2003 YAMAHA TW125 lock

6-20
PERIODIC MAINTENANCE AND MINOR REPAIR
6 5. Loosen the locknut at the
crankcase.
6. To increase the clutch lever free
play, turn the adjusting nut in
direction a. To decrease the
clutch lever free play, turn the
adjusting nut in direction b.
7. Tighten the locknut at the clutch
lever and the crankcase.
21
ba
1. Locknut (crankcase)
2. Adjusting nut
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Adjusting the brake lever
free play
The brake lever free play should
measure 5–8 mm as shown.
Periodically check the brake lever
free play and, if necessary, adjust it
as follows.
1. Loosen the locknut at the brake
lever.
2. To increase the brake lever free
play, turn the adjusting bolt in
direction a. To decrease the
brake lever free play, turn the
adjusting bolt in direction b.
c12
a
b
1. Locknut
2. Adjusting bolt
c. Free play
3. Tighten the locknut.EW000099
w
8After adjusting the brake lever
free play, check the free play
and make sure that the brake
is working properly.
8A soft or spongy feeling in the
brake lever can indicate the
presence of air in the
hydraulic system. If there is air
in the hydraulic system, have
a Yamaha dealer bleed the
system before operating the
motorcycle. Air in the
hydraulic system will diminish
the braking performance,
which may result in loss of
control and an accident.
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6-21
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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Adjusting the brake pedal
position and free play
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It is advisable to have a Yamaha
dealer make these adjustments.
Brake pedal position
The top of the brake pedal should be
positioned approximately 30 mm
below the top of the footrest.
Periodically check the brake pedal
position and, if necessary, adjust it as
follows.
c
2 1
a
b
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.
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After adjusting the brake pedal
position, the brake pedal free play
must be adjusted.
Brake pedal free play
The brake pedal free play should
measure 20–30 mm as shown.
Periodically check the brake pedal
free play and, if necessary, adjust it
as follows.
a
a. Brake pedal free play
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6-24
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04856
Checking the brake fluid
level
Insufficient 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 fluid level is low,
be sure to check the brake pads for
wear and the brake system for leak-
age.
1
1. Minimum level mark
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.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.
Recommended brake fluid:
DOT 4
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6-36
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03497
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
2
3
1. Screw
2. Lens
3. Bulb
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cC
Do not overtighten the screw, oth-
erwise the lens may break.
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Replacing the tail/brake light
bulb
1. Remove the tail/brake light lens
by removing the screws.
1
1. Screw (×2)
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6-37
PERIODIC MAINTENANCE AND MINOR REPAIR
62. 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
screws.
EC000108
cC
Do not overtighten the screws,
otherwise the lens may break.
1
1. Bulb
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Supporting the motorcycle
Since this model is not equipped with
a centerstand, follow these precau-
tions when removing the front and
rear wheel or performing other main-
tenance requiring the motorcycle to
stand upright. Check that the motor-
cycle is in a stable and level position
before starting any maintenance. A
strong wooden box can be placed
under the engine for added stability.
To service the front wheel
1. Stabilize the 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.To service the rear wheel
Raise the rear wheel off the ground
by using a motorcycle stand or, if a
motorcycle stand is not available, by
placing a jack either under each side
of the frame in front of the rear wheel
or under each side of the swingarm.
5RS-9-E1 (TW125) 8/23/02 11:37 AM Page 68