Yamaha TW125 Owner'S Manual Download Page 53 | Manualshive

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6-22

PERIODIC MAINTENANCE AND MINOR REPAIR

1

2

3

4

5

6

7

8

9

To increase the brake pedal free
play, turn the adjusting nut at the
brake rod in direction

a

. To

decrease the brake pedal free play,
turn the adjusting nut in direction

b

.

1

2

a

b

EAU00713

Adjusting the rear brake light
switch

The rear brake light switch, which is
activated by the brake pedal, is prop-
erly adjusted when the brake light
comes on just before braking takes
effect. If necessary, adjust the brake
light switch as follows.
Turn the adjusting nut while holding
the rear brake light switch in place.
To make the brake light come on ear-
lier, turn the adjusting nut in direction

a

. To make the brake light come on

later, turn the adjusting nut in direc-
tion

b

.

1.

Brake light switch

2.

Adjusting nut

b

a

1

1.

Brake pedal free play adjusting nut

EW000106

w

8

After adjusting the drive chain
slack or removing and
installing the rear wheel,
always check the brake pedal
free play.

8

If proper adjustment cannot be
obtained as described, have a
Yamaha dealer make this
adjustment.

8

After adjusting the brake pedal
free play, check the operation
of the brake light.

5EK-9-E2 (TW125)<3.3Passport> 5/23/00 9:47 AM Page 51

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Summary of Contents for TW125

Page 1: ...PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2000 5 0 1 1 E OWNER S MANUAL 5EK 28199 E2 TW125 YAMAHA MOTOR CO LTD ...

Page 2: ...PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2000 5 0 1 1 E OWNER S MANUAL 5EK 28199 E2 TW125 YAMAHA MOTOR CO LTD ...

Page 3: ...ly so as to enjoy all advantages of your TW125 The owner s 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 keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yam...

Page 4: ...aken to avoid damage to the motorcycle A NOTE provides key information to make procedures easier or clearer Q w cC NOTE NOTE 8 This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold 8 Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product in...

Page 5: ...IMPORTANT MANUAL INFORMATION 1 2 3 4 5 6 7 8 9 EW000002 w PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE 5EK 9 E2 TW125 3 3Passport 5 23 00 9 47 AM Page 3 ...

Page 6: ...Yamaha Motor Co Ltd 1st Edition May 2000 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan EAU03337 5EK 9 E2 TW125 3 3Passport 5 23 00 9 47 AM Page 4 ...

Page 7: ...s 3 10 Sidestand 3 11 Ignition circuit cut off system 3 11 PRE OPERATION CHECKS 4 1 Pre operation check list 4 1 OPERATION AND IMPORTANT RIDING POINTS 5 1 Starting the engine 5 1 Starting a warm engine 5 2 Shifting 5 3 Recommended shift points for Switzerland only 5 3 Tips for reducing fuel consumption 5 4 Engine break in 5 4 Parking 5 5 PERIODIC MAINTENANCE AND MINOR REPAIR 6 1 Owner s tool kit 6...

Page 8: ...rake and shift pedals 6 28 Checking and lubricating the brake and clutch levers 6 29 Checking and lubricating the sidestand 6 29 Lubricating the rear suspension 6 29 Checking the front fork 6 30 Checking the steering 6 30 Checking the wheel bearings 6 31 Battery 6 31 Replacing the fuse 6 34 Replacing the headlight bulb 6 35 Replacing a turn signal light bulb 6 36 Replacing the tail brake light bul...

Page 9: ...uence of even small amounts of alcohol there is a tendency to take dangerous risks Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passen gers Always wear a complete motorcycle suit whether made of leather or tear resistant synthetic materials with protectors sturdy boots motorcycle gloves and a properly fitting helmet Optimum pro tective wear how...

Page 10: ...nk page 3 5 2 Fuel cock page 3 7 3 Helmet holder page 3 9 4 Luggage strap holders page 3 10 5 Chain adjusting plates page 6 26 6 Air filter element page 6 12 7 Shift pedal page 3 4 1 2 3 4 5 6 7 Left view 5EK 9 E2 TW125 3 3Passport 5 23 00 9 47 AM Page 8 ...

