u5aee3 yamaha tdr 125

TDR1255AE-28199-E3

OWNERS MANUAL

TDR125(5AE-E3)Hyoshi 4/11/0 11:09 AM Page 1 (2,1) (Magenta plate)

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INTRODUCTION

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Welcome to the Yamaha world of motorcycling!

As the owner of a TDR125, you are benefiting from Yamahas vast experience in and newest tech-nology for the design and the manufacture of high-quality products, which have earned Yamaha areputation for dependability.

Please take the time to read this manual thoroughly, so as to enjoy all your TDR125s advantages.The owners manual does not only instruct you in how to operate, inspect and maintain your motorcy-cle, but also in how to safeguard yourself and others from trouble and injury.

In addition, the many tips given in this manual will help to keep your motorcycle in the best possiblecondition. 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!

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IMPORTANT MANUAL INFORMATION

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Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETYIS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to themotorcycle operator, a bystander or a person inspecting or repairing the motorcycle.

A CAUTION indicates special precautions that must be taken to avoid damage tothe motorcycle.

A NOTE provides key information to make procedures easier or clearer.

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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, theremay be minor discrepancies between your motorcycle and this manual. If there is any ques-tion concerning this manual, please consult your Yamaha dealer.

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IMPORTANT MANUAL INFORMATION

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PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATINGTHIS MOTORCYCLE.

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TDR125OWNERS MANUAL

1999 by Yamaha Motor Co., Ltd.1st Edition, August 1999

All rights reserved. Any reprinting orunauthorized use without the written

permission of Yamaha Motor Co., Ltd.is expressly prohibited.

Printed in Japan

EAU00008

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TABLE OF CONTENTS

1 GIVE SAFETY THE RIGHT OF WAY

2 DESCRIPTION

3 INSTRUMENT AND CONTROL FUNCTIONS

4 PRE-OPERATION CHECKS

5 OPERATION AND IMPORTANT RIDING POINTS

6 PERIODIC MAINTENANCE AND MINOR REPAIR

7 MOTORCYCLE CARE AND STORAGE

8 SPECIFICATIONS

9 CONSUMER INFORMATION

INDEX

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GIVE SAFETY THE RIGHT OF

GIVE SAFETY THE RIGHT OF WAY ................................................1-11

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1-1

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 motorcycledoes not ignore the laws of physics.

Regular care and maintenance are essential for preserving your motorcycles value and operatingcondition. Moreover, what is true for the motorcycle is also true for the rider: good performancedepends on being in good shape. Riding under the influence of medication, drugs and alcohol is, ofcourse, out of the question. Motorcycle riders more than car drivers must always be at their mentaland physical best. Under the influence of even small amounts of alcohol, there is a tendency to takedangerous 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 syntheticmaterials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet. Optimum pro-tective wear, however, should not encourage carelessness. Though 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 iseven more dangerous in wet weather. The good motorcyclist rides safely, predictably and defensivelyavoiding all dangers, including those caused by others.

Enjoy your ride!

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Q GIVE SAFETY THE RIGHT OF WAY

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DESCRIPTION

Left view .............................................................................................2-1Right view...........................................................................................2-2Controls/Instruments ..........................................................................2-3

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DESCRIPTION

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2-1

1. Dual headlight (page 3-6)2. Fuel cock (page 3-12)3. Engine oil tank (page 3-12)4. Helmet holder (page 3-12)5. Starter 1 (page 3-13)

6. Y.E.I.S. (page 3-15)7. Y.P.V.S. (page 3-16)

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Left view

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DESCRIPTION

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2-2

8. Tool kit (page 6-1)9. Fuse (page 6-32)

10. Air filter (page 6-15)11. Radiator cap (page 6-11)12. Rear brake pedal (page 3-9, 6-22)13. Coolant reservoir tank (page 6-10)

14. Rear shock absorber springpreload adjusting ring (page 3-14)

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Right view

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DESCRIPTION

2-3

15. Clutch lever (page 3-8, 6-20)16. Left handlebar switches (page 3-5)17. Speedometer (page 3-4)18. Engine temperature gauge (page 3-5)19. Tachometer (page 3-5)

20. Right handlebar switches (page 3-6)21. Front brake lever (page 3-9, 6-21)22. Throttle grip (page 6-17)23. Fuel tank cap (page 3-9)24. Main switch/Steering lock (page 3-1)

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Controls/Instruments

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INSTRUMENT AND CONTROL FUNCTIONS

Main switch/steering lock........................................3-1Indicator lights ........................................................3-2Oil level indicator circuit check ...............................3-3Speedometer ..........................................................3-4Tachometer ............................................................3-4Engine temperature gauge.....................................3-5Handlebar switches ................................................3-5Headlight beam variation........................................3-6Clutch lever.............................................................3-8Shift pedal...............................................................3-8Front brake lever ....................................................3-8Rear brake pedal ....................................................3-9Fuel tank cap..........................................................3-9Fuel.......................................................................3-10Catalyzer (for Switzerland and Austria) ................3-11Two-stroke engine oil ...........................................3-12Fuel cock ..............................................................3-12Starter (choke) 1 ..............................................3-13Seat ......................................................................3-13Helmet holder .......................................................3-14Rear shock absorber adjustment..........................3-14Note on handling of the Yamaha EnergyInduction System (Y.E.I.S.) ..................................3-15

Y.P.V.S. (Yamaha Power Valve System).............3-16Sidestand..............................................................3-16Sidestand/clutch switch operation check..............3-17

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3-1

OFF ON

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IGNITIO

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ONOFF

LOCKPARKING

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Main switch/Steering lockThe main switch controls the ignitionand lighting systems. Its operation isdescribed below.

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ONElectrical circuits are switched on.The engine can be started. The keycannot be removed in this position.

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OFFAll electrical circuits are switched off.The key can be removed in this posi-tion.

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LOCKThe steering is locked in this positionand all electrical circuits are switchedoff.The key can be removed in this posi-tion.To lock the steering, turn the handle-bars all the way to the left. With thekey at OFF, push it into the mainswitch and release it, turn it counter-clockwise to LOCK and remove it.To release the lock, turn the key toOFF.

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Never turn the key to OFF orLOCK when the motorcycle ismoving. The electrical circuits willbe switched off which may resultin loss of control or an accident.Be sure the motorcycle is stoppedbefore turning the key to OFF orLOCK.

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.. (Parking)The steering is locked in this position,and the taillight and auxiliary lightcome on but all other circuits are off.The key can be removed in this posi-tion.To use the parking position, first lockthe steering, then turn the key to ..Do not use this position for anextended length of time as the bat-tery may discharge.

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1. Push 2. Turn

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1234 5

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12~1000r/minkm/h

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Indicator lights

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Turn indicator light 55This indicator flashes when the turnswitch is moved to the left or right.

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Neutral indicator light NThis indicator comes on when thetransmission is in neutral.

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High beam indicator light &&This indicator comes on when theheadlight high beam is used.

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Oil level indicator light 77This indicator comes on when the oillevel is low. This light circuit can bechecked by the procedure on page 3-3.

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Do not run the motorcycle untilyou know it has sufficient engineoil.

NOTE:Even if the oil is filled to the specifiedlevel, the indicator light may flickerwhen riding on a slope or during sud-den acceleration or deceleration, butthis is normal.

1. Turn indicator light 52. High beam indicator light &3. Neutral indicator light N4. Oil level indicator light 7


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Oil level indicator circuitcheck


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Oil level indicator light

Check engine oil level.

Oil level indicator light

Put the transmission in neutral or apply the

Oil level indicator light Oil level indicator light Oil level Oil level

Engine oil level and Ask a Yamaha dealer Supply

Turn the main switch to ONand the engine stop switch to #.

does not come on. comes on.

clutch lever, then push the start switch.

comes on. does not come on. is OK. is low.

engine oil.to inspect electricalcircuit.

electrical circuit are OK.Go ahead with riding.

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SpeedometerThe speedometer shows ridingspeed. This speedometer is equippedwith an odometer and trip odometer.The trip odometer can be reset to 0with the reset knob. Use the tripodometer to estimate how far youcan ride on a tank of fuel. This infor-mation will enable you to plan fuelstops in the future.

