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FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
TW125 2002. 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 2002
SUPPLEMENTARY
SERVICE MANUAL
E2001 by Yamaha Motor Co., Ltd.
First Edition, August 2001
Any reproduction or unauthorized use without the written permission of
Yamaha Motor Co., Ltd. is expressly prohibited.
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.
NOTE:
Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
WARNING
CAUTION:
NOTE:
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.
A NOTE provides key information to make procedures easier or clearer.
5
6
7
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 sequentially.
2 1 4
3
8
17
20
23
13
15
1
GEN
INFO
3
CHK
ADJ
5
CARB
7
ELEC
9
11
18
21
12
14
16
24
2
SPEC
4
ENG
6
CHAS
8
TRBL
SHTG
10
19
22
EAS00009
SYMBOLS
The following symbols are not relevant to every vehicle.
Symbols 1 to 9 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
12
Lubricant
Special tool
13
14
Tightening torque
Wear limit, clearance
15
16
Engine speed
Electrical data
Symbols 17 to 22 in the exploded diagrams indicate the types of lubricants and lubrication points.
17
18
Engine oil
Gear oil
19
20
Molybdenum disulfide oil
Wheel bearing grease
21
22
Lithium soap base grease
Molybdenum disulfide grease
Symbols 23 to 24 in the exploded diagrams indicate the following:
23 Apply locking agent (LOCTITE
R
)
24 Replace the part
CONTENTS
SPECIFICATIONS
MAINTENANCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
5
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE / LUBRICATION INTERVALS
ADJUSTING THE ENGINE IDLING SPEED
. . . . . . . . . . . . . . . . . . . . .
18
ADJUSTING THE THROTTLE CABLE FREE PLAY
CHECKING AND CHARGING THE BATTERY
REPLACING THE HEADLIGHT BULB
ADJUSTING THE HEADLIGHT BEAM
. . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .
19
21
27
28
ENGINE
CARBURETOR
CHECKING THE CARBURETOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE CARBURETOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
36
INSTALLING THE CARBURETOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURING AND ADJUSTING THE FUEL LEVEL
. . . . . . . . . . . .
37
37
CHASSIS
FRONT WHEEL AHD BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
REAR WHEEL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
REAR BRAKE AND REAR WHEEL SPROCKET
. . . . . . . . . . . . . . . .
42
LOWER BRACKET
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
ELECTRICAL SYSTEM
CIRCUIT DIAGRAM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE IGNITION SYSTEM
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
49
50
GENERAL SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model
Model code:
Dimensions:
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
Carburetor:
Type / quantity
Manufacturer
Transmission:
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Transmission type
Operation
Gear ratio 1st
2nd
3rd
4th
5th
Chassis:
Frame type
Caster angle
Trail
Tire:
Type
Size front
5RS1, 5RS2
2,135 mm
, 820 mm
1,120 mm
, 820 mm
1,350 mm
, 255 mm
2,100 mm
MV28 / 1
TEIKEI
Spur gear
74 / 20 (3.700)
Chain drive
51 / 14 (3.643)
Constant mesh 5 speed
Left foot operation
36 / 16 (2.250)
31 / 21 (1.476)
27 / 24 (1.125)
25 / 27 (0.926)
23 / 29 (0.793)
Diamond
25
_50’
93 mm rear
Manufacture front rear
Type front rear
Tube type
130 / 80-18 66P
130 / 80-18 M / C 66P
180 / 80-14 M / C 78P
BRIDGESTONE
BRIDGESTONE
TW203
TW204
TW125
SPEC
–1–
Model
Wheel travel:
Front wheel travel
Rear wheel travel
Electrical:
Ignition system
Generator system
Battery type
Battery capacity
Bulb wattage
quantity:
Headlight
Auxiliary light
Tail / brake light
Turn signal light
Meter light
High beam indicator light
Neutral indicator light
Turn signal indicator light
GENERAL SPECIFICATIONS
TW125
150 mm
150 mm
C.D.I.
A.C. magneto
GT6B-3
12 V 6 AH
12 V 60 W / 55 W 1
12 V 4 W
1
12 V 5 W / 21 W
1
12 V 21 W
4
12 V 3.4 W
1
12 V 3.4 W
1
12 V 3.4 W
1
12 V 3.4 W 1
SPEC
–2–
MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE
Item
Clutch:
Friction plate thickness
Quantity
Clutch plate thickness
Quantity
Clutch spring free length
Quantity
Push rod bending limit
Carburetor:
Type
I.D. mark
Main jet
Main air jet
Jet needle
Needle jet
Pilot air jet 1
Pilot air jet 2
Pilot outlet
Pilot jet
Bypass 1
Bypass 2
Bypass 3
Bypass 4
Pilot screw
Valve seat size
Starter jet 1
Starter jet 2
Fuel level
Engine idle speed
Intake vacuum
(M.J)
(M.A.J)
(J.N)
(N.J)
(P.A.J.1)
(P.A.J.2)
(P.O)
(P.J)
(B.P.1)
(B.P.2)
(B.P.3)
(B.P.4)
(P.S)
(V.S)
(G.S.1)
(G.S.2)
(F.L)
2.9 X 3.1 mm
5 pcs.
1.6 mm
4 pcs.
34.9 mm
4 pcs.
