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
E2002 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.
2 1
5
7 6
4 3
8
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. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS” on the following page.
2 Each 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.)
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 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step.
6 Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).
7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.
8 Jobs requiring more information (such as special tools and technical data) are described sequen- tially.
21 1
3
5
7
9
2
4
8 6
23 24
22 20
18 19
17 15
14 13
11 12
10
GEN
INFO SPEC
ENG
CARB
ELEC
CHAS CHK
ADJ
TRBL SHTG
16
EAS00009
SYMBOLS
The following symbols are not relevant to every vehicle.
Symbols 1 to 8 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 8 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 Lithium soap base grease 22 Molybdenum disulfide grease
Symbols 23 to 24 in the exploded diagrams indi- cate the following:
23 Apply locking agent (LOCTITER) 24 Replace the part
CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . 1
CHASSIS SPECIFICATIONS . . . 1
ELECTRICAL SPECIFICATIONS . . . 2
CABLE ROUTING . . . 3
ELECTRICAL
CHECKING THE SWITCHES . . . 13LIGHTING SYSTEM . . . 14
CIRCUIT DIAGRAM . . . 14
TROUBLESHOOTING . . . 15
TROUBLESHOOTING
FAULTY LIGHTING SYSTEM. . . 17HEADLIGHT 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 SSS
CHASSIS SPECIFICATIONS
Item Standard Limit
Frame Frame type Caster angle Trail
Diamond 25_83’
93 mm
SSSSSS SSS 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 X 90 kg
150 kPa (1.5 kg / cm2, 1.5 bar) 150 kPa (1.5 kg / cm2, 1.5 bar) 90 X 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)
SSSSSS SSSSSS SSSSSS SSS SSSSSS
SSSSSS
*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 X 150 mm
0.259 L (259 cm3) 122 mm
Fork oil 10 WT or equivalent SSS
SSS 324 mm SSSSSS SSSSSS SSSSSS 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 X 32 mm
32 X 48 mm
SSS 173 mm SSSSSS SSSSSS SSS Drive chain
Type / manufacturer No. of links
Chain free play
428HD / DAIDO 126
35 X 60 mm
SSSSSS SSS Rear brake
Type
Drum inside diameter Shoe thickness
Shoe spring free length
Leading, trailing 130 mm
4 mm 52 mm
SSS 131 mm 2 mm SSS
ELECTRICAL SPECIFICATIONS
Item Standard Limit
C.D.I.
Pickup coil resistance / color Source coil resistance / color C.D.I. unit model / manufacturer
656 X 984 Ω at 20_C/
Red – White
624 X 936 Ω at 20_C/
Brown – Green 5BT / YAMAHA
SSS SSS SSS Headlight relay
Model / manufacturer Coil resistance
G8MS-1A48T-L2-F28 / OMRON
90 X 110 Ω SSS
SSS
–3–
12 Wire harness
13 Front turn signal light lead (right)
14 Indicator lead
1 Brake hose
2 Throttle cables
3 Front brake light switch lead
4 Right handlebar switch lead
5 Main switch lead
6 Clutch cable
7 Clutch 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 ROUTING
–4–
1 Battery positive lead
2 Starter relay
3 Starter motor lead
4 Ignition coil
5 Throttle cable (pull side)
6 Throttle cable (return side)
7 Throttle cable holder
8 Horn lead
9 Throttle 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.
–5–
C Clamp the wire harness, handle- bar switch lead (right), front brake light switch lead, clutch switch lead, main switch lead, resonator hose and starter cable.
D Clamp the ignition coil lead and the ignition coil grand lead horn lead.
E Route the wire harness, handle- bar switch lead (right) and front brake light switch lead through the guide.
CABLE ROUTING SPEC
F Do not bend the lead sharply just after 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 turn signal relay lead at the outmost posi- tion. Next, point the surplus part of the band to the inner side and then cut it.
J Relay lead can be routed either the front or the rear side of the relay.
–6–
CABLE ROUTING SPEC
K Push the wire harness in be- tween frame and box.
