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Yamaha TT-R125(P), Owner'S Service Manual


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SPEC

 

2 - 13

 

MAINTENANCE SPECIFICATIONS

 

Part to be tightened

Thread size

Q’ty

Tightening torque

Nm

m•kg

ft•lb

Spark plug

M10 

 

×

 

 1.0

1

13

1.3

9.4

Cylinder head bolt

M8 

 

×

 

 1.25

4

22

2.2

16

Cylinder head bolt

M6 

 

×

 

 1.0

2

10

1.0

7.2

Oil pressure check bolt

M6 

 

×

 

 1.0

1

7

0.7

5.1

Cylinder head side cover

M6 

 

×

 

 1.0

2

10

1.0

7.2

Tappet cover

M45 

 

×

 

 1.5

2

18

1.8

13

Timing chain guide

M6 

 

×

 

 1.0

1

10

1.0

7.2

Adjusting screw (valve) and locknut

M5 

 

×

 

 0.5

2

8

0.8

5.8

Camshaft sprocket

M8 

 

×

 

 1.25

1

20

2.0

14

Bearing plate cover (camshaft)

M6 

 

×

 

 1.0

1

10

1.0

7.2

Timing chain tensioner cap bolt

M6 

 

×

 

 1.0

1

8

0.8

5.8

Timing chain tensioner

M6 

 

×

 

 1.0

2

10

1.0

7.2

Oil pump assembly

M6 

 

×

 

 1.0

2

7

0.7

5.1

Oil pump cover

M5 

 

×

 

 0.8

1

5

0.5

3.6

Engine oil drain bolt

M12 

 

×

 

 1.5

1

20

2.0

14

Carburetor joint

M6 

 

×

 

 1.0

2

10

1.0

7.2

Carburetor joint clamp (air filter)

M4 

 

×

 

 0.7

1

2

0.2

1.4

Coasting enricher cover

M4 

 

×

 

 0.7

2

2

0.2

1.4

Air filter case

M6 

 

×

 

 1.0

3

7

0.7

5.1

Muffler

M6 

 

×

 

 1.0

2

10

1.0

7.2

Muffler

M10 

 

×

 

 1.25

1

60

6.0

43

Muffler

M8 

 

×

 

 1.25

1

30

3.0

22

Muffler guard

M6 

 

×

 

 1.0

7

10

1.0

7.2

Spark arrester

M6 

 

×

 

 1.0

3

10

1.0

7.2

Crankcase

M6 

 

×

 

 1.0

10

10

1.0

7.2

Left crankcase cover

M6 

 

×

 

 1.0

7

10

1.0

7.2

Drive sprocket cover

M6 

 

×

 

 1.0

2

12

1.2

8.7

Right crankcase cover

M6 

 

×

 

 1.0

9

10

1.0

7.2

Lead guide (CDI magneto lead)

M6 

 

×

 

 1.0

1

7

0.7

5.1

Timing mark accessing screw

M14 

 

×

 

 1.5

1

7

0.7

5.1

Crankshaft end accessing screw

M32 

×

 1.5

1

7

0.7

5.1

Kickstarter crank

M12 

×

 1.0

1

50

5.0

36

Primary drive gear

M12 

×

 1.0

1

70

7.0

50

Clutch spring

M5 

×

 0.8

4

6

0.6

4.3

Clutch boss

M12 

×

 1.0

1

60

6.0

43

Adjusting screw (push rod) and locknut

M6 

×

 1.0

1

8

0.8

5.8

Bearing plate cover (main axle)

M6 

×

 1.0

2

7

0.7

5.1

Drive sprocket

M5 

×

 0.8

2

6

0.6

4.3

Shift arm

M6 

×

 1.0

1

10

1.0

7.2

Shift rod and shift pedal

M6 

×

 1.0

1

7

0.7

5.1

Shift rod and shift arm

M6 

×

 1.0

1

7

0.7

5.1

Shift pedal

M6 

×

 1.0

1

12

1.2

8.7

Segment

M6 

×

 1.0

1

12

1.2

8.7

Stopper lever

M6 

×

 1.0

1

10

1.0

7.2

Summary of Contents for TT-R125(P)

Page 1: ...5HP 28199 83 TT R125 P TT R125LW P OWNER S SERVICE MANUAL MANUEL D ATELIER DU PROPRIETAIRE FAHRER UND WARTUNGS HANDBUCH...

Page 2: ...W P OWNER S SERVICE MANUAL 2001 by Yamaha Motor Co Ltd 1st Edition June 2001 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly p...

Page 3: ...uch auszugsweise ist ohne schriftliche Genehmigung der Yamaha Motor Co Ltd nicht gestattet Gedruckt in Japan TT R125 P TT R125LW P MANUEL D ATELIER DU PROPRIETAIRE 2001 Yamaha Motor Co Ltd Premi re di...

Page 4: ...OTE As improvements are made on this model some data in this manual may become out dated If you have any questions please con sult your Yamaha dealer WARNING READ THIS MANUAL CAREFULLY FOR INSTRUCTION...

Page 5: ...erden siehe Seite 3 3 Dieses Fahrzeug ist nur f r eine Person zugelassen Zweipersonen Betrieb ist nicht zul ssig Dieses Fahrzeug ist ausschlie lich f r den Einsatz abseits ffentlicher Stra en vorgeseh...

Page 6: ...while smoking or in the vicinity of an open flame 2 If you should swallow some gasoline or inhale a lot of gasoline vapor or allow some gasoline to get in your eye s see your doctor immediately If an...

Page 7: ...Untergrund abstellen damit es nicht umfallen kann SICHERHEITSINFORMATION REMARQUE IMPORTANTE Ce v hicule est con u uniquement pour une utilisa tion tout terrain par des pilotes tr s jeunes roulant sou...

Page 8: ...k out of the car buretor or fuel tank 5 Never start your engine or let it run for any length of time in a closed area The exhaust fumes are poisonous and may cause loss of consciousness and death with...

Page 9: ...Helm und spezielle Motorradbekleidung Hand schuhe Stiefel Hosen und Jacken tragen 4 Lors du transport de l engin dans un autre v hicule veiller ce qu il soit bien droit et ce que le robinet de carbur...

Page 10: ...one seater motorbike Do not give any person a ride 4 Let s learn how to ride properly Ask your parents for any question 5 When riding the machine be sure to wear the protective apparel as illustrated...

Page 11: ...dschuhe 5 Motorradstiefel 6 Motocross Hose 7 Lang rmeliges Trainingshemd 8 Brustschutz INFORMATION DE SECURITE 1 Ne pas rouler sur la route 2 Ne pas faire tourner le moteur dans un b ti ment 3 Il s ag...

Page 12: ...ne 7 Before riding the machine ask your par ents to check the machine very carefully 8 Do not touch the areas shown or you will get burnt in the hand 9 Do not touch rotating or moving parts 10 Before...

Page 13: ...er sich bewegen den Teile ber hren 10 Vor dem Starten des Motors sicherstellen da sich das Getriebe in der Leerlaufstel lung befindet 6 Ne jamais partir seul moto Toujours partir avec son instructeur...

Page 14: ...any questions regarding the operation or maintenance of your machine please consult your Yamaha dealer NOTE This manual should be considered a perma nent part of this machine and should remain with it...

Page 15: ...Aufgrund der konti nuierlichen Bem hungen von Yamaha um technischen Fortschritt und Qualit tsstei gerung k nnen einige Angaben jedoch f r Ihr Modell nicht mehr zutreffen Richten Sie Fragen zu dieser A...

Page 16: ...taken to avoid damage to the machine NOTE A NOTE provides key information to make pro cedures easier or clearer FINDING THE REQUIRED PAGE 1 This manual consists of six chapters General Information Spe...

Page 17: ...particulier Arquer le manuel son bord comme illustr pour trouver le symbole du chapitre recher ch puis aller la page du th me recherch AVERTISSEMENT ATTENTION BENUTZERHINWEISE KENNZEICHNUNG WICHTIGER...

Page 18: ...start of each removal and disassembly section 1 An easy to see exploded diagram 1 is provided for removal and disassembly jobs 2 Numbers 2 are given in the order of the jobs in the exploded diagram A...

Page 19: ...meiden 6 F r Arbeiten f r die weitere Informatio nen ben tigt werden sind schrittweise Erg nzungen 6 zus tzlich zu dem Explo sionsdiagramm und der Arbeitsanwei sungstabelle aufgef hrt FORMAT DU MANUE...

Page 20: ...ightening B Specified value Service limit C Engine speed D Resistance Voltage V Electric current A Illustrated symbols E to H in the exploded diagrams indicate grade of lubricant and loca tion of lubr...

Page 21: ...tel LOCTITE J Erneuern SYMBOLES GRAPHIQUES voir les illustrations Les symboles graphiques 1 6 servent rep rer les diff rents chapitres et indiquer leur contenu 1 Renseignements g n raux 2 Caract risti...

Page 22: ...INDEX GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENT ENGINE CHASSIS ELECTRICAL...

Page 23: ...DATEN SPEC 2 REGELM SSIGE WARTUNGS UND EINSTELLARBEITEN 3 MOTOR ENG 4 RAHMEN CHAS 5 ELEKTRIK ELEC 6 GEN INFO INSP ADJ INDEX RENSEIGNEMENTS G N RAUX CARACT RISTI QUES CONTR LES ET R GLAGES P RIODIQUES...

Page 24: ...T R125LW 1 16 CLEANING AND STORAGE 1 17 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 TT R125 2 1 TT R125LW 2 4 MAINTENANCE SPECIFICATIONS 2 7 ENGINE 2 7 CHASSIS 2 15 TT R125 2 15 TT R125LW 2 19...

Page 25: ...NG VOR INBETRIEBNAHME 3 3 MOTOR 3 4 FAHRWERK 3 15 ELEKTRISCHE ANLAGE 3 29 TABLES DES MATIERES CHAPITRE 1 RENSEIGNEMENTS G N RAUX DESCRIPTION 1 1 IDENTIFICATION DE LA MACHINE 1 2 INFORMATIONS IMPORTANT...

Page 26: ...SHAFT 4 53 CDI MAGNETO 4 58 ENGINE REMOVAL 4 61 CRANKCASE CRANKSHAFT AND BALANCER 4 65 TRANSMISSION SHIFT CAM AND SHIFT FORK 4 73 CHAPTER 5 CHASSIS FRONT WHEEL AND FRONT BRAKE TT R125 5 1 FRONT WHEEL...

Page 27: ...6 ELEKTRIK ELEKTRISCHE ANLAGE UND SCHALTPLAN 6 1 Z NDANLAGE 6 2 CHAPITRE 4 MOTEUR SELLE R SERVOIR DE CARBURANT ET CACHES LAT RAUX 4 1 POT D CHAPPEMENT 4 2 CARBURATEUR 4 3 CULASSE 4 12 ARBRE CAMES ET C...

Page 28: ...hrottle grip 6 Fuel tank cap 7 Air filter 8 Kickstarter crank 9 Fuel tank 0 Dipstick A Rear brake pedal B Fuel cock C Drive chain D Shift pedal E Front fork The illustration shows the TT R125LW NOTE T...

Page 29: ...hnischen Da ten jederzeit vorbehalten Die Abbildung zeigt die TT R125LW RENSEIGNEMENTS G N RAUX DESCRIPTION 1 Levier d embrayage 2 Coupe circuit du moteur 3 Bouton de starter 4 Levier de frein avant 5...

Page 30: ...hine is stolen the authorities will need the number to search for and identify your machine EC121001 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped on the right of the st...

Page 31: ...acht Die Codenummer und das Info K rzel werden zur Ersatzteil Bestellung ben tigt IDENTIFICATION DE LA MACHINE Il y a deux bonnes raisons de conna tre le num ro de s rie de son v hicule 1 Le num ro fa...

Page 32: ...tools and cleaning equip ment Refer to SPECIAL TOOLS sec tion 3 When disassembling the machine keep mated parts together They include gears cylinders pistons and other mated parts that have been mated...

Page 33: ...hrleistet einen z gigen und korrekten Zusammenbau 5 Alle Teile von offenem Feuer fernhalten INFORMATIONS IMPORTANTES PR PARATION LA D POSE ET AU D MONTAGE 1 liminer soigneusement crasse boue pous si...

Page 34: ...along the bolt or nut flat s after the bolt or nut has been properly tightened EC135001 BEARINGS AND OIL SEALS 1 Install the bearing s 1 and oil seal s 2 with their manufacturer s marks or num bers fa...

Page 35: ...DE RECHANGE 1 Il est recommand d utiliser des pi ces Yamaha d origine pour tous les remplace ments Utiliser les graisses et ou huiles recommand es par Yamaha lors des remonta ges et r glages JOINTS BA...

Page 36: ...check that it will not come off 5 If the terminal comes off bend up the pin 1 and reinsert the terminal into the con nector 6 Connect Connector NOTE The two connectors click together 7 Check for cont...

Page 37: ...Schritte 1 bis 7 durchf hren Zur schnellen Abhilfe kann ein handels bli ches Kontaktspray verwendet werden Die Steckverbinder wie abgebildet mit dem Me ger t pr fen V RIFICATION DES CONNEXIONS Traite...

Page 38: ...se tools are used to split the crankcase as well as remove the crankshaft from either case YU 1135 A 90890 01135 YU 3097 90890 01252 YU 1256 Dial gauge stand set Stand These tools are used to check ea...

Page 39: ...YU 33975 90890 01403 YS 1880 A 90890 01701 Sheave holder This tool is used for when loosening or tightening the flywheel magneto securing nut YS 1880 A 90890 01701 YU 3112 C 90890 03112 Pocket tester...

Page 40: ...4097 YM 4098 YM 04099 90890 04097 90890 04098 90890 04099 YM 34487 90890 06754 Dynamic spark tester Ignition checker This instrument is necessary for checking the ignition system components YM 34487 9...

Page 41: ...r de demi carters Ces outils permettent de s parer le carter moteur ainsi que de retirer le vilebrequin d un demi carter YU 1135 A 90890 01135 YU 3097 90890 01252 YU 1256 Comparateur cadran et base Ba...

Page 42: ...us cr n l s comme sp cifi YU 33975 90890 01403 YS 1880 A 90890 01701 Cl sangle Cet outil permet de desserrer et de resserrer l crou de fixation du volant magn tique YS 1880 A 90890 01701 YU 3112 C 908...

Page 43: ...s YM 4097 YM 4098 YM 04099 90890 04097 90890 04098 90890 04099 YM 34487 90890 06754 Testeur d tincelle dynamique Testeur d allumage Cet instrument sert contr ler les composants du syst me d allumage Y...

Page 44: ...90890 01085 YU 1135 A 90890 01135 Kurbelgeh use Trennwerkzeug Zum Trennen der Kurbelgeh useh lften und Ausbau der Kurbelwelle YU 1135 A 90890 01135 YU 3097 90890 01252 YU 1256 Me uhr und Zubeh r St n...

Page 45: ...schl ssel Zum Festziehen der Lenkkopf Ringmutter YU 33975 90890 01403 YS 1880 A 90890 01701 Kupplungskorb Halter Zum Halten des Kupplungskorbes YS 1880 A 90890 01701 YU 3112 C 90890 03112 Taschen Mult...

Page 46: ...n der neuen Ventilf hrungen YM 4097 YM 4098 YM 04099 90890 04097 90890 04098 90890 04099 YM 34487 90890 06754 Z ndfunkenstreckentester Z ndungspr fer Zur berpr fung der Z ndanlage YM 34487 90890 06754...

Page 47: ...GEN INFO MEMO...

Page 48: ...wly for smooth starts EC153000 SHIFT PEDAL The gear ratios of the constant mesh 5 speed transmission are ideally spaced The gears can be shifted by using the shift pedal 1 on the left side of the engi...

Page 49: ...l schwungvoll durchtreten GASDREHGRIFF Der Gasdrehgriff 1 befindet sich auf der rech ten Seite des Lenkers Zum Erh hen der Mo tordrehzahl Beschleunigung den Gasdreh griff in Gegenfahrtrichtung drehen...

Page 50: ...fuel will not flow Always return the lever to this position when the engine is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this...

Page 51: ...startanreiche rung des Gemischs den Chokehebel 1 bis zum Anschlag herausziehen Zum Abschalten des Chokemechanismus normaler Fahrbe trieb mit warmem Motor den Hebel bis zum Anschlag zur ckschieben LEVI...

Page 52: ...oun terclockwise WARNING Do not overfill the fuel tank Avoid spilling fuel on the hot engine SIDESTAND This sidestand 1 is used to support only the machine when standing or transporting it WARNING Nev...

Page 53: ...m Gewicht belasten Vor dem Losfahren sicherstellen da der Seitenst nder hochgeklappt ist BOUCHON DE R SERVOIR DE CARBURANT Retirer le bouchon de r servoir de carburant 1 en le tournant dans le sens in...

Page 54: ...r flow when the fuel heats up later and expands a Fuel level CAUTION Use only unleaded gasoline The use of leaded gasoline will cause severe damage to the engine internal parts such as valves piston r...

