Yamaha TW125 Owner's Manual
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Yamaha TW125 Owner's Manual

2003
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OWNER'S MANUAL
TW125
5RS-28199-E2

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Summary of Contents for Yamaha TW125

  • Page 1 OWNER’S MANUAL TW125 5RS-28199-E2...
  • Page 2 Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your TW125. The owner’s manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself and oth- ers from trouble and injury.

  • Page 3: Important Manual Information

    This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual.
  • Page 4 IMPORTANT MANUAL INFORMATION EAU10200 TW125 OWNER’S MANUAL ©2003 by Yamaha Motor Co., Ltd. 1st edition, August 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SAFETY INFORMATION .....1-1 Ignition circuit cut-off system ...3-11 Adjusting the engine idling speed ........6-12 DESCRIPTION ......2-1 PRE-OPERATION CHECKS ..4-1 Adjusting the throttle cable free Left view ........2-1 Pre-operation check list ....4-2 play ........6-13 Right view........2-2 Adjusting the valve Controls and instruments ...2-3 OPERATION AND IMPORTANT...
  • Page 6 TABLE OF CONTENTS Checking and lubricating the Storage ........7-3 brake and shift pedals ...6-24 Checking and lubricating the SPECIFICATIONS ....... 8-1 brake and clutch levers ..6-24 Checking and lubricating the CONSUMER INFORMATION ..9-1 sidestand .......6-25 Identification numbers ....9-1 Lubricating the rear suspension ......6-25 Checking the front fork ....6-25...

  • Page 7: Safety Information

    SAFETY INFORMATION EAU10310 SARY BY MECHANICAL CONDI- Ride where other motorists can MOTORCYCLES SINGLE TIONS. see you. Avoid riding in another TRACK VEHICLES. THEIR SAFE Safe riding motorist’s blind spot. USE AND OPERATION ARE DEPEN- Always make pre-operation Many accidents involve inexperi- DENT UPON THE USE OF PROPER checks.
  • Page 8 Modifications made to this motorcycle never travel faster than warrant- single most critical factor in the preven- not approved by Yamaha, or the re- ed by road and traffic conditions. tion or reduction of head injuries. moval of original equipment, may ren- Always signal before turning or Always wear an approved helmet.
  • Page 9 If accessories 180 kg (397 lb) . When loading within this motorcycle. Since Yamaha cannot are added to the handlebar or this weight limit, keep the following in test all other accessories that may be...
  • Page 10 SAFETY INFORMATION motorcycle’s electrical system an cle, note the following: eyes, see your doctor immediate- electric failure could result, which The engine and exhaust system ly. If any gasoline spills on your could cause a dangerous loss of may be hot, therefore, park the skin or clothing, immediately wash lights or engine power.

  • Page 11: Description

    DESCRIPTION EAU10410 Left view 1. Headlight (page 6-29) 9. Shift pedal (page 3-4) 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.

  • Page 12: Right View

    DESCRIPTION EAU10420 Right view 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)

  • Page 13: Controls And Instruments

    DESCRIPTION EAU10430 Controls and instruments 1. Clutch lever (page 3-4) 9. Throttle grip (page 6-13) 2. Left handlebar switches (page 3-3) 10. Fuel tank cap (page 3-5) 3. Speedometer unit (page 3-2) 4. Starter (choke) knob (page 3-8) 5. Main switch (page 3-1) 6.

  • Page 14: Instrument And Control Functions

    INSTRUMENT AND CONTROL FUNCTIONS EAU10450 EAU10660 EAU10980 Main switch Indicator lights All electrical systems are off. The key can be removed. The main switch controls the ignition 1. Turn signal indicator light “ ” and lighting systems. The various main 2.

  • Page 15: Speedometer Unit

    INSTRUMENT AND CONTROL FUNCTIONS EAU11640 NOTE: Speedometer unit Only for the German model equipped with a speed limiter: The speed limiter prevents the vehicle from exceeding a riding speed of 80 km/h. 1. Speedometer 2. Odometer 3. Tripmeter 4. Reset knob The speedometer unit is equipped with a speedometer, an odometer and a tripmeter.

