engine oil YAMAHA TW125 2004 Owners Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2004, Model line: TW125, Model: YAMAHA TW125 2004Pages: 80, PDF Size: 2.39 MB
Page 5 of 80
TABLE OF CONTENTS
SAFETY INFORMATION ............. 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 ................... 3-3
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 ............ 4-2
OPERATION AND IMPORTANT
RIDING POINTS ........................... 5-1
Starting a cold engine ............... 5-1
Starting a warm engine ............. 5-2
Shifting ...................................... 5-2
Tips for reducing fuel
consumption ............................ 5-3
Engine break-in ......................... 5-4
Parking ...................................... 5-4
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 ........... 6-6
Engine oil and oil filter
element ................................... 6-7
Cleaning the air filter element
and check hose ..................... 6-10
Adjusting the carburetor .......... 6-12Adjusting the engine idling
speed .................................... 6-12
Adjusting the throttle cable free
play ....................................... 6-13
Adjusting the valve
clearance .............................. 6-13
Tires ........................................ 6-13
Spoke wheels .......................... 6-16
Adjusting the clutch lever free
play ....................................... 6-16
Adjusting the brake lever free
play ....................................... 6-17
Adjusting the brake pedal
position and free play ............ 6-18
Adjusting the rear brake light
switch .................................... 6-19
Checking the front brake pads
and rear brake shoes ............ 6-19
Checking the brake fluid
level ....................................... 6-20
Changing the brake fluid ......... 6-21
Drive chain slack ..................... 6-21
Lubricating the drive chain ...... 6-23
Checking and lubricating the
cables .................................... 6-23
Checking and lubricating the
throttle grip and cable ........... 6-24
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Page 12 of 80
DESCRIPTION
2-2
2
3
4
5
6
7
8
9
EAU10420
Right view
1
2
65 3
4
7
1. Carrier
2. Battery (page 6-27)
3. Engine oil filter element (page 6-7)
4. Engine oil level check window (page 6-7)
5. Brake pedal (page 3-5)
6. Owner’s tool kit (page 6-1)
7. Fuse (page 6-28)
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Page 27 of 80
PRE-OPERATION CHECKS
4-2
1
2
3
4
5
6
7
8
9
EAU15602
Pre-operation check list
ITEM CHECKS PAGE
Fuel
Check fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-6
Engine oil
Check oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-7
Front brake
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check lever free play.
Adjust if necessary.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-17, 6-19, 6-20
Rear brake
Check operation.
Check pedal free play.
Adjust if necessary.6-18, 6-19
Clutch
Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-16
Throttle grip
Make sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.6-13, 6-24
Control cables
Make sure that operation is smooth.
Lubricate if necessary.6-23
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Page 32 of 80
OPERATION AND IMPORTANT RIDING POINTS
5-4
2
3
4
56
7
8
9
EAU16830
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1000 km (600 mi). For
this reason, you should read the follow-
ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1000 km (600 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that might
result in engine overheating must be
avoided.
EAU16990
0–500 km (0–300 mi)
Avoid prolonged operation above 1/3
throttle.
500–1000 km (300–600 mi)
Avoid prolonged operation above 1/2
throttle.
CAUTION:
ECA11500
After 1000 km (600 mi) of operation,the engine oil must be changed, and
the oil filter element and the oil
strainer cleaned.
1000 km (600 mi) and beyond
The vehicle can now be operated nor-
mally.
CAUTION:
ECA10270
If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
EAU17170
Parking
When parking, stop the engine, remove
the key from the main switch, and then
turn the fuel cock lever to “OFF”.
WARNING
EWA10310
Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.
Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn.
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Page 35 of 80
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
1
2
3
4
5
6
7
8
9
10
*
Tires
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
√
√
√
√
√
11
*
Wheel bearings
Check bearing for looseness or damage.
√
√
√
√
12
*
Swingarm
Check operation and for excessive play.
√
√
√
√
Lubricate with lithium-soap-based grease. Every 24000 km
13
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 or
riding in the rain
14
*
Steering bearings
Check bearing play and steering for roughness.
