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Yamaha TT-R125E(R), Owner'S Service Manual


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SPEC

2 - 22

MAINTENANCE SPECIFICATIONS

NOTE:

- marked portion shall be checked for torque tightening after break-in or before each ride.

Part to be tightened

Thread size

Q’ty

Tightening torque

Nm

m•kg

ft•lb

Bead stopper

M8 

×

 1.25

1

3

0.3

2.2

Driven sprocket (nut)

M10 

×

 1.25

4

43

4.3

31

Driven sprocket (stud)

M10 

×

 1.25

4

30

3.0

22

Sidestand mounting (nut)

M10 

×

 1.25

1

44

4.4

32

Engine mounting:

Engine bracket (front) and frame

M8 

×

 1.25

2

40

4.0

29

Engine bracket (front) and engine

M8 

×

 1.25

2

40

4.0

29

Engine bracket (upper) and frame

M8 

×

 1.25

2

40

4.0

29

Engine bracket (upper) and cylinder head

M8 

×

 1.25

1

40

4.0

29

Engine and frame (rear)

M8 

×

 1.25

2

40

4.0

29

Pivot shaft and nut

M12 

×

 1.25

1

53

5.3

38

Relay arm and 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 absorber assembly and relay arm

M10 

×

 1.25

1

35

3.5

25

Rear shock 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

Drive chain guide and swingarm

M6 

×

 1.0

2

7

0.7

5.1

Drive chain guard mounting

M6 

×

 1.0

2

7

0.7

5.1

Fuel tank mounting

M6 

×

 1.0

2

10

1.0

7.2

Fuel tank and fuel cock

M6 

×

 1.0

2

7

0.7

5.1

Fuel tank and fuel tank bracket

M6 

×

 1.0

4

7

0.7

5.1

Front fender mounting

M6 

×

 1.0

4

7

0.7

5.1

Rear fender mounting

M6 

×

 1.0

4

7

0.7

5.1

Flap guard mounting

M6 

×

 1.0

2

4

0.4

2.9

Left side cover mounting

M6 

×

 1.0

2

7

0.7

5.1

Seat mounting

M6 

×

 1.0

2

7

0.7

5.1

Battery cover and battery box

M6 

×

 1.0

1

5

0.5

3.6

Battery box and frame

M6 

×

 1.0

2

7

0.7

5.1

Summary of Contents for TT-R125E(R)

Page 1: ...5HP 28199 8A OWNER S SERVICE MANUAL MANUEL D ATELIER DU PROPRIETAIRE FAHRER UND WARTUNGS HANDBUCH TT R125E R TT R125LWE R...

Page 2: ...R OWNER S SERVICE MANUAL 2002 by Yamaha Motor Co Ltd 1st Edition November 2002 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressl...

Page 3: ...uch auszugsweise ist ohne schriftliche Genehmigung der Yamaha Motor Co Ltd nicht gestattet Gedruckt in Japan TT R125E R TT R125LWE R MANUEL D ATELIER DU PROPRIETAIRE 2002 Yamaha Motor Co Ltd Premi re...

Page 4: ...NOTE 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 INSTRUCTIO...

Page 5: ...r den 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: ...un point 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...

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: ...TE 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 ristiques 3 Co...

Page 22: ...INDEX GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS 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: ...R125LWE 1 17 CLEANING AND STORAGE 1 18 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 TT R125E 2 1 TT R125LWE 2 4 MAINTENANCE SPECIFICATIONS 2 7 ENGINE 2 7 CHASSIS 2 15 TT R125E 2 15 TT R125LWE 2...

Page 25: ...NG VOR INBETRIEBNAHME 3 3 MOTOR 3 4 FAHRWERK 3 15 ELEKTRISCHE ANLAGE 3 32 TABLES DES MATIERES CHAPITRE 1 RENSEIGNEMENTS G N RAUX DESCRIPTION 1 1 IDENTIFICATION DE LA MACHINE 1 2 INFORMATIONS IMPORTANT...

Page 26: ...CLUTCH 4 58 ENGINE REMOVAL 4 63 CRANKCASE CRANKSHAFT AND BALANCER 4 67 TRANSMISSION SHIFT CAM AND SHIFT FORK 4 75 CHAPTER 5 CHASSIS FRONT WHEEL AND FRONT BRAKE TT R125E 5 1 FRONT WHEEL TT R125LWE 5 8...

Page 27: ...NLAGE 6 2 ELEKTROSTARTERSYSTEM 6 6 LADESYSTEM 6 16 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 CULBUTEURS 4 2...

Page 28: ...ottle grip 8 Fuel tank cap 9 Air filter 0 Kickstarter crank A Fuel tank B Dipstick C Rear brake pedal D Fuel cock E Drive chain F Shift pedal G Front fork The illustration shows the TT R125LWE NOTE Th...

Page 29: ...a ten jederzeit vorbehalten Die Abbildung zeigt die TT R125LWE RENSEIGNEMENTS G N RAUX DESCRIPTION 1 Levier d embrayage 2 Coupe circuit du moteur 3 Commutateur principal 4 Bouton de starter 5 Commutat...

Page 30: ...machine KEY IDENTIFICATION NUMBER The key identification number 1 is stamped on the key as shown in the following illustra tion This number can be used for ordering a new key EC121001 VEHICLE IDENTIFI...

Page 31: ...em Rahmen angebracht 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 hicul...

Page 32: ...per 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 m...

Page 33: ...istet 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 re et...

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 f...

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: ...r 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 90890 0...

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

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 nd...

Page 45: ...ziehen 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 Multimeter Zur Pr fung...

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

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

Page 48: ...to a stop START SWITCH The start switch 1 is located on the right han dlebar Push this switch to crank the engine with the starter 1 EC152000 CLUTCH LEVER The clutch lever 1 is located on the left han...