1. Speedometer2. Odometer3. Trip odometer4. Reset knob


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12~1000r/min

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NOTE:(for German model equipped withspeed limiter only)This motorcycle is equipped with aspeed limiter which prevents it fromexceeding a top speed of 80 km/h.

1. Tachometer2. Red zone

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TachometerThis model is equipped with atachometer so the rider can monitorthe engine speed and keep it withinthe ideal power range.

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Do not operate in the red zone.Red zone: 10,000 r/min and above

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1. Engine temperature gauge2. Red zone

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Engine temperature gaugeThis gauge indicates the coolant tem-perature when the main switch is on.The engine operating temperaturewill vary with changes in weather andengine load. If the needle points tothe red zone or higher, stop yourmotorcycle and let the engine cool.(See page 6-10 for details.)

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When the engine is overheated, donot continue riding.


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Handlebar switches

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Lights switchTurning the light switch to ',turns on the auxiliary light, meterlights and taillight. Turning the lightswitch to :, turns the headlight onalso.

EAU00121

Dimmer switchTurn the switch to & for the highbeam and to % for the low beam.

EAU00127

Turn signal switchTo signal a right-hand turn, push theswitch to 6. To signal a left-handturn, push the switch to 4. Oncethe switch is released it will return tothe center position. To cancel the sig-nal, push the switch in after it hasreturned to the center position.

EAU00129

Horn switch **Press the switch to sound the horn.

1. Lights switch 2. Dimmer switch3. Turn signal switch 4. Horn switch *

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3-6


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Left Right Bulb to be used Destination3

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Halogenbulb

Halogenbulb

France Sweden Portugal SpainGreece Belgium GermanySwitzerland Finland Austria

EnglandIreland

3 : High beam light on , 2 : Low beam light on' : Auxiliary light on

12V 60/55W

12V60/55W

12V 35/35W

12V 35/35W

EAU00136

Headlight beam variation

NOTE:Right and left directions are those assumed from the position of a person facing the front of the motorcycle.

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Engine stop switchThe engine stop switch is a safetydevice for use in an emergency suchas when the motorcycle overturns orif trouble occurs in the throttle sys-tem. Turn the switch to # to startthe engine.In case of emergency, turn the switchto $ to stop the engine.

1. Engine stop switch2. Start switch ,

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Start switch ,,The starter motor cranks the enginewhen pushing the start switch.

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See starting instructions prior tostarting the engine.

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3-8

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Clutch leverThe clutch lever is located on the lefthandlebar, and the ignition circuit cut-off system is incorporated in theclutch lever holder. Pull the clutchlever to the handlebar to disengagethe clutch, and release the lever toengage the clutch. The lever shouldbe pulled rapidly and released slowlyfor smooth clutch operation. (Refer tothe engine starting procedures for adescription of the ignition circuit cut-off system.)

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Front brake leverThe front brake lever is located onthe right handlebar. Pull it toward thehandlebar to apply the front brake.

1. Front brake lever


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1. Clutch lever

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Shift pedalThis motorcycle is equipped with aconstant-mesh 6-speed transmission.The shift pedal is located on the leftside of the engine and is used incombination with the clutch whenshifting.

1. Shift pedalN. Neutral

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1. Rear brake pedalEAU00162

Rear brake pedalThe rear brake pedal is on the rightside of the motorcycle. Press downon the brake pedal to apply the rearbrake.

NOTE:This tank cap cannot be closedunless the key is in the lock. The keycannot be removed if the cap is notlocked properly.

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Be sure the cap is properlyinstalled and locked in placebefore riding the motorcycle.

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Fuel tank capTo openOpen the lock cover. Insert the keyand turn it 1/4 turn clockwise. Thelock will be released and the cap canbe opened.

To closePush the tank cap into position withthe key inserted. To remove the key,turn it counterclockwise to the originalposition. Then, close the lock cover.

1. Open2. Unlock

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Do not overfill the fuel tank. Avoidspilling fuel on the hot engine. Donot fill the fuel tank above the bot-tom of the filler tube or it mayoverflow when the fuel heats uplater and expands.

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Always wipe off spilled fuel imme-diately with a dry and clean softcloth. Fuel may deteriorate paintedsurfaces or plastic parts.

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1. Filler tube2. Filling nozzle3. Fuel level

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Fuel(except for Switzerland andAustria)Make sure there is sufficient fuel inthe tank. Fill the fuel tank to the bot-tom of the filler tube as shown in theillustration.

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Do not overfill the fuel tank. Avoidspilling fuel on the hot engine. Donot fill the fuel tank above the bot-tom of the filler tube or it mayoverflow when the fuel heats uplater and expands.

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1. Filler tube2. Filling nozzle3. Leaf valve4. Fuel level

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(for Switzerland and Austria)Make sure there is sufficient fuel inthe tank. When refueling, be sure toinsert the filling nozzle into the fillerhole and fill the tank to the bottom ofthe filler tube as shown in the illustra-tion.

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NOTE:If knocking or pinging occurs, use adifferent brand of gasoline or higheroctane grade.

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Catalyzer(for Switzerland and Austria)This motorcycle is equipped with acatalytic converter in the exhaustchamber.

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The exhaust system is hot duringand directly after engine operation.Make sure the exhaust system hascooled down before making anyadjustment to or lubricating themotorcycle.

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The following must be observed toprevent a fire hazard or other dam-ages.88 Use only unleaded gasoline.

Use of leaded gasoline willcause unrepairable damage tothe catalytic converter.

88 Never park this motorcycle inan area that would cause a firehazard such as grass or othermaterials that may easily burn.

88 Do not allow the engine to idlefor very long.

Recommended fuel:Regular unleaded gasolinewith a research octanenumber of 91 or higher.

Fuel tank capacity:Total:

11.0 LReserve:

2.2 L

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ON 1

1. Arrow mark pointing to ONEAU03050

Fuel cockThe fuel cock supplies fuel from thetank to the carburetor while filtering italso.The fuel cock has three positions:

OFFWith the lever in this position, fuel willnot flow. Always return the lever tothis position when the engine is notrunning.

ONWith the lever in this position, fuelflows to the carburetor. Normal ridingis done with the lever in this position.

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OFF

1. Arrow mark pointing to OFFEAU02956

Two-stroke engine oilMake sure the two-stroke engine oilis at the specified level. Fill with oil asnecessary.

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1. Filler cap

Recommended oil:Yamalube 2 or 2-stroke engine oil (JASO FC grade or ISO EG-C, EG-D grade)

Oil quantity:1.2 L

OFF: closed position ON: normal position

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RESThis indicates reserve. If you run outof fuel while riding, move the lever tothis position. Fill the tank at the firstopportunity. Be sure to set the leverback to ON after refueling!

EAU02976

Starter (choke) 1Starting a cold engine requires a rich-er air-fuel mixture. A separate startercircuit supplies this mixture.Move in direction a to turn on thestarter (choke).Move in direction b to turn off thestarter (choke).

EAU01619

SeatTo removeInsert the key into the lock and turn itclockwise.

1. Starter(choke) 1 1. Unlock

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RES

1. Arrow mark pointing to RES

RES: reserve position

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Helmet holderTo open the helmet holder, insert thekey in the lock and turn it as shown.To lock the helmet holder, replacethe holder in its original position.

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Never ride with a helmet in the hel-met holder. The helmet may hitobjects, causing loss of controland possibly an accident.

EAU00295

Rear shock absorberadjustmentThis shock absorber is equipped witha spring preload adjusting ring.Adjust spring preload as follows.Turn the adjusting ring in direction ato increase spring preload and indirection b to decrease spring pre-load.Make sure that the appropriate notchin the adjusting ring is aligned withthe position indicator on the rearshock absorber.

To installInsert the projection on the front ofthe seat into the seat holder. Pushdown on the seat and remove thekey.

NOTE:Make sure that the seat is securelyfitted.

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1. Adjusting ring

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1. Position indicator 1. Y.E.I.S.2. Y.P.V.S.

