Yamaha 2002 TW125 Supplementary Service Manual
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Yamaha 2002 TW125 Supplementary Service Manual

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  • Page 2 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...

  • Page 3: Important Information

    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 4: How To Use This Manual

    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 5 EAS00009 SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 9 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 6: Table Of Contents

    CONTENTS SPECIFICATIONS GENERAL SPECIFICATIONS ........MAINTENANCE SPECIFICATIONS .

  • Page 7: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model TW125 Model code: 5RS1, 5RS2 Dimensions: Overall length 2,135 mm Overall width ,820 mm Overall height 1,120 mm Seat height ,820 mm Wheelbase 1,350 mm Minimum ground clearance ,255 mm Minimum turning radius 2,100 mm Carburetor: Type/quantity...
  • Page 8 SPEC GENERAL SPECIFICATIONS Model TW125 Wheel travel: Front wheel travel 150 mm Rear wheel travel 150 mm Electrical: Ignition system C.D.I. Generator system A.C. magneto Battery type GT6B-3 Battery capacity 12 V 6 AH Bulb wattage quantity: Headlight 12 V 60 W/55 W Auxiliary light 12 V 4 W Tail/brake light...

  • Page 9: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Clutch: 2.9 X 3.1 mm Friction plate thickness 2.7 mm Quantity 5 pcs. Clutch plate thickness 1.6 mm 0.05 mm Quantity 4 pcs. Clutch spring free length 34.9 mm 33.9 mm Quantity 4 pcs.

  • Page 10: Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Front suspension: Front fork travel 150 mm Fork spring free length 330 mm 323 mm Fitting length 325 mm Spring rate (K1) 4.9 N/mm (0.49 kg/mm) 0 X 150 mm Stroke (K1) Oil capacity 0.259 L (259 cm Oil level 122 mm...

  • Page 11: Electrical

    ELECTRICAL Item Standard Limit Charging system: Type C.D.I. magneto Model/manufacturer F5BT/YAMAHA Standard output 14 V 170 W/5,000 r/min 0.48 X 0.72 Ω at 20_C/ Stator coil resistance/color White – White Battery: Specific gravity 1.320...

  • Page 12: 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 13 SPEC CABLE ROUTING Battery positive lead Diode A After clamping the wire harness, Starter relay Resister lead point the surplus part to the Starter motor lead Turn signal relay downward. Clamp the part im- Clamp mediately before the junction to Ignition coil the C.D.I.
  • Page 14 SPEC CABLE ROUTING D Clamp the wire harness, handle switch lead, main switch lead, I Pass the throttle cables through bar switch lead (right), front resonator hose starter the engine bracket hole. Point brake light switch lead, clutch cable. the surplus part to the downward switch lead and main switch F Clamp the ignition coil lead and and cut the end.
  • Page 15 SPEC CABLE ROUTING L Clamp the rear brake switch lead O Clamp the wire harness and connector and turn signal relay diode. Point the surplus part to lead with the band and point the the downward. surplus part to the inner side, then cut it.
  • Page 16 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 Handlebar switch lead (left) B Starter cable, clutch switch lead Sidestand switch lead Clamp and main switch lead should not...
  • Page 17 SPEC CABLE ROUTING E Clamp the rectifier / regulator side, then cut it. tween engine and swingarm. lead and resonator hose. Point H Clamp the sidestand switch M Route the neutral switch lead be- the surplus part toward the inner lead.
  • Page 18 SPEC CABLE ROUTING R Clamp the brake hose and V Place the speedometer cable in speedometer cable. Align the the inner side. clamping position with the center W After tightening screws, insert of white paint mark on the brake the hose in the screw section. hose.
  • Page 19 SPEC CABLE ROUTING Handlebar switch lead (right) Battery negative lead C.D.I. magneto leads, neutral Front brake light switch lead Grommet switch lead Brake hose Rectifier/ regulator Throttle cable (return side) Clamp (rectifier / regulator lead) Throttle cable (pull side) Handlebar switch lead (left) Starter motor lead Clutch switch lead Battery positive lead...
  • Page 20 SPEC CABLE ROUTING A Clamp the handlebar switch lead D Clamp the wire harness and rear H Pass the rear turn signal light and front brake light switch lead turn signal light lead (right). Point lead (right) between the rear with a band.
  • Page 21 SPEC CABLE ROUTING K Clamp the thermo switch lead O Clamp the handlebar switch lead coupler. After clamping, point (left) and clutch switch lead. the surplus part to the inner side. P After clamping, cut where it is not L Pass the C.D.I. magneto lead (2 visible either from the top or the leads) through the grommet rear.

