check engine YAMAHA TW125 2001 Owners Manual

EAU00009
TABLE OF CONTENTS
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GIVE SAFETY THE RIGHT OF WAY ..................1-1
DESCRIPTION ....................................................2-1
Left view .............................................................2-1
Right view ..........................................................2-2
Controls and instruments ...................................2-3
INSTRUMENT AND CONTROL
FUNCTIONS ........................................................3-1
Main switch ........................................................3-1
Indicator lights ....................................................3-1
Speedometer unit ..............................................3-2
Handlebar switches............................................3-2
Clutch lever ........................................................3-4
Shift pedal ..........................................................3-4
Brake lever .........................................................3-4
Brake pedal ........................................................3-5
Fuel tank cap .....................................................3-5
Fuel ....................................................................3-6
Fuel cock............................................................3-7
Starter (choke) knob Ò1Ó ...................................3-8
Steering lock ......................................................3-8
Seat ...................................................................3-9
Helmet holder.....................................................3-9
Shock absorber ................................................3-10
Carrier ..............................................................3-10
Luggage strap holders .....................................3-10Sidestand .........................................................3-11
Ignition circuit cut-off system............................3-11
PRE-OPERATION CHECKS ...............................4-1
Pre-operation check list .....................................4-1
OPERATION AND IMPORTANT RIDING
POINTS................................................................5-1
Starting the engine .............................................5-1
Starting a warm engine ......................................5-2
Shifting ...............................................................5-3
Recommended shift points
(for Switzerland only) .......................................5-3
Tips for reducing fuel consumption ....................5-4
Engine break-in ..................................................5-4
Parking ...............................................................5-5
PERIODIC MAINTENANCE AND MINOR
REPAIR................................................................6-1
OwnerÕs tool kit ..................................................6-1
Periodic maintenance and lubrication chart .......6-2
Removing and installing cowling and panels .....6-5
Checking the spark plug ....................................6-7
Engine oil and oil filter element ..........................6-9
Cleaning the air filter element and
check hose .....................................................6-12
Adjusting the carburetor ...................................6-14
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Adjusting the engine idling speed ....................6-14
Adjusting the throttle cable free play ................6-15
Adjusting the valve clearance ..........................6-16
Tires .................................................................6-16
Spoke wheels ..................................................6-18
Adjusting the clutch lever free play ..................6-19
Adjusting the brake lever free play...................6-20
Adjusting the brake pedal position and
free play .........................................................6-21
Adjusting the rear brake light switch ................6-22
Checking the front brake pads and
rear brake shoes ............................................6-23
Checking the brake fluid level ..........................6-24
Changing the brake fluid ..................................6-25
Drive chain slack ..............................................6-25
Lubricating the drive chain ...............................6-26
Checking and lubricating the cables ................6-27
Checking and lubricating the throttle grip
and cable .......................................................6-28
Checking and lubricating the brake and
shift pedals .....................................................6-28
Checking and lubricating the brake and
clutch levers ...................................................6-29
Checking and lubricating the sidestand ...........6-29
Lubricating the rear suspension .......................6-29
Checking the front fork .....................................6-30
Checking the steering ......................................6-30Checking the wheel bearings ...........................6-31
Battery..............................................................6-31
Replacing the fuse ...........................................6-34
Replacing the headlight bulb ...........................6-35
Replacing a turn signal light bulb .....................6-36
Replacing the tail/brake light bulb ....................6-37
Supporting the motorcycle ...............................6-37
Front wheel ......................................................6-38
Rear wheel .......................................................6-39
Troubleshooting ...............................................6-41
Troubleshooting chart ......................................6-42
MOTORCYCLE CARE AND STORAGE .............7-1
Care ...................................................................7-1
Storage ..............................................................7-4
SPECIFICATIONS ...............................................8-1
Conversion table ................................................8-5
CONSUMER INFORMATION ..............................9-1
Identification numbers ........................................9-1
Key identification number...................................9-1
Vehicle identification number .............................9-1
Model label.........................................................9-2
TABLE OF CONTENTS
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2-2
DESCRIPTION
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8. Carrier (page 3-10)
9. Battery (page 6-31)
10. Engine oil level check window (page 6-9)11. Brake pedal (page 3-5, 6-21)
12. OwnerÕs tool kit (page 6-1)
13. Fuse (page 6-34)
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1211 10
Right view
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3-8
INSTRUMENT AND CONTROL FUNCTIONS
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EAU03032
Starter (choke) knob Ò1ÓStarting a cold engine requires a rich-
er air-fuel mixture, which is supplied
by the starter (choke).
Move the knob in direction ato turn
on the starter (choke).
Move the knob in direction bto turn
off the starter (choke).1. Starter (choke) knob Ò1Ó
EAU02934
Steering lockTo lock the steering
1. Turn the handlebar all the way to
the right.
2. Open the steering lock cover,
and then insert the key.
3. Turn the key 1/8 turn counter-
clockwise, push it in while turning
the handlebar slightly to the left,
and then turn the key 1/8 turn
clockwise.
4. Check that the steering is locked,
remove the key, and then close
the lock cover.1. Steering lock
2. Cover
To unlock the steering
1. Open the steering lock cover,
and then insert the key.
2. Push the key in, turn it 1/8 turn
counterclockwise so that it
moves out, and then release it.
3. Remove the key, and then close
the lock cover.
a
b
1
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3-11
INSTRUMENT AND CONTROL FUNCTIONS
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EAU00330
SidestandThe sidestand is located on the left
side of the frame. Raise the side-
stand or lower it with your foot while
holding the motorcycle upright.NOTE:
The built-in sidestand switch is part of
the ignition circuit cut-off system,
which cuts the ignition in certain situ-
ations. (See further down for an
explanation of the ignition circuit cut-
off system.)
