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Yamaha TW125 1999 Workshop Service Manual Repair

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🏷️ Basic Information Identification Make: Yamaha Model: TW125 Year: 1999 Market Segment: Dual-Sport/Trail Motorcycle Codes Chassis Code: Likely 5FL or similar Yamaha internal code 👋 Introduction Market Position Vehicle Class: Lightweight dual-sport motorcycle known for its simplicity, ease of use, and off-road capability, particularly favored for trail riding and light adventure. Competitive Analysis Competitors: Competed with other 125cc dual-sport motorcycles from manufacturers like Honda (e.g., XR125), Suzuki (e.g., DR125), and Kawasaki (e.g., KLR125) of the era. Key Features Unique Selling Points: Fat tires (hence 'TW'), which provide exceptional traction and comfort on varied terrain, simple air-cooled engine, robust construction. Manual Value Proposition Target Audience: Professional motorcycle technicians, independent repair shops, and ambitious DIY owners seeking to maintain or restore their 1999 Yamaha TW125. 📋 Manual Details Coverage Areas Geographical Coverage: Global (likely focused on markets where TW125 was officially sold, e.g., Europe, Japan) Page Count Estimated Page Count: Hundreds of pages (as stated in product description) Manual Type Manual Type: Workshop Service Manual / Repair Manual Language Language: English Format Digital Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed overhaul, tuning, troubleshooting of the 125cc engine. Transmission: Clutch, gearbox, final drive maintenance and repair. Fuel System: Carburetor (likely Mikuni VM series), fuel lines, fuel tank inspection and service. Ignition System: CDI unit, ignition coil, spark plug, timing checks. Electrical System: Wiring diagrams, lighting, battery, charging system (stator, regulator/rectifier), starting system. Suspension: Front telescopic forks (oil change, seal replacement) and rear monoshock absorber (adjustment, overhaul). Braking System: Front and rear drum or disc brakes (depending on specific market variant), hydraulic components, pad/shoe replacement, fluid. Chassis And Frame: Frame inspection, steering head bearings, swingarm bearings. Bodywork And Trim: Fenders, seat, fuel tank removal and installation, minor body panel repairs. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, lubrication, tire pressure checks. Troubleshooting: Systematic diagnostic procedures for common and uncommon faults. Engine Rebuild: Complete engine disassembly, inspection, part replacement, and reassembly. Carburetor Overhaul: Jet cleaning, float level adjustment, mixture screw settings. Electrical Diagnostics: Using wiring diagrams to trace faults, testing components. Suspension Service: Fork seal replacement, fork oil viscosity and level specifications. Brake System Maintenance: Bleeding procedures, inspection of brake components. Technical Depth Depth Of Information: Comprehensive, suitable for professional technicians and advanced DIY mechanics. Diagnostic Capability: Advanced diagnostic flowcharts and troubleshooting trees. Rebuild Information: Detailed overhaul procedures for major components including engine, transmission, and suspension. 📊 Manual Specifications File Format File Format: PDF Print Quality Printability: Full Printable Zoom Capability: YES Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Software Requirements PDF Reader: Adobe PDF Reader Compression Utility: WinRAR Compatibility Operating Systems: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: Air-cooled, four-stroke, SOHC, single-cylinder Displacement: 124 cc Bore X Stroke: 54 mm x 54 mm (Typical for this era Yamaha 125cc) Compression Ratio: Likely around 9.5:1 to 10.5:1 Performance Horsepower: Approximately 10-12 HP (actual figures vary by market and tuning) Torque: Approximately 9-10 Nm (actual figures vary by market and tuning) Fuel System Carburetor Type: Mikuni VM Series (e.g., VM20 or VM22), single carburetor Fuel Capacity: Approximately 9 Liters (including reserve) Lubrication Oil Type: API SE, SF, SG, SH or higher, SAE 10W-40 recommended (check manual for exact specification) Oil Capacity: Approximately 1.0-1.2 Liters (with oil filter change) 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Clutch Type: Wet, multiple-disc Final Drive: Chain drive Features Gear Ratios: Specific ratios detailed in the manual, designed for tractable off-road power delivery. Transmission Oil Type: Yamalube 4 (or equivalent) SAE 10W-40, API SE, SF, SG, SH or higher 📐 Dimensions Exterior Overall Length: Approx. 