lock YAMAHA TW125 2004 Owners Manual

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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2-1
1
2
3
4
5
6
7
8
9

DESCRIPTION
EAU10410
Left view
3
456
7
8 9
1
2

1. Headlight (page 6-29)
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 holder (page 3-10)
7. Drive chain slack adjusting plate
8. Air filter element (page 6-10)9. Shift pedal (page 3-4)

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INSTRUMENT AND CONTROL FUNCTIONS
3-5
2
34
5
6
7
8
9

EAU12941
Brake pedal
The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
EAU32280
Fuel tank cap
To remove the fuel tank cap
1. Insert the key into the lock and turn
it 1/3 turn counterclockwise.
2. Turn the fuel tank cap 1/3 turn
counterclockwise and pull it off.
To install the fuel tank cap
1. Insert the fuel tank cap into the tank
opening with the key inserted in the
lock, and then turn the cap 1/3 turn
clockwise.

2. Turn the key 1/3 turn clockwise,
and then remove it.
NOTE:

The fuel tank cap cannot be installedunless the key is in the lock. In addition,
the key cannot be removed if the cap is
not properly installed and locked.
WARNING

EWA10120
Make sure that the fuel tank cap is
properly closed and locked before
riding.
1. Brake pedal
1

1. Fuel tank cap
2. Unlock.1 2

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INSTRUMENT AND CONTROL FUNCTIONS
3-8
1
2
3
4
5
6
7
8
9

EAU13600
Starter (choke) knob “”
Starting a cold engine requires a richer
air-fuel mixture, which is supplied by
the starter (choke).
Move the knob in direction (a) to turn on
the starter (choke).
Move the knob in direction (b) to turn off
the starter (choke).
EAU13770
Steering lock
To lock the steering
1. Turn the handlebar all the way to
the right.
2. Open the steering lock cover, and
then insert the steering lock key.
3. Turn the key 1/8 turn counterclock-
wise, push it in while turning the
handlebar slightly to the left, and
then turn the key 1/8 turn clock-
wise.
4. Check that the steering is locked,
remove the key, and then close the
lock cover.
To unlock the steering
1. Open the steering lock cover, and
then insert the steering lock 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.

1. Starter (choke) knob “”
1
(a)
(b)

1. Steering lock cover
2. Steering lock
21

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INSTRUMENT AND CONTROL FUNCTIONS
3-9
2
34
5
6
7
8
9

EAU13970
Seat
To remove the seat
Remove the bolts, and then pull the
seat off.
To install the seat
1. Insert the projection on the front of
the seat into the seat holder as
shown.2. Place the seat in the original posi-
tion, and then tighten the bolts.
NOTE:

Make sure that the seat is properly se-
cured before riding.
EAU14281
Helmet holder
To open the helmet holder, insert the
key into the lock, and then turn the key
as shown.
To lock the helmet holder, place it in the
original position, and then remove the
key.
WARNING

EWA10160
Never ride with a helmet attached to
the helmet holder, since the helmet
may hit objects, causing loss of con-
trol and possibly an accident.
1. Bolt
1

1. Projection
2. Seat holder
1
2

1. Helmet holder
1

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
2
3
4
5
67
8
9

EAU21940
Spoke wheels
To maximize the performance, durabil-
ity, and safe operation of your motorcy-
cle, note the following points regarding
the specified wheels.

The wheel rims should be checked
for cracks, bends or warpage, and
the spokes for looseness or dam-
age before each ride. If any dam-
age is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.

The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.

Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
EAU22040
Adjusting the clutch lever free
play
The clutch lever free play should mea-
sure 10.0–15.0 mm (0.39–0.59 in) as
shown. Periodically check the clutch le-
ver free play and, if necessary, adjust it
as follows.
1. Loosen the locknut at the clutch le-
ver.
2. To increase the clutch lever free
play, turn the adjusting bolt in di-
rection (a). To decrease the clutch
lever free play, turn the adjusting
bolt in direction (b).3. If the specified clutch lever free
play could be obtained as de-
scribed above, tighten the locknut
and skip the rest of the procedure,
otherwise proceed as follows.
4. Fully turn the adjusting bolt at the
clutch lever in direction (a) to loos-
en the clutch cable.
5. Loosen the locknut at the crank-
case.
6. To increase the clutch lever free
play, turn the adjusting nut in direc-
tion (a). To decrease the clutch le-
ver free play, turn the adjusting nut
in direction (b).
1. Locknut (clutch lever)
2. Adjusting bolt
3. Clutch lever free play
1
2
3(a)
(b)

1. Locknut (crankcase)
2. Adjusting nut
(b)(a)
2
1

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
1
2
3
4
5
6
7
8
9
7. Tighten the locknut at the clutch le-
ver and the crankcase.