EW000044
wThe motorcycle must not be ridden
with the sidestand down, or if the
sidestand cannot be properly
moved up (or does not stay up),
otherwise the sidestand could con-
tact the ground and distract the
operator, resulting in a possible
loss of control. YamahaÕs ignition
circuit cut-off system has been
designed to assist the operator in
fulfilling the responsibility of rais-
ing the sidestand before starting
off. Therefore, check this system
regularly as described below and
have a Yamaha dealer repair it if it
does not function properly.
EAU00331
Ignition circuit cut-off
systemThe ignition circuit cut-off system
(comprising the sidestand switch,
clutch switch and neutral switch) has
the following functions.
8It prevents starting when the
transmission is in gear and the
sidestand is up, but the clutch
lever is not pulled.
8It prevents starting when the
transmission is in gear and the
clutch lever is pulled, but the
sidestand is still down.
8It cuts the running engine when
the sidestand is moved down.
Periodically check the operation of
the ignition circuit cut-off system
according to the following procedure.
EW000045
wIf a malfunction is noted, have a
Yamaha dealer check the system
before riding.
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3-12
INSTRUMENT AND CONTROL FUNCTIONS
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With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is set to Ò
#Ó.
3. Turn the key to ÒONÓ.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
The sidestand switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.The clutch switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
NO
NOTE:This check is most reliable if performed with
a warmed-up engine.
YESYES NO
The system is OK. The motorcycle can be ridden.
YES NO
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4-1
EAU01114
PRE-OPERATION CHECKS
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9 The condition of a vehicle is the ownerÕs responsibility. Vital components can start to deteriorate quickly and unexpect-
edly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leak-
age or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thor-
ough visual inspection, to check the following points before each ride.
EAU03328
Pre-operation check list
ITEM CHECKS PAGE
Front brake9Check operation, free play, fluid level and vehicle for fluid leakage.
3-4, 6-20, 6-23Ð6-25
9Fill with DOT 4 brake fluid if necessary.
Rear brake9Check operation, condition and free play.
3-5, 6-21Ð6-239Adjust if necessary.
Clutch9Check operation, condition and free play.
3-4, 6-19Ð6-209Adjust if necessary.
Throttle grip and housing9Check smooth operation.
6-15, 6-289Lubricate if necessary.
Engine oil9Check oil level.
6-9Ð6-129Add oil if necessary.
Drive chain9Check chain slack and condition.
6-25Ð6-279Adjust if necessary.
Wheels and tires9Check tire air pressure, for wear, damage and spoke tightness.
6-16Ð6-199Tighten spokes if necessary.
Brake and shift pedal shafts9Check smooth operation.
6-289Lubricate if necessary.
Brake and clutch lever pivots9Check smooth operation.
6-299Lubricate if necessary.
Sidestand pivot9Check smooth operation.
6-299Lubricate if necessary.
Chassis fasteners9Make sure that all nuts, bolts and screws are properly tightened.
Ñ
9Tighten if necessary.
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5-1
EAU00372
OPERATION AND IMPORTANT RIDING POINTS
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EAU00373
w8Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer
regarding any control or func-
tion that you do not thorough-
ly understand.
8Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
8Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
EAU03515
Starting the engineIn order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
8The transmission is in the neutral
position.
8The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EW000054
w8Before starting the engine,
check the function of the igni-
tion circuit cut-off system
according to the procedure
described on page 3-12.
8Never ride with the sidestand
down.
1. Turn the fuel cock lever to ÒONÓ.
2. Turn the key to ÒONÓ and make
sure that the engine stop switch
is set to Ò#Ó.
3. Shift the transmission into the
neutral position.NOTE:
When the transmission is in the neu-
tral position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical
circuit.1. Arrow mark positioned over ÒONÓ
ON
FUEL
RES
OFF
1
ON
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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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6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
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*Wheels¥ Check runout, spoke tightness and for damage.
¥ Tighten spokes if necessary.ÖÖÖÖ
11*Tires¥ Check tread depth and for damage.
¥ Replace if necessary.
¥ Check air pressure.
¥ Correct if necessary.ÖÖÖÖ
12*Wheel bearings¥ Check bearing for looseness or damage.ÖÖÖÖ
13*Swingarm¥ Check operation and for excessive play.ÖÖÖÖ
¥ Lubricate with lithium-soap-based grease. Every 24,000km
14 Drive chain¥ Check chain slack.
¥ Make sure that the rear wheel is properly aligned.
¥ Clean and lubricate.Every 500 km and after washing
the motorcycle in the rain
15*Steering bearings¥ Check bearing play and steering for roughness.ÖÖÖÖÖ
¥ Lubricate with lithium-soap-based greaseEvery 24,000km
16*Chassis fasteners¥ Make sure that all nuts, bolts and screws are properly tightened.ÖÖÖÖ Ö
17 Sidestand¥ Check operation.
¥ Lubricate.ÖÖÖÖ Ö
18*Sidestand switch¥ Check operation.ÖÖÖÖÖ Ö
19*Front fork¥ Check operation and for oil leakage.ÖÖÖÖ
20*Rear shock absorber
assembly pivoting
points¥ Check operation and shock absorber for oil leakage.ÖÖÖÖ
¥ Lubricate with lithium-soap-based grease.ÖÖ
21*Carburetor¥ Check starter (choke) operation.
¥ Adjust engine idling speed.ÖÖÖÖÖ Ö NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 6 12 18 24
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