2000 YAMAHA TW125 wheel

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
1
2
3
4
5
6
7
8
9
7
8
9
5EK-9-E1 (TW125)<3.1> 4/6/0 11:50 PM Page 6

4-1
EAU01114
PRE-OPERATION CHECKS
1
2
3
4
5
6
7
8
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.
5EK-9-E1 (TW125)<3.1> 4/6/0 11:50 PM Page 23

6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
EAU00473PERIODIC MAINTENANCE AND LUBRICATION
Every Every
6,000 km 12,000 km
No. ITEM CHECKS AND MAINTENANCE JOBSINITIAL or or
1,000 km 6 months 12 months
(Whichever (Whichever
comes first) comes first)
1 * Fuel line 9Check fuel hoses for cracks or damage.
ÖÖ
9Replace if necessary.
2 Spark plug9Check condition.
ÖÖÖ
9Clean, regap or replace if necessary.
3 * Valves 9Check valve clearance.
ÖÖÖ
9Adjust if necessary.
4 Air filter9Clean or replace if necessary.ÖÖ
9Check electrolyte level and specific gravity.
5 * Battery9Correct or recharge if necessary.ÖÖ
9Make sure that the breather hose is properly routed.
6 Clutch9Check operation.
ÖÖÖ
9Adjust or replace cable.
9Check operation, fluid level and vehicle for fluid leakage.
7 * Front brake (See NOTE on page 6-5.)
ÖÖÖ
9Correct accordingly.
9Replace brake pads if necessary.
8 * Rear brake 9Check operation.
ÖÖÖ
9Adjust brake pedal freeplay and replace brake shoes if necessary.
9 * Wheels 9Check balance, runout, spoke tightness and for damage.
ÖÖ
9Tighten spokes and rebalance, replace if necessary.
9Check tread depth and for damage.
10 * Tires9Replace if necessary.
ÖÖ
9Check air pressure.
9Correct if necessary.
5EK-9-E1 (TW125)<3.1> 4/6/0 11:50 PM Page 33

6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
Every Every
6,000 km 12,000 km
No. ITEM CHECKS AND MAINTENANCE JOBSINITIAL or or
1,000 km 6 months 12 months
(Whichever (Whichever
comes first) comes first)
11 * Wheel bearings9Check bearing for looseness or damage.
ÖÖ
9Replace if necessary.
9Check swingarm pivoting point for play.
12 * Swingarm9Correct if necessary. ÖÖ
9Lubricate with lithium soap base grease.
9Check chain slack.
Every 500 km and after washing
13 Drive chain9
Adjust if necessary. Make sure that the rear wheel is properly aligned.the motorcycle or riding in the rain9Clean and lubricate.
9Check bearing play and steering for roughness.
14 * Steering bearings9Correct accordingly.
ÖÖ
9Lubricate with lithium soap base grease every 24,000 km or
24 months (whichever comes first).
15 * Chassis fasteners9Make sure that all nuts, bolts and screws are properly tightened.
ÖÖ
9Tighten if necessary.
16 Sidestand9Check operation.
ÖÖ
9Lubricate and repair if necessary.
17 * Sidestand switch9Check operation.
ÖÖÖ
9Replace if necessary.
18 * Front fork9Check operation and for oil leakage.
ÖÖ
9Correct accordingly.
19 *Rear shock absorber 9Check operation and shock absorber for oil leakage.
ÖÖ
assembly9Replace shock absorber assembly if necessary.
Rear shock absorber 9Check operation.
20 assembly pivoting 9Lubricate with lithium soap base grease every 24,000 km or ÖÖ
points24 months (whichever comes first).
5EK-9-E1 (TW125)<3.1> 4/6/0 11:50 PM Page 34