L Place the C.D.I. unit on the at- taching section 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.
–7–
1 Resonator hose
2 Fuel hose
3 Rectifier / regulator lead
4 Thermo switch lead
5 Sidestand switch lead
6 Air filter case
7 Breather hose
8 Battery negative lead
9 C.D.I. magneto two leads
10 Over flow hose
11 Air vent hose
12 Clutch cable
13 Horn lead clamp
CABLE ROUTING SPEC
14 Clutch 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 torn. Do not pinch the resonator hose.
D Place the coupler below the res- onator hose.
–8–
G Clamp the C.D.I. magneto lead at the frame pipe bend and point the surplus part to the inner side, then cut it.
H Clamp the sidestand switch lead.
I Clamp the air vent hose, over flow hosed and neutral switch lead.
J Hold down the side stand switch lead using the special washer.
CABLE ROUTING SPEC
E Clamp the rectifier / regulator lead and resonator hose. Point 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 lead be- tween engine and swingarm.
M Pass the air vent hose and over- flow hose through the engine guide.
N To the fuel cock.
O Insert the starter cable to the clamp.
–9–
T Place the speedometer cable in the inner side.
U After tightening screws, insert the hose in the screw section.
V Distortion should be within this range toward the traveling direc- tion of vehicle.
W Place the brake 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 ROUTING SPEC
–10–
13 Rectifier / regulator
14 Clamp (rectifier / regulator lead)
15 Handlebar switch lead (left)
16 Clutch switch lead
17 Clutch cable
18 Starter cable
19 Neutral switch lead
20 Connect cover
21 C.D.I. magneto leads
CABLE ROUTING SPEC
1 Brake hose
2 Throttle cable (return side)
3 Throttle cable (pull side)
4 Front brake light switch 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 lead (right). Point the surplus part to the inner side.
D Cover the naked part of rear turn signal light lead (right) with the hose.
–11–
E Cover the naked part of rear turn signal light lead (left) with the hose.
F Clamp the wire harness and rear turn signal lead (right).
G Pass the rear turn signal light lead (right) between the rear frame and license bracket, avoiding to be caught.
H Rout the lead by the outside of the frame so that it does not con- tact with the tip of the bolt as shown in the illustration.
CABLE ROUTING SPEC
I Pass the rear turn signal light lead (left) between the rear frame and license bracket, 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 the C.D.I. magneto lead (2 leads), neutral switch lead, starter motor lead and battery negative lead.
O Clamp the handlebar switch lead (left) and clutch switch lead.
P Route the thermo switch lead un- der the cover connector.
Q Route the starter motor lead un- der the cover connector.
–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.
–13–
1 Turn signal switch
2 Dimmer switch
3 Horn switch
4 Clutch switch
5 Front brake switch
6 Engine stop switch
7 Start switch
8 Main switch
9 Neutral switch
10 Sidestand switch
11 Rear brake switch
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 ³ Repair or replace the switch.
Improperly connected ³ Properly connect.
Incorrect continuity reading ³ Replace the switch.
–14–
1 C.D.I magneto
3 Rectifier/Regulator
4 Battery
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
–15–
2. Battery
SCheck the condition of the battery.
Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. (Manual No. : 5EK1-AE2)
Minimum open-circuit voltage 12.8 V more at 20 _C
SIs the battery OK?
YES
SClean the battery terminals.
SRecharge or replace the battery.
NO
EAS00749
SCheck the main switch for continuity.
Refer to “CHECKING THE SWITCHES” in P13.
SIs the main switch OK?
YES
Replace the main switch.
NO 3. Main switch
EAS00760
SDisconnect the diode B from the wire har- ness.
SConnect the pocket tester (Ω 1) to the diode B terminals as shown.
SMeasure the diode B for continuity as follows.
4. Diode B
LIGHTING SYSTEM ELEC
NOTE:
YES NO
Replace the fuse(-s).
1. Fuse
SCheck the fuse for continuity.