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This shock absorber containshighly pressurized nitrogen gas.Read and understand the followinginformation before handling theshock absorber. The manufacturercannot be held responsible forproperty damage or personalinjury that may result from improp-er handling.88 Do not tamper with or attempt

to open the cylinder assembly.88 Do not subject the shock

absorber to an open flame orother high heat source. Thismay cause the unit to explodedue to excessive gas pres-sure.

88 Do not deform or damage thecylinder in any way. Cylinderdamage will result in poordamping performance.

88 Take your shock absorber to aYamaha dealer for any service.

EAU00325

Note on handling of theYamaha Energy InductionSystem (Y.E.I.S.)Handle the air chamber and hosewith special care. Improper installa-tion or damaged parts will result inpoor performance. Replace anycracked or damaged parts immedi-ately. No modification of this systemin any form can be made.

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Never attempt to modify theYamaha Energy Induction System.


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Hard Stan- SoftdardAdjusting 9 8 7 6 5 4 3 2 1Position

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Y.P.V.S. (Yamaha Power ValveSystem)The Y.P.V.S. is a vital part of theengine and requires very sophisticat-ed adjustment. Adjustment should beleft to a Yamaha dealer who has theprofessional knowledge and experi-ence to do so.

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The Y.P.V.S. was set at theYamaha factory after many tests. Ifthe settings are disturbed bysomeone without sufficient techni-cal knowledge, poor engine perfor-mance and damage may result.

The Y.P.V.S. operation can be heardin the following instances:8 When the main switch is turned

on and the engine is started.8 When the engine stalls while the

main switch is on.

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If the Y.P.V.S. does not operate,ask a Yamaha dealer to inspect thevehicle.

EAU00330

SidestandThis model is equipped with an igni-tion circuit cut-off system. The motor-cycle must not be ridden when thesidestand is down. The sidestand islocated on the left side of the frame.(Refer to page 5-1 for an explanationof this system.)


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This motorcycle must not be oper-ated with the sidestand in thedown position. If the stand is notproperly retracted, it could contactthe ground and distract the opera-tor, resulting in a possible loss ofcontrol. Yamaha has designed intothis motorcycle a lockout systemto assist the operator in fulfillingthe responsibility of retracting thesidestand. Please check carefullythe operating instructions listedbelow and if there is any indicationof a malfunction, return the motor-cycle to a Yamaha dealer immedi-ately for repair.

EAU00331

Sidestand/clutch switchoperation checkCheck the operation of the sidestandswitch and clutch switch against theinformation below.

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If improper operation is noted,consult a Yamaha dealer immedi-ately.


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TURN THE MAIN SWITCH TO ON ANDTHE ENGINE STOP SWITCH TO #.

TRANSMISSION IS IN GEAR AND SIDESTAND IS UP.

PULL IN CLUTCH LEVER AND PUSH THE START SWITCH.

ENGINE WILL START.

CLUTCH SWITCH IS OK.

SIDESTAND IS DOWN.

ENGINE WILL STALL.

SIDESTAND SWITCH IS OK.

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PRE-OPERATION CHECKS

Pre-operation check list ......................................................................4-1

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4-1


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Owners are personally responsible for their vehicles condition. Your motorcycle/scooters vital functions can start todeteriorate quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any dam-age, fluid leak or loss of tire pressure could have serious consequences. Therefore, it is very important that, in additionto a thorough visual inspection, you check the following points before each ride.

EAU00340

PRE-OPERATION CHECK LISTITEM CHECKS PAGE

Front brake 9 Check operation, free play, fluid level and vehicle for fluid leakage.9 Fill with DOT 4 (or DOT 3) brake fluid if necessary.

3-8~3-9, 6-21 ~ 6-24Rear brake 9 Check operation, free play, fluid level and vehicle for fluid leakage.

9 Fill with DOT 4 brake fluid if necessary.

Clutch 9 Check operation, condition and free play. 3-8, 6-20 ~ 6-219 Adjust if necessary.9 Check for smooth operation.

Throttle grip and housing 9 Lubricate. 6-17 ~ 6-18, 6-279 Adjust throttle cable free play if necessary.

Engine oil 9 Check oil level. 3-129 Fill with oil if necessary.

Transmission oil 9 Check oil level. 6-9 ~ 6-109 Fill with oil if necessary.

Coolant 9 Check coolant level. 6-10 ~ 6-119 Fill with coolant if necessary.

Drive chain 9 Check chain slack and condition. 6-25 ~ 6-269 Adjust if necessary.

Wheels and tires 9 Check tire pressure, wear, damage. 6-18 ~ 6-20

Control and meter cable 9 Check for smooth operation. 6-279 Lubricate if necessary.

EAU01114

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ITEM CHECKS PAGE

Brake and shift pedal shafts 9 Check for smooth operation.

6-289 Lubricate if necessary.

Brake and clutch lever pivots 9 Check for smooth operation.9 Lubricate if necessary.

Sidestand pivot 9 Check for smooth operation. 6-289 Lubricate if necessary.

Chassis fasteners 9 Make sure that all nuts, bolts, and screws are properly tightened. 9 Tighten if necessary.

Fuel tank 9 Check fuel level. 3-9 ~ 3-109 Fill with fuel if necessary.

Lights, signals and9 Check for proper operation. 6-32 ~ 6-34switches

NOTE:Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in avery short time; and the added safety it assures is more than worth the time involved.

w

If any item in the Pre-Operation Check is not working properly, have it inspected and repaired before operatingthe motorcycle.

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5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 34

OPERATION AND IMPORTANT RIDING POINTS

Starting the engine .............................................................................5-1Starting a warm engine.......................................................................5-4Shifting................................................................................................5-4Recommended shift points (for Switzerland only) ..............................5-5Tips for reducing fuel consumption.....................................................5-5Engine break-in ..................................................................................5-5Parking ...............................................................................................5-6

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5-1

EAU00373

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88 Before riding this motorcycle,become thoroughly familiarwith all operating controls andtheir functions. Consult aYamaha dealer regarding anycontrol or function that you donot thoroughly understand.

88 Never start your engine or letit run for any length of time ina closed area. The exhaustfumes are poisonous and cancause loss of consciousnessand death within a short time.Always operate your motorcy-cle in an area with adequateventilation.

88 Before starting out, always besure the sidestand is up.Failure to retract the sidestandcompletely can result in a seri-ous accident when you try toturn a corner.

EAU00381

Starting the engine

NOTE:This motorcycle is equipped with anignition circuit cut-off system. Theengine can be started only under thefollowing conditions:88 The transmission is in neutral.88 The sidestand is up, the trans-

mission is in gear and the clutchis disengaged

The motorcycle must not be riddenwhen the sidestand is down.

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Before going through the followingsteps, check the function of thesidestand switch and clutchswitch. (Refer to page 3-17.)

EAU00372


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5-2


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IF TRANSMISSION IS IN NEUTRAL AND SIDESTAND IS DOWN,

PUSH THE START SWITCH.ENGINE WILL START.

RETRACT SIDESTAND AND PUTTRANSMISSION IN GEAR.

MOTORCYCLE CAN BE RIDDEN.MOTORCYCLE CAN BE RIDDEN.

IF TRANSMISSION IS IN GEARAND SIDESTAND IS UP,

PULL IN THE CLUTCH LEVER AND PUSHTHE START SWITCH.ENGINE WILL START.

TURN THE MAIN SWITCH TO ON AND THE ENGINE STOP SWITCH TO #.

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5-3

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 beon. If the light does not come on, aska Yamaha dealer to inspect it.

4. Turn on the starter (choke) andcompletely close the throttle grip.

5. Start the engine by pushing thestart switch.

NOTE:If the engine fails to start, release thestart switch, wait a few seconds, thentry again. Each attempt should be asshort as possible to preserve the bat-tery. Do not crank the engine morethan 10 seconds on any one attempt.

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The oil level indicator light shouldcome on when the start switch ispushed and should go off whenthe start switch is released. If theindicator light flickers or remainson, immediately stop the engineand check the engine oil level andfor oil leakage. If necessary, fill theengine with oil and check to seethat the oil level indicator lightgoes off. If the light does not go offeven with sufficient oil in thecrankcase or the light does notcome on when pushing the startswitch, consult a Yamaha dealer.

