the motorcycle so there is no danger of it falling over. 1. Remove the speedometer cable from the front wheel side. 6-33 1.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 77 PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 3 1 2 3 EAU01394 Front wheel installation 1. Install the speedometer gear unit into the wheel hub. Make sure the wheel hub and the speedometer gear unit are installed with the projections meshed into the slots. 2. Lift up the wheel between the front fork legs and guide the brake disc between the brake pads. Make sure the slot in the speedometer gear unit fits over the stopper on the front fork outer tube. 3.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 78 PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: 8 Do not depress the brake pedal when the disc and caliper are separated. 8 You do not have to disassemble the chain in order to remove or install the rear wheel. 1 2 3 4 5 6 7 8 9 EAU01620 2. Elevate the rear wheel by placing a suitable stand under the engine. 3. Remove the axle nut. 4. Loosen the locknuts and chain adjusting nuts on each side. 5. Push the wheel forward and remove the drive chain. 6.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 79 PERIODIC MAINTENANCE AND MINOR REPAIR 4. Adjust the drive chain. (See page 6-24 for adjusting the drive chain slack.) 5. Tighten the axle nut to the specified torque. Tightening torque: Axle nut: 104 Nm (10.4 m0kg) EAU01008 Troubleshooting Although Yamaha motorcycles receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 80 PERIODIC MAINTENANCE AND MINOR REPAIR EAU01581 Troubleshooting chart 1 EW000125 w Never check the fuel system while smoking or in the vicinity of an open flame. 2 3 1. Fuel Go to compression check. No fuel. Supply fuel. Check if there is fuel in the fuel tank. 4 5 Enough fuel. 2. Compression Engine doesn’t start, go to compression check. There is compression. Go to ignition check. No compression. Ask a Yamaha dealer to inspect. Use electric starter.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 81 PERIODIC MAINTENANCE AND MINOR REPAIR 5. Engine overheating w 1 Do 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. Open the radiator cap as follows. Wait until the engine has cooled. Remove the radiator cap stopper by removing the screw. Place a thick rag like a towel over the radiator cap and slowly rotate the cap counterclockwise to the detent.
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5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 83 MOTORCYCLE CARE AND STORAGE Care....................................................................................................7-1 Storage ...............................................................................................
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 84 EAU01518 MOTORCYCLE CARE AND STORAGE Care 1 2 3 4 5 6 7 The exposure of its technology makes a motorcycle charming but also vulnerable. Although high-quality components are used, they are not all rust-resistant. While a rusty exhaust pipe may remain unnoticed on a car, it does look unattractive on a motorcycle. Frequent and proper care, however, will keep your motorcycle looking good, extend its life and maintain its performance.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 85 MOTORCYCLE CARE AND STORAGE 8 Improper cleaning can damage windshields, cowlings, panels and other plastic parts. Use only a soft, clean cloth or sponge with mild detergent and water to clean plastic. 8 Do not use any harsh chemical products on plastic parts.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 86 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 stainlesssteel parts, including the exhaust system. (Even the thermally induced discoloring of stainlesssteel exhaust systems can be removed through polishing.) 4.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 87 MOTORCYCLE CARE AND STORAGE Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover. cC ECA00014 8 Storing the motorcycle in a poorly ventilated room or covering it with a tarp while it is still wet will allow water and humidity to seep in and cause rust. 8 To prevent corrosion, avoid damp cellars, stables (because of the presence of ammonia) and areas where strong chemicals are stored.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 88 MOTORCYCLE CARE AND STORAGE 6. 1 7. 2 3 4 5 6 8. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/centerstand. Check and, if necessary, correct the tire air pressure, then raise the motorcycle so that both of its wheels are off the ground. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 89 SPECIFICATIONS Specifications .....................................................................................8-1 How to use the conversion table ........................................................
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 90 EAU01038 SPECIFICATIONS Specifications 1 Model TDR125 Engine oil (2-cycle) Dimensions 2 Overall length Type 2,120 mm (F, GB, IRL, B, P, GR, E) Capacity 2,185 mm (S, SF, D, CH, A) 3 Overall width Overall height 4 5 850 mm 1,405 mm Minimum turning radius 6 7 8 840 mm Wheel base Ground clearance Basic weight (with oil and full fuel tank) Total amount 1.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 91 SPECIFICATIONS Spark plug Tire 1 Type/Manufacturer BR9ES/NGK Type Spark plug gap 0.7 ~ 0.8 mm Front 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 57/16 (3.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 92 SPECIFICATIONS 1 Wheels Shock absorber Front 2 3 4 5 Cast wheel Size 18 × MT2.15 Type Cast wheel Size 17 × MT2.50 Type Coil spring/oil damper Type Coil-gas spring/oil damper Rear Wheel travel Brakes Front Front 180 mm Rear 180 mm Electrical Type Single disc brake Ignition system Operation Right hand operation Charging system Fluid DOT 3 or DOT 4 Type Single disc brake Rear 8 9 Type Rear 6 7 Front C.D.I. Type C.D.I.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 93 SPECIFICATIONS Stop/tail light 12 V, 21/5W × 2 Front flasher light 12 V, 21W × 2 Rear flasher light 12 V, 21W × 2 Auxiliary light 12 V, 4W × 2 Meter light 12 V, 3.4W × 3 Neutral indicator light 12 V, 3.4W × 1 High beam indicator light 12 V, 3.4W × 1 Oil level indicator light 12 V, 3.4W × 1 Turn indicator light 12 V, 3.4W × 1 1 2 12 V, 3.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 94 SPECIFICATIONS CONVERSION TABLE EAU01064 HOW TO USE THE CONVERSION TABLE 1 2 3 METRIC TO IMPERIAL 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. Metric unit Ex. 4 METRIC 5 ** mm 2 mm MULTIPLIER × × 0.03937 0.03937 IMPERIAL = = ** in 0.08 in 6 7 8 9 8-5 Multiplier Imperial unit Torque m • kg m • kg cm • kg cm • kg 7.233 86.794 0.0723 0.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 95 CONSUMER INFORMATION Identification number records .............................................................9-1 Key identification number ...................................................................9-1 Vehicle identification number..............................................................9-1 Model label .........................................................................................
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 96 EAU01039 CONSUMER INFORMATION EAU02944 Identification number records 1 2 3 4 5 Record the key identification number, vehicle identification number and model label information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. Key identification number 1. Vehicle identification number EAU01041 1. KEY IDENTIFICATION NUMBER: 6 7 1 1 2.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 97 CONSUMER INFORMATION 1 1 2 3 1. Model label 4 EAU01050 Model label The model label is affixed to the frame under the seat. (See page 3-13 for seat removal procedures.) Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 98 INDEX A Air filter ..................................................6-13 Autolube pump adjustment....................6-26 B Battery ...................................................6-29 Brake and clutch lever lubrication .........6-27 Brake and shift pedal lubrication ...........6-26 Brake fluid replacement.........................6-23 Brake light switch adjustment................6-21 C Cable inspection and lubrication ...........6-25 Carburetor adjustment.........
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 99 INDEX Recommended shift points (for Switzerland only) ............................5-5 Right view................................................2-2 S Seat .......................................................3-13 Shift pedal ...............................................3-8 Shifting ....................................................5-4 Sidestand ..............................................3-16 Sidestand lubrication .............................
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siro page 4/6/0 3:58 AM Page 1
TDR125(5AE-E3)Hyoshi 4/11/0 11:09 AM Page 1 (1,1) (Magenta plate) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 99·8–0.