Refer to “CHECKING THE FUSES” in chap- ter 3. (Manual No. : 5EK1-AE1)
SIs 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:
1. fuse 2. battery 3. main switch 4. diode B
5. headlight relay 6. dimmer switch 7. wiring
(of the entire charging system)
SBefore troubleshooting, remove the following part(-s):
1) side covers (left and right) 2) seat
3) fuel tank
STroubleshoot with the following special tool(-s).
Pocket tester 90890-03112
EAS00738
–16–
LIGHTING SYSTEM ELEC
Tester positive probe ! brown / white Tester negative probe !
white 1 2 Tester positive probe !
brown / white Tester negative probe !
blue / black 1 3
Continuity
YES
Replace the diode B.
NO NOTE:
When you switch the tester’s positive and negative probes, the readings in the above chart will be reversed.
SAre the testing readings correct?
Tester positive probe ! white Tester negative probe !
brown / white 2 1 Tester positive probe !
blue / black Tester negative probe !
brown / white 3 1
No
continuity
5. Headlight relay
SDisconnect the headlight relay from the wire harness.
SConnect the pocket tester (Ω 1) and bat- tery (12 V) to the headlight relay terminal as shown.
SCheck the headlight relay for continuity.
YES
Replace the head- light relay.
NO Battery positive terminal ! brown / white Battery negative terminal ! skyblue
SDoes the headlight relay have continuity be- tween brown and blue / black?
Tester positive probe ! brown Tester negative probe ! blue / black
1 2
SCheck the dimmer switch for continuity.
Refer to “CHECKING THE SWITCHES” in P13.
SIs the dimmer switch OK?
YES
The dimmer switch is faulty. Replace the left handlebar switch.
NO 6. Dimmer switch
SCheck the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
SIs the lighting system’s wiring properly con- nected and without defects?
YES
Properly connect or repair the lighting system’s wiring.
NO 7. Wiring
Check the condition of each of the lighting system’s circuits.
Refer to “CHECKING THE LIGHTING SYSTEM”. (Manual No. : 5EK1-AE1)
–17–
FAULTY LIGHTING SYSTEM TRBL SHTG
EAS00866
TROUBLESHOOTING
FAULTY LIGHTING SYSTEM
HEADLIGHT DOES NOT COME ON SWrong headlight bulb
SToo many electrical accessories SHard charging
SIncorrect connection
SImproperly grounded circuit
SPoor contacts (main or dimmer switch) SHeadlight relay
SBurnt-out headlight bulb
HEADLIGHT BULB BURNT OUT SWrong headlight bulb
SFaulty battery
SFaulty rectifier / regulator SImproperly grounded circuit SFaulty main switch
SFaulty dimmer switch SFaulty headlight relay SHeadlight bulb life expired
1 C.D.I. magneto
2 Neutral switch
3 Rectifier / Regulator
4 Battery
5 Main fuse
6 Starter relay
7 Starter motor
8 Right handlebar switch
9 Start switch
10 Engine stop switch
11 Main switch
12 Diode A
13 Clutch switch
14 Sidestand switch
15 Neutral relay
16 C.D.I. unit
17 Ignition coil
18 Spark plug
19 Speedometer
20 Reed switch
21 Meter light
22 Neutral indicator light
23 Turn signal indicator light
24 Hi-beam indicator light
25 Thermo switch
26 Carburetor heater
27 Rear brake light switch
28 Front 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 . . . Green L . . . Blue O . . . Orange Sb. . . Sky blue P. . . Pink R. . . Red Y. . . Yellow W . . . White B / R . . . . Black / Red
B / W . . . . Black / White B / Y . . . . Black / Yellow Br / W . . . Brown / White G / W. . . . Green / White G / Y . . . . Green / Yellow L / B. . . Blue / Black L / W . . . . Blue / White L / Y. . . Blue / Yellow R / L . . . . Red / Blue R / W. . . . Red / White W / B . . . . White / Black W/L . . . . White / Blue W / R. . . . White / Red
