Yamaha 2002 TW125 Handbuch

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the

TW125 2002. For complete service information procedures it is necessary to use this Supplementary

Service Manual together with the following manual.

TW125 SERVICE MANUAL: 5EK1-AE1

TW125 2002

SUPPLEMENTARY

SERVICE MANUAL

E2001 by Yamaha Motor Co., Ltd.

First Edition, August 2001

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd. is expressly

prohibited.

NOTE:

WARNING

CAUTION:

EB001000

NOTICE

This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and

their qualified mechanics. 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. Repairs attempted by anyone without this knowledge are likely to render the motorcycle unsafe

and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and

significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers

and will appear in future editions of this manual where applicable.

Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT INFORMATION

Particularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to

the motorcycle operator, a bystander or a person inspecting or repairing the

motorcycle.

A CAUTION indicates special precautions that must be taken to avoid damage

to the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

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.

1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each

page indicate the current chapter. Refer to “SYMBOLS” on the following page.

2Each chapter is divided into sections. The current section title is shown at the top of each page,

except in Chapter 3 (“Periodic Inspections and Adjustments”), where the sub-section title(-s) appear.

(In Chapter 3, “Periodic Inspections and Adjustments”, the sub-section title appears at the top of each

page, instead of the section title.)

3Sub-section titles appear in smaller print than the section title.

4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section.

5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a

disassembly step.

6Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).

7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

8Jobs requiring more information (such as special tools and technical data) are described sequen-

tially.

23 24

2220

18 1917

1413

11 12

GEN

INFO SPEC

ENG

CARB

ELEC

CHAS

CHK

ADJ

TRBL

SHTG

EAS00009

SYMBOLS

The following symbols are not relevant to every

vehicle.

Symbols 1to 9indicate the subject of each

chapter.

1General information

2Specifications

3Periodic checks and adjustments

4Engine

5Carburetor(-s)

6Chassis

7Electrical system

8Troubleshooting

Symbols 9to 16 indicate the following.

9Serviceable with engine mounted

10 Filling fluid

11 Lubricant

12 Special tool

13 Tightening torque

14 Wear limit, clearance

15 Engine speed

16 Electrical data

Symbols 17 to 22 in the exploded diagrams indi-

cate the types of lubricants and lubrication

points.

17 Engine oil

18 Gear oil

19 Molybdenum disulfide oil

20 Wheel bearing grease

21 Lithium soap base grease

22 Molybdenum disulfide grease

Symbols 23 to 24 in the exploded diagrams indi-

cate the following:

23 Apply locking agent (LOCTITER)

24 Replace the part

CONTENTS

SPECIFICATIONS

GENERAL SPECIFICATIONS 1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION 16

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC MAINTENANCE/LUBRICATION INTERVALS 16. . . . . . . . .

ENGINE 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING THE ENGINE IDLING SPEED 18. . . . . . . . . . . . . . . . . . . . .

ADJUSTING THE THROTTLE CABLE FREE PLAY 19. . . . . . . . . . . .

ELECTRICAL SYSTEM 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING AND CHARGING THE BATTERY 21. . . . . . . . . . . . . . . . . .

REPLACING THE HEADLIGHT BULB 27. . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING THE HEADLIGHT BEAM 28. . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE

CLUTCH 29

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CARBURETOR

CARBURETOR 31

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE CARBURETOR 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ASSEMBLING THE CARBURETOR 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLING THE CARBURETOR 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MEASURING AND ADJUSTING THE FUEL LEVEL 37. . . . . . . . . . . .

CHASSIS

FRONT WHEEL AHD BRAKE DISC 39

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR WHEEL AND REAR BRAKE 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR WHEEL 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR BRAKE AND REAR WHEEL SPROCKET 42. . . . . . . . . . . . . . . .

FRONT FORK 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HANDLEBAR 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STEERING HEAD 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOWER BRACKET 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SYSTEM

IGNITION SYSTEM 49

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCUIT DIAGRAM 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE IGNITION SYSTEM 50. . . . . . . . . . . . . . . . . . . . . . . . . . . .