Page 11: ... 8 Carrier page 3 10 9 Battery page 6 31 10 Engine oil level check window page 6 9 11 Brake pedal page 3 5 6 21 12 Owner s tool kit page 6 1 13 Fuse page 6 34 8 9 13 12 11 10 Right view 5EK 9 E2 TW125 3 3Passport 5 23 00 9 47 AM Page 9 ...

Page 12: ...it page 3 2 4 Starter choke knob page 3 8 5 Main switch page 3 1 6 Indicator lights panel page 3 1 7 Right handlebar switches page 3 3 8 Brake lever page 3 4 6 20 9 Throttle grip page 6 15 6 28 10 Fuel tank cap page 3 5 1 2 3 4 5 6 7 8 9 10 Controls and instruments 5EK 9 E2 TW125 3 3Passport 5 23 00 9 47 AM Page 10 ...

Page 13: ...off The key can be removed EAU00056 Indicator lights EAU00057 Turn signal indicator light 5 This indicator light flashes when the turn signal switch is pushed to the left or right EAU00061 Neutral indicator light N This indicator light comes on when the transmission is in the neutral position 1 Turn indicator light 5 2 High beam indicator light 3 Neutral indicator light N EAU00063 High beam indica...

Page 14: ...imate the distance that can be traveled with a full tank of fuel This information will enable you to plan future fuel stops 1 Speedometer 2 Odometer 3 Trip odometer 4 Reset knob EAU00118 Handlebar switches EAU00121 Dimmer switch Set this switch to for the high beam and to for the low beam 1 Lights switch 2 Dimmer switch 3 Turn signal switch 4 Horn switch NOTE Only for the German model equipped wit...

Page 15: ... sound the horn EAU00134 Light switch Set this switch to to turn on the auxiliary light meter lighting and taillight Set the switch to to turn on the headlight also EAU00143 Start switch Push this switch to crank the engine with the starter EC000005 cC See page 5 1 for starting instruc tions prior to starting the engine 1 2 EAU00138 Engine stop switch Set this switch to to stop the engine in case ...

Page 16: ... the clutch pull the lever toward the han dlebar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of the igni tion circuit cut off system See page 3 11 for an explanation of the ignition circuit cut off system 1 Clutch lever EAU00158 Brake lever The brake le...

Page 17: ... and then pull it off 1 Fuel tank cap a Unlock b Open To close the fuel tank cap 1 Insert the fuel tank cap into the tank opening with the key insert ed in the lock and then turn the cap clockwise 2 Turn the key clockwise to the original position and then remove it NOTE The fuel tank cap cannot be installed unless the key is in the lock In addi tion the key cannot be removed if the cap is not prop...

Page 18: ... 8 Avoid spilling fuel on the hot engine 1 Filler tube 2 Fuel level EAU00185 cC Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted sur faces or plastic parts EAU00191 NOTE If knocking or pinging occurs use gasoline of a different brand or with a higher octane grade Recommended fuel Regular unleaded gasoline with a research octane number of 91 or higher...

Page 19: ...er OFF ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position 1 Arrow mark positioned over ON RES This indicates reserve If you run out of fuel while riding move the lever to this position Fill the tank at the first opportunity Be sure to set the lever back to ON after refueling 1 Arrow mark positioned over RES RES ON FUEL OFF 1 OFF Cl...

Page 20: ...way to the right 2 Open the steering lock cover and then insert the key 3 Turn the key 1 8 turn counter clockwise push it in while turning the handlebar slightly to the left and then turn the key 1 8 turn clockwise 4 Check that the steering is locked remove the key and then close the lock cover 1 Steering lock 2 Cover To unlock the steering 1 Open the steering lock cover and then insert the key 2 ...

Page 21: ...s NOTE Make sure that the seat is properly secured before riding 1 Projection 2 Seat holder EAU00260 Helmet holder To open the helmet holder insert the key into the lock and then turn the key as shown To lock the helmet holder place it in the original position and then remove the key EW000030 w Never ride with a helmet attached to the helmet holder since the hel met may hit objects causing loss of...