2055 mm Overall Width: Approx. 820 mm Overall Height: Approx. 1115 mm Seat Height: Approx. 800 mm Weights Dry Weight: Approx. 110-115 kg Wet Weight: Approx. 117-122 kg Wheels Tires Front Tire Size: 130/80-18 (distinctive fat tire) Rear Tire Size: 180/80-14 (distinctive fat tire) 🛡️ Safety Features Ratings Safety Standards: Complies with relevant local motorcycle safety and emissions standards of the time. Active Features Lighting: Headlight, taillight, brake lights, turn signals. Passive Features Frame Design: Steel cradle frame providing good stability and durability for trail use. 💡 Technology Features Infotainment Infotainment System: N/A (Basic motorcycle instrumentation: speedometer, odometer, neutral indicator, high beam indicator). Driver Assistance Driver Assistance Features: N/A (No electronic rider aids typical for this era and class of motorcycle). Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000 km or 6 months (refer to manual for precise recommendations) Air Filter Cleaning: Every 2,000 km or 12 months Spark Plug Replacement: Every 10,000 km Fluid Specifications Fork Oil Viscosity: Yamaha Fork Oil 10W or equivalent (check manual for capacity) Brake Fluid: DOT 3 or DOT 4 (check manual for specific recommendation and bleeding procedure) Known Issues Common Wear Items: Tire wear...
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Yamaha TW125 1999 Workshop Service Manual Repair
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
TW125
Year:
1999
Market Segment:
Dual-Sport/Trail Motorcycle
Codes
Chassis Code:
Likely 5FL or similar Yamaha internal code
👋 Introduction
Market Position
Vehicle Class:
Lightweight dual-sport motorcycle known for its simplicity, ease of use, and off-road capability, particularly favored for trail riding and light adventure.
Competitive Analysis
Competitors:
Competed with other 125cc dual-sport motorcycles from manufacturers like Honda (e.g., XR125), Suzuki (e.g., DR125), and Kawasaki (e.g., KLR125) of the era.
Key Features
Unique Selling Points:
Fat tires (hence 'TW'), which provide exceptional traction and comfort on varied terrain, simple air-cooled engine, robust construction.
Manual Value Proposition
Target Audience:
Professional motorcycle technicians, independent repair shops, and ambitious DIY owners seeking to maintain or restore their 1999 Yamaha TW125.
📋 Manual Details
Coverage Areas
Geographical Coverage:
Global (likely focused on markets where TW125 was officially sold, e.g., Europe, Japan)
Page Count
Estimated Page Count:
Hundreds of pages (as stated in product description)
Manual Type
Manual Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
Digital Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Detailed overhaul, tuning, troubleshooting of the 125cc engine.
Transmission:
Clutch, gearbox, final drive maintenance and repair.
Fuel System:
Carburetor (likely Mikuni VM series), fuel lines, fuel tank inspection and service.
Ignition System:
CDI unit, ignition coil, spark plug, timing checks.
Electrical System:
Wiring diagrams, lighting, battery, charging system (stator, regulator/rectifier), starting system.
Suspension:
Front telescopic forks (oil change, seal replacement) and rear monoshock absorber (adjustment, overhaul).
Braking System:
Front and rear drum or disc brakes (depending on specific market variant), hydraulic components, pad/shoe replacement, fluid.
Chassis And Frame:
Frame inspection, steering head bearings, swingarm bearings.
Bodywork And Trim:
Fenders, seat, fuel tank removal and installation, minor body panel repairs.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, lubrication, tire pressure checks.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon faults.
Engine Rebuild:
Complete engine disassembly, inspection, part replacement, and reassembly.
Carburetor Overhaul:
Jet cleaning, float level adjustment, mixture screw settings.
Electrical Diagnostics:
Using wiring diagrams to trace faults, testing components.
Suspension Service:
Fork seal replacement, fork oil viscosity and level specifications.
Brake System Maintenance:
Bleeding procedures, inspection of brake components.
Technical Depth
Depth Of Information:
Comprehensive, suitable for professional technicians and advanced DIY mechanics.