Page 49: ...da Anfahren Bergauffah ren und schnelles Beschleunigen m glich sind Die G nge dieses 5 Gang Getriebes werden ber den Fu schalthebel 1 linksseitig des Motors bei ausger ckter Kupplung ge schaltet FONC...

Page 50: ...engine EC155001 THROTTLE GRIP The throttle grip 1 is located on the right han dlebar it accelerates or decelerates the engine For acceleration turn the grip toward you for deceleration turn it away fr...

Page 51: ...echten Seite des Lenkers FUSSBREMSHEBEL Der Fu bremshebel 1 zur Bet tigung der Hin terradbremse befindet sich auf der rechten Fahrzeugseite P DALE DE KICK AVERTISSEMENT Avant de mettre le moteur en ma...

Page 52: ...AT THE FIRST OPPORTUNITY BE SURE TO SET THE LEVER TO ON AFTER REFUELING EC159000 STARTER KNOB CHOKE When cold the engine requires a richer air fuel mixture for starting A separate starter circuit whi...

Page 53: ...der Transportieren der Maschine ausgelegt WARNUNG Niemals den Seitenst nder mit zus tzli chem Gewicht belasten Vor dem Losfahren sicherstellen da der Seitenst nder hochgeklappt ist ROBINET DE CARBURAN...

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 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 Immer frischen Markenkraftstoff eine...

Page 56: ...ollowing conditions When the transmission is in neutral When the clutch is disengaged with the transmission in any position However it is recommended to shift into neutral before starting the engine 1...

Page 57: ...f das Gasgeben anspricht 1 13 D MARRAGE ET RODAGE ATTENTION Avant de mettre le moteur en marche effectuer les contr les repris dans la liste Contr les et entretiens avant utilisation AVERTISSEMENT Ne...

Page 58: ...fully with firm stroke CAUTION Observe the following break in procedures during initial operation to ensure optimum performance and avoid engine damage BREAK IN Break in is important to better fit the...

Page 59: ...Sitz pr fen und gegebenenfalls mit dem vorgeschriebenen Anzugsmoment festziehen D MARRAGE ET RODAGE STARTEN UND EINFAHREN N B Si le moteur ne d marre pas avec le commutateur de d marrage rel cher le c...

Page 60: ...ne This is required especially when the following engine related parts are replaced Cylinder Piston Piston ring Valve Camshaft Crankshaft Clutch Transmission gear Shift fork For warming up and inspect...

Page 61: ...UNGSARBEITEN in KAPITEL 3 aufgef hrt Tritt ein Problem auf ist der Motor sofort abzustellen und die Ursache herauszufinden D MARRAGE ET RODAGE STARTEN UND EINFAHREN RODAGE APR S REMPLACEMENT Il est to...

Page 62: ...Muffler to cylinder 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 f...

Page 63: ...tem to frame 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 S...

Page 64: ...Pot d chappement 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...

Page 65: ...tant de selle 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 Lia...

Page 66: ...er und Hinterradabdek 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 Telesko...

Page 67: ...chaft und obere Gabelbr cke Obere Gabelbr cke und Lenker Teleskopgabel und obere Gabelbr cke Teleskopgabel und untere Gabelbr cke bertragungs und Umlenkhebel bertragungshebel und Rahmen Umlenkhebel un...

Page 68: ...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 69: ...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...

Page 70: ...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 Rein stall the chain or store it in a...

Page 71: ...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 72: ...in Minimum ground clearance 265 mm 10 4 in Basic weight With oil and full fuel tank 90 kg 198 4 lb Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Single cylinder forward inclined Di...

Page 73: ...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 74: ...ic fork Rear suspension Swingarm link type monocross suspension Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring gas oil damper Wheel travel Front wheel trave...

Page 75: ...nce 295 mm 11 6 in Basic weight With oil and full fuel tank 90 kg 198 4 lb Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Single cylinder forward inclined Displacement 124 cm3 7 57 c...

Page 76: ...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 77: ...scopic fork Rear suspension Swingarm link type monocross suspension Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring gas oil damper Wheel travel Front wheel t...

Page 78: ...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 79: ...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 80: ...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 81: ...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 82: ...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 83: ...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 84: ...her 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...

Page 85: ...portion shall be checked for torque tightening after break in or before each ride Cylinder head tightening sequence Segment M6 1 0 1 12 1 2 8 7 Stopper lever M6 1 0 1 10 1 0 7 2 Part to be tightened...

Page 86: ...lent 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 178 mm 7 01 in Fitting length 165 mm 6 50 in Spri...

Page 87: ...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 88: ...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 89: ...2 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 Drive chain guide and swingarm M6 1 0 2 7 0...

Page 90: ...170 5 mm 6 71 in Fitting length 160 5 mm 6 32 in Spring rate STD K 61 8 N mm 6 3 kg mm 352 lb in Optional spring No Enclosed gas pressure 1 200 kPa 12 kg cm2 171 psi Wheel Front wheel type Spoke whee...

Page 91: ...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 92: ...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 93: ...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 absorber assembly and relay arm M10 1 25 1 35...

Page 94: ...magneto Model manufacturer 5HP 10 YAMAHA Normal output 14 V 100 W at 5 000 r min Charging coil resistance color 0 64 0 96 at 20 C 68 F White Black Lighting coil resistance color 0 52 0 78 at 20 C 68 F...

Page 95: ...M33221 MATSUSHITA Coil winding resistance 75 69 92 51 at 20 C 68 F Fuse amperage quantity Main fuse 10 A 1 Reserve fuse 10 A 1 Part to be tightened Thread size Q ty Tightening torque Nm m kg ft lb Pic...

Page 96: ...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 97: ...Avec huile et r servoir de carburant rempli 90 kg 198 4 lb Moteur Type de moteur 4 temps refroidissement par air un arbre cames en t te SOHC Disposition du cylindre Monocylindre inclin vers l avant Cy...

Page 98: ...m 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 ne...

