YAMAHA TW125 2000 Workshop Manual

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9 If the specified free play cannot be
obtained, proceed with the follow-
ing steps.
4. Loosen the locknut at the
clutch lever.
5. Turn the adjusting bolt at the
clutch lever in direction ato
loosen the cable.
6. Loosen the locknut at the
crankcase side.
7. Turn the adjusting nut at the
crankcase in direction ato
increase free play or in direc-
tion bto decrease free play.
8. Tighten the locknut at the
crankcase and the clutch lever.
1. Locknut
2. Adjusting nut
EAU00694Clutch lever free play
adjustment
The clutch lever free play should
be adjusted to 10 ~ 15 mm.
1. Loosen the locknut at the
clutch lever.
2. Turn the adjusting bolt at the
clutch lever in direction ato
increase free play or in direc-
tion bto decrease free play.
3. Tighten the locknut at the
clutch lever.
1. Locknut
2. Adjusting bolt
c. Free play
EAU00696
Front brake lever free play
adjustment
The free play at the front brake
lever should be 2 ~ 5 mm.
1. Loosen the locknut.
2. Turn the adjusting bolt in
direction ato increase free
play or in direction bto
decrease free play.
3. After adjusting, tighten the
locknut.
1. Locknut
2. Adjusting bolt
c. Free play
c1
2
a
b
1
ab
2
12c
a b
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d
c
2 1
a
b
EAU00707Rear brake pedal height and
free play adjustment
EW000104
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It is advisable to have a Yamaha
dealer make this adjustment.
Pedal height
The brake pedal should be posi-
tioned so that its top end is
approximately 15 mm below the
top of the footrest.
1. Loosen the locknut.
1. Locknut
2. Adjusting bolt
c. Pedal height
d. Free play
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8Check the brake lever free
play. Be sure the brake is
working properly.
8A soft or spongy feeling in the
brake lever can indicate the
presence of air in the brake
system. This air must be
removed by bleeding the
brake system before the
motorcycle is operated. Air in
the system will cause greatly
diminished braking capability
and can result in loss of con-
trol and an accident. Have a
Yamaha dealer inspect and
bleed the system if necessary.
2. Turn the adjusting bolt in
direction ato raise pedal
height or in direction bto
lower pedal height.
3. Tighten the locknut.
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After adjusting the pedal height
adjust brake pedal free play.
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1
ba
Free play
The rear brake pedal free play
should be adjusted to 20 ~ 30 mm
at the brake pedal end. Turn the
adjusting nut on the brake rod in
direction ato increase free play or
in direction bto decrease free
play.
1. Adjusting nut
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8Brake pedal free play should
be checked whenever the
chain is adjusted or the rear
wheel is removed and then
reinstalled.
8Check the operation of the
brake light after adjusting the
rear brake.
8If it is impossible to make
proper adjustment, consult a
Yamaha dealer.
1
2
a
b
EAU00713Brake light switch
adjustment
The rear brake light switch is acti-
vated by the brake pedal and is
properly adjusted when the brake
light comes on just before braking
takes effect. To adjust the rear
brake light switch, hold the switch
body so it does not rotate while
turning the adjusting nut.
Turn the adjusting nut in direction
ato make the brake light come on
earlier.
Turn the adjusting nut in direction
bto make the brake light come on
later.
1. Brake light switch
2. Adjusting nut
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EAU00720Checking the front brake
pads and rear brake shoes
EAU01119
Front brake
Wear indicator grooves are provid-
ed on each brake pad. These indi-
cators allow checking of brake pad
wear without disassembling the
brake. Inspect the grooves. If they
have almost disappeared, ask a
Yamaha dealer to replace the pads.
1. Indicator grooves
EAU00727
Rear brake
Apply the brake and inspect the
wear indicator.
If the indicator reaches the wear
limit line, ask a Yamaha dealer to
replace the shoes.
1. Wear limit line
2. Wear indicator
EAU00732Inspecting the brake fluid
level
Insufficient brake fluid may let air
enter the brake system, possibly
causing the brakes to become inef-
fective.
Before riding, check that the brake
fluid is above the minimum level
and fill when necessary.
Observe these precautions:
8When checking the fluid level,
make sure the top of the mas-
ter cylinder is level by turning
the handlebars.
1. Minimum level mark
1
FRONT
2
1
REAR
1
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9 8Use only the designated quali-
ty brake fluid. Otherwise, the
rubber seals may deteriorate,
causing leakage and poor
brake performance.
NOTE:
If DOT 4 is not available, DOT 3 can
be used.
8Refill with the same type of
brake fluid. Mixing fluids may
result in a harmful chemical
reaction and lead to poor
brake performance.