  • Page 16: Handlebar Switches

    INSTRUMENT AND CONTROL FUNCTIONS EAU12342 Right EAU12500 Handlebar switches Horn switch “ ” Press this switch to sound the horn. Left EAU12660 Engine stop switch “ ” Set this switch to “ ” before starting the engine. Set this switch to “ ”...

  • Page 17: Clutch Lever

    INSTRUMENT AND CONTROL FUNCTIONS EAU12820 EAU12870 EAU12890 Clutch lever Shift pedal Brake lever 1. Clutch lever 1. Shift pedal 1. Brake lever The clutch lever is located at the left The shift pedal is located on the left The brake lever is located at the right handlebar grip.

  • Page 18: Brake Pedal

    INSTRUMENT AND CONTROL FUNCTIONS EAU12941 EAU32280 unless the key is in the lock. In addition, Brake pedal Fuel tank cap the key cannot be removed if the cap is not properly installed and locked. EWA10120 WARNING Make sure that the fuel tank cap is properly closed and locked before riding.

  • Page 19: Fuel

    Avoid spilling fuel on the hot en- Your Yamaha engine has been de- gine. signed to use regular unleaded gaso- ECA10070...

  • Page 20: Fuel Cock

    INSTRUMENT AND CONTROL FUNCTIONS EAU13560 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it al- The fuel cock has three positions: FUEL FUEL 1. Arrow mark positioned over “ON” 1. Arrow mark positioned over “RES” With the lever in this position, fuel flows This indicates reserve.

  • Page 21: Starter (Choke) Knob

    INSTRUMENT AND CONTROL FUNCTIONS EAU13600 EAU13770 To unlock the steering Starter (choke) knob “ ” Steering lock 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.

  • Page 22: Seat

    INSTRUMENT AND CONTROL FUNCTIONS EAU13970 EAU14281 Seat Helmet holder To remove the seat Remove the bolts, and then pull the seat off. 1. Projection 2. Seat holder 1. Helmet holder 2. Place the seat in the original posi- To open the helmet holder, insert the tion, and then tighten the bolts.

  • Page 23: Shock Absorber

    180 kg (397 lb) for the ve- may explode due to excessive hicle. gas pressure. Do not deform or damage the gas cylinder in any way, as this will result in poor damping per- formance. Always have a Yamaha dealer service the shock absorber. 3-10...

  • Page 24: Sidestand

    EAU15311 Sidestand Ignition circuit cut-off system below and have a Yamaha dealer re- The sidestand is located on the left side The ignition circuit cut-off system (com- pair it if it does not function proper- of the frame.
  • Page 25 5. Push the start switch. Does the engine start? The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. With the engine still running: 6. Move the sidestand up. 7. Keep the clutch lever pulled.

  • Page 26: Pre-Operation Checks

    PRE-OPERATION CHECKS EAU15591 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences.

  • Page 27: Pre-Operation Check List

    Adjust if necessary. Make sure that operation is smooth. Check cable free play. Throttle grip 6-13, 6-24 If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. Make sure that operation is smooth. Control cables 6-23...
  • Page 28 Make sure that all nuts, bolts and screws are properly tightened. Chassis fasteners — Tighten if necessary. Instruments, lights, signals Check operation. — and switches Correct if necessary. Check operation of ignition circuit cut-off system. Sidestand switch 3-11 If system is defective, have Yamaha dealer check vehicle.

  • Page 29: Operation And Important Riding Points

    Yamaha dealer check the electrical cir- their functions before riding. The transmission is in the neutral cuit.

  • Page 30: Starting A Warm Engine

    OPERATION AND IMPORTANT RIDING POINTS cold! EAU16640 EAU16671 Starting a warm engine Shifting 7. When the engine is warm, turn the Follow the same procedure as for start- starter (choke) off. ing a cold engine with the exception NOTE: that the starter (choke) is not required The engine is warm when it responds when the engine is warm.

  • Page 31: Consumption

    OPERATION AND IMPORTANT RIDING POINTS EAU16800 ECA10260 Tips reducing fuel Shift up points: CAUTION: 1st → 2nd: 23 km/h (14 mi/h) consumption Even with the transmission in 2nd → 3rd: 36 km/h (22 mi/h) Fuel consumption depends largely on the neutral position, do not 3rd →...