6. After starting the engine, movethe starter (choke) halfway back.

NOTE:For maximum engine life, neveraccelerate hard with a cold engine!

7. After the engine is warm, turn offthe starter (choke) completely.

NOTE:The engine is warm when it respondsnormally to the throttle with the starter(choke) turned off.


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5-4

EAU01258

Starting a warm engineThe starter (choke) is not requiredwhen the engine is warm.

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See the Engine break-in sectionprior to operating the motorcyclefor the first time.

EAU00423

ShiftingThe transmission lets you control theamount of power you have availableat a given speed for starting, acceler-ating, climbing hills, etc. The use ofthe shift pedal is shown in the illustra-tion.To shift into neutral, depress the shiftpedal repeatedly until it reaches theend of its travel, then raise the pedalslightly.

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88 Do not coast for long periodswith the engine off, and do nottow the motorcycle a long dis-tance. Even with gears in neu-tral, the transmission is onlyproperly lubricated when theengine is running. Inadequatelubrication may damage thetransmission.

88 Always use the clutch whenchanging gears. The engine,transmission, and driveline arenot designed to withstand theshock of forced shifting andcan be damaged by shiftingwithout using the clutch.


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65432

1N

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1. Shift pedalN. Neutral

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5-5

EAU00424

Tips for reducing fuel consumptionYour motorcycles fuel consumptiondepends to a large extent on your rid-ing style. The following tips can helpreduce fuel consumption:8 Warm up the engine before rid-

ing.8 Turn off the starter (choke) as

soon as possible.8 Shift up swiftly and avoid high

engine speeds during accelera-tion.

8 Do not double-clutch or rev theengine while shifting down andavoid high engine speeds withno load on the engine.

8 Turn off the engine instead of let-ting it idle for an extended lengthof time, i.e. in traffic jams, at traf-fic lights or railroad crossings.

EAU00436

Engine break-inThere is never a more important peri-od in the life of your motorcycle thanthe period between zero and 1,000km. For this reason we ask that youcarefully read the following material.Because the engine is brand new,you must not put an excessive loadon it for the first 1,000 km. The vari-ous parts in the engine wear and pol-ish themselves to the correct operat-ing clearances. During this period,prolonged full throttle operation, orany condition which might result inexcessive heating of the engine,must be avoided.


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EAU02937

Recommended shift points(for Switzerland only)The recommended shift points areshown in the table below.

Acceleration shift pointkm/h

1st fi 2nd 202nd fi 3rd 303rd fi 4th 404th fi 5th 505th fi 6th 60

NOTE:When shifting two gears down from5th to 3rd, bring your motorcycle to aspeed of 35 km/h.

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5-6

EAU00453

0 ~ 500 kmAvoid operation above 6,000 r/min.Stop the engine and let it cool for 5 to10 minutes after every hour of opera-tion. Vary the speed of the motorcy-cle from time to time. Do not operateit at one set throttle position.500 ~ 1,000 kmAvoid prolonged operation above7,000 r/min. Rev the motorcyclefreely through the gears, but do notuse full throttle at any time.

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After 1,000 km of operation, besure to replace the transmissionoil.

1,000 km and beyondFull throttle can be used.

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88 Never let engine speeds enterthe red zone.

88 If any engine trouble shouldoccur during the break-in peri-od, consult a Yamaha dealerimmediately.

EAU00458

ParkingWhen parking the motorcycle, stopthe engine and remove the ignitionkey. Turn the fuel cock to OFFwhenever stopping the engine.

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The exhaust system is hot. Parkthe motorcycle in a place wherepedestrians or children are notlikely to touch the motorcycle. Donot park the motorcycle on a slopeor soft ground; the motorcyclemay overturn.

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Never park this motorcycle in anarea that would cause a fire hazardsuch as grass or other materialsthat may easily burn.


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5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 42

PERIODIC MAINTENANCE AND MINOR REPAIR

Tool kit ...................................................................6-1Periodic maintenance and lubrication ....................6-3Cowling and panel removal and installation...........6-6Cowling A, B ..........................................................6-7Panel A ..................................................................6-7Spark plug inspection.............................................6-8Transmission oil .....................................................6-9Cooling system ....................................................6-10Changing the coolant ...........................................6-11Air filter.................................................................6-13Carburetor adjustment .........................................6-15Idle speed adjustment..........................................6-15Throttle cable free play adjustment......................6-16Tires .....................................................................6-17Wheels .................................................................6-19Clutch lever free play adjustment.........................6-19Front brake lever free play adjustment ................6-20Rear brake pedal height adjustment ....................6-20Brake light switch adjustment ..............................6-21Checking the front and rear brake pads...............6-21Inspecting the brake fluid level.............................6-22Brake fluid replacement .......................................6-23Drive chain slack check .......................................6-23Drive chain slack adjustment ...............................6-24

Drive chain lubrication............................................6-25Cable inspection and lubrication ............................6-25Throttle cable and grip lubrication..........................6-26Autolube pump adjustment ....................................6-26Brake and shift pedal lubrication............................6-26Brake and clutch lever lubrication ..........................6-27Sidestand lubrication..............................................6-27Rear suspension lubrication...................................6-27Front fork inspection ..............................................6-28Steering inspection ................................................6-28Wheel bearings ......................................................6-29Battery....................................................................6-29Fuse replacement ..................................................6-30Headlight bulb replacement ...................................6-31Taillight bulb replacement ......................................6-32Turn signal light bulb replacement .........................6-32Front wheel removal ..............................................6-33Front wheel installation ..........................................6-34Rear wheel removal ...............................................6-34Rear wheel installation...........................................6-35Troubleshooting .....................................................6-36Troubleshooting chart ............................................6-37

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EAU00464

Periodic inspection, adjustment andlubrication will keep your motorcyclein the safest and most efficient condi-tion possible. Safety is an obligationof the motorcycle owner. The mainte-nance and lubrication schedule chartshould be considered strictly as aguide to general maintenance andlubrication intervals.YOU MUST TAKE INTO CONSIDER-ATION THAT WEATHER, TERRAIN,GEOGRAPHICAL LOCATIONS, ANDA VARIETY OF INDIVIDUAL USESALL TEND TO DEMAND THATEACH OWNER ALTER THIS TIMESCHEDULE TO SHORTER INTER-VALS TO MATCH THE ENVIRON-MENT. The most important points ofmotorcycle inspection, adjustment,and lubrication are explained in thefollowing pages.

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If you are not familiar with motor-cycle service, this work should bedone by a Yamaha dealer.

EAU00462


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EAU00469

Tool kitThe service information included inthis manual is intended to provideyou, the owner, with the necessaryinformation for completing some ofyour own preventive maintenanceand minor repairs.The tools provided in the owners toolkit are to assist you in the perfor-mance of periodic maintenance.However, some other tools such as atorque wrench are also necessary toperform the maintenance correctly.

1. Tool kit

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6-2

NOTE:If you do not have necessary toolsrequired during a service operation,take your motorcycle to a Yamahadealer for service.

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Modifications to this motorcyclenot approved by Yamaha maycause loss of performance, andrender it unsafe for use. Consult aYamaha dealer before attemptingany changes.


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5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 45

EVERY6,000 km 12,000 km

No. ITEM CHECKS AND MAINTENANCE JOBS Initial or or(1,000 km) 6 months 12 months(Whichever (Whichever

comes first) 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.

4 Clutch 9 Check operation. 9 Adjust or replace cable.9 Check operation, fluid level and vehicle for fluid leakage.

(See NOTE on page 6-5.)5 * Front brake

9 Correct accordingly. 9 Replace brake pads if necessary.9 Check operation, fluid level and vehicle for fluid leakage.

(See NOTE on page 6-5.)6 * Rear brake9 Correct accordingly. 9 Replace brake pads if necessary.

7 * Wheels 9 Check balance, runout and for damage. 9 Rebalance or replace if necessary.9 Check tread depth and for damage.

8 * Tires 9 Replace if necessary. 9 Check air pressure.9 Correct if necessary.

