2001 YAMAHA TW125 Owners Manual

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PERIODIC MAINTENANCE AND MINOR REPAIR
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Periodic maintenance and lubrication chart
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 6 12 18 24
1
*Fuel line¥ Check fuel hoses for cracks or damage.ÖÖÖÖ Ö
2 Spark plug¥ Check condition.
¥ Clean and regap.ÖÖ
¥ Replace.ÖÖ
3*Valves¥ Check valve clearance.
¥ Adjust.ÖÖÖÖ
4 Air filter element¥ Clean.ÖÖ
¥ Replace.ÖÖ
5*Battery¥ Check electrolyte level and specific gravity.
¥ Make sure that the breather hose is properly routed.ÖÖÖÖ Ö
6 Clutch¥ Check operation.
¥ Adjust.ÖÖÖÖÖ
7*Front brake¥ Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)ÖÖÖÖÖ Ö
¥ Replace brake pads.Whenever worn to the limit
8*Rear brake¥ Check operation and adjust brake pedal freeplay.ÖÖÖÖÖ Ö
¥ Replace brake shoes.Whenever worn to the limit
9*Brake hose¥ Check for cracks or damage.ÖÖÖÖ Ö
¥ Replace. (See NOTE on page 6-4.)Every 4 years
NOTE:
8The annual checks must be performed every year, except if kilometer-based maintenance is performed instead.
8From 30,000 km, repeat the maintenance intervals starting from 6,000 km.
8Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
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*Wheels¥ Check runout, spoke tightness and for damage.
¥ Tighten spokes if necessary.ÖÖÖÖ
11*Tires¥ Check tread depth and for damage.
¥ Replace if necessary.
¥ Check air pressure.
¥ Correct if necessary.ÖÖÖÖ
12*Wheel bearings¥ Check bearing for looseness or damage.ÖÖÖÖ
13*Swingarm¥ Check operation and for excessive play.ÖÖÖÖ
¥ Lubricate with lithium-soap-based grease. Every 24,000km
14 Drive chain¥ Check chain slack.
¥ Make sure that the rear wheel is properly aligned.
¥ Clean and lubricate.Every 500 km and after washing
the motorcycle in the rain
15*Steering bearings¥ Check bearing play and steering for roughness.ÖÖÖÖÖ
¥ Lubricate with lithium-soap-based greaseEvery 24,000km
16*Chassis fasteners¥ Make sure that all nuts, bolts and screws are properly tightened.ÖÖÖÖ Ö
17 Sidestand¥ Check operation.
¥ Lubricate.ÖÖÖÖ Ö
18*Sidestand switch¥ Check operation.ÖÖÖÖÖ Ö
19*Front fork¥ Check operation and for oil leakage.ÖÖÖÖ
20*Rear shock absorber
assembly pivoting
points¥ Check operation and shock absorber for oil leakage.ÖÖÖÖ
¥ Lubricate with lithium-soap-based grease.ÖÖ
21*Carburetor¥ Check starter (choke) operation.
¥ Adjust engine idling speed.ÖÖÖÖÖ Ö NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 6 12 18 24
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NOTE:
8The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8Hydraulic brake service
8
Regularly check and, if necessary, correct the brake fluid level.
8
Every two years replace the internal components of 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.ÖÖÖÖÖ Ö
23 Engine oil filter element¥ Replace.ÖÖÖ
24
*Engine oil strainer¥ Clean.ÖÖÖ
25*Front and rear brake
switches¥ Check operation.ÖÖÖÖÖ Ö
26 Moving parts and cables¥ Lubricate.ÖÖÖÖ Ö
27*Lights, signals and
switches¥ Check operation.
¥ Adjust headlight beam.ÖÖÖÖÖ Ö NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 6 12 18 24
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6-5
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Removing and installing the
cowling and panelsThe cowling and panels shown above
need to be removed to perform some
of the maintenance jobs described 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
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Cowling A
To remove the cowlingRemove the screw, and then pull the
cowling off as shown.
To install the cowlingPlace the cowling in the original posi-
tion, and then install the screw.1. Cowling A
2. Screw
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Panel A
To remove the panelRemove the screws, and then pull
the panel out at the area shown.1. Panel A
2. Screw (´2)
2
1
To install the panelPlace the panel in the original posi-
tion, and then install the screws.
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Panel B
To remove the panelPull the panel off as shown.1. Panel B
1
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Checking the spark plugThe spark plug is an important
engine component, which is easy to
check. Since heat and deposits will
cause any spark plug to slowly erode,
the spark plug should 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 wrenchTo 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 ownerÕs
tool kit.
1
To install the panelPlace the panel in the original posi-
tion.
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To check the spark plug
1. Check that the porcelain insula-
tor around the center electrode
of the spark plug is a medium-to-
light tan (the ideal color when the
motorcycle is ridden normally).NOTE:
If the spark plug shows a distinctly
different color, the engine could be
defective. Do not attempt to diagnose
such problems yourself. Instead,
have a Yamaha dealer check the
motorcycle.2. Check the spark plug for elec-
trode erosion and excessive car-
bon or other deposits, and
replace it if necessary.
NOTE:
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is
1/4Ð1/2 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.
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9 Specified spark plug:
DR8EA (NGK)
a
a. Spark plug gapTo install the spark plug
1. Measure the spark plug gap with
a wire thickness gauge and, if
necessary, adjust the gap to
specification.
2. Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then
tighten it to the specified torque. Spark plug gap:
0.6Ð0.7 mm
Tightening torque:
Spark plug:
17.5 Nm (1.75 mákg)
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93. Wait a few minutes until the oil
settles, and then check the oil
level through the check window
located at the bottom-left side of
the crankcase.
NOTE:
The engine oil should be between the
minimum and maximum level marks.4. If the engine oil is below the
minimum level mark, add suffi-
cient oil of the recommended
type to raise it to the correct
level.1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
To change the engine oil (with or
without oil filter element cleaning)
1. Start the engine, warm it up for
several minutes, and then 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
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Engine oil and oil filter
elementThe 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 periodic maintenance
and lubrication chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:
Make sure that the motorcycle is
positioned straight up when checking
the oil level. A slight tilt to the side
can result in a false reading.2. Start the engine, warm it up for
several minutes, and then turn it
off.
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