Page 22: ...s cylinder 8 Do not subject the shock absorber to an open flame or other high heat sources other wise it may explode due to excessive gas pressure 8 Do not deform or damage the gas cylinder in any way as this will result in poor damp ing performance 8 Always have a Yamaha dealer service the shock absorber EAU00320 Carrier EW000032 w 8 Do not exceed the load limit of 3 kg for the carrier 8 Do not e...

Page 23: ...ssist the operator in fulfilling the responsibility of rais ing the sidestand before starting off Therefore check this system regularly as described below and have a Yamaha dealer repair it if it does not function properly EAU00331 Ignition circuit cut off system The ignition circuit cut off system comprising the sidestand switch clutch switch and neutral switch has the following functions 8 It pr...

Page 24: ...ep the clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle ...

Page 25: ...ration condition and free play 3 5 6 21 6 23 9 Adjust if necessary Clutch 9 Check operation condition and free play 3 4 6 19 6 20 9 Adjust if necessary Throttle grip and housing 9 Check smooth operation 6 15 6 28 9 Lubricate if necessary Engine oil 9 Check oil level 6 9 6 12 9 Add oil if necessary Drive chain 9 Check chain slack and condition 6 25 6 27 9 Adjust if necessary Wheels and tires 9 Chec...

Page 26: ...e time involved EWA00033 w If any item in the Pre operation check list is not working properly have it inspected and repaired before operat ing the motorcycle ITEM CHECKS PAGE Fuel tank 9 Check fuel level 3 5 3 6 9 Add fuel if necessary Lights signals and 9 Check proper operation 3 2 3 3 6 35 6 37 switches Battery 9 Check fluid level 6 31 6 34 9 Add distilled water if necessary 5EK 9 E2 TW125 3 3P...

Page 27: ...le loss of control EAU03515 Starting the engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met 8 The transmission is in the neutral position 8 The transmission is in gear with the clutch lever pulled and the sidestand up EW000054 w 8 Before starting the engine check the function of the igni tion circuit cut off system according to th...

Page 28: ...e than 10 seconds on any one attempt 6 After starting the engine move the starter choke knob lever back halfway ECA00055 cC For maximum engine life always warm the engine up before starting off Never accelerate hard when the engine is cold 7 When the engine is warm turn the starter choke off NOTE The engine is warm when it responds normally to the throttle with the starter choke turned off EAU0125...

Page 29: ...AU00423 Shifting Shifting gears lets you control the amount of engine power available for starting off accelerating climbing hills etc The gear positions are shown in the illustration NOTE To shift the transmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it 1 Shift pedal N Neutral EAU02941 Recommended shift poi...

Page 30: ...iod between 0 and 1 600 km For this reason you should read the fol lowing material carefully Since the engine is brand new do not put an excessive load on it for the first 1 600 km The various parts in the engine wear and polish them selves to the correct operating clear ances During this period prolonged full throttle operation or any condition that might result in engine overheat ing must be avo...

Page 31: ...n the fuel cock lever to OFF EW000058 w 8 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them 8 Do not park on a slope or on soft ground otherwise the motorcycle may overturn 1 Arrow mark positioned over OFF RES ON FUEL OFF 1 5EK 9 E2 TW125 3 3Passport 5 23 00 9 47 AM Page 29 ...

Page 32: ...with motor cycle maintenance work have a Yamaha dealer do it for you 1 EAU01175 Owner s tool kit The owner s tool kit is located behind panel B See page 6 6 for panel removal and installation procedures The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of pre ventive maintenance and minor repairs However add...

Page 33: ...on Adjust 7 Front brake Check operation fluid level and vehicle for fluid leakage See NOTE on page 6 4 Replace brake pads Whenever worn to the limit 8 Rear brake Check operation and adjust brake pedal freeplay Replace brake shoes Whenever worn to the limit 9 Brake hose Check for cracks or damage Replace See NOTE on page 6 4 Every 4 years NOTE 8 The annual checks must be performed every year except...

Page 34: ... and after washing the motorcycle in the rain 15 Steering bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 24 000km 16 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 17 Sidestand Check operation Lubricate 18 Sidestand switch Check operation 19 Front fork Check operation and for oil leakage 20 Rear shock absorbe...

