2003 YAMAHA TW125 brake

6-26
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04369
To adjust the drive chain slack
1. Loosen the brake pedal free play
adjusting nut.
2. Loosen the axle nut.
3. To tighten the drive chain, turn
the adjusting plate on each side
of the swingarm in direction a.
To loosen the drive chain, turn
the adjusting plate on each side
of the swingarm in direction b,
and then push the rear wheel for-
ward.
32
a
b
1
1. Brake pedal free play adjusting nut
2. Axle nut
3. Drive chain adjusting plate
NOTE:
Make sure that both adjusting plates
are in the same position for proper
wheel alignment.
EC000096
cC
Improper drive chain slack will
overload the engine as well as
other vital parts of the motorcycle
and can lead to chain slippage or
breakage. To prevent this from
occurring, keep the drive chain
slack within the specified limits.
4. Tighten the axle nut to the speci-
fied torque.5. Adjust the brake pedal free play.
(See page 6-21 for brake pedal
free play adjustment proce-
dures.)
EW000103
w
After adjusting the brake pedal
free play, check the operation of
the brake light.
Tightening torque:
Axle nut:
90 Nm (9.0 m·kgf)
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6-28
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EW000112
w
Damage to the outer sheath may
interfere with proper cable opera-
tion and will cause the inner cable
to rust. Replace a damaged cable
as soon as possible to prevent
unsafe conditions.
EAU04034
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip
should be checked before each ride.
In addition, the cable should be lubri-
cated or replaced at the intervals
specified in the periodic maintenance
chart.
EAU03370
Checking and lubricating the
brake and shift pedals
The operation of the brake and shift
pedals should be checked before
each ride, and the pedal pivots
should be lubricated if necessary.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
5RS-9-E1 (TW125) 8/23/02 11:37 AM Page 59

6-29
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03164
Checking and lubricating the
brake and clutch levers
The operation of the brake and clutch
levers should be checked before
each ride, and the lever pivots should
be lubricated if necessary.
EAU03165
Checking and lubricating the
sidestand
The operation of the sidestand
should be checked before each ride,
and the sidestand pivot and metal-to-
metal contact surfaces should be
lubricated if necessary.
EW000113
w
If the sidestand does not move up
and down smoothly, have a
Yamaha dealer check or repair it.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
5RS-9-E1 (TW125) 8/23/02 11:37 AM Page 60

6-30
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04282
Lubricating the rear
suspension
The pivoting points of the rear sus-
pension must be lubricated at the
intervals specified in the periodic
maintenance and lubrication chart.
1
1. Grease nipple (×2)
EAU02939
Checking the front fork
The condition and operation of the
front fork must be checked as follows
at the intervals specified in the peri-
odic maintenance and lubrication
chart.
To check the condition
EW000115
w
Securely support the motorcycle
so that there is no danger of it
falling over.
Check the inner tubes for scratches,
damage and excessive oil leakage.To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and
rebounds smoothly.
EC000098
cC
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
Recommended lubricant:
Lithium-soap-based grease
5RS-9-E1 (TW125) 8/23/02 11:37 AM Page 61

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
ECA00065
cC
Do not overtighten the screw, oth-
erwise the lens may break.
EAU01623
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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6-39
PERIODIC MAINTENANCE AND MINOR REPAIR
63. Disconnect the speedometer
cable from the front wheel.
4. Loosen the axle nut.
5. Lift the front wheel off the ground
according to the procedure on
page 6-37.
6. Remove the axle nut, pull the
wheel axle out, and then remove
the wheel.
1
2
1. Speedometer cable
2. Axle nut
ECA00048
cC
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
EAU04388
To install the front wheel
1. Install the speedometer gear unit
into the wheel hub so that the
projections mesh with the slots.
2. Lift the wheel up between the
fork legs.
1
1. Speedometer gear unit
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6-40
PERIODIC MAINTENANCE AND MINOR REPAIR
6
NOTE:
Make sure that there is enough
space between the brake pads
before inserting the brake disc and
that the slot in the speedometer gear
unit fits over the retainer on the fork
leg.
3. Insert the wheel axle, and then
install the axle nut.
4. Lower the front wheel so that it is
on the ground.
2 1
1. Retainer
2. Speedometer cable
5. Tighten the axle nut to the speci-
fied torque.
6. Place the rubber cover at the
bottom of the right-side fork leg
in the original position.
7. Install the rubber cover at the
bottom of the left-side fork leg.
8. Connect the speedometer cable.
EAU03519
Rear wheel
To remove the rear wheelEW000122
w
8It is advisable to have a
Yamaha dealer service the
wheel.
8Securely support the motorcy-
cle so that there is no danger
of it falling over.
1. Loosen the axle nut.
5a
2
1
34
1. Axle nut
2. Brake pedal free play adjusting nut
3. Brake rod
4. Brake camshaft lever
5. Drive chain adjusting plate
Tightening torque:
Axle nut:
90 Nm (9.0 m·kgf)
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6-41
PERIODIC MAINTENANCE AND MINOR REPAIR
62. Remove the brake pedal free
play adjusting nut, and then dis-
connect the brake rod from the
brake camshaft lever.
3. Turn the drive chain adjusting
plate on each side of the
swingarm fully in direction a.
4. Lift the rear wheel off the ground
according to the procedure on
page 6-37.
5. Remove the axle nut, and then
pull the wheel axle out.
6. Push the wheel forward, and
then remove the drive chain from
the rear sprocket.
NOTE:
The drive chain does not need to be
disassembled in order to remove and
install the wheel.
7. Remove the wheel.
EAU03520
To install the rear wheel
1. Insert the wheel axle from the
left-hand side.
NOTE:
Make sure that the drive chain adjust-
ing plates are installed with the
punched sides facing to the outside
and that the slot in the brake shoe
plate fits over the retainer on the
swingarm.
1
1. Retainer
2. Install the drive chain onto the
rear sprocket, and then adjust
the drive chain slack. (See page
6-26 for drive chain slack adjust-
ment procedures.)
3. Install the axle nut, and then
lower the rear wheel so that it is
on the ground.
4. Tighten the axle nut to the speci-
fied torque.
5. Install the brake rod onto the
brake camshaft lever, and then
install the brake pedal free play
adjusting nut onto the brake rod.
6. Adjust the brake pedal free play.
(See page 6-21 for brake pedal
free play adjustment proce-
dures.) Tightening torque:
Axle nut:
90 Nm (9.0 m·kgf)
5RS-9-E1 (TW125) 8/23/02 11:37 AM Page 72