SSS
Standard
MV28
5RS1 00
#134
ø1.2
5A50-3 / 5
B1/ 60
#90
#120
0.8
#34
0.7
0.7
0.7
0.7
1-1 / 2
1.6
0.6
0.8
0
X 2.0 mm
1,450 X 1,650 r/min
190
X 230 mmHg
TIGHTENING TORQUES
ENGINE
Cam sprocket cover
Oil filter cover
Crankcase (left and right)
Generator cover
Clutch cover
Clutch boss
Drive sprocket
Pick up coil
Stator coil
Part name
Thread
Screw
Screw
Screw
Screw
Screw
Nut
Bolt
Screw
Screw
M6
M6
M6
M6
M6
M14
M5
M6
M6
2
2
12
10
10
2
3
1
2
SPEC
Tightening torque
Nm m
Skg
10
10
10
10
10
50
4
10
10
1.0
1.0
1.0
1.0
1.0
5.0
0.4
1.0
1.0
Limit
Remarks
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
2.7 mm
SSS
0.05 mm
SSS
33.9 mm
SSS
0.2 mm
–3–
MAINTENANCE SPECIFICATIONS
CHASSIS
Item
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
Rear suspension:
Shock absorber stroke
Spring free length
Fitting length
Spring rate (K1)
Stroke (K1)
Drive chain:
Type / manufacturer
No. of links
Chain free play
Maximum ten-link section
Rear brake:
Type
Drum inside diameter
Shoe thickness
Shoe spring free length
Brake lever:
Brake lever free play (at lever end)
Standard
150 mm
330 mm
325 mm
4.9 N / mm (0.49 kg / mm)
0 X 150 mm
0.259 L (259 cm
3
)
122 mm
Fork oil 10 WT or equivalent
SSS
48 mm
190 mm
185 mm
127 N / mm (12.7 kg / mm)
0
X 48 mm
428HD / DAIDO
125
35
X 60 mm
129.5 mm
Leading, trailing
130 mm
4 mm
Cam side 52 mm
Pin side 48 mm
5
X 8 mm
SPEC
SSS
Limit
SSS
323 mm
SSS
SSS
SSS
SSS
SSS
SSS
0.2 mm
SSS
SSS
SSS
SSS
SSS
171 mm
SSS
SSS
SSS
SSS
131 mm
2 mm
SSS
–4–
MAINTENANCE SPECIFICATIONS
SPEC
TIGHTENING TORQUES
CHASSIS
Headlight and headlight stay
Handle crown and steering shaft
Steering ring nut
Brake hose union bolt (front brake)
Swingarm pivot shaft
Footrest (left)
(right)
Rear footrest
Brake caliper and front fork
Rear wheel sprocket and hub
Thread size
M8
M22
M25
M10
M12
M12
M10
M8
M10
M8
Tightening torque
Nm m Skg
16
110
4
30
83
88
48
16
40
43
1.6
11.0
0.4
3.0
8.3
8.8
4.8
1.6
4.0
4.3
Remarks
Refer to NOTE
NOTE:
1. When tighten the ring nut, should be steady the ball bearings and the steering shaft moving smoothly.
2. First, tighten the ring nut approximately 38 Nm (3.8 m Skg) by using the torque wrench, then loosen the ring nut one turn and retighten the ring nut to specification.
ELECTRICAL
Item
Charging system:
Type
Model / manufacturer
Standard output
Stator coil resistance / color
Battery:
Specific gravity
Electric starter system:
Type
Starter motor:
Model / manufacturer
Output
Armature coil resistance
Brush overall length
Brush spring pressure
Commutator diameter
Mica undercut (depth)
Standard
C.D.I. magneto
F5BT / YAMAHA
14 V 170 W / 5,000 r / min
0.48
X 0.72 Ω at 20_C/
White – White
1.320
Constant mesh type
5RS/ YAMAHA
0.4 kW
0.0126
X 0.0154 Ω at 20_C
10 mm
5.52
X 8.28 N (552 X 828 g)
22 mm
1.5 mm
Limit
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
SSS
3.5 mm
SSS
21 mm
SSS
–5–
CABLE ROUTING
SPEC
CABLE ROUTING
1
2
3
Brake hose
Throttle cables
Front brake light switch lead
4
5
6
7
Right handlebar switch lead
Main switch lead
Clutch cable
Clutch switch lead
8
9
10
11
Speedometer cable
Left handlebar switch lead
Front turn signal light lead (left)
Meter lead
12
13
14
Wire harness
Front turn signal light lead (right)
Indicator lead
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
–6–
1
2
3
4
5
Battery positive lead
Starter relay
Starter motor lead
Clamp
Ignition coil
6
7
8
9
Throttle cable (pull side)
Throttle cable (return side)
Throttle cable holder
Horn lead
10
11
Spark plug lead
Relay (White)
12 C.D.I. unit
13
14
Diode
Resister lead
15 Turn signal relay
CABLE ROUTING
SPEC
A After clamping the wire harness, point the surplus part to the downward. Clamp the part immediately before the junction to the C.D.I. unit and relay.
B Cut it to be 10 mm or less.
C Handlebar switch lead (right) and front brake light switch lead should not be twined around.
–7–
CABLE ROUTING
SPEC
D Clamp the wire harness, handle bar switch lead (right), front brake light switch lead, clutch switch lead and main switch lead. After clamping, point the surplus part to the downward and then cut it. Do not clamp the resonator hose and starter cable.
E Clamp the wire harness, handlebar switch lead (right), front brake light switch lead, clutch switch lead, main switch lead, resonator hose and starter cable.
F Clamp the ignition coil lead and the ignition coil grand lead horn lead.
G Route the wire harness, handlebar switch lead (right) and front brake light switch lead through the guide.
H Do not bend the lead sharply just after the terminal connection.
I Pass the throttle cables through the engine bracket hole. Point the surplus part to the downward and cut the end.
J Pass the carburetor heater lead in front of the seat pillar tube so that it is not caught between the side cover flange and seat pillar tube frame.
