2002 YAMAHA TW125 brake fluid

Adjusting the throttle cable free play ............ 6-15
Adjusting the valve clearance ...................... 6-16
Tires ............................................................. 6-16
Spoke wheels ............................................... 6-18
Adjusting the clutch lever free play .............. 6-19
Adjusting the brake lever free play ............... 6-20
Adjusting the brake pedal position and
free play .................................................... 6-21
Adjusting the rear brake light switch ............ 6-22
Checking the front brake pads and
rear brake shoes ....................................... 6-23
Checking the brake fluid level ...................... 6-24
Changing the brake fluid .............................. 6-25
Drive chain slack .......................................... 6-25
Lubricating the drive chain ........................... 6-27
Checking and lubricating the cables ............ 6-27
Checking and lubricating the throttle grip
and cable .................................................. 6-28
Checking and lubricating the brake 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 ................... 6-30
Checking the front fork ................................. 6-30
Checking the steering .................................. 6-31
Checking the wheel bearings ....................... 6-31Battery .......................................................... 6-32
Replacing the fuse ....................................... 6-33
Replacing the headlight bulb ........................ 6-34
Replacing a turn signal light bulb ................. 6-36
Replacing the tail/brake light bulb ................ 6-36
Supporting the motorcycle ........................... 6-37
Front wheel .................................................. 6-38
Rear wheel ................................................... 6-40
Troubleshooting ........................................... 6-42
Troubleshooting chart .................................. 6-43
MOTORCYCLE CARE AND STORAGE .......... 7-1
Care ............................................................... 7-1
Storage .......................................................... 7-4
SPECIFICATIONS ............................................ 8-1
Conversion table ............................................ 8-5
CONSUMER INFORMATION ........................... 9-1
Identification numbers .................................... 9-1
Key identification number ............................... 9-1
Vehicle identification number ......................... 9-1
Model label ..................................................... 9-2
TABLE OF CONTENTS
789
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4-1
EAU01114
PRE-OPERATION CHECKS
4 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpect-
edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak-
age or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thor-
ough visual inspection, to check the following points before each ride.
EAU03439
Pre-operation check list
ITEM CHECKS PAGE
Fuel•Check fuel level in fuel tank.
•Refuel if necessary.
•Check fuel line for leakage.3-5–3-6
Engine oil•Check oil level in engine.
•If necessary, add recommended oil to specified level.
•Check vehicle for oil leakage.6-9–6-12
Front brake•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
•Check lever free play.
•Adjust if necessary.
•Check fluid level in reservoir.
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.3-4, 6-20, 6-23–6-25
Rear brake•Check operation.
•Check pedal free play.
•Adjust if necessary.3-5, 6-21–6-23
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6-2
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03686
Periodic maintenance and lubrication chart
NOTE:
8The annual checks must be performed every year, except if a 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.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.√√√√ √
2 Spark plug•Check condition.
•Clean and regap.√√
•Replace.√√
3*Valves•Check valve clearance.
•Adjust.√√√√
4 Air filter element•Clean.√√
•Replace.√√
5 Clutch•Check operation.
•Adjust.√√√√√
6*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
7*Rear brake•Check operation and adjust brake pedal free play.√√√√√ √
•Replace brake shoes.Whenever worn to the limit
8*Brake hose•Check for cracks or damage.√√√√ √
•Replace. (See NOTE on page 6-4.)Every 4 years
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6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03541
NOTE:
8The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8Hydraulic brake service
9Regularly check and, if necessary, correct the brake fluid level.
9Every two years replace the internal components of the brake master cylinder and caliper, and change the brake
fluid.
9Replace the brake hoses every four years and if cracked or damaged.21
*Carburetor•Check starter (choke) operation.
•Adjust engine idling speed.√√√√√ √
22 Engine oil•Change.
•Check oil level and vehicle for oil leakage.√√√√√ √
23 Engine oil filter element•Clean.√√√
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 MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 6 12 18 24
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6-24
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03774
Checking the brake fluid
levelInsufficient brake fluid may allow air
to enter the brake system, possibly
causing it to become ineffective.