Diagnostic Capability:
Advanced diagnostic flowcharts and troubleshooting trees.
Rebuild Information:
Detailed overhaul procedures for major components including engine, transmission, and suspension.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Printability:
Full Printable
Zoom Capability:
YES
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Software Requirements
PDF Reader:
Adobe PDF Reader
Compression Utility:
WinRAR
Compatibility
Operating Systems:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, four-stroke, SOHC, single-cylinder
Displacement:
124 cc
Bore X Stroke:
54 mm x 54 mm (Typical for this era Yamaha 125cc)
Compression Ratio:
Likely around 9.5:1 to 10.5:1
Performance
Horsepower:
Approximately 10-12 HP (actual figures vary by market and tuning)
Torque:
Approximately 9-10 Nm (actual figures vary by market and tuning)
Fuel System
Carburetor Type:
Mikuni VM Series (e.g., VM20 or VM22), single carburetor
Fuel Capacity:
Approximately 9 Liters (including reserve)
Lubrication
Oil Type:
API SE, SF, SG, SH or higher, SAE 10W-40 recommended (check manual for exact specification)
Oil Capacity:
Approximately 1.0-1.2 Liters (with oil filter change)
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh
Clutch Type:
Wet, multiple-disc
Final Drive:
Chain drive
Features
Gear Ratios:
Specific ratios detailed in the manual, designed for tractable off-road power delivery.
Transmission Oil Type:
Yamalube 4 (or equivalent) SAE 10W-40, API SE, SF, SG, SH or higher
📐 Dimensions
Exterior
Overall Length:
Approx. 2055 mm
Overall Width:
Approx. 820 mm
Overall Height:
Approx. 1115 mm
Seat Height:
Approx. 800 mm
Weights
Dry Weight:
Approx. 110-115 kg
Wet Weight:
Approx. 117-122 kg
Wheels Tires
Front Tire Size:
130/80-18 (distinctive fat tire)
Rear Tire Size:
180/80-14 (distinctive fat tire)
🛡️ Safety Features
Ratings
Safety Standards:
Complies with relevant local motorcycle safety and emissions standards of the time.
Active Features
Lighting:
Headlight, taillight, brake lights, turn signals.
Passive Features
Frame Design:
Steel cradle frame providing good stability and durability for trail use.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic motorcycle instrumentation: speedometer, odometer, neutral indicator, high beam indicator).
Driver Assistance
Driver Assistance Features:
N/A (No electronic rider aids typical for this era and class of motorcycle).
Connectivity
Connectivity Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 km or 6 months (refer to manual for precise recommendations)
Air Filter Cleaning:
Every 2,000 km or 12 months
Spark Plug Replacement:
Every 10,000 km
Fluid Specifications
Fork Oil Viscosity:
Yamaha Fork Oil 10W or equivalent (check manual for capacity)
Brake Fluid:
DOT 3 or DOT 4 (check manual for specific recommendation and bleeding procedure)
Known Issues
Common Wear Items:
Tire wear (due to fat profile), chain and sprockets, brake pads/shoes, fork seals.
Carburetor Tuning:
Carburetors can sometimes require fine-tuning or cleaning due to age and fuel quality, especially if the bike has been sitting.
Electrical Connections:
Corrosion in electrical connectors can lead to intermittent issues, particularly on bikes used in damp environments.
📚 Vehicle History
Brand Heritage
Yamaha Legacy:
Yamaha has a long history of producing reliable and capable motorcycles across various segments, known for innovation and performance.
Model Evolution
Tw Series:
The TW series, known for its distinctive fat tires, originated with the TW200 and later evolved to include models like the TW125, emphasizing ease of use and versatility for off-road and urban commuting.
Production
Production Period:
The TW125 was produced for a period from the late 1990s into the early 2000s, with variations in specification across different markets.
🏆 Awards & Recognition
Recognitions
Industry Recognition:
While not typically winning specific awards, the TW series is recognized for its unique design and functional capability, making it a popular choice for niche applications and dedicated enthusiasts.
Ratings
Reliability Reputation:
Yamaha's reputation for reliability generally extends to the TW125, making it a dependable platform when properly maintained.
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