Yamaha TDR125 User manual

PRINTED ON RECYCLED PAPER PRINTED IN JAPAN
2000·9–0.1×1(E)
!
TDR125
YAMAHA MOTOR CO.,LTD. 5AE-28199-E4
OWNER’S MANUAL

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 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 to enjoy all advantages of your TDR125.
The owner’s manual does not only instruct you in how to operate, inspect and maintain your motor-
cycle, 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!
5AE-9-E4 (ENG) 8/30/00 5:04 PM Page 1

EAU00005
IMPORTANT MANUAL INFORMATION
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 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.
Q
w
cC
NOTE:
NOTE:
8This manual should be considered a permanent part of this motorcycle and should remain
with it even if the motorcycle is subsequently sold.
8Yamaha 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 ques-
tions concerning this manual, please consult your Yamaha dealer.
5AE-9-E4 (ENG) 8/30/00 5:04 PM Page 2

IMPORTANT MANUAL INFORMATION
EW000002
w
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING
THIS MOTORCYCLE.
5AE-9-E4 (ENG) 8/30/00 5:04 PM Page 3

TDR125
OWNER’S MANUAL
©2000 by Yamaha Motor Co., Ltd.
1st Edition, August 2000
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-9-E4 (ENG) 8/30/00 5:04 PM Page 4

EAU00009 TABLE OF CONTENTS
GIVE SAFETY THE RIGHT OF WAY .................1-1
DESCRIPTION....................................................2-1
Left view ...........................................................2-1
Right view.........................................................2-2
Controls and instruments..................................2-3
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..............................................................3-14
Sidestand........................................................3-15
Ignition circuit cut-off system..........................3-16
PRE-OPERATION CHECKS...............................4-1
Pre-operation check list....................................4-1
OPERATION AND IMPORTANT RIDING
POINTS...............................................................5-1
Starting a cold engine.......................................5-1
Starting a warm engine.....................................5-2
Shifting..............................................................5-3
Recommended shift points
(for Switzerland only)......................................5-3
Tips for reducing fuel consumption...................5-4
Engine break-in ................................................5-4
Parking .............................................................5-5
PERIODIC MAINTENANCE AND MINOR
REPAIR...............................................................6-1
Owner’s tool kit.................................................6-1
Periodic maintenance and lubrication chart......6-2
Removing and installing cowlings and panel....6-5
Checking the spark plug...................................6-7
1
2
34
5
6
5AE-9-E4 (ENG) 8/30/00 5:04 PM Page 5

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
Wheels............................................................6-20
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
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
7
8
9
5AE-9-E4 (ENG) 8/30/00 5:04 PM Page 6

1-1
EAU00021 QGIVE SAFETY THE RIGHT OF WAY
1
2
3
4
5
6
7
8
9
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 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 passen-
gers. 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 pro-
tective 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!
5AE-9-E4 (ENG) 8/30/00 5:04 PM Page 7

2-1
EAU00026
DESCRIPTION
1
2
3
4
5
6
7
8
91. 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)
1234
5
67
Left view
5AE-9-E4 (ENG) 8/30/00 5:04 PM Page 8

2-2
DESCRIPTION
1
2
3
4
5
6
7
8
9
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)
8 9 10 11
12
1314
Right view
5AE-9-E4 (ENG) 8/30/00 5:04 PM Page 9

DESCRIPTION
1
2
3
4
5
6
7
8
9
2-3
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 (page 3-1)
123 4 56 7
89
10
Controls and instruments
5AE-9-E4 (ENG) 8/30/00 5:04 PM Page 10

3-1
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 removed.
EAU00038
OFF
All electrical systems are off. The key
can be removed.
EAU00042
LOCK
The steering is locked, and all electri-
cal 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, release it, and then turn
it to “LOCK”.
3. Remove the key.
To unlock the steering
Insert the key and turn it to “OFF”.
EW000016
w
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 turn-
ing the key to “OFF” or “LOCK”.
EAU00048
..
(Parking)
The steering is locked, and the tail-
light and auxiliary light 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 “P”. ECA00043
cC
Do not use the parking position for
an extended length of time, other-
wise the battery may discharge.
EAU00027 INSTRUMENT AND CONTROL FUNCTIONS
1
2
3
4
5
6
7
8
9
O
F
F
O
N
L
O
C
K
P
P
U
S
H
Y M - 8
I
G
N
I
T
I
O
N
ON
OFF
LOCK
PARKING
ab
a. Push.
b. Turn.
5AE-9-E4 (ENG) 8/30/00 5:04 PM Page 11