  • Page 22: Periodic Checks And Adjustments

    S The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. S From 30,000 km, repeat the maintenance intervals starting from 6,000 km. S Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING...
  • Page 23 PERIODIC MAINTENANCE/LUBRICATION INTERVALS ODOMETER READING ANNUAL 1,000 km) ITEM CHECK OR MAINTENANCE JOB CHECK CHECK S Check operation. √ √ √ √ Rear suspension relay arm and connecting arm and connecting S Lubricate with lithium-soap-based grease. √ √ arm pivoting points S Check starter (choke) operation.

  • Page 24: Engine

    ADJUSTING THE ENGINE IDLING SPEED ENGINE EAS00054 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the air filter should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for several minutes.

  • Page 25: Adjusting The Throttle Cable Free Play

    ADJUSTING THE THROTTLE CABLE FREE PLAY EAS00058 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted. 1. Check: S throttle cable free play a Out of specification ! Adjust. Throttle cable free play (at the flange of the throttle grip) 3 X 5 mm...
  • Page 26 ADJUSTING THE THROTTLE CABLE FREE PLAY Throttle cable free play Direction is increased. Throttle cable free play Direction is decreased. d. Tighten the locknut. WARNING After adjusting the throttle cable free play, turn the handlebars to the right and to the left to ensure that this does not cause the en- gine idling speed to change.

  • Page 27: Electrical System

    CHECKING AND CHARGING THE BATTERY EAS00178 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poi- sonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: S Wear protective eye gear when handling or working near batteries.
  • Page 28 CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by mea- suring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
  • Page 29 CHECKING AND CHARGING THE BATTERY 5. Charge: Charging S battery Ambient temperature 20_C (refer to the appropriate charging method il- lustration) WARNING Do not quick charge a battery. Time (minutes) Check the open-circuit CAUTION: voltage. S Make sure that the battery vent is free of ob- structions.
  • Page 30 CHECKING AND CHARGING THE BATTERY Charging method using a variable voltage charger Measure the open-circuit NOTE: voltage prior to charging. Voltage should be measured 30 minutes after the machine is stopped. Connect a charged and NOTE: AMP meter to the battery Set the charging voltage at 16 X 17 V.
  • Page 31 CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger Measure the open-circuit NOTE: voltage prior to charging. Voltage should be measured 30 minutes after the machine is stopped. Connect a charger and AMP meter to the battery and start charging.
  • Page 32 CHECKING AND CHARGING THE BATTERY 6. Check: S battery vent Obstruction ! Clean. Damage ! Replace. 7. Install: S battery 8. Connect: S battery leads (to the battery terminals) CAUTION: First, connect the positive lead 1 , then the negative lead 2 . 9.

  • Page 33: Replacing The Headlight Bulb

    REPLACING THE HEADLIGHT BULB EAS00182 REPLACING THE HEADLIGHT BULB 1. Remove: S bolts 1 S headlight unit 2. Disconnect: S headlight coupler 1 S headlight bulb cover 2 3. Remove: S headlight bulb holder 1 S headlight bulb 2 WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.

  • Page 34: Adjusting The Headlight Beam

    ADJUSTING THE HEADLIGHT BEAM EAS00184 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: S headlight beam (vertically) a. Turn the adjusting screw 1 in direction a or ! Headlight beam is Direction raised. ! Headlight beam is Direction lowered. 2. Adjust: S headlight beam (horizontally) a.

  • Page 35: Engine

    CLUTCH EAS00274 ENGINE CLUTCH 8 Nm (0.8 mSkg) 70 Nm (7.0 mSkg) 12 Nm (1.2 mSkg) 6 Nm (0.6 mSkg) Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Clutch springs Pressure plate Friction plates Refer to “REMOVING/INSTALLING Clutch plates THE CLUTCH”...
  • Page 36 CLUTCH 70 Nm (7.0 mSkg) 8 Nm (0.8 mSkg) 12 Nm (1.2 mSkg) 6 Nm (0.6 mSkg) Order Job/Part Q’ty Remarks Push lever axle Refer to “INSTALLING THE CLUTCH” section in chapter 4. (Manual No.: 5EK1-AE1) Torsion spring Circlip Oil seal Nut/Washer Refer to “INSTALLING THE CLUTCH”...

