YAMAHA TW125 2001 Workshop Manual

6-20
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU00696
Adjusting the brake lever
free playThe brake lever free play should
measure 2Ð5 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.
3. Tighten the locknut.1. Locknut
2. Adjusting bolt
c. Free play
12
c
a b
5. Loosen the locknuts at the
crankcase.
6. To increase the clutch lever free
play, turn the adjusting bolt in
direction a. To decrease the
clutch lever free play, turn the
adjusting bolt in direction b.
7. Tighten the locknuts at the clutch
lever and the crankcase.1. Locknut (´2)
2. Adjusting bolt
ab
2
1
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.
5EK-9-E2 (TW125)<3.3Passport> 5/23/00 9:47 AM Page 49

6-21
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
c
2 1
a
b
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 15 mm
below the top of the footrest.
Periodically check the brake pedal
position and, if necessary, adjust it as
follows.1. Locknut
2. Adjusting bolt
c. Brake pedal position
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.
EW000105
wAfter adjusting the brake pedal
height, the brake pedal free play
must be adjusted.
a
Brake pedal free play
The brake pedal free play should
measure 20Ð30 mm as shown.
Periodically check the brake pedal
free play and, if necessary, adjust it
as follows.a. Brake pedal free play
5EK-9-E2 (TW125)<3.3Passport> 5/23/00 9:47 AM Page 50

6-22
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
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.
5EK-9-E2 (TW125)<3.3Passport> 5/23/00 9:47 AM Page 51

6-23
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU01119
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 indicators have almost dis-
appeared, have a Yamaha dealer
replace the brake pads as a set.1. Indicator groove (´3)
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.1. Wear limit line
2. Wear indicator
1
FRONT
21
REAR
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.
5EK-9-E2 (TW125)<3.3Passport> 5/23/00 9:47 AM Page 52

6-24
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU03196
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. Minimum level mark1
Observe these precautions:
8When checking the fluid level,
make sure that the top of the
master cylinder or 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 master cylinder when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.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.
Recommended brake fluid:
DOT 4
5EK-9-E2 (TW125)<3.3Passport> 5/23/00 9:47 AM Page 53

6-25
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
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.
a. Drive chain slack2. 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
Drive chain slack:
35Ð60 mm
EAU03238
Changing the brake fluidHave a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrica-
tion chart. In addition, have the oil
seals of the brake master cylinder
and caliper as well as the brake hose
replaced at the intervals listed below
or whenever it is damaged or leaking.
8Oil seals: Replace every two
years.
8Brake hose: Replace every four
years.
5EK-9-E2 (TW125)<3.3Passport> 5/23/00 9:47 AM Page 54

6-26
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
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)
5EK-9-E2 (TW125)<3.3Passport> 5/23/00 9:47 AM Page 55

6-27
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
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.
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.
Recommended lubricant:
Engine oil
5EK-9-E2 (TW125)<3.3Passport> 5/23/00 9:47 AM Page 56

6-28
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU03209
Checking and lubricating the
throttle grip and cableThe operation of the throttle grip and
the condition of the throttle cable
should be checked before each ride,
and the cable should be lubricated or
replaced if necessary.NOTE:
Since the throttle grip must be
removed to access the throttle cable
end, the throttle grip and the cable
should always be lubricated at the
same time.1. Remove the throttle grip by
removing the screws.
2. Disconnect the throttle cable,
hold it up, and then apply several
drops of oil to the cable end,
allowing it to trickle into the
sheath.
3. Connect the throttle cable, and
then grease the inside of the
throttle grip housing.
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.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
4. Grease the metal-to-metal con-
tact surface of the throttle grip,
and then install the grip by
installing the screws.
Recommended lubricant:
Throttle cable:
Engine oil
Throttle grip housing and grip:
Lithium-soap-based grease
(all-purpose grease)
5EK-9-E2 (TW125)<3.3Passport> 5/23/00 9:47 AM Page 57

6-29
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
56
7
8
9
EAU03166
Lubricating the rear
suspensionThe pivoting points of the rear sus-
pension must be lubricated at the
intervals specified in the periodic
maintenance and lubrication chart.1. Grease nipple (´2)
1
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
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)
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.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
5EK-9-E2 (TW125)<3.3Passport> 5/23/00 9:47 AM Page 58