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

(Magenta plate)

OWNERS MANUAL

TDR125

5AE-28199-E3
siro page 4/6/0 3:58 AM Page 1
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 1

INTRODUCTION

EAU00001
Welcome to the Yamaha world of motorcycling! As the owner of a TDR125, you are benefiting from Yamahas vast experience in and newest technology for the design and the manufacture of high-quality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all your TDR125s advantages. The owners manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself and others from trouble and injury. In addition, the many tips given in this manual will help to 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-E3 (ENG) 4/11/0 11:06 AM Page 2

EAU00005

IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations: 9
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.
NOTE: 8 This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. 8 Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual. If there is any question concerning this manual, please consult your Yamaha dealer.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 3

EW000002

PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 4

EAU00008

TDR125 OWNERS MANUAL 1999 by Yamaha Motor Co., Ltd. 1st Edition, August 1999 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 5

EAU00009

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
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 6
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 7

GIVE SAFETY THE RIGHT OF

GIVE SAFETY THE RIGHT OF WAY..1-1 1
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 8
Q GIVE SAFETY THE RIGHT OF WAY

EAU00021

Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. However, they also impose certain limits, which you must accept; even the best motorcycle does not ignore the laws of physics. Regular care and maintenance are essential for preserving your motorcycles value and operating condition. Moreover, what is true for the motorcycle is also true for the rider: good performance depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of course, out of the question. Motorcycle riders more than car drivers must always be at their mental and physical best. Under the influence of even small amounts of alcohol, there is a tendency to take dangerous risks. Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passengers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant synthetic materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet. Optimum protective wear, however, should not encourage carelessness. 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 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-E3 (ENG) 4/11/0 11:06 AM Page 19

EAU00136

Headlight beam variation

Left 1 Right

3 : High beam light on , ' : Auxiliary light on Bulb to be used Halogen bulb Halogen bulb

12V 60/55W 12V 60/55W

2 : Low beam light on Destination 9

& %

France Sweden Portugal Spain Greece Belgium Germany Switzerland Finland Austria England Ireland

12V 35/35W

NOTE: Right and left directions are those assumed from the position of a person facing the front of the motorcycle.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 20

EAU00143

, Start switch , The starter motor cranks the engine when pushing the start switch.
1. Engine stop switch 2. Start switch ,

EAU00138

EC000005
See starting instructions prior to starting the engine.
Engine stop switch The engine stop switch is a safety device for use in an emergency such as when the motorcycle overturns or if trouble occurs in the throttle system. Turn the switch to # to start the engine. In case of emergency, turn the switch to $ to stop the engine.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 21

1. Clutch lever

EAU00152
1. Shift pedal N. Neutral

EAU00157

1. Front brake lever

EAU00158

Clutch lever
The clutch lever is located on the left handlebar, and the ignition circuit cutoff system is incorporated in the clutch lever holder. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth clutch operation. (Refer to the engine starting procedures for a description of the ignition circuit cutoff system.)

Shift pedal

This motorcycle is equipped with a constant-mesh 6-speed transmission. The shift pedal is located on the left side of the engine and is used in combination with the clutch when shifting.

Front brake lever

The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 22
1 NOTE: This tank cap cannot be closed unless the key is in the lock. The key cannot be removed if the cap is not locked properly.

1. Rear brake pedal

EAU00162

1. Open 2. Unlock

EAU02935

EW000023

Rear brake pedal
The rear brake pedal is on the right side of the motorcycle. Press down on the brake pedal to apply the rear brake.

Fuel tank cap

To open Open the lock cover. Insert the key and turn it 1/4 turn clockwise. The lock will be released and the cap can be opened. To close Push the tank cap into position with the key inserted. To remove the key, turn it counterclockwise to the original position. Then, close the lock cover.

Be sure the cap is properly installed and locked in place before riding the motorcycle.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 23

EW000130

Do not overfill the fuel tank. Avoid spilling fuel on the hot engine. Do not fill the fuel tank above the bottom of the filler tube or it may overflow when the fuel heats up later and expands.
1. Filler tube 2. Filling nozzle 3. Fuel level

EAU01183

Filler tube Filling nozzle Leaf valve Fuel level

EAU01184*

EAU00185
(except for Switzerland and Austria) Make sure there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown in the illustration.
(for Switzerland and Austria) Make sure there is sufficient fuel in the tank. When refueling, be sure to insert the filling nozzle into the filler hole and fill the tank to the bottom of the filler tube as shown in the illustration.
Always wipe off spilled fuel immediately with a dry and clean soft cloth. Fuel may deteriorate painted surfaces or plastic parts.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 24

EAU00191 EAU01084

Recommended fuel: Regular unleaded gasoline with a research octane number of 91 or higher. Fuel tank capacity: Total: 11.0 L Reserve: 2.2 L NOTE: If knocking or pinging occurs, use a different brand of gasoline or higher octane grade.

Catalyzer

(for Switzerland and Austria) This motorcycle is equipped with a catalytic converter in the exhaust chamber.