EAU22092
Adjusting the brake lever free
play
The brake lever free play should mea-
sure 5.0–8.0 mm (0.20–0.31 in) as
shown. Periodically check the brake le-
ver free play and, if necessary, adjust it
as follows.
1. Loosen the locknut at the brake le-
ver.
2. To increase the brake lever free
play, turn the adjusting screw in di-
rection (a). To decrease the brake
lever free play, turn the adjusting
screw in direction (b).3. Tighten the locknut.
WARNING

EWA10630

After adjusting the brake lever
free play, check the free play
and make sure that the brake is
working properly.

A soft or spongy feeling in the
brake lever can indicate the
presence of air in the hydraulic
system. If there is air in the hy-
draulic system, have a Yamaha
dealer bleed the system before
operating the motorcycle. Air in
the hydraulic system will dimin-
ish the braking performance,
which may result in loss of con-
trol and an accident.
1. Locknut
2. Brake lever free play adjusting screw
3. Brake lever free play
12
3
(b)
(a)

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
2
3
4
5
67
8
9

EAU22191
Adjusting the brake pedal
position and free play
WARNING

EWA10670
It is advisable to have a Yamaha
dealer make these adjustments.
Brake pedal position
The top of the brake pedal should be
positioned approximately 30.0 mm
(1.18 in) below the top of the footrest.
Periodically check the brake pedal po-
sition and, if necessary, adjust it as fol-
lows.
1. Loosen the locknut at the brake
pedal.
2. To raise the brake pedal, turn the
adjusting bolt in direction (a). To
lower the brake pedal, turn the ad-
justing bolt in direction (b).3. Tighten the locknut.
WARNING

EWA11230
After adjusting the brake pedal posi-
tion, the brake pedal free play must
be adjusted.Brake pedal free play
The brake pedal free play should mea-
sure 20.0–30.0 mm (0.79–1.18 in) as
shown. Periodically check the brake
pedal free play and, if necessary, adjust
it as follows.
To increase the brake pedal free play,
turn the adjusting nut at the brake rod in
direction (a). To decrease the brake
pedal free play, turn the adjusting nut in
direction (b).
1. Locknut
2. Brake pedal position adjusting bolt
3. Brake pedal position
3
2 1
(a)
(b)

1. Brake pedal free play
1

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
2
3
4
5
67
8
9
peared, have a Yamaha dealer replace
the brake pads as a set.

EAU22540
Rear brake shoes
The rear brake is provided with a wear
indicator, which allows you to check the
brake shoe wear without having to dis-
assemble the brake. To check the
brake shoe wear, check the position of
the wear indicator while applying the
brake. If a brake shoe has worn to the
point that the wear indicator reaches
the wear limit line, have a Yamaha
dealer replace the brake shoes as a
set.
EAU32341
Checking the brake fluid level
Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
Observe these precautions:

When checking the fluid level,
make sure that the top of the mas-ter cylinder is level by turning the
handlebars.

Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.

Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.

Be careful that water does not en-
ter the master cylinder when refill-
ing. Water will significantly lower
the boiling point of the fluid and
may result in vapor lock.

Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.

As the brake pads wear, it is nor-
mal for the brake fluid level to grad-
ually go down. However, if the
1. Brake shoe wear limit line
2. Brake shoe wear indicator
21

1. Minimum level mark
1

Recommended brake fluid:
DOT 4

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
1
2
3
4
5
6
7
8
9

EAU24131
Replacing the tail/brake light
bulb
1. Remove the tail/brake light lens by
removing the screws.
2. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.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.
CAUTION:

ECA10680
Do not overtighten the screws, oth-
erwise the lens may break.
EAU24201
Replacing a turn signal light
bulb
1. Remove the turn signal light lens
by removing the screw.
2. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
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. Screw
1(×2)

1. Tail/brake light bulb
1

1. Screw
2. Turn signal light lens
3. Bulb
1
2
3

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