Yamaha TW125 1999 User manual

EAS00000

TW125

SERVICE MANUAL

1998 by Yamaha Motor Co., Ltd.

1st Edition, July 1998

unauthorized use without the written

permission of Yamaha Motor Co., Ltd.

is expressly prohibited.

NOTE:

WARNING

CAUTION:

EAS00002 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 mo-

torcycle 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.

YamahaMotorCompany,Ltd.,iscontinuallystrivingtoimproveallitsmodels.Modificationsandsignif-

icant 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!

FailuretofollowWARNINGinstructionscouldresultinsevereinjuryor

deathtothemotorcycleoperator,abystanderorapersoninspectingor

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

explanationsofallinstallation,removal,disassembly,assembly, repair and inspection proceduresare

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.

(InChapter 3, “Periodic Inspections and Adjustments”, the sub-section title appears atthe topof 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 inspections 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 intheexplodeddiagramsindi-

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 intheexplodeddiagramsindi-

cate the following:

23 Apply locking agent (LOCTITE)

24 Replace the part

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC INSPECTION AND

ADJUSTMENT

ENGINE OVERHAUL

CARBURATION

CHASSIS

ELECTRICAL

TROUBLESHOOTING

GEN

INFO 1

SPEC 2

ENG 4

CARB 5

CHAS 6

ELEC 7

TRBL

SHTG 8

CHK

ADJ

INDEX

GEN

INFO

CHAPTER 1.

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VEHICLE IDENTIFICATION NUMBER 1–1. . . . . . . . . . . . . . . . . . . . . . . . .

MODEL CODE 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IMPORTANT INFORMATION 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREPARATION FOR REMOVAL AND DISASSEMBLY 1–2. . . . . . . . . .

REPLACEMENT PARTS 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GASKETS, OIL SEALS AND O-RINGS 1–2. . . . . . . . . . . . . . . . . . . . . . . .

LOCK WASHERS/PLATES AND COTTER PINS 1–3. . . . . . . . . . . . . . . .

BEARINGS AND OIL SEALS 1–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCLIPS 1–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE CONNECTIONS 1–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 1–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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