Page 99: ...rtisseur Amortisseur avant Ressort h lico dal amortisseur hydraulique Amortisseur arri re Ressort h lico dal pneumatique amortisseur hydraulique D battement de roue D battement de roue avant 180 mm 7...

Page 100: ...voir de carburant rempli 90 kg 198 4 lb Moteur Type de moteur 4 temps refroidissement par air un arbre cames en t te SOHC Disposition du cylindre Monocylindre inclin vers l avant Cylindr e 124 cm3 7 5...

Page 101: ...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 ne T...

Page 102: ...Amortisseur Amortisseur avant Ressort h lico dal amortisseur hydraulique Amortisseur arri re Ressort h lico dal pneumatique amortisseur hydraulique D battement de roue D battement de roue avant 180 mm...

Page 103: ...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 104: ...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 105: ...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 106: ...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 107: ...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 108: ...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 109: ...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 M6 1 0 3...

Page 110: ...r s d un apr s le rodage et avant chaque d marrage Ordre de serrage de la culasse toile de verrouillage M6 1 0 1 12 1 2 8 7 Doigt de verrouillage M6 1 0 1 10 1 0 7 2 Pi ce serrer Diam tre de filet Qt...

Page 111: ...tube 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 178 mm 7 01 in Longueur mont 165 mm 6 50 in Con...

Page 112: ...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 113: ...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 114: ...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 Fixation de patin de cha ne de transmission M6 1 0...

Page 115: ...in Longueur mont 160 5 mm 6 32 in Constante standard de ressort K 61 8 N mm 6 3 kg mm 352 lb in Ressort optionnel Non Pression du gaz 1 200 kPa 12 kg cm2 171 psi Roue Type de roue avant Roue rayons Ty...

Page 116: ...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 117: ...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 118: ...sseur 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 5 1 42 4 2 30 Tendeur de cha ne de transmission...

Page 119: ...AMAHA Sortie normale 14 V 100 W 5 000 tr mn R sistance de la bobine de charge couleur 0 64 0 96 20 C 68 F blanc noir R sistance de la bobine d allumage couleur 0 52 0 78 20 C 68 F jaune noir Redresseu...

Page 120: ...de la bobine 75 69 92 51 20 C 68 F Fusible amp res quantit Fusible principal 10 A 1 Fusible de r serve 10 A 1 Pi ce serrer Diam tre de filet Qt Couple de serrage Nm m kg ft lb Bobine d excitation M6 1...

Page 121: ...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 122: ...odenfreiheit 265 mm 10 4 in Gewicht fahrfertig Mit l und vollgetankt 90 kg 198 4 lb Motor Bauart Luftgek hlter 4 Takt Motor SOHC Zylinderanordnung Einzylinder in Fahrtrichtung geneigt Hubraum 124 cm3...

Page 123: ...U Hersteller NGK DENSO Elektrodenabstand 0 6 0 7 mm 0 02 0 03 in Kupplungstyp Mehrscheiben lbadkupplung Getriebe Prim rantrieb Zahnrad Prim r bersetzung 68 19 3 579 Sekund rantrieb Kettenantrieb Seku...

Page 124: ...fh ngung Teleskopgabel Hinterradaufh ngung Schwinge mit Umlenkhebelabst tzung Sto d mpfung Federelemente vorne Spiralfeder hydraulisch ged mpft Federelemente hinten Spiralfeder hydraulisch ged mpft ga...

Page 125: ...11 6 in Gewicht fahrfertig Mit l und vollgetankt 90 kg 198 4 lb Motor Bauart Luftgek hlter 4 Takt Motor SOHC Zylinderanordnung Einzylinder in Fahrtrichtung geneigt Hubraum 124 cm3 7 57 cu in Bohrung H...

Page 126: ...U Hersteller NGK DENSO Elektrodenabstand 0 6 0 7 mm 0 02 0 03 in Kupplungstyp Mehrscheiben lbadkupplung Getriebe Prim rantrieb Zahnrad Prim r bersetzung 68 19 3 579 Sekund rantrieb Kettenantrieb Sekun...

Page 127: ...radaufh ngung Teleskopgabel Hinterradaufh ngung Schwinge mit Umlenkhebelabst tzung Sto d mpfung Federelemente vorne Spiralfeder hydraulisch ged mpft Federelemente hinten Spiralfeder hydraulisch ged mp...

Page 128: ...in Max Ovalit t 0 05 mm 0 0020 in Nockenwelle Antrieb Kettenantrieb links Nockenwellen Abmessungen Einla 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...

Page 129: ...0 1181 in AUS 1 7 2 8 mm 0 0669 0 1102 in C Ventilsitz Breite EIN 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in AUS 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in D Ventilteller St rke EIN 0 4 0 8 mm 0 0...

Page 130: ...n 31 2 mm 1 23 in AUS 32 55 mm 1 28 in 31 2 mm 1 23 in Einbaul nge Ventil geschlossen EIN 25 6 mm 1 01 in AUS 25 6 mm 1 01 in Federdruck bei Einbaul nge EIN 137 5 158 1 N 14 0 16 1 kg 30 86 35 49 lb A...

Page 131: ...6 in 14 971 mm 0 5894 in Kolbenringe 1 Kompressionsring Topring Ausf hrung Abgerundet Abmessungen B T 1 0 2 1 mm 0 04 0 08 in Ringsto eingebaut 0 15 0 30 mm 0 006 0 012 in 0 4 mm 0 016 in Ringnutspiel...

Page 132: ...Schaltung Bauart Nockenwalze und Druckstange Kickstarter Kickstarter Bauart Kick und Eingriff Kickstarterclip Reibkraft 6 4 13 2 N 0 65 1 35 kg 1 4 3 0 lb Vergaser Kennzeichnung 5HP1 10 Hauptd se M J...