Page 55: ...Essence sans plomb uniquement NZ Essence normale Capacit du r servoir de carburant Total 6 6 L 1 45 lmp gal 1 74 US gal R serve 1 9 L 0 42 lmp gal 0 5 US gal 1 12 KRAFTSTOFF Normalbenzin verwenden Imm...

Page 56: ...3 With the throttle completely closed start the engine by kicking the kickstarter crank forcefully with firm stroke 4 Run the engine at idle or slightly higher until it warms up this usually takes ab...

Page 57: ...otor darf w hrend der Einfahrzeit nicht zu stark beansprucht werden Darum sollten die nachfolgenden Anweisungen sorgf ltig gelesen und genau beachtet wer den 1 13 D MARRAGE ET RODAGE ATTENTION Avant d...

Page 58: ...okes CAUTION After the break in or before each ride you must check the entire machine for loose fit tings and fasteners as per TORQUE CHECK POINTS Tighten all such fasteners as required BREAKING IN AF...

Page 59: ...t ein Problem auf ist der Motor sofort abzustellen und die Ursache heraus zufinden D MARRAGE ET RODAGE STARTEN UND EINFAHREN RODAGE Un rodage est important car les organes mobiles et immobiles du mote...

Page 60: ...linder head Muffler to rear fender bracket Muffler to seat pillar tube Steering stem to frame Steering stem to upper bracket Upper bracket to handlebar Front fork to upper bracket Front fork to lower...

Page 61: ...Steering stem to upper bracket Upper bracket to handlebar Front fork to upper bracket Front fork to lower bracket Assembly of links Link to frame Link to shock absorber Link to swingarm Shock absorber...

Page 62: ...ent culasse Pot d chappement support de garde bove arri re Pot d chappement sur tuyau de montant de selle Colonne de direction au cadre Colonne de direction au t sup rieur T sup rieur au guidon Fourch...

Page 63: ...Colonne de direction au cadre Colonne de direction au t sup rieur T sup rieur au guidon Fourche avant au t sup rieur Fourche avant au t inf rieur Toutes les liaisons Liaison au cadre Liaison l amorti...

Page 64: ...radabdek kungs Halterung Schalld mpfer und Sitzstrebenr hre Lenkschaft und Rahmen Lenkschaft und obere Gabelbr cke Obere Gabelbr cke und Lenker Teleskopgabel und obere Gabelbr cke Teleskopgabel und un...

Page 65: ...re Gabelbr cke Obere Gabelbr cke und Lenker Teleskopgabel und obere Gabelbr cke Teleskopgabel und untere Gabelbr cke bertragungs und Umlenkhebel bertragungshebel und Rahmen Umlenkhebel und Sto d mpfer...

Page 66: ...n of wheel bear ings front forks brakes and transmission seals Many expensive repair bills have resulted from improper high pressure detergent applications such as those avail able in coin operated ca...

Page 67: ...NETTOYAGE ET REMISAGE NETTOYAGE Il est conseill de nettoyer le v hicule fond aussi souvent que possible non seulement pour des raisons esth tiques mais aussi parce que ces nettoyages con tribuent am l...

Page 68: ...witch pushed in kick the engine over several times to coat the cylinder walls with oil 3 Remove the drive chain clean it thor oughly with solvent and lubricate it Reinstall the chain or store it in a...

Page 69: ...UND STILLEGUNG REMISAGE Si la motocyclette doit tre remis e pendant 60 jours ou plus certaines pr cautions devront tre observ es pour la maintenir en parfait tat Apr s un nettoyage complet de la motoc...

Page 70: ...in Wheelbase 1 250 mm 49 2 in Minimum ground clearance 265 mm 10 4 in Basic weight With oil and full fuel tank 83 kg 183 lb Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Single cyl...

Page 71: ...22FSR U Manufacturer NGK DENSO Gap 0 6 0 7 mm 0 02 0 03 in Clutch type Wet multiple disc Transmission Primary reduction system Gear Primary reduction ratio 68 19 3 579 Secondary reduction system Chain...

Page 72: ...foot operation Suspension Front suspension Telescopic fork Rear suspension Swingarm link type monocross suspension Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil s...

Page 73: ...50 0 in Minimum ground clearance 295 mm 11 6 in Basic weight With oil and full fuel tank 84 kg 185 lb Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Single cylinder forward inclined...

Page 74: ...U22FSR U Manufacturer NGK DENSO Gap 0 6 0 7 mm 0 02 0 03 in Clutch type Wet multiple disc Transmission Primary reduction system Gear Primary reduction ratio 68 19 3 579 Secondary reduction system Chai...

Page 75: ...ght foot operation Suspension Front suspension Telescopic fork Rear suspension Swingarm link type monocross suspension Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Co...

Page 76: ...2 1260 2 1267 in Out of round limit 0 05 mm 0 0020 in Camshaft Drive method Chain drive left Cam dimensions Intake A 25 881 25 981 mm 1 0189 1 0229 in 25 851 mm 1 0178 in B 21 195 21 295 mm 0 8344 0 8...

Page 77: ...width IN 1 1 3 0 mm 0 0433 0 1181 in EX 1 7 2 8 mm 0 0669 0 1102 in C seat width IN 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in EX 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in D margin thickness IN 0...

Page 78: ...e length IN 32 55 mm 1 28 in 31 2 mm 1 23 in EX 32 55 mm 1 28 in 31 2 mm 1 23 in Set length valve closed IN 25 6 mm 1 01 in EX 25 6 mm 1 01 in Compressed pressure installed IN 137 5 158 1 N 14 0 16 1...

Page 79: ...tside diameter 14 991 15 000 mm 0 5902 0 5906 in 14 971 mm 0 5894 in Piston rings Top ring Type Barrel Dimensions B T 1 0 2 1 mm 0 04 0 08 in End gap installed 0 15 0 30 mm 0 006 0 012 in 0 4 mm 0 016...

Page 80: ...cam push Push rod bending limit 0 5 mm 0 020 in Shifter Shifter type Cam drum and guide bar Kick starter Type Kick and mesh type Kick clip friction force 6 4 13 2 N 0 65 1 35 kg 1 4 3 0 lb Carburetor...

Page 81: ...ilter type Wire mesh type Oil pump type Trochoid type Tip clearance 0 15 mm 0 0059 in 0 2 mm 0 0079 in Side clearance 0 06 0 10 mm 0 0024 0 0039 in 0 15 mm 0 0059 in Housing and rotor clearance 0 06 0...

Page 82: ...ng enricher cover M4 0 7 2 2 0 2 1 4 Air filter case M6 1 0 3 7 0 7 5 1 Muffler M6 1 0 2 10 1 0 7 2 Muffler M10 1 25 1 60 6 0 43 Muffler M8 1 25 1 30 3 0 22 Muffler guard M6 1 0 7 10 1 0 7 2 Spark arr...

Page 83: ...SPEC 2 14 MAINTENANCE SPECIFICATIONS NOTE marked portion shall be checked for torque tightening after break in or before each ride Cylinder head tightening sequence...

Page 84: ...ent Inner tube outer diameter 30 mm 1 18 in Front fork top end Zero mm Zero in Rear suspension Shock absorber travel 65 mm 2 56 in Spring free length 175 mm 6 89 in Fitting length 165 mm 6 50 in Sprin...

Page 85: ...n 2 0 mm 0 08 in Rear lining thickness 4 0 mm 0 16 in 2 0 mm 0 08 in Front shoe spring free length 50 5 mm 1 99 in Rear shoe spring free length 50 5 mm 1 99 in Brake lever and brake pedal Brake lever...

Page 86: ...1 4 Brake lever mounting bolt M6 1 0 1 7 0 7 5 1 Brake lever mounting nut M6 1 0 1 7 0 7 5 1 Brake lever holder M5 0 8 2 4 0 4 2 9 Clutch lever mounting bolt M6 1 0 1 7 0 7 5 1 Clutch lever mounting...

Page 87: ...hock absorber and locknut preload M46 1 5 1 42 4 2 30 Drive chain tensioner upper M8 1 25 1 23 2 3 17 Drive chain tensioner lower M6 1 0 1 7 0 7 5 1 Drive chain support and swingarm M6 1 0 2 7 0 7 5 1...

Page 88: ...178 mm 7 01 in Fitting length 165 mm 6 50 in Spring rate STD K 58 9 N mm 6 0 kg mm 336 lb in Optional spring No Enclosed gas pressure 1 500 kPa 15 kg cm2 213 psi Wheel Front wheel type Spoke wheel Rea...

Page 89: ...2 0 mm 0 08 in Shoe spring free length 50 5 mm 1 99 in Brake lever and brake pedal Brake lever free play lever end 2 5 mm 0 08 0 20 in Brake pedal position vertical height below footrest top 1 mm 0 0...

Page 90: ...hrottle cable cap M4 0 7 2 2 0 2 1 4 Front brake master cylinder M6 1 0 2 9 0 9 6 5 Front brake master cylinder cap M4 0 7 2 2 0 2 1 4 Brake lever mounting bolt M6 1 0 1 7 0 7 5 1 Brake lever mounting...

Page 91: ...d swingarm M12 1 25 1 53 5 3 38 Relay arm and connecting arm M10 1 25 1 35 3 5 25 Connecting arm and frame M10 1 25 1 35 3 5 25 Rear shock absorber assembly and frame M12 1 25 1 53 5 3 38 Rear shock a...

Page 92: ...d CDI unit model manufacturer 5HP 00 YAMAHA Ignition coil Model manufacturer 4KJ 10 YAMAHA Minimum spark gap 6 mm 0 24 in Primary coil resistance 0 18 0 28 at 20 C 68 F Secondary coil resistance 6 3 9...

Page 93: ...threads Com ponents should be at room temperature A Nut B Bolt TORQUE SPECIFICATION Nm m kg ft lb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 6 15 30 55 85 130 0 6 1 5 3 0 5...

Page 94: ...265 mm 10 4 in Poids net Avec huile et r servoir de carburant rempli 83 kg 183 lb Moteur Type de moteur 4 temps refroidissement par air un arbre cames en t te SOHC Disposition du cylindre Monocylindre...

Page 95: ...7 mm 0 02 0 03 in Type d embrayage Humide multidisque Bo te de vitesses Syst me de r duction primaire Pignon Taux de r duction primaire 68 19 3 579 Syst me de r duction secondaire Entra nement par cha...

Page 96: ...ion arri re Bras oscillant suspension monocross liaison Amortisseur Amortisseur avant Ressort h lico dal amortisseur hydraulique Amortisseur arri re Ressort h lico dal pneumatique amortisseur hydrauli...

Page 97: ...ds net Avec huile et r servoir de carburant rempli 84 kg 185 lb Moteur Type de moteur 4 temps refroidissement par air un arbre cames en t te SOHC Disposition du cylindre Monocylindre inclin vers l ava...

Page 98: ...mm 0 02 0 03 in Type d embrayage Humide multidisque Bo te de vitesses Syst me de r duction primaire Pignon Taux de r duction primaire 68 19 3 579 Syst me de r duction secondaire Entra nement par cha n...

Page 99: ...ension arri re Bras oscillant suspension monocross liaison Amortisseur Amortisseur avant Ressort h lico dal amortisseur hydraulique Amortisseur arri re Ressort h lico dal pneumatique amortisseur hydra...

Page 100: ...Arbre cames M thode d entra nement Transmission par cha ne c t gau che Dimensions de came Admission A 25 881 25 981 mm 1 0189 1 0229 in 25 851 mm 1 0178 in B 21 195 21 295 mm 0 8344 0 8384 in 21 165 m...

Page 101: ...AD 1 1 3 0 mm 0 0433 0 1181 in CH 1 7 2 8 mm 0 0669 0 1102 in C largeur de si ge AD 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in CH 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in D paisseur de rebord A...

Page 102: ...1 28 in 31 2 mm 1 23 in Longueur mont soupape ferm e AD 25 6 mm 1 01 in CH 25 6 mm 1 01 in Pression la compression install AD 137 5 158 1 N 14 0 16 1 kg 30 86 35 49 lb CH 137 5 158 1 N 14 0 16 1 kg 30...

Page 103: ...4 971 mm 0 5894 in Segments Segment de feu Type Cylindrique Dimensions B T 1 0 2 1 mm 0 04 0 08 in cartement des becs segment mont 0 15 0 30 mm 0 006 0 012 in 0 4 mm 0 016 in Jeu lat ral mont 0 035 0...

Page 104: ...r Tambour de s lection et guide Kick Type Kick et mise en prise Force de friction du clip de kick 6 4 13 2 N 0 65 1 35 kg 1 4 3 0 lb Carburateur Marque d identification 5HP1 10 Gicleur principal M J N...

Page 105: ...pe huile Trocho dale Jeu en bout 0 15 mm 0 0059 in 0 2 mm 0 0079 in Jeu lat ral 0 06 0 10 mm 0 0024 0 0039 in 0 15 mm 0 0059 in Jeu de lubrification entre le logement et le rotor 0 06 0 10 mm 0 0024 0...

Page 106: ...tre air M6 1 0 3 7 0 7 5 1 Pot d chappement M6 1 0 2 10 1 0 7 2 Pot d chappement M10 1 25 1 60 6 0 43 Pot d chappement M8 1 25 1 30 3 0 22 Prot ge pot d chappement M6 1 0 7 10 1 0 7 2 Pare tincelles M...

Page 107: ...SPEC 2 14 N B Contr ler le serrage au couple des l ments rep r s d un apr s le rodage et avant chaque d marrage Ordre de serrage de la culasse CARACT RISTIQUES D ENTRETIEN...

Page 108: ...ube plongeur 30 mm 1 18 in Sommet de fourche avant Z ro mm z ro in Suspension arri re D battement d amortisseur 65 mm 2 56 in Longueur libre de ressort 175 mm 6 89 in Longueur mont 165 mm 6 50 in Cons...

Page 109: ...n arri re 4 0 mm 0 16 in 2 0 mm 0 08 in Longueur libre de ressort de m choire de frein avant 50 5 mm 1 99 in Longueur libre de ressort de m choire de frein arri re 50 5 mm 1 99 in Levier de frein et p...

Page 110: ...tage du levier de frein M6 1 0 1 7 0 7 5 1 crou de montage du levier de frein M6 1 0 1 7 0 7 5 1 Support de levier de frein M5 0 8 2 4 0 4 2 9 Boulon de montage du levier d embrayage M6 1 0 1 7 0 7 5...

Page 111: ...Tendeur de cha ne de transmission bas M6 1 0 1 7 0 7 5 1 Support de cha ne de transmission et bras oscillant M6 1 0 2 7 0 7 5 1 Patin de cha ne de transmission et bras oscillant M6 1 0 2 7 0 7 5 1 Fi...

Page 112: ...Longueur mont 165 mm 6 50 in Constante standard de ressort K 58 9 N mm 6 0 kg mm 336 lb in Ressort optionnel Non Pression du gaz 1 500 kPa 15 kg cm2 213 psi Roue Type de roue avant Roue rayons Type d...

Page 113: ...de m choire 50 5 mm 1 99 in Levier de frein et p dale de frein Jeu du levier de frein l extr mit 2 5 mm 0 08 0 20 in Position de la p dale de frein distance verticale sous le sommet du repose pied 1 m...

Page 114: ...cylindre de frein avant M6 1 0 2 9 0 9 6 5 Couvercle de ma tre cylindre de frein avant M4 0 7 2 2 0 2 1 4 Boulon de montage du levier de frein M6 1 0 1 7 0 7 5 1 crou de montage du levier de frein M6...

Page 115: ...accordement et cadre M10 1 25 1 35 3 5 25 Amortisseur arri re et cadre M12 1 25 1 53 5 3 38 Amortisseur arri re et basculeur M10 1 25 1 35 3 5 25 Amortisseur arri re et contre crou pr contrainte M46 1...

Page 116: ...Bobine d allumage Mod le fabricant 4KJ 10 YAMAHA Longueur minimum d tincelle 6 mm 0 24 in R sistance de l enroulement primaire 0 18 0 28 20 C 68 F R sistance de l enroulement secondaire 6 3 9 5 k 20...

Page 117: ...ins que ce ne soit sp cifi autrement les sp cifications de couple s entendent pour des filetages propres et secs Les composants doivent tre temp rature ambiante A crou B vis CARACT RISTIQUES DE COUPLE...

Page 118: ...tzh he 775mm Radstand 1 250mm Bodenfreiheit 265mm Gewicht fahrfertig Mit l und vollgetankt 83 kg Motor Bauart Luftgek hlter 4 Takt Motor SOHC Zylinderanordnung Einzylinder in Fahrtrichtung geneigt Hub...

Page 119: ...upplungstyp Mehrscheiben lbadkupplung Getriebe Prim rantrieb Zahnrad Prim r bersetzung 68 19 3 579 Sekund rantrieb Kettenantrieb Sekund r bersetzung 49 13 3 769 Getriebe Klauengeschaltetes 5 Gang Getr...

