engine YAMAHA TW125 2001 Owners Manual

EAU00009
TABLE OF CONTENTS
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3
4
5
6
7
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9
1
5
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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3
4
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6
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8
9
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)
89
13
1211 10
Right view
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3-1
EAU00027
INSTRUMENT AND CONTROL FUNCTIONS
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EAU00028
Main switchThe main switch controls the ignition
and lighting systems. The various
main switch positions are described
below.
EAU00036
ON
All electrical systems are supplied
with power, and the engine can be
started. The key cannot be removed.
EAU00038
OFF
All electrical systems are off. The key
can be removed.
EAU00056
Indicator lights
EAU00057
Turn signal indicator light Ò5Ó
This indicator light flashes when the
turn signal switch is pushed to the left
or right.
EAU00061
Neutral indicator light ÒNÓ
This indicator light comes on when
the transmission is in the neutral
position.1. Turn indicator light Ò5Ó
2. High beam indicator light Ò&Ó
3. Neutral indicator light ÒNÓ
EAU00063
High beam indicator light Ò&Ó
This indicator light comes on when
the high beam of the headlight is
switched on.
OFFON
3
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3-3
INSTRUMENT AND CONTROL FUNCTIONS
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EAU00127
Turn signal switch
To signal a right-hand turn, push this
switch to Ò6Ó. To signal a left-hand
turn, push this switch to Ò4Ó. When
released, the switch returns to the
center position. To cancel the turn
signal lights, push the switch in after
it has returned to the center position.
EAU00129
Horn switch Ò*Ó
Press this switch to sound the horn.
EAU00134
Light switch
Set this switch to Ò
'
Ó to turn on
the auxiliary light, meter lighting and
taillight. Set the switch to Ò:Ó to turn
on the headlight also.
EAU00143
Start switch Ò,Ó
Push this switch to crank the engine
with the starter.
EC000005
cCSee page 5-1 for starting instruc-
tions prior to starting the engine.
12
EAU00138
Engine stop switch
Set this switch to Ò$Ó to stop the
engine in case of an emergency,
such as when the motorcycle over-
turns or when the throttle cable is
stuck.1. Engine stop switch
2. Start switch Ò,Ó
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3-4
INSTRUMENT AND CONTROL FUNCTIONS
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EAU00157
Shift pedalThe shift pedal is located on the left
side of the engine and is used in
combination with the clutch lever
when shifting the gears of the
5-speed constant-mesh transmission
equipped on this motorcycle.1. Shift pedal
N. Neutral
EAU00152
Clutch leverThe clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the han-
dlebar grip. To engage the clutch,
release the lever. The lever should
be pulled rapidly and released slowly
for smooth clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the igni-
tion circuit cut-off system. (See page
3-11 for an explanation of the ignition
circuit cut-off system.)1. Clutch lever
EAU00158
Brake leverThe brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the han-
dlebar grip.1. Brake lever
1
1
1
N5
4
3
2
1
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3-6
INSTRUMENT AND CONTROL FUNCTIONS
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2
EAU01183
FuelMake sure that there is sufficient fuel
in the tank. Fill the fuel tank to the
bottom of the filler tube as shown in
the illustration.
EW000130
w8Do not overfill the fuel tank,
otherwise it may overflow
when the fuel warms up and
expands.
8Avoid spilling fuel on the hot
engine.1. Filler tube
2. Fuel level
EAU00185
cCImmediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted sur-
faces or plastic parts.
EAU00191
NOTE:
If knocking (or pinging) occurs, use
gasoline of a different brand or with a
higher octane grade.
Recommended fuel:
Regular unleaded gasoline
with a research octane number
of 91 or higher
Fuel tank capacity:
Total amount:
7.0 L
Reserve amount:
1.0 L
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3-7
INSTRUMENT AND CONTROL FUNCTIONS
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EAU03050
Fuel cockThe fuel cock supplies fuel from the
tank to the carburetor while filtering it
also.
The fuel cock has three positions:
OFF
With the lever in this position, fuel will
not flow. Always return the lever to
this position when the engine is not
running.1. Arrow mark positioned over ÒOFFÓ
ON
With the lever in this position, fuel
flows to the carburetor. Normal riding
is done with the lever in this position.1. Arrow mark positioned over ÒONÓ
RES
This indicates reserve. If you run out
of fuel while riding, move the lever to
this position. Fill the tank at the first
opportunity. Be sure to set the lever
back to ÒONÓ after refueling!1. Arrow mark positioned over ÒRESÓ
RES
ONFUEL
OFF
1
OFF: Closed position
OFF
ONFUEL RES
1
RES
RES: Reserve position
ON
FUEL
RES
OFF
1
ON
ON: Normal position
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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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