brake YAMAHA TW125 2004 Owners Manual

TABLE OF CONTENTS
SAFETY INFORMATION ............. 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 ................................ 3-4
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 ............................ 3-9
Shock absorber ....................... 3-10
Carrier ..................................... 3-10
Luggage strap holders ............ 3-10
Sidestand ................................ 3-11Ignition circuit cut-off system ... 3-11
PRE-OPERATION CHECKS ........ 4-1
Pre-operation check list ............ 4-2
OPERATION AND IMPORTANT
RIDING POINTS ........................... 5-1
Starting a cold engine ............... 5-1
Starting a warm engine ............. 5-2
Shifting ...................................... 5-2
Tips for reducing fuel
consumption ............................ 5-3
Engine break-in ......................... 5-4
Parking ...................................... 5-4
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 ........... 6-6
Engine oil and oil filter
element ................................... 6-7
Cleaning the air filter element
and check hose ..................... 6-10
Adjusting the carburetor .......... 6-12Adjusting the engine idling
speed .................................... 6-12
Adjusting the throttle cable free
play ....................................... 6-13
Adjusting the valve
clearance .............................. 6-13
Tires ........................................ 6-13
Spoke wheels .......................... 6-16
Adjusting the clutch lever free
play ....................................... 6-16
Adjusting the brake lever free
play ....................................... 6-17
Adjusting the brake pedal
position and free play ............ 6-18
Adjusting the rear brake light
switch .................................... 6-19
Checking the front brake pads
and rear brake shoes ............ 6-19
Checking the brake fluid
level ....................................... 6-20
Changing the brake fluid ......... 6-21
Drive chain slack ..................... 6-21
Lubricating the drive chain ...... 6-23
Checking and lubricating the
cables .................................... 6-23
Checking and lubricating the
throttle grip and cable ........... 6-24

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TABLE OF CONTENTS
Checking and lubricating the
brake and shift pedals ........... 6-24
Checking and lubricating the
brake and clutch levers ......... 6-24
Checking and lubricating the
sidestand ............................... 6-25
Lubricating the rear
suspension ............................ 6-25
Checking the front fork ............ 6-25
Checking the steering ............. 6-26
Checking the wheel
bearings ................................ 6-27
Battery ..................................... 6-27
Replacing the fuse .................. 6-28
Replacing the headlight bulb ... 6-29
Replacing the tail/brake light
bulb ....................................... 6-31
Replacing a turn signal light
bulb ....................................... 6-31
Supporting the motorcycle ...... 6-32
Front wheel ............................. 6-33
Rear wheel .............................. 6-34
Troubleshooting ...................... 6-36
Troubleshooting chart ............. 6-37
MOTORCYCLE CARE AND
STORAGE..................................... 7-1
Care .......................................... 7-1Storage ..................................... 7-3
SPECIFICATIONS ....................... 8-1
CONSUMER INFORMATION ....... 9-1
Identification numbers ............... 9-1

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DESCRIPTION
2-2
2
3
4
5
6
7
8
9

EAU10420
Right view
1
2
65 3
4
7
1. Carrier
2. Battery (page 6-27)
3. Engine oil filter element (page 6-7)
4. Engine oil level check window (page 6-7)
5. Brake pedal (page 3-5)
6. Owner’s tool kit (page 6-1)
7. Fuse (page 6-28)

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DESCRIPTION
2-3
1
2
3
4
5
6
7
8
9

EAU10430
Controls and instruments
1
23
45
678
9
10

1. Clutch lever (page 3-4)
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 3-4)9. Throttle grip (page 6-13)
10. Fuel tank cap (page 3-5)

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INSTRUMENT AND CONTROL FUNCTIONS
3-4
1
2
3
4
5
6
7
8
9

EAU12820
Clutch lever
The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handle-
bar 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 3-11.)
EAU12870
Shift pedal
The shift pedal is located on the left
side of the engine and is used in com-
bination with the clutch lever when
shifting the gears of the 5-speed con-
stant-mesh transmission equipped on
this motorcycle.
EAU12890
Brake lever
The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handle-
bar grip.
1. Clutch lever
1

1. Shift pedal1
1. Brake lever
1

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INSTRUMENT AND CONTROL FUNCTIONS
3-5
2
34
5
6
7
8
9

EAU12941
Brake pedal
The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
EAU32280
Fuel tank cap
To remove the fuel tank cap
1. Insert the key into the lock and turn
it 1/3 turn counterclockwise.
2. Turn the fuel tank cap 1/3 turn
counterclockwise and pull it off.
To install the fuel tank cap
1. Insert the fuel tank cap into the tank
opening with the key inserted in the
lock, and then turn the cap 1/3 turn
clockwise.