Page 133: ...ilter Drahtgeflecht lpumpe Rotorpumpe Spalt 0 15 mm 0 0059 in 0 2 mm 0 0079 in Spiel 0 06 0 10 mm 0 0024 0 0039 in 0 15 mm 0 0059 in Geh use und Rotor Laufspiel 0 06 0 10 mm 0 0024 0 0039 in 0 15 mm 0...

Page 134: ...Luftfiltergeh use M6 1 0 3 7 0 7 5 1 Kr mmer M6 1 0 2 10 1 0 7 2 Kr mmer M10 1 25 1 60 6 0 43 Kr mmer M8 1 25 1 30 3 0 22 Kr mmer Schutzabdeckung M6 1 0 7 10 1 0 7 2 Funkenf nger M6 1 0 3 10 1 0 7 2...

Page 135: ...nach der Einfahrzeit oder vor jedem Rennen auf richtiges Anzugs moment gepr ft werden Anzugsreihenfolge Zylinderkopfschrauben Lamelle M6 1 0 1 12 1 2 8 7 Anschlaghebel M6 1 0 1 10 1 0 7 2 Festzuziehe...

Page 136: ...mm 1 18 in Teleskopgabel Oberkante 0 mm 0 in Hinterradaufh ngung Sto d mpferhub 65 mm 2 56 in Ungespannte Federl nge 178 mm 7 01 in Einbaul nge 165 mm 6 50 in Standard Federrate K 50 5 N mm 5 1 kg mm...

Page 137: ...in 2 0 mm 0 08 in Belagst rke hinten 4 0 mm 0 16 in 2 0 mm 0 08 in Bremsschuhfeder ungespannte L nge vorne 50 5 mm 1 99 in Bremsschuhfeder ungespannte L nge hinten 50 5 mm 1 99 in Bremshebel und Brems...

Page 138: ...ng Schraube M6 1 0 1 7 0 7 5 1 Handbremshebel Befestigung Mutter M6 1 0 1 7 0 7 5 1 Handbremshebel Halter M5 0 8 2 4 0 4 2 9 Kupplungshebel Befestigung Schraube M6 1 0 1 7 0 7 5 1 Kupplungshebel Befes...

Page 139: ...spanner oben M8 1 25 1 23 2 3 17 Antriebskettenspanner unten M6 1 0 1 7 0 7 5 1 Antriebsketten Stiite und Schwinge M6 1 0 2 7 0 7 5 1 Kettenf hrung und Schwinge M6 1 0 2 7 0 7 5 1 Kettenschutz Befesti...

Page 140: ...32 in Standard Federrate K 61 8 N mm 6 3 kg mm 352 lb in Umr stfeder Kein Gasd mpferdruck 1 200 kPa 12 kg cm2 171 psi R der Vorderrad Speichenrad Hinterrad Speichenrad Felgengr e Felgen Baustoff 19 1...

Page 141: ...mm 0 08 in Bremsschuhfeder ungespannte L nge 50 5 mm 1 99 in Bremshebel und Bremspedal Handbremshebelspiel am Hebelende 2 5 mm 0 08 0 20 in Bremspedalh he Vertikale H he unterhalb Fu rasten Oberkante...

Page 142: ...0 2 9 0 9 6 5 Hauptbremszylinder Verschlu deckel Vorder radbremse M4 0 7 2 2 0 2 1 4 Handbremshebel Befestigung Schraube M6 1 0 1 7 0 7 5 1 Handbremshebel Befestigung Mutter M6 1 0 1 7 0 7 5 1 Handbr...

Page 143: ...1 25 1 35 3 5 25 Verbindungsgelenk und Rahmen M10 1 25 1 35 3 5 25 Hinterradsto d mpfer und Rahmen M12 1 25 1 53 5 3 38 Hinterradsto d mpfer und Umlenkhebel M10 1 25 1 35 3 5 25 Hinterradsto d mpfer u...

Page 144: ...p CDI Magnetz nder Modell Hersteller 5HP 10 YAMAHA Normalausgang 14 V 100 W bei 5 000 U min Ladespulenwiderstand Farbe 0 64 0 96 bei 20 C 68 F wei schwarz Lichtspulenwiderstand Farbe 0 52 0 78 bei 20...

Page 145: ...ulenwicklungswiderstand 75 69 92 51 bei 20 C 68 F Sicherung St rke Anzahl Hauptsicherung 10 A 1 Reservesicherung 10 A 1 Festzuziehende Bauteile Gewinde gr e Anzahl Anzugsmoment Nm m kg ft lb Aufnahmes...

Page 146: ...gegeben gelten alle Anzugsmomente f r saubere trockene Gewin de Die Bauteile sollten Raumtemperatur auf weisen A Mutter B Schrau be ANZUGSMOMENTE Nm m kg ft lb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 6 mm...

Page 147: ...SPEC MEMO...

Page 148: ...rake cable for the TT R125E F Cable guide G Main switch lead H Engine stop switch lead I Clutch switch lead J Start switch lead K CDI unit band L CDI unit M Connector cover N Rubber cover O Starter ca...

Page 149: ...utzr hre f r die CDI Ma gnetz nderleitung befestigen CHEMINEMENT DES C BLES 1 Fil de terre 2 Fil de bobine primaire 3 Bride 4 Faisceau de fils 5 Fil de relais de d marreur 6 Fil de redresseur r gulate...

Page 150: ...t off relay lead under the frame and at the right of the chassis Fasten the rear shock absorber assembly sub tank TT R125LWE only Pass the CDI unit lead on the outside of the main switch lead engine s...

Page 151: ...CDI Einheit B gel setzen Den Bremsseilzug befestigen Apr s avoir attach le fil de relais de d marreur faire passer le fil la gauche du ch ssis Attacher le fil de magn to CDI et le fil de relais de d...

Page 152: ...engine stop switch lead clutch switch lead and start switch lead together Position the starter cable throt tle cable CDI magneto lead wire harness and rear shock absorber assembly sub tank hose TT R1...