9 * Wheel bearings 9 Check bearing for looseness or damage. 9 Replace if necessary.

6-3


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EAU00473

PERIODIC MAINTENANCE AND LUBRICATION

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6-4


6

EVERY6,000 km 12,000 km


comes first) comes first)9 Check swingarm pivoting point for play.

10 * Swingarm 9 Correct if necessary. 9 Lubricate with lithium soap base grease every

24,000 km or 24 months (whichever comes first).9 Check chain slack.

11 Drive chain 9 Adjust if necessary. Make sure that the rear wheel is properly aligned. Every 1,000 km and after washing9 Clean and lubricate. the motorcycle or riding in the rain

9 Check bearing play and steering for roughness.12 * Steering bearings 9 Correct accordingly.

9 Lubricate with lithium soap base grease every 24,000 km or24 months (whichever comes first).

13 * Chassis fasteners 9Make sure that all nuts, bolts and screws are properly tightened. 9 Tighten if necessary.

14 Sidestand 9 Check operation. 9 Lubricate and repair if necessary.

15 * Sidestand switch 9 Check operation. 9 Replace if necessary.

16 * Front fork 9 Check operation and for oil leakage. 9 Correct accordingly.

17 * Rear shock absorber 9 Check operation and shock absorber for oil leakage. assembly 9 Replace shock absorber assembly if necessary. Rear shock absorber 9 Check operation.

18 * assembly pivoting 9 Lubricate with lithium grease every 24,000 km points or 24 months (whichever comes first).

19 * Carburetor 9 Check engine idling speed and starter operation. 9 Adjust if necessary.

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EVERY6,000 km 12,000 km


comes first) comes first)9 Check operation.

20 * Autolube pump 9 Correct if necessary. 9 Bleed if necessary.9 Check oil level and vehicle for oil leakage.

21 Transmission oil 9 Correct accordingly. 9 Change oil at initial 1,000 km and thereafter every

24,000 km or 24 months (whichever comes first).9 Check coolant level and vehicle for coolant leakage.

22 * Cooling system 9 Correct if necessary. 9 Change coolant every 24,000 km or 24 months (whichever

comes first).

* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.EAU02970

NOTE8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas.8 Hydraulic brake system9 When disassembling the master cylinder or caliper, always replace the brake fluid. Check the brake fluid level

regularly and fill as required.9 Replace the oil seals on the inner parts of the master cylinder and caliper every two years.9 Replace the brake hoses every four years or if cracked or damaged.

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6-6


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1

1. Cowling B

1

1. Panel AEAU01139

Cowling and panel removaland installationThe cowlings and panels illustratedneed to be removed to perform someof the maintenance described in thischapter.Refer to this section each time acowling or panel has to be removedor reinstalled.

1

1. Cowling A

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6-7

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EAU01088

Cowling A, BTo remove

1. Remove the seat.2. Remove the radiator cover

screws and the radiator cover.

1. Radiator cover2. Screw ( 2)

1. Screw ( 10) 1. Screw ( 2)2. Panel A

3. Remove the screws and pull out-ward on the areas shown.

To install1. Place the cowling in the original

position and install the screws.2. Place the radiator cover in the

original position and install thescrews.

3. Install the seat.

EAU01691

Panel ATo remove

1. Remove the seat. (See page 3-13 for removal and installationprocedures.)

2. Remove the screw.

To install1. Place the panel in the original

position and install the screw.2. Install the seat.


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6-8

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EAU01651

Spark plug inspectionThe spark plug is an importantengine component and should beinspected periodically, preferably bya Yamaha dealer. The condition ofthe spark plug can indicate the condi-tion of the engine. The ideal color onthe white insulator around the centerelectrode is a medium-to-light tancolor for a motorcycle that is beingridden normally. Do not attempt todiagnose any problems yourself.Instead, take the motorcycle to aYamaha dealer. The spark plugshould be periodically removed andinspected because heat and deposits

will cause the spark plug to slowlybreak down and erode. If electrodeerosion becomes excessive, or if car-bon and other deposits are exces-sive, the spark plug should bereplaced with the specified plug.

Before installing the spark plug, mea-sure the electrode gap with a wirethickness gauge and adjust it tospecification.

When installing the plug, the gasketsurface should always be cleanedand a new gasket used. Any grimeshould be wiped off from the threadsand the spark plug tightened to thespecified torque.

NOTE:If a torque wrench is not availablewhen installing a spark plug, a goodestimate of the correct torque is 1/4to 1/2 turn past finger tight. The sparkplug should be tightened to the speci-fied torque as soon as possible.

1. Spark plug wrench


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Specified spark plug:BR9ES (NGK)

Spark plug gap:0.7 ~ 0.8 mm

Tightening torque:Spark plug:

20 Nm (2.0 m0kg)

1

1. Spark plug gap

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6-9

1

1. Transmission oil filler cap

2. With the engine stopped, checkthe oil level through the levelwindow located at the right sidecrankcase cover.

NOTE:Wait a few minutes until the oil levelsettles before checking.

3. The oil level should be above theminimum level mark on the levelwindow. If the level is low, addsufficient oil to raise it to theproper level.

Transmission oil replacement1. Warm up the engine for several

minutes.2. Stop the engine. Place an oil pan

under the engine and remove theoil filler cap.


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EAU01080

Transmission oilOil level measurement

1. Place the motorcycle on a levelplace and hold it an upright posi-tion. Warm up the engine forseveral minutes.

NOTE:Be sure the motorcycle is positionedstraight up when checking the oillevel. A slight tilt toward the side canresult in false readings.

1. Level window2. Minimum level

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6-10

1

3. Remove the drain bolt and drainthe oil.

4. Reinstall the drain bolt and tight-en it to the specified torque.

5. Fill the engine with oil. Install theoil filler cap and tighten it.

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88 Do not put in any chemicaladditives. Transmission oilalso lubricates the clutch andadditives could cause clutchslippage.

88 Be sure no foreign materialenters the crankcase.

6. Start the engine and warm up fora few minutes. While warmingup, check for oil leakage. If oilleakage is found, stop the engineimmediately and check forcause.

1. Drain bolt


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Tightening torque:Drain bolt:

15 Nm (1.5 m0kg)

Recommended oil:See page 8-1

Oil quantity:Total amount: 0.8 LPeriodic oil change: 0.75 L

1

2

1. Maximum level mark2. Minimum level mark

EAU01621*

Cooling system1. Check the coolant level in the

reservoir tank when the engine iscold as the coolant level will varywith engine temperature. Thecoolant level should be betweenthe minimum and maximummarks on the tank.

2. If the coolant level is at or belowthe minimum mark, fill with tapwater (soft water) to bring thelevel up to the specified level.Change the coolant every twoyears.

3. If your motorcycle overheats, seepage 6-38 for details.

5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 53

EAU01622*

Changing the coolant1. Put the motorcycle on a level

place.2. Remove the seat (See page

3-13 for seat removal proce-dures.)

3. Remove cowling B and radiatorcover. (See page 6-7 for removaland installation procedures.)

6-11


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4. Remove the radiator cap.

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Do not remove the radiator capwhen the engine is hot.

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Hard water or salt water is harmfulto the engine. You may use dis-tilled water if you cant get softwater.

1

1. Radiator cap

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5. Place a container under theengine and remove the coolantdrain bolt.

1. Drain bolt

1

6. Disconnect the reservoir tankhose on the reservoir tank sideand drain the coolant from thereservoir tank.

7. After draining the coolant, thor-oughly flush the cooling systemwith clean tap water.

8. Replace the coolant drain boltwasher if it is damaged and tight-en the coolant drain bolt to thespecified torque.

1. Reservoir tank hose

Tightening torque:Coolant drain bolt:

8 Nm (0.8 m0kg)

9. Install the reservoir tank hose.10. Pour the recommended coolant

into the radiator until it is full.

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Hard water or salt water is harmfulto the engine. You may use dis-tilled water if you cant get softwater.