0
0
0 10 0
0 10 0
140
180
120
100
80
1
2
3456789
10
11
12
X1000r/min
km/h
C H
1 2
4 3
EAU03034
Indicator and warning lights
EAU03201
Oil level warning light “7”
This warning light comes on when
the engine oil level is low.
The electrical circuit of the warning
light can be checked according to the
following procedure.
1. Set the engine stop switch to “#”
and turn the key to “ON”.
2. Shift the transmission into the
neutral position or pull the clutch
lever.
3. Push the start switch. If the
warning light does not come on
while pushing the start switch,
have a Yamaha dealer check the
electrical circuit.
NOTE:
Even if the oil level is sufficient, the
warning light may flicker when riding
on a slope or during sudden acceler-
ation or deceleration, but this is not a
malfunction.
EAU00057
Turn signal indicator light “5”
This indicator light flashes when the
turn signal switch is pushed to the left
or right. EAU00061
Neutral indicator light “N”
This indicator light comes on when
the transmission is in the neutral
position.
EAU00063
High beam indicator light “&”
This indicator light comes on when
the high beam of the headlight is
switched on.
1. Turn signal indicator light “5”
2. High beam indicator light “&”
3. Oil level warning light “7”
4. Neutral indicator light “N”
3-2
INSTRUMENT AND CONTROL FUNCTIONS
1
2
3
4
5
6
7
8
9
5AE-9-E4 (ENG) 8/30/00 5:04 PM Page 12

3-3
INSTRUMENT AND CONTROL FUNCTIONS
1
2
3
4
5
6
7
8
9
0
0
0 10 0
0 10 0 0
140
180
120
100
80
60
40
20
km/h
C H
3
2
4
1
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 to estimate the distance
that can be traveled with a full tank of
fuel. This information will enable you
to plan future fuel stops.
1. Speedometer
2. Odometer
3. Tripmeter
4. Reset knob
0
1
2
3456789
10
11
12
~ 1000r/min
C H
1
2
NOTE:
Only for the German model equipped
with a speed limiter:
The speed limiter prevents the motor-
cycle from exceeding a riding speed
of 80 km/h.
1. Tachometer
2. Red zone EAU00102
Tachometer
The tachometer allows the rider to
monitor the engine speed and keep it
within the ideal power range. EC000003
cC
Do not operate the engine in the
tachometer red zone.
Red zone: 10,000 r/min and above
5AE-9-E4 (ENG) 8/30/00 5:04 PM Page 13

3-4
0 1
140
120
10
0
3
456
C H
12
1. Coolant temperature gauge
2. Red zone
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 instructions.) EC000002
cC
Do not operate the engine if it is
overheated.
INSTRUMENT AND CONTROL FUNCTIONS
1
2
3
4
5
6
7
8
9
1
234
EAU00118
Handlebar switches EAU00134
Light switch
Set this switch to “'” to turn on the
auxiliary light, meter lighting and tail-
light. Set the switch to “:” to turn on
the headlight also. EAU00121
Dimmer switch
Set this switch to “&” for the high
beam and to “%” for the low beam.
EAU00127
Turn signal switch
To signal a right-hand turn, push this
switch to “6”. To signal a left-hand
turn, push this switch to “4”. When
released, the switch returns to the
center position. To cancel the turn
signal lights, push the switch in after
it has returned to the center position.
EAU00129
Horn switch “*”
Press this switch to sound the horn.
1. Light switch
2. Dimmer switch
3. Turn signal switch
4. Horn switch “*”
5AE-9-E4 (ENG) 8/30/00 5:04 PM Page 14

3-5
INSTRUMENT AND CONTROL FUNCTIONS
1
2
3
4
5
6
7
8
9
1
2
&
&
%
%
Left Right Bulb to be used Destination
3
'
3
2
'
2
3
2
Halogen
bulb
Halogen
bulb
France Sweden Portugal Spain
Greece Belgium Germany
Switzerland Finland Austria
England
Ireland
3 : High beam light on , 2: Low beam light on
': Auxiliary light on
12V
60/55W 12V
60/55W
12V
35/35W 12V
35/35W
EAU00136
Headlight variations
NOTE:
Right and left are defined as seen when standing in front of the motorcycle.
5AE-9-E4 (ENG) 8/30/00 5:04 PM Page 15

