YAMAHA TW125 2001 Repair Manual

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EAU02939
Checking the front forkThe condition and operation of the
front fork must be checked as follows
at the intervals specified in the peri-
odic maintenance and lubrication
chart.
To check the condition
EW000115
wSecurely support the motorcycle
so that there is no danger of it
falling over.Check the inner tubes for scratches,
damage and excessive oil leakage.To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and
rebounds smoothly.
EC000098
cCIf any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
EAU00794
Checking the steeringWorn or loose steering bearings may
cause danger. Therefore, the opera-
tion of the steering must be checked
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
1. Place a stand under the engine
to raise the front wheel off the
ground.
EW000115
wSecurely support the motorcycle
so that there is no danger of it
falling over.
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EAU03503
BatteryA poorly maintained battery will cor-
rode and discharge quickly. The elec-
trolyte level, battery lead connections
and breather hose routing should be
checked before each ride and at the
intervals specified in the periodic
maintenance and lubrication chart.
EAU01144
Checking the wheel bearingsThe front and rear wheel bearings
must be checked at the intervals
specified in the periodic maintenance
and lubrication chart. If there is play
in the wheel hub or if the wheel does
not turn smoothly, have a Yamaha
dealer check the wheel bearings.
2. Hold the lower ends of the front
fork legs and try to move them
forward and backward. If any
free play can be felt, have a
Yamaha dealer check or repair
the steering.
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5
1. Battery
2. Negative lead (brack)
3. Positive lead (red)
4. Breather hose
5. BandTo check the electrolyte level
1. Remove the rider seat. (See
page 3-9 for rider seat removal
and installation procedures.)
2. Disconnect the negative battery
lead from the battery.
3. Disconnect the positive battery
lead and the battery breather
hose from the battery.
4. Unhook the battery band, and
then pull the battery out of the
battery compartment.
1
2
5. Place the battery on a level sur-
face, and then check the elec-
trolyte level in the battery.NOTE:
The electrolyte should be between
the minimum and maximum level
marks.6. If the electrolyte is at or below
the minimum level mark, add dis-
tilled water to raise the elec-
trolyte to the maximum level
mark.1. Maximum level mark
2. Minimum level mark
EW000116
w8Electrolyte is poisonous and
dangerous since it contains
sulfuric acid, which causes
severe burns. Avoid any con-
tact with skin, eyes or clothing
and always shield your eyes
when working near batteries.
In case of contact, administer
the following FIRST AID.
8EXTERNAL: Flush with
plenty of water.
8INTERNAL: Drink large quan-
tities of water or milk and
immediately call a physician.
8EYES: Flush with water for
15 minutes and seek prompt
medical attention.
8Batteries produce explosive
hydrogen gas. Therefore, keep
sparks, flames, cigarettes,
etc., away from the battery and
provide sufficient ventilation
when charging it in an
enclosed space.
8KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
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9To store the battery
1. If the motorcycle will not be used
for more than one month,
remove the battery, fully charge
it, and then place it in a cool, dry
place.
2. If the battery will be stored for
more than two months, check the
specific gravity of the electrolyte
at least once a month and fully
charge the battery whenever
necessary.
3. Fully charge the battery before
installation.
4. After installation, make sure that
the battery leads are properly
connected to the battery termi-
nals and that the breather hose
is properly routed, in good condi-
tion, and not obstructed.
1. Battery
2. Battery breather hose
1
2
9. Connect and tighten the positive
battery lead to the batteryÕs posi-
tive (+) terminal.
10. Connect and tighten the negative
battery lead to the batteryÕs neg-
ative (-) terminal.
11. Install the seat.
1. Battery breather hose
1
EC000100
cCUse only distilled water, as tap
water contains minerals that are
harmful to the battery.7. Place the battery in the battery
compartment, and then hook the
battery band onto the holder.
8. Connect the breather hose to the
battery and make sure that it is
properly routed.
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EC000103
cCDo not use a fuse of a higher
amperage rating than recommend-
ed to avoid causing extensive
damage to the electrical system
and possibly a fire.3. Turn the key to ÒONÓ and turn on
the electrical circuits to check if
the devices operate.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
Specified fuse: 20A
EAU01307
Replacing the fuseThe fuse holder is located behind
panel B. (See page 6-6 for panel
removal and installation procedures.)
If the fuse is blown, replace it as fol-
lows.
1. Turn the key to ÒOFFÓ and turn
off all electrical circuits.
2. Remove the blown fuse, and
then install a new fuse of the
specified amperage.1. Fuse
2. Spare fuse
1 2
EC000099
cCIf the breather hose is positioned
in such a way that the frame is
exposed to electrolyte or gas
expelled from the battery, the
frame could suffer structural and
external damages.
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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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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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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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9 To service the rear wheel
Raise the rear wheel off the ground
by using a motorcycle stand or, if a
motorcycle stand is not available, by
placing a jack either under each side
of the frame in front of the rear wheel
or under each side of the swingarm.
1
2
EAU03517
Front wheelTo remove the front wheel
EW000122
w8It is advisable to have a
Yamaha dealer service the
wheel.
8Securely support the motorcy-
cle so that there is no danger
of it falling over.1. Disconnect the speedometer
cable from the front wheel.
2. Loosen the axle nut.1. Speedometer cable
2. Axle nut
3. Lift the front wheel off the ground
according to the procedure on
page 6-37.
4. Remove the axle nut, pull the
wheel axle out, and then remove
the wheel.
ECA00048
cCDo not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
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EAU03519
Rear wheelTo remove the rear wheel
EW000122
w8It is advisable to have a
Yamaha dealer service the
wheel.
8Securely support the motorcy-
cle so that there is no danger
of it falling over.1. Loosen the axle nut.1. Axle nut
2. Chain adjusting plate
3. Brake adjusting nut
4. Brake rod
21
a3
4
EAU03518
To install the front wheel
1. Install the speedometer gear unit
into the wheel hub so that the
projections mesh with the slots.
2. Lift the wheel up between the
fork legs.NOTE:
Make sure that there is enough
space between the brake pads
before inserting the brake disc and
that the slot in the speedometer gear
unit fits over the retainer on the fork
leg.
3. Insert the wheel axle, and then
install the axle nut.
4. Lower the front wheel so that it is
on the ground.
5. Tighten the axle nut to the speci-
fied torque.
6. Connect the speedometer cable.Tightening torque:
Axle nut:
90 Nm (9.0 mákg)
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