Yamaha TW125 (5RS1) Service Manual

MAINTENANCE SPECIFICATIONSSPECCHASSISItemStandard LimitFront suspension:Front fork travelFork spring free lengthFitting lengthSpring rate (K1)Stroke (

MAINTENANCE SPECIFICATIONSSPECNOTE:TIGHTENING TORQUESCHASSISPart to be tightenedThread sizeTighteningtorqueRemarksgNm mSkgHeadlight and headlight stay

CABLE ROUTINGSPEC12 Wire harness13 Front turn signal light lead (right)14 Indicator lead1 Brake hose2 Throttle cables3 Front brake light switch lead4

A After clamping the wire harness,point the surplus part to thedownward. Clamp the part im-mediately before the junction tothe C.D.I. unit and relay.B

CABLE ROUTINGSPECI Pass the throttle cables throughthe engine bracket hole. Pointthe surplus part to the downwardand cut the end.J Pass the carburetor

CABLE ROUTINGSPECO Clamp the wire harness anddiode. Point the surplus part tothe downward.L Clamp the rear brake switch leadconnector and turn signal

CABLE ROUTINGSPECA Clamp between the positioningbelts of resonator hose. Do notpinch the resonator hose.B Starter cable, clutch switch leadand main sw

CABLE ROUTINGSPECtween engine and swingarm.M Route the neutral switch lead be-tween engine and swingarm.N Route the air vent hose and overflow hose th

CABLE ROUTINGSPECV Place the speedometer cable inthe inner side.W After tightening screws, insertthe hose in the screw section.X Distortion should be

CABLE ROUTINGSPEC24 C.D.I. magneto leads, neutralswitch lead1 Handlebar switch lead (right)2 Front brake light switch lead3 Brake hose4 Throttle cable

FOREWORDThis Supplementary Service Manual has been prepared to introduce new service and data for theTW125 2002. For complete service information proc

CABLE ROUTINGSPECH Pass the rear turn signal lightlead (right) between the rearframe and license bracket,avoiding to be caught.I Pass the rear turn si

CABLE ROUTINGSPECO Clamp the handlebar switch lead(left) and clutch switch lead.P After clamping, cut where it is notvisible either from the top or th

INTRODUCTIONPERIODIC MAINTENANCE/LUBRICATION INTERVALSCHKADJNOTE:EAS00036PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all informat

PERIODIC MAINTENANCE/LUBRICATION INTERVALSCHKADJNOTE:NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING( 1,000 km)ANNUALCHECK1 6 12 18 24CHECK20*Rear

ADJUSTING THE ENGINE IDLING SPEEDCHKADJNOTE:abENGINEEAS00054ADJUSTING THE ENGINE IDLING SPEEDPrior to adjusting the engine idling speed, the airfilter

ADJUSTING THE THROTTLE CABLE FREE PLAYCHKADJNOTE:NOTE:abNOTE:EAS00058ADJUSTING THE THROTTLE CABLE FREEPLAYPrior to adjusting the throttle cable free p

ADJUSTING THE THROTTLE CABLE FREE PLAYCHKADJabWARNINGDirectionThrottle cable free playis increased.DirectionThrottle cable free playis decreased.d. Ti

CHECKING AND CHARGING THE BATTERYCHKADJWARNINGCAUTION:EAS00178ELECTRICAL SYSTEMCHECKING AND CHARGING THE BATTERYBatteries generate explosive hydrogen

CHECKING AND CHARGING THE BATTERYCHKADJRelationship between the open-circuit voltageand the charging time at 20_COpen-circuit voltage (V)These values

CHECKING AND CHARGING THE BATTERYCHKADJChargingAmbient temperature 20_COpen-circuit voltage (V)Check the open-circuitvoltage.Time (minutes)Ambienttemp

NOTE:WARNINGCAUTION:EB001000NOTICEThis manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers andtheir qualified mechanic

CHECKING AND CHARGING THE BATTERYCHKADJMeasure the open-circuitvoltage prior to charging.Connect a charged andAMP meter to the batteryand start chargi

CHECKING AND CHARGING THE BATTERYCHKADJMeasure the open-circuitvoltage prior to charging.Connect a charger andAMP meter to the batteryand start chargi

CHECKING AND CHARGING THE BATTERYCHKADJCAUTION:6. Check:S battery ventObstruction ! Clean.Damage ! Replace.7. Install:S battery8. Connect:S battery le

REPLACING THE HEADLIGHT BULBCHKADJWARNINGCAUTION:EAS00182REPLACING THE HEADLIGHT BULB1. Remove:S bolts 1S headlight unit2. Disconnect:S headlight coup

ADJUSTING THE HEADLIGHT BEAMCHKADJababEAS00184ADJUSTING THE HEADLIGHT BEAM1. Adjust:S headlight beam (vertically)a. Turn the adjusting screw 1 in dire

CLUTCHENGOrder Job/Part Q’ty Remarks1234567891011Removing the clutchClutch springsPressure plateFriction platesClutch platesNut/Lock washerClutch boss

