YAMAHA TW125 2002 Workshop Manual

6-20
PERIODIC MAINTENANCE AND MINOR REPAIR
65. Loosen the locknut at the
crankcase.
6. To increase the clutch lever free
play, turn the adjusting nut in
direction a. To decrease the
clutch lever free play, turn the
adjusting nut in direction b.
7. Tighten the locknut at the clutch
lever and the crankcase.3. Tighten the locknut.
EW000099
w8After adjusting the brake lever
free play, check the free play
and make sure that the brake
is working properly.
8A soft or spongy feeling in the
brake lever can indicate the
presence of air in the
hydraulic system. If there is air
in the hydraulic system, have
a Yamaha dealer bleed the
system before operating the
motorcycle. Air in the
hydraulic system will diminish
the braking performance,
which may result in loss of
control and an accident.
2
1
ba
1. Locknut (crankcase)
2. Adjusting nut
EAU00696
Adjusting the brake lever
free playThe brake lever free play should
measure 5–8 mm as shown.
Periodically check the brake lever
free play and, if necessary, adjust it
as follows.
1. Loosen the locknut at the brake
lever.
2. To increase the brake lever free
play, turn the adjusting bolt in
direction a. To decrease the
brake lever free play, turn the
adjusting bolt in direction b.
c
12
a
b
1. Locknut
2. Adjusting bolt
c. Free play
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6-21
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00707
Adjusting the brake pedal
position and free play
EW000104
wIt is advisable to have a Yamaha
dealer make these adjustments.Brake pedal position
The top of the brake pedal should be
positioned approximately 30 mm
below the top of the footrest.
Periodically check the brake pedal
position and, if necessary, adjust it as
follows.1. Loosen the locknut at the brake
pedal.
2. To raise the brake pedal, turn the
adjusting bolt in direction a. To
lower the brake pedal, turn the
adjusting bolt in direction b.
3. Tighten the locknut.
EWA00044
wAfter adjusting the brake pedal
position, the brake pedal free play
must be adjusted.
c
2 1
a
b
1. Locknut
2. Adjusting bolt
c. Brake pedal position
Brake pedal free play
The brake pedal free play should
measure 20–30 mm as shown.
Periodically check the brake pedal
free play and, if necessary, adjust it
as follows.
a
a. Brake pedal free play
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6-22
PERIODIC MAINTENANCE AND MINOR REPAIR
6To 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.
ba
1
1. Brake pedal free play adjusting nut
EAU00713
Adjusting the rear brake light
switchThe 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
EW000106
w8After 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.
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6-23
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00720
Checking the front brake
pads and rear brake shoesThe front brake pads and the rear
brake shoes must be checked for
wear at the intervals specified in the
periodic maintenance and lubrication
chart.
EAU00727
Rear brake shoes
The rear brake is provided with a
wear indicator, which allows you to
check the brake shoe wear without
having to disassemble the brake. To
check the brake shoe wear, check
the position of the wear indicator
while applying the brake. If a brake
shoe has worn to the point that the
wear indicator reaches the wear limit
line, have a Yamaha dealer replace
the brake shoes as a set.
21
1. Wear limit line
2. Wear indicator
EAU03938
Front brake pads
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear
without having to disassemble the
brake. To check the brake pad wear,
check the wear indicator grooves. If a
brake pad has worn to the point that
the wear indicator grooves have
almost disappeared, have a Yamaha
dealer replace the brake pads as a
set.
1
1
1. Brake pad wear indicator groove (×3)FRONT
REAR
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6-24
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03774
Checking the brake fluid
levelInsufficient brake fluid may allow air
to enter the brake system, possibly
causing it to become ineffective.
Before riding, check that the brake
fluid is above the minimum level mark
and replenish if necessary. A low
brake fluid level may indicate worn
brake pads and/or brake system
leakage. If the brake level is low, be
sure to check the brake pads for
wear and the brake system for leak-
age.
1
1. Minimum level mark
8Brake fluid may deteriorate paint-
ed surfaces or plastic parts.
Always clean up spilled fluid
immediately.
8As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if
the brake fluid level goes down
suddenly, have a Yamaha dealer
check the cause. Observe these precautions:
8When checking the fluid level,
make sure that the top of the
brake fluid reservoir is level.
8Use only the recommended qual-
ity brake fluid, otherwise the rub-
ber seals may deteriorate, caus-
ing leakage and poor braking
performance.
8Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking perfor-
mance.
8Be careful that water does not
enter the brake fluid reservoir
when refilling. Water will signifi-
cantly lower the boiling point of
the fluid and may result in vapor
lock. Recommended brake fluid:
DOT 4
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6-25
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03985
Changing the brake fluidHave a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addi-
tion, have the oil seals of the brake
master cylinder and caliper as well as
the brake hose replaced at the inter-
vals listed below or whenever they
are damaged or leaking.
8Oil seals: Replace every two
years.
8Brake hose: Replace every four
years.2. Shift the transmission into the
neutral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain,
and then measure the drive
chain slack as shown.
4. If the drive chain slack is incor-
rect, adjust it as follows.
a
a. Drive chain slack
EAU00744
Drive chain slackThe drive chain slack should be
checked before each ride and adjust-
ed if necessary.
To check the drive chain slack
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:
When checking and adjusting the
drive chain slack, the motorcycle
should be positioned straight up and
there should be no weight on it.
Drive chain slack:
35–60 mm
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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.
NOTE:
Make sure that both adjusting plates
are in the same position for proper
wheel alignment.
EC000096
cCImproper 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
wAfter adjusting the brake pedal
free play, check the operation of
the brake light.
32
a
b
1
1. Brake pedal free play adjusting nut
2. Axle nut
3. Drive chain adjusting plate
Tightening torque:
Axle nut:
90 Nm (9.0 m·kgf)
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6-27
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU01106
Lubricating the drive chainThe drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly
wear out, especially when riding in
dusty or wet areas. Service the drive
chain as follows.
EC000097
cCThe drive chain must be lubricated
after washing the motorcycle or
riding in the rain.1. Remove all dirt and mud from
the drive chain with a brush or
cloth.
2. Spray a drive chain lubricant on
both sides and on the middle of
the chain, making sure that all
side plates and rollers have been
sufficiently oiled.
NOTE:
For a thorough cleaning, have a
Yamaha dealer remove the drive
chain and soak it in solvent.
EAU02962
Checking and lubricating the
cablesThe operation of all control cables
and the condition of the cables
should be checked before each ride,
and the cables and cable ends
should be lubricated if necessary. If a
cable is damaged or does not move
smoothly, have a Yamaha dealer
check or replace it.
Recommended lubricant:
Engine oil
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6-28
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EW000112
wDamage 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.
EAU03370
Checking and lubricating the
brake and shift pedalsThe operation of the brake and shift
pedals should be checked before
each ride, and the pedal pivots
should be lubricated if necessary.
EAU04034
Checking and lubricating the
throttle grip and cableThe 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.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
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6-29
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03164
Checking and lubricating the
brake and clutch leversThe 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
sidestandThe 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
wIf 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)
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