2003 YAMAHA TW125 tires

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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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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6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
6
9*Wheels•Check runout, spoke tightness and for damage.
•Tighten spokes if necessary.√√√√
10
*Tires•Check tread depth and for damage.
•Replace if necessary.
•Check air pressure.
•Correct if necessary.√√√√ √
11
*Wheel bearings•Check bearing for looseness or damage.√√√√
12
*Swingarm•Check operation and for excessive play.√√√√
•Lubricate with lithium-soap-based grease. Every 24,000 km
13 Drive chain•Check chain slack.
•Make sure that the rear wheel is properly aligned.
•Clean and lubricate.Every 500 km and after washing
the motorcycle or riding in the rain
14
*Steering bearings•Check bearing play and steering for roughness.√√√√√
•Lubricate with lithium-soap-based grease.Every 24,000 km
15
*Chassis fasteners•Make sure that all nuts, bolts and screws are properly tightened.√√√√ √
16 Sidestand•Check operation.
•Lubricate.√√√√ √
17
*Sidestand switch•Check operation.√√√√√ √
18
*Front fork•Check operation and for oil leakage.√√√√
19
*Shock absorber
assembly•Check operation and shock absorber for oil leakage.√√√√
20
*
Rear suspension relay
arm and connecting arm
pivoting points•Check operation.√√√√
•Lubricate with lithium-soap-based grease.√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 6 12 18 24
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6-16
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00637
Adjusting the valve
clearance
The valve clearance changes with
use, resulting in improper air-fuel mix-
ture and/or engine noise. To prevent
this from occurring, the valve clear-
ance must be adjusted by a Yamaha
dealer at the intervals specified in the
periodic maintenance and lubrication
chart.
EAU04401
Tires
To maximize the performance, dura-
bility, and safe operation of your
motorcycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
EW000082
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8The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the tempera-
ture of the tires equals the
ambient temperature).
8The tire air pressure must be
adjusted in accordance with
the riding speed and with the
total weight of rider, passen-
ger, cargo, and accessories
approved for this model.
Tire air pressure
(measured on cold tires)
Load* Front Rear
Up to 90 kg150 kPa
(1.50 kgf/cm
2,
1.50 bar)150 kPa
(1.50 kgf/cm2,
1.50 bar)
90 kg–maximum150 kPa
(1.50 kgf/cm
2,
1.50 bar)175 kPa
(1.75 kgf/cm2,
1.75 bar)
Maximum load* 180 kg
* Total weight of rider, passenger, cargo and
accessories
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6-17
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EWA00040
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Because loading has an enormous
impact on the handling, braking,
performance and safety character-
istics of your motorcycle, you
should keep the following precau-
tions in mind.
8NEVER OVERLOAD THE
MOTORCYCLE! Operation of
an overloaded motorcycle may
result in tire damage, loss of
control, or severe injury. Make
sure that the total weight of
rider, passenger, cargo, and
accessories does not exceed
the specified maximum load
for the vehicle.
8Do not carry along loosely
packed items, which can shift
during a ride.
8Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.8Adjust the tire air pressure
with regard to the load.
8Check the tire condition and
air pressure before each ride.
Tire inspection
The tires must be checked before
each ride. If the center tread depth
reaches the specified limit, if the tire
has a nail or glass fragments in it, or
if the sidewall is cracked, have a
Yamaha dealer replace the tire imme-
diately.
NOTE:
The tire tread depth limits may differ
from country to country. Always com-
ply with the local regulations.
1a
1. Tire side wall
a. Tire tread depth
Minimum tire tread depth
(front and rear)1.6 mm
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6-18
PERIODIC MAINTENANCE AND MINOR REPAIR
6 Tire information
This motorcycle is equipped with tube
tires.
EW000078
w
8The front and rear tires should
be of the same make and
design, otherwise the handling
characteristics of the motorcy-
cle cannot be guaranteed.
8After extensive tests, only the
tires listed below have been
approved for this model by
Yamaha Motor Co., Ltd.
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8Have a Yamaha dealer replace
excessively worn tires.
Besides being illegal, operat-
ing the motorcycle with exces-
sively worn tires decreases
riding stability and can lead to
loss of control.
8The replacement of all wheel-
and brake-related parts,
including the tires, should be
left to a Yamaha dealer, who
has the necessary profession-
al knowledge and experience.
8It is not recommended to
patch a punctured tube. If
unavoidable, however, patch
the tube very carefully and
replace it as soon as possible
with a high-quality product.
EAU00685
Spoke wheels
To maximize the performance, dura-
bility, and safe operation of your
motorcycle, note the following points
regarding the specified wheels.
8The wheel rims should be
checked for cracks, bends or
warpage, and the spokes for
looseness or damage before
each ride. If any damage is
found, have a Yamaha dealer
replace the wheel. Do not
attempt even the smallest repair
to the wheel. A deformed or
cracked wheel must be replaced.
8The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced.
An unbalanced wheel can result
in poor performance, adverse
handling characteristics, and a
shortened tire life.
FRONT
Manufacturer Size Type
BRIDGESTONE130/80-18 M/C 66P TW-203
REAR
Manufacturer Size Type
BRIDGESTONE180/80-14 M/C 78P TW-204
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7-3
MOTORCYCLE CARE AND STORAGE
7 After cleaning
1. Dry the motorcycle with a
chamois or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally
induced discoloring of stainless-
steel exhaust systems can be
removed through polishing.)
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal, includ-
ing chrome- and nickel-plated,
surfaces.
5. Use spray oil as a universal
cleaner to remove any remaining
dirt.6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry complete-
ly before storing or covering it.
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8Make sure that there is no oil
or wax on the brakes or tires.
If necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or
acetone, and wash the tires
with warm water and a mild
detergent.
8Before operating the motorcy-
cle test its braking perfor-
mance and cornering behav-
ior.
ECA00013
cC
8Apply spray oil and wax spar-
ingly and make sure to wipe
off any excess.
8Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
8Avoid using abrasive polish-
ing compounds as they will
wear away the paint.
NOTE:
Consult a Yamaha dealer for advice
on what products to use.
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7-5
MOTORCYCLE CARE AND STORAGE
7 6. Lubricate all control cables and
the pivoting points of all levers
and pedals as well as of the
sidestand/centerstand.
7. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground.
Alternatively, turn the wheels a
little every month in order to pre-
vent the tires from becoming
degraded in one spot.
8. Cover the muffler outlet with a
plastic bag to prevent moisture
from entering it.9. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a
month. Do not store the battery
in an excessively cold or warm
place (less than 0 °C) or more
than 30 °C). For more informa-
tion on storing the battery, see
page 6-33.
NOTE:
Make any necessary repairs before
storing the motorcycle.
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