2000 YAMAHA TW125 clutch

EAU00009
TABLE OF CONTENTS
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3
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1
5
GIVE SAFETY THE RIGHT OF WAY ..................1-1
DESCRIPTION .....................................................2-1
Left view............................................................2-1
Right view .........................................................2-2
Controls/Instruments .......................................2-3
INSTRUMENT AND CONTROL
FUNCTIONS ........................................................3-1
Main switch ......................................................3-1
Indicator lights..................................................3-1
Speedometer ....................................................3-2
Handlebar switches..........................................3-2
Clutch lever .......................................................3-4
Shift pedal.........................................................3-4
Front brake lever ..............................................3-4
Rear brake pedal ..............................................3-5
Fuel tank cap.....................................................3-5
Fuel ....................................................................3-6
Fuel cock ...........................................................3-7
Starter (choke) “1” .........................................3-8
Steering lock .....................................................3-8
Seat ...................................................................3-9
Helmet holder ...................................................3-9
Rear shock absorber ......................................3-10
Rear carrier .....................................................3-10
Luggage strap holders ...................................3-10Sidestand ........................................................3-11
Sidestand/clutch switch operation check .....3-12
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 ...................................5-4
Shifting..............................................................5-4
Tips for reducing fuel consumption ...............5-5
Engine break-in ................................................5-5
Parking ..............................................................5-6
PERIODIC MAINTENANCE AND MINOR
REPAIR ................................................................6-1
Tool kit ..............................................................6-1
Periodic maintenance and lubrication............6-3
Cowling and panel removal and
installation ........................................................6-6
Panel A ..............................................................6-6
Panel B ..............................................................6-7
Cowling C..........................................................6-8
Spark plug.........................................................6-8
Engine oil ..........................................................6-9
Air filter ...........................................................6-121
2
3
4
6
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Carburetor adjustment ..................................6-14
Idle speed adjustment ...................................6-14
Throttle cable free play inspection ...............6-15
Valve clearance adjustment ..........................6-15
Tires.................................................................6-16
Wheels ............................................................6-18
Clutch lever free play adjustment .................6-19
Front brake lever free play adjustment ........6-19
Rear brake pedal height and free play
adjustment ......................................................6-20
Brake light switch adjustment.......................6-21
Checking the front brake pads and
rear brake shoes .............................................6-22
Inspecting the brake fluid level .....................6-22
Brake fluid replacement.................................6-23
Drive chain slack check ..................................6-24
Drive chain slack adjustment ........................6-24
Drive chain lubrication...................................6-25
Cable inspection and lubrication ..................6-26
Throttle cable and grip lubrication ...............6-26
Brake and shift pedal lubrication ..................6-27
Brake and clutch lever lubrication ................6-27
Sidestand lubrication .....................................6-27
Rear suspension lubrication..........................6-28
Front fork inspection ......................................6-28
Steering inspection ........................................6-29
Wheel bearings ..............................................6-29Battery .............................................................6-30
Fuse replacement ...........................................6-31
Headlight bulb replacement ..........................6-32
Turn signal and taillight bulb
replacement ....................................................6-33
Supporting the motorcycle ...........................6-34
Front wheel removal ......................................6-35
Front wheel installation .................................6-36
Rear wheel removal .......................................6-36
Rear wheel installation ..................................6-37
Troubleshooting .............................................6-38
Troubleshooting chart ...................................6-39
MOTORCYCLE CARE AND STORAGE ..............7-1
Care ...................................................................7-1
Storage..............................................................7-4
SPECIFICATIONS................................................8-1
How to use the conversion table ....................8-5
CONSUMER INFORMATION .............................9-1
Identification numbers record.........................9-1
Key identification number ...............................9-1
Vehicle identification number .........................9-1
Model label .......................................................9-2
TABLE OF CONTENTS
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2-3
DESCRIPTION
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3
4
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6
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14. Clutch lever (page 3-4, 6-19)
15. Left handlebar switches (page 3-2)
16. Speedometer (page 3-2)
17. Starter (choke) (page 3-8)
18. Main switch (page 3-1)19. Indicator lights panel (page 3-1)
20. Right handlebar switches (page 3-3)
21. Front brake lever (page 3-4, 6-19)
22. Throttle grip (page 6-15, 6-26)
23. Fuel tank cap (page 3-5)
14 15 16 17 18 19 20 21
22
23
Controls/Instruments
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3-4
INSTRUMENT AND CONTROL FUNCTIONS
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EAU00157Shift pedal
This motorcycle is equipped with a
constant-mesh 5-speed transmis-
sion.