Before riding, check that the brake
fluid is above the minimum level mark
and replenish if necessary. A low
brake fluid level may indicate worn
brake pads and/or brake system
leakage. If the brake level is low, be
sure to check the brake pads for
wear and the brake system for leak-
age.
1
1. Minimum level mark
8Brake fluid may deteriorate paint-
ed surfaces or plastic parts.
Always clean up spilled fluid
immediately.
8As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if
the brake fluid level goes down
suddenly, have a Yamaha dealer
check the cause. Observe these precautions:
8When checking the fluid level,
make sure that the top of the
brake fluid reservoir is level.
8Use only the recommended qual-
ity brake fluid, otherwise the rub-
ber seals may deteriorate, caus-
ing leakage and poor braking
performance.
8Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking perfor-
mance.
8Be careful that water does not
enter the brake fluid reservoir
when refilling. Water will signifi-
cantly lower the boiling point of
the fluid and may result in vapor
lock. Recommended brake fluid:
DOT 4
5RS-9-E0 (TW125) 7/30/01 6:03 PM Page 54

6-25
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03985
Changing the brake fluidHave a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addi-
tion, have the oil seals of the brake
master cylinder and caliper as well as
the brake hose replaced at the inter-
vals listed below or whenever they
are damaged or leaking.
8Oil seals: Replace every two
years.
8Brake hose: Replace every four
years.2. Shift the transmission into the
neutral position.
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
a. Drive chain slack
EAU00744
Drive chain slackThe drive chain slack should be
checked before each ride and adjust-
ed if necessary.
To check the drive chain slack
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:
When checking and adjusting the
drive chain slack, the motorcycle
should be positioned straight up and
there should be no weight on it.
Drive chain slack:
35–60 mm
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7-2
MOTORCYCLE CARE AND STORAGE
7 8Do 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 abra-
sive cleaning products, sol-
vent or thinner, fuel (gasoline),
rust removers or inhibitors,
brake fluid, antifreeze or elec-
trolyte.
8Do not use high-pressure
washers or steam-jet cleaners
since they cause water seep-
age and deterioration in the
following areas: seals (of
wheel and swingarm bearings,
fork and brakes), electric com-
ponents (couplers, connec-
tors, instruments, switches
and lights), breather hoses
and vents.8For motorcycles equipped
with a windshield: Do not use
strong cleaners or hard
sponges as they will cause
dulling or scratching. Some
cleaning compounds for plas-
tic may leave scratches on the
windshield. Test the product
on a small hidden part of the
windshield to make sure that it
does not leave any marks. If
the windshield is scratched,
use a quality plastic polishing
compound after washing.
After normal useRemove 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
before cleaning.After riding in the rain, near the sea
or on salt-sprayed roadsSince sea salt or salt sprayed on
roads during 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.NOTE:
Salt sprayed on roads in the winter
may remain well into spring.1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.
ECA00012
cCDo not use warm water since it
increases the corrosive action of
the salt.2. Apply a corrosion protection
spray on all metal, including
chrome- and nickel-plated, sur-
faces to prevent corrosion.
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8-3
SPECIFICATIONS
8
Maximum load* 180 kg
Air pressure (cold tire)
up to 90 kg load*
Front
150 kPa (1.50 kgf/cm
2, 1.50 bar)
Rear
150 kPa (1.50 kgf/cm
2, 1.50 bar)
90 kg load–Maximum
load*
Front
150 kPa (1.50 kgf/cm
2, 1.50 bar)
Rear
175 kPa (1.75 kgf/cm
2, 1.75 bar)
*Total weight of rider, passenger, cargo and accessoriesWheels
Front
Type Spoke wheel
Size 18 ×2.50
Rear
Type Spoke wheel
Size 14M/C ×MT4.50Brakes
Front
Type Single disc brake
Operation Right hand
Fluid DOT 4
Rear
Type Drum brake
Operation Right foot
Suspension
Front
Type Telescopic fork
Rear
Type Swingarm (Monocross
suspension)
Spring/shock absorber
Front Coil spring/oil damper
Rear Coil spring/gas-oil damper
Wheel travel
Front 150 mm
Rear 150 mm
5RS-9-E0 (TW125) 7/30/01 6:03 PM Page 81