YAMAHA TW125 2002 Repair 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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6-31
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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.
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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6-32
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00800
BatteryThis motorcycle is equipped with a
sealed-type (MF) battery, which does
not require any maintenance. There
is no need to check the electrolyte or
to add distilled water.
EC000101
cCNever attempt to remove the bat-
tery cell seals, as this would per-
manently damage the battery.
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.
9EXTERNAL: Flush with plen-
ty of water.
9INTERNAL: Drink large quan-
tities of water or milk and
immediately call a physician.
9EYES: 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.
1
1. Battery
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6-33
PERIODIC MAINTENANCE AND MINOR REPAIR
6 To charge the battery
Have a Yamaha dealer charge the
battery as soon as possible if it
seems to have discharged. Keep in
mind that the battery tends to dis-
charge more quickly if the motorcycle
is equipped with optional electrical
accessories.
To 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 it
at least once a month and fully
charge it if 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.
EC000102
cC8Always keep the battery
charged. Storing a discharged
battery can cause permanent
battery damage.
8To charge a sealed-type (MF)
battery, a special (constant-
voltage) battery charger is
required. Using a conventional
battery charger will damage
the battery. If you do not have
access to a sealed-type (MF)
battery charger, have a
Yamaha dealer charge your
battery.
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 “OFF” and turn
off all electrical circuits.
2. Remove the blown fuse, and
then install a new fuse of the
specified amperage.
1 2
1. Fuse
2. Spare fuse
Specified fuse: 20A
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6-34
PERIODIC MAINTENANCE AND MINOR REPAIR
6
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 “ON” 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.2. Disconnect the headlight cou-
pler, and then remove the bulb
cover.
1
2
1. Headlight coupler
2. Bulb cover
EAU04189
Replacing the headlight bulbThis motorcycle is equipped with a
quartz bulb headlight. If the headlight
bulb burns out, replace it as follows.
1. Remove the headlight unit by
removing the screws.11. Screw (×2)
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6-35
PERIODIC MAINTENANCE AND MINOR REPAIR
6 3. Unhook the headlight bulb hold-
er, and then remove the defec-
tive 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.4. Place a new headlight bulb into
position, and then secure it with
the bulb holder.
1
1. Headlight bulb holder
5. Install the headlight bulb cover,
and then connect the coupler.
6. Install the headlight unit by
installing the screws.
7. Have a Yamaha dealer adjust
the headlight beam if necessary.
EC000105
cCDo not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the
bulb, and the bulb life will be
adversely affected. Thoroughly
clean off any dirt and fingerprints
on the headlight bulb using a cloth
moistened with alcohol or thinner.
a
a. Do not touch this area.
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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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6-37
PERIODIC MAINTENANCE AND MINOR REPAIR
6 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
1. Bulb
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.
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.
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6-38
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04387
Front wheelWheel (front)To remove the front wheelRemoving
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
1. Rubber cover
2. Pull outward on the rubber cover
at the bottom of the left-side fork
leg, and then pull it off.
1
1. Rubber cover
1. Pull outward on the rubber cover
at the bottom of the right-side
fork leg, and then slide it up
along the fork leg.
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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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