8Be careful that water does not
enter the master cylinder when
refilling. Water will significant-
ly lower the boiling point of
the fluid and may result in
vapor lock.8Brake fluid may deteriorate
painted surfaces or plastic
parts. Always clean up spilled
fluid immediately.
8Have a Yamaha dealer check
the cause if the brake fluid
level goes down.
EAU00742Brake fluid replacement
The brake fluid should be replaced
only by trained Yamaha service
personnel. Have the Yamaha deal-
er replace the following compo-
nents during periodic maintenance
or when they are damaged or leak-
ing:
8oil seals (every two years)
8brake hoses (every four years) Recommended brake fluid:
DOT 4
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EAU00744Drive chain slack check
NOTE:
Spin the wheel several times and
find the tightest position of the
chain. Check and/or adjust the
chain slack while it’s in this tightest
position.
a. Chain slack
To check the chain slack the motor-
cycle must be held straight up with
both wheels on the ground and
without rider. Check the slack at
the position shown in the illustra-
tion. Normal slack is approximately
35 ~ 60 mm. If the slack exceeds
60 mm, adjust.
EAU01533Drive chain slack adjustment
1. Loosen the rear brake adjust-
ing nut.
2. Loosen the wheel axle nut.
3. To tighten the chain, turn the
chain adjusting plates in direc-
tion a. To loosen the chain,
turn the chain adjusting plates
in direction band push the
wheel forward. Turn each
chain adjusting plate to exactly
the same position to maintain
correct axle alignment.
1. Wheel axle nut
2. Chain adjusting plate
3. Rear brake adjusting nut
a21
a
b
3
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EC000096
cC
Too little chain slack will overload
the engine and other vital parts.
Keep the slack within the specified
limits.
4. Tighten the wheel axle nut to
the specified torque.
5. Adjust the brake pedal free
play.
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Check the operation of the brake
light after adjusting the rear brake.
EAU01106*Drive chain lubrication
The chain consists of many parts
which work with each other. If the
chain is not maintained properly, it
will wear out quickly. Therefore,
the chain must be serviced regular-
ly. This service is especially neces-
sary when riding in dusty areas.
The drive chain should be lubri-
cated every 500 km. First, remove
all dirt and mud from the chain
with a brush or cloth. Then, spray
any of the many brands of spray-
type chain lubricant between
both rows of side plates and on
all center rollers.
To clean the chain thoroughly,
remove it from the motorcycle,
dip it in solvent, and clean out as
much dirt as possible. Then, take
the chain out of the solvent to
dry it, and immediately lubricate
it to prevent it from rusting.
EC000097
cC
Be sure to oil the chain after wash-
ing the motorcycle or riding in the
rain.
Tightening torque:
Wheel axle nut:
90 Nm (9.0 m·kg)
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EAU02962Cable inspection and
lubrication
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Damage to the outer housing of
cables may lead to internal rusting
and interfere with the cable move-
ment. Replace damaged cables as
soon as possible to prevent unsafe
conditions.
Lubricate the cables and cable
ends. If a cable does not operate
smoothly, ask a Yamaha dealer to
replace it.EAU00773Throttle cable and grip
lubrication
The throttle twist grip assembly
should be greased at the time that
the cable is lubricated, since the
grip must be removed to get at the
end of the throttle cable. After
removing the screws, hold the end
of the cable up in the air and put in
several drops of lubricant. With the
throttle grip disassembled, coat the
metal surface of the grip assembly
with a suitable all-purpose grease. Recommended lubricant:
Engine oil
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EAU02984Brake and shift pedal
lubrication
Lubricate the pivoting parts.
EAU02985Brake and clutch lever
lubrication
Lubricate the pivoting parts.
EAU02986Sidestand lubrication
Lubricate the sidestand pivoting
point and metal-to-metal contact
surfaces. Check that the sidestand
moves up and down smoothly.
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If the sidestand does not move
smoothly, consult a Yamaha deal-
er.
Recommended lubricant:
Engine oilRecommended lubricant:
Engine oil
Recommended lubricant:
Engine oil
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EAU00791Rear suspension lubrication
Lubricate the pivoting parts.
1. Grease nipple (´2)
EAU02939Front fork inspection
Visual checkEW000115
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Securely support the motorcycle
so there is no danger of it falling
over.
Check for scratches or damage on
the inner tube and excessive oil
leakage from the front fork.Operation check
1. Place the motorcycle on a level
place.
2. Hold the motorcycle in an
upright position and apply the
front brake.
3. Push down hard on the han-
dlebars several times and
check if the fork rebounds
smoothly.
EC000098
cC
If any damage or unsmooth move-
ment is found with the front fork,
consult a Yamaha dealer.
1
Recommended lubricant:
Lithium soap base grease
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