K Point the rear brake switch lead wire to the rear side of frame.
–8–
CABLE ROUTING
L Clamp the rear brake switch lead connector and turn signal relay lead with the band and point the surplus part to the inner side, then cut it. Secure the connector at the front part of frame.
M Push the wire harness in between frame and box.
N Place the C.D.I. unit on the mounting port for the left side relay.
O Clamp the wire harness and diode. Point the surplus part to the downward.
SPEC
–9–
1
2
3
4
5
Resonator hose
Fuel hose
Rectifier / regulator lead
Thermo switch lead
Sidestand switch lead
6
7
8
9
Air filter case
Breather hose
Battery negative lead
C.D.I. magneto leads
10
11
Over flow hose
Air vent hose
12 Clutch cable
CABLE ROUTING
13
14
Clutch cable guide
Brake hose
15
16
17
Speedometer cable
Handlebar switch lead (left)
Clamp
18
19
Flange bolt
Brake hose holder
SPEC
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 protector is torn. Do not pinch the resonator hose.
D Place the coupler below the resonator hose.
–10–
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 protector is torn. Do not pinch the resonator hose.
F Place the air vent hose in the inner side of the main pipe.
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 hose, starter motor lead and neutral switch lead.
J Hold down the side stand switch lead using the special washer.
K Route the air vent hose and over flow hose between engine and swingarm.
L Route the starter motor lead between engine and swingarm.
M Route the neutral switch lead between engine and swingarm.
N Route the air vent hose and over flow hose through the engine guide.
O To the fuel cock.
P Route the horn lead through inside the clutch cable.
Q Insert the starter cable to the clamp.
–11–
CABLE ROUTING
R Clamp the brake hose and speedometer cable. Align the clamping position with the center of white paint mark on the brake hose.
S Clamp the brake hose and speedometer cable with a holder.
T Point the speedometer cable cap to the backward.
U Make sure to push in the boot fully.
V Place the speedometer cable in the inner side.
W After tightening screws, insert the hose in the screw section.
X Distortion should be within this range toward the traveling direction of vehicle.
Y Place the brake hose in the outer side.
SPEC
–12–
1
2
3
4
5
Handlebar switch lead (right)
Front brake light switch lead
Brake hose
Throttle cable (return side)
Throttle cable (pull side)
6
7
8
9
Starter motor lead
Battery positive lead
Wire harness
Clamp (wire harness)
10
11
Thermo switch lead
Sidestand switch lead
12 Negative lead
CABLE ROUTING
SPEC
13
14
Battery negative lead
Grommet
15
16
17
Rectifier / regulator
Clamp (rectifier / regulator lead)
Handlebar switch lead (left)
18
19
Clutch switch lead
Clutch cable
20
21
Master cylinder
Starter cable
22
23
Rear turn signal light lead
Turn signal light stay
24 C.D.I. magneto leads, neutral switch lead
–13–
CABLE ROUTING
SPEC
A Clamp the handlebar switch lead and front brake light switch lead with a band.
B Clamp the throttle cables.
C Clamp the C.D.I. magneto lead
(2 leads), starter motor lead, neutral switch lead, battery negative lead and pass them through the frame gusset hole, then point the surplus part to the inner side.
D Clamp the wire harness and rear turn signal light lead (right). Point the surplus part to the inner side.
E Cover the naked part of rear turn signal light lead (right) with the hose.
F Cover the naked part of rear turn signal light lead (left) with the hose.
G Clamp the wire harness and rear turn signal lead (right).
H Pass the rear turn signal light lead (right) between the rear frame and license bracket, avoiding to be caught.
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.
–14–
CABLE ROUTING
K Clamp the thermo switch lead coupler. After clamping, point the surplus part to the inner side.
L Pass the C.D.I. magneto lead (2 leads) through the grommet side.
M Place the cover to the corner of rectifier / regulator.
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 After clamping, cut where it is not visible either from the top or the rear.
SPEC
–15–
INTRODUCTION
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
CHK
ADJ
EAS00036
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter.
EAS00037
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
NOTE:
SThe annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
SFrom 30,000 km, repeat the maintenance intervals starting from 6,000 km.
SItems marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
NO.
ITEM
1 * Fuel line
2
3 * Valves
5 Clutch
* Front brake
* Rear brake
* Brake hose
9 * Wheels
10 * Tires
11 * Wheel bearings
12 * Swingarm
13 Drive chain
14 * Steering bearings
15 * Chassis fasteners
16 Sidestand
17 * Sidestand switch
18 * Front fork
19 *
Shock absorber assembly
CHECK OR MAINTENANCE JOB
S Check fuel hoses for cracks or damage.
S Check condition.
S Clean and regap.
S Replace.
S Check valve clearance.
S Adjust.
S Clean.
S Replace.
S Check operation.
S Adjust.
S Check operation, fluid level and vehicle for fluid leakage.
S Replace brake pads.
S Check operation and adjust brake pedal free play.
S Replace brake shoes.
S Check for cracks or damage.
S Replace.
S Check runout, spoke tightness and for damage.
S Tighten spokes if necessary.
S Check tread depth and for damage.
S Replace if necessary.
S Check air pressure.
S Correct if necessary.
S Check bearing for looseness or damage.
S Check operation and for excessive play.
S Lubricate with lithium-soap-based grease.
S Check chain slack.
S Make sure that the rear wheel is properly aligned.
S Clean and lubricate.
S Check bearing play and steering for roughness.
S Lubricate with lithium-soap-based grease.
S Make sure that all nuts, bolts and screws are properly tightened.
S Check operation.
S Lubricate.
S Check operation.
S Check operation and for oil leakage.