EC000114

EW000128
The exhaust system is hot during and directly after engine operation. Make sure the exhaust system has cooled down before making any adjustment to or lubricating the motorcycle.
The following must be observed to prevent a fire hazard or other damages. 8 Use only unleaded gasoline. Use of leaded gasoline will cause unrepairable damage to the catalytic converter. 8 Never park this motorcycle in an area that would cause a fire hazard such as grass or other materials that may easily burn. 8 Do not allow the engine to idle for very long.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 25
1 OFF: closed position ON: normal position

1. Filler cap

EAU02956
1. Arrow mark pointing to OFF

EAU03050

1. Arrow mark pointing to ON

Two-stroke engine oil

Make sure the two-stroke engine oil is at the specified level. Fill with oil as necessary. Recommended oil: Yamalube 2 or 2-stroke engine oil (JASO FC grade or ISO EG-C, EG-D grade) Oil quantity: 1.2 L

5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 28

EAU00315

1. Position indicator
Hard Adjusting Position 5 Standard 4 Soft 1
This shock absorber contains highly pressurized nitrogen gas. Read and understand the following information before handling the shock absorber. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling. 8 Do not tamper with or attempt to open the cylinder assembly. 8 Do not subject the shock absorber to an open flame or other high heat source. This may cause the unit to explode due to excessive gas pressure. 8 Do not deform or damage the cylinder in any way. Cylinder damage will result in poor damping performance. 8 Take your shock absorber to a Yamaha dealer for any service.

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

EAU00325
Note on handling of the Yamaha Energy Induction System (Y.E.I.S.)
Handle the air chamber and hose with special care. Improper installation or damaged parts will result in poor performance. Replace any cracked or damaged parts immediately. No modification of this system in any form can be made.

EC000022

Never attempt to modify the Yamaha Energy Induction System.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 29

EAU00326

Y.P.V.S. (Yamaha Power Valve System)
The Y.P.V.S. is a vital part of the engine and requires very sophisticated adjustment. Adjustment should be left to a Yamaha dealer who has the professional knowledge and experience to do so.

EC000024

EAU00330

Sidestand

This model is equipped with an ignition circuit cut-off system. The motorcycle must not be ridden when the sidestand is down. The sidestand is located on the left side of the frame. (Refer to page 5-1 for an explanation of this system.) 9
If the Y.P.V.S. does not operate, ask a Yamaha dealer to inspect the vehicle.

EC000023

The Y.P.V.S. was set at the Yamaha factory after many tests. If the settings are disturbed by someone without sufficient technical knowledge, poor engine performance and damage may result. The Y.P.V.S. operation can be heard in 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.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 30

EW000044 EAU00331

Rear brake Clutch Throttle grip and housing Engine oil
3-8, 6-20 ~ 6-21 6-17 ~ 6-18, 6-27 3-12 6-9 ~ 6-10 6-10 ~ 6-11 6-25 ~ 6-26 6-18 ~ 6-20 6-27
Transmission oil Coolant Drive chain Wheels and tires Control and meter cable
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 33
ITEM 9 Brake and shift pedal shafts Brake and clutch lever pivots Sidestand pivot Chassis fasteners Fuel tank 9 Lights, signals and 9 switches CHECKS Check for smooth operation. Lubricate if necessary. Check for smooth operation. Lubricate if necessary. Check for smooth operation. Lubricate if necessary. Make sure that all nuts, bolts, and screws are properly tightened. Tighten if necessary. Check fuel level. Fill with fuel if necessary. Check for proper operation. PAGE
6-28 3-9 ~ 3-10 6-32 ~ 6-34
NOTE: Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very short time; and the added safety it assures is more than worth the time involved.
If any item in the Pre-Operation Check is not working properly, have it inspected and repaired before operating the motorcycle.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 34
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 35
OPERATION AND IMPORTANT RIDING POINTS
Starting the engine....5-1 Starting a warm engine...5-4 Shifting...5-4 Recommended shift points (for Switzerland only)..5-5 Tips for reducing fuel consumption...5-5 Engine break-in....5-5 Parking....5-6
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 36

EAU00373 EAU00381

EAU00372

Starting the engine

NOTE: This motorcycle is equipped with an ignition circuit cut-off system. The engine can be started only under the following conditions: 8 The transmission is in neutral. 8 The sidestand is up, the transmission is in gear and the clutch is disengaged The motorcycle must not be ridden when the sidestand is down.
8 Before riding this motorcycle, become thoroughly familiar with all operating controls and their functions. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. 8 Never start your engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and can cause loss of consciousness and death within a short time. Always operate your motorcycle in an area with adequate ventilation. 8 Before starting out, always be sure the sidestand is up. Failure to retract the sidestand completely can result in a serious accident when you try to turn a corner.

Drive chain

Every 1,000 km and after washing the motorcycle or riding in the rain

12 * Steering bearings

13 * Chassis fasteners 14 Sidestand
15 * Sidestand switch 16 * Front fork 17 * Rear shock absorber assembly
Rear shock absorber 18 * assembly pivoting points 19 * Carburetor
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 48

20 * Autolube pump

9 Check operation. 9 Correct if necessary. 9 Bleed if necessary. 9 Check oil level and vehicle for oil leakage. 9 Correct accordingly. 9 Change oil at initial 1,000 km and thereafter every 24,000 km or 24 months (whichever comes first). 9 Check coolant level and vehicle for coolant leakage. 9 Correct if necessary. 9 Change coolant every 24,000 km or 24 months (whichever comes first).

