User Manuals: Yamaha TW125 1999 Lightweight Motorcycle

User Manuals: Yamaha TW125 1999 Lightweight Motorcycle

Manuals and User Guides for Yamaha TW125 1999 Lightweight Motorcycle. We have 1 Yamaha TW125 1999 Lightweight Motorcycle manual available for free PDF download: Service Manual

Yamaha TW125 1999 Service Manual

Yamaha TW125 1999 Service Manual (283 pages)

Brand: Yamaha | Category: Motorcycle | Size: 4 MB

Table of Contents

Chapter 1. General Information

10
- How to Use this Manual
  5
- Table of Contents
  10
- General Information
  12
- Motorcycle Identification
  12
  - Vehicle Identification Number
    12
  - Model Code
    12
- Important Information
  13
  - Preparation for Removal and Disassembly
    13
  - Replacement Parts
    13
  - Gaskets, Oil Seals and O-Rings
    13
  - Lock Washers/Plates and Cotter Pins
    14
  - Bearings and Oil Seals
    14
  - Circlips
    14
- Checking the Connections
  15
- Special Tools
  16
Chapter 2. Specifications

21
- Specifications
  21
- General Specifications
  23
- Maintenance Specifications
  26
  - Engine
    26
  - Chassis
    31
  - Electrical
    34
  - Conversion Table
    36
- General Torque Specifications
  36
- Lubrication Point and Grade of Lubricant
  37
  - Engine
    37
  - Chassis
    38
- Lubrication Diagram
  39
- Cable Routing
  41
Chapter 3. Periodic Inspections and Adjustments

48
- Introduction
  50
- Periodic Inspections and Adjustments
  50
- Periodic Maintenance/Lubrication Intervals
  50
- Seat, Fuel Tank and Side Cover
  52
- Engine
  53
- Chassis
  68
- Electrical System
  82
  - Checking the Battery
    82
  - Checking the Fuse
    85
  - Replacing the Headlight Bulb
    86
  - Adjusting the Headlight Beam
    87
Overhauling the Engine Chapter 4.

91
- Chapter 4. Overhauling the Engine
  95
- Engine
  95
  - Lead and Exhaust Pipe
    95
  - Carburetor and Drive Sprocket
    96
  - Engine
    97
  - Installing the Engine
    98
- Cylinder Head
  99
  - Camshaft Sprocket Cover
    99
  - Cylinder Head
    100
  - Removing the Cylinder Head
    101
  - Checking the Cylinder Head
    102
  - Checking the Timing Chain Tensioner
    103
  - Checking the Tappet Covers and Camshaft Sprocket Cover
    103
  - Installing the Cylinder Head
    103
  - Installing the Camshaft Sprocket
    104
- Camshaft
  106
- Valves and Valve Springs
  111
  - Removing the Valves
    112
  - Checking the Valves and Valve Guides
    113
  - Checking the Valve Seats
    114
  - Checking the Valve Springs
    116
  - Installing the Valves
    117
- Cylinder and Piston
  118
  - Removing the Piston and Piston Rings
    119
  - Checking the Cylinder and Piston
    119
  - Checking the Piston Rings
    120
  - Checking the Piston Pin
    121
  - Installing the Piston and Cylinder
    122
- Clutch
  124
  - Clutch Cover
    124
  - Clutch
    125
  - Removing the Clutch
    127
  - Checking the Friction Plates
    127
  - Checking the Clutch Plates
    127
  - Checking the Clutch Springs
    128
  - Checking the Clutch Housing
    128
  - Checking the Clutch Boss
    128
  - Installing the Clutch
    129
- Shift Shaft and Stopper Lever
  132
  - Checking the Shift Shaft
    134
  - Checking the Stopper Lever
    134
  - Installing the Segment
    134
  - Installing the Shift Shaft
    135
- Oil Pump
  136
  - Checking the Oil Pump
    138
  - Assembling the Oil Pump
    139
  - Installing the Oil Pump
    139
  - Installing the Primary Drive Gear
    140
- Balancer Gear
  141
- Starter Clutch and Generator
  144
  - Generator Cover
    144
  - Stator Coil
    145
  - Starter Clutch and Generator
    145
  - Removing the Generator Rotor
    147
  - Checking the Starter Clutch
    147
  - Installing the Starter Clutch
    148
  - Installing the Generator Rotor
    149
- Crankshaft Crankcase
  150
- Transmission
  157
  - Transmission, Shift Drum Assembly and Shift Forks
    157
  - Drive Axle and Main Axle
    158
  - Removing the Transmission
    159
  - Checking the Shift Forks
    159
  - Checking the Shift Drum Assembly
    159
Chapter 6. Chassis

