2004 YAMAHA TW125 maintenance

PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
2
3
4
5
67
8
9
WARNING

EWA10790
Headlight bulbs get very hot. There-
fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down.
4. Place a new headlight bulb into po-
sition, and then secure it with the
bulb holder.
CAUTION:

ECA10660
Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency ofthe glass, the luminosity of the bulb,
and the bulb life will be adversely af-
fected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with al-
cohol or thinner.
5. Install the headlight bulb cover,
and then connect the coupler.6. Install the headlight unit by install-
ing the screws.
7. Have a Yamaha dealer adjust the
headlight beam if necessary.
1. Headlight bulb holder
1

1. Do not touch the glass part of the bulb.
1

✹✺✬✲✥ ✦✣



PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
1
2
3
4
5
6
7
8
9

EAU24131
Replacing the tail/brake light
bulb
1. Remove the tail/brake light lens by
removing the screws.
2. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.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.
CAUTION:

ECA10680
Do not overtighten the screws, oth-
erwise the lens may break.
EAU24201
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 counter-
clockwise.
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. Screw
1(×2)

1. Tail/brake light bulb
1

1. Screw
2. Turn signal light lens
3. Bulb
1
2
3

✹✺✬✲✥ ✦✤ 



PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
2
3
4
5
67
8
9
CAUTION:

ECA11190
Do not overtighten the screw, other-
wise the lens may break.
EAU24350
Supporting the motorcycle
Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance
requiring the motorcycle to stand up-
right. Check that the motorcycle 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 motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack un-
der 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 motor-
cycle stand is not available, by placing
a jack either under each side of theframe in front of the rear wheel or under
each side of the swingarm.

✹✺✬✲✥ ✦✥ 



PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
1
2
3
4
5
6
7
8
9

EAU24360
Front wheel
EAU24590
To remove the front wheel
WARNING

EWA10820

It is advisable to have a Yamaha
dealer service the wheel.

Securely support the motorcy-
cle so that there is no danger of
it falling over.
1. Pull outward on the rubber cover at
the bottom of the right-side fork
leg, and then slide it up along the
fork leg.
2. Pull outward on the rubber cover at
the bottom of the left-side fork leg,and then pull it off.
3. Disconnect the speedometer ca-
ble from the front wheel.
4. Loosen the axle nut.
5. Lift the front wheel off the groundaccording to the procedure on
page 6-32.
6. Remove the axle nut, pull the
wheel axle out, and then remove
the wheel.
CAUTION:

ECA11070
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
EAU24991
To install the front wheel
1. Install the speedometer gear unit
into the wheel hub so that the pro-
jections mesh with the slots.
1. Rubber cover
1

1. Rubber cover
1. Speedometer cable
2. Axle nut
1
1
2
1. Speedometer gear unit
1

✹✺✬✲✥ ✦✦ 



PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
2
3
4
5
67
8
9
2. Lift the wheel up between the fork
legs.
NOTE:

Make sure that there is enough space
between the brake pads before insert-
ing 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 in-
stall the axle nut.
4. Lower the front wheel so that it is
on the ground.
5. Tighten the axle nut to the speci-fied torque.
6. Place the rubber cover at the bot-
tom of the right-side fork leg in the
original position.
7. Install the rubber cover at the bot-
tom of the left-side fork leg.
8. Connect the speedometer cable.
EAU25080
Rear wheel
EAU25420
To remove the rear wheel
WARNING

EWA10820

It is advisable to have a Yamaha
dealer service the wheel.

Securely support the motorcy-
cle so that there is no danger of
it falling over.
1. Loosen the axle nut.
2. Remove the brake pedal free play
1. Retainer
2. Speedometer cable
2 1

Tightening torque:
Axle nut:
90 Nm (9.0 m·kgf, 65.1 ft·lbf)
1. Axle nut
2. Brake pedal free play adjusting nut
3. Brake rod
4. Brake camshaft lever
5. Drive chain slack adjusting plate
5
2
1
3
4
(a)

✹✺✬✲✥ ✦✧ 



PERIODIC MAINTENANCE AND MINOR REPAIR
6-35
1
2
3
4
5
6
7
8
9
adjusting nut, and then disconnect
the brake rod from the brake cam-
shaft 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 6-32.
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.
EAU25761
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 thepunched sides facing to the outside
and that the slot in the brake shoe plate
fits over the retainer on the swingarm.
2. Install the drive chain onto the rear
sprocket, and then adjust the drive
chain slack. (See page 6-21.)
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 6-18.)
WARNING

EWA10660
After adjusting the brake pedal free
play, check the operation of the
brake light.
1. Retainer
Tightening torque:
Axle nut:
90 Nm (9.0 m·kgf, 65.1 ft·lbf)
1

✹✺✬✲✥ ✦




PERIODIC MAINTENANCE AND MINOR REPAIR
6-36
2
3
4
5
67
8
9

EAU25850
Troubleshooting
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi-
or, have a shorter service life and can
lead to expensive repair bills.

✹✺✬✲✥ ✦✩ 



PERIODIC MAINTENANCE AND MINOR REPAIR
6-37
1
2
3
4
5
6
7
8
9

EAU25901
Troubleshooting chart
WARNING

EWA10840
Keep away open flames and do not smoke while checking or working on the fuel system.
Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plug
and check the electrodes.3. Ignition
Wipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.
The battery is good.Check the battery lead connections,
and charge the battery if necessary.
DryWet
Open the throttle halfway and operate
the electric starter.

✹✺✬✲✥ ✦✪