S Check operation and shock absorber for oil leakage.
–16–
1
√
√
√
ODOMETER READING
( 1,000 km)
6
√
12
√
18
√
√ √
24
√
√
√
√
√ √
√
√
√
√
√
√ √
√
√
√ √ √ √
Whenever worn to the limit
√ √ √ √
√
Whenever worn to the limit
√ √ √
Every 4 years
ANNUAL
√
√
√
√
√ √ √ √
√ √ √ √ √
√
√
√
√
√
√
√
√
√
√
√
√
Every 24,000 km
√
√
Every 500 km and after washing the motorcycle or riding in the rain
√ √ √
Every 24,000 km
√
√ √ √ √ √
√
√
√
√
√
√
√
√
√
√
√
√
√
√
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
CHK
ADJ
NO.
ITEM CHECK OR MAINTENANCE JOB
Rear suspension relay
20 * arm and connecting arm pivoting points
21
22
26
27
*
*
Carburetor
Engine oil
23
Engine oil filter element
24 * Engine oil strainer
25 *
Front and rear brake switches
Moving parts and cables
Lights, signals and switches
S Check operation.
S Lubricate with lithium-soap-based grease.
S Check starter (choke) operation.
S Adjust engine idling speed.
S Change.
S Check oil level and vehicle for oil leakage.
S Clean.
S Clean.
S Check operation.
S Lubricate.
S Check operation.
S Adjust headlight beam.
√
√
√
1
√
ODOMETER READING
(
1,000 km)
6
√
12
√
18
√
√
24
√
√
√ √ √ √
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
ANNUAL
√
√
√
√
√
NOTE:
D The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
D Hydraulic brake service
SRegularly check and, if necessary, correct the brake fluid level.
SEvery two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.
SReplace the brake hoses every four years and if cracked or damaged.
–17–
ADJUSTING THE ENGINE IDLING SPEED
CHK
ADJ
ENGINE
EAS00054
ADJUSTING THE ENGINE IDLING SPEED
NOTE:
Prior to adjusting the engine idling speed, the air filter should be clean, and the engine should have adequate compression.
1. Start the engine and let it warm up for several minutes.
2. Install:
Sengine tachometer
(to the spark plug lead)
Engine tachometer
90890-03113
3. Measure:
Sengine idling speed
Out of specification
! Adjust.
Engine idling speed
1,450
X 1,650 r/min
4. Adjust:
Sengine idling speed a. Turn the pilot screw 1 in or out until it is lightly seated.
b. Turn the pilot screw out the specified number of turns.
Pilot screw
1-1 / 2 turns out c. Turn the throttle stop screw 2 in direction a or b until the specified engine idling speed is obtained.
increased.
decreased.
–18–
5. Adjust:
Sthrottle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play
(at the flange of the throttle grip)
3
X 5 mm
ADJUSTING THE THROTTLE CABLE FREE PLAY
CHK
ADJ
EAS00058
ADJUSTING THE THROTTLE CABLE FREE
PLAY
NOTE:
Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted.
1. Check:
Sthrottle cable free play a
Out of specification
! Adjust.
Throttle cable free play
(at the flange of the throttle grip)
3
X 5 mm
2. Adjust:
Sthrottle cable free play
NOTE:
When the motorcycle is accelerating, the accelerator cable 1 is pulled.
Carburetor side a. Loosen the locknut 2 on the decelerator cable.
b. Turn the adjusting nut 3 in direction a or b to take up any slack on the decelerator cable.
c. Loosen the locknut 4 on the accelerator cable 1 .
d. Turn the adjusting nut 5 in direction a or b until the specified throttle cable free play is obtained.
Direction
Direction a b
Throttle cable free play is increased.
Throttle cable free play is decreased.
e. Tighten the locknuts.
NOTE:
If the specified throttle cable free play cannot be obtained on the carburetor side of the cable, use the adjusting nut on the handlebar side.
Handlebar side a. Slide back the rubber cover 1 .
b. Loosen the locknut 2 .
c. Turn the adjusting nut 3 in direction a or b until the specified throttle cable free play is obtained.
–19–
ADJUSTING THE THROTTLE CABLE FREE PLAY
Direction a
Direction b
CHK
ADJ
Throttle cable free play is increased.
Throttle cable free play is decreased.
d. Tighten the locknut.
WARNING
After adjusting the throttle cable free play, turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change.
–20–
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
EAS00178
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY
WARNING
Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive measures:
SWear protective eye gear when handling or working near batteries.
SCharge batteries in a well-ventilated area.
SKeep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes).
SDO NOT SMOKE when charging or han- dling batteries.
SKEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
SAvoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury.
First aid in case of bodily contact:
External
SSKIN – Wash with water.
SEYES – Flush with water for 15 minutes and get immediate medical attention.
Internal
SDrink large quantities of water or milk fol- lowed with milk of magnesia, beaten egg or vegetable oil. Get immediate medical attention.
CAUTION:
SThis is a sealed battery. Never remove the sealing caps because the balance between cells will not be maintained and battery performance will deteriorate.
SCharging time, charging amperage and charging voltage for a MF battery are different from those of conventional batteries.
The MF battery should be charged as explained in the charging method illustrations. If the battery is overcharged, the electrolyte level will drop considerably.
Therefore, take special care when charging the battery.
–21–
13.0
12.5
12.0
11.5
CHECKING AND CHARGING THE BATTERY
CHK
ADJ
NOTE:
Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte.
Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
Relationship between the open-circuit voltage and the charging time at 20
_C
1. Remove:
Sseat
2. Disconnect:
Sbattery leads
(from the battery terminals)
CAUTION:
First, disconnect the negative lead 1 , then the positive lead 2 .