  • Page 32: Engine Break-In

    1000 km (600 mi). The various parts in during the engine break-in period, ans or children are not likely to the engine wear and polish themselves immediately have a Yamaha dealer touch them. to the correct operating clearances. check the vehicle.

  • Page 33: Periodic Maintenance And Minor Repair

    Yamaha dealer certain maintenance work correctly. do it for you. NOTE: If you do not have the tools or experi- ence required for a particular job, have a Yamaha dealer perform it for you.

  • Page 34: Periodic Maintenance And Lubrication Chart

    From 30000 km, repeat the maintenance intervals starting from 6000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× × × × 1000 km)
  • Page 35 PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× × × × 1000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK Check tread depth and for damage. Replace if necessary. √ √ √ √ √ 10 * Tires Check air pressure. Correct if necessary.
  • Page 36 PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× × × × 1000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK Front and rear brake √ √ √ √ √ √ 25 * Check operation. switches √ √ √ √ √ Moving parts and cables Lubricate.

  • Page 37: Removing And Installing

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU18771 To install the panel Removing installing Place the panel in the original position, panels and then install the screws. The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed.

  • Page 38: Checking The Spark Plug

    Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the vehicle. 1. Spark plug cap 2. Check the spark plug for electrode 2. Remove the spark plug as shown,...

  • Page 39: Element

    PERIODIC MAINTENANCE AND MINOR REPAIR necessary. 3. Install the spark plug with the EAU19792 Engine filter spark plug wrench, and then tight- Specified spark plug: element en it to the specified torque. NGK/DR8EA The engine oil level should be checked Tightening torque: before each ride.
  • Page 40 PERIODIC MAINTENANCE AND MINOR REPAIR crankcase. to collect the used oil. 3. Remove the engine oil filler cap NOTE: and drain bolt to drain the oil from The engine oil should be between the minimum and maximum level marks. the crankcase. 1.
  • Page 41 PERIODIC MAINTENANCE AND MINOR REPAIR 7. Check the O-ring for damage and replace it if necessary. 8. Clean the oil filter element with sol- vent, and then install it. NOTE: Check the oil filter element for damage and replace it if necessary. 9.

  • Page 42: Cleaning The Air Filter Element And Check Hose

    PERIODIC MAINTENANCE AND MINOR REPAIR 11. Install the oil strainer, compression not use oils with a diesel speci- EAU20830 Cleaning the air filter element spring, O-ring and engine oil drain fication of “CD” or oils of a high- and check hose bolt, and then tighten the drain bolt er quality than specified.
  • Page 43 PERIODIC MAINTENANCE AND MINOR REPAIR material, and then squeeze the ex- To clean the air filter check hose 1. Check the hose at the bottom of cess oil out. the air filter case for accumulated NOTE: dirt or water. The sponge material should be wet but not dripping.

  • Page 44: Adjusting The Carburetor

    Therefore, most car- checked and, if necessary, adjusted as buretor adjustments should be left to a follows at the intervals specified in the Yamaha dealer, who has the neces- periodic maintenance and lubrication sary professional knowledge and expe- chart.

  • Page 45: Adjusting The Throttle Cable Free Play

    To prevent this cle, note the following points regarding from occurring, the valve clearance the specified tires. must be adjusted by a Yamaha dealer Tire air pressure The tire air pressure should be checked at the intervals specified in the periodic and, if necessary, adjusted before each maintenance and lubrication chart.
  • Page 46 Check the tire condition and air glass fragments in it, or if the sidewall is pressure before each ride. cracked, have a Yamaha dealer re- EWA11200 WARNING place the tire immediately. Because loading has an enormous...
  • Page 47 EWA10570 tires listed below have been ap- WARNING proved this model Have a Yamaha dealer replace Yamaha Motor Co., Ltd. excessively worn tires. Besides being illegal, operating the mo- torcycle with excessively worn tires decreases riding stability and can lead to loss of control.