175
- Front Wheel and Brake Disc
  177
  - Removing the Front Wheel
    179
  - Checking the Front Wheel
    179
  - Checking the Brake Disc
    182
  - Installing the Front Wheel
    183
  - Adjusting the Front Wheel Static Balance
    184
- Rear Wheel and Rear Brake
  186
  - Rear Wheel
    186
  - Rear Brake and Rear Wheel Sprocket
    188
  - Removing the Rear Wheel
    191
  - Checking the Rear Wheel
    191
  - Checking and Replacing the Rear Wheel Sprocket
    192
  - Checking the Brake
    192
  - Assembling the Brake Shoe Plate
    193
  - Installing the Rear Wheel
    194
  - Adjusting the Rear Wheel Static Balance
    194
- Front Brake
  195
  - Front Brake Pads
    195
  - Replacing the Front Brake Pads
    196
  - Front Brake Master Cylinder
    199
  - Disassembling the Front Brake Master Cylinder
    201
  - Checking the Front Brake Master Cylinder
    201
  - Master Cylinder
    202
  - Front Brake Caliper
    204
  - Disassembling the Front Brake Caliper
    206
  - Checking the Front Brake Caliper
    206
  - Assembling and Installing the Front Brake
    207
  - Caliper
    207
- Front Fork
  210
  - Removing the Front Fork Legs
    212
  - Disassembling the Front Fork Legs
    212
  - Checking the Front Fork Legs
    213
  - Assembling the Front Fork Legs
    214
  - Installing the Front Fork Legs
    217
- Handlebar
  218
  - Removing the Handlebar
    220
  - Checking the Handlebar
    220
  - Installing the Handlebar
    221
- Steering Head
  223
  - Removing the Lower Bracket
    225
  - Checking the Steering Head
    225
  - Installing the Steering Head
    226
- Rear Shock Absorber and Swingarm
  227
  - Handling the Rear Shock Absorber
    228
  - Disposing of a Rear Shock Absorber
    228
  - Removing the Rear Shock Absorber Assembly
    229
  - Removing the Drive Chain
    229
  - Removing the Swingarm
    230
  - Checking the Rear Shock Absorber Assembly
    231
  - Checking the Swingarm
    231
  - Checking the Drive Chain
    232
  - Installing the Rear Shock Absorber Assembly
    233
  - Installing the Swingarm
    234
  - Installing the Drive Chain
    234
  - Rear Shock Absorber and Swingarm
    235
Chapter 7. Electrical

238
- Electrical Components
  240
- Switches
  241
  - Checking Switch Continuity
    241
- Switch Continuity Inspection
  242
- Checking the Bulbs and Bulb Sockets
  243
- Ignition System
  246
  - Circuit Diagram
    246
  - Troubleshooting
    247
- Electric Starting System
  251
  - Circuit Diagram
    251
  - Starting Circuit Cutoff System Operation
    252
  - Troubleshooting
    253
  - Starter Motor
    256
- Charging System
  259
  - Circuit Diagram
    259
  - Troubleshooting
    260
- Lighting System
  262
  - Circuit Diagram
    262
  - Troubleshooting
    263
  - Checking the Lighting System
    264
- Signal System
  267
  - Circuit Diagram
    267
  - Troubleshooting
    268
  - Checking the Signaling System
    269
    
    Faulty Gear Shifting
    278
    
    Poor Braking Performance
    280
    
    Unstable Handling
    280

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