  • Page 37: Carburetor

    CARBURETOR EAS00480 CARBURETOR CARBURETOR Order Job/Part Q’ty Remarks Removing the carburetor Remove the parts in order listed. Side cover Refer to “SEAT, FUEL TANK AND SIDE Seat COVER” section in chapter 3. Fuel tank (Manual No.: 5EK1-AE1) NOTE: Heater unit lead S Disconnect the connector from Starter cable carburetor.
  • Page 38 CARBURETOR EAS00483 Order Job/Part Q’ty Remarks Disassembly the carburetor Disassemble the parts in the order listed. Vacuum chamber cover Piston valve spring Jet needle holder Jet needle spring Jet needle Piston valve Carburetor heater Adjusting screw Drain screw Float chamber Refer to “ASSEMBLING THE Gasket CARBURETOR”.
  • Page 39 CARBURETOR Order Job/Part Q’ty Remarks Float pin Float Needle valve Needle valve seat Refer to “ASSEMBLING THE Main jet CARBURETOR”. Main jet holder Needle jet Pilot jet Pilot screw Rubber diaphragm spring Rubber diaphragm Starter plunger For assembly, reverse the disassembly procedure.

  • Page 40: Checking The Carburetor

    CARB CARBURETOR EAS00485 CHECKING THE CARBURETOR 1. Check: S carburetor body S float chamber S jet housing Cracks/damage ! Replace. 2. Check: S fuel passages Obstruction ! Clean. a. Wash the carburetor in a petroleum-based solvent. Do not use any caustic carburetor cleaning solution.
  • Page 41 CARB CARBURETOR 8. Check: S piston valve 1 Damage/scratches/wear ! Replace. S rubber diaphragm 2 Cracks/tears ! Replace. 9. Check: S vacuum chamber cover 1 S piston valve spring 2 S jet needle holder 3 S jet needle spring 4 Cracks/damage ! Replace.

  • Page 42: Assembling The Carburetor

    CARB CARBURETOR 13. Check: S fuel hoses Cracks/damage/wear ! Replace. Obstruction ! Clean. Blow out the hoses with compressed air. EAS00487 ASSEMBLING THE CARBURETOR CAUTION: S Befor assembling the carburetor, wash all of the parts in a petroleum-based solvent. S Always use a new gasket. 1.

  • Page 43: Installing The Carburetor

    CARB CARBURETOR 4. Install: S float chamber 1 S pilot screw 2 5. Install: S starter plunger kit 1 EAS00492 INSTALLING THE CARBURETOR 1. Adjust: S engine idling speed Engine idling speed 1,450 X 1,650 r/min Refer to “ADJUSTING THE ENGINE IDLING SPEED”...
  • Page 44 CARB CARBURETOR a. Stand the motorcycle on a level surface. b. Place the motorcycle on a suitable stand to ensure that the motorcycle is standing straight up. c. Install the fuel level gauge 1 to the fuel drain pipe 2 . Fuel level gauge 90890-01312 d.

  • Page 45: Chassis

    CHAS FRONT WHEEL AND BRAKE DISC EAS00512 CHASSIS FRONT WHEEL AND BRAKE DISC 90 Nm (9.0 mSkg) 13 Nm (1.3 mSkg) Order Job/Part Q’ty Remarks Removing the front wheel and brake Remove the parts in the order listed. disc NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.

  • Page 46: Rear Wheel And Rear Brake

    CHAS REAR WHEEL AND REAR BRAKE REAR WHEEL AND REAR BRAKE REAR WHEEL 90 Nm (9.0 mSkg) Order Job/Part Q’ty Remarks Removing the rear wheel Remove the parts in the order listed. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
  • Page 47 CHAS REAR WHEEL AND REAR BRAKE 90 Nm (9.0 mSkg) Order Job/Part Q’ty Remarks Rear wheel assembly Refer to “REMOVING /INSTALLING THE REAR WHEEL” section in chapter 6. (Manual No.: 5EK1-AE1) Collar For installation, reverse the removal procedure. –41–...