  • Page 48: Spoke Wheels

    5. Loosen the locknut at the crank- age before each ride. If any dam- case. age is found, have a Yamaha dealer replace the wheel. Do not attempt even the smallest repair to 1. Locknut (clutch lever) the wheel.

  • Page 49: Adjusting The Brake Lever Free Play

    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 1. Locknut 2. Brake lever free play adjusting screw operating the motorcycle.

  • Page 50: Adjusting The Brake Pedal Position And Free Play

    Brake pedal free play Adjusting the brake pedal position and free play EWA10670 WARNING 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.

  • Page 51: Adjusting The Rear Brake Light Switch

    If obtained as described, have a 1. Brake pad wear indicator groove necessary, adjust the brake light switch Yamaha dealer make this ad- Each front brake pad is provided with as follows. justment. wear indicator grooves, which allow...

  • Page 52: Checking The Brake Fluid Level

    Yamaha Observe these precautions: As the brake pads wear, it is nor- dealer replace the brake shoes as a When checking the fluid level, mal for the brake fluid level to grad- set.

  • Page 53: Changing The Brake Fluid

    EAU22760 Changing the brake fluid Drive chain slack denly, have a Yamaha dealer Have a Yamaha dealer change the The drive chain slack should be check the cause. brake fluid at the intervals specified in checked before each ride and adjusted the NOTE after the periodic mainte- if necessary.
  • Page 54 PERIODIC MAINTENANCE AND MINOR REPAIR ECA10570 CAUTION: Improper drive chain slack will over- load the engine as well as other vital parts of the motorcycle and can lead to chain slippage or breakage. To prevent this from occurring, keep the drive chain slack within the specified limits.

  • Page 55: Lubricating The Drive Chain

    Service the drive chain as ed if necessary. If a cable is damaged follows. or does not move smoothly, have a ECA10580 Yamaha dealer check or replace it. CAUTION: Recommended lubricant: The drive chain must be lubricated Engine oil after washing the motorcycle or riding in the rain.

  • Page 56: Checking And Lubricating The Throttle Grip And Cable

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU23110 EAU23131 EAU23140 Checking and lubricating the Checking and lubricating the Checking and lubricating the throttle grip and cable brake and shift pedals brake and clutch levers The operation of the throttle grip should be checked before each ride. In addi- tion, the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart.

  • Page 57: Checking And Lubricating The Sidestand

    If the sidestand does not move up Lithium-soap-based grease several times to check if the front and down smoothly, have a Yamaha fork compresses and rebounds dealer check or repair it. smoothly. Recommended lubricant:...

  • Page 58: Checking The Steering

    EWA10750 WARNING fork does not operate smoothly, Securely support the vehicle so that have a Yamaha dealer check or re- there is no danger of it falling over. pair it. 2. Hold the lower ends of the front fork legs and try to move them for- ward and backward.

  • Page 59: Checking The Wheel Bearings

    If there is play in the wheel of contact, administer the fol- hub or if the wheel does not turn lowing FIRST AID. smoothly, have a Yamaha dealer check EXTERNAL: Flush with plenty the wheel bearings. of water.

  • Page 60: Replacing The Fuse

    To charge the battery battery damage. EAU23500 Replacing the fuse Have a Yamaha dealer charge the bat- To charge a sealed-type (MF) tery as soon as possible if it seems to battery, a special (constant-volt- have discharged. Keep in mind that the age) battery charger is required.

  • Page 61: Replacing The Headlight Bulb

    (×2) bulb. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. 1. Screw 2. Disconnect the headlight coupler, and then remove the bulb cover. 6-29...
  • Page 62 6. Install the headlight unit by install- 1. Headlight bulb holder ing the screws. EWA10790 7. Have a Yamaha dealer adjust the WARNING headlight beam if necessary. Headlight bulbs get very hot. There- fore, keep flammable products away...

  • Page 63: Replacing The Tail/Brake Light Bulb

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU24131 EAU24201 Replacing the tail/brake light Replacing a turn signal light bulb bulb 1. Remove the tail/brake light lens by 1. Remove the turn signal light lens removing the screws. by removing the screw. (×2) 1.