√
√
√
√
√
Lubricate with lithium-soap-based grease. Every 24000 km
15
*
Chassis fasteners
Make sure that all nuts, bolts and screws are properly
tightened.
√
√
√
√
√
16
Sidestand
Check operation.
Lubricate.
√
√
√
√
√
17
*
Sidestand switch
Check operation.
√
√
√
√
√
√
18
*
Front fork
Check operation and for oil leakage.
√
√
√
√
19
*
Shock absorber assem-
bly
Check operation and shock absorber for oil leakage.
√
√
√
√
20
*
Rear suspension relay
arm and connecting arm
pivoting points
Check operation.
√
√
√
√
Lubricate with lithium-soap-based grease.
√
√
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.
√
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×× × ×
1000 km)
ANNUAL
CHECK
1 6 12 18 24
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Page 39 of 80
PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
1
2
3
4
5
6
7
8
9
necessary.
To install the spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible.
4. Install the spark plug cap.
EAU19792
Engine oil and oil filter
element
The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment cleaned at the intervals specified
in the periodic maintenance and lubri-
cation chart.
To check the engine oil level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
NOTE:
Make sure that the vehicle 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 set-
tles, and then check the oil level
through the check window located
at the bottom-right side of the Specified spark plug:
NGK/DR8EA
1. Spark plug gap
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
1
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf,
12.7 ft·lbf)
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Page 40 of 80
PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
2
3
4
5
67
8
9
crankcase.
NOTE:
The engine oil should be between the
minimum and maximum level marks.
4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
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 engineto collect the used oil.
3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
CAUTION:
ECA11000
When removing the engine oil drain
bolt, the O-ring, compression
spring, and oil strainer will fall out.
Take care not to lose these parts.
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
2
3 1
1. Engine oil filler cap
1
1. Engine oil drain bolt
1
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Page 42 of 80
PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
2
3
4
5
67
8
9
11. Install the oil strainer, compression
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.
CAUTION:
ECA11620
In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Donot use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.
Make sure that no foreign mate-
rial 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, im-
mediately 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.
EAU20830
Cleaning the air filter element
and check hose
The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre-
quently if you are riding in unusually
wet or dusty areas. In addition, 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.)
2. Remove the air filter case cover by
removing the screws.
3. Pull the air filter element out.
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf, 31.1 ft·lbf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element removal:
1.00 L (1.06 US qt)
(0.88 Imp.qt)
With oil filter element removal:
1.10 L (1.16 US qt)
(0.97 Imp.qt)
1. Air filter case cover
2. Screw
1
2
2(×4)
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Page 43 of 80
PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
1
2
3
4
5
6
7
8
9
4. Remove the sponge material from
the air filter element frame, clean it
with solvent, and then squeeze the
remaining solvent out.
5. Apply oil of the recommended type
to the entire surface of the spongematerial, and then squeeze the ex-
cess 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 filter
case.
CAUTION:
ECA10480
Make sure that the air filter ele-
ment is properly seated in the
air filter case.
The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
8. Install the air filter case cover by in-
stalling the screws.
9. Install the panel.
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. Sponge material
2. Air filter element frame
1
2
Recommended oil:
Engine oil
1. Air filter check hose
1
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Page 55 of 80
PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
1
2
3
4
5
6
7
8
9
EAU23011
Lubricating the drive chain
The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.
CAUTION:
ECA10580
The drive chain must be lubricated
after washing the motorcycle or
riding in the rain.
1. Remove all dirt and mud from the
drive chain with a brush or cloth.
NOTE:
For a thorough cleaning, have a
Yamaha dealer remove the drive chain
and soak it in solvent.
2. Spray Yamaha Chain and Cable
Lube or a high-quality spray-type
drive chain lubricant on both sides
and on the middle of the chain,
making sure that all side plates
and rollers have been sufficientlyoiled.
EAU23100
Checking and lubricating the
cables
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING
EWA10720
Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions.
Recommended lubricant:
Engine oil
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