TW125 2002 WIRING DIAGRAM

GENERAL SPECIFICATIONS SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Model TW125

Model code: 5RS1, 5RS2

Dimensions:

Overall length

Overall width

Overall height

Seat height

Wheelbase

Minimum ground clearance

Minimum turning radius

2,135 mm

,820 mm

1,120 mm

,820 mm

1,350 mm

,255 mm

2,100 mm

Carburetor:

Type/quantity

Manufacturer

MV28/1

TEIKEI

Transmission:

Primary reduction system

Primary reduction ratio

Secondary reduction system

Secondary reduction ratio

Transmission type

Operation

Gear ratio 1st

2nd

3rd

4th

5th

Spur gear

74/20 (3.700)

Chain drive

51/14 (3.643)

Constant mesh 5 speed

Left foot operation

36/16 (2.250)

31/21 (1.476)

27/24 (1.125)

25/27 (0.926)

23/29 (0.793)

Chassis:

Frame type

Caster angle

Trail

Diamond

25_50’

93 mm

Tire:

Type

Size front

rear

Manufacture front

rear

Type front

rear

Tube type

130/80-18 66P

130/80-18 M/C 66P

180/80-14 M/C 78P

BRIDGESTONE

TW203

TW204

–1–

GENERAL SPECIFICATIONS SPEC

Model TW125

Wheel travel:

Front wheel travel

Rear wheel travel

150 mm

Electrical:

Ignition system

Generator system

Battery type

Battery capacity

C.D.I.

A.C. magneto

GT6B-3

12 V 6 AH

Bulb wattage quantity:

Headlight

Auxiliary light

Tail/brake light

Turn signal light

Meter light

High beam indicator light

Neutral indicator light

Turn signal indicator light

12 V 60 W/55 W 1

12 V 4 W 1

12 V 5 W/21 W 1

12 V 21 W 4

12 V 3.4 W 1

–2–

MAINTENANCE SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONS

ENGINE

Item Standard Limit

Clutch:

Friction plate thickness

Quantity

Clutch plate thickness

Quantity

Clutch spring free length

Quantity

Push rod bending limit

2.9 X3.1 mm

5 pcs.

1.6 mm

4 pcs.

34.9 mm

4 pcs.

SSS

2.7 mm

SSS

0.05 mm

SSS

33.9 mm

SSS

0.2 mm

Carburetor:

Type

I.D. mark

Main jet (M.J)

Main air jet (M.A.J)

Jet needle (J.N)

Needle jet (N.J)

Pilot air jet 1 (P.A.J.1)

Pilot air jet 2 (P.A.J.2)

Pilot outlet (P.O)

Pilot jet (P.J)

Bypass 1 (B.P.1)

Bypass 2 (B.P.2)

Bypass 3 (B.P.3)

Bypass 4 (B.P.4)

Pilot screw (P.S)

Valve seat size (V.S)

Starter jet 1 (G.S.1)

Starter jet 2 (G.S.2)

Fuel level (F.L)

Engine idle speed

Intake vacuum

MV28

5RS1 00

#134

ø1.2

5A50-3/5

B1/60

#90

#120

0.8

#34

0.7

1-1/2

1.6

0.6

0.8

0 X2.0 mm

1,450 X1,650 r/min

190 X230 mmHg

SSS

TIGHTENING TORQUES

ENGINE

Part to be tightened Part name Thread

size

Q’ty

Tightening

torque Remarks

size

Nm mSkg

Cam sprocket cover

Oil filter cover

Crankcase (left and right)

Generator cover

Clutch cover

Clutch boss

Drive sprocket

Pick up coil

Stator coil

Screw

Nut

Bolt

Screw

M14

1.0

5.0

0.4

1.0

–3–

MAINTENANCE SPECIFICATIONS SPEC

CHASSIS

Item Standard Limit

Front suspension:

Front fork travel

Fork spring free length

Fitting length

Spring rate (K1)

Stroke (K1)

Oil capacity

Oil level

Oil grade

Inner tube vend limit

150 mm

330 mm

325 mm

4.9 N/mm (0.49 kg/mm)

0 X150 mm

0.259 L (259 cm3)

122 mm

Fork oil 10 WT or equivalent

SSS

323 mm

SSS

0.2 mm

Rear suspension:

Shock absorber stroke

Spring free length

Fitting length

Spring rate (K1)

Stroke (K1)

48 mm

190 mm

185 mm

127 N/mm (12.7 kg/mm)

0 X48 mm

SSS

171 mm

SSS

Drive chain:

Type/manufacturer

No. of links

Chain free play

Maximum ten-link section

428HD/DAIDO

125

35 X60 mm

129.5 mm

SSS

Rear brake:

Type

Drum inside diameter

Shoe thickness

Shoe spring free length

Leading, trailing

130 mm

4 mm

Cam side 52 mm

Pin side 48 mm

SSS

131 mm

2 mm

SSS

Brake lever:

Brake lever free play (at lever end) 5 X8 mm SSS

–4–

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