Transmission oil

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

EAU02970

NOTE 8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 8 Hydraulic brake system 9 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.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 49

1. Cowling A

EAU01139

1. Cowling B

1. Panel A
Cowling and panel removal and installation
The cowlings and panels illustrated need to be removed to perform some of the maintenance described in this chapter. Refer to this section each time a cowling or panel has to be removed or reinstalled.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 50
1. Radiator cover 2. Screw (2)

EAU01088

1. Screw (10)

Cowling A, B

To remove 1. Remove the seat. 2. Remove the radiator cover screws and the radiator cover.
3. Remove the screws and pull outward on the areas shown. To install 1. Place the cowling in the original position and install the screws. 2. Place the radiator cover in the original position and install the screws. 3. Install the seat.

1. Screw (2) 2. Panel A

EAU01691

Panel A

To remove 1. Remove the seat. (See page 3-13 for removal and installation procedures.) 2. Remove the screw. To install 1. Place the panel in the original position and install the screw. 2. Install the seat.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 51
When installing the plug, the gasket surface should always be cleaned and a new gasket used. Any grime should be wiped off from the threads and the spark plug tightened to the specified torque. Tightening torque: Spark plug: 20 Nm (2.0 m0kg) NOTE: If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight. The spark plug should be tightened to the specified torque as soon as possible.

13. Fill the reservoir tank with coolant up to specified level. 14. Install the reservoir tank cap and check for coolant leakage. NOTE: If any leakage is found, ask a Yamaha dealer to inspect the cooling sytem. 15. Install the cowling, radiator cover and the seat.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 57

EW000071

8 Support the fuel tank carefully during this procedure. 8 Do not tilt the fuel tank too much or pull it too hard because the fuel hose connections may become loose causing fuel leakage.
1. Relay (2) 2. Screw (7) 1. Air filter
5. Remove the relays and the screws holding the air filter case cover.
6. Remove the air filter element from its case and clean it with solvent. After cleaning, remove the remaining solvent by squeezing the air filter. 7. Apply recommended oil to the entire surface of the air filter and squeeze out the excess oil. The air filter should be wet but not dripping. Recommended oil: 2-stroke engine oil 8. Install the air filter element in its case. 9. Reinstall the parts removed for access.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 58

EC000082 EAU00629

Carburetor adjustment
The carburetor is a vital part of the engine and requires very sophisticated adjustment. Most adjustments should be left to a Yamaha dealer who has the professional knowledge and experience to do so. However, the following may be serviced by the owner as part of routine maintenance.
8 Make sure the air filter is properly seated in the air filter case. 8 The engine should never be run without the air filter installed. Excessive piston and/or cylinder wear may result.

1. Throttle stop screw

EAU00632

EW000131

EC000094

Idle speed adjustment

1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle. 2. Set the idle to the specified engine speed by adjusting the throttle stop screw. Turn the screw in direction a to increase engine speed and in direction b to decrease engine speed.
Make sure that the fuel hoses and vacuum hose are properly connected, in place and not pinched. If a hose is damaged, be sure to replace it.
The carburetor was set at the Yamaha factory after many tests. If the settings are changed, poor engine performance and damage may result.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 59
Standard idle speed: 1,300 ~ 1,500 r/min 1,400 ~ 1,500 r/min (A, CH only) NOTE: If the specified idle speed cannot be obtained by performing the above adjustment, consult a Yamaha dealer.

a. Free play

EAU00634
1. Locknut 2. Adjusting nut
Throttle cable free play adjustment
NOTE: Before checking the throttle cable free play, the engine idling speed should be adjusted. Adjust the throttle cable by turning the adjusting nut so that specified free play at the throttle grip is obtained. Free play: 3 ~ 5 mm

1. Loosen the locknut. 2. Turn the adjusting nut in direction a to increase free play and in direction b to decrease free play. 3. Tighten the locknut.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 60

EAU00647

9 To ensure maximum performance, long service, and safe operation, note the following: Tire air pressure Always check and adjust the tire pressure before operating the motorcycle.
Maximum load* Cold tire pressure Up to 90 kg load* Front
180 kg 179 kg (CH, A) Rear 175 kPa 200 kPa (1.75 kg/cm2, (2.00 kg/cm2, 1.75 bar) 2.00 bar) 175 kPa 225 kPa (1.75 kg/cm2, (2.25 kg/cm2, 1.75 bar) 2.25 bar)