Page 120: ...erradbremse Bet tigung Fu bremshebel rechts Radaufh ngung Vorderradaufh ngung Teleskopgabel Hinterradaufh ngung Schwinge mit Umlenkhebelabst tzung Sto d mpfung Federelemente vorne Spiralfeder hydrauli...

Page 121: ...and 1 270mm Bodenfreiheit 295mm Gewicht fahrfertig Mit l und vollgetankt 84 kg Motor Bauart Luftgek hlter 4 Takt Motor SOHC Zylinderanordnung Einzylinder in Fahrtrichtung geneigt Hubraum 124 cm3 Bohru...

Page 122: ...pplungstyp Mehrscheiben lbadkupplung Getriebe Prim rantrieb Zahnrad Prim r bersetzung 68 19 3 579 Sekund rantrieb Kettenantrieb Sekund r bersetzung 54 13 4 154 Getriebe Klauengeschaltetes 5 Gang Getri...

Page 123: ...Hinterradbremse Bet tigung Fu bremshebel rechts Radaufh ngung Vorderradaufh ngung Teleskopgabel Hinterradaufh ngung Schwinge mit Umlenkhebelabst tzung Sto d mpfung Federelemente vorne Spiralfeder hydr...

Page 124: ...Max Verzug 0 03 mm Zylinder Bohrung 54 000 54 019 mm Max Ovalit t 0 05 mm Nockenwelle Antrieb Kettenantrieb links Nockenwellen Abmessungen Einla A 25 881 25 981 mm 25 851 mm B 21 195 21 295 mm 21 165...

Page 125: ...ser EIN 25 9 26 1 mm AUS 21 9 22 1 mm B Ventilkegel Breite EIN 1 1 3 0 mm AUS 1 7 2 8 mm C Ventilsitz Breite EIN 0 9 1 1 mm 1 6 mm AUS 0 9 1 1 mm 1 6 mm D Ventilteller St rke EIN 0 4 0 8 mm AUS 0 8 1...

Page 126: ...EIN 32 55 mm 31 2 mm AUS 32 55 mm 31 2 mm Einbaul nge Ventil geschlossen EIN 25 6 mm AUS 25 6 mm Federdruck bei Einbaul nge EIN 137 5 158 1 N 14 0 16 1 kg AUS 137 5 158 1 N 14 0 16 1 kg Federneigungsw...

Page 127: ...messer 14 991 15 000 mm 14 971 mm Kolbenringe 1 Kompressionsring Topring Ausf hrung Abgerundet Abmessungen B T 1 0 2 1 mm Ringsto eingebaut 0 15 0 30 mm 0 4 mm Ringnutspiel eingebaut 0 035 0 090 mm 0...

Page 128: ...kstarter Kickstarter Bauart Kick und Eingriff Kickstarterclip Reibkraft 6 4 13 2 N 0 65 1 35 kg Vergaser Kennzeichnung 5HP1 10 Hauptd se M J Nr 105 Hauptd senstock N J N 6M Hauptluftd se M A J 1 2 D s...

Page 129: ...C 2 12 WARTUNGSDATEN Schmiersystem lfilter Drahtgeflecht lpumpe Rotorpumpe Spalt 0 15 mm 0 2 mm Spiel 0 06 0 10 mm 0 15 mm Geh use und Rotor Laufspiel 0 06 0 10 mm 0 15 mm Bauteil Spezifikation Grenzw...

Page 130: ...icherung M4 0 7 2 2 0 2 Luftfiltergeh use M6 1 0 3 7 0 7 Kr mmer M6 1 0 2 10 1 0 Kr mmer M10 1 25 1 60 6 0 Kr mmer M8 1 25 1 30 3 0 Kr mmer Schutzabdeckung M6 1 0 7 10 1 0 Funkenf nger M6 1 0 3 10 1 0...

Page 131: ...SPEC 2 14 WARTUNGSDATEN HINWEIS Mit markierte Punkte m ssen nach der Einfahrzeit oder vor jedem Rennen auf richtiges Anzugs moment gepr ft werden Anzugsreihenfolge Zylinderkopfschrauben...

Page 132: ...rchmesser 30 mm Teleskopgabel Oberkante 0 mm Hinterradaufh ngung Sto d mpferhub 65 mm Ungespannte Federl nge 175 mm Einbaul nge 165 mm Standard Federrate K 48 1 N mm 4 9 kg mm Umr stfeder Kein Gasd mp...

Page 133: ...111 mm Belagst rke vorne 4 0 mm 2 0 mm Belagst rke hinten 4 0 mm 2 0 mm Bremsschuhfeder ungespannte L nge vorne 50 5 mm Bremsschuhfeder ungespannte L nge hinten 50 5 mm Bremshebel und Bremspedal Hand...

Page 134: ...mshebel Befestigung Schraube M6 1 0 1 7 0 7 Handbremshebel Befestigung Mutter M6 1 0 1 7 0 7 Handbremshebel Halter M5 0 8 2 4 0 4 Kupplungshebel Befestigung Schraube M6 1 0 1 7 0 7 Kupplungshebel Befe...

Page 135: ...und Sicherungsmutter Vorspannung M46 1 5 1 42 4 2 Antriebskettenspanner oben M8 1 25 1 23 2 3 Antriebskettenspanner unten M6 1 0 1 7 0 7 Antriebsketten Stiite und Schwinge M6 1 0 2 7 0 7 Kettenf hrun...

Page 136: ...nge 165 mm Standard Federrate K 58 9 N mm 6 0 kg mm Umr stfeder Kein Gasd mpferdruck 1 500 kPa 15 bar R der Vorderrad Speichenrad Hinterrad Speichenrad Felgengr e Felgen Baustoff 19 1 40 Stahl vorne...

Page 137: ...mm Belagst rke 4 0 mm 2 0 mm Bremsschuhfeder ungespannte L nge 50 5 mm Bremshebel und Bremspedal Handbremshebelspiel am Hebelende 2 5 mm Bremspedalh he Vertikale H he unterhalb Fu rasten Oberkante 1 m...

Page 138: ...erradbremse M6 1 0 2 9 0 9 Hauptbremszylinder Verschlu deckel Vorder radbremse M4 0 7 2 2 0 2 Handbremshebel Befestigung Schraube M6 1 0 1 7 0 7 Handbremshebel Befestigung Mutter M6 1 0 1 7 0 7 Handbr...

Page 139: ...hwinge M12 1 25 1 53 5 3 Umlenkhebel und Verbindungsgelenk M10 1 25 1 35 3 5 Verbindungsgelenk und Rahmen M10 1 25 1 35 3 5 Hinterradsto d mpfer und Rahmen M12 1 25 1 53 5 3 Hinterradsto d mpfer und U...

Page 140: ...wei rot C D I Einheit Modell Hersteller 5HP 00 YAMAHA Z ndspule Typ Hersteller 4KJ 10 YAMAHA Minimale Z ndfunkenstrecke 6 mm Prim rwicklungs Widerstand 0 18 0 28 bei 20 C Sekund rwicklungs Widerstand...

Page 141: ...t anders angegeben gelten alle Anzugsmomente f r saubere trockene Gewin de Die Bauteile sollten Raumtemperatur auf weisen A Mutter B Schrau be ANZUGSMOMENTE Nm m kg 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm...

Page 142: ...T R125LW Fit the CDI unit band over the CDI unit bracket till it stops Clamp the ignition coil lead Clamp the wire harness coupler Clamp the CDI magneto lead throttle cable and starter cable Clamp the...

Page 143: ...markie rungen festklammern Bremsschlauch zwischen den farbigen Markie rungen befestigen CHEMINEMENT DES C BLES 1 Reniflard de r servoir de carburant 2 Bloc CDI 3 Sangle du bloc CDI 4 Bride 5 Fil de ma...

Page 144: ...tall the primary coil terminal orange to the ignition coil Fasten the ground lead together with the ignition coil Pass the clutch cable on the inside of the throttle and starter cable Clamp the clutch...

Page 145: ...iflard 2 Fil de bougie 3 C ble de starter 4 C ble des gaz 5 C ble d embrayage 6 Bride 7 Guide de c ble 8 Reniflard de carter 9 Flexible de trop plein Apr s avoir brid le c ble du starter le pousser co...

Page 146: ...iddle of the clutch holder Clamp the engine stop switch lead to the handlebar to 3 clicks Pass the brake cable brake hose for the TT R125LW in front of the number plate and through the cable guide Pas...

Page 147: ...ten weisen 1 Fil de coupe circuit du moteur 2 Coupe circuit du moteur 3 Reniflard de r servoir de carburant 4 Bride 5 C ble de frein Flexible de frein pour la TT R125LW 6 C ble d embrayage 7 C ble des...

Page 148: ...ssary Replace gasket if necessary Engine oil Check oil level and vehicle for oil leakage Correct if necessary Change Warm engine before draining Clutch Check operation Adjust or replace cable Front br...

Page 149: ...and for oil leakage Correct accordingly Rear shock absorber assembly Check operation and shock absorber for oil leakage Replace shock absorber assembly if necessary Chassis fasteners Make sure that a...

Page 150: ...er le niveau d huile et l tanch it Corriger si n cessaire Changer Faire chauffer le moteur avant la vidange Embrayage V rifier le fonctionnement R gler ou remplacer le c ble Frein avant V rifier le fo...

Page 151: ...essaire Pare tincelles 1 Nettoyer Fourche avant Contr ler le fonctionnement et l tanch it Corriger si n cessaire Ensemble amortis seur arri re Contr ler le fonctionnements et l tanch it Remplacer le c...

Page 152: ...len gegebe nenfalls erneuern Ventile Ventilspiel kontrollieren Gegebenenfalls einstellen Luftfilter Luftfiltereinsatz gegebenenfalls reinigen oder erneuern Vergaser Leerlaufdrehzahl und Choke Funktion...

Page 153: ...it pr fen Entsprechend korrigieren Sp testens nach 120 Betriebsstunden mit Lithium fett schmieren Seitenst nder Funktion pr fen Gegebenenfalls schmieren oder reparieren Funkenl scher 1 Reinigen Telesk...

Page 154: ...ar brake Check fluid level and leakage TT R125LW only P 3 15 20 Drive chain Check chain slack and alignment Check that the chain is lubri cated properly P 3 21 22 Wheels Check for excessive wear and t...

Page 155: ...le niveau de fluide et les fuites TT R125LW seulement P 3 15 20 Cha ne de transmission Contr ler la tension et l alignement de la cha ne Contr ler et si n cessaire lubrifier la cha ne P 3 21 22 Roues...

Page 156: ...Undichtigkeit achten Nur TT R125LW 3 15 20 Antriebskette Durchhang und Einstellung der Antriebskette pr fen Kontrollie ren ob die Kette ausreichend geschmiert ist 3 21 22 R der Auf berm igen Verschlei...

Page 157: ...INSP ADJ MEMO...

Page 158: ...k proper operation of clutch lever Clutch lever free play adjustment steps Loosen the locknut 1 Turn the adjuster 2 until free play a is within the specified limits Tighten the locknut EC35A001 THROTT...

Page 159: ...r 2 hinein oder herausdrehen bis das vorgeschriebene Spiel korrekt ein gestellt ist Kontermutter wieder festdrehen MOTEUR R GLAGE DE L EMBRAYAGE 1 Contr ler Garde du levier d embrayage a Hors sp cific...

Page 160: ...engine idling does not run faster 2 Apply Lithium soap base grease On the throttle cable end a and tube guide cable winding portion b 3 Install Throttle cable cap T R 2 Nm 0 2 m kg 1 4 ft lb AIR FILT...

Page 161: ...t Andernfalls kann Schmutz und Staub in den Motor eindringen und raschen Ver schlei und m glicherweise Besch digun gen im Motor verursachen LUBRIFICATION DU C BLE DES GAZ 1 D poser Couvercle du logeme...

Page 162: ...case cover 2 3 Remove Air filter assembly 1 Wing nut 2 Washer 3 Air filter element 4 Air filter guide 5 4 Clean Air filter element Clean them with solvent NOTE After cleaning remove the remaining sol...

Page 163: ...em Luftfiltereinsatz ausdr cken ACHTUNG Den Luftfiltereinsatz beim Ausdr cken nicht verdrehen 5 Kontrollieren Luftfiltereinsatz Besch digung Erneuern 1 D poser Cache lat ral droit 1 N B Desserrer la v...

Page 164: ...nt 1 On air filter guide 2 8 Apply Lithium soap base grease On the matching surface a on air filter element 9 Install Air filter element 1 Washer 2 Wing nut 3 ENGINE OIL LEVEL INSPECTION 1 Start the e...

Page 165: ...uf einem ebenen Unter grund mit Hilfe eines geeigneten St n ders abstellen 3 Herausdrehen lme stab 1 6 Appliquer Huile pour filtre air en mousse ou huile de m lange Sur l l ment N B Comprimer pour lim...

Page 166: ...t 10 C 10 F or higher Yamalube 4 10W 30 or SAE 10W 30 type SE motor oil At 5 C 40 F or higher Yamalube 4 20W 40 or SAE 20W 40 type SE motor oil Except for USA and CDN CAUTION Do not add any chemical a...

Page 167: ...swahl der richtigen lsorte die f r die entspre chenden Temperaturen geeig net ist Empfohlene Motor l Spezifikation API NORM API SE oder besser vorzugsweise Motorrad l 4 Contr ler Niveau d huile Le niv...

Page 168: ...warm it up for sev eral minutes and wait for five minute 2 Place the machine on a level place and hold it on upright position by placing the suitable stand under the engine 3 Place a suitable containe...

Page 169: ...Hineinschrauben lme stab 2 F llmenge Regelm iger lwechsel 1 0 L 5 Installer Jauge 6 Mettre le moteur en marche et le laisser chauffer pendant quelques minutes 7 Couper le moteur et v rifier une nouve...

Page 170: ...l pressure check bolt T R Oil pressure check bolt 7 Nm 0 7 m kg 5 1 ft lb PILOT AIR SCREW ADJUSTMENT 1 Adjust Pilot air screw 1 Adjustment steps NOTE To optimize the fuel flow at a smaller throttle op...

Page 171: ...or dem Einstellen leicht bis zum Anschlag hineindrehen und die Anzahl der Umdrehungen z hlen Diese Zahl als werk seitige Anzahl der Umdrehungen notieren CONTR LE DE LA PRESSION D HUILE DE MOTEUR 1 Con...

Page 172: ...ERS section in the CHAPTER 4 Adjustment steps Adjust the pilot air screw Refer to PILOT AIR SCREW ADJUST MENT section Turn the throttle stop screw 1 until the specified engine idling speed To increase...

Page 173: ...ufdrehzahl 1 300 1 500 U min 3 Demontieren Z ndeinstell Verschlu schraube 1 Kurbelwellen Verschlu schraube 2 O Ring CONTR LE ET R GLAGE DU JEU DE SOUPAPES N B Le jeu de soupapes doit tre r gl quand le...

Page 174: ...he crankcase cover when piston is at T D C on compression stroke Measure the valve clearance using a feeler gauge 1 Out of specification Adjust clearance 5 Adjust Valve clearance Adjustment steps Loos...

Page 175: ...d Kontermutter festziehen T R Kontermutter 8 Nm 0 8 m kg CONTR LE ET R GLAGE DU JEU DE SOUPAPES VENTILSPIEL KONTROLLIEREN UND EINSTELLEN 4 Contr ler Jeu de soupapes Hors sp cifications R gler 5 R gler...

Page 176: ...lithium soap base grease on the O rings New T R 7 Nm 0 7 m kg 5 1 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb 7 Install O ring 1 Exhaust tappet cover 2 Intake tappet cover 3 NOTE Apply the lithium soap base gr...

Page 177: ...Nm 1 8 m kg T R 13 Nm 1 3 m kg T R 10 Nm 1 0 m kg T R 7 Nm 0 7 m kg Mesurer le jeu de soupapes Si le jeu est incorrect r p ter les tapes ci des sus jusqu obtention du jeu correct 6 Installer Joint tor...

Page 178: ...gine when cleaning the exhaust system 1 Remove Bolt spark arrester 1 2 Remove Spark arrester 1 Pull the spark arrester out of the muf fler 3 Clean Spark arrester Tap the spark arrester lightly then us...

Page 179: ...challd mpfer hineinschieben und auf die Bohrungen f r die Schrauben ausrichten Schraube Funkenl scher T R 10 Nm 1 0 m kg NETTOYAGE DU PARE TINCELLES pour les USA AVERTISSEMENT S assurer que le tuyau e...

Page 180: ...the reservoir b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect the clear plastic tube 2 tightly to the caliper bleed screw 1 d Place the other end...

Page 181: ...offschlauch befinden PARTIE CYCLE PURGE DE L AIR DU SYST ME DE FREINAGE TT R125LW FAHRWERK HYDRAULISCHE BREMSANLAGE ENTL FTEN TT R125LW PARTIE CYCLE PURGE DE L AIR DU SYST ME DE FREINAGE TT R125LW AVE...