EAU00152
Clutch lever
The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the han-
dlebar grip. To engage the clutch,
release the lever. The lever should
be pulled rapidly and released slowly
for smooth clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the igni-
tion circuit cut-off system. (See page
3-16 for an explanation of the ignition
circuit cut-off system.)
3-6
INSTRUMENT AND CONTROL FUNCTIONS
1
2
3
4
5
6
7
8
9
1
1. Clutch lever
6
5
4
3
2
1
N
1
EAU00157
Shift pedal
The shift pedal is located on the left
side of the engine and is used in
combination with the clutch lever
when shifting the gears of the
6-speed constant-mesh transmission
equipped on this motorcycle.
1. Shift pedal
N. Neutral
2
1
EAU00138
Engine stop switch
Set this switch to “$” to stop the
engine in case of an emergency,
such as when the motorcycle over-
turns or when the throttle cable is
stuck. EAU00143
Start switch “,”
Push this switch to crank the engine
with the starter. EC000005
cC
See page 5-1 for starting instruc-
tions prior to starting the engine.
1. Engine stop switch
2. Start switch “,”
5AE-9-E4 (ENG) 8/30/00 5:04 PM Page 16

3-7
1
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.
1. Brake lever
INSTRUMENT AND CONTROL FUNCTIONS
1
2
3
4
5
6
7
8
9
1
1. Brake pedal
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.
1
a
b
EAU02935
Fuel tank cap
To open the fuel tank cap
Open the fuel tank cap lock cover,
insert the key into the lock, and then
turn it 1/4 turn clockwise. The lock will
be released and the fuel tank cap can
be opened.
To close the fuel tank cap
1. Push the fuel tank cap into posi-
tion with the key inserted in the
lock.
2. Turn the key counterclockwise to
the original position, remove it,
and then close the lock cover.
1. Fuel tank cap lock cover
a. Open.
b. Unlock.
5AE-9-E4 (ENG) 8/30/00 5:04 PM Page 17

3-8
INSTRUMENT AND CONTROL FUNCTIONS
1
2
3
4
5
6
7
8
9
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.
2
1
1. Filler tube
2. Fuel level EAU03753
Fuel
(except for Switzerland and
Austria)
Make sure that there is sufficient fuel
in the tank. Fill the fuel tank to the
bottom of the filler tube as shown.
EW000130
w
8Do not overfill the fuel tank,
otherwise it may overflow
when the fuel warms up and
expands.
8Avoid spilling fuel on the hot
engine.
1
3
5
4
2
1. Pump nozzle
2. Fuel tank filler hole
3. Filler tube
4. Fuel level
5. Leaf valve
EAU03754
Fuel
(for Switzerland and Austria)
Make sure that there is sufficient fuel
in the tank. When refueling, be sure
to insert the pump nozzle into the fuel
tank filler hole and to fill the tank to
the bottom of the filler tube as shown.
5AE-9-E4 (ENG) 8/30/00 5:04 PM Page 18

3-9
INSTRUMENT AND CONTROL FUNCTIONS
1
2
3
4
5
6
7
8
9
EW000130
w
8Do not overfill the fuel tank,
otherwise it may overflow
when the fuel warms up and
expands.
8Avoid spilling fuel on the hot
engine.
EAU00185
cC
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted sur-
faces or plastic parts.
EAU00191
NOTE:
If knocking (or pinging) occurs, use
gasoline of a different brand or with a
higher octane grade.
EAU01084
Catalytic converter
(for Switzerland and Austria)
This motorcycle is equipped with a
catalytic converter in the exhaust
chamber. EW000128
w
The exhaust system is hot after
operation. Make sure that the
exhaust system has cooled down
before doing any maintenance
work.
Recommended fuel:
Regular unleaded gasoline
with a research octane
number of 91 or higher
Fuel tank capacity:
Total amount:
11.0 L
Reserve amount:
2.2 L
5AE-9-E4 (ENG) 8/30/00 5:04 PM Page 19