EW000083

90 kg load ~ Maximum load*

EW000082

* Load is the total weight of cargo, rider, passenger and accessories.
Tire inflation pressure should be checked and adjusted when the temperature of the tire equals the ambient air temperature. Tire inflation pressure must be adjusted according to total weight of cargo, rider, passenger, and accessories (fairing, saddlebags, etc. if approved for this model), and vehicle speed.
Proper loading of your motorcycle is important for several characteristics of your motorcycle, such as handling, braking, performance and safety. Do not carry loosely packed items that can shift. Securely pack your heaviest items close to the center of the motorcycle, and distribute the weight evenly from side to side. Properly adjust the suspension for your load, and check the condition and pressure of your tires. NEVER OVERLOAD YOUR MOTORCYCLE. Make sure the total weight of the cargo, rider, passenger, and accessories (fairing, saddlebags, etc. if approved for this model) does not exceed the maximum load of the motorcycle. Operation of an overloaded motorcycle could cause tire damage, an accident, or even injury.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 61
Manufacturer BRIDGESTONE DUNLOP
Size 100/90-18 56P 100/90-18 56P

Type TW53 D602F

EAU00683
REAR Manufacturer BRIDGESTONE DUNLOP Size 130/80-17 65P 130/80-17 65P Type TW54 D602
1. Tread depth 2. Side wall
Minimum tire tread depth (front and rear)

0.8 mm

Operating the motorcycle with excessively worn tires decrease riding stability and can lead to loss of control. Have excessively worn tires replaced by a Yamaha dealer immediately. Brakes, tires, and related wheel parts replacement should be left to a Yamaha Service Technician.
Tire inspection Always check the tires before operating the motorcycle. If center tread depth reaches the limit as shown, if the tire has a nail or glass fragments in it, or if the side wall is cracked, contact a Yamaha dealer immediately and have the tire replaced.

Rear brake pedal height adjustment
The top of the brake pedal should be positioned 23 mm below the top of the footrest. If not, ask a Yamaha dealer to adjust it.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 64

EW000109

A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. This air must be removed by bleeding the brake system before the motorcycle is operated. Air in the system will cause greatly diminished braking capability and can result in loss of control and an accident. Have a Yamaha dealer inspect and bleed the system if necessary.
1. Brake light switch 2. Adjusting nut

EAU00713

1. Wear indicator groove

EAU00721

Brake light switch adjustment
The rear brake light switch is activated by the brake pedal and is properly adjusted when the brake light comes on just before braking takes effect. To adjust the rear brake light switch, hold the switch body so it does not rotate while turning the adjusting nut. Turn the adjusting nut in direction a to make the brake light come on earlier. Turn the adjusting nut in direction b to make the brake light come on later.
Checking the front and rear brake pads

EAU00725

Front brake A wear indicator groove is provided on each brake pad. This indicator allows checking of brake pad wear without disassembling the brake. Inspect the groove. If the groove has almost disappeared, ask a Yamaha dealer to replace the pads.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 65

REAR FRONT REAR

1. Wear limit: 0.8 mm

EAU00730

1. Minimum level mark

EAU00733

Rear brake Inspect the pads through the window as shown. If the thickness is less than the specified value, have a Yamaha dealer replace the pads.
Inspecting the brake fluid level
Insufficient brake fluid may let air enter the brake system, possibly causing the brakes to become ineffective. Before riding, check that the brake fluid is above the minimum level and replenish when necessary. Observe these precautions: 8 When checking the fluid level, make sure the top of the master cylinder is level by turning the handlebars.

EAU03006 EAU02962 EAU00773

Drive chain lubrication

9 The chain consists of many parts which work with each other. If the chain is not maintained properly, it will wear out quickly. Therefore, the chain must be serviced regularly. This service is especially necessary when riding in dusty areas. This motorcycle is equipped with a sealed type chain. Steam cleaning, highpressure washers, and solvents can damage the drive chain, so do not use these for cleaning it. Use only kerosene to clean the drive chain. Wipe it dry, and thoroughly lubricate it with SAE 30 ~ 50W motor oil. Do not use any other lubricants on the drive chain. They may contain solvents that could damage the sealed chain.
Cable inspection and lubrication
Throttle cable and grip lubrication

EW000112

Damage to the outer housing of cables may lead to internal rusting and interfere with the cable movement. Replace damaged cables as soon as possible to prevent unsafe conditions. Lubricate the cables and cable ends. If a cable does not operate smoothly, ask a Yamaha dealer to replace it. Recommended lubricant: Engine oil
The throttle twist grip assembly should be greased at the time that the cable is lubricated, since the grip must be removed to get at the end of the throttle cable. After removing the screws, hold the end of the cable up in the air and put in several drops of lubricant. With the throttle grip disassembled, coat the metal surface of the grip assembly with a suitable allpurpose grease.

EC000097

Be sure to oil the chain after washing the motorcycle or riding in the rain.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 69
EAU00774 EAU02984 EAU02985

Autolube pump adjustment

The autolube pump is a vital part of the engine and requires very sophisticated adjustment. Adjusting should be left to a Yamaha dealer who has the professional knowledge and experience to do so.
Brake and shift pedal lubrication
Lubricate the pivoting parts. Recommended lubricant: Engine oil
Brake and clutch lever lubrication
Lubricate the pivoting parts. Recommended lubricant: Engine oil 9
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 70

EAU02986 EAU00791

Sidestand lubrication
9 Lubricate the sidestand pivoting point and metal-to-metal contact surfaces. Check that the sidestand moves up and down smoothly. Recommended lubricant: Engine oil
Rear suspension lubrication
Lubricate the pivoting parts. Recommended lubricant: Lithium soap base grease

EW000113 EAU02939

If the sidestand does not move smoothly, consult a Yamaha dealer.