Page 182: ...system FRONT BRAKE ADJUSTMENT TT R125 1 Check Brake lever free play a Out of specification Adjust 2 Adjust Brake lever free play NOTE For minute adjustment loosen the locknut 2 on the lever side and a...

Page 183: ...rehen bis sich das freie Spiel a innerhalb des vorgeschriebenen Wertes befindet Kontermuttern festziehen 3 Monter Diaphragme Couvercle du ma tre cylindre de frein N B Si la purge est difficile il peut...

Page 184: ...oosen the locknut 1 Turn the adjuster 2 until the free play a is within the specified limits Tighten the locknut REAR BRAKE ADJUSTMENT 1 Check Brake pedal free play a Out of specification Adjust 2 Adj...

Page 185: ...r herausdrehen bis das vorgeschriebene Spiel a eingestellt ist TT R125LW 1 Contr ler Garde du levier de frein a Hors sp cifications R gler 2 R gler Garde du levier de frein ATTENTION Apr s avoir r gl...

Page 186: ...height a 1 mm 0 04 in Pedal height adjustment steps Loosen the locknut 1 Turn the adjusting bolt 2 until the pedal height a is within specified height Tighten the locknut Brake pad thickness a Standar...

Page 187: ...S DE FREIN AVANT TT R125LW BREMSPEDAL H HE EINSTELLEN VORDERRAD BREMSBEL GE KONTROLLIEREN UND ERNEUERN TT R125LW R GLAGE DE LA HAUTEUR DE LA P DALE DE FREIN 1 Contr ler Hauteur de p dale de frein a Ho...

Page 188: ...the brake caliper piston in CAUTION Do not reuse the drained brake fluid Tighten the bleed screw T R Bleed screw 6 Nm 0 6 m kg 4 3 ft lb Install the brake caliper 6 and brake cali per support bolt 7...

Page 189: ...enden HINWEIS Bremssattel Halteschraube vor dem Einbau mit Lithiumfett bestreichen 4 Examiner Niveau du liquide de frein Se reporter CONTR LE DU NIVEAU DU LIQUIDE DE FREIN au CHAPITRE 3 5 Contr ler Fo...

Page 190: ...contaminants do not enter brake master cylinder when refilling Clean up spilled fluid immediately to avoid erosion of painted surfaces or plas tic parts Brake shoe lining wear limit checking steps Ful...

Page 191: ...chriebenen Bereichs a befindet Grenzwert berschritten Bremsbelag erneuern Siehe unter HINTERRAD UND HINTER RADBREMSE in KAPITEL 5 Empfohlene Bremsfl ssigkeit DOT 4 CONTR LE DES M CHOIRES DE FREIN 1 Ex...

Page 192: ...ain from the kerosene and dry the chain 3 Measure Drive chain length 10 links a Out of specification Replace Drive chain length 10 links Limit 121 4 mm 4 78 in 4 Check Drive chain stiffness a Clean an...

Page 193: ...schlo Clip unbedingt gem Abbil dung montieren a Antriebsketten Drehrichtung New CONTR LE DE LA CHA NE DE TRANSMISSION 1 D poser Agrafe de maillon d tachable Maillon d tachable 1 Cha ne de transmission...

Page 194: ...ns and check the slack several times to find the tight est point Check and or adjust chain slack with rear wheel in this tight chain position Drive chain slack 35 50 mm 1 4 2 0 in 3 Adjust Drive chain...

Page 195: ...urch hang belastet den Motor und andere wichtige Teile Deshalb den Antriebsket ten Durchhang laut Vorschrift einstellen 6 Lubrifier Cha ne de transmission R GLAGE DE LA TENSION DE LA CHA NE DE TRANSMI...

Page 196: ...tion Abnormal noise unsmooth action Grease the pivoting points or repair the pivoting points Damage oil leakage Replace REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 1 Elevate the rear wheel by placin...

Page 197: ...RE R GLAGE DE LA PR CONTRAINTE DE RESSORT DE L AMORTISSEUR ARRI RE TELESKOPGABEL KONTROLLIEREN HINTERRADSTOSSD MPFER KONTROLLIEREN HINTERRADSTOSSD MPFER FEDERVORSPANNUNG EINSTELLEN INSPECTION DE LA F...

Page 198: ...ver T R 42 Nm 4 2 m kg 30 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb EC36Q000 TIRE PRESSURE CHECK 1 Measure Tire pressure Out of specification Adjust NOTE Check the tire while it is cold Loose bead stoppers al...

Page 199: ...Reifenventil anzeigt da sich der Reifen auf der Felge bewegt hat mu die Reifenstellung korrigiert werden Standard Reifendruck 100 kPa 1 0 bar N B Avant d effectuer le r glage bien veiller ce que le d...

Page 200: ...ctice check spokes for looseness T R Front 2 Nm 0 2 m kg 1 4 ft lb Rear 3 Nm 0 3 m kg 2 2 ft lb EC36T000 WHEEL INSPECTION 1 Inspect Wheel runout Elevate the wheel and turn it Abnormal runout Replace 2...

Page 201: ...unter dem Motor plazieren um Vorderrad anzuheben 2 Kontrollieren Lenkwelle Die Gleitrohre am unteren Ende umfas sen und die Teleskopgabel hin und her bewegen Spiel Lenkkopf einstellen INSPECTION ET S...

Page 202: ...g nut 2 and rubber washer 3 Loosen the lower ring nut 4 using the steering nut wrench 5 Steering nut wrench YU 33975 90890 01403 Tighten the lower ring nut 6 using steer ing nut wrench 7 and turn the...

Page 203: ...el im rechten Win kel zum Hakenschl ssel ansetzen WARNUNG Ringmutter nicht berm ig festziehen 3 Contr ler Fonctionnement en douceur de la direction Tourner le guidon de but e but e Fonctionnement dur...

Page 204: ...n the upper ring nut for alignment Install the upper bracket A steering stem nut B cap C handlebar D upper han dlebar holder E starter knob nut F and number plate G NOTE The upper handlebar holder sho...

Page 205: ...r Vorder seite des Lenkerhalters festziehen und anschlie end die Schrauben auf der R ckseite festziehen 3 27 T R crou annulaire serrage final 20 Nm 2 0 m kg 14 ft lb V rifier la colonne de direction e...

Page 206: ...hift pedal pivot 4 Footrest pivot 5 Throttle to handlebar contact 6 Drive chain 7 Tube guide cable winding portion 8 Throttle cable end 9 Brake and clutch cable ends Clutch cable end only for the TT R...

Page 207: ...inem qualitativ hoch wertigen leichten Lithiumfett abschmieren LUBRIFICATION Afin de garantir le bon fonctionnement de tous les l ments il convient de lubrifier la machine avant la premi re utilisatio...

Page 208: ...ds the spark plug insulator will become sooty even if the engine and carburetor are in good operating condition 3 Measure Plug gap a Use a wire gauge or thickness gauge Out of specification Regap 4 Cl...

Page 209: ...t Z ndkerze per Hand hineindrehen a und anschlie end mit dem vorgeschriebe nen Drehmoment b festziehen T R 13 Nm 1 3 m kg PARTIE LECTRIQUE INSPECTION DE LA BOUGIE 1 D poser Bougie 2 Examiner lectrodes...

Page 210: ...xtent of removal Order Part name Q ty Remarks Preparation for removal SEAT FUEL TANK AND SIDE COVERS REMOVAL Turn the fuel cock to OFF 1 Seat 1 2 Air scoop left and right 2 3 Fuel hose 1 Remove on fue...

Page 211: ...tartnummernblech 1 1 3 4 2 3 SELLE R SERVOIR DE CARBURANT ET CACHES LAT RAUX SITZ KRAFTSTOFFTANK UND SEITENDECKEL MOTEUR SELLE R SERVOIR DE CARBURANT ET CACHES LAT RAUX D poses effectuer 1 D pose de l...

Page 212: ...removal Extent of removal Order Part name Q ty Remarks MUFFLER REMOVAL Preparation for removal Right side cover Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Bolt spark arrester 3 2 Spark arreste...

Page 213: ...kenl scher 1 3 Mutter Schalld mpfer 2 4 Schraube Schalld mpfer 1 5 Schalld mpfer 1 1 POT D CHAPPEMENT D poses effectuer 1 D pose du pot d chappement D poses effectuer Ordre Nom de pi ce Qt Remarques D...

Page 214: ...REMOVAL Preparation for removal Fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Fuel hose 1 2 Over flow hose 1 3 Air vent hose 2 4 Starter plunger 1 5 Carburetor top cover 1 6 Clamp air cl...

Page 215: ...eil 7 Klemme Vergaser Anschlu teil 1 Schrauben lockern Vergaser Anschlu teil 8 Vergaser 1 1 CARBURATEUR D poses effectuer 1 D pose du carburateur D poses effectuer Ordre Nom de pi ce Qt Remarques D PO...

Page 216: ...Refer to REMOVAL POINTS 3 Jet needle set 1 4 Carburetor top cover 1 5 Starter plunger 1 6 Float chamber 1 7 Float pivot pin 1 8 Float 1 9 Needle valve 1 0 Main jet washer 1 A Needle valve seat holder...

Page 217: ...UNKTE I Leerlaufeinstellschraube 1 J Leerlaufanreicherung 1 1 D MONTAGE DU CARBURATEUR D poses effectuer 1 D montage du carburateur D poses effectuer Ordre Nom de pi ce Qt Remarques D MONTAGE DU CARBU...

Page 218: ...MOVAL POINTS Throttle valve 1 Remove Throttle valve 1 Spring throttle valve 2 Carburetor top cover 3 Throttle cable 4 NOTE While compressing the spring throttle valve disconnect the throttle cable Pil...

Page 219: ...em Demontie ren leicht bis zum Anschlag hineindrehen und die Anzahl der Umdrehungen z hlen Diese Zahl als werkseitige Anzahl der Umdrehungen notieren REMARQUE altitude lev e la pression atmosph rique...

Page 220: ...ets with com pressed air Never use a wire 2 Inspect Main jet 1 Main jet nozzle 2 Pilot jet 3 NOTE Use a petroleum based solvent for cleaning Blow out all passages and jets with com pressed air Never u...

Page 221: ...lenbildung a Erneuern Staub b Reinigen HINWEIS Nadelventil und Nadelventilsitz immer kom plett erneuern INSPECTION Carburateur 1 Examiner Corps de carburateur Encrassement Nettoyer N B Nettoyer avec d...

Page 222: ...Below the float chamber mat ing surface Measurement and adjustment steps Connect the fuel level gauge 1 to the float chamber Fuel level gauge YM 1312 A 90890 01312 Hold the fuel level gauge vertically...

Page 223: ...htes Bie gen des Schwimmerhabels b eingestellt werden Kraftstoffstand erneut messen Boisseau 1 Contr ler Souplesse du mouvement Calage R parer ou remplacer N B Introduire le boisseau 1 dans le carbura...

Page 224: ...retor 1 Install Diaphragm 1 Spring 2 Cover 3 Screw 4 T R 2 Nm 0 2 m kg 1 4 ft lb LT 2 Install Throttle stop screw 1 Pilot air screw 2 3 Install Pilot air jet 1 1 Pilot air jet 2 2 Note the following i...

Page 225: ...e um die Anzahl der Umdrehungen herausdrehen die vor dem Demontieren notiert wurde Leerlaufluft Regulierschraube 2 1 2 3 1 2 Beispiel Flotteur 1 Examiner Flotteur 1 Endommagement Remplacer Enrichisseu...

Page 226: ...installing the needle valve to the float install them to the carburetor Check the float for smooth movement 6 Install Gasket Float chamber 1 Screw float chamber 2 7 Install Spring 1 Starter plunger 2...

Page 227: ...Support d aiguille 2 Sur le boisseau 3 N B Aligner les saillies a sur le boisseau et les gorges b du support d aiguille 4 Montieren Leerlaufd se 1 Hauptd senstock 2 Hauptd se 3 Nadelventilsitz 4 Nadel...

Page 228: ...Throttle valve 3 On throttle cable 4 NOTE While compressing the spring connect the throttle cable Carburetor installation 1 Install Carburetor assembly 1 NOTE Install the projection between the carbur...

Page 229: ...2 Festziehen Schraube Vergaser Verbindungsteil 1 Schraube Luftfilter Anschlu teil 2 9 Installer Cache sup rieur du carburateur 1 Ressort boisseau 2 Boisseau 3 Sur le c ble d acc l ration 4 N B Connect...

Page 230: ...op cover 1 Starter plunger 2 Air vent hose 3 Over flow hose 4 Fuel hose 5 NOTE Align the slit a of the throttle valve with the tab b of the carburetor body 4 Adjust Idle speed Refer to ENGINE IDLING S...

Page 231: ...corps du carburateur 4 R gler R gime de ralenti Se reporter R GLAGE DU R GIME DE RALENTI au CHAPITRE 3 CARBURATEUR VERGASER 3 Montieren Vergaserdeckel 1 Chokeschieber 2 Bel ftungsschlauch 3 berlaufsc...

Page 232: ...s CYLINDER HEAD SIDE COVER AND TAPPET COVER REMOVAL Preparation for removal Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Muffler Refer to MUFFLER section Carburetor Refer to CARB...

Page 233: ...ckel 1 4 Ventildeckel 2 5 Kurbelwellen Verschlu schraube 1 6 Z ndeinstell Verschlu schraube 1 1 CULASSE CACHE LAT RAL DE CULASSE ET COUVRE POUSSOIRS D poses effectuer 1 D pose du cache lat ral de cula...

Page 234: ...removal Extent of removal Order Part name Q ty Remarks CYLINDER HEAD REMOVAL 1 Bolt camshaft sprocket 1 Refer to REMOVAL POINTS 2 Bolt timing chain tensioner cap 1 3 Timing chain tensioner 1 4 Gasket...

Page 235: ...Deckel 1 3 Steuerkettenspanner 1 4 Dichtung 1 5 Nockenwellen Kettenrad 1 6 Zylinderkopf 1 7 Pa h lse 2 8 Dichtung 1 1 CULASSE D poses effectuer 1 D pose de la culasse D poses effectuer Ordre Nom de pi...

Page 236: ...ed with the stationary pointer the piston is at the Top Dead Center T D C NOTE In order to be sure that the piston is at Top Dead Center the match mark c on the camshaft sprocket must align with the s...

Page 237: ...mutter mit einem Schraubenschl ssel halten und Schraube demontieren 3 Demontieren Schraube Steuerkettenspanner Dek kel 1 Schraube Steuerkettenspanner 2 Steuerkettenspanner 3 PI CES D POSER Culasse 1 A...

Page 238: ...the bolts starting with the lowest number one INSPECTION Cylinder head 1 Eliminate Carbon deposits from the combustion chambers Use a rounded scraper NOTE Do not use a sharp instrument to avoid dam ag...

Page 239: ...t berschritten Planschlei fen Arbeitsschritte Lineal und F hlerlehre auf den Zylinder kopf legen Den Verzug messen 4 D poser Boulon pignon d arbre cames 1 Pignon d arbre cames 2 N B Attacher un fil m...

Page 240: ...side ASSEMBLY AND INSTALLATION Cylinder head 1 Install Dowel pin 1 Gasket 2 New 2 Install Cylinder head Copper washer Bolt cylinder head NOTE Apply Quick gasket YAMAHA Bond No 1215 on end of the cyli...

Page 241: ...Quick gasket ACC QUICK GS KT YAMAHA Dichtmasse Nr 1215 90890 85505 T R M8 22 Nm 2 2 m kg M6 10 Nm 1 0 m kg Limite de d formation 0 03 mm 0 0012 in Si la d formation est hors sp cifications surfa cer...

Page 242: ...inter b on the crankcase cover Align the match mark c on the camshaft sprocket with the stationary pointer d on the cylinder head Fit the timing chain 1 onto camshaft sprocket 2 and install the camsha...

Page 243: ...dernfalls zu Motorsch den oder einer ungenauen Ventilsteuerung kommt Den Sicherungsdraht von der Steuerkette entfernen 3 Installer Cha ne de distribution Pignon d arbre cames 4 Installer Rondelle Boul...

Page 244: ...se a thin screwdriver and wind the tensioner rod up fully clockwise With the rod fully wound install the gasket 1 and the chain tensioner 2 and tighten the bolts 3 to the specified torque T R Bolt cha...

Page 245: ...estziehen Schraube 1 HINWEIS Rotormutter mit einem Schraubenschl ssel festhalten und Schraube festziehen T R 20 Nm 2 0 m kg 5 Installer Tendeur de la cha ne de distribution 6 Tourner Vilebrequin De qu...

Page 246: ...y Engine oil On camshaft 11 Install Tappet cover 1 Cylinder head side cover 2 T R 18 Nm 1 8 m kg 13 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 12 Install Timing mark accessing screw 1 Crankshaft end accessing...

Page 247: ...Montieren Z ndkerze Motorhalterung T R 13 Nm 1 3 m kg T R 40 Nm 4 0 m kg 9 Contr ler Jeu de soupapes Hors sp cifications R gler Se reporter la section CONTR LE ET R GLAGE DU JEU DE SOUPAPES au CHAPITR...