Page 35: ...f the brake master cylinder and caliper and change the brake fluid 8 Replace the brake hoses every four years and if cracked or damaged 22 Engine oil Change 23 Engine oil filter element Replace 24 Engine oil strainer Clean 25 Front and rear brake switches Check operation 26 Moving parts and cables Lubricate 27 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHECK OR MAINT...

Page 36: ...cribed in this chapter Refer to this section each time the cowling or a panel needs to be removed and installed 1 Panel B 1 Cowling A 2 Panel A 1 2 1 2 1 EAU01145 Cowling A To remove the cowling Remove the screw and then pull the cowling off as shown To install the cowling Place the cowling in the original posi tion and then install the screw 1 Cowling A 2 Screw 5EK 9 E2 TW125 3 3Passport 5 23 00 ...

Page 37: ...ve the screws and then pull the panel out at the area shown 1 Panel A 2 Screw 2 2 1 To install the panel Place the panel in the original posi tion and then install the screws EAU00494 Panel B To remove the panel Pull the panel off as shown 1 Panel B 1 5EK 9 E2 TW125 3 3Passport 5 23 00 9 47 AM Page 35 ...

Page 38: ...be removed and checked in accordance with the periodic maintenance and lubrication chart In addition the condition of the spark plug can reveal the condition of the engine 1 Spark plug wrench To remove the spark plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench included in the owner s tool kit 1 To install the panel Place the panel in the original posi ti...

Page 39: ... estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the specified torque as soon as possible 4 Install the spark plug cap 6 8 PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 3 4 5 6 7 8 9 Specified spark plug DR8EA NGK a a Spark plug gap To install the spark plug 1 Measure the spark plug gap with a wire thickness gauge and if necessary adjust t...

Page 40: ... turn it off 2 Place an oil pan under the engine to collect the used oil 3 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase 1 Engine oil filler cap 1 2 3 1 EAU03564 Engine oil and oil filter element The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter element cleaned at the intervals specified in the perio...

Page 41: ...will fall out Take care not to lose these parts 1 Strainer 2 Compression spring 3 O ring 4 Remove the oil filter element drain bolt to drain the oil from the oil filter element NOTE Skip steps 5 9 if the oil filter element is not being cleaned 1 Oil filter element cover 2 Screw 2 3 Oil filter element drain bolt 1 2 3 1 2 3 5EK 9 E2 TW125 3 3Passport 5 23 00 9 47 AM Page 39 ...

Page 42: ...bolt to the specified torque Tightening torque Engine oil drain bolt 43 Nm 4 3 m kg 5 Remove the oil filter element cover by removing the screws 6 Remove the oil filter element and O rings 7 Check the O rings for damage and replace it if necessary 8 Clean the oil filter element with solvent and then install it NOTE Check the oil filter element for dam age and replace it if necessary 1 Oil filter e...

Page 43: ...lation procedures 1 Air filter case cover 2 Screw 4 EC000072 cC 8 In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives with the oil or use oils of a higher grade than CD In addition do not use oils labeled ENERGY CONSERV ING II or higher 8 Make sure that no foreign material enters the crankcase 13 Start the engine and then let it id...

Page 44: ...4 Remove the sponge material from the air filter element frame clean it with solvent and then squeeze the remaining solvent out 1 Sponge material 2 Air filter element frame Recommended oil Engine oil 1 2 EC000082 cC 8 Make sure that the air filter ele ment is properly seated in the air filter case 8 The engine should never be operated without the air filter element installed otherwise the piston s...

Page 45: ...perfor mance of or damage to the engine EAU01168 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrica tion chart NOTE A diagnostic tachometer is needed to make this adjustment 1 Attach the tachometer to the spark plug lead 2 Start the engine and warm it up for several minute...

Page 46: ... idling speed 1 300 1 500 r min EAU00634 Adjusting the throttle cable free play The throttle cable free play should measure 3 5 mm at the throttle grip Periodically check the throttle cable free play and if necessary adjust it as follows NOTE The engine idling speed must be cor rectly adjusted before checking and adjusting the throttle cable free play 1 Adjusting nut 2 Locknut c Free play 1 Loosen...