Front fork inspection

Visual check

EW000115

Securely support the motorcycle so there is no danger of it falling over. Check for scratches or damage on the inner tube and excessive oil leakage from the front fork.

5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 71
Operation check 1. Place the motorcycle on a level place. 2. Hold the motorcycle in an upright position and apply the front brake. 3. Push down hard on the handlebars several times and check if the fork rebounds smoothly.
Securely support the motorcycle so there is no danger of it falling over.

EC000098 EAU00794

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

Steering inspection

Periodically inspect the condition of the steering. Worn out or loose steering bearings may be dangerous. Place a stand under the engine to raise the front wheel off the ground. Hold the lower end of the front forks and try to move them forward and backward. If any free play can be felt, ask a Yamaha dealer to inspect and adjust the steering. Inspection is easier if the front wheel is removed.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 72

EAU01144 EAU00800

Wheel bearings
9 If there is play in the front or rear wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer inspect the wheel bearings.

Battery

This motorcycle is equipped with a sealed-type battery. Therefore it is not necessary to check the electrolyte or fill the battery with distilled water. 8 If the battery seems to have discharged, consult a Yamaha dealer. 8 If the motorcycle is equipped with optional electrical accessories, the battery tends to discharge more quickly, so be sure to recharge it periodically.

EW000116

EC000101
Never try to remove the sealing caps of the battery cells. The battery will be damaged.
Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid contact with skin, eyes or clothing. ANTIDOTE: 8 EXTERNAL: Flush with water. 8 INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call a physician immediately. 8 EYES: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes etc., away. Ventilate when charging or using in an enclosed space. Always shield your eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 73
Battery storage When the motorcycle is not used for a month or longer, remove the battery, fully charge it and store it in a cool, dry place.

EC000103

1. Main fuse 2. Spare fuse

EAU00806

EC000102
8 Completely recharge the battery before storing. Storing a discharged battery can cause permanent battery damage. 8 Use a battery charger designed for a sealed-type (MF) battery. Using a conventional battery charger will cause battery damage. If you do not have a sealed-type battery charger, contact your Yamaha dealer. 8 Always make sure the connections are correct when reinstalling the battery.
Do not use fuses of higher amperage rating than those recommended. Substitution of a fuse of improper rating can cause extensive electrical system damage and possibly a fire. Specified fuse: 20A

Fuse replacement

The fuse box is located under the seat. If the fuse is blown, turn off the main switch and the switch of the circuit in question. Install a new fuse of specified amperage. Turn on the switches and see if the electrical device operates. If the fuse immediately blows again, consult a Yamaha dealer.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 74

Type 1

Type 2
5. Put a new bulb into position and secure it in place with the bulb holder.

Unhook

Turn Type 3 Type 4

EC000105

1. Headlight connector 2. Bulb holder cover

EAU01079*

Unhock
Headlight bulb replacement
If the headlight bulb burns out, replace the bulb as follows: 1. Remove cowling A and B. (See page 6-7 for removal and installation procedures.) 2. Disconnect the headlight connector and remove the bulb holder cover. 3. Remove the bulb holder.
NOTE: Removal procedure is different depending on the bulb holder type. Remove your bulb holder by referring to the above illustration. 4. Remove the defective bulb.
Avoid touching the glass part of a bulb. Keep it free from oil; otherwise, the transparency of the glass, life of the bulb, and luminous flux will be adversely affected. If oil gets on a bulb, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 6. Install the bulb holder cover. 7. Install the headlight connector and the cowling. If the headlight beam adjustment is necessary, ask a Yamaha dealer to make adjustment.

EW000119

Keep flammable products and your hands away from a bulb while it is on, as it is hot. Do not touch a bulb until it cools down.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 75

EAU01078

1. Socket
Taillight bulb replacement
1. Remove the seat. 2. Remove panel A. (See page 6-7 for panel removal and installation procedures.) 3. To remove the socket, turn it counterclockwise.
4. To remove the defective bulb, turn it counterclockwise. 5. Push a new bulb into the socket and turn it clockwise. 6. Install the socket and turn it clockwise. 7. Install the panel and the seat.

1. Lens 2. Screw

EAU01095
Turn signal light bulb replacement

5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 85
8 Improper cleaning can damage windshields, cowlings, panels and other plastic parts. Use only a soft, clean cloth or sponge with mild detergent and water to clean plastic. 8 Do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte. 8 Do not use high-pressure washers or steam-jet cleaners since they cause water seepage and deterioration in the following areas: seals (of wheel bearings, swingarm bearings, forks and brakes), electric components (couplers, connectors, instruments, switches and lights), breather hoses and vents. 8 For motorcycles equipped with a windshield: Do not use strong cleaners or hard sponges as they will cause dulling or scratching. Some cleaning compounds for plastic may leave scratches on the windshield. Test the product on a small hidden part of the windshield to make sure they do not leave any marks. If the windshield is scratched, use a quality plastic polishing compound after washing. After riding in the rain, near the sea or on salt-sprayed roads Since sea salt or salt sprayed on the roads in the winter are extremely corrosive in combination with water, carry out the following steps after each ride in the rain, near the sea or on salt-sprayed roads. (Salt sprayed in the winter may remain on the roads well into spring.) 1. Clean your motorcycle with cold water and soap after the engine has cooled down.