Page 248: ...oval Order Part name Q ty Remarks CAMSHAFT AND ROCKER ARMS REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Camshaft bearing holder 1 2 Intake rocker arm shaft 1 Refer to...

Page 249: ...TE 3 Kipphebelwelle Ausla seite 1 4 Nockenwelle 1 Siehe unter DEMONTAGEPUNKTE 5 Kipphebel Einla seite 1 6 Kipphebel Ausla seite 1 1 2 ARBRE CAMES ET CULBUTEURS D poses effectuer 1 D pose de l arbre ca...

Page 250: ...890 01084 Camshaft 1 Remove Camshaft 1 Camshaft bearing 2 NOTE Screw in a suitable length of 8 mm bolt 3 into the threaded end of the camshaft and pull out the camshaft INSPECTION Camshaft 1 Inspect C...

Page 251: ...vorschriftsm ig Erneuern Nockenh he Grenzwert Einla a 25 851 mm b 21 165 mm Ausla a 25 811 mm b 21 020 mm PI CES D POSER Axes de culbuteur 1 D poser Axes de culbuteur N B Se servir d un boulon d extra...

Page 252: ...rocker arm 10 000 10 015 mm 0 3937 0 3943 in Limit 10 03 mm 0 3949 in Measure the outside diameter b of the rocker arm shafts Out of specification Replace Outside diameter rocker arm shaft 9 981 9 991...

Page 253: ...3 Auftragen Motor l auf die Kipphebelwelle 4 Montieren Kipphebelwelle Culbuteurs et axes de culbuteur 1 Examiner Surface de contact de bossage de came a Surface du dispositif de r glage 1 Usure piq r...

Page 254: ...4 23 ENG CAMSHAFT AND ROCKER ARMS 5 Install Camshaft bearing holder 1 Bolt 2 T R 10 Nm 1 0 m kg 7 2 ft lb LT...

Page 255: ...BRE CAMES ET CULBUTEURS NOCKENWELLE UND KIPPHEBEL 5 Montieren Nockenwellenlager Halter 1 Schraube 2 T R 10 Nm 1 0 m kg LT 5 Installer Support de roulement d arbre cames 1 Boulon 2 T R 10 Nm 1 0 m kg 7...

Page 256: ...Q ty Remarks VALVES AND VALVE SPRINGS REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section Camshaft and rocker arms Refer to CAMSHAFT AND ROCKER ARMS section 1 Valve cotter 4...

Page 257: ...Ventilfeder 2 4 Einla ventil 1 5 Ausla ventil 2 6 Ventilschaftdichtung 2 7 Ventilfedersitz 2 1 SOUPAPES ET RESSORTS DE SOUPAPE D poses effectuer 1 D poses des soupapes et des ressorts de soupape D po...

Page 258: ...als properly There should be no leakage at the valve seat 2 2 Remove Valve cotters 1 NOTE Attach a valve spring compressor 2 between the valve spring retainer and the cylinder head to remove the valve...

Page 259: ...upape 4 Si ge de ressort de soupape 5 N B Marquer la position de chaque pi ce avec soin afin de pouvoir les remonter dans leur position d origine DEMONTAGEPUNKTE Ventil 1 Kontrollieren Ventil Dichthei...

Page 260: ...e Replacement steps NOTE To ease guide removal installation and to maintain correct fit heat the cylinder head in an over to 100 C 212 F Remove the valve guide using a valve guide remover 1 Install th...

Page 261: ...hleifen INSPECTION Soupape 1 Mesurer Jeu de queue dans le guide Hors sp cifications Remplacer le guide de soupape Jeu de queue dans le guide de soupape diam tre int rieur de guide de soupape a diam tr...

Page 262: ...ce 5 Measure Runout valve stem Out of specification Replace NOTE When installing a new valve always replace the guide If the valve is removed or replaced always replace the oil seal Margin thickness I...

Page 263: ...und Ventilsitz 7 Kontrollieren Ventilsitze Pitting Bildung Verschlei Ventilsitz neu fr sen 3 Examiner Face de soupape Piq res usure Surfacer la face de sou pape Embout de queue de soupape En forme de...

Page 264: ...o the valve seat to make a clear pattern Measure the valve seat width Where the valve seat and valve face made contact blueing will have been removed If the valve seat is too wide too narrow or the se...

Page 265: ...gelangen Molybd ndisulfid auf den Ventilschaft auf tragen 8 Mesurer Largeur de si ge de soupape a Hors sp cifications Surfacer le si ge de soupape Largeur du si ge de soupape Admission 0 9 1 1 mm 0 0...

Page 266: ...lapping operation be sure to clean off all of the compound from the valve face and valve seat Apply Mechanic s blueing dye Dykem to the valve face Install the valve into the cylinder head Press the va...

Page 267: ...Nicht vorschriftsm ig Erneuern Ungespannte L nge Ventilfeder Einla 32 55 mm Grenzwert 31 2 mm Ausla 32 55 mm Grenzwert 31 2 mm Installer la soupape dans la culasse Tourner la soupape jusqu ce que la...

Page 268: ...1 kg at 25 6 mm 30 86 35 49 lb at 1 01 in Spring tilt limit Intake 2 5 1 4 mm 0 06 in Exhaust 2 5 1 4 mm 0 06 in ASSEMBLY AND INSTALLATION Valve 1 Apply Molybdenum disulfide oil onto the valve stem an...

Page 269: ...der gr eren Federteilung a nach oben montieren b Kleinere Federteilung New 2 Mesurer Force de ressort comprim a Hors sp cifications Remplacer b Longueur mont 3 Mesurer Inclinaison de ressort a Hors sp...

Page 270: ...valve spring with a valve spring compressor 2 install the valve cotters Valve spring compressor YM 4019 90890 04019 4 To secure the valve cotters onto the valve stem lightly tap the valve tip with a p...

Page 271: ...Klopfen auf die Ventil schaftenden k nnten die Ventile besch digt werden Ventilfederspanner YM 4019 90890 04019 3 Installer Clavettes de soupape 1 N B Installer les clavettes de soupape en comprimant...

Page 272: ...Order Part name Q ty Remarks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Exhaust timing chain guide 1 2 Cylinder O ring 1 1 3 Dowel pin 2 4 Gaske...

Page 273: ...benbolzensicherung 2 Siehe unter DEMONTAGEPUNKTE 6 Kolbenbolzen 1 7 Kolben 1 8 Kolbenring Satz 1 Siehe unter DEMONTAGEPUNKTE 1 2 CYLINDRE ET PISTON D poses effectuer 1 D pose du cylindre 2 D pose du p...

Page 274: ...pin hole area If the piston pin groove is deburred and the piston pin is still difficult to remove use the piston pin puller 4 CAUTION Do not use a hammer to drive the piston pin out Piston ring 1 Re...

Page 275: ...enbolzen Austreiber YU 1304 90890 01304 PR FEN Zylinder und Kolben 1 Kontrollieren Zylinder und Kolbenhemd Senkrechte Kratzer Zylinder und Kolben erneuern PI CES D POSER Piston 1 D poser Circlips d ax...

Page 276: ...T maximum of D1 or D2 maximum of D5 or D6 R maximum of D1 D3 or D5 minimum of D2 D4 or D6 If out of specification replace the cylinder and replace the piston and piston rings as set 2nd step Measure t...

Page 277: ...el 0 020 0 026 mm Grenzwert 0 15 mm 2 Mesurer Jeu entre piston et cylindre tapes de la mesure du jeu piston cylindre 1re tape Mesurer l al sage de cylindre C au moyen d un comparateur d al sage N B Me...

Page 278: ...cation system 2 Measure Piston pin to piston clearance Measurement steps Measure the piston pin outside diameter a If out of specification replace the piston pin Outside diameter piston pin 14 991 15...

Page 279: ...Kolbenbol zenauge 15 002 15 013 mm Grenzwert 15 043 mm Si la valeur obtenue ne correspond pas aux sp cifications remplacer le cylindre et rempla cer la fois le piston et ses segments Axe de piston 1...

Page 280: ...ton ring in cylinder NOTE Insert a ring into the cylinder and push it approximately 40 mm 1 57 in into the cylin der Push the ring with the piston crown so that the ring will be at a right angle to th...

Page 281: ...onsring 0 30 0 45 mm 0 55 mm lab streifring 0 20 0 70 mm Segment de piston 1 Mesurer Jeu lat ral de segment Utiliser une cale d paisseur Hors sp cifications Remplacer la fois le piston et les segments...

Page 282: ...er size A 54 000 54 003 mm 2 1260 2 1261 in B 54 004 54 007 mm 2 1261 2 1263 in C 54 008 54 011 mm 2 1263 2 1264 in D 54 012 54 015 mm 2 1265 2 1266 in E 54 016 54 019 mm 2 1266 2 1267 in Cylinder mar...

Page 283: ...D D violett E E blau Combinaisons de piston et cylindre 1 Contr ler Rep re sur le cylindre a 2 Contr ler Rep re sur le piston a 3 Combiner Combiner un piston et un cylindre en sui vant le tableau ci...

Page 284: ...own a Top ring end b 2nd ring end c Oil ring end upper d Oil ring end lower 3 Install Piston 1 Piston pin 2 Piston pin clips 3 NOTE Apply engine oil onto the piston pin piston rings and piston Be sure...

Page 285: ...ren Kolben Kolbenringe Zylinderlauffl che HINWEIS Reichlich Motor l auftragen New ASSEMBLAGE ET REPOSE Segments et piston 1 Installer Segments de piston sur le piston N B S assurer d installer le segm...

Page 286: ...t timing chain guide CAUTION Install the cylinder with one hand while compressing the piston rings with the other hand Pass the timing chain through the cylin der timing chain cavity Be careful not to...

Page 287: ...rf bei der Montage nicht besch digt werden HINWEIS Nach der Montage die Leichtg ngigkeit des Kolbens pr fen New Cylindre 1 Installer Goujons 1 Joint cylindre 2 New 2 Installer Joint torique Cylindre 1...

Page 288: ...e Q ty Remarks CLUCTH PLATE AND FRIC TION PLATE REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Engine skidplate Refer to ENGINE REMOVAL s...

Page 289: ...te 1 7 Kugel 1 8 Reibscheibe 5 9 Kupplungsscheibe 4 10 Mutter Unterlegscheibe 1 1 11 Druckstange 1 1 12 Druckplatte 1 1 EMBRAYAGE ET PIGNON MEN PRIMAIRE DISQUES D EMBRAYAGE ET DE FRICTION D poses effe...

Page 290: ...xtent of removal Order Part name Q ty Remarks PRIMARY DRIVEN GEAR REMOVAL 1 Nut clutch boss 1 Use special tool Refer to REMOVAL POINTS 2 Lock washer 1 3 Clutch boss 1 4 Thrust plate 1 5 Primary driven...

Page 291: ...porter PI CES D POSER 9 Pignon menant primaire 1 10 Clavette droite 1 2 1 EMBRAYAGE ET PIGNON MEN PRIMAIRE KUPPLUNG UND PRIM RABTRIEBSZAHNRAD PRIM RABTRIEBSZAHNRAD Demontage Arbeiten 1 Prim rabtriebsz...

Page 292: ...CH AND PRIMARY DRIVEN GEAR PUSH LEVER Extent of removal 1 Push lever removal Extent of removal Order Part name Q ty Remarks PUSH LEVER REMOVAL 1 Clutch cable 1 2 Push lever 1 3 Spring 1 4 Circlip 1 5...

Page 293: ...e Bauteil Anz Bemerkungen AUSR CKHEBEL DEMONTIE REN 1 Kupplungszug 1 2 Ausr ckhebel 1 3 Feder 1 4 Sicherungsring 1 5 Dichtring 1 1 LEVIER DE POUSS E D poses effectuer 1 D pose du levier de pouss e D p...

Page 294: ...6 Primary drive gear 1 Remove Nut primary drive gear 1 Primary drive gear 2 NOTE Place a folded rag or aluminum plate between the teeth of the primary drive gear and primary driven gear Take care not...

Page 295: ...n Verschlei Besch digung Erneuern Prim rabtriebszahnrad 1 Kontrollieren Umfangsspiel Spiel vorhanden Erneuern Zandrad Z hne a Verschlei Besch digung Erneuern PI CES D POSER Noix d embrayage 1 D poser...

Page 296: ...plate 1 Measure Friction plate thickness Out of specification Replace friction plate as a set Measure at all four points EC484600 Clutch plate 1 Measure Clutch plate warpage Out of specification Repla...

Page 297: ...Grenzwert 2 8 mm Verzugsgrenze 0 2 mm Ressort d embrayage 1 Mesurer Longueur libre de ressort d embrayage a Hors sp cifications Remplacer tous les ressorts Longueur libre de ressort d embrayage 33 mm...

Page 298: ...ush lever 1 NOTE Apply the lithium soap base grease on the oil seal lip Apply the engine oil on the push lever Primary drive gear 1 Install Straight key Primary drive gear 1 Washer 2 Nut primary drive...

Page 299: ...umplatte 5 zwischen die Z hne des Prim rantriebszahnrades und des Pri m rabtriebszahnrades stecken T R 70 Nm 7 0 m kg Tige de commande 1 Examiner Tige de commande 1 1 Bille 2 Usure endommagement d for...

Page 300: ...holding tool YM 91042 90890 04086 New T R 60 Nm 6 0 m kg 43 ft lb 4 Install Friction plate 1 Clutch plate 2 NOTE Install the clutch plates and friction plates alternately on the clutch boss starting...

Page 301: ...z von etwa 90 zur Nase der vorhergehen den Scheibe montieren Im Uhrzeigersinn vorgehen bis alle Kupplungsscheiben mon tiert sind Embrayage 1 Installer Rondelle lastique conique 1 Plaque de pouss e 2 P...

Page 302: ...Bolt clutch spring 3 NOTE Align the arrow mark a on the pressure plate with the punched mark b on the clutch boss Tighten the bolts in stage using a crisscross pattern T R 6 Nm 0 6 m kg 4 3 ft lb 8 Ch...

Page 303: ...ichtet sind Einstellen a Markierung auf dem Ausr ckhebel b Markierung auf dem Kurbelgeh use 5 Installer Bille N B Enduire la bille d huile de moteur 6 Installer Tige de commande 1 1 Plaque de pouss e...

Page 304: ...l pins Gasket right crankcase cover Right crankcase cover Bolts right crankcase cover NOTE Apply Quick gasket YAMAHA Bond No 1215 to end of the right crankcase cover bolts as shown Tighten the bolts i...

Page 305: ...n da ein Abstand von 5 10 mm a zwischen der Kick starterkurbel und dem rechten Kurbelgeh use deckel besteht T R 50 Nm 5 0 m kg 9 R gler Position du levier de pouss e tapes du r glage Desserrer le cont...

Page 306: ...l Extent of removal Order Part name Q ty Remarks OIL PUMP REMOVAL Preparation for removal Clutch and primary drive gear Refer to CLUTCH AND PRIMARY DRIVEN GEAR section 1 Rotary filter 1 2 Oil pump dri...

Page 307: ...ifugalfilter 1 2 lpumpen Antriebsrad 1 3 lpumpe komplett 1 4 Dichtung 1 5 lpumpensieb 1 1 POMPE HUILE D poses effectuer 1 D pose de la pompe huile D poses effectuer Ordre Nom de pi ce Qt Remarques D P...

Page 308: ...assembly Extent of removal Order Part name Q ty Remarks OIL PUMP DISASSEMBLY 1 Circlip 1 2 Oil pump driven gear 1 3 Conical spring washer 1 4 Circlip 1 5 Washer 1 6 Oil pump cover 1 7 Pin 2 8 Oil pump...

Page 309: ...lle 1 9 Stift 1 0 Innenrotor 1 A Au enrotor 1 B lpumpengeh use 1 1 D MONTAGE DE LA POMPE HUILE D poses effectuer 1 D montage de la pompe huile D poses effectuer Ordre Nom de pi ce Qt Remarques D MONTA...

Page 310: ...the oil pump housing 3 Out of specification Replace the oil pump assembly Housing and rotor clearance between the pump housing 3 and the rotors 1 2 Out of specification Replace the oil pump assembly T...

Page 311: ...trollieren Zentrifugalfilter Risse Besch digung Erneuern INSPECTION Pompe huile 1 Examiner Pignon menant de pompe huile Pignon men de pompe huile Logement de la pompe huile Couvercle de pompe huile Cr...

Page 312: ...o the outer rotor inner rotor and oil pump shaft Install the conical spring washer in the direc tion as shown 2 Install Oil strainer Gasket Oil pump assembly Screws oil pump assembly NOTE Apply engine...

Page 313: ...0 5 m kg New T R 7 Nm 0 7 m kg Cr pine huile 1 Examiner Cr pine huile Craquelures endommagement Rempla cer Crasses obstructions Nettoyer ASSEMBLAGE ET REPOSE Pompe huile 1 Installer Logement de la po...