2. Turn the key 1/3 turn clockwise,
and then remove it.
NOTE:

The fuel tank cap cannot be installedunless the key is in the lock. In addition,
the key cannot be removed if the cap is
not properly installed and locked.
WARNING

EWA10120
Make sure that the fuel tank cap is
properly closed and locked before
riding.
1. Brake pedal
1

1. Fuel tank cap
2. Unlock.1 2

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PRE-OPERATION CHECKS
4-2
1
2
3
4
5
6
7
8
9

EAU15602
Pre-operation check list
ITEM CHECKS PAGE
Fuel

Check fuel level in fuel tank.

Refuel if necessary.

Check fuel line for leakage.3-6
Engine oil

Check oil level in engine.

If necessary, add recommended oil to specified level.

Check vehicle for oil leakage.6-7
Front brake

Check operation.

If soft or spongy, have Yamaha dealer bleed hydraulic system.

Check lever free play.

Adjust if necessary.

Check brake pads for wear.

Replace if necessary.

Check fluid level in reservoir.

If necessary, add recommended brake fluid to specified level.

Check hydraulic system for leakage.6-17, 6-19, 6-20
Rear brake

Check operation.

Check pedal free play.

Adjust if necessary.6-18, 6-19
Clutch

Check operation.

Lubricate cable if necessary.

Check lever free play.

Adjust if necessary.6-16
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.6-13, 6-24
Control cables

Make sure that operation is smooth.

Lubricate if necessary.6-23

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PRE-OPERATION CHECKS
4-3
2
3
45
6
7
8
9

Drive chain

Check chain slack.

Adjust if necessary.

Check chain condition.

Lubricate if necessary.6-21, 6-23
Wheels and tires

Check for damage.

Check tire condition and tread depth.

Check air pressure.

Correct if necessary.6-13, 6-16
Brake and shift pedals

Make sure that operation is smooth.

Lubricate pedal pivoting points if necessary.6-24
Brake and clutch levers

Make sure that operation is smooth.

Lubricate lever pivoting points if necessary.6-24
Sidestand

Make sure that operation is smooth.

Lubricate pivot if necessary.6-25
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.—
Sidestand switch

Check operation of ignition circuit cut-off system.

If system is defective, have Yamaha dealer check vehicle.3-11
ITEM CHECKS PAGE

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

EAU17710
Periodic maintenance and lubrication chart
NOTE:


The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.

From 30000 km, repeat the maintenance intervals starting from 6000 km.

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×× × ×
1000 km)
ANNUAL
CHECK
1 6 12 18 24
1*
Fuel line


Check fuel hoses for cracks or damage.
√

√

√

√

√

2
Spark plug


Check condition.

Clean and regap.
√

√


Replace.
√

√

3*
Valves


Check valve clearance.

Adjust.
√

√

√

√

4
Air filter element


Clean.
√

√



Replace.
√

√

5
Clutch


Check operation.

Adjust.
√

√

√

√

√

6*
Front brake


Check operation, fluid level and vehicle for fluid leak-
age.
√

√

√

√

√

√



Replace brake pads. Whenever worn to the limit
7*
Rear brake

Check operation and adjust brake pedal free play.
√

√

√

√

√

√



Replace brake shoes. Whenever worn to the limit
8*
Brake hose

Check for cracks or damage.
√

√

√

√

√



Replace. Every 4 years
9*
Wheels

Check runout, spoke tightness and for damage.

Tighten spokes if necessary.
√

√

√

√


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

EAU18660
NOTE:


The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

Hydraulic brake service

Regularly check and, if necessary, correct the brake fluid level.

Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.

Replace the brake hoses every four years and if cracked or damaged.
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 (
×× × ×
1000 km)
ANNUAL
CHECK
1 6 12 18 24

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