light YAMAHA TW125 2001 User Guide

5-4
OPERATION AND IMPORTANT RIDING POINTS
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EAU00424
Tips for reducing fuel
consumptionFuel consumption depends largely on
your riding style. Consider the follow-
ing tips to reduce fuel consumption:
8Thoroughly warm up the engine.
8Turn the starter (choke) off as
soon as possible.
8Shift up swiftly, and avoid high
engine speeds during accelera-
tion.
8Do not rev the engine while shift-
ing down, and avoid high engine
speeds with no load on the
engine.
8Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at
traffic lights or at railroad cross-
ings).
EAU01128
Engine break-inThere is never a more important peri-
od in the life of your engine than the
period between 0 and 1,600 km. For
this reason, you should read the fol-
lowing material carefully.
Since the engine is brand new, do
not put an excessive load on it for the
first 1,600 km. The various parts in
the engine wear and polish them-
selves to the correct operating clear-
ances. During this period, prolonged
full-throttle operation or any condition
that might result in engine overheat-
ing must be avoided.
EAU01500
0Ð1,000 km
Avoid prolonged operation above 1/3
throttle.
1,000Ð1,600 km
Avoid prolonged operation above 1/2
throttle.
EC000057
cCAfter 1,000 km of operation, the
engine oil must be changed, the oil
filter cartridge/element replaced,
and the oil strainer cleaned.1,600 km and beyond
The vehicle can now be operated
normally.
EC000049
cCIf any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
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6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
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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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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.
6-8
PERIODIC MAINTENANCE AND MINOR REPAIR
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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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6-9
PERIODIC MAINTENANCE AND MINOR REPAIR
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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
1
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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6-22
PERIODIC MAINTENANCE AND MINOR REPAIR
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9 To 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.
1
2
a
b
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. Brake light switch
2. Adjusting nut
ba
1
1. Brake pedal free play 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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6-26
PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU03526
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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6-35
PERIODIC MAINTENANCE AND MINOR REPAIR
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94. Remove the headlight bulb hold-
er by turning it counterclockwise,
and then remove the defective
bulb.
EW000119
wHeadlight bulbs get very hot.
Therefore, keep flammable prod-
ucts away from a lit headlight bulb,
and do not touch the bulb until it
has cooled down.5. Place a new bulb into position,
and then secure it with the bulb
holder.1. Headlight bulb holder
1
3. Disconnect the headlight cou-
pler, and then remove the head-
light bulb cover.1. Coupler
2. Headlight bulb cover
1
2
EAU01158
Replacing the headlight bulbIf the headlight bulb burns out,
replace it as follows.
1. Remove cowling A. (See page
6-5 for cowling removal and
installation procedures.)
2. Remove the headlight unit by
removing the bolts.1. Bolt (´2)
1
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6-36
PERIODIC MAINTENANCE AND MINOR REPAIR
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9 6. Install the bulb cover, and then
connect the coupler.
7. Install the headlight unit by
installing the bolts.
8. Install the cowling.
9. Have a Yamaha dealer adjust
the headlight beam if necessary.
EAU03497
Replacing a turn signal light
bulb1. Remove the turn signal light lens
by removing the screw.
2. Remove the defective bulb by
pushing it in and turning it coun-
terclockwise.
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
2. Lens
3. bulb
1
2
3
ECA00065
cCDo not overtighten the screw, oth-
erwise the lens may break.
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6-37
PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU01579
Supporting the motorcycleSince this model is not equipped with
a centerstand, follow these precau-
tions when removing the front and
rear wheel or performing other main-
tenance requiring the motorcycle to
stand upright. Check that the motor-
cycle 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 motorcy-
cle by using a motorcycle stand
or, if an additional motorcycle
stand is not available, by placing
a jack under the frame in front of
the rear wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand. 2. Remove the defective bulb by
pushing it in and turning it coun-
terclockwise.
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.
EC000108
cCDo not overtighten the screws,
otherwise the lens may break.1. Bulb
1
EAU01623
Replacing the tail/brake light
bulb1. Remove the tail/brake light lens
by removing the screws.1. Screw (´2)
1
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6-40
PERIODIC MAINTENANCE AND MINOR REPAIR
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9 2. Remove the brake pedal free
play adjusting nut, and then dis-
connect the brake rod from the
brake camshaft 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 6-37.
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.
EAU03520
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 the
punched 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
6-26 for drive chain slack adjust-
ment procedures.)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 6-21 for brake pedal
free play adjustment proce-
dures.)
EW000103
wAfter adjusting the brake pedal
free play, check the operation of
the brake light.
Tightening torque:
Axle nut:
90 Nm (9.0 mákg)
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