Yamaha TW125 2003 Manual

FOREWORD

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

TW125 2003. 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 SUPPLEMENTARY SERVICE MANUAL : 5EK1-AE2

TW125 2003

SUPPLEMENTARY

SERVICE MANUAL

!2002 by Yamaha Motor Co., Ltd.

First Edition, October 2002

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 8indicate 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 (LOCTITE")

24 Replace the part

CONTENTS

SPECIFICATIONS

GENERAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL

CHECKING THE SWITCHES 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIGHTING SYSTEM 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCUIT DIAGRAM 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING

FAULTY LIGHTING SYSTEM 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HEADLIGHT DOES NOT COME ON 17. . . . . . . . . . . . . . . . . . . . . . . . . .

HEADLIGHT BULB BURNT OUT 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TW125 2003 WIRING DIAGRAM

–1–

GENERAL SPECIFICATIONS/CHASSIS SPECIFICATIONS SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard Limit

Model code 5RS3, 5RS4 !!!

CHASSIS SPECIFICATIONS

Item Standard Limit

Frame

Frame type

Caster angle

Trail

Diamond

25"83’

93 mm

!!!

Tire pressure (cold tire)

Maximum load-except motorcycle

Loading condition A*

front

rear

Loading condition B*

front

rear

Off road riding

front

rear

High speed riding

front

rear

180 kg

0 !90 kg

150 kPa (1.5 kg/cm2, 1.5 bar)

90 !180 kg

150 kPa (1.5 kg/cm2, 1.5 bar)

175 kPa (1.75 kg/cm2, 1.75 bar)

125 kPa (1.25 kg/cm2, 1.25 bar)

150 kPa (1.5 kg/cm2, 1.5 bar)

175 kPa (1.75 kg/cm2, 1.75 bar)

!!!

*Load is the total weight of cargo, rider, passenger, and accessories.

–2–

CHASSIS SPECIFICATIONS/

ELECTRICAL SPECIFICATIONS SPEC

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

330.4 mm

325.4 mm

4.9 N/mm (0.5 kg/mm)

0 !150 mm

0.259 L (259 cm3)

122 mm

Fork oil 10 WT or equivalent

!!!

324 mm

!!!

0.2 mm

Rear suspension

Shock absorber stroke

Spring free length

Fitting length

Spring rate (K1)

(K2)

Stroke (K1)

(K2)

48 mm

190 mm

185 mm

127.5 N/mm (12.8 kg/mm)

186.4 N/mm (18.6 kg/mm)

0 !32 mm

32 !48 mm

!!!

173 mm

!!!

Drive chain

Type/manufacturer

No. of links

Chain free play

428HD/DAIDO

126

35 !60 mm

!!!

Rear brake

Type

Drum inside diameter

Shoe thickness

Shoe spring free length

Leading, trailing

130 mm

4 mm

52 mm

!!!

131 mm

2 mm

!!!

ELECTRICAL SPECIFICATIONS

Item Standard Limit

C.D.I.

Pickup coil resistance/color

Source coil resistance/color

C.D.I. unit model/manufacturer

656 !984 Ωat 20"C/

Red – White

624 !936 Ωat 20"C/

Brown – Green

5BT/YAMAHA

!!!

Headlight relay

Model/manufacturer

Coil resistance

G8MS-1A48T-L2-F28 /OMRON

90 !110 Ω

!!!

Table of contents

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