air filter YAMAHA TW125 2002 Owners Manual

EAU00009
TABLE OF CONTENTS
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 ...................................... 3-8
Steering lock .................................................. 3-8
Seat ................................................................ 3-9
Helmet holder ................................................. 3-9
Shock absorber ............................................ 3-10
Carrier .......................................................... 3-10
Luggage strap holders ................................. 3-10
Sidestand ..................................................... 3-11Ignition 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
Owner’s tool kit .............................................. 6-1
Periodic maintenance and lubrication chart ... 6-2
Removing and installing 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
Adjusting the engine idling speed ................ 6-14
123
456
5RS-9-E0 (TW125) 7/30/01 6:02 PM Page 5

2-1
EAU00026
DESCRIPTION
2
Left view1. Headlight (page 6-34)
2. Steering lock (page 3-8)
3. Fuel tank (page 3-5)
4. Fuel cock (page 3-7)
5. Helmet holder (page 3-9)6. Luggage strap holders (page 3-10)
7. Drive chain adjusting plates (page 6-26)
8. Air filter element (page 6-12)
9. Shift pedal (page 3-4)
3
456
7
8 9
1
2
5RS-9-E0 (TW125) 7/30/01 6:02 PM Page 8

6-2
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03686
Periodic maintenance and lubrication chart
NOTE:
8The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
8From 30,000 km, repeat the maintenance intervals starting from 6,000 km.
8Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 6 12 18 24
1
*Fuel line•Check fuel hoses for cracks or damage.√√√√ √
2 Spark plug•Check condition.
•Clean and regap.√√
•Replace.√√
3*Valves•Check valve clearance.
•Adjust.√√√√
4 Air filter element•Clean.√√
•Replace.√√
5 Clutch•Check operation.
•Adjust.√√√√√
6*Front brake•Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)√√√√√ √
•Replace brake pads.Whenever worn to the limit
7*Rear brake•Check operation and adjust brake pedal free play.√√√√√ √
•Replace brake shoes.Whenever worn to the limit
8*Brake hose•Check for cracks or damage.√√√√ √
•Replace. (See NOTE on page 6-4.)Every 4 years
5RS-9-E0 (TW125) 7/30/01 6:03 PM Page 32

6-4
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03541
NOTE:
8The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8Hydraulic brake service
9Regularly check and, if necessary, correct the brake fluid level.
9Every two years replace the internal components of the brake master cylinder and caliper, and change the brake
fluid.
9Replace the brake hoses every four years and if cracked or damaged.21
*Carburetor•Check starter (choke) operation.
•Adjust engine idling speed.√√√√√ √
22 Engine oil•Change.
•Check oil level and vehicle for oil leakage.√√√√√ √
23 Engine oil filter element•Clean.√√√
24*Engine oil strainer•Clean.√
25*Front and rear brake
switches•Check operation.√√√√√ √
26 Moving parts and cables•Lubricate.√√√√ √
27*Lights, signals and
switches•Check operation.
•Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 6 12 18 24
5RS-9-E0 (TW125) 7/30/01 6:03 PM Page 34

6-9
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04400
Engine oil and oil filter
elementThe engine oil level should be
checked before each ride. In addition,
the oil must be changed and the oil
filter element cleaned at the intervals
specified in the periodic maintenance
and lubrication chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:
Make sure that the motorcycle is
positioned straight up when checking
the oil level. A slight tilt to the side
can result in a false reading.2. Start the engine, warm it up for
several minutes, and then turn it
off.3. Wait a few minutes until the oil
settles, and then check the oil
level through the check window
located at the bottom-right side
of the crankcase.
NOTE:
The engine oil should be between the
minimum and maximum level marks.4. If the engine oil is below the
minimum level mark, add suffi-
cient oil of the recommended
type to raise it to the correct
level.
2
3 1
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
To change the engine oil (with or
without oil filter element cleaning)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the
engine to collect the used oil.
3. Remove the engine oil filler cap
and drain bolt to drain the oil
from the crankcase.
1
1. Engine oil filler cap
5RS-9-E0 (TW125) 7/30/01 6:03 PM Page 39

6-10
PERIODIC MAINTENANCE AND MINOR REPAIR
6
ECA00039
cCWhen removing the engine oil
drain bolt, the O-ring, compression
spring, and oil strainer will fall out.
Take care not to lose these parts.
12 3
1. Strainer
2. Compression spring
3. O-ring
NOTE:
Skip steps 4–9 if the oil filter element
is not being cleaned.4. Remove the oil filter element
drain bolt to drain the oil from the
oil filter element.
5. Remove the oil filter element
cover by removing the bolts.
1
2
3
1. Oil filter element drain bolt
2. Oil filter element cover
3. Oil filter element cover bolt (×2)
1
1. Engine oil drain bolt
5RS-9-E0 (TW125) 7/30/01 6:03 PM Page 40