Page 314: ...ND SHIFT SHAFT REMOVAL Preparation for removal Shift pedal link Refer to ENGINE REMOVAL section Clutch Refer to CLUTCH AND PRIMARY DRIVEN GEAR section 1 Kick axle assembly 1 Refer to REMOVAL POINTS 2...

Page 315: ...9 R ckholfeder 1 10 Schraube Kickstarter Anschlag 1 11 Kickstarter Anschlag 1 12 Feder 1 13 Kickstarter Zahnsegment 1 Siehe unter DEMONTAGEPUNKTE 1 2 AXE DE KICK ET ARBRE DE S LECTEUR AXE DE KICK ET...

Page 316: ...le and kickstarter segment gear 1 Check Kickstarter segment gear smooth movement Unsmooth movement Replace 2 Inspect Kick axle 1 Wear damage Replace Kickstarter segment gear and kick idle gear 1 Inspe...

Page 317: ...kstarterritzel Clip 1 Messen Kickstarterritzel Clip Friktionskraft R ckholfeder Nicht vorschriftsm ig Erneuern Dynamometer 1 verwenden Kickstarterritzel Clip Friktionskraft 0 65 1 35 kg PI CES D POSER...

Page 318: ...g 2 Broken Replace EC4C5000 ASSEMBLY AND INSTALLATION Segment 1 Install Segment 1 Screw segment 2 NOTE Align the notch a on the segment with the pin b on the shift cam Tighten the screw using the T30...

Page 319: ...eder 3 HINWEIS Kickstarter Anschlag Rolle auf den Schlitz im Kickstarter Zahnsegment ausrichten T R 12 Nm 1 2 m kg LT T R 10 Nm 1 0 m kg LT Arbre de s lecteur 1 Examiner Arbre de s lecteur 1 D formati...

Page 320: ...of the torsion spring fits into the hole b on the kick axle 2 Install Spring guide 1 NOTE Slide the spring guide into the kick axle make sure the groove a in the spring guide fits on the stopper of th...

Page 321: ...Einh ngen R ckholfeder 1 HINWEIS R ckholfeder im Uhrzeigersinn drehen und in die entsprechende Bohrung a im Kurbelge h use einh ngen Arbre de s lecteur 1 Installer Arbre de s lecteur 1 N B Enduire le...

Page 322: ...FT SHAFT Kick idle gear 1 Install Circlip 1 Washer 2 Kick idle gear 3 Washer 4 Circlip 5 NOTE Apply the engine oil on the kick idle gear inner circumference Install the kick idle gear with its depress...

Page 323: ...Motor l auf das gesamte Kickstarterritzel auftragen Kickstarterritzel mit der flachen Seite nach au en montieren New New Pignon libre de kick 1 Installer Circlip 1 Rondelle 2 Pignon libre de kick 3 Ro...

Page 324: ...l Seat and fuel tank Refer to SAET FUEL TANK AND SIDE COVERS section Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Drive sprocket cover Refer to ENGINE REMOVAL section...

Page 325: ...verwenden Siehe unter DEMONTAGEPUNKTE 4 Rotor 1 5 Scheibenfeder 1 6 Aufnahmespule 1 7 Kabelf hrung 1 8 Stator 1 1 MAGN TO CDI D poses effectuer 1 D pose de la magn to CDI D poses effectuer Ordre Nom d...

Page 326: ...o 1 Inspect Rotor inner surface a Stator outer surface b Damage Inspect the crankshaft runout and crankshaft bearing If necessary replace CDI magneto and or stator EC4L4200 Woodruff key 1 Inspect Wood...

Page 327: ...R 10 Nm 1 0 m kg LT T R 7 Nm 0 7 m kg LT T R 10 Nm 1 0 m kg LT MAGN TO CDI LICHTMASCHINENROTOR PI CES D POSER Rotor 1 D poser crou rotor 1 Rondelle plate 2 Se servir d une cl sangle 3 Cl sangle YS 188...

Page 328: ...ing the rotor align the keyway of the rotor with the woodruff key 3 Install Plain washer 1 Nut rotor 2 Use the sheave holder 3 Sheave holder YS 1880 A 90890 01701 T R 80 Nm 8 0 m kg 58 ft lb 4 Install...

Page 329: ...se ber Kreuz festziehen New T R 10 Nm 1 0 m kg 5 Anschlie en Lichtmaschinenrotor Kabel Siehe unter KABELF HRUNG in KAPITEL 2 2 Installer Clavette demi lune 1 Rotor 2 N B Nettoyer la partie conique du...

Page 330: ...machine by placing the suitable stand under the frame Seat fuel tank and side covers Refer to SEAT FUEL TANK AND SIDE COVERS section Carburetor Refer to CARBURETOR section Muffler Refer to MUFFLER sec...

Page 331: ...enstecker Lichtmaschinenrotor Kabel abtrennen Motor l ablassen Siehe unter MOTOR L WECHSELN in KAPITEL 3 D POSE DU MOTEUR D poses effectuer 1 D pose du moteur D poses effectuer Ordre Nom de pi ce Qt R...

Page 332: ...over 1 2 Bolt drive sprocket 2 Refer to REMOVAL POINTS 3 Drive sprocket holder 1 4 Drive sprocket 1 5 Shift pedal link 1 6 Crankcase breather hose 1 7 Engine bracket upper 1 8 Engine skidplate 1 9 Eng...

Page 333: ...wannenschutz 1 9 Motorhalterung vorne 1 10 Motorbefestigungsschraube hinten 2 11 Motor 1 Siehe unter DEMONTAGEPUNKTE 1 D poses effectuer Ordre Nom de pi ce Qt Remarques 1 Cache de pignon menant 1 2 Bo...

Page 334: ...les are disconnected ASSEMBLY AND INSTALLATION Engine installation 1 Install Engine 1 Install the engine from left side Engine mounting bolt rear 2 Engine bracket front 3 Bolt engine bracket 4 Engine...

Page 335: ...40 Nm 4 0 m kg T R 40 Nm 4 0 m kg T R 40 Nm 4 0 m kg T R 40 Nm 4 0 m kg T R 40 Nm 4 0 m kg PI CES D POSER Pignon menant 1 D poser Boulon pignon menant Support de pignon menant 1 Pignon menant 2 Cha ne...

Page 336: ...olt shift pedal link 2 NOTE Adjust the center a of the front end of the shift pedal to match the highest point of the foot rest T R 10 Nm 1 0 m kg 7 2 ft lb Drive sprocket 1 Install Drive sprocket 1 D...

Page 337: ...Deckel 1 Schraube Antriebsritzel Deckel 2 T R 12 Nm 1 2 m kg N B Enduire le filet des boulons de montage du moteur 2 de graisse base de savon au lithium Serrer le boulon de montage du moteur sup rieu...

Page 338: ...emoval Order Part name Q ty Remarks CRANKCASE CRANKSHAFT AND BALANCER REMOVAL Preparation for removal Engine Refer to ENGINE REMOVAL section Piston Refer to CYLINDER AND PISTON sec tion Primary drive...

Page 339: ...ND PRI M RABTRIEBSZAHNRAD Kickstarterwelle komplett Siehe unter KICKSTARTERWELLE UND SCHALTWELLE Kickstarter Zahnsegment Rotor und Stator Siehe unter LICHTMASCHINENRO TOR CARTER MOTEUR VILEBREQUIN ET...

Page 340: ...1 2 Timing chain 1 3 Bolt 45 mm 1 8 in 7 4 Bolt 55 mm 2 2 in 1 5 Bolt 30 mm 1 2 in 2 6 Lead guide 1 7 Clutch cable holder 1 8 Right crankcase 1 Use special tool Refer to REMOVAL POINTS 9 Left crankcas...

Page 341: ...gleichswelle 1 11 Kurbelwelle 1 Spezialwerkzeug verwenden Siehe unter DEMONTAGEPUNKTE 12 Lager 3 Siehe unter DEMONTAGEPUNKTE 3 2 1 D poses effectuer Ordre Nom de pi ce Qt Remarques 1 Patin de cha ne d...

Page 342: ...case If necessary one screw may be backed out slightly to level tool body As pressure is applied alternately tap on the front engine mounting boss and transmission shafts CAUTION Use soft hammer to t...

Page 343: ...lften nicht trennen lassen mu gepr ft werden ob eine Geh u seschraube oder befestigung vergessen wurde Keinesfalls rohe Kraft anwenden Kurbelgeh use Trennwerkzeug YU 1135 A 90890 01135 PI CES D POSER...

Page 344: ...kcase separating tool YU 1135 A 90890 01135 Bearing 1 Remove Bearing 1 NOTE Remove the bearing from the crankcase by pressing its inner race as shown in Do not use the removed bearing INSPECTION Timin...

Page 345: ...eifheit Steuerkette und Nok kenwellen Kettenrad komplett erneu ern 2 Kontrollieren Steuerkettenf hrung Verschlei Besch digung Erneuern Vilebrequin 1 D poser Vilebrequin 1 Se servir d un s parateur de...

Page 346: ...with a finger Rough spot seizure Replace Crankshaft 1 Measure Runout limit a Connecting rod big end side clearance b Crank width c Out of specification Replace Use the dial gauge and a thickness gaug...

Page 347: ...wert Max Schlag 0 03 mm Axial spiel 0 15 0 45 mm 0 50 mm Kurbel breite 46 95 47 00 mm Carter moteur 1 Examiner Plan de joint a Rayures Remplacer Noix de montage du moteur b Craquelures endommagement R...

Page 348: ...cept for USA and CDN NOTE Hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other Operate the installing tool until the crankshaft bottoms...

Page 349: ...3 YU 90050 90890 01275 Adapter 4 YU 90063 90890 01278 Distanzh lse 5 YM 91044 90890 04081 Balancier 1 Examiner Balancier Craquelures endommagement Rempla cer ASSEMBLAGE ET REPOSE Roulement 1 Installer...

Page 350: ...crankcase 1 NOTE Clean the contacting surface of crankcase left and right before applying the sealant Quick gasket ACC QUICK GS KT YAMAHA Bond No 1215 90890 85505 2 Install Dowel pin 1 Right crankcas...

Page 351: ...seh lfte aufsetzen Vorsichtig mit einem weichen Hammer auf die Geh u seh lfte klopfen Bei der Montage des Kurbelgeh uses sollte sich die Pleuelstange im oberen Totpunkt TDC befinden 2 Installer Balanc...

Page 352: ...ankcase bolts 45 mm 1 8 in 3 as shown Tighten the crankcase bolts in stage using a crisscross pattern Quick gasket ACC QUICK GS KT YAMAHA Bond No 1215 90890 85505 T R 10 Nm 1 0 m kg 7 2 ft lb T R 10 N...

Page 353: ...Einla seite 2 Schraube Steuerkettenf hrung Ein la seite T R 10 Nm 1 0 m kg LT 3 Serrer Guide de fil 1 Support de c ble d embrayage 2 Boulon carter moteur 45 mm 1 8 in 3 Boulon carter moteur 55 mm 2 2...

Page 354: ...Remarks TRANSMISSION SHIFTCAM AND SHIFT FORK REMOVAL Preparation for removal Engine Refer to ENGINE REMOVAL section Separate the crankcase Refer to CRANKCASE CRANKSHAFT AND BALANCER section 1 Shift f...

Page 355: ...swelle 1 Siehe unter DEMONTAGEPUNKTE 8 Ausgangswelle 1 9 Druckstange 2 1 10 Anlaufscheibe 1 1 2 BO TE DE VITESSES TAMBOUR ET FOURCHETTES DE S LECTION D poses effectuer 1 D pose du tambour et des fourc...

Page 356: ...mmer to remove Remove assembly carefully Note the posi tion of each part Pay particular attention to the location and direction of shift forks EC4H4000 INSPECTION EC4H4200 Gears 1 Inspect Matching dog...

Page 357: ...ge 2 1 Verschlei Besch digung Verbiegung Erneuern PI CES D POSER Bo te de vitesses 1 D poser Arbre primaire 1 Arbre secondaire 2 N B D poser l arbre secondaire de la bo te de vitesse en le tapotant l...

Page 358: ...hift cam 1 Inspect Shift fork 1 Wear damage scratches Replace 2 Inspect Shift cam 1 Shift fork guide bar 2 Bend wear damage Replace 3 Check Shift fork movement On its guide bar Unsmooth operation Repl...

Page 359: ...die sich neben der Schaltgabel befinden Roulement 1 Examiner Roulement 1 Faire tourner la cage interne avec un doigt Duret grippage Remplacer Fourchette de s lection et tambour 1 Examiner Fourchette d...

Page 360: ...xle 5 NOTE Apply the molybdenum disulfide oil on the gears inner circumference Install the 5th pinion gear so that measure ment a is 83 25 83 45 mm 3 278 3 285 in 2 Install 2nd wheel gear 32T 1 5th wh...

Page 361: ...f den Innenring der Zahn r der auftragen Bo te de vitesses 1 Installer 4e pignon menant 22T 1 3e pignon menant 19T 2 2e pignon menant 18T 3 5e pignon menant 24T 4 Sur l arbre primaire 5 N B Enduire la...

Page 362: ...end c is positioned at axle spline groove d New 4 Install Push rod 2 On main axle NOTE Apply the engine oil on the push rod 2 5 Install Washer 1 On drive axle 6 Install Main axle Drive axle Install t...

Page 363: ...et werden da die Dichtlippe des Kurbelge h use Dichtrings nicht besch digt wird 3 Installer Rondelle plate 1 Circlip 2 N B S assurer de diriger le c t ouvert a du circlip du c t oppos de la rondelle e...

Page 364: ...he drive axle Mesh the shift fork 2 C with the 3rd pinion gear on the main axle 2 Install Shift cam 1 NOTE Apply the engine oil on the shift cam 3 Install Shift fork guide bar 1 short 1 Shift fork gui...

Page 365: ...eren Tambour et fourchette de s lection 1 Installer Fourchette de s lection 1 L 1 Fourchette de s lection 2 C 2 Fourchette de s lection 3 R 3 N B Engrener la fourchette de s lection n 1 L avec le 2e p...

Page 366: ...e Q ty Remarks Preparation for removal FRONT WHEEL AND DRUM BRAKE Hold the machine by placing the suitable stand under the engine WARNING Support the machine securely so there is no danger of it falli...

Page 367: ...mit sie nicht umfallen kann 2 3 1 ROUE AVANT ET FREIN AVANT TT R125 VORDERRAD UND VORDERRADBREMSE TT R125 PARTIE CYCLE ROUE AVANT ET FREIN AVANT TT R125 D poses effectuer 1 D pose de la roue avant 2 D...

Page 368: ...FRONT WHEEL AND FRONT BRAKE TT R125 Extent of removal Order Part name Q ty Remarks 11 Brake shoe 2 12 Spring 2 13 Brake camshaft lever 1 14 Wear indicator plate 1 15 Brake camshaft 1 16 Brake shoe pl...

Page 369: ...ebel 1 14 Verschlei anzeige 1 15 Bremsnocken 1 16 Bremsankerplatte 1 3 ROUE AVANT ET FREIN AVANT TT R125 VORDERRAD UND VORDERRADBREMSE TT R125 D poses effectuer Ordre Nom de pi ce Qt Remarques 11 M ch...

Page 370: ...unout limit Radial 1 2 0 mm 0 08 in Lateral 2 2 0 mm 0 08 in 2 Inspect Bearing Rotate inner race with a finger Rough spot seizure Replace NOTE Replace the bearings oil seal and wheel collar as a set E...

Page 371: ...g 0 5 mm ROUE AVANT ET FREIN AVANT TT R125 VORDERRAD UND VORDERRADBREMSE TT R125 PI CES D POSER Roulement de roue si n cessaire 1 D poser Roulement 1 N B D poser le roulement l aide de l extracteur de...

Page 372: ...ce NOTE Replace the brake shoes and springs as a set if either is worn to the limit Brake shoe lining thickness Standard Limit 40 mm 0 16 in 2 0 mm 0 08 in 3 Measure Brake drum inside diameter a Out o...

Page 373: ...chm ig polieren ROUE AVANT ET FREIN AVANT TT R125 VORDERRAD UND VORDERRADBREMSE TT R125 Frein tambour 1 Examiner Surface de garniture de m choire de frein Zones brillantes Poncer Utiliser du papier de...

Page 374: ...tor plate 1 NOTE When installing the wear indicator plate to the brake camshaft align the projection a on the wear indicator plate with the slots b on the brake camshaft 4 Install Brake camshaft lever...

Page 375: ...bel ge auftra gen T R 10 Nm 1 0 m kg New ROUE AVANT ET FREIN AVANT TT R125 VORDERRAD UND VORDERRADBREMSE TT R125 REMONTAGE ET INSTALLATION Flasque de frein complet 1 Installer Came de frein 1 N B Endu...

Page 376: ...am eter of the race of the bearing Left side of wheel bearing shall be installed first Install the oil seal with its manufacture s marks or numbers facing outward CAUTION Do not strike the inner race...