Page 153: ...rband Enden positionieren wie in der Abbildung gezeigt A A A B A C Apr s avoir raccord le raccord du commutateur prin cipal le raccord de coupe circuit du moteur le rac cord du commutateur d embrayage...

Page 154: ...ather hose C Positive battery lead D Overflow hose E Air vent hose F Primary coil lead G Ground lead Pass the clutch cable on the inside of the throttle cable and starter cable Pass the fuel tank brea...

Page 155: ...d den Starterseilzug durch die Seilzugf hrung verlegen 1 C ble d acc l rateur 2 C ble d embrayage 3 C ble de d marreur 4 Flexible de reniflard de r servoir essence 5 Guide de flexible 6 Bride 7 Guide...

Page 156: ...frame as shown Fasten the engine oil breather hose overflow hose and air vent hoses to 2 clicks After fastening the starter cable push it against the starter plunger Put the tip of the air vent hose...

Page 157: ...n an der Z ndspule anbringen Die Masseleitung zusammen mit der Z ndspule befestigen Attacher le fil du moteur de d marreur Faire passer le flexible du reniflard d huile moteur et le flexible de trop p...

Page 158: ...umber plate Starting at the forepart pass the main switch lead clutch cable and start switch lead in that order Pass the start switch lead in back of the starter cable Pass the main switch lead on the...

Page 159: ...chalters verlegen 1 Bride 2 Fil de commutateur d embrayage 3 Fil de coupe circuit du moteur 4 Flexible de frein c ble de frein pour le mod le TT R125E 5 C ble d embrayage 6 C ble d acc l rateur 7 Fil...

Page 160: ...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 161: ...Rear shock absorber assembly Check operation and shock absorber for oil leakage Replace shock absorber assembly if necessary Chassis fasteners Make sure that all nuts bolts and screws are properly ti...

Page 162: ...r 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 fon...

Page 163: ...ontr 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 combin ressort amortisseur si n cessaire Attaches...

Page 164: ...len gegebe nenfalls erneuern Ventile Ventilspiel kontrollieren Gegebenenfalls einstellen Luftfilter Luftfiltereinsatz gegebenenfalls reinigen oder erneuern Vergaser Leerlaufdrehzahl und Choke Funktion...

Page 165: ...ach 120 Betriebsstunden mit Lithium fett schmieren Seitenst nder Funktion pr fen Gegebenenfalls schmieren oder reparieren Funkenl scher 1 Reinigen Teleskopgabel Funktion und auf Undichtigkeit pr fen G...

Page 166: ...r brake Check fluid level and leakage TT R125LWE 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 167: ...e niveau de fluide et les fuites TT R125LWE 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 168: ...Undichtigkeit achten Nur TT R125LWE 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 Verschle...

Page 169: ...INSP ADJ MEMO...

Page 170: ...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 171: ...er 1 l sen Einsteller 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 embra...

Page 172: ...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 173: ...montiert ist 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 Couverc...

Page 174: ...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 175: ...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 176: ...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 177: ...inem ebenen Unter grund mit Hilfe eines geeigneten St n ders abstellen 3 Demontieren lme stab 1 6 Appliquer Huile pour filtre air en mousse ou huile de m lange Sur l l ment N B Comprimer pour liminer...

Page 178: ...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 179: ...e Auswahl 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...

Page 180: ...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 181: ...Montieren lme stab 2 F llmenge Regelm iger lwechsel 1 0 L 0 88 Imp qt 1 06 US qt 5 Monter Jauge 6 Mettre le moteur en marche et le laisser chauffer pendant quelques minutes 7 Couper le moteur et v rif...

Page 182: ...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 183: ...ierschraube um die angegebene Anzahl von Umdrehungen herausdrehen Leerlaufluft Regulierschraube einstellen Um 2 1 2 3 1 2 Umdrehungen herausdrehen Beispiel CONTR LE DE LA PRESSION D HUILE DE MOTEUR 1...

Page 184: ...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 185: ...zahl 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 moteu...

Page 186: ...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 187: ...ehen kann und Kontermutter festziehen T R Kontermutter 8 Nm 0 8 m kg 5 8 ft lb CONTR LE ET R GLAGE DU JEU DE SOUPAPES VENTILSPIEL KONTROLLIEREN UND EINSTELLEN 4 Contr ler Jeu de soupapes Hors sp cific...

Page 188: ...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 189: ...m kg 13 ft lb T R 13 Nm 1 3 m kg 9 4 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb Mesurer le jeu de soupapes Si le jeu est incorrect r p ter les tapes ci des sus jusqu obtention du...

Page 190: ...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 191: ...lld mpfer hineinschieben und auf die Bohrungen f r die Schrauben ausrichten Schraube Funkenl scher T R 10 Nm 1 0 m kg 7 2 ft lb NETTOYAGE DU PARE TINCELLES pour les USA AVERTISSEMENT S assurer que le...

Page 192: ...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 193: ...t stoffschlauch befinden PARTIE CYCLE PURGE DE L AIR DU SYST ME DE FREINAGE TT R125LWE FAHRWERK HYDRAULISCHE BREMSANLAGE ENTL FTEN TT R125LWE PARTIE CYCLE PURGE DE L AIR DU SYST ME DE FREINAGE TT R125...

Page 194: ...ystem FRONT BRAKE ADJUSTMENT TT R125E 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 195: ...ttern drehen 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...

Page 196: ...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 197: ...1 hinein oder herausdrehen bis das vorgeschriebene Spiel a eingestellt ist TT R125LWE 1 Contr ler Garde du levier de frein a Hors sp cifications R gler 2 R gler Garde du levier de frein ATTENTION Apr...

Page 198: ...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 199: ...S PLAQUETTES DE FREIN AVANT TT R125LWE BREMSPEDAL H HE EINSTELLEN VORDERRAD BREMSBEL GE KONTROLLIEREN UND ERNEUERN TT R125LWE R GLAGE DE LA HAUTEUR DE LA P DALE DE FREIN 1 Contr ler Hauteur de p dale...

