2003 YAMAHA TW125 brake light

EAU00009
TABLE OF CONTENTS
GIVE SAFETY THE RIGHT OF WAY ................1-1
DESCRIPTION ...................................................2-1
Left view ..........................................................2-1
Right view ........................................................2-2
Controls and instruments ................................2-3
INSTRUMENT AND CONTROL FUNCTIONS ..3-1
Main switch .....................................................3-1
Indicator lights .................................................3-1
Speedometer unit ...........................................3-2
Handlebar switches .........................................3-3
Clutch lever .....................................................3-4
Shift pedal .......................................................3-4
Brake lever ......................................................3-5
Brake pedal .....................................................3-5
Fuel tank cap ...................................................3-5
Fuel .................................................................3-6
Fuel cock .........................................................3-7
Starter (choke) knob ........................................3-8
Steering lock ...................................................3-8
Seat .................................................................3-9
Helmet holder ................................................3-10
Shock absorber .............................................3-10
Carrier ...........................................................3-10
Luggage strap holders ..................................3-11
Sidestand ......................................................3-11Ignition circuit cut-off system .........................3-12
PRE-OPERATION CHECKS .............................4-1
Pre-operation check list ...................................4-1
OPERATION AND IMPORTANT RIDING
POINTS ..............................................................5-1
Starting a cold engine .....................................5-1
Starting a warm engine ...................................5-2
Shifting ............................................................5-3
Recommended shift points
(for Switzerland only) ....................................5-3
Tips for reducing fuel consumption .................5-4
Engine break-in ...............................................5-4
Parking ............................................................5-5
PERIODIC MAINTENANCE AND MINOR
REPAIR ..............................................................6-1
Owner’s tool kit ................................................6-1
Periodic maintenance and lubrication chart ....6-2
Removing and installing panels ......................6-5
Checking the spark plug ..................................6-7
Engine oil and oil filter element .......................6-9
Cleaning the air filter element and check
hose ...........................................................6-12
Adjusting the carburetor ................................6-14
Adjusting the engine idling speed .................6-141
2
3
4
5
6
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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
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
7
8
9
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2-3
DESCRIPTION
2
1. Clutch lever (page 3-4, 6-19)
2. Left handlebar switches (page 3-3)
3. Speedometer unit (page 3-2)
4. Starter (choke) knob (page 3-8)
5. Main switch (page 3-1)6. Indicator lights (page 3-1)
7. Right handlebar switches (page 3-3)
8. Brake lever (page 3-5, 6-20)
9. Throttle grip (page 6-15, 6-28)
10. Fuel tank cap (page 3-5)
1
23
45
678
9
10
Controls and instruments
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4-2
PRE-OPERATION CHECKS
4
Throttle grip•Make sure that operation is smooth.
•Check cable free play.
•If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.6-15, 6-28
Control cables•Make sure that operation is smooth.
•Lubricate if necessary.6-27
Drive chain•Check chain slack.
•Adjust if necessary.
•Check chain condition.
•Lubricate if necessary.6-25–6-27
Wheels and tires•Check for damage.
•Check tire condition and tread depth.
•Check air pressure.
•Correct if necessary.6-16–6-19
Brake and shift pedals•Make sure that operation is smooth.
•Lubricate pedal pivoting points if necessary.6-28
Brake and clutch levers•Make sure that operation is smooth.
•Lubricate lever pivoting points if necessary.6-29
Sidestand•Make sure that operation is smooth.
•Lubricate pivot if necessary.6-29
Chassis fasteners•Make sure that all nuts, bolts and screws are properly tightened.
•Tighten if necessary.—
Instruments, lights, signals
and switches•Check operation.
•Correct if necessary.3-1–3-4, 6-34–6-37
Sidestand switch•Check operation of ignition circuit cut-off system.
•If system is defective, have Yamaha dealer check vehicle.3-12–3-13 ITEM CHECKS PAGE
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6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
6EAU03541
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
*Throttle grip housing
and cable•Check operation and free play.
•Adjust the throttle cable free play if necessary.
•Lubricate the throttle grip housing and cable.√√√√ √
28
*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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6-22
PERIODIC MAINTENANCE AND MINOR REPAIR
6 To increase the brake pedal free
play, turn the adjusting nut at the
brake rod in direction a. To
decrease the brake pedal free play,
turn the adjusting nut in direction b.
b
a1
1. Brake pedal free play adjusting nut
EW000106
w
8After adjusting the drive chain
slack or removing and
installing the rear wheel,
always check the brake pedal
free play.
8If proper adjustment cannot be
obtained as described, have a
Yamaha dealer make this
adjustment.
8After adjusting the brake pedal
free play, check the operation
of the brake light.
EAU00713
Adjusting the rear brake light
switch
The rear brake light switch, which is
activated by the brake pedal, is prop-
erly adjusted when the brake light
comes on just before braking takes
effect. If necessary, adjust the brake
light switch as follows.
Turn the adjusting nut while holding
the rear brake light switch in place.
To make the brake light come on ear-
lier, turn the adjusting nut in direction
a. To make the brake light come on
later, turn the adjusting nut in direc-
tion b.
1
2
a
b
1. Rear brake light switch
2. Adjusting nut
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6-26
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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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.)
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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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6-36
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.
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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