6-11
PERIODIC MAINTENANCE AND MINOR REPAIR
6 6. Remove the oil filter element and
O-rings.
7. Check the O-ring for damage
and replace it if necessary.
8. Clean the oil filter element with
solvent, and then install it.
NOTE:
Check the oil filter element for dam-
age and replace it if necessary.9. Install the oil filter element cover
by installing the bolts and the
drain bolt, then tightening them
to the specified torques.
1 2
2
1. Oil filter element
2. O-ring (×2)
NOTE:
Make sure that the O-rings are prop-
erly seated.10. Clean the oil strainer with sol-
vent, and then check it for dam-
age and replace it if necessary.
11. Install the oil strainer, compres-
sion spring, O-ring and engine oil
drain bolt, and then tighten the
drain bolt to the specified torque.12. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil
filler cap. Tightening torques:
Oil filter element cover bolt:
10 Nm (1.0 m·kgf)
Oil filter element drain bolt:
10 Nm (1.0 m·kgf)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element
removal:
1.0 L
With oil filter element removal:
1.1 L
Total amount (dry engine):
1.3 L
5RS-9-E0 (TW125) 7/30/01 6:03 PM Page 41

6-12
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU04216
Cleaning the air filter ele-
ment and check hoseThe air filter element should be
cleaned at the intervals specified in
the periodic maintenance and lubrica-
tion chart. Clean the air filter element
more frequently if you are riding in
unusually wet or dusty areas. In addi-
tion, the air filter check hose must be
frequently checked and cleaned if
necessary.
To clean the air filter element
1. Remove panel A. (See page 6-5
for panel removal and installation
procedures.)2. Remove the air filter case cover
by removing the screws.
1
2
2
1. Air filter case cover
2. Screw (×4)
ECA00105
cC8In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives
with the oil or use oils of grade
“CD” or higher. In addition, do
not use oils labeled “ENERGY
CONSERVING
II” or higher.
8Make sure that no foreign
material enters the crankcase.
13. Start the engine, and then let it
idle for several minutes while
checking it for oil leakage. If oil is
leaking, immediately turn the
engine off and check for the
cause.
14. Turn the engine off, and then
check the oil level and correct it if
necessary.
5RS-9-E0 (TW125) 7/30/01 6:03 PM Page 42

6-13
PERIODIC MAINTENANCE AND MINOR REPAIR
6 3. Pull the air filter element out.
4. Remove the sponge material
from the air filter element frame,
clean it with solvent, and then
squeeze the remaining solvent
out.
1
2
1. Sponge material
2. Air filter element frame
5. Apply oil of the recommended
type to the entire surface of the
sponge material, and then
squeeze the excess oil out.NOTE:
The sponge material should be wet
but not dripping.6. Pull the sponge material over the
air filter element frame.
7. Insert the element into the air fil-
ter case.
EC000082
cC8Make sure that the air filter ele-
ment is properly seated in the
air filter case.
8The engine should never be
operated without the air filter
element installed, otherwise
the piston and/or cylinder may
become excessively worn.8. Install the air filter case cover by
installing the screws.
9. Install the panel.
Recommended oil:
Engine oil
5RS-9-E0 (TW125) 7/30/01 6:03 PM Page 43

6-14
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU00629
Adjusting the carburetorThe carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, most
carburetor adjustments should be left
to a Yamaha dealer, who has the
necessary professional knowledge
and experience. The adjustment
described in the following section,
however, may be serviced by the
owner as part of routine mainte-
nance.
EC000094
cCThe carburetor has been set and
extensively tested at the Yamaha
factory. Changing these settings
without sufficient technical knowl-
edge may result in poor perfor-
mance of or damage to the engine.
EAU01168
Adjusting the engine idling
speedThe engine idling speed must be
checked and, if necessary, adjusted
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.NOTE:
A diagnostic tachometer is needed to
make this adjustment.1. Attach the tachometer to the
spark plug lead.
2. Start the engine and warm it up
for several minutes at 1,000–
2,000 r/min while occasionally
revving it to 4,000–5,000 r/min.NOTE:
The engine is warm when it quickly
responds to the throttle.
To clean the air filter check hose
1. Check the hose at the bottom of
the air filter case for accumulated
dirt or water.
2. If dirt or water is visible, remove
the hose, clean it, and then
install it.
1
1. Air filter check hose
5RS-9-E0 (TW125) 7/30/01 6:03 PM Page 44