Page 47: ...hecked and if necessary adjusted before each ride EW000082 w 8 The tire air pressure must be checked and adjusted on cold tires i e when the tempera ture of the tires equals the ambient temperature 8 The tire air pressure must be adjusted in accordance with the riding speed and with the total weight of rider passen ger cargo and accessories approved for this model Tire air pressure measured on col...

Page 48: ...th regard to the load 8 Check the tire condition and air pressure before each ride 1 a Tire inspection The tires must be checked before each ride If the center tread depth reaches the specified limit if the tire has a nail or glass fragments in it or if the sidewall is cracked have a Yamaha dealer replace the tire imme diately NOTE The tire tread depth limits may differ from country to country Alw...

Page 49: ...t recommended to patch a punctured tube If unavoidable however patch the tube very carefully and replace it as soon as possible with a high quality product EAU00685 Spoke wheels To maximize the performance dura bility and safe operation of your motorcycle note the following points regarding the specified wheels 8 The wheel rims should be checked for cracks bends or warpage and the spokes for loose...

Page 50: ... turn the adjusting bolt at the clutch lever in direction a to loosen the clutch cable EAU03460 Adjusting the clutch lever free play The clutch lever free play should measure 10 15 mm as shown Periodically check the clutch lever free play and if necessary adjust it as follows 1 Loosen the locknut at the clutch lever 2 To increase the clutch lever free play turn the adjusting bolt in direction a To...

Page 51: ... increase the clutch lever free play turn the adjusting bolt in direction a To decrease the clutch lever free play turn the adjusting bolt in direction b 7 Tighten the locknuts at the clutch lever and the crankcase 1 Locknut 2 2 Adjusting bolt a b 2 1 EW000099 w 8 After adjusting the brake lever free play check the free play and make sure that the brake is working properly 8 A soft or spongy feeli...

Page 52: ... it as follows 1 Locknut 2 Adjusting bolt c Brake pedal position 1 Loosen the locknut at the brake pedal 2 To raise the brake pedal turn the adjusting bolt in direction a To lower the brake pedal turn the adjusting bolt in direction b 3 Tighten the locknut EW000105 w After adjusting the brake pedal height the brake pedal free play must be adjusted a Brake pedal free play The brake pedal free play ...

Page 53: ... follows Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on ear lier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direc tion b 1 Brake light switch 2 Adjusting nut b a 1 1 Brake pedal free play adjusting nut EW000106 w 8 After adjusting the drive chain slack or removing and installing th...

Page 54: ...he rear brake is provided with a wear indicator which allows you to check the brake shoe wear without having to disassemble the brake To check the brake shoe wear check the position of the wear indicator while applying the brake If a brake shoe has worn to the point that the wear indicator reaches the wear limit line have a Yamaha dealer replace the brake shoes as a set 1 Wear limit line 2 Wear in...

Page 55: ...fluid reservoir is level 8 Use only the recommended qual ity brake fluid otherwise the rub ber seals may deteriorate caus ing leakage and poor braking performance 8 Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking perfor mance 8 Be careful that water does not enter the master cylinder when refilling Water will significantly l...

Page 56: ...3 Move the rear wheel by pushing the motorcycle to locate the tight est portion of the drive chain and then measure the drive chain slack as shown 4 If the drive chain slack is incor rect adjust it as follows a Drive chain slack 35 60 mm EAU03238 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the periodic maintenance and lubrica tion chart In add...

Page 57: ...ree play adjusting nut and then tighten the axle nut to the specified torque 4 Adjust the brake pedal free play See page 6 21 for brake pedal free play adjustment proce dures EW000103 w After adjusting the brake pedal free play check the operation of the brake light EAU01106 Lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic mainte...

Page 58: ...ables and cable ends should be lubricated if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it EW000112 w Damage to the outer sheath may interfere with proper cable opera tion and will cause the inner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions Recommended lubricant Engine oil 5EK 9 E2 TW125 3 3Passport 5 2...

Page 59: ...it up and then apply several drops of oil to the cable end allowing it to trickle into the sheath 3 Connect the throttle cable and then grease the inside of the throttle grip housing EAU03370 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lubricated if necessary Recommended lubricant ...