3. Remove:
Sbattery
4. Check:
Sbattery charge a. Connect a pocket tester to the battery terminals.
Tester positive lead ! battery positive
Tester positive lead
! terminal
Tester negative lead ! battery negative
Tester negative lead
! terminal
NOTE:
SThe charge state of a MF battery can be checked by measuring its open-circuit voltage
(i.e., the voltage when the positive terminal is disconnected).
SNo charging is necessary when the open-circuit voltage equals or exceeds 12.8 V.
5 6.5
10
Charging time (hours)
These values vary with the temperature, the condition of the battery plates, and the electrolyte level.
b. Check the charge of the battery, as shown in the charts and the following example.
Example c. Open-circuit voltage = 12.0 V d. Charging time = 6.5 hours e. Charge of the battery = 20
X 30%
–22–
Charging
CHECKING AND CHARGING THE BATTERY
Ambient temperature 20 _C
CHK
ADJ
5. Charge:
Sbattery
(refer to the appropriate charging method illustration)
WARNING
Do not quick charge a battery.
Time (minutes)
Check the open-circuit voltage.
Charging condition of the battery (%)
Ambient temperature
20
_C
CAUTION:
SMake sure that the battery vent is free of ob- structions.
SNever remove the MF battery sealing caps.
SDo not use a high-rate battery charger.
They force a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage.
SIf it is impossible to regulate the charging current on the battery charger, be careful not to overcharge the battery.
SWhen charging a battery, be sure to remove it from the motorcycle. (If charging has to be done with the battery mounted on the motorcycle, disconnect the negative lead from the battery terminal.)
STo reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery.
SBefore removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger.
SMake sure that the battery charger lead clips are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks.
SIf the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode!
SAs shown in the following illustration, the open-circuit voltage of a MF battery stabilizes about 30 minutes after charging has been completed. Therefore, wait 30 minutes after charging is completed before measuring the open-circuit voltage.
–23–
CHECKING AND CHARGING THE BATTERY
Charging method using a variable voltage charger
CHK
ADJ
YES
Adjust the voltage so that the current is at the standard charging level.
Measure the open-circuit voltage prior to charging.
NOTE:
Voltage should be measured 30 minutes after the machine is stopped.
Connect a charged and
AMP meter to the battery and start charging.
NOTE:
Set the charging voltage at 16
X 17 V.
(If the setting is lower, charging will be insufficient. If too high, the battery will be over-charged.)
Make sure that the current is higher than the standard charging current written on the battery.
NO
By turning the charging voltage adjust dial, set the charging voltage at 20
X 24 V.
YES
Monitor the amperage for
3
X 5 minutes to check if the standard charging current is reached.
NO
Set the time according to the charging time suitable for the open-circuit voltage.
Refer to “Battery condition checking steps”.
If the current does not exceed the standard charging current after 5 minutes, replace the battery.
If charging requires more than 5 hours, it is advisable to check the charging current after a lapse of 5 hours. If there is any change in the amperage, readjust the voltage to obtain the standard charging current.
Measure the battery open-circuit voltage after leaving the battery unused for more than 30 minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
–24–
CHECKING AND CHARGING THE BATTERY
Charging method using a constant voltage charger
Measure the open-circuit voltage prior to charging.
CHK
ADJ
NOTE:
Voltage should be measured 30 minutes after the machine is stopped.
Connect a charger and
AMP meter to the battery and start charging.
YES
Make sure that the current is higher than the standard charging current written on the battery.
NO
Charge the battery until the battery’s charging voltage is 15 V. Charge the battery until the battery’s charging voltage is 15 V.
NOTE:
Set the charging time at 20 hours
(maximum).
Measure the battery open-circuit voltage after leaving the battery unused for more than 30 minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
This type of battery charger cannot charge the MF battery. A variable voltage charger is recommended.
–25–
CHECKING AND CHARGING THE BATTERY
6. Check:
Sbattery vent
Obstruction
! Clean.
Damage
! Replace.
7. Install:
Sbattery
CHK
ADJ
8. Connect:
Sbattery leads
(to the battery terminals)
CAUTION:
First, connect the positive lead 1 , then the negative lead 2 .
9. Check:
Sbattery terminals
Dirt ! Clean with a wire brush.
Loose connection
! Connect properly.
10. Lubricate:
Sbattery terminals
Recommended lubricant
Dielectric grease
11. Install:
Sseat
–26–
REPLACING THE HEADLIGHT BULB
CHK
ADJ
EAS00182
REPLACING THE HEADLIGHT BULB
1. Remove:
Sbolts 1
Sheadlight unit
2. Disconnect:
Sheadlight coupler
1
Sheadlight bulb cover
2
3. Remove:
Sheadlight bulb holder
1
Sheadlight bulb
2
WARNING
Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.
4. Install:
Sheadlight bulb
New
Secure the new headlight bulb with the headlight bulb holder.
CAUTION:
Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner.
–27–
5. Install:
Sheadlight bulb holder
6. Connect:
Sheadlight bulb holder
Sheadlight coupler
7. Install:
Sheadlight unit
ADJUSTING THE HEADLIGHT BEAM
CHK
ADJ
EAS00184
ADJUSTING THE HEADLIGHT BEAM
1. Adjust:
Sheadlight beam (vertically) a. Turn the adjusting screw 1 in direction a or b .
raised.
lowered.
2. Adjust:
Sheadlight beam (horizontally) a. Turn the adjusting knob 2 in direction a or b .
to the right.
to the left.