ECA00012

Do not use warm water since it increases the corrosive action of the salt. 2. Be sure to apply a corrosion protection spray on all (even chrome- and nickel-plated) metal surfaces to prevent corrosion.
5AE-9-E3 (ENG) 4/11/0 11:06 AM Page 86
After cleaning 1. Dry the motorcycle with a chamois or an absorbing cloth. 2. Immediately dry the drive chain and lubricate it to prevent it from rusting. 3. Use a chrome polish to shine chrome, aluminum and stainlesssteel parts, including the exhaust system. (Even the thermally induced discoloring of stainlesssteel exhaust systems can be removed through polishing.) 4. To prevent corrosion, it is recommended to apply a corrosion protection spray on all (even chrome- and nickel-plated) metal surfaces. 5. Use spray oil as a universal cleaner to remove any remaining dirt. 6. Touch up minor paint damage caused by stones, etc. 7. Wax all painted surfaces. 8. Let the motorcycle dry completely before storing it or covering it.

EWA00001

Make sure that there is no oil or wax on the brakes and tires. If necessary, clean the brake discs and linings with a regular brake disc cleaner or acetone, and wash the tires with warm water and mild soap. Then, carefully test the motorcycle for its braking performance and cornering behavior.
NOTE: Consult a Yamaha dealer for advice on what products to use.

4CU3 4EE1 4EE3 4EF1 4EF2 4EF3 4FW1 4FW2 4FW3 4FX1 4HU1 4KR1 4EE5 4EF4 4FW4 4FW5 4FX2 4HU2 4KR2 4FW6 4FW7 4LN3 4LN4 4SY1 5EU8 5JB2 5LD4 5EU9 5JB3 5LD5 4SY1

4CU7 4EF5

3WG-E4451-00 4CU5 4FW7 4LN3 5EU2 5FV2 5FV4 5JB7 5EU7 5JB3 5EU3 5FW1 5JB4 5PF1
5EU4 5EU5 5FW2 5JB1 5JB5 5LD3 5PF2
5EU-E4451-00 5KG1 5LD1 5LD6 5LD2

5EU-E4451-10

2000 5JB5JB5PF2002 5UB3 5UB6 4KH1 4KH3 4MV3 5AD1 5BX1 5AD1 5BV2 5ADC 5ADP 5BW2 5BV5 5BV7 5MRC 5RN1 5RNC 1P91 1P97 5RNE 5BR1 5DR2 5BS2 5HE1 5HEE 5KL1 5HEG 5HEX 5LC5 5KH9 5PE5 5SB2 5SB6 3C61 5CN1 5HEA 5HEK 5PU1 5BR3 5PEB
5JB5 5JB7 5PF4 5UB4 5UB7 4KH2 4KH4 4MV4 5AD2 5BX2 5AD2 5BW1 5ADD 5ADR 5BW3 5BV6 5BV8

YM50 YM50 YN50

Breeze Breeze Neo's
4MV1 4RC1 4RH1 5AD3 5AD3 5BX1 5ADE 5ADS 5BX3 5MR2 5MR3
4MV2 4RC2 4RH2 4RJ2 4RJ1 4SY2 5AD4 5AD5 5AD6 5AD7 5AD8 5BV1 5AD4 5BX2 5ADF 5ADT 5BX4
3KJ-14451-00 3WG-E4451-00 5BW1 3WG-E4451-00

2,89 2,80 2,80

5AD5 5AD6 5AD7 5AD8 5ADA 5ADB 5BV1 5ADG 5ADH 5ADJ 5ADK 5ADL 5ADM 5ADN 5ADU 5ADV 5ADW 5ADX 5ADY 5BV3 5BV4 5BX5 5BX6
5MR4 5MR5 5MR6 5MR7 5MR8 5MR9 5MRA 5MRB
5RN2 5RN3 5RN4 5RN5 5RN6 5RN7 5RN8 5RN9 5RNA 5RNB 5RND 1P92 1P98 5RNF 5BR2 5BS4 5HE2 5HEF 5KL3 5HEH 5HEY 5LC6 5KHA 5PE6 5SB7

YN50 YQ50

Neo's Alpinstar Aerox
5RNG 5RNH 5BS1 5BS2 5CK1 5CL3 5HE3 5HER 5LC1 5HEJ 5KF5 5LC7 5KL4 5PU3 5SB8 5CL4 5HE4 5KF1 5LC2 5HEL 5KF6 5LC8 5PE1 5PU4 5SB9 5DN3 5HE5 5KF2 5LC3 5HEM 5KF7 5PE2 5PEA
5CL1 5DN4 5HE6 5KF3 5LC4 5HEN 5KF8

