Yamaha TW125 2003, Supplementary Service Manual

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Page 3: ...cessary 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 ...

Page 4: ...l 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...

Page 5: ...pections 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 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 N...

Page 6: ... Troubleshooting Symbols 9 to 16 indicate the following 9 Serviceable 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 Lith...

Page 7: ...IONS 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 ...

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Page 9: ...imum 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 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 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 ...

Page 10: ...th 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 resistan...

Page 11: ...utch switch lead 8 Speedometer cable 9 Left handlebar switch lead 10 Meter lead 11 Front turn signal light lead left CABLE ROUTING SPEC A Clamp the grommet of brake hose with the band After completion of clamping cut the surplus part and point it to the backward B No positioning for the headlight body is specified C To the headlight D Clamp the left handle bar switch lead and the meter lead CABLE ...

Page 12: ...e cable guide 10 Spark plug lead 11 Headlight relay Black 12 Relay White CABLE ROUTING SPEC 13 C D I unit 14 Diode 15 Turn signal relay A Point the surplus part of the clamp of the wire harness to the downward Clamp the immedi ate front part of the junction sec tion to the C D I unit relay B Handlebar switch lead right and front brake light switch lead should not be twined around ...

Page 13: ...ter the terminal connection G Point the rear brake light switch lead to the rear side of the ve hicle H Route the lead by the front side of the sheet pillar tube so that it is not be caught between the side cover flange and the frame sheet pillar tube I Secure the rear brake switch knob shape part of the lead car buretor heater lead and turn sig nal relay lead At this time make sure to secure the ...

Page 14: ... of the left side relay M Route the carburetor heater lead in the inner side of the turn signal relay N Clamp the wire harness and diode Point the surplus part to the downward O Point the surplus part of the clamp for the wire harness and the diode to the inner side Place the diode section between the pipes of the frame ...

Page 15: ...lutch cable guide 15 Brake hose 16 Speedometer cable 17 Horn 18 Horn lead 19 Flange bolt 20 Brake hose holder 21 Meter lead 22 Handlebar switch lead left A Clamp between the positioning belts of resonator hose Do not pinch the resonator hose B Starter cable clutch switch lead and main switch lead should not be twined around C Clamp at the point ahead of the part where resonator hose pro tector is ...

Page 16: ...nt the surplus part toward the inner side Clamp within a range where the resonator hose pro tector is torn Do not pinch the resonator hose F Point the surplus part of the clamp to the rear side Clamp the C D I magnet leads 2 pieces starter motor lead neutral switch lead and battery negative lead K Route the air vent hose and over flow hose between engine and swingarm L Route the neutral switch lea...

Page 17: ...rake hose in the outer side X Cut the surplus part of the clamp for the left handle bar switch lead and the meter lead P Clamp the brake hose and speedometer cable Align the clamping position with the center of white paint mark on the brake hose Q Clamp the brake hose and speedometer cable with a hold er R Point the speedometer cable cap to the backward S Make sure to push in the boot ful ly CABLE...

Page 18: ...tch lead 5 Handlebar switch lead right 6 Starter motor lead 7 Battery positive lead 8 Wire harness 9 Clamp wire harness 10 Thermo switch lead 11 Sidestand switch lead 12 Grommet A Clamp the handlebar switch lead and front brake light switch lead with a band B Pass the C D I magnet leads 3 pieces neutral switch lead through the cover connector C Clamp the wire harness and rear turn signal light lea...

Page 19: ...cket avoiding to be caught J Clamp the rear turn signal light lead left After clamping point the surplus part to the inner side K Clamp the thermo switch lead coupler After clamping point the surplus part to the inner side L Battery negative lead to be con nected with the ground M Route the battery negative lead above the side stand switch lead and thermo switch lead N No special order is set for ...

Page 20: ... 12 CABLE ROUTING SPEC R Route the sidestand switch lead under the cover connector S Assemble so that the coupler and the lead are positioned low er than the battery s top face ...

Page 21: ...itch 12 Fuse 13 Thermo switch CHECKING THE SWITCHES ELEC EAS00731 ELECTRICAL CHECKING THE SWITCHES Check each switch for damage or wear proper connections and also for continuity between the termi nals Refer to CHECKING SWITCH CONTINUITY in chapter 7 Manual No 5EK1 AE1 Damage wear Repair or replace the switch Improperly connected Properly connect Incorrect continuity reading Replace the switch ...

Page 22: ...tery 5 Main fuse 11 Main switch 16 C D I unit 21 Meter light 24 Hi beam indicator light 29 Tail Brake light 30 Diode B 31 Headlight relay 37 Dimmer switch 42 Headlight 43 Auxiliary light LIGHTING SYSTEM ELEC EB804000 LIGHTING SYSTEM CIRCUIT DIAGRAM ...

Page 23: ... to the diode B terminals as shown Measure the diode B for continuity as follows 4 Diode B LIGHTING SYSTEM ELEC NOTE YES NO Replace the fuse s 1 Fuse Check the fuse for continuity Refer to CHECKING THE FUSES in chap ter 3 Manual No 5EK1 AE1 Is the fuse OK EAS00781 TROUBLESHOOTING Any of the following fail to light head light high beam indicator light taillight auxiliary light or meter light Check ...

Page 24: ...ight relay terminal as shown Check the headlight relay for continuity YES Replace the head light relay NO Battery positive terminal brown white Battery negative terminal skyblue Does the headlight relay have continuity be tween brown and blue black Tester positive probe brown Tester negative probe blue black 1 2 Check the dimmer switch for continuity Refer to CHECKING THE SWITCHES in P13 Is the di...

Page 25: ...cessories Hard charging Incorrect connection Improperly grounded circuit Poor contacts main or dimmer switch Headlight relay Burnt out headlight bulb HEADLIGHT BULB BURNT OUT Wrong headlight bulb Faulty battery Faulty rectifier regulator Improperly grounded circuit Faulty main switch Faulty dimmer switch Faulty headlight relay Headlight bulb life expired ...

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Page 29: ...t brake light switch 29 Tail Brake light 30 Diode B 31 Headlight relay 32 Turn signal relay 33 Horn 34 Left handlebar switch 35 Horn switch 36 Turn signal switch 37 Dimmer switch 38 Rear turn signal light right 39 Front turn signal light right 40 Front turn signal light left 41 Rear turn signal light left 42 Headlight 43 Auxiliary light COLOR CODE B Black Br Brown Ch Chocolate Dg Dark green G Gree...