Recommended antifreeze:High quality ethylene glycolantifreeze containingcorrosion inhibitors foraluminum engines

Antifreeze and water mixing ratio:1:1

Total amount:1.05 L

Reservoir tank capacity:0.35 L

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3

1. Reservoir tank cap2. Stopper3. Stopper bolt4. Maximum level mark5. Minimum level mark

11. Install the radiator cap.12. Run the engine several minutes.

Stop the engine and recheck thecoolant level in the radiator. If itis low, add more coolant until itreaches the top of the radiator.

13. Fill the reservoir tank withcoolant up to specified level.

14. Install the reservoir tank cap andcheck for coolant leakage.

NOTE:If any leakage is found, ask aYamaha dealer to inspect the coolingsytem.

15. Install the cowling, radiator coverand the seat.

1

EAU01476*

Air filterThe air filter should be cleaned at thespecified intervals. It should becleaned more frequently if you areriding in unusually wet or dustyareas.

1. Remove the seat.2. Remove cowling A and B. (See

page 6-7 for cowling removaland installation steps.)

3. Remove the fuel tank bolt.4. Lift the front of the fuel tank

upward and position it away fromthe air filter case. (Do notremove the fuel hoses.)

1. Bolt

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88 Support the fuel tank carefullyduring this procedure.

88 Do not tilt the fuel tank toomuch or pull it too hardbecause the fuel hose connec-tions may become loose caus-ing fuel leakage.

1

2 2

1. Relay ( 2)2. Screw ( 7)

5. Remove the relays and thescrews holding the air filter casecover.

1

1. Air filter

6. Remove the air filter elementfrom its case and clean it withsolvent. After cleaning, removethe remaining solvent by squeez-ing the air filter.

7. Apply recommended oil to theentire surface of the air filter andsqueeze out the excess oil. Theair filter should be wet but notdripping.

8. Install the air filter element in itscase.

9. Reinstall the parts removed foraccess.

Recommended oil:2-stroke engine oil

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88 Make sure the air filter is prop-erly seated in the air filtercase.

88 The engine should never berun without the air filterinstalled. Excessive pistonand/or cylinder wear mayresult.

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Make sure that the fuel hoses andvacuum hose are properly con-nected, in place and not pinched. Ifa hose is damaged, be sure toreplace it.

EAU00629

Carburetor adjustmentThe carburetor is a vital part of theengine and requires very sophisticat-ed adjustment. Most adjustmentsshould be left to a Yamaha dealerwho has the professional knowledgeand experience to do so. However,the following may be serviced by theowner as part of routine mainte-nance.

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The carburetor was set at theYamaha factory after many tests. Ifthe settings are changed, poorengine performance and damagemay result.

b a

1

EAU00632

Idle speed adjustment1. Start the engine and warm it up

for a few minutes at approxi-mately 1,000 to 2,000 r/min.Occasionally rev the engine to4,000 to 5,000 r/min. The engineis warm when it quickly respondsto the throttle.

2. Set the idle to the specifiedengine speed by adjusting thethrottle stop screw. Turn thescrew in direction a to increaseengine speed and in direction bto decrease engine speed.

1. Throttle stop screw

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NOTE:If the specified idle speed cannot beobtained by performing the aboveadjustment, consult a Yamaha deal-er.

Standard idle speed:1,300 ~ 1,500 r/min1,400 ~ 1,500 r/min (A, CH only)

EAU00634

Throttle cable free playadjustmentNOTE:Before checking the throttle cablefree play, the engine idling speedshould be adjusted.

Adjust the throttle cable by turningthe adjusting nut so that specifiedfree play at the throttle grip isobtained.

a. Free play

a

Free play:3 ~ 5 mm

2

1b

a

1. Loosen the locknut.2. Turn the adjusting nut in direc-

tion a to increase free play andin direction b to decrease freeplay.

3. Tighten the locknut.

1. Locknut2. Adjusting nut

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EAU00647

TiresTo ensure maximum performance,long service, and safe operation, notethe following:Tire air pressureAlways check and adjust the tirepressure before operating the motor-cycle.

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Tire inflation pressure should bechecked and adjusted when thetemperature of the tire equals theambient air temperature. Tire infla-tion pressure must be adjustedaccording to total weight of cargo,rider, passenger, and accessories(fairing, saddlebags, etc. ifapproved for this model), and vehi-cle speed.

* Load is the total weight of cargo, rider, passengerand accessories.

Maximum load* 180 kg 179 kg (CH, A)

Cold tire pressure Front Rear175 kPa 200 kPa

Up to 90 kg load* (1.75 kg/cm2, (2.00 kg/cm2,1.75 bar) 2.00 bar)

90 kg load ~ 175 kPa 225 kPa

Maximum load* (1.75 kg/cm2, (2.25 kg/cm2,

1.75 bar) 2.25 bar)

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Proper loading of your motorcycleis important for several character-istics of your motorcycle, such ashandling, braking, performanceand safety. Do not carry looselypacked items that can shift.Securely pack your heaviest itemsclose to the center of the motorcy-cle, and distribute the weight even-ly from side to side. Properlyadjust the suspension for yourload, and check the condition andpressure of your tires. NEVEROVERLOAD YOUR MOTORCYCLE.Make sure the total weight of thecargo, rider, passenger, andaccessories (fairing, saddlebags,etc. if approved for this model)does not exceed the maximumload of the motorcycle. Operationof an overloaded motorcycle couldcause tire damage, an accident, oreven injury.

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Tire inspectionAlways check the tires before operat-ing the motorcycle. If center treaddepth reaches the limit as shown, ifthe tire has a nail or glass fragmentsin it, or if the side wall is cracked,contact a Yamaha dealer immediate-ly and have the tire replaced.

1

2

1. Tread depth2. Side wall

NOTE:These limits may be different by regu-lation from country to country. If so,conform to the limits specified by theregulations of your own country.

Manufacturer Size TypeBRIDGESTONE 100/90-18 56P TW53DUNLOP 100/90-18 56P D602F

FRONT

Manufacturer Size TypeBRIDGESTONE 130/80-17 65P TW54DUNLOP 130/80-17 65P D602

REAR

Minimum tire treaddepth 0.8 mm(front and rear)

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Operating the motorcycle withexcessively worn tires decreaseriding stability and can lead to lossof control. Have excessively worntires replaced by a Yamaha dealerimmediately. Brakes, tires, andrelated wheel parts replacementshould be left to a Yamaha ServiceTechnician.

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EAU00687

WheelsTo ensure maximum performance,long service, and safe operation, notethe following:8 Always inspect the wheels

before a ride. Check for cracks,bends, or warpage of the wheels.If any abnormal condition existsin a wheel, consult a Yamahadealer. Do not attempt evensmall repairs to the wheel. If awheel is deformed or cracked, itmust be replaced.

8 Tires and wheels should be bal-anced whenever either one ischanged or replaced. Failure tohave a wheel balanced canresult in poor performance,adverse handling characteristics,and shortened tire life.

8 Ride at moderate speeds afterchanging a tire since the tire sur-face must first be broken in for itto develop its optimal character-istics.

a

b1 2

3

EAU00694

Clutch lever free playadjustmentThe clutch lever free play should beadjusted to 10 ~ 15 mm.

1. Loosen the locknut at the clutchlever.

2. Turn the adjusting bolt at theclutch lever in directiona toincrease free play or in direction bto decrease free play.

3. Tighten the locknut at the clutchlever.If the specified free play cannotbe obtained, proceed with thefollowing steps.

1. Locknut2. Adjusting bolt3. Free play

b

a

12

4. Loosen the locknut at the clutchlever.

5. Turn the adjusting bolt at theclutch lever in directiona toloosen the cable.

6. Loosen the locknut at thecrankcase side.

7. Turn the adjusting nut at thecrankcase in direction a toincrease free play or in direction bto decrease free play.

8. Tighten the locknut at thecrankcase and the clutch lever.

1. Locknut2. Adjusting nut

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EAU00696

Front brake lever free playadjustmentThe free play at the front brake levershould be 2 ~ 5 mm.

1. Loosen the locknut.2. Turn the adjusting bolt in direc-

tiona to increase free play or indirectionb to decrease free play.

3. After adjusting, tighten the lock-nut.

1. Locknut2. Adjusting bolt3. Free play

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88 Check the brake lever freeplay. Be sure the brake isworking properly.