–28–
EAS00274
CLUTCH
8 Nm (0.8 m Skg)
ENGINE
70 Nm (7.0 m Skg)
CLUTCH
ENG
12 Nm (1.2 m Skg)
6 Nm (0.6 m Skg)
1
2
3
4
5
6
7
8
9
10
11
Order Job / Part
Removing the clutch
Clutch springs
Pressure plate
Friction plates
Clutch plates
Nut / Lock washer
Clutch boss
Thrust washer
Clutch housing
Ball
Long clutch push rod
Push lever screw / Gasket
Q’ty Remarks
Remove the parts in the order listed.
4
1
5
4
1 / 1
1
1
1
1
1
1 / 1
Refer to “REMOVING / INSTALLING
THE CLUTCH” section in chapter 4.
(Manual No.: 5EK1-AE1)
–29–
8 Nm (0.8 m Skg) 70 Nm (7.0 m Skg)
CLUTCH
ENG
12 Nm (1.2 m Skg)
6 Nm (0.6 m Skg)
Order
12 Push lever axle
Job / Part
13
14
15
16
Torsion spring
Circlip
Oil seal
Nut / Washer
17
18
Short clutch push rod / O-ring
Push plate
Q’ty
1
Remarks
Refer to “INSTALLING THE CLUTCH” section in chapter 4.
(Manual No.: 5EK1-AE1)
1
1
1
1 / 1 Refer to “INSTALLING THE CLUTCH” section in chapter 4.
(Manual No.: 5EK1-AE1)
1 / 1
1
For installation, reverse the removal procedure.
–30–
EAS00480
CARBURETOR
CARBURETOR
CARBURETOR
ENG
Order Job / Part
Removing the carburetor
Side cover
Seat
Fuel tank
Heater unit lead
Starter cable
1
2
3
4
Carburetor joint clamp screw
Air filter joint clamp screw
Carburetor assembly
Throttle cables
1
1
1
2
Q’ty Remarks
Remove the parts in order listed.
Refer to “SEAT, FUEL TANK AND SIDE
COVER” section in chapter 3.
(Manual No.: 5EK1-AE1)
NOTE:
S Disconnect the connector from carburetor.
S Disconnect the starter cable.
Loosen.
For installation, reverse the removal procedure.
–31–
EAS00483
CARBURETOR
ENG
1
2
3
4
7
8
5
6
9
10
11
Order Job / Part
Disassembly the carburetor
Vacuum chamber cover
Piston valve spring
Jet needle holder
Jet needle spring
Jet needle
Piston valve
Carburetor heater
Adjusting screw
Drain screw
Float chamber
Gasket
Q’ty Remarks
Disassemble the parts in the order listed.
1
1
1
1
1
1
1
1
1
1
1
Refer to “ASSEMBLING THE
CARBURETOR”.
–32–
CARBURETOR
ENG
Order
20
21
22
23
16
17
18
19
12
13
14
15
Job / Part
Float pin
Float
Needle valve
Needle valve seat
Main jet
Main jet holder
Needle jet
Pilot jet
Pilot screw
Rubber diaphragm spring
Rubber diaphragm
Starter plunger
Q’ty
1
1
1
1
1
1
1
1
1
1
1
1
Remarks
Refer to “ASSEMBLING THE
CARBURETOR”.
For assembly, reverse the disassembly procedure.
–33–
CARBURETOR
CARB
EAS00485
CHECKING THE CARBURETOR
1. Check:
Scarburetor body
Sfloat chamber
Sjet housing
Cracks / damage
! Replace.
2. Check:
Sfuel passages
Obstruction
! Clean.
a. Wash the carburetor in a petroleum-based solvent. Do not use any caustic carburetor cleaning solution.
b. Blow out all of the passages and jets with compressed air.
3. Check:
Sfloat chamber body
Dirt
! Clean.
4. Check:
Sfloat chamber rubber gasket
Cracks / damage / wear
! Replace.
5. Check:
Sfloat
Damage
! Replace.
–34–
6. Check:
Sneedle valve
1
Sneedle valve seat
2
Damage / obstruction / wear
! Replace the needle valve, needle valve seat and O-ring as a set.
7. Check:
SO-ring
3
Damage / wear ! Replace the needle valve, needle valve seat and O-ring as a set.
–35–
CARBURETOR
CARB
8. Check:
Spiston valve
1
Damage / scratches / wear
! Replace.
Srubber diaphragm
2
Cracks / tears
! Replace.
9. Check:
Svacuum chamber cover
1
Spiston valve spring 2
Sjet needle holder
3
Sjet needle spring 4
Cracks / damage
! Replace.
10. Check:
Sjet needle kit
1
Sneedle jet
2
Smain jet
3
Smain jet holder
4
Spilot jet
5
Spilot screw
6
Bends / damage / wear ! Replace.
Obstruction
! Clean.
Blow out the jets with compressed air.
11. Check:
Spiston valve movement
Insert the piston valve into the carburetor body and move it up and down.
Tightness ! Replace the piston valve.
12 Check:
Sstarter plunger
1
Sstarter plunger spring 2
Bends / cracks / damage
! Replace.
CARBURETOR
CARB
13. Check:
Sfuel hoses
Cracks / damage / wear
! Replace.
Obstruction
! Clean.
Blow out the hoses with compressed air.
EAS00487
ASSEMBLING THE CARBURETOR
CAUTION:
SBefor assembling the carburetor, wash all of the parts in a petroleum-based solvent.
SAlways use a new gasket.
1. Install:
Sneedle jet
Smain jet
1
Smain jet holder
2
Spilot jet
3
2. Install:
Sneedle valve seat
1
–36–
3. Install:
Sfloat
1
Sneedle valve
Sfloat pin
2
NOTE:
Install the float pin from the side opposite the arrow.