Page 200: ...e 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 NOTE Appl...

Page 201: ...ten Bremsbelag erneuern Siehe unter VORDERRAD UND VORDER RADBREMSE in KAPITEL 5 4 Contr ler Niveau du liquide de frein Se reporter la section CONTR LE DU NIVEAU DU LIQUIDE DE FREIN 5 Contr ler Fonctio...

Page 202: ...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 203: ...enen 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 Contr le...

Page 204: ...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 205: ...Kettenschlo 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 transm...

Page 206: ...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 207: ...ang laut Vorschrift einstellen Achsmutter bei heruntergedr ckter Antriebs kette festziehen T R Achsmutter 60 Nm 6 0 m kg 43 ft lb 6 Lubrifier Cha ne de transmission R GLAGE DE LA TENSION DE LA CHA NE...

Page 208: ...load By turning the adjuster 1 STANDARD POSITION CAUTION Grooves are provided to indicate the adjustment position Never go beyond the maximum or mini mum adjustment positions WARNING Always adjust eac...

Page 209: ...PECTION DE LA FOURCHE AVANT AJUSTEMENT DE LA PR TENSION DU RESSORT DE FOURCHES AVANT TT R125LWE TELESKOPGABEL KONTROLLIEREN EINSTELLUNG DER TELEGABEL FEDERVORSPANNUNG TT R125LWE INSPECTION DE LA FOURC...

Page 210: ...move all dirt and mud from around the locknut and adjuster before adjustment The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster CAUTION Never attempt to turn the adjust...

Page 211: ...a Standardl nge Einstellbereich TT R125E 165 mm 6 50 in TT R125LWE 160 5 mm 6 32 in TT R125E 155 175 mm 6 10 6 89 in TT R125LWE 147 5 167 5 mm 5 81 6 59 in CONTR LE DE L AMORTISSEUR ARRI RE 1 Contr le...

Page 212: ...is back by the spe cific number of clicks from the fully turned in position CAUTION Never go beyond the maximum or mini mum adjustment positions Stiffer a Increase the rebound damp ing force Turn the...

Page 213: ...ellungen Maximal Minimal Vollst ndig hinein gedreht 20 Rasten gel st nach vollst ndi gem Hineindrehen Normaleinstellung Ungef hr 12 Rasten gel st 5 Serrer Contre crou 6 Monter Cache lat ral gauche T R...

Page 214: ...ompression damping force Turn the adjuster 1 out Extent of adjustment Maximum Minimum Fully turned in position 12 clicks out from maximum position b a 1 STANDARD POSITION This is the position which is...

Page 215: ...leinstellung Ungef hr 9 Rasten gel st REGLAGE DE LA FORCE D AMORTISSEMENT A COMPRESSION DE L AMORTISSEUR ARRIERE TT R125LWE EINSTELLUNG DER FEDERBEIN DRUCKSTUFEND MPFUNG TT R125LWE REGLAGE DE LA FORCE...

Page 216: ...on on the rim If the tire valve stem is found tilted the tire is considered to be slipping off its position Cor rect the tire position Standard tire pressure 100 kPa 1 00 kgf cm2 15 psi SPOKES INSPECT...

Page 217: ...rden Speichenspannung nach Probefahrt kontrollie ren T R Vorderrad 2 Nm 0 2 m kg 1 4 ft lb Hinterrad 3 Nm 0 3 m kg 2 2 ft lb R DER KONTROLLIEREN 1 Kontrollieren Schlag Rad anheben und drehen berm iger...

Page 218: ...assembly back and forth Free play Adjust steering head 3 Check Steering smooth action Turn the handlebar lock to lock Unsmooth action Adjust steering ring nut 4 Adjust Steering ring nut Steering ring...

Page 219: ...gmutter 4 mit Hilfe des Haken schl ssels 5 lockern Hakenschl ssel YU 33975 90890 01403 3 28 2 Contr ler Jeu de roulement Jeu Remplacer CONTR LE ET R GLAGE DE LA T TE DE FOURCHE 1 Sur lever la roue ava...

Page 220: ...assembly and inspect the steering bearings Install the rubber washer 8 upper ring nut 9 and special washer 0 NOTE Tighten the upper ring nut until it contacts the rubber washer Insert the special wash...

Page 221: ...e Markierung a in Fahrtrich tung zeigen Schlauchende des Kraftstoff Entl ftungs schlauchs I in die Schlaucklammer f hren Resserrer l crou cr nel inf rieur 6 l aide de la cl ergots 7 puis tourner quelq...

Page 222: ...t side of the handlebar holder and then tighten the bolts on the rear side T R Pinch bolt upper bracket 25 Nm 2 5 m kg 18 ft lb Steering stem nut 110 Nm 11 0 m kg 80 ft lb Handlebar upper holder 23 Nm...

Page 223: ...kg 80 ft lb Oberer Lenkerhalter 23 Nm 2 3 m kg 17 ft lb Chokezug Befestigungsmutter 1 Nm 0 1 m kg 0 7 ft lb Startnummernblech 7 Nm 0 7 m kg 5 1 ft lb ATTENTION Serrer d abord les boulons situ s l ava...

Page 224: ...ift 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 R1...

Page 225: ...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 226: ...s 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 Cle...

Page 227: ...st Z ndkerze per Hand hineindrehen a und anschlie end mit dem vorgeschriebe nen Drehmoment b festziehen T R 13 Nm 1 3 m kg 9 4 ft lb PARTIE LECTRIQUE INSPECTION DE LA BOUGIE 1 D poser Bougie 2 Contr l...

Page 228: ...bodily contact with electrolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get imm...

Page 229: ...er wichtig da die Batterie vor schriftsm ig geladen wird CONTROLE ET RECHARGE DE LA BATTERIE AVERTISSEMENT Les batteries produisent de l hydrog ne qui est un gaz explosif et elles contiennent de l lec...