5CL2 5DP2 5HE7 5KF4

5DN1 5DN2 5DP1
3WG-E4451-00 3WG-E4451-00

2,80 2,80

5DR3 5DR4 5FF1 5FF2 5HE8 5HE9 5HEC 5HED 5KH1 5KH2 5KH5 5KH6
5HEP 5HES 5HET 5HEU 5HEV 5KH3 5KH4 5KH7 5KH8 5KL2

5PU1 5PU2 5PUC 5KFE

YQ50 YQ50L

Aerox F1A Aerox Tech 3

5CN2 5HEB 5HEW 5PU2 5BR4 5BS3

5CN-E4451-00

YQ50L YQ50L DT80LC
Aerox Toyota Aerox Racing Replica
TZR80 TZR80E TZR80RR YE80 YE80 YZ80 YZ80

Zest Zest

YZ80E YZ80F YZ80LC YZ80LW
5WJ3 5SB8 3WC1 3JX2 4ED1 4BC3 4BC4 4BC5 4BC6 4BC7 4BC8 4BC9 4BCA 4BCB 4BCC 4BCD 4BCE 4BCF 4BCG 3YG1 4BA2 4BA1 4BA3 4JC1 4JC3 4JC3 3ML2 3ML3 4GT1 4GT3 4GT5 4GT7 4GT9 4ES7 4ES8 4ES9 4ESA 4ES1 4ES3 3ML4 4LB1 4LB3 4LB5 4LB7 4LB9
3WG-E4451-00 3WG-E4451-01 34X-14451-00

2,80 2,80 13,90

4ED2 21W-14451-00 2,17
4BC-14451-00 4BC-14451-00 2RH-14451-00 2RH-14451-00 2RH-14451-00 3KJ-14451-00 3WG-E4451-00 2HF-14451-00 4ES-14451-00
1,90 1,90 5,72 5,72 5,72 2,89 2,80 16,17 18,75

4JC2 4JC4 4JC4

4MU1 4MU2 4MU3 4RG1 4MU4

4GTB 4GTD

4LC1 4LC2 4LC3 4LC4 4LC5
4ES-14451-00 4ES-14451-00 2HF-14451-00 4ES-14451-00

18,75 18,75 16,17 18,75

YZ85 YZ85 / YZ85LW
TTR90 / TTR90E YA90 YA90 Axis Axis Neo's 100 Aerox 100 BWs 100

100 YNYQYW100

125 DTDT125E

125 DT125MX 125 DT125R

4LBB 4LC7 4LC8 5PA1 5PA4 5SH7 5PAA 5PAD 5HN3 5HN6 5HN9 5HNC 5HNJ 5HNW 3VR3 4CY1 4CY6 5KK1 5KK9 5ME1 5ME4 4VP5 4VPB 5ME2 4VPR 3TT2 4BL1 4BL2 4BL3 4BL4 4BL5 4BL6 3YV1 3NC2 3NC4 3NC5 3RM5 3RM6 3RM7 3RM8 3RM9 3RMB 3RMD 3RMG 3RMK

5SH1 5SH4 5SHA 5SHD

5PA-14451-00

23,86

5HN-14451-00
5HNM 3KJ-14451-00 4CY-14451-00 5KK2 5KKA 5ME2 5ME5 4VPF 5JY2 4DK1 4DK2 4DK4 4DK5 4DK6 3PY2 3PY3 3PY4 3RN7 3RN8 3RN9 3RMA 3RMC 3RME 3RMH 3RML 3RM2 3RN2 3RP2 3RM3 3RN4 4CJ1 3RM4 3RN5 4CJ2 4CJ4 4CJ5 4CJ6 4CJ7 4CJ8 3RMF 3RMJ 3RMM 4DJ4 4DJ5 4DJ6 4DJ7 4DJ8 4DJ9 4DJA 4DJB

2,89 4,45 3,86 3,86 3,86

5KK8 5KKB 5ME3 5ME6 4VPG 4VPH 4VPJ 4VPK 4VPL 4VPM 5JU1 5JY1 5ME1
4VP-E4451-00 4VP-E4451-00 4VP-E4451-00
3TK-14451-00 3BN-14451-01

5,08 15,35

3J0-14451-01 3BN-14451-01 4DJ1 4DJ2

5,82 15,35

125 DT125RE
1990 3MB3 3ME4BL7 4DK4BL8 4DK1D01 1D02 1D02 2C81 5ML1 3MW3 3MW5 3MW6 3MW7 3MW8 3MW9 3SH2 3SH1 3SH2 4GW1 4FU2 4FU3 4FU4 4GX5 4GX6 4GX7 4GX8 4GX9 4GXA 5EK1 5EK3 5EK5 5RS1 5RS3 3PA2 3PB4 4FL1 4FL2 4FL4 4KY1 4KY2 4TH1 4TH7 4TH8 4THE 3TE1

3BN-14451-01

15,35
DT125RE MX 125 DT125X 125 NXCSR125

Everts

3BN-14451-01 5TY-E4451-00 5H0-14451-00

15,35 6,88 3,09

125 TDRTDRTDR125
3XE2 4GX1 4GW2 4GW3 4GW4 5AE1 5AE2 5AE3 5AE4 5AE5 5AE6 5EK2 5EK4 5EK6 5RS2 5RS4 3PB2 3PC4 4HW1 4FL3 4HW3 4KY2 4TH2 4TH8 4THF 3TF1
34K-14451-01 3BN-14451-01 4FU-14451-00 4GX2 4GX3 4GX4 5AN1 5AN3 5AN5 5AN7 5AN9 5ANB