CARBURETOR
4. Install:
Sfloat chamber
1
Spilot screw
2
CARB
5. Install:
Sstarter plunger kit
1
EAS00492
INSTALLING THE CARBURETOR
1. Adjust:
Sengine idling speed
Engine idling speed
1,450
X 1,650 r/min
Refer to “ADJUSTING THE ENGINE IDLING
SPEED”
2. Adjust:
Sthrottle cable free play
Throttle cable free play
(at the flange of the throttle grip)
3
X 5 mm
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
–37–
EAS00498
MEASURING AND ADJUSTING THE FUEL
LEVEL
1. Measure:
Sfuel level a
Out of specification
! Adjust.
Fuel level (below the float chamber mating surface)
0
X 2.0 mm
–38–
CARBURETOR
CARB a. Stand the motorcycle on a level surface.
b. Place the motorcycle on a suitable stand to ensure that the motorcycle is standing straight up.
c. Install the fuel level gauge 1 to the fuel drain pipe 2 .
Fuel level gauge
90890-01312 d. Loosen the fuel drain screw 3 .
e. Hold the fuel level gauge vertically next to the float chamber.
f. Measure the fuel level a .
2. Adjust:
Sfuel level a. Remove the carburetor.
b. Check the needle valve seat and needle valve.
c. If either is worn, replace them as a set.
d. If both are fine, adjust the float level by slightly bending the float tang 1 .
e. Install the carburetor.
f. Measure the fuel level again.
g. Repeat steps (a) to (f) until the fuel level is within specification.
FRONT WHEEL AND BRAKE DISC
EAS00512
CHASSIS
FRONT WHEEL AND BRAKE DISC
CHAS
90 Nm (9.0 m Skg)
13 Nm (1.3 m
Skg)
5
6
7
3
4
1
2
Order Job / Part
Removing the front wheel and brake disc
Q’ty Remarks
Remove the parts in the order listed.
NOTE:
Place the motorcycle on a suitable stand so that the front wheel is elevated.
Caps
Speedometer cable
Wheel axle
Front wheel assembly
Collar
Meter gear unit assembly
Brake disc
1
1
1
1
1
2
1
Refer to “REMOVING/INSTALLING THE
FRONT WHEEL” section in chapter 6.
(Manual No.: 5EK1-AE1)
For installation, reverse the removal procedure.
–39–
REAR WHEEL AND REAR BRAKE
REAR WHEEL AND REAR BRAKE
REAR WHEEL
CHAS
90 Nm (9.0 m Skg)
Order Job / Part
Removing the rear wheel
7
8
5
6
3
4
1
2
Adjuster
Brake rod
Pin
Compression spring
Chain case
Axle nut / washer
Chain pullers
Wheel axle
Q’ty Remarks
Remove the parts in the order listed.
NOTE:
Place the motorcycle on a suitable stand so that the rear wheel is elevated.
1
1 / 1
2
1
1
1
1
1
Refer to “REMOVING / INSTALLING THE
REAR WHEEL” section in chapter 6.
(Manual No.: 5EK1-AE1)
–40–
90 Nm (9.0 m Skg)
REAR WHEEL AND REAR BRAKE
CHAS
Order
9
Job / Part
Rear wheel assembly
10 Collar
Q’ty
1
Remarks
Refer to “REMOVING / INSTALLING THE
REAR WHEEL” section in chapter 6.
(Manual No.: 5EK1-AE1)
2
For installation, reverse the removal procedure.
–41–
REAR WHEEL AND REAR BRAKE
REAR BRAKE AND REAR WHEEL SPROCKET
CHAS
43 Nm (4.3 m Skg)
Order
1
2
3
Job / Part
Removing the rear brake and rear wheel sprocket
Shoe plate
Nuts
Driven sprocket
Q’ty Remarks
Remove the parts in the order listed.
1
6
1
Refer to “ASSEMBLYNG THE REAR
WHEEL” section in chapter 6.
(Manual No.: 5EK1-AE1)
For installation, reverse the removal procedure.
–42–
REAR WHEEL AND REAR BRAKE
CHAS
Order
1
2
3
4
Job / Part
Disassembling the rear wheel
Bearing
Spacer
Oil seal
Bearing
Q’ty Remarks
Disassemble the parts in the order listed.
1
1
1
1
For assembly, reverse the disassembly procedure.
–43–
FRONT FORK
23 Nm (2.3 m
Skg)
FRONT FORK
CHAS
23 Nm (2.3 m Skg)
23 Nm (2.3 m Skg)
Order Job / Part
Removing the front fork
Front wheel
1
2
3
4
7
8
5
6
Brake hose holder
Caliper
Front fender
Cap bolt / O-ring
Bolt (upper bracket)
Bolts (under bracket)
Front fork assembly (left)
Front fork assembly (right)
30 Nm (3.0 m Skg)
Q’ty Remarks
Remove the parts in the order listed.
Refer to “FRONT WHEEL AND BRAKE
DISC”.
1
1
1
1 / 1
1
1
1
2
Refer to “REMOVING / INSTALLING
THE FRONT FORK” section in cahpter 6. (Manual No.: 5EK1-AE1)
NOTE:
Loosen the bolt.
For installation, reverse the removal procedure.
–44–
HANDLEBAR
HANDLEBAR
CHAS
20 Nm (2.0 m
Skg)
4
5
6
7
1
2
3
Order Job / Part
Removing the handlebar
Master cylinder bracket
Master cylinder
Housing (throttle grip)
Throttle grip assembly
Handlebar switch (right)
Clutch switch
Clutch cable
Q’ty Remarks
Remove the parts in the order listed.
