brake YAMAHA TW125 2002 Owner's Manual

6-30
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04282
Lubricating the rear suspen-
sionThe pivoting points of the rear sus-
pension must be lubricated at the
intervals specified in the periodic
maintenance and lubrication chart.
1
1. Grease nipple (×2)
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.
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.
Recommended lubricant:
Lithium-soap-based grease
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6-36
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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
2
3
1. Screw
2. Lens
3. bulb
EAU01623
Replacing the tail/brake light
bulb1. Remove the tail/brake light lens
by removing the screws.
1
1. Screw (×2)
ECA00065
cCDo not overtighten the screw, oth-
erwise the lens may break.
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6-39
PERIODIC MAINTENANCE AND MINOR REPAIR
6 3. Disconnect the speedometer
cable from the front wheel.
4. Loosen the axle nut.
5. Lift the front wheel off the ground
according to the procedure on
page 6-37.
6. 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.
1
2
1. Speedometer cable
2. Axle nut
EAU04388
To install the front wheelInstalling1. 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.
1
1. Speedometer gear unit
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6-40
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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. Place the rubber cover at the
bottom of the right-side fork leg
in the original position.
7. Install the rubber cover at the
bottom of the left-side fork leg.
8. Connect the speedometer cable.
2 1
1. Retainer
2. Speedometer cable
Tightening torque:
Axle nut:
90 Nm (9.0 m·kgf)
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.
5
a2
1
3
4
1. Axle nut
2. Brake pedal free play adjusting nut
3. Brake rod
4. Brake camshaft lever
5. Drive chain adjusting plate
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6-41
PERIODIC MAINTENANCE AND MINOR REPAIR
6 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.
1
1. Retainer
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.) Tightening torque:
Axle nut:
90 Nm (9.0 m·kgf)
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6-42
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EW000103
wAfter adjusting the brake pedal
free play, check the operation of
the brake light.
EAU01008
TroubleshootingAlthough Yamaha motorcycles
receive a thorough inspection before
shipment from the factory, trouble
may occur during operation. Any
problem in the fuel, compression, or
ignition systems, for example, can
cause poor starting and loss of
power.
The following troubleshooting chart
represents a quick and easy proce-
dure for checking these vital systems
yourself. However, should your
motorcycle require any repair, take it
to a Yamaha dealer, whose skilled
technicians have the necessary tools,
experience, and know-how to service
the motorcycle properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life
and can lead to expensive repair
bills.
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7-2
MOTORCYCLE CARE AND STORAGE
7 8Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abra-
sive cleaning products, sol-
vent or thinner, fuel (gasoline),
rust removers or inhibitors,
brake fluid, antifreeze or elec-
trolyte.
8Do not use high-pressure
washers or steam-jet cleaners
since they cause water seep-
age and deterioration in the
following areas: seals (of
wheel and swingarm bearings,
fork and brakes), electric com-
ponents (couplers, connec-
tors, instruments, switches
and lights), breather hoses
and vents.8For motorcycles equipped
with a windshield: Do not use
strong cleaners or hard
sponges as they will cause
dulling or scratching. Some
cleaning compounds for plas-
tic may leave scratches on the
windshield. Test the product
on a small hidden part of the
windshield to make sure that it
does not leave any marks. If
the windshield is scratched,
use a quality plastic polishing
compound after washing.
After normal useRemove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottle-
brush for hard-to-reach areas.
Stubborn dirt and insects will come
off more easily if the area is covered
with a wet cloth for a few minutes
before cleaning.After riding in the rain, near the sea
or on salt-sprayed roadsSince sea salt or salt sprayed on
roads during winter are extremely
corrosive in combination with water,
carry out the following steps after
each ride in the rain, near the sea or
on salt-sprayed roads.NOTE:
Salt sprayed on roads in the winter
may remain well into spring.1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.
ECA00012
cCDo not use warm water since it
increases the corrosive action of
the salt.2. Apply a corrosion protection
spray on all metal, including
chrome- and nickel-plated, sur-
faces to prevent corrosion.
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7-3
MOTORCYCLE CARE AND STORAGE
7After cleaning
1. Dry the motorcycle with a
chamois or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally
induced discoloring of stainless-
steel exhaust systems can be
removed through polishing.)
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal, includ-
ing chrome- and nickel-plated,
surfaces.
5. Use spray oil as a universal
cleaner to remove any remaining
dirt.6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry complete-
ly before storing or covering it.
EWA00001
w8Make sure that there is no oil
or wax on the brakes or tires.
If necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or
acetone, and wash the tires
with warm water and a mild
detergent.
8Before operating the motorcy-
cle test its braking perfor-
mance and cornering behav-
ior.
ECA00013
cC8Apply spray oil and wax spar-
ingly and make sure to wipe
off any excess.
8Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
8Avoid using abrasive polish-
ing compounds as they will
wear away the paint.NOTE:
Consult a Yamaha dealer for advice
on what products to use.
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8-3
SPECIFICATIONS
8
Maximum load* 180 kg
Air pressure (cold tire)
up to 90 kg load*
Front
150 kPa (1.50 kgf/cm
2, 1.50 bar)
Rear
150 kPa (1.50 kgf/cm
2, 1.50 bar)
90 kg load–Maximum
load*
Front
150 kPa (1.50 kgf/cm
2, 1.50 bar)
Rear
175 kPa (1.75 kgf/cm
2, 1.75 bar)
*Total weight of rider, passenger, cargo and accessoriesWheels
Front
Type Spoke wheel
Size 18 ×2.50
Rear
Type Spoke wheel
Size 14M/C ×MT4.50Brakes
Front
Type Single disc brake
Operation Right hand
Fluid DOT 4
Rear
Type Drum brake
Operation Right foot
Suspension
Front
Type Telescopic fork
Rear
Type Swingarm (Monocross
suspension)
Spring/shock absorber
Front Coil spring/oil damper
Rear Coil spring/gas-oil damper
Wheel travel
Front 150 mm
Rear 150 mm
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8-4
SPECIFICATIONS
8
Electrical
Ignition system C.D.I.
Charging system
Type A.C. magneto
Standard output 14 V, 170W @ 5,000 r/min
Battery
Type GT6B-3
Voltage, capacity 12 V, 6 Ah
Headlight bulb typeHalogen bulb
Bulb voltage, wattage ×quantity
Headlight 12 V, 60/55 W ×1
Tail/brake light 12 V, 5/21 W ×1
Front turn signal light 12 V, 21 W ×2
Rear turn signal light 12 V, 21 W ×2
Auxiliary light 12 V, 4 W ×1
Meter lighting 12 V, 3.4 W ×1
Neutral indicator light 12 V, 3.4 W ×1
High beam indicator light 12 V, 3.4 W ×1
Turn indicator light 12 V, 3.4 W ×1
Fuse20 A
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