Page 377: ...R125 VORDERRAD UND VORDERRADBREMSE TT R125 Roue avant 1 Installer Roulement de roue 1 Entretoise 2 Roulement de roue 3 Bague d tanch it 4 N B Enduire le roulement de roue et la l vre de la bague d ta...

Page 378: ...R 45 Nm 4 5 m kg 32 ft lb 6 Install Brake cable NOTE Brake camshaft lever side of brake cable shall be installed first 7 Install Brake cable holder 1 T R 7 Nm 0 7 m kg 5 1 ft lb 8 Adjust Brake lever...

Page 379: ...nter VORDERRADBREMSE EINSTELLEN IN KAPITEL 3 ROUE AVANT ET FREIN AVANT TT R125 VORDERRAD UND VORDERRADBREMSE TT R125 5 Installer crou d axe 1 T R 45 Nm 4 5 m kg 32 ft lb 6 Installer C ble de frein N B...

Page 380: ...Preparation for removal FRONT WHEEL REMOVAL Hold the machine by placing the suitable stand under the engine WARNING Support the machine securely so there is no danger of it falling over 1 Axle nut 1 2...

Page 381: ...ager 2 Siehe unter DEMONTAGEPUNKTE 8 Distanzst ck 1 9 Bremsscheibe 1 2 3 1 3 ROUE AVANT TT R125LW VORDERRAD TT R125LW ROUE AVANT TT R125LW D poses effectuer 1 D pose de la roue avant 2 D pose des roul...

Page 382: ...ing Rotate inner race with a finger Rough spot seizure Replace NOTE Replace the bearings oil seal and wheel collar as a set Wheel runout limit Radial 1 2 0 mm 0 08 in Lateral 2 2 0 mm 0 08 in EC514200...

Page 383: ...ne verbogene Achse zu richten Maximal zul ssige Achsbiegung 0 5 mm PI CES D POSER Roulement de roue si n cessaire 1 D poser Roulement 1 N B D poser le roulement l aide d un extracteur de roulements un...

Page 384: ...AND INSTALLATION Front wheel 1 Install Wheel bearing 1 Spacer 2 Wheel bearing 3 Oil seal 4 NOTE Apply the lithium soap base grease on the wheel bearing and oil seal lip when installing Install the whe...

Page 385: ...de frein 1 Mesurer D formation du disque de frein Utiliser un comparateur cadran 1 Hors sp cifications V rifier la d forma tion de la roue Si la d formation de la roue est dans les limites remplacer...

Page 386: ...T R 12 Nm 1 2 m kg 8 7 ft lb LT 3 Install Collar 1 NOTE Apply the lithium soap base grease on the oil seal lips Install the longer collar on the brake disc 2 side 4 Install Front wheel NOTE Install t...

Page 387: ...hren 5 Montieren Radachse 1 6 Montieren Unterlegscheibe 1 Achsmutter 2 T R 45 Nm 4 5 m kg 2 Installer Disque de frein 1 Boulon disque de frein 2 N B Serrer les boulons par tapes et dans un ordre entr...

Page 388: ...he machine by placing the suitable stand under the engine Drain the brake fluid WARNING Support the machine securely so there is no danger of it falling over Refer to REMOVAL POINTS 1 Brake hose holde...

Page 389: ...l 1 Siehe unter AUSBAU 7 Handbremshebel 1 8 Hauptbremszylinder Halterung 1 9 Hauptbremszylinder 1 2 3 1 3 2 FREIN AVANT TT R125LW D poses effectuer 1 D pose du flexible de frein 2 D pose de l trier de...

Page 390: ...SEMBLY Hold the machine by placing the suitable stand under the engine WARNING Support the machine securely so there is no danger of it falling over 1 Brake pad 2 2 Brake caliper bracket 1 3 Brake ca...

Page 391: ...Membran 1 0 Staubschutzkappe 1 A Sicherungsring 1 B Unterlegscheibe 1 C Hauptbremszylinder Bauteile 1 2 1 D MONTAGE DE L TRIER ET DU MA TRE CYLINDRE DE FREIN D poses effectuer 1 D montage de l trier...

Page 392: ...parts Always clean up spilled fluid immediately Brake caliper 1 Remove Brake caliper 1 NOTE Turn the brake caliper counterclockwise and pull out it from the guide pin 2 on the brake caliper bracket B...

Page 393: ...Bremssattelkolben vorsichtig mit Druckluft aus dem Bremssattel heraus pressen FREIN AVANT TT R125LW VORDERRADBREMSE TT R125LW PI CES D POSER Liquide de frein 1 D poser Couvercle de ma tre cylindre de...

Page 394: ...s WARNING Replace the brake caliper piston seals and brake caliper dust seals whenever a brake caliper is disassembled INSPECTION Brake master cylinder 1 Inspect Brake master cylinder inner surface a...

Page 395: ...ptbremszylinder Bauteile erneuern Joints de piston d trier de frein 1 D poser Joint antipoussi re d trier de frein 1 Joint de piston d trier de frein 2 N B Retirer les joints de piston d trier et les...

Page 396: ...rake caliper piston seals and brake caliper dust seals 2 whenever a brake caliper is disassembled 3 Inspect Brake caliper bracket 1 Cracks damage Replace the brake caliper assembly Guide pin 2 Rust da...

Page 397: ...FREIN AVANT TT R125LW VORDERRADBREMSE TT R125LW trier de frein 1 Examiner Surface int rieure du cylindre d trier de frein a Endommagement striation par usage Remplacer l trier de frein complet 2 Exam...

Page 398: ...al Brake caliper piston Clean them with brake fluid 2 Install Brake caliper piston seal 1 Brake caliper dust seal 2 WARNING Always use new brake caliper piston seals and brake caliper dust seals NOTE...

Page 399: ...teschraube 1 Auf Bremssattel Halterung 2 aufset zen FREIN AVANT TT R125LW VORDERRADBREMSE TT R125LW REMONTAGE ET INSTALLATION AVERTISSEMENT Nettoyer les pi ces internes exclusivement avec du liquide d...

Page 400: ...Nm 3 0 m kg 22 ft lb 4 Install Brake caliper 1 NOTE Apply the lithium soap base grease on the guide pin 2 Install the brake caliper into the guide pin and turn it clockwise 5 Install Brake caliper sup...

Page 401: ...l ssigkeit reinigen FREIN AVANT TT R125LW VORDERRADBREMSE TT R125LW 2 Installer Manchon sup rieur 1 sur l trier de frein 2 N B Enduire la surface interne du manchon sup rieur de graisse base de savon...

Page 402: ...inder cup should be installed as shown direction Wrong instal lation cause improper brake performance 3 Install Spring 1 On brake master cylinder piston 2 NOTE Install the spring at the smaller diamet...

Page 403: ...age des Sicherungsrings eine Zange mit langen Backen verwenden FREIN AVANT TT R125LW VORDERRADBREMSE TT R125LW 2 Installer Coupelle primaire de ma tre cylindre de frein 1 Coupelle secondaire de ma tre...

Page 404: ...ring 2 Bolt brake lever 3 Nut brake lever 4 NOTE Apply the lithium soap base grease on the bolt and brake lever sliding surface Apply the molybdenum disulfide grease on the tip of the adjuster bolt T...

Page 405: ...125LW VORDERRADBREMSE TT R125LW Ma tre cylindre de frein 1 Installer Ma tre cylindre de frein 1 Demi palier de fixation de ma tre cylindre de frein 2 Boulon demi palier de fixation de ma tre cylindre...

Page 406: ...3 WARNING Always use a new copper washer NOTE When turning the joint over the brake hose hold the brake hose so that it may not be twisted New T R 26 Nm 2 6 m kg 19 ft lb T R 14 Nm 1 4 m kg 10 ft lb 4...

Page 407: ...Schrauben Bremsschlauch Halterung 2 T R 7 Nm 0 7 m kg FREIN AVANT TT R125LW VORDERRADBREMSE TT R125LW 2 Faire passer le flexible de frein par le guide de c ble 1 3 Installer Rondelle en cuivre 1 Racc...

Page 408: ...performance Be careful that water does not enter the brake master cylinder when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock CAUTION Brake fluid...

Page 409: ...in KAPI TEL 3 FREIN AVANT TT R125LW VORDERRADBREMSE TT R125LW Liquide de frein 1 Verser Liquide de frein jusqu ce que le niveau du liquide atteigne la ligne LOWER a AVERTISSEMENT Utiliser exclusivemen...

Page 410: ...master cylinder cap 2 CAUTION After installation while pulling in the lever check whether there is any brake fluid leak ing where the union bolts are installed respectively at the brake master cylinde...

Page 411: ...emsfl ssigkeit austritt T R 2 Nm 0 2 m kg FREIN AVANT TT R125LW VORDERRADBREMSE TT R125LW 4 Installer Diaphragme Couvercle de ma tre cylindre de frein 1 Vis couvercle de ma tre cylindre de frein 2 ATT...

Page 412: ...l REAR WHEEL AND DRUM BRAKE Hold the machine by placing the suitable stand under the engine WARNING Support the machine securely so there is no danger of it falling over 1 Brake rod 1 2 Axle nut 1 3 D...

Page 413: ...emsankerplatte 1 10 Distanzh lse links 1 2 3 1 ROUE ARRI RE ET FREIN ARRI RE HINTERRAD UND HINTERRADBREMSE ROUE ARRI RE ET FREIN ARRI RE D poses effectuer 1 D pose de la roue arri re 2 D pose des roul...

Page 414: ...ut wheel sprocket 4 12 Wheel sprocket 1 13 Oil seal 1 14 Wheel bearing 2 Refer to REMOVAL POINTS 15 Spacer 1 16 Brake shoe 2 17 Spring 2 18 Brake camshaft lever 1 19 Wear indicator plate 1 20 Brake ca...

Page 415: ...elag 2 17 Feder 2 18 Bremsnocken Bet tigungshebel 1 19 Verschlei anzeiger 1 20 Bremsnocken 1 21 Bremsankerplatte 1 3 2 D poses effectuer Ordre Nom de pi ce Qt Remarques 11 crou pignon de roue arri re...

Page 416: ...uller 2 INSPECTION EC514100 Wheel 1 Measure Wheel runout Out of limit Repair replace 2 Inspect Bearing Rotate inner race with a finger Rough spot seizure Replace NOTE Replace the bearings oil seal and...

Page 417: ...iftsm ig Erneuern Me uhr 1 verwenden Maximal zul ssige Achsbiegung 0 5 mm PI CES D POSER Roue arri re 1 D poser Roue 1 N B Pousser la roue vers l avant et d poser la cha ne de transmission 2 Roulement...

Page 418: ...and paper NOTE After polishing wipe the polished particles with a cloth 2 Measure Brake shoe lining thickness a Out of specification Replace NOTE Replace the brake shoes and springs as a set if either...

Page 419: ...ftsm ig Erneuern Bremstrommel Innendurchmes ser Standard Grenzwert 110 mm 111 mm N B Pour obtenir la d formation il faut diviser en deux la valeur affich e sur le comparateur cadran AVERTISSEMENT Ne p...

Page 420: ...ake camshaft 1 NOTE Apply the lithium soap base grease on the brake camshaft 2 Check Brake camshaft operation Unsmooth operation Repair 3 Install Wear indicator plate 1 NOTE When installing the wear i...

Page 421: ...a montieren wie in der Abbildung gezeigt T R 10 Nm 1 0 m kg ROUE ARRI RE ET FREIN ARRI RE HINTERRAD UND HINTERRADBREMSE 4 Examiner Surface int rieure du tambour de frein Taches d huile rayures limine...

Page 422: ...e brake shoe lin ings New Rear wheel 1 Install Wheel bearing 1 Spacer 2 Wheel bearing 3 Oil seal 4 NOTE Apply the lithium soap base grease on the oil seal lip when installing Install the bearing with...

Page 423: ...FREIN ARRI RE HINTERRAD UND HINTERRADBREMSE 5 Installer Ressorts 1 M choires de frein 2 sur le flasque de frein 3 N B Enduire la goupille pivot de graisse base de savon au lithium Bien veiller ne pas...

Page 424: ...hoe plate assembly Collar right NOTE Apply the lithium soap base grease on the oil seal lip 4 Install Rear wheel NOTE Make sure that the slot a on the brake shoe plate with the stopper b on the swinga...

Page 425: ...ite aus montie ren ROUE ARRI RE ET FREIN ARRI RE HINTERRAD UND HINTERRADBREMSE 2 Installer Pignon de roue arri re 1 Rondelles d arr t 2 crou pignon de roue arri re 3 N B Serrer les crous par tapes et...

Page 426: ...int 8 Adjust Drive chain slack a Refer to DRIVE CHAIN SLACK ADJUSTMENT section in the CHAP TER 3 Drive chain slack 35 50 mm 1 4 2 0 in 9 Tighten Axle nut 1 T R 60 Nm 6 0 m kg 43 ft lb 10 Install Sprin...

Page 427: ...r HINTERRADBREMSE EINSTELLEN in KAPITEL 3 ROUE ARRI RE ET FREIN ARRI RE HINTERRAD UND HINTERRADBREMSE 7 Installer Tendeur de cha ne de transmission droit 1 Rondelle plate 2 crou d axe 3 N B Serrer l c...

Page 428: ...stand under the engine WARNING Support the machine securely so there is no danger of it falling over Front wheel Refer to FRONT WHEEL AND FRONT BRAKE section Refer to FRONT WHEEL section for the TT R...

Page 429: ...bel zerlegt wird 4 Klemmschraube untere Gabelbr cke 1 Nur lockern 5 Teleskopgabel 1 1 FOURCHE AVANT TELESKOPGABEL FOURCHE AVANT D poses effectuer 1 D pose de la fourche avant D poses effectuer Ordre N...

Page 430: ...name Q ty Remarks FRONT FORK DISASSEMBLY 1 Dust boot 1 2 Cap bolt 1 Refer to REMOVAL POINTS 3 Spacer 1 4 Washer 1 5 Fork spring 1 Drain the fork oil 6 Dust seal 1 Use special tool Refer to REMOVAL POI...

Page 431: ...1 B Metallh lse 1 C Dichtring 1 D Tauchrohr 1 2 1 FOURCHE AVANT TELESKOPGABEL D MONTAGE DE LA FOURCHE AVANT D poses effectuer 1 D pose de la bague d tanch it 2 D pose de la tige d amortisseur D poses...

Page 432: ...n material Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disassembled and reassembled EC553000 REMOVAL POINTS Cap bolt 1 Remove Cap bo...

Page 433: ...mpferrohrbuchse Dichtring HINWEIS Den D mpferrohr Halter 1 und den T Hand griff 2 zum L sen der D mpferrohr Schraube verwenden FOURCHE AVANT TELESKOPGABEL REMARQUE CONCERNANT LA MANIPULATION N B Les t...

Page 434: ...ork with a built in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material Use enough care not to allow any foreign material to come in when the oi...

Page 435: ...HE AVANT TELESKOPGABEL Support de tige d amortisseur YM 1300 90890 01294 Poign e en T YM 1326 90890 01326 3 D poser Bague d tanch it 1 Se servir d un tournevis t te plate ATTENTION Veiller ne pas grif...

Page 436: ...ge 1 NOTE The bending value is shown by one half of the dial gauge reading WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube 2 Inspect Piston metal 1 Wear...

Page 437: ...ei Besch digung Erneuern FOURCHE AVANT TELESKOPGABEL Tube plongeur 1 Examiner Surface du tube plongeur a Striation par usage R parer ou rempla cer Utiliser du papier de verre humide d un grain de n 1...

Page 438: ...per rod into the inner tube hold the inner tube aslant If the inner tube is held vertically the damper rod may fall into it and be damaged 3 Install Inner tube On outer tube 4 Install Copper washer Bo...

Page 439: ...Handgriff YM 01326 90890 01326 New T R 23 Nm 2 3 m kg LT FOURCHE AVANT TELESKOPGABEL REMONTAGE ET INSTALLATION Fourche avant 1 Nettoyer toutes les pi ces dans du dissolvant propre 2 Installer Bague co...

Page 440: ...the oil seal into the outer tube with fork seal driver attachment 30 2 and fork seal driver weight 3 Fork seal driver weight YM 33963 90890 01367 Fork seal driver attachment YM 33281 90890 01400 New 6...

Page 441: ...ELESKOPGABEL 5 Installer Bague d tanch it 1 N B Enduire le tube plongeur d huile de fourche Pour installer la bague d tanch it sans ab mer les l vres de la bague d tanch it se servir d une toile en pl...

Page 442: ...ntity each front fork leg TT R125 159 cm3 5 60 Imp oz 5 38 US oz TT R125LW 156 cm3 5 49 lmp oz 5 27 US oz 11 After filling pump the inner tube slowly up and down more than 10 times to dis tribute the...

Page 443: ...e HINWEIS Verschlu schraube vorl ufig festziehen FOURCHE AVANT TELESKOPGABEL 9 Comprimer fond la fourche avant 10 Verser Huile de fourche avant 1 ATTENTION Utiliser sans faute le type d huile de fourc...

