2003 YAMAHA TW125 clutch

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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3-4
INSTRUMENT AND CONTROL FUNCTIONS
3
EAU00152
Clutch lever
The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the han-
dlebar grip. To engage the clutch,
release the lever. The lever should
be pulled rapidly and released slowly
for smooth clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the igni-
tion circuit cut-off system. (See page
3-12 for an explanation of the ignition
circuit cut-off system.)
1
1. Clutch lever
EAU00157
Shift pedal
The shift pedal is located on the left
side of the engine and is used in
combination with the clutch lever
when shifting the gears of the
5-speed constant-mesh transmission
equipped on this motorcycle.
1
1. Shift pedal
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Start switch “,”
Push this switch to crank the engine
with the starter.
EC000005
cC
See page 5-1 for starting instruc-
tions prior to starting the engine.
1
2
1. Engine stop switch “#/$”
2. Start switch “,”
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3-12
EAU03720
Ignition circuit cut-off
system
The ignition circuit cut-off system
(comprising the sidestand switch,
clutch switch and neutral switch) has
the following functions.
8It prevents starting when the
transmission is in gear and the
sidestand is up, but the clutch
lever is not pulled.
8It prevents starting when the
transmission is in gear and the
clutch lever is pulled, but the
sidestand is still down.
8It cuts the running engine when
the transmission is in gear and
the sidestand is moved down.
Periodically check the operation of
the ignition circuit cut-off system
according to the following procedure.
EW000045
w
If a malfunction is noted, have a
Yamaha dealer check the system
before riding.
INSTRUMENT AND CONTROL FUNCTIONS
3
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3-13
INSTRUMENT AND CONTROL FUNCTIONS
3
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is set to “
#”.
3. Turn the key to “ON”.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
The sidestand switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The clutch switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
NO
NOTE:
This check is most reliable if performed with
a warmed-up engine.
YES
YES NO
The system is OK. The motorcycle can be ridden.
YES NO
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4-1
EAU01114
PRE-OPERATION CHECKS
4The 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 listPre-operation check list
ITEM CHECKS PAGE
Fuel•Check fuel level in fuel tank.
•Refuel if necessary.
•Check fuel line for leakage.3-5–3-7
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.3-5, 6-20, 6-23–6-25
Rear brake•Check operation.
•Check pedal free play.
•Adjust if necessary.3-5, 6-21–6-23
Clutch•Check operation.
•Lubricate cable if necessary.
•Check lever free play.
•Adjust if necessary.3-4, 6-19–6-20
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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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