check engine YAMAHA TW125 2001 User Guide

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EAU03541
NOTE:
8The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8Hydraulic brake service
8
Regularly check and, if necessary, correct the brake fluid level.
8
Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.
8
Replace the brake hoses every four years and if cracked or damaged.
22 Engine oil¥ Change.ÖÖÖÖÖ Ö
23 Engine oil filter element¥ Replace.ÖÖÖ
24
*Engine oil strainer¥ Clean.ÖÖÖ
25*Front and rear brake
switches¥ Check operation.ÖÖÖÖÖ Ö
26 Moving parts and cables¥ Lubricate.ÖÖÖÖ Ö
27*Lights, signals and
switches¥ Check operation.
¥ Adjust headlight beam.ÖÖÖÖÖ Ö NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 6 12 18 24
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Checking the spark plugThe spark plug is an important
engine component, which is easy to
check. Since heat and deposits will
cause any spark plug to slowly erode,
the spark plug should be removed
and checked in accordance with the
periodic maintenance and lubrication
chart. In addition, the condition of the
spark plug can reveal the condition of
the engine.
1. Spark plug wrenchTo remove the spark plug
1. Remove the spark plug cap.
2. Remove the spark plug as
shown, with the spark plug
wrench included in the ownerÕs
tool kit.
1
To install the panelPlace the panel in the original posi-
tion.
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To check the spark plug
1. Check that the porcelain insula-
tor around the center electrode
of the spark plug is a medium-to-
light tan (the ideal color when the
motorcycle is ridden normally).NOTE:
If the spark plug shows a distinctly
different color, the engine could be
defective. Do not attempt to diagnose
such problems yourself. Instead,
have a Yamaha dealer check the
motorcycle.2. Check the spark plug for elec-
trode erosion and excessive car-
bon or other deposits, and
replace it if necessary.
NOTE:
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is
1/4Ð1/2 turn past finger tight.
However, the spark plug should be
tightened to the specified torque as
soon as possible.4. Install the spark plug cap.
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9 Specified spark plug:
DR8EA (NGK)
a
a. Spark plug gapTo install the spark plug
1. Measure the spark plug gap with
a wire thickness gauge and, if
necessary, adjust the gap to
specification.
2. Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then
tighten it to the specified torque. Spark plug gap:
0.6Ð0.7 mm
Tightening torque:
Spark plug:
17.5 Nm (1.75 mákg)
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93. Wait a few minutes until the oil
settles, and then check the oil
level through the check window
located at the bottom-left side of
the crankcase.
NOTE:
The engine oil should be between the
minimum and maximum level marks.4. If the engine oil is below the
minimum level mark, add suffi-
cient oil of the recommended
type to raise it to the correct
level.1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
To change the engine oil (with or
without oil filter element cleaning)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the
engine to collect the used oil.
3. Remove the engine oil filler cap
and drain bolt to drain the oil
from the crankcase.1. Engine oil filler cap
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2
3 1
EAU03564
Engine oil and oil filter
elementThe engine oil level should be
checked before each ride. In addition,
the oil must be changed and the oil
filter element cleaned at the intervals
specified in the periodic maintenance
and lubrication chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:
Make sure that the motorcycle is
positioned straight up when checking
the oil level. A slight tilt to the side
can result in a false reading.2. Start the engine, warm it up for
several minutes, and then turn it
off.
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912. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil
filler cap. 9. Install the oil filter element cover
by installing the screws and the
drain bolt. Then tightening them
to the specified torque.
NOTE:
Make sure that the O-rings are prop-
erly seated.10. Clean the oil strainer with sol-
vent, and then check it for dam-
age and replace it if necessary.
11. Install the oil strainer, spring, O-
ring and engine oil drain bolt,
and then tighten the drain bolt to
the specified torque.Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 mákg)
5. Remove the oil filter element
cover by removing the screws.
6. Remove the oil filter element and
O-rings.
7. Check the O-rings for damage
and replace it if necessary.