23,55 15,35 7,04

5AN2 5AN4 5AN6 5AN8 5ANA 5ANC 2JX-14451-00 3,78

125 TW125

125 TZRTZR125

125 XC125

Cygnus
3PD2 4CL2 4HX1 4HW2 4HX3 4KY3 4TH3
2RH-14451-00 4GM1 4JB1 4HX2 4JB2 4JB3 4KY4 4LA1 4TH4 4TH5 3XV-14451-00

5,72 4,58

4LA2 4TH6

4NB1 4UT1 4UT2

4CW-E4451-02

3LF2 3LE3 3LE4 3LF6 3LF7

3LG2 3LF3 3LF4 3LG6 3LG7

3LH2 3LG3 3LG4 3LH6 3LH7

3GM-14451-00 3LH3 3LH4 4PM1 4PM2 5LV-14451-00

16,26

25,73

5LVP 1C26 4BH-14451-00

23,36

1000 GTS1000A

1000 YZFYZF1000R

Thunderace Thunderace

1000 YZF1000RJ 1000 YZF-R1

Thunderace R1

1100 BT1100

Bulldog

1100 XV1100

1100 XVS1100

1100 XVS1100A

1200 FJ1200

1200 FJ1200A
4BH3 4BH5 4BH6 4FE3 4FE5 4FE6 4VF1 4SV1 4SV3 4SV4 4SV5 4YW1 4XV1 4XV7 5JJ1 5JJ8 5PW1 5PW7 5VY1 5VY7 5JN1 5JN2 5JN3 5JN4 3EF3 3EF4 3EF5 3EF6 3EF7 3EF8 3EF9 5EL1 5EL8 5PB2 5PBB 5KS4 5KSB 5KSG 5KSN 5YSF 3CV6 3XW1 3XW5 3XW9 3YA2
4BH4 4FV3 4BH7 4FV5 4FE4 4FV4 4FE7 4VD1 4VD2 4VD3 4VD5 4XV2 4XV8 5JJ2 5JJ9 5PW2 4FV6 4VE1 4VE2 4VD4 4VD6 5EG1 5EG2 5JJ7 5JJA 4VG1 4VF2 4VE3 4VF3 4VF4 3GM-14451-00 3GM-14451-00 16,29 16,29

4BH-14451-00

3GM-14451-00 4XV-14451-00

16,29 26,25

5PW-14451-00 5VY-14451-00 1AE-14451-00

26,32 26,76 19,46

3LP2 3LP4 3LP7 3LP9 3LPB 3LPE 3LPG 5EL2 5EL9
3LP3 3LP5 3LP8 3LPA 3LPD 3LPF 3LPH

42X-14451-00

5EL-14451-00

16,84

3CV7 3CW2 3CX2 3XW4 3YA1 3YY1 3XW6 3YA3 3YY3 3YY2 4BS2

3CY2 4BS1 4BS3

36Y-14451-00

18,94

1200 FJ1200ABS 1200 V-MAX

1200 XJR1200

1200 XJR1200SP 1300 FJR1300

1300 XJR1300

1300 XJR1300SP

1300 XVZ1300A

Royal Star
XVZ13AH XVZ13AHC XVZ13ATH XVZ13ATHC XVZ13TD
Royal Star Royal Star Royal Star Tour Classic Royal Star Tour Classic
1300 XVZ13TF 1600 XV1600A
Royal Star Venture Wild Star
3XW7 3XW2 3LR5 3LR8 3LRA 3LRB 3JPU 3JPX 5GK2 3LRD 5GK9 4PU1 4PU3 4PU5 4PU9 4PUB 5JW1 5JW4 5VS7 5VSD 5EA2 5EAA 5EAH 5EAT 5WM2 5WM8 5WMB 5EA5 5EAD 5EAL 4YP1 4YP2 4YP3 4YP4 4NK1 4NK2 4NL1 4NL2 3JS2 3JS3 5JC1 5JC2 5JA1 5JA5 5JA8
3YA4 3YY4 3XW3 3LR6 3LR7 3LR9
4BS4 36Y-14451-00 1FK-14451-00 18,94 34,84
3JPV 3LRC 5GK4 5GK5 5GKB 4PU2 4PU4 4PU6 4PUA 4PUC 5JW5
5GK1 5GK7 4RB1 4RB2 4PU7 4RB5 4RB6 4KG-14451-00 4PU8 4RB3 4RB4 4KG-14451-00 5JW-14451-00 35,11 24,99 35,11
5EA3 5EAB 5EAJ 5EAU 5EAW 5EAX 5WM4

4KG-14451-00

35,11

5EA6 5EAE 5EAM

4NK-14451-00

34,84

3JT2 3JT3 5JL1
4NK-14451-00 4NK-14451-00 4NK-14451-00 4NK-14451-00 26H-14451-00 4XY-14451-00 4WM-14451-00