Page 60: ...ould be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary EW000113 w If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it Recommended lubricant Lithium soap based grease all purpose grease EAU03164 Checking and lubricating the brake and clutch levers The operation of the brake and clutch lev...

Page 61: ...right position 2 While applying the front brake push down hard on the handle bars several times to check if the front fork compresses and rebounds smoothly EC000098 cC If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or repair it EAU00794 Checking the steering Worn or loose steering bearings may cause danger Therefore the opera tion of the steering must...

Page 62: ...ubrication chart EAU01144 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings 2 Hold the lower ends of the front fork legs and try to move them forward and backward If any free p...

Page 63: ...low the minimum level mark add dis tilled water to raise the elec trolyte to the maximum level mark 1 Maximum level mark 2 Minimum level mark EW000116 w 8 Electrolyte is poisonous and dangerous since it contains sulfuric acid which causes severe burns Avoid any con tact with skin eyes or clothing and always shield your eyes when working near batteries In case of contact administer the following FI...

Page 64: ...y connected to the battery termi nals and that the breather hose is properly routed in good condi tion and not obstructed 1 Battery 2 Battery breather hose 1 2 9 Connect and tighten the positive battery lead to the battery s posi tive terminal 10 Connect and tighten the negative battery lead to the battery s neg ative terminal 11 Install the seat 1 Battery breather hose 1 EC000100 cC Use only dist...

Page 65: ...Specified fuse 20A EAU01307 Replacing the fuse The fuse holder is located behind panel B See page 6 6 for panel removal and installation procedures If the fuse is blown replace it as fol lows 1 Turn the key to OFF and turn off all electrical circuits 2 Remove the blown fuse and then install a new fuse of the specified amperage 1 Fuse 2 Spare fuse 1 2 EC000099 cC If the breather hose is positioned ...

Page 66: ...cooled down 5 Place a new bulb into position and then secure it with the bulb holder 1 Headlight bulb holder 1 3 Disconnect the headlight cou pler and then remove the head light bulb cover 1 Coupler 2 Headlight bulb cover 1 2 EAU01158 Replacing the headlight bulb If the headlight bulb burns out replace it as follows 1 Remove cowling A See page 6 5 for cowling removal and installation procedures 2 ...

Page 67: ...3497 Replacing a turn signal light bulb 1 Remove the turn signal light lens by removing the screw 2 Remove the defective bulb by pushing it in and turning it coun terclockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screw 1 Screw 2 Lens 3 bulb 1 2 3 ECA00065 cC Do not overtighten the screw oth erwise the lens ma...

Page 68: ...he rear of the motorcy cle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack under the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand 2 Remove the defective bulb by pushing it in and turning it coun terclockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it s...

Page 69: ...visable to have a Yamaha dealer service the wheel 8 Securely support the motorcy cle so that there is no danger of it falling over 1 Disconnect the speedometer cable from the front wheel 2 Loosen the axle nut 1 Speedometer cable 2 Axle nut 3 Lift the front wheel off the ground according to the procedure on page 6 37 4 Remove the axle nut pull the wheel axle out and then remove the wheel ECA00048 c...

Page 70: ...nstall the speedometer gear unit into the wheel hub so that the projections mesh with the slots 2 Lift the wheel up between the fork legs NOTE Make sure that there is enough space between the brake pads before inserting the brake disc and that the slot in the speedometer gear unit fits over the retainer on the fork leg 3 Insert the wheel axle and then install the axle nut 4 Lower the front wheel s...

Page 71: ...E Make sure that the drive chain adjust ing plates are installed with the punched sides facing to the outside and that the slot in the brake shoe plate fits over the retainer on the swingarm 2 Install the drive chain onto the rear sprocket and then adjust the drive chain slack See page 6 26 for drive chain slack adjust ment procedures 3 Install the axle nut and then lower the rear wheel so that it...

Page 72: ...llowing troubleshooting chart represents a quick and easy proce dure for checking these vital systems yourself However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are oft...

Page 73: ...lean with dry cloth and Open throttle half way and start Ask a Yamaha dealer to inspect Engine turns over Engine turns over Battery good Check fluid recharge Use the electric starter Check if there is fuel Enough fuel No fuel Go to compression check Supply fuel in the fuel tank electrodes plug and check quickly slowly check connections Engine doesn t start go to battery check the engine correct sp...