  • Page 64: Supporting The Motorcycle

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU24350 frame in front of the rear wheel or under ECA11190 Supporting the motorcycle CAUTION: each side of the swingarm. Since this model is not equipped with a Do not overtighten the screw, other- centerstand, follow these precautions wise the lens may break.

  • Page 65: Front Wheel

    To remove the front wheel wheel axle out, and then remove EWA10820 WARNING the wheel. ECA11070 It is advisable to have a Yamaha CAUTION: dealer service the wheel. Do not apply the brake after the Securely support the motorcy- wheel has been removed together...

  • Page 66: Rear Wheel

    WARNING ing the brake disc and that the slot in It is advisable to have a Yamaha 6. Place the rubber cover at the bot- the speedometer gear unit fits over the dealer service the wheel.
  • Page 67 PERIODIC MAINTENANCE AND MINOR REPAIR adjusting nut, and then disconnect punched sides facing to the outside 5. Install the brake rod onto the brake the brake rod from the brake cam- and that the slot in the brake shoe plate camshaft lever, and then install the shaft lever.

  • Page 68: Troubleshooting

    However, should your motorcycle require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the motorcycle properly.

  • Page 69: Troubleshooting Chart

    Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Check the battery. 4. Battery The engine turns over The battery is good.

  • Page 70: Motorcycle Care And Storage

    MOTORCYCLE CARE AND STORAGE EAU26000 brush, but never apply such prod- sponges which have been in Care ucts onto seals, gaskets, sprock- contact with strong or abrasive While the open design of a motorcycle ets, the drive chain and wheel cleaning products, solvent or reveals the attractiveness of the tech- axles.
  • Page 71 MOTORCYCLE CARE AND STORAGE any marks. If the windshield is ter and a mild detergent, after the tection spray metal, scratched, use a quality plastic engine has cooled down. including chrome- and nickel-plat- polishing compound after ed, surfaces. ECA10790 CAUTION: washing.

  • Page 72: Storage

    5. Perform the following steps to pro- ing it with a tarp, while it is still NOTE: tect the cylinder, piston rings, etc. Consult a Yamaha dealer for advice on wet, will allow water and humid- from corrosion. what products to use.
  • Page 73 MOTORCYCLE CARE AND STORAGE from the spark plug, and then place and charge it once a month. install the spark plug and the Do not store the battery in an ex- spark plug cap. cessively cold or warm place [less EWA10950 than 0 °C (30 °F) or more than 30 WARNING...

  • Page 74: Specifications

    SPECIFICATIONS EAU26333 Engine oil: Carburetor: Dimensions: Type: Manufacturer: Overall length: SAE10W30 or SAE10W40 or SAE15W40 TEIKEI 2135 mm (84.1 in) or SAE20W40 or SAE20W50 Type x quantity: Overall width: MV28 x 1 -20 -10 10 20 30 40 50 ˚C 820 mm (32.3 in) Spark plug(s): Overall height:...
  • Page 75 SPECIFICATIONS 4th: Tire air pressure (measured on cold Rear brake: 25/27 (0.926) tires): Type: 5th: Drum brake Loading condition: 23/29 (0.793) Operation: 0–90 kg (0–198 lb) Chassis: Right foot operation Front: Front suspension: Frame type: 150 kPa (22 psi) (1.50 kgf/cm Diamond Rear: Type:...
  • Page 76 SPECIFICATIONS Bulb voltage, wattage x quantity: Headlight: 12 V, 60 W/55.0 W × 1 Tail/brake light: 12 V, 5.0/21.0 W × 1 Front turn signal light: 12 V, 21.0 W × 2 Rear turn signal light: 12 V, 21.0 W × 2 Auxiliary light: 12 V, 4.0 W ×...

  • Page 77: Consumer Information

    Record the key identification number, vehicle identification number and mod- el label information in the spaces pro- vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi- cle is stolen. KEY IDENTIFICATION NUMBER: 1.
  • Page 78 EAU26460 Model label 1. Model label The model label is affixed to the loca- tion shown. Record the information on this label in the space provided. This in- formation will be needed when ordering spare parts from a Yamaha dealer.
  • Page 80 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003.9–0.2×1 !

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