Yamaha TW125 2003 Supplementary Service Manual
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Yamaha TW125 2003 Supplementary Service Manual

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Summary of Contents for Yamaha TW125 2003

  • Page 3 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the TW125 2003. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. TW125 SERVICE MANUAL: 5EK1-AE1...
  • Page 4 It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha motorcycle has a basic understanding of the mechanical ideas and the procedures of motorcycle repair.
  • Page 5 EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and inspection procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters.
  • Page 6 EAS00009 SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 8 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Carburetor(-s) 6 Chassis 7 Electrical system CARB CHAS 8 Troubleshooting...

  • Page 7: Table Of Contents

    ......HEADLIGHT BULB BURNT OUT ......TW125 2003 WIRING DIAGRAM...

  • Page 9: Specifications

    SPEC GENERAL SPECIFICATIONS/CHASSIS SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5RS3, 5RS4 CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Diamond Caster angle 25_83’ Trail 93 mm Tire pressure (cold tire) Maximum load-except motorcycle 180 kg Loading condition A* 0 X 90 kg front 150 kPa (1.5 kg/cm...

  • Page 10: Electrical Specifications

    656 X 984 Ω at 20_C/ Pickup coil resistance/color Red – White 624 X 936 Ω at 20_C/ Source coil resistance/color Brown – Green C.D.I. unit model/manufacturer 5BT/YAMAHA Headlight relay Model/manufacturer G8MS-1A48T-L2-F28 /OMRON 90 X 110 Ω Coil resistance –2–...

  • Page 11: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING Brake hose Wire harness A Clamp the grommet of brake Throttle cables Front turn signal light lead (right) hose with the band. After Front brake light switch lead Indicator lead completion of clamping, cut the Right handlebar switch lead surplus part and point it to the Main switch lead...
  • Page 12 SPEC CABLE ROUTING Battery positive lead C.D.I. unit A Point the surplus part of the Starter relay Diode clamp of the wire harness to the Starter motor lead Turn signal relay downward. Clamp the immedi- Ignition coil ate front part of the junction sec- Throttle cable (pull side) tion to the C.D.I.
  • Page 13 SPEC CABLE ROUTING C Clamp the wire harness, handle- F Do not bend the lead sharply just I Secure the rear brake switch, bar switch lead (right), front after the terminal connection. knob-shape part of the lead, car- brake light switch lead, clutch G Point the rear brake light switch buretor heater lead and turn sig- switch lead, main switch lead,...
  • Page 14 SPEC CABLE ROUTING K Push the wire harness in be- O Point the surplus part of the tween frame and box. clamp for the wire harness and L Place the C.D.I. unit on the at- the diode to the inner side. taching section of the left side Place the diode section between relay.
  • Page 15 SPEC CABLE ROUTING Resonator hose Clutch cable guide A Clamp between the positioning Fuel hose Brake hose belts of resonator hose. Do not Rectifier/ regulator lead Speedometer cable pinch the resonator hose. Thermo switch lead Horn B Starter cable, clutch switch lead Sidestand switch lead Horn lead and main switch lead should not...
  • Page 16 SPEC CABLE ROUTING E Clamp the rectifier / regulator G Clamp the C.D.I. magneto lead K Route the air vent hose and over lead and resonator hose. Point at the frame pipe bend and point flow hose between engine and the surplus part toward the inner the surplus part to the inner side, swingarm.
  • Page 17 SPEC CABLE ROUTING P Clamp the brake hose and T Place the speedometer cable in speedometer cable. Align the the inner side. clamping position with the center U After tightening screws, insert of white paint mark on the brake the hose in the screw section. hose.
  • Page 18 SPEC CABLE ROUTING Brake hose Rectifier/ regulator A Clamp the handlebar switch lead Throttle cable (return side) Clamp (rectifier / regulator lead) and front brake light switch lead Throttle cable (pull side) Handlebar switch lead (left) with a band. Front brake light switch lead Clutch switch lead B Pass the C.D.I.
  • Page 19 SPEC CABLE ROUTING E Cover the naked part of rear turn I Pass the rear turn signal light M Route the battery negative lead signal light lead (left) with the lead (left) between the rear above the side stand switch lead hose.
  • Page 20 SPEC CABLE ROUTING R Route the sidestand switch lead under the cover connector. S Assemble so that the coupler and the lead are positioned low- er than the battery’s top face. –12–...

  • Page 21: Electrical

    ELEC CHECKING THE SWITCHES EAS00731 ELECTRICAL CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the termi- nals. Refer to “CHECKING SWITCH CONTINUITY” in chapter 7 (Manual No.: 5EK1-AE1) Damage/wear ³ Repair or replace the switch. Improperly connected ³...

  • Page 22: Lighting System

    ELEC LIGHTING SYSTEM EB804000 LIGHTING SYSTEM CIRCUIT DIAGRAM C.D.I magneto Rectifier/Regulator Battery Main fuse Main switch C.D.I unit Meter light Hi-beam indicator light Tail/Brake light Diode B Headlight relay Dimmer switch Headlight Auxiliary light –14–...

  • Page 23: Troubleshooting

    ELEC LIGHTING SYSTEM EAS00781 2. Battery TROUBLESHOOTING S Check the condition of the battery. Any of the following fail to light: head Refer to “CHECKING AND CHARGING THE light, high beam indicator light, taillight, BATTERY” in chapter 3. (Manual No. : auxiliary light or meter light.
  • Page 24 ELEC LIGHTING SYSTEM Tester positive probe ! Battery positive terminal ! brown/white brown/white Battery negative terminal ! skyblue Tester negative probe ! Tester positive probe ! brown white Tester negative probe ! blue/black Continuity Tester positive probe ! brown/white Tester negative probe ! blue/black Tester positive probe ! white...

  • Page 25: Faulty Lighting System

    TRBL FAULTY LIGHTING SYSTEM SHTG EAS00866 TROUBLESHOOTING FAULTY LIGHTING SYSTEM HEADLIGHT DOES NOT COME ON S Wrong headlight bulb S Too many electrical accessories S Hard charging S Incorrect connection S Improperly grounded circuit S Poor contacts (main or dimmer switch) S Headlight relay S Burnt-out headlight bulb HEADLIGHT BULB BURNT OUT...

  • Page 29: Tw125 2003 Wiring Diagram

    TW125 2003 WIRING DIAGRAM C.D.I. magneto Neutral switch Rectifier/ Regulator Battery Main fuse Starter relay Starter motor Right handlebar switch Start switch Engine stop switch Main switch Diode A Clutch switch Sidestand switch Neutral relay C.D.I. unit Ignition coil Spark plug...

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