8. Clean the oil filter element with
solvent, and then install it. NOTE:
Check the oil filter element for dam-
age and replace it if necessary.1. Oil filter element
2. O-ring (´2)
1 2
2
Tightening torques:
Oil filter element cover screw:
7.0 Nm (0.7 mákg)
Oil filter element drain bolt:
10 Nm (1.0 mákg)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element
removal:
1.0 L
With oil filter element removal:
1.1 L
Total amount (dry engine):
1.3 L
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Cleaning the air filter
element and check hoseThe air filter element should be
cleaned at the intervals specified in
the periodic maintenance and lubrica-
tion chart. Clean the air filter element
more frequently if you are riding in
unusually wet or dusty areas. In addi-
tion, the air filter check hose must be
frequently checked and cleaned if
necessary.
To clean the air filter element
1. Remove panel A. (See page 6-6
for panel removal and installation
procedures.)
1. Air filter case cover
2. Screw (´4)
EC000072
cC8In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives
with the oil or use oils of a
higher grade than ÒCDÓ. In
addition, do not use oils
labeled ÒENERGY CONSERV-
ING
IIÓ or higher.
8Make sure that no foreign
material enters the crankcase.
13. Start the engine, and then let it
idle for several minutes while
checking it for oil leakage. If oil is
leaking, immediately turn the
engine off and check for the
cause.
14. Turn the engine off, and then
check the oil level and correct it if
necessary.2. Remove the air filter case cover
by removing the screws.
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Adjusting the carburetorThe carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, most
carburetor adjustments should be left
to a Yamaha dealer, who has the
necessary professional knowledge
and experience. The adjustment
described in the following section,
however, may be serviced by the
owner as part of routine mainte-
nance.
EC000094
cCThe carburetor has been set and
extensively tested at the Yamaha
factory. Changing these settings
without sufficient technical knowl-
edge may result in poor perfor-
mance of or damage to the engine.
EAU01168
Adjusting the engine idling
speedThe engine idling speed must be
checked and, if necessary, adjusted
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.NOTE:
A diagnostic tachometer is needed to
make this adjustment.1. Attach the tachometer to the
spark plug lead.
2. Start the engine and warm it up
for several minutes at
1,000Ð2,000 r/min while occa-
sionally revving it to 4,000Ð5,000
r/min.NOTE:
The engine is warm when it quickly
responds to the throttle.
To clean the air filter check hose
1. Check the hose at the bottom of
the air filter case for accumulated
dirt or water.
2. If dirt or water is visible, remove
the hose, clean it, and then
install it.1. Air filter check hose
1
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93. Check the engine idling speed
and, if necessary, adjust it to
specification by turning the throt-
tle stop screw. To increase the
engine idling speed, turn the
screw in direction a.To
decrease the engine idling speed,
turn the screw in direction b.
NOTE:
If the specified idling speed cannot
be obtained as described above,
have a Yamaha dealer make the
adjustment.1. Throttle stop screw
1
a
b
Engine idling speed:
1,300Ð1,500 r/min
EAU00634
Adjusting the throttle cable
free playThe throttle cable free play should
measure 3Ð5 mm at the throttle grip.
Periodically check the throttle cable
free play and, if necessary, adjust it
as follows.NOTE:
The engine idling speed must be cor-
rectly adjusted before checking and
adjusting the throttle cable free play.
1. Adjusting nut
2. Locknut
c. Free play1. Loosen the locknut.
2. To increase the throttle cable
free play, turn the adjusting nut
in direction a. To decrease the
throttle cable free play, turn the
adjusting nut in direction b.
3. Tighten the locknut.
1
2
abc
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Adjusting the valve
clearanceThe 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.
EAU03563
TiresTo 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
w8The 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
150 kPa 150 kPa
Up to 80 kg 1.50 kg/cm
2, 1.50 kg/cm
2,
1.50 bar 1.50 bar
80 kgÐ150 kPa 175 kPa
Maximum *1.50 kg/cm
2, 1.75 kg/cm
2,
1.50 bar 1.75 bar
125 kPa 125 kPa
Off-road riding 1.25 kg/cm
2, 1.25 kg/cm
2,
1.25 bar 1.25 bar
Maximum load* 180 kg
* Total weight of rider, passenger, cargo and
accessories
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To adjust the drive chain slack
1. Loosen the brake pedal free play
adjusting nut and the axle nut.
2. 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.1. Axle nut
2. Chain adjusting plate
3. Rear brake pedal free play adjusting nut
21
a
b
3
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.3. Tighten the brake pedal free play
adjusting nut, and then tighten
the axle nut to the specified
torque.
4. 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.
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.
Tightening torque:
Axle nut:
90 Nm (9.0 mákg)
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