88 A soft or spongy feeling in thebrake lever can indicate thepresence of air in the brakesystem. This air must beremoved by bleeding the brakesystem before the motorcycleis operated. Air in the systemwill cause greatly diminishedbraking capability and canresult in loss of control and anaccident. Have a Yamahadealer inspect and bleed thesystem if necessary.

a

1

EAU00712

Rear brake pedal heightadjustmentThe top of the brake pedal should bepositioned 23 mm below the top ofthe footrest. If not, ask a Yamahadealer to adjust it.

1. Footresta. Pedal height

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A soft or spongy feeling in thebrake pedal can indicate the pres-ence of air in the brake system.This air must be removed bybleeding the brake system beforethe motorcycle is operated. Air inthe system will cause greatlydiminished braking capability andcan result in loss of control and anaccident. Have a Yamaha dealerinspect and bleed the system ifnecessary.

EAU00713

Brake light switchadjustmentThe rear brake light switch is activat-ed by the brake pedal and is properlyadjusted when the brake light comeson just before braking takes effect.To adjust the rear brake light switch,hold the switch body so it does notrotate while turning the adjusting nut.Turn the adjusting nut in direction ato make the brake light come on earli-er.Turn the adjusting nut in direction bto make the brake light come onlater.

ba

1

2

1. Brake light switch2. Adjusting nut EAU00721

Checking the front and rearbrake pads

EAU00725

Front brakeA wear indicator groove is providedon each brake pad. This indicatorallows checking of brake pad wearwithout disassembling the brake.Inspect the groove. If the groove hasalmost disappeared, ask a Yamahadealer to replace the pads.

1

1. Wear indicator groove

FRONT

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1. Wear limit: 0.8 mm

REAR

EAU00733

Inspecting the brake fluidlevelInsufficient brake fluid may let airenter the brake system, possiblycausing the brakes to become inef-fective.Before riding, check that the brakefluid is above the minimum level andreplenish when necessary.Observe these precautions:8 When checking the fluid level,

make sure the top of the mastercylinder is level by turning thehandlebars.

1

1. Minimum level mark

FRONT

1

1. Minimum level mark

8 Use only the designated qualitybrake fluid. Otherwise, the rub-ber seals may deteriorate, caus-ing leakage and poor brake per-formance.

NOTE:If DOT 4 is not available, DOT 3 canbe used for the front brake only.

REAR

Recommended fluid:DOT 4

EAU00730

Rear brakeInspect the pads through the windowas shown.If the thickness is less than the speci-fied value, have a Yamaha dealerreplace the pads.

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8 Refill with the same type of brakefluid. Mixing fluids may result in aharmful chemical reaction andlead to poor brake performance.

8 Be careful that water does notenter the master cylinder whenrefilling. Water will significantlylower the boiling point of the fluidand may result in vapor lock.

8 Brake fluid may deteriorate paint-ed surfaces or plastic parts.Always clean up spilled fluidimmediately.

8 Have a Yamaha dealer checkthe cause if the brake fluid levelgoes down.

EAU00742

Brake fluid replacementThe brake fluid should be replacedonly by trained Yamaha service per-sonnel. Have the Yamaha dealerreplace the following componentsduring periodic maintenance or whenthey are damaged or leaking:8 oil seals (every two years)8 brake hoses (every four years)

EAU00744

Drive chain slack check

NOTE:Spin the wheel several times and findthe tightest position of the chain.Check and/or adjust the chain slackwhile its in this tightest position.

a

a. Chain slack

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To check the chain slack the motor-cycle must be held straight up withboth wheels on the ground and with-out rider. Check the slack at the posi-tion shown in the illustration. Normalslack is approximately 25 ~ 40 mm. Ifthe slack exceeds 40 mm, adjust.

EAU00762

Drive chain slack adjustment1. Loosen the axle nut.2. Loosen the locknuts on each

side. To tighten the chain, turnthe chain adjusting nuts in direc-tiona. To loosen the chain, turnthe adjusting nuts in directionband push the wheel forward.

3

4

1 2

a

b

1. Locknut2. Adjusting nut3. Axle nut4. Alignment marks

Turn each adjusting nut exactlythe same amount to maintaincorrect axle alignment. There aremarks on each side of theswingarm. Use these marks toalign the rear wheel.

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Too little chain slack will overloadthe engine and other vital parts.Keep the slack within the specifiedlimits.

3. After adjusting, tighten the lock-nuts. Then tighten the axle nut tothe specified torque.

Tightening torque:Axle nut:

104 Nm (10.4 m0kg)

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EAU03006

Drive chain lubricationThe chain consists of many partswhich work with each other. If thechain is not maintained properly, itwill wear out quickly. Therefore, thechain must be serviced regularly.This service is especially necessarywhen riding in dusty areas. Thismotorcycle is equipped with a sealedtype chain. Steam cleaning, high-pressure washers, and solvents candamage the drive chain, so do notuse these for cleaning it. Use onlykerosene to clean the drive chain.Wipe it dry, and thoroughly lubricate itwith SAE 30 ~ 50W motor oil. Do notuse any other lubricants on the drivechain. They may contain solventsthat could damage the sealed chain.

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Be sure to oil the chain after wash-ing the motorcycle or riding in therain.

EAU02962

Cable inspection and lubrication

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Damage to the outer housing ofcables may lead to internal rustingand interfere with the cable move-ment. Replace damaged cables assoon as possible to prevent unsafeconditions.

Lubricate the cables and cable ends.If a cable does not operate smoothly,ask a Yamaha dealer to replace it.

Recommended lubricant:Engine oil

EAU00773

Throttle cable and griplubricationThe throttle twist grip assemblyshould be greased at the time thatthe cable is lubricated, since the gripmust be removed to get at the end ofthe throttle cable. After removing thescrews, hold the end of the cable upin the air and put in several drops oflubricant. With the throttle grip disas-sembled, coat the metal surface ofthe grip assembly with a suitable all-purpose grease.

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EAU00774

Autolube pump adjustmentThe autolube pump is a vital part ofthe engine and requires very sophisti-cated adjustment.Adjusting should be left to a Yamahadealer who has the professionalknowledge and experience to do so.

EAU02984

Brake and shift pedal lubricationLubricate the pivoting parts.


EAU02985

Brake and clutch lever lubricationLubricate the pivoting parts.


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EAU02986

Sidestand lubricationLubricate the sidestand pivoting pointand metal-to-metal contact surfaces.Check that the sidestand moves upand down smoothly.

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If the sidestand does not movesmoothly, consult a Yamaha deal-er.


EAU00791

Rear suspension lubricationLubricate the pivoting parts.

Recommended lubricant:Lithium soap base grease

EAU02939

Front fork inspectionVisual check

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Securely support the motorcycleso there is no danger of it fallingover.

Check for scratches or damage onthe inner tube and excessive oil leak-age from the front fork.

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Operation check1. Place the motorcycle on a level

place.2. Hold the motorcycle in an upright

position and apply the frontbrake.

3. Push down hard on the handle-bars several times and check ifthe fork rebounds smoothly.

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If any damage or unsmooth move-ment is found with the front fork,consult a Yamaha dealer.

EAU00794

Steering inspectionPeriodically inspect the condition ofthe steering. Worn out or loose steer-ing bearings may be dangerous.Place a stand under the engine toraise the front wheel off the ground.Hold the lower end of the front forksand try to move them forward andbackward. If any free play can be felt,ask a Yamaha dealer to inspect andadjust the steering. Inspection is eas-ier if the front wheel is removed.

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Securely support the motorcycleso there is no danger of it fallingover.

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EAU01144

Wheel bearingsIf there is play in the front or rearwheel hub or if the wheel does notturn smoothly, have a Yamaha dealerinspect the wheel bearings.

EAU00800

BatteryThis motorcycle is equipped with asealed-type battery. Therefore it isnot necessary to check the elec-trolyte or fill the battery with distilledwater.88 If the battery seems to have dis-

charged, consult a Yamaha deal-er.

88 If the motorcycle is equippedwith optional electrical acces-sories, the battery tends to dis-charge more quickly, so be sureto recharge it periodically.