The shift pedal is located on the
left side of the engine and is used
in combination with the clutch
when shifting.
1. Shift pedal
N. Neutral
EAU00152Clutch lever
The clutch lever is located on the
left handlebar, and the ignition cir-
cuit cut-off system is incorporated
in the clutch lever holder. Pull the
clutch lever to the handlebar to dis-
engage 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 descrip-
tion of the ignition circuit cut-off
system.)
1. Clutch lever
EAU00158Front brake lever
The front brake lever is located on
the right handlebar. Pull it toward
the handlebar to apply the front
brake.
1. Front brake lever
11
1
N5
4
3
2
1
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3-12
INSTRUMENT AND CONTROL FUNCTIONS
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EAU00331Sidestand/clutch switch
operation check
Check the operation of the side-
stand switch and clutch switch
against the information below.
EW000045
w
If improper operation is noted,
consult a Yamaha dealer immedi-
ately.
SIDESTAND IS DOWN.
ENGINE WILL STALL.
SIDESTAND SWITCH IS OK.
TURN THE MAIN SWITCH TO “ON”
AND THE 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.
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4-1
EAU01114
PRE-OPERATION CHECKS
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9 Owners are personally responsible for their vehicle’s condition. Your motorcycle’s vital functions can start to
deteriorate quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements).
Any damage, fluid leak or loss of tire pressure could have serious consequences. Therefore, it is very important
that, in addition to a thorough visual inspection, you check the following points before each ride.
EAU00340PRE-OPERATION CHECK LIST
ITEM CHECKS PAGE
Front
brake9Check operation, free play, fluid level and vehicle for fluid leakage.
3-4, 6-19 ~ 6-20, 6-22 ~ 6-23
9Fill with DOT 4 (or DOT 3) brake fluid if necessary.
Rear brake9Check operation, condition and free play.
3-5, 6-20 ~ 6-22
9Adjust if necessary.
Clutch9Check operation, condition and free play.
3-4, 6-19
9Adjust if necessary.
Throttle grip and housing9Check for smooth operation.
6-15, 6-26
9Lubricate if necessary.
Engine oil9Check oil level.
6-9 ~ 6-12
9Fill with oil if necessary.
Drive chain9Check chain slack and condition.
6-24 ~ 6-25
9Adjust if necessary.
Wheels and tires9Check tire pressure, wear, damage and spoke tightness.
6-16 ~ 6-18
9Tighten spokes if necessary.
Brake and shift pedal shafts9Check for smooth operation.
6-27
9Lubricate if necessary.
Brake and clutch lever pivots9Check for smooth operation.
6-27
9Lubricate if necessary.
Sidestand pivot9Check for smooth operation.
6-27
9Lubricate if necessary.
Chassis fasteners9Make sure that all nuts, bolts and screws are properly tightened.
—
9Tighten if necessary.
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5-1
EAU00372
OPERATION AND IMPORTANT RIDING POINTS
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EAU00373
w
8Before 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.
8Never 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 motorcy-
cle in an area with adequate
ventilation.
8Before starting out, always be
sure the sidestand is up.
Failure to retract the sidestand
completely can result in a seri-
ous accident when you try to
turn a corner.
EAU03011Starting the engine
NOTE:
This motorcycle is equipped with
an ignition circuit cut-off system.
The engine can be started only
under one of the following condi-
tions:
8The transmission is in neutral.
8The sidestand is up, the trans-
mission is in gear and the
clutch is disengaged.
The motorcycle must not be ridden
when the sidestand is down.
EW000054
w
Before going through the follow-
ing steps, check the function of the
sidestand switch and clutch
switch. (Refer to page 3-12.)
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5-2
OPERATION AND IMPORTANT RIDING POINTS
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IF THE TRANSMISSION IS IN NEUTRAL AND
THE SIDESTAND IS DOWN, PUSH START
SWITCH.
THE ENGINE WILL START.
RETRACT THE SIDESTAND AND PUT THE
TRANSMISSION IN GEAR.
THE MOTORCYCLE CAN BE RIDDEN.THE MOTORCYCLE CAN BE RIDDEN.
IF THE TRANSMISSION IS IN GEAR AND THE
SIDESTAND IS UP, PULL IN THE CLUTCH
LEVER AND PUSH THE START SWITCH.
TURN THE MAIN SWITCH TO “ON” AND
THE ENGINE STOP SWITCH TO “#”.
THE ENGINE WILL START.
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