Page 230: ...irst disconnect the negative battery lead 1 and then the positive battery lead 2 3 Remove Battery 4 Measure Battery charge Measurement steps Connect a pocket tester 1 to the battery terminals Tester p...

Page 231: ...erden Kein Laden ist erforderlich wenn die Ruhespannung mindestens 12 8 V betr gt N B Comme une batterie MF est scell e il est impossi ble de v rifier son tat de charge en mesurant la densit de l lect...

Page 232: ...ppropriate charging method illustration WARNING Do not quick charge a battery CAUTION Never remove the MF battery sealing caps Do not use a high rate battery charger since it forces a high amperage cu...

Page 233: ...emmen des Ladeger ts an den Batteriepolen angeschlossen worden sind Relation entre la tension en circuit ouvert et le temps de charge 20 C 68 F Ces valeurs varient selon la temp rature l tat des plaqu...

Page 234: ...ontact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process disconnect the battery charger and let the battery cool before recon...

Page 235: ...uhen lassen CONTROLE ET RECHARGE DE LA BATTERIE BATTERIE KONTROLLIEREN UND LADEN Ne pas oublier de couper l alimentation du chargeur avant de retirer les pinces du char geur des bornes de la batterie...

Page 236: ...3 37 INSP ADJ Charging method using a variable voltage charger BATTERY INSPECTION AND CHARGING...

Page 237: ...3 38 INSP ADJ Charging method using a constant voltage charger BATTERY INSPECTION AND CHARGING...

Page 238: ...rage est il sup rieur l amp rage standard de charge indiqu sur la batte rie R gler la tension de charge 20 25 V Surveiller l amp rage pendant 3 5 minutes L amp rage de charge standard est il d pass Si...

Page 239: ...eures Laisser reposer la batterie pendant 30 minutes avant de mesurer sa tension en circuit ouvert 12 8 V La charge est termin e 12 0 12 7 V Il est n cessaire de recharger Moins de 12 0 V Changer la b...

Page 240: ...adestromst rke zu erhalten Ist die Amperezahl h her als die auf der Batterie abgegeben normalen Ladestromst rke Die Ladespannung auf 20 25 V stellen Die Stromst rke 3 5 Minuten lang berwachen Wird die...

Page 241: ...Messen der Ruhespannung die Batterie ber 30 Minuten lang nicht benut zen 12 8 V Der Ladevorgang ist abgeschlos sen 12 0 12 7 V Die Batterie erneut laden Unter 12 0 V Die Batterie erneuern ACHTUNG Lade...

Page 242: ...ttery cover FUSE INSPECTION CAUTION To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 Remove Battery cover 2 Check Continuity 2 Reserve fuse Recommended lu...

Page 243: ...Multime ters auf 1 stellen Taschen Multimeter YU 03112 C 90890 03112 Falls das Multimeter anzeigt die Sicherung erneuern 6 Monter Batterie 7 Contr ler Bornes de batterie Crasse Nettoyer avec une bros...

Page 244: ...rical system cause the starting and ignition systems to malfunction and could possibly cause a fire 4 Install Battery cover Replacement steps Set the main switch to OFF Install a new fuse of the corre...

Page 245: ...fen Brennt die Sicherung sofort wieder durch den entsprechenden Stromkreis kontrollie ren Sicherung Ampere Anzahl Hauptsicherung 10 A 1 3 Remplacer Fusible grill AVERTISSEMENT Ne jamais utiliser un fu...

Page 246: ...Extent 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 fu...

Page 247: ...ernblech 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 Organisation de la d pose 1 D pose de l...

Page 248: ...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 249: ...Mutter Schalld mpfer 2 4 Schraube Schalld mpfer 1 5 Schalld mpfer 1 1 POT D CHAPPEMENT Organisation de la d pose 1 D pose du pot d chappement Organisation de la d pose Ordre Nom de pi ce Qt Remarques...

Page 250: ...ration for removal Fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Number plate 1 Fuel hose 1 2 Over flow hose 1 3 Air vent hose 2 4 Starter plunger starter knob 1 5 Carburetor top cover 1 6...

Page 251: ...Anschlu teil 1 Schrauben lockern Vergaser Anschlu teil 8 Vergaser 1 1 CARBURATEUR Organisation de la d pose 1 D pose du carburateur Organisation de la d pose Ordre Nom de pi ce Qt Remarques D POSE DU...

Page 252: ...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 253: ...tellschraube 1 J Leerlaufanreicherung 1 1 D MONTAGE DU CARBURATEUR Organisation de la d pose 1 D montage du carburateur Organisation de la d pose Ordre Nom de pi ce Qt Remarques D MONTAGE DU CARBURA T...

Page 254: ...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 255: ...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 256: ...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 257: ...nbildung a Erneuern Staub b Reinigen HINWEIS Nadelventil und Nadelventilsitz immer kom plett erneuern INSPECTION Carburateur 1 Contr ler Corps de carburateur Encrassement Nettoyer N B Nettoyer avec du...

Page 258: ...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 259: ...h leichtes 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 c...

Page 260: ...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 261: ...rschraube um die Anzahl der Umdrehungen herausdrehen die vor dem Demontieren notiert wurde Leerlaufluft Regulierschraube 2 1 2 3 1 2 Beispiel Flotteur 1 Contr ler Flotteur 1 Endommagement Remplacer En...

Page 262: ...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 263: ...t 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 Nadelventil...

Page 264: ...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 265: ...en 2 Festziehen Schraube Vergaser Verbindungsteil 1 Schraube Luftfilter Anschlu teil 2 9 Monter Cache sup rieur du carburateur 1 Ressort boisseau 2 Boisseau 3 Sur le c ble d acc l ration 4 N B Connect...

Page 266: ...ose 5 NOTE Align the slit a of the throttle valve with the tab b of the carburetor body CAUTION In order to release the starter cable from the twist install the starter knob after tight ening the nut...