1
1
1
1
1
1
1 Refer to “INSTALLING THE
HANDLEBAR” section in chapter 6.
(Manual No.: 5EK1-AE1)
–45–
HANDLEBAR
CHAS
20 Nm (2.0 m Skg)
Order
8
9
Job / Part
Handlebar switch (left)
Grip (left)
10
11
12
13
Clutch lever
Starter cable holder
Upper holders
Handlebar
Q’ty
1
1
Remarks
Refer to “REMOVING THE HANDLEBAR” section in chapter 6.
(Manual No.: 5EK1-AE1)
1
1
2
Refer to “INSTALLING THE
HANDLEBAR” section in chapter 6.
(Manual No.: 5EK1-AE1)
1
For installation, reverse the removal procedure.
–46–
STEERING HEAD
LOWER BRACKET
STEERING HEAD
CHAS
90 Nm (9.0 m Skg)
1st 38 Nm (3.8 m Skg)
2nd 18 Nm (1.8 m
Skg)
1
2
3
4
7
8
5
6
9
10
11
12
13
Order Job / Part
Removing the lower bracket
Front fork
Handlebar
Headlight unit
Headlight body
Turn signal light assembly (left)
Turn signal light assembly (right)
Meter cable / Meter lead
Meter assembly
Headlight stay
Steering stem nut
Handlebar crown
Lock washer
Upper ring nut
Rubber washer
Lower ring nut
Q’ty Remarks
Remove the parts in the order listed.
Refer to “FRONT FORK”.
Refer to “HANDLEBAR”
1
1
1
1
1 / 1
1
2
1
1
1
1
1
1
NOTE:
Disconnect the connector.
Refer to “INSTALLING THE STEERING
HEAD” section chapter 6.
(Manual No.: 5EK1-AE1)
–47–
STEERING HEAD
CHAS
90 Nm (9.0 m Skg)
1st 38 Nm (3.8 m Skg)
2nd 18 Nm (1.8 m Skg)
Order
14
15
16
17
18
19
20
Job / Part
Ball race ccver
Lower bracket
Ball race (upper)
Ball
Ball
Ball race (center)
Ball race (lower)
Q’ty
1
1
1
22
19
1
1
Remarks
Refer to “INSTALLING THE STEERING” section in chapter 6.
(Manual No.: 5EK1-AE1)
For installation, reverse the removal procedure.
–48–
EAS00734
IGNITION SYSTEM
CIRCUIT DIAGRAM
IGNITION SYSTEM
ELEC
ELECTRLCAL SYSTEM
–49–
1
2
4
6
C.D.I. magneto
Neutral switch
Battery
Fuse
10
11
13
Engine stop switch
Main switch
Diode
14
15
C.D.I. unit
Ignition coil
16
22
Spark plug
Neutral relay
24 Reed switch
EAS00798
CHECKING THE IGNITION SYSTEM.
1. The speedometer fail to come on.
1. Reed switch
S Remove the meter assembly.
S Connect the pocket tester (Ω 1) to the reed switch coupler as shown.
Tester positive probe
! white/black
Tester negative probe
! red/blue
2
1
IGNITION SYSTEM
ELEC
S Make the speedometer indicate
S Check the continuity or open circuit status.
S If it counts 4 cycles of continuity and open actions per speedometer rotation, the result is acceptable.
S Is the reed switch OK?
YES NO
Properly connect or repair the ignition system.
Replace the reed switch.
–50–
TW125 2002 WIRING DIAGRAM
COLOR CODE
B . . . . . . . . . Black
Br . . . . . . . . . Brown
Ch
Dg
. . . . . . . .
. . . . . . . .
Chocolate
Dark green
G
L
. . . . . . . . . Green
. . . . . . . . . . Blue
O . . . . . . . . . Orange
Sb
P
. . . . . . . .
Sky blue
. . . . . . . . .
Pink
R
Y
. . . . . . . . .
. . . . . . . . .
Red
Yellow
W . . . . . . . . .
B / R . . . . . .
White
Black / Red
B / W . . . . . . Black / White
Br / L
Br / W
. . . . . .
Brown / Blue
. . . . .
Brown / White
G / R
G / W
. . . . . .
. . . . . .
Green / Red
Green / White
G / Y
L / B
. . . . . . Green / Yellow
. . . . . . . Blue / Black
L / R . . . . . . . Blue / Red
L / W
L / Y
. . . . . . Blue / White
. . . . . . . Blue / Yellow
R / L
R / W
. . . . . . . Red / Blue
. . . . . . Red / White
W / B
W / L
. . . . . . White / Black
. . . . . . White / Blue
W / R . . . . . . White / Red
33
34
35
36
29
30
31
32
23
24
25
26
27
28
19
20
21
22
37
38
39
40
41
42
15
16
17
18
11
12
13
14
7
8
5
6
9
10
3
4
1
2
C.D.I. magneto
Neutral switch
Rectifier / Regulator
Battery
Starter relay
Fuse
Starter motor
Right handlebar switch
Start switch
Engine stop switch
Main switch
Clutch switch
Diode
C.D.I. unit
Ignition coil
Spark plug
Thermo switch
Carbuletor heater
Horn
Turn signal relay
Sidestand switch
Neutral relay
Speedometer
Reed switch
Meter light
Neutral indicator light
Turn signal indicator light
Hi-beam indicator light
Left handlebar switch
Horn switch
Turn signal switch
Light switch
Dimmer switch
Front brake light switch
Rear brake light switch
Rear turn signal light (right)
Front turn signal light (right)
Front turn signal light (left)
Rear turn signal light (left)
Headlight
Auxiliary light
Tail / Brake light
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