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Never try to remove the sealingcaps of the battery cells. The bat-tery will be damaged.

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Battery electrolyte is poisonousand dangerous, causing severeburns, etc. It contains sulfuricacid. Avoid contact with skin, eyesor clothing.ANTIDOTE:88 EXTERNAL: Flush with water.88 INTERNAL: Drink large quanti-

ties of water or milk. Followwith milk of magnesia, beatenegg, or vegetable oil. Call aphysician immediately.

88 EYES: Flush with water for 15minutes and get prompt med-ical attention.

Batteries produce explosivegases. Keep sparks, flame, ciga-rettes etc., away. Ventilate whencharging or using in an enclosedspace. Always shield your eyeswhen working near batteries.KEEP OUT OF REACH OF CHIL-DREN.

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Battery storageWhen the motorcycle is not used fora month or longer, remove the bat-tery, fully charge it and store it in acool, dry place.

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88 Completely recharge the bat-tery before storing. Storing adischarged battery can causepermanent battery damage.

88 Use a battery chargerdesigned for a sealed-type(MF) battery. Using a conven-tional battery charger willcause battery damage. If youdo not have a sealed-type bat-tery charger, contact yourYamaha dealer.

88 Always make sure the connec-tions are correct when rein-stalling the battery.

1

2

EAU00806

Fuse replacementThe fuse box is located under theseat.If the fuse is blown, turn off the mainswitch and the switch of the circuit inquestion. Install a new fuse of speci-fied amperage. Turn on the switchesand see if the electrical device oper-ates. If the fuse immediately blowsagain, consult a Yamaha dealer.

1. Main fuse2. Spare fuse

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Do not use fuses of higher amper-age rating than those recommend-ed. Substitution of a fuse ofimproper rating can cause exten-sive electrical system damage andpossibly a fire.

Specified fuse:20A

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1. Headlight connector2. Bulb holder cover

EAU01079*

Headlight bulb replacementIf the headlight bulb burns out,replace the bulb as follows:

1. Remove cowling A and B. (Seepage 6-7 for removal and instal-lation procedures.)

2. Disconnect the headlight con-nector and remove the bulb hold-er cover.

3. Remove the bulb holder.

NOTE:Removal procedure is differentdepending on the bulb holder type.Remove your bulb holder by referringto the above illustration.

4. Remove the defective bulb.EW000119

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Keep flammable products and yourhands away from a bulb while it ison, as it is hot. Do not touch abulb until it cools down.

Type 1 Type 2

Type 3 Type 4

Turn Unhook

Unhock Turn

5. Put a new bulb into position andsecure it in place with the bulbholder.

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Avoid touching the glass part of abulb. Keep it free from oil; other-wise, the transparency of theglass, life of the bulb, and lumi-nous flux will be adversely affect-ed. If oil gets on a bulb, thoroughlyclean it with a cloth moistenedwith alcohol or lacquer thinner.

6. Install the bulb holder cover.7. Install the headlight connector

and the cowling.If the headlight beam adjustmentis necessary, ask a Yamahadealer to make adjustment.

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EAU01078

Taillight bulb replacement1. Remove the seat.2. Remove panel A. (See page

6-7 for panel removal and instal-lation procedures.)

3. To remove the socket, turn itcounterclockwise.

1. Screw ( 2)2. Panel A

1

4. To remove the defective bulb,turn it counterclockwise.

5. Push a new bulb into the socketand turn it clockwise.

6. Install the socket and turn itclockwise.

7. Install the panel and the seat.

1. Socket

12

EAU01095

Turn signal light bulbreplacement

1. Remove the screw and the lens.2. Remove the defective bulb by

pushing it inward and turning itcounterclockwise.

1. Lens2. Screw

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1. Speedometer cableEAU00894

Front wheel removalEW000122

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88 It is advisable to have aYamaha dealer service thewheel.

88 Securely support the motorcy-cle so there is no danger of itfalling over.

1. Remove the speedometer cablefrom the front wheel side.

21

1. Pinch bolt2. Wheel axle

2. Loosen the pinch bolt and wheelaxle.

3. Elevate the front wheel by plac-ing a suitable stand under theengine.

4. Remove the wheel axle and thefront wheel.

NOTE:Do not depress the brake lever whenthe disc and caliper are separated.

1

1. Bulb

3. Install a new bulb by pushing itinward and turning it clockwise.

4. Install the lens and tighten thescrew.

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3. Install the wheel axle and let themotorcycle down.

4. Push down hard on the handle-bars several times to check forproper fork operation.

5. Tighten the wheel axle to thespecified torque.

6. Install the pinch bolt and tightenit to the specified torque.

7. Install the speedometer cable.

Tightening torque:Wheel axle:

59 Nm (5.9 m0kg)Pinch bolt:

20 Nm (2.0 m0kg)

31 2

EAU01618

Rear wheel removalEW000122

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88 It is advisable to have aYamaha dealer service thewheel.

88 Securely support the motorcy-cle so there is no danger of itfalling over.

1. Loosen the axle nut.

1. Locknut2. Adjusting nut3. Axle nutEAU01394Front wheel installation

1. Install the speedometer gear unitinto the wheel hub. Make surethe wheel hub and thespeedometer gear unit areinstalled with the projectionsmeshed into the slots.

2. Lift up the wheel between thefront fork legs and guide thebrake disc between the brakepads. Make sure the slot in thespeedometer gear unit fits overthe stopper on the front forkouter tube.

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2. Elevate the rear wheel by placinga suitable stand under theengine.

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. While supporting the brake

caliper, pull out the wheel axle.7. Remove the wheel assembly.

NOTE:8 Do not depress the brake pedal

when the disc and caliper areseparated.

8 You do not have to disassemblethe chain in order to remove orinstall the rear wheel.

EAU01620

Rear wheel installation1. Install the rear brake caliper.

Make sure the slot in the caliperbracket is fit over the stopper onthe swingarm.

2. Install the rear wheel and chain.Guide the brake disc betweenthe brake pads. Make sure thereis enough gap between thebrake pads before inserting thebrake disc.

3. Install the wheel axle and axlenut, and let the motorcycle down.

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4. Adjust the drive chain. (See page6-24 for adjusting the drive chainslack.)

5. Tighten the axle nut to the speci-fied torque.

Tightening torque:Axle nut:

104 Nm (10.4 m0kg)

EAU01008

TroubleshootingAlthough Yamaha motorcyclesreceive a rigid inspection before ship-ment from the factory, trouble mayoccur during operation.Any problem in the fuel, compres-sion, or ignition systems can causepoor starting and loss of power. Thetroubleshooting chart describes aquick, easy procedure for makingchecks.If your motorcycle requires anyrepair, bring it to a Yamaha dealer.The skilled technicians at a Yamahadealership have the tools, experi-ence, and know-how to properly ser-vice your motorcycle. Use only gen-uine Yamaha parts on yourmotorcycle. Imitation parts may looklike Yamaha parts, but they are ofteninferior. Consequently, they have ashorter service life and can lead toexpensive repair bills.

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EAU01581

Troubleshooting chartEW000125

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Never check the fuel system while smoking or in the vicinity of an open flame.

1. Fuel

2. Compression

3. Ignition

4. Battery

Use electric starter.

Remove spark

There is compression. Go to ignition check.

No compression. Ask a Yamaha dealer to inspect.

Wet.

Dry.

Wipe clean with dry cloth and correct Open throttle half-way and start

Ask a Yamaha dealer to inspect.

Check if there is fuel

Enough fuel.

No fuel.

Go to compression check.

Supply fuel.

in the fuel tank.

electrodes.plug and check

Engine doesnt start, go to batterycheck.

the engine.spark gap or replace spark plug.

Engine turns over

Engine turns over

Battery good.

Check connections or

quickly.

slowly. recharge.

Engine doesnt start, ask aYamaha dealer to inspect.

Engine doesnt start, go to compression check.

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5. Engine overheating

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Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may beblown out under pressure, which could cause serious injury. Open the radiator cap as follows. Wait until theengine has cooled. R

u5aee3 yamaha tdr 125

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