6-18
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
EAU00681
w
8Operating 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 replace-
ment should be left to a
Yamaha Service Technician.
8Patching a punctured tube is
not recommended. If it is
absolutely necessary to do so,
use great care and replace the
tube as soon as possible with
a good quality replacement.
EAU00685
Wheels
To ensure maximum performance,
long service, and safe operation,
note the following:
8Always inspect the wheels
before a ride. Check for cracks,
bends or warpage of the
wheel. Be sure the spokes are
tight and undamaged. If any
abnormal condition exists in a
wheel, consult a Yamaha deal-
er. Do not attempt even small
repairs to the wheel. If a wheel
is deformed or cracked, it must
be replaced.
8Tires and wheels should be
balanced whenever either one
is changed or replaced. Failure
to have a wheel balanced can
result in poor performance,
adverse handling characteris-
tics, and shortened tire life.8Ride at moderate speeds after
changing a tire since the tire
surface must first be broken in
for it to develop its optimal
characteristics.
5EK-9-E1 (TW125)<3.1> 4/6/0 11:50 PM Page 48

6-21
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
1
ba
Free play
The rear brake pedal free play
should be adjusted to 20 ~ 30 mm
at the brake pedal end. Turn the
adjusting nut on the brake rod in
direction ato increase free play or
in direction bto decrease free
play.
1. Adjusting nut
EW000106
w
8Brake pedal free play should
be checked whenever the
chain is adjusted or the rear
wheel is removed and then
reinstalled.
8Check the operation of the
brake light after adjusting the
rear brake.
8If it is impossible to make
proper adjustment, consult a
Yamaha dealer.
1
2
a
b
EAU00713Brake light switch
adjustment
The rear brake light switch is acti-
vated 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
ato make the brake light come on
earlier.
Turn the adjusting nut in direction
bto make the brake light come on
later.
1. Brake light switch
2. Adjusting nut
5EK-9-E1 (TW125)<3.1> 4/6/0 11:50 PM Page 51

6-24
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
EAU00744Drive chain slack check
NOTE:
Spin the wheel several times and
find the tightest position of the
chain. Check and/or adjust the
chain slack while it’s in this tightest
position.
a. Chain slack
To check the chain slack the motor-
cycle must be held straight up with
both wheels on the ground and
without rider. Check the slack at
the position shown in the illustra-
tion. Normal slack is approximately
35 ~ 60 mm. If the slack exceeds
60 mm, adjust.
EAU01533Drive chain slack adjustment
1. Loosen the rear brake adjust-
ing nut.
2. Loosen the wheel axle nut.
3. To tighten the chain, turn the
chain adjusting plates in direc-
tion a. To loosen the chain,
turn the chain adjusting plates
in direction band push the
wheel forward. Turn each
chain adjusting plate to exactly
the same position to maintain
correct axle alignment.
1. Wheel axle nut
2. Chain adjusting plate
3. Rear brake adjusting nut
a21
a
b
3
5EK-9-E1 (TW125)<3.1> 4/6/0 11:50 PM Page 54

6-25
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
EC000096
cC
Too little chain slack will overload
the engine and other vital parts.
Keep the slack within the specified
limits.
4. Tighten the wheel axle nut to
the specified torque.
5. Adjust the brake pedal free
play.
EW000103
w
Check the operation of the brake
light after adjusting the rear brake.
EAU01106*Drive chain lubrication
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 regular-
ly. This service is especially neces-
sary when riding in dusty areas.
The drive chain should be lubri-
cated every 500 km. First, remove
all dirt and mud from the chain
with a brush or cloth. Then, spray
any of the many brands of spray-
type chain lubricant between
both rows of side plates and on
all center rollers.
To clean the chain thoroughly,
remove it from the motorcycle,
dip it in solvent, and clean out as
much dirt as possible. Then, take
the chain out of the solvent to
dry it, and immediately lubricate
it to prevent it from rusting.
EC000097
cC
Be sure to oil the chain after wash-
ing the motorcycle or riding in the
rain.
Tightening torque:
Wheel axle nut:
90 Nm (9.0 m·kg)
5EK-9-E1 (TW125)<3.1> 4/6/0 11:50 PM Page 55