Order Job/Part Q’ty Remarks12131415161718Push lever axleTorsion springCirclipOil sealNut/WasherShort clutch push rod/O-ringPush plate11111/11/11Refer

CARBURETORENGOrder Job/Part Q’ty Remarks1234Removing the carburetorSide coverSeatFuel tankHeater unit leadStarter cableCarburetor joint clamp screwAir

Order Job/Part Q’ty RemarksDisassembly the carburetorVacuum chamber coverPiston valve springJet needle holderJet needle springJet needlePiston valveCa

CARBURETORENGOrder Job/Part Q’ty RemarksFloat pinFloatNeedle valveNeedle valve seatMain jetMain jet holderNeedle jetPilot jetPilot screwRubber diaphra

12576438EAS00007HOW TO USE THIS MANUALThis manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensiveexplanations of a

CARBURETORCARBEAS00485CHECKING THE CARBURETOR1. Check:S carburetor bodyS float chamberS jet housingCracks/damage ! Replace.2. Check:S fuel passagesObs

CARBURETORCARB8. Check:S piston valve 1Damage/scratches/wear ! Replace.S rubber diaphragm 2Cracks/tears ! Replace.9. Check:S vacuum chamber cover 1S p

CARBURETORCARBCAUTION:NOTE:13. Check:S fuel hosesCracks/damage/wear ! Replace.Obstruction ! Clean.Blow out the hoses with compressed air.EAS00487ASSEM

CARBURETORCARB4. Install:S float chamber 1S pilot screw 25. Install:S starter plunger kit 1EAS00492INSTALLING THE CARBURETOR1. Adjust:S engine idling

CARBURETORCARBa. Stand the motorcycle on a level surface.b. Place the motorcycle on a suitable stand toensure that the motorcycle is standingstraight

FRONT WHEEL AND BRAKE DISCCHASOrder Job/Part Q’ty Remarks1234567Removing the front wheel and brakediscCapsSpeedometer cableWheel axleFront wheel assem

Order Job/Part Q’ty Remarks12345678Removing the rear wheelAdjusterBrake rodPinCompression springChain caseAxle nut/washerChain pullersWheel axle111111

Order Job/Part Q’ty Remarks910Rear wheel assemblyCollar12Refer to “REMOVING /INSTALLING THEREAR WHEEL” section in chapter 6.(Manual No.: 5EK1-AE1)For

Order Job/Part Q’ty Remarks123Removing the rear brake and rearwheel sprocketShoe plateNutsDriven sprocket161Remove the parts in the order listed.For i

Order Job/Part Q’ty RemarksDisassembling the rear wheelBearingSpacerOil sealBearing1111Disassemble the parts in the order listed.For assembly, reverse

2113579248623 24222018 191715141311 1210GENINFOSPECENGCARBELECCHASCHKADJTRBLSHTG16EAS00009SYMBOLSThe following symbols are not relevant to everyvehicl

Order Job/Part Q’ty Remarks12345678Removing the front forkFront wheelBrake hose holderCaliperFront fenderCap bolt/O-ringBolt (upper bracket)Bolts (und

Order Job/Part Q’ty Remarks1234567Removing the handlebarMaster cylinder bracketMaster cylinderHousing (throttle grip)Throttle grip assemblyHandlebar s

Order Job/Part Q’ty Remarks8910111213Handlebar switch (left)Grip (left)Clutch leverStarter cable holderUpper holdersHandlebar111121Refer to “REMOVING

Order Job/Part Q’ty Remarks12345678910111213Removing the lower bracketFront forkHandlebarHeadlight unitHeadlight bodyTurn signal light assembly (left)

STEERING HEADCHASOrder Job/Part Q’ty Remarks14151617181920Ball race ccverLower bracketBall race (upper)BallBallBall race (center)Ball race (lower)1112

IGNITION SYSTEMELEC1 C.D.I. magneto2 Neutral switch4 Battery6 Fuse10 Engine stop switch11 Main switch13 Diode14 C.D.I. unit15 Ignition coil16 Spark pl

IGNITION SYSTEMELECNOYESS Make the speedometer indicateS Check the continuity or open circuit status.S If it counts 4 cycles of continuity and openact

COLOR CODEB Black. . . . . . . . . Br Brown. . . . . . . . . Ch Chocolate. . . . . . . . Dg Dark green. . . . . . . . G Green. . . . . . . . . L Blue.

CONTENTSSPECIFICATIONSGENERAL SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE SPECIFICATIO

GENERAL SPECIFICATIONSSPECSPECIFICATIONSGENERAL SPECIFICATIONSModel TW125Model code: 5RS1, 5RS2Dimensions:Overall lengthOverall widthOverall heightSea

GENERAL SPECIFICATIONSSPECModel TW125Wheel travel:Front wheel travelRear wheel travel150 mm150 mmElectrical:Ignition systemGenerator systemBattery typ

MAINTENANCE SPECIFICATIONSSPECMAINTENANCE SPECIFICATIONSENGINEItemStandard LimitClutch:Friction plate thicknessQuantityClutch plate thicknessQuantityC