  • Page 48: Rear Brake And Rear Wheel Sprocket

    CHAS REAR WHEEL AND REAR BRAKE REAR BRAKE AND REAR WHEEL SPROCKET 43 Nm (4.3 mSkg) Order Job/Part Q’ty Remarks Removing the rear brake and rear Remove the parts in the order listed. wheel sprocket Shoe plate Refer to “ASSEMBLYNG THE REAR Nuts WHEEL”...
  • Page 49 CHAS REAR WHEEL AND REAR BRAKE Order Job/Part Q’ty Remarks Disassembling the rear wheel Disassemble the parts in the order listed. Bearing Spacer Oil seal Bearing For assembly, reverse the disassembly procedure. –43–...

  • Page 50: Front Fork

    CHAS FRONT FORK FRONT FORK 23 Nm (2.3 mSkg) 23 Nm (2.3 mSkg) 23 Nm (2.3 mSkg) 30 Nm (3.0 mSkg) Order Job/Part Q’ty Remarks Removing the front fork Remove the parts in the order listed. Front wheel Refer to “FRONT WHEEL AND BRAKE DISC”.

  • Page 51: Handlebar

    CHAS HANDLEBAR HANDLEBAR 20 Nm (2.0 mSkg) Order Job/Part Q’ty Remarks Removing the handlebar Remove the parts in the order listed. Master cylinder bracket Master cylinder Refer to “INSTALLING THE Housing (throttle grip) HANDLEBAR” section in chapter 6. Throttle grip assembly (Manual No.: 5EK1-AE1) Handlebar switch (right) Clutch switch...
  • Page 52 CHAS HANDLEBAR 20 Nm (2.0 mSkg) Order Job/Part Q’ty Remarks Handlebar switch (left) Grip (left) Refer to “REMOVING THE HANDLEBAR” section in chapter 6. (Manual No.: 5EK1-AE1) Clutch lever Starter cable holder Refer to “INSTALLING THE Upper holders HANDLEBAR” section in chapter 6. (Manual No.: 5EK1-AE1) Handlebar For installation, reverse the removal...

  • Page 53: Steering Head

    CHAS STEERING HEAD STEERING HEAD LOWER BRACKET 90 Nm (9.0 mSkg) 1st 38 Nm (3.8 mSkg) 2nd 18 Nm (1.8 mSkg) Order Job/Part Q’ty Remarks Removing the lower bracket Remove the parts in the order listed. Front fork Refer to “FRONT FORK”. Handlebar Refer to “HANDLEBAR”...
  • Page 54 CHAS STEERING HEAD 90 Nm (9.0 mSkg) 1st 38 Nm (3.8 mSkg) 2nd 18 Nm (1.8 mSkg) Order Job/Part Q’ty Remarks Ball race ccver Lower bracket Ball race (upper) Refer to “INSTALLING THE STEERING” Ball section in chapter 6. Ball (Manual No.: 5EK1-AE1) Ball race (center) Ball race (lower)

  • Page 55: Electrical System

    ELEC IGNITION SYSTEM EAS00734 ELECTRLCAL SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM C.D.I. magneto Neutral switch Battery Fuse Engine stop switch Main switch Diode C.D.I. unit Ignition coil Spark plug Neutral relay Reed switch –49–...

  • Page 56: Checking The Ignition System

    ELEC IGNITION SYSTEM EAS00798 CHECKING THE IGNITION SYSTEM. 1. The speedometer fail to come on. 1. Reed switch S Remove the meter assembly. S Connect the pocket tester (Ω 1) to the reed switch coupler as shown. Tester positive probe ! white/black Tester negative probe ! red/blue S Make the speedometer indicate S Check the continuity or open circuit status.

  • Page 57: Tw125 2002 Wiring Diagram

    TW125 2002 WIRING DIAGRAM C.D.I. magneto Neutral switch Rectifier/ Regulator Battery Starter relay Fuse Starter motor Right handlebar switch Start switch Engine stop switch Main switch Clutch switch Diode C.D.I. unit Ignition coil Spark plug Thermo switch Carbuletor heater Horn Turn signal relay Sidestand switch Neutral relay...

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