Page 74: ... as all electrical cou plers and connectors including the spark plug cap are tightly installed 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such products onto seals gaskets sprockets the drive chain and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00010 cC 8 Avoid using strong acidic wheel clean...

Page 75: ...t leave any marks If the windshield is scratched use a quality plastic polishing compound after washing After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottle brush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes ...

Page 76: ...minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry complete ly before storing or covering it EWA00001 w 8 Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or acetone and wash the tires with warm water and a mild detergent 8 Before operating the motorcy cle tes...

Page 77: ...t this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 5 Perform the following steps to protect the cylinder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spar...

Page 78: ...a little every month in order to pre vent the tires from becoming degraded in one spot 8 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an excessively cold or warm place less than 0 C or more than 30 C For more informa tion on storing the ba...

Page 79: ...ic starter Lubrication system Wet sump Engine oil Type Recommended engine oil classification API Service SE SF SG type or higher cC Be sure to use motor oils that do not contain anti friction modifiers Passenger car motor oils often labeled Energy Conserving contain anti friction additives which will cause clutch and or starter clutch slippage resulting in reduced component life and poor engine pe...

Page 80: ...ratio 74 20 3 700 Secondary reduction system Chain drive Secondary reduction ratio 3 571 Number of drive chain sprocket teeth rear front 50 14 Transmission type Constant mesh 5 speed Operation Left foot operation Gear ratio 1st 2 250 2nd 1 476 3rd 1 125 4th 0 926 5th 0 793 Chassis Frame type Diamond Caster angle 26 Trail 95 mm Tires Type With tube Front Size 130 80 18 66P Manufacturer BRIDGESTONE ...

Page 81: ...s Front Type Spoke wheel Size 2 50 18 Rear Type Spoke wheel Size 14M C MT4 50 Brakes Front Type Single disc brake Operation Right hand operation Fluid DOT 4 Rear Type Drum brake Operation Right foot operation Suspension Front Type Telescopic fork Rear Type Swingarm Monocross suspension Spring shock absorber Front Coil spring oil damper Rear Coil gas spring oil damper Wheel travel Front 160 mm Rear...

Page 82: ...1 Tail brake light 12 V 5 21 W 1 Front turn signal light 12 V 21 W 2 Rear turn signal light 12 V 21 W 2 Marker light 12 V 4 W 1 Meter lighting 12 V 3 4 W 1 Neutral indicator light 12 V 3 4 W 1 High beam indicator light 12 V 3 4 W 1 Turn indicator light 12 V 3 4 W 1 Fuse 20 A 5EK 9 E2 TW125 3 3Passport 5 23 00 9 47 AM Page 80 ...

Page 83: ...Multiplier Imperial unit m kg 7 233 ft lb Torque m kg 86 794 in lb cm kg 0 0723 ft lb cm kg 0 8679 in lb Weight kg 2 205 lb g 0 03527 oz Speed km hr 0 6214 mph km 0 6214 mi m 3 281 ft Distance m 1 094 yd cm 0 3937 in mm 0 03937 in cc cm3 0 03527 oz IMP liq Volume cc cm3 0 06102 cu in Capacity L liter 0 8799 qt IMP liq L liter 0 2199 gal IMP liq kg mm 55 997 lb in Misc kg cm2 14 2234 psi lb in2 Cen...

Page 84: ...1 Key identification number The key identification number is stamped into the key tag Record this number in the space pro vided and use it for reference when ordering a new key 1 Key identification number EAU01043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is...

Page 85: ...he model label is affixed to the loca tion shown in the figure Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Model label 1 5EK 9 E2 TW125 3 3Passport 5 23 00 9 47 AM Page 83 ...

Page 86: ...5EK 9 E2 TW125 3 3Passport 5 23 00 9 47 AM Page 84 ...

Page 87: ...PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2000 5 0 1 1 E OWNER S MANUAL 5EK 28199 E2 TW125 YAMAHA MOTOR CO LTD ...

Page 88: ...PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2000 5 0 1 1 E OWNER S MANUAL 5EK 28199 E2 TW125 YAMAHA MOTOR CO LTD ...

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