Page 444: ...rk top end a Front fork top end standard a Zero mm Zero in T R 23 Nm 2 3 m kg 17 ft lb 4 Tighten Pinch bolt lower bracket 1 Pinch bolt upper bracket 2 Screw dust boot 3 NOTE Make sure that the dust bo...

Page 445: ...R 60 Nm 6 0 m kg T R 25 Nm 2 5 m kg 5 Montieren Schutzkappe 1 FOURCHE AVANT TELESKOPGABEL Installation 1 Installer Fourche avant N B Serrer le boulon de pincement du t inf rieur de quelques tours Ne...

Page 446: ...aration for removal HANDLEBAR REMOVAL Number plate 1 Clutch cable 1 2 Clutch lever 1 3 Engine stop switch 1 4 Front brake cable 1 5 Front brake lever 1 6 Grip cap lower 1 7 Grip cap upper 1 8 Throttle...

Page 447: ...riff links 1 Siehe unter DEMONTAGEPUNKTE 12 Lenkerhalter 2 13 Lenker 1 1 GUIDON LENKER GUIDON TT R125 D poses effectuer 1 D pose du guidon D poses effectuer Ordre Nom de pi ce Qt Remarques Pr paration...

Page 448: ...oval Order Part name Q ty Remarks Preparation for removal HANDLEBAR REMOVAL Number plate 1 Clutch cable 1 2 Clutch lever 1 3 Engine stop switch 1 4 Brake master cylinder 1 Refer to REMOVAL POINTS 5 Gr...

Page 449: ...halterung Unterteil 1 6 Griffhalterung Oberteil 1 7 Gaszug 1 8 Gasdrehgriff 1 1 GUIDON LENKER TT R125LW D poses effectuer 1 D pose du guidon D poses effectuer Ordre Nom de pi ce Qt Remarques Pr parati...

Page 450: ...5 43 CHAS HANDLEBAR Extent of removal Order Part name Q ty Remarks 9 Collar 1 10 Handlebar grip left 1 Refer to REMOVAL POINTS 11 Upper handlebar holder 2 12 Handlebar 1 1...

Page 451: ...e 1 10 Lenkergriff links 1 Siehe unter DEMONTAGEPUNKTE 11 Lenkerhalter 2 12 Lenker 1 1 GUIDON LENKER D poses effectuer Ordre Nom de pi ce Qt Remarques 9 Entretoise paul e 1 10 Poign e de guidon gauche...

Page 452: ...ASSEMBLY DISASSEMBLY Extent of removal 1 Throttle grip assembly disassembly Extent of removal Order Part name Q ty Remarks THROTTLE GRIP ASSEMBLY DISASSEMBLY 1 Handlebar grip right 1 Refer to REMOVAL...

Page 453: ...N E DES GAZ 1 Poign e de guidon droite 1 Se reporter L MENTS D POSER 2 Entretoise paul e 2 3 Tube de commande des gaz 1 1 GASDREHGRIFF ZERLEGEN Demontage Arbeiten 1 Gasdrehgriff zerlegen Demontage Arb...

Page 454: ...ake master cylinder cap side horizontal to prevent air from coming in Handlebar grip 1 Remove Handlebar grip 1 NOTE Blow in air between the handlebar or tube guide and the grip Then remove the grip wh...

Page 455: ...ker zu richten weil dadurch seine Stabilit t verloren geht GUIDON LENKER PI CES D POSER Ma tre cylindre de frein TT R125LW 1 D poser Demi palier de fixation de ma tre cylindre de frein 1 Ma tre cylind...

Page 456: ...a lac quer thinner Handlebar 1 Install Handlebar 1 Handlebar holder 2 Bolt handlebar holder 3 NOTE Align the punched mark a on the handlebar with the upper surface of the handlebar holder on the upper...

Page 457: ...en und dann die hinteren Schrauben festziehen T R 23 Nm 2 3 m kg GUIDON LENKER REMONTAGE ET INSTALLATION Poign e des gaz compl te 1 Installer Entretoise paul e 1 Poign e de guidon droite 2 Enduire le...

Page 458: ...pper 2 Throttle cables 3 On tube guide 4 NOTE Apply the lithium soap base grease on the throttle cable end and tube guide cable wind ing portion 5 Install Throttle cable cap 1 Screw throttle cable cap...

Page 459: ...kg T R 4 Nm 0 4 m kg GUIDON LENKER 2 Installer Poign e de guidon gauche 1 Enduire le guidon 2 d adh sif N B Avant d enduire le guidon a d adh sif nettoyer tout r sidu de graisse ou d huile avec du dil...

Page 460: ...the bolts on the lower side 7 Install Engine stop switch 1 Clutch lever holder 2 Bolts clutch lever holder 3 NOTE The engine stop switch and clutch lever holder should be installed according to the d...

Page 461: ...on du levier de frein avant 1 Boulons bride de fixation du levier de frein avant 2 C ble de frein avant 3 Bride N B Enduire de graisse base de savon au lithium l extr mit du c ble de frein TT R125LW M...

Page 462: ...lacing the suitable stand under the engine WARNING Support the machine securely so there is no danger of it falling over Front forks Refer to FRONT FORK section Handlebar Refer to HANDLEBAR section Fr...

Page 463: ...Ringmutter unten 1 7 Untere Gabelbr cke 1 8 Lager Schutzkappe 1 1 2 DIRECTION LENKUNG DIRECTION D poses effectuer 1 D pose du t inf rieur 2 D pose de la tige d amortisseur ETAPES DE SERRAGE Serrer l...

Page 464: ...tent of removal Order Part name Q ty Remarks 9 Bearing inner race upper 1 10 Bearing upper 1 11 Bearing outer race upper 1 Refer to REMOVAL POINTS 12 Bearing outer race lower 1 13 Bearing lower 1 Refe...

Page 465: ...UNKTE 12 u erer Lager Laufring unten 1 13 Lager unten 1 Siehe unter DEMONTAGEPUNKTE 2 DIRECTION LENKUNG D poses effectuer Ordre Nom de pi ce Qt Remarques 9 Cage interne haut de roulement 1 10 Roulemen...

Page 466: ...l down Steering nut wrench YU 33975 90890 01403 Bearing race 1 Remove Bearing race 1 Remove the bearing race using long rod 2 and the hammer EC563300 Bearing lower 1 Remove Bearing lower 1 Use the flo...

Page 467: ...Pr fen Lenkschaft 1 Verbiegung Besch digung Erneu ern DIRECTION LENKUNG PI CES D POSER crou cr nel 1 D poser crou cr nel 1 Utiliser la cl pour crou de direction 2 AVERTISSEMENT Soutenir la colonne de...

Page 468: ...are not smooth in their operation in the bearing races replace bearings and bearing races as a set EC565000 ASSEMBLY AND INSTALLATION Lower bracket 1 Install Bearing lower 1 NOTE Apply the lithium soa...

Page 469: ...Dichtlippe der Lager Schutzkappe auftragen DIRECTION LENKUNG Billes et cages du roulement 1 Nettoyer les billes et les cages du roulement dans du dissolvant 2 Examiner Billes de roulement Cages de rou...

Page 470: ...G HEAD INSPEC TION AND ADJUSTMENT section in the CHAPTER 3 6 Check the steering shaft by turning it lock to lock If there is any binding remove the steering shaft assembly and inspect the steering bea...

Page 471: ...uben der oberen Gabel br cke noch nicht festziehen DIRECTION LENKUNG 4 Installer T inf rieur 1 N B Enduire le roulement de graisse base de savon au lithium 5 Installer crou cr nel inf rieur 1 Rondelle...

Page 472: ...ovement If not adjust the steering by loosening the ring nut little by little T R 110 Nm 11 0 m kg 80 ft lb 12 Adjust Front fork top end a Front fork top end standard a Zero mm Zero in 13 Tighten Pinc...

Page 473: ...elbr cke 1 Klemmschrauben obere Gabelbr cke 2 T R 60 Nm 6 0 m kg T R 25 Nm 2 5 m kg DIRECTION LENKUNG 9 Serrer crou de colonne de direction 1 10 Installer Capuchon 2 11 Apr s avoir serr l crou contr l...

Page 474: ...machine by placing the suitable stand under the engine WARNING Support the machine securely so there is no danger of it falling over Rear wheel Refer to REAR WHEEL AND REAR BRAKE section 1 Drive chai...

Page 475: ...tisseur arri re bascu leur 1 Maintenir le bras oscillant 5 Axe 1 6 Bras oscillant 1 1 SCHWINGE Demontage Arbeiten 1 Schwinge demontieren Demontage Arbeiten Reihen folge Bauteil Anz Bemerkungen Vorbere...

Page 476: ...y 3 Relay arm removal and disassembly Extent of removal Order Part name Q ty Remarks SWINGARM DISASSEMBLY 1 Drive chain guard 1 2 Drive chain support 1 3 Drive chain guide 1 4 Dust cover 4 5 Collar 1...

Page 477: ...z 2 C Gleitbuchse 1 D Schwinge 1 3 1 2 BRAS OSCILLANT SCHWINGE D MONTAGE DU BRAS OSCILLANT D poses effectuer 1 D montage du bras oscillant 2 D pose et d montage du bras de raccordement 3 D pose et d m...

Page 478: ...gs as a set 2 Inspect Dust cover Damage Replace 3 Inspect Swingarm Damage bends cracks Replace Relay arm 1 Inspect Collar 1 Bushing 2 Damage pitting Replace collar and bushing as a set Bushing 3 Bushi...

Page 479: ...fen Dichtring 8 Staubschutz 9 Besch digung Erneuern 3 Pr fen Umlenkhebel 0 Besch digung Verbiegung Kratzer Erneuern BRAS OSCILLANT SCHWINGE PI CES D POSER Bague 1 D poser Bague 1 N B Retirer la bague...

Page 480: ...ng arm 4 Damage bends cracks Replace EC575000 ASSEMBLY AND INSTALLATION Bushing 1 Install Bushing NOTE Make sure to press in the bushing so that they are flush with the surface of the connecting arm a...

Page 481: ...Schwinge HINWEIS Lagerbuchsen und Dichtlippen der Staub schutzabdeckungen mit Molybd ndisulfid bestreichen BRAS OSCILLANT SCHWINGE Bras de raccordement 1 Examiner Entretoise paul e 1 Bague 2 Endommage...

Page 482: ...g arm NOTE Apply the molybdenum disulfide grease on the collar and dust cover lip 4 Install Relay arm 1 Bolt relay arm Plain washer Nut relay arm On swingarm NOTE Apply the molybdenum disulfide grease...

Page 483: ...estreichen T R 53 Nm 5 3 m kg T R 35 Nm 3 5 m kg BRAS OSCILLANT SCHWINGE 2 Installer Bagues d tanch it 1 Entretoises paul es 2 Bague 3 Caches antipoussi re 4 Caches antipoussi re 5 Manchon en caoutcho...

Page 484: ...Swingarm Pivot shaft 1 Plain washer Nut pivot shaft NOTE Apply the molybdenum disulfide grease on the pivot shaft 2 Check Swingarm side play a Free play exists Replace bushing Swingarm up and down mov...

Page 485: ...auftragen T R 35 Nm 3 5 m kg BRAS OSCILLANT SCHWINGE 6 Installer Patin de cha ne de transmission 1 Entretoises paul es Boulons patin de cha ne de transmission 2 T R 7 Nm 0 7 m kg 5 1 ft lb 7 Installer...

Page 486: ...arm frame T R 35 Nm 3 5 m kg 25 ft lb 5 Install Drive chain tensioner lower 1 Collar Bolt drive chain tensioner lower T R 7 Nm 0 7 m kg 5 1 ft lb 6 Install Bushing 1 Drive chain tensioner upper 2 Pla...

Page 487: ...Lithiumfett bestreichen T R 23 Nm 2 3 m kg BRAS OSCILLANT SCHWINGE 4 Installer Boulon bras de raccordement cadre 1 Rondelle plate crou bras de raccordement cadre N B Enduire le boulon bras de raccord...

Page 488: ...SORBER ASSEMBLY REMOVAL Hold the machine by placing the suitable stand under the engine WARNING Support the machine securely so there is no danger of it falling over Seat and side covers Refer to SEAT...

Page 489: ...unten DEMONTAGEPUNKTE 4 Hinterrad Sto d mpfer 1 1 COMBIN RESSORT AMORTISSEUR ARRI RE HINTERRAD STOSSD MPFER COMBIN RESSORT AMORTISSEUR ARRI RE D poses effectuer 1 D pose du combin ressort amortisseur...

Page 490: ...result of nitrogen gas expansion and or damage to the hose 3 Be careful not to damage any part of the rear shock absorber A damaged rear shock absorber will impair the damping performance or cause a m...

Page 491: ...schutz tragen um Augensch den durch austretendes Gas oder Metallsp ne zu vermeiden COMBIN RESSORT AMORTISSEUR ARRI RE HINTERRAD STOSSD MPFER REMARQUE CONCERNANT LA MANIPULATION AVERTISSEMENT Cet amort...

Page 492: ...rear shock absorber assembly Shock absorber 2 Oil leaks Replace rear shock absorber assembly Gas leaks Replace rear shock absorber assembly Spring 3 Damage Replace rear shock absorber assembly Fatigue...

Page 493: ...IS Lagerbuchse hineinpressen COMBIN RESSORT AMORTISSEUR ARRI RE HINTERRAD STOSSD MPFER PI CES D POSER Bague 1 D poser Bague 1 N B Retirer la bague en la poussant CONTR LE Combin ressort amortisseur ar...

Page 494: ...asher 1 Nut rear shock absorber assembly frame 2 NOTE Apply the molybdenum disulfide grease on the bolt rear shock absorber assembly frame T R 53 Nm 5 3 m kg 38 ft lb 3 Install Bolt rear shock absorbe...

Page 495: ...kg COMBIN RESSORT AMORTISSEUR ARRI RE HINTERRAD STOSSD MPFER Installation 1 Installer Combin ressort amortisseur arri re sur le cadre N B Monter le combin ressort amortisseur arri re en veillant ce qu...

Page 496: ...CTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS 1 CDI unit 2 Engine stop switch 3 Ignition coil 4 CDI magneto 5 Spark plug COLOR CODE B Black Br Brown G Green O Orange R Red W Whi...

Page 497: ...rz rot B W schwarz wei G L gr n blau G W gr n wei W L wei blau W R wei rot Die Abbildung zeigt die TT R125LW SCHALTPLAN PARTIE LECTRIQUE QUIPEMENT LECTRIQUE ET SCH MA DE C BLAGE COMPOSANTS LECTRIQUES...

Page 498: ...e inspection 1 Seat 2 Fuel tank Use the following special tools in this inspection Spark gap test Clean or replace spark plug Check entire ignition system for connection Repair or replace Check engine...

Page 499: ...t Effectuer le contr le l aide des outils sp ciaux Test de longueur d tincelle Nettoyer ou remplacer la bougie Contr ler toutes connexions du syst me d allumage R parer ou remplacer Contr ler coupe ci...

Page 500: ...e Pr fung verwenden Z ndfunke testen Z ndkerze reinigen oder erneuern Gesamte Z ndanlage auf Durchgang pr fen Reparieren oder Erneuern Motorstoppschalter pr fen Erneuern Z ndspule pr fen Prim rwick lu...

Page 501: ...ELEC MEMO...

Page 502: ...ne and increase spark gap until misfire occurs for USA and CDN only Minimum spark gap 6 0 mm 0 24 in EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1 Check Couplers and leads connection Rust dust l...

Page 503: ...bel schwarz 2 B W 1 B 2 Pr fger t Position HINEIN DR C KEN 1 LOS LASSEN TEST DE LA LONGUEUR D TINCELLE 1 D connecter le capuchon de bougie 2 Brancher un testeur d tincelle dynamique 1 testeur d alluma...

Page 504: ...ack lead 2 Primary coil resistance Tester selector position 0 18 0 28 at 20 C 68 F 1 2 Inspect Secondary coil resistance Out of specification Replace NOTE When inspecting the secondary coil resis tanc...

Page 505: ...lec teur du multim tre 0 18 0 28 20 C 68 F 1 6 4 2 Examiner R sistance de l enroulement secondaire Hors sp cifications Remplacer N B D poser le capuchon de bougie avant de mesurer la r sistance de l...

Page 506: ...ter selector position 248 372 at 20 C 68 F 100 2 Inspect Charging coil resistance Out of specification Replace Tester lead Brown lead 1 Tester lead Green lead 2 Charging coil resistance Tester selecto...

Page 507: ...ie end elektrische Bauteile erneut pr fen CONTR LE DE LA MAGN TO CDI 1 Examiner R sistance de la bobine d excitation Hors sp cifications Remplacer Fil de multim tre fil rouge 1 Fil du multim tre fil b...

Page 508: ......

Page 509: ...PRINTED IN JAPAN 2001 6 0 9 1 CR E F G PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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