Page 267: ...marreur 4 R gler R gime de ralenti Se reporter la section R GLAGE DU R GIME DE RALENTI au CHAPITRE 3 CARBURATEUR VERGASER 3 Montieren Vergaserdeckel 1 Chokeschieber 2 Bel ftungsschlauch 3 berlaufschl...

Page 268: ...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 269: ...Kurbelwellen Verschlu schraube 1 6 Z ndeinstell Verschlu schraube 1 1 CULASSE CACHE LAT RAL DE CULASSE ET COUVRE POUSSOIRS Organisation de la d pose 1 D pose du cache lat ral de culasse et des couvre...

Page 270: ...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 271: ...Steuerkettenspanner 1 4 Dichtung 1 5 Nockenwellenrad 1 6 Zylinderkopf 1 7 Pa h lse 2 8 Dichtung 1 1 CULASSE Organisation de la d pose 1 D pose de la culasse Organisation de la d pose Ordre Nom de pi...

Page 272: ...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 273: ...tter 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 Ali...

Page 274: ...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 275: ...ritten 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 tallique...

Page 276: ...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 277: ...Quick gasket ACC QUICK GS KT YAMAHA Dichtmasse Nr 1215 90890 85505 T R M8 22 Nm 2 2 m kg 16 ft lb M6 10 Nm 1 0 m kg 7 2 ft lb Limite de d formation 0 03 mm 0 0012 in Si la d formation est hors sp cifi...

Page 278: ...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 279: ...n oder einer ungenauen Ventilsteuerung kommt Den Sicherungsdraht von der Steuerkette entfernen 3 Monter Cha ne de distribution Pignon d arbre cames 4 Monter Rondelle Boulon pignon d arbre cames N B Se...

Page 280: ...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 281: ...lb 8 Festziehen Schraube 1 HINWEIS Rotormutter mit einem Schraubenschl ssel festhalten und Schraube festziehen T R 20 Nm 2 0 m kg 14 ft lb 5 Monter Tendeur de la cha ne de distribution 6 Tourner Vile...

Page 282: ...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 283: ...g 5 1 ft lb 13 Montieren Z ndkerze Motorhalterung T R 13 Nm 1 3 m kg 9 4 ft lb T R 40 Nm 4 0 m kg 29 ft lb 9 Contr ler Jeu de soupapes Hors sp cifications R gler Se reporter la section CONTR LE ET R G...

Page 284: ...xtent of removal 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 shaf...

Page 285: ...TAGEPUNKTE 3 Kipphebelwelle Ausla seite 1 4 Nockenwelle 1 5 Kipphebel Einla seite 1 6 Kipphebel Ausla seite 1 1 2 ARBRE CAMES ET CULBUTEURS Organisation de la d pose 1 D pose de l arbre cames 2 D pose...

Page 286: ...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 287: ...uern Nockenh he Grenzwert Einla a 25 851 mm 1 0178 in b 21 165 mm 0 8333 in Ausla a 25 811 mm 1 0162 in b 21 020 mm 0 8276 in PI CES D POSER Axes de culbuteur 1 D poser Axes de culbuteur N B Se servir...

Page 288: ...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 289: ...tieren Kipphebel Nockenwelle 1 3 Auftragen Motor l auf die Kipphebelwelle 4 Montieren Kipphebelwelle Culbuteurs et axes de culbuteur 1 Contr ler Surface de contact de bossage de came a Surface du disp...

Page 290: ...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 291: ...CAMES ET CULBUTEURS NOCKENWELLE UND KIPPHEBEL 5 Montieren Nockenwellenlager Halter 1 Schraube 2 T R 10 Nm 1 0 m kg 7 2 ft lb LT 5 Monter Support de roulement d arbre cames 1 Boulon 2 T R 10 Nm 1 0 m k...

Page 292: ...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 293: ...nla ventil 1 5 Ausla ventil 2 6 Ventilschaftdichtung 2 7 Ventilfedersitz 2 1 SOUPAPES ET RESSORTS DE SOUPAPE Organisation de la d pose 1 D poses des soupapes et des ressorts de soupape Organisation de...

Page 294: ...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 295: ...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 296: ...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 297: ...Ventilf hrung den Ventilsitz nachschleifen INSPECTION Soupape 1 Mesurer Jeu de queue dans le guide Hors sp cifications Remplacer le guide de soupape Jeu de queue dans le guide diam tre int rieur de g...

Page 298: ...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 299: ...ungen von Ventilkegel und Ventilsitz 7 Kontrollieren Ventilsitze Pitting Bildung Verschlei Ventilsitz neu fr sen 3 Contr ler Face de soupape Piq res usure Surfacer la face de sou pape Embout de queue...

Page 300: ...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 301: ...chaft und Ventilf hrung 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 A...

Page 302: ...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 303: ...tsm ig Erneuern Ungespannte L nge Ventilfeder Einla 32 55 mm 1 28 in Grenzwert 31 2 mm 1 23 in Ausla 32 55 mm 1 28 in Grenzwert 31 2 mm 1 23 in Installer la soupape dans la culasse Tourner la soupape...

Page 304: ...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 305: ...telle montiert wird Ventilfedern mit 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 Mes...

Page 306: ...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 307: ...Klopfen auf die Ventil schaftenden k nnten die Ventile besch digt werden Ventilfederspanner YM 4019 90890 04019 3 Monter Clavettes de soupape 1 N B Installer les clavettes de soupape en comprimant le...

Page 308: ...of removal 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 p...

Page 309: ...1 5 Kolbenbolzensicherung 2 Siehe unter DEMONTAGEPUNKTE 6 Kolbenbolzen 1 7 Kolben 1 8 Kolbenring Satz 1 1 2 CYLINDRE ET PISTON Organisation de la d pose 1 D pose du cylindre 2 D pose du piston Organi...

Page 310: ...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 311: ...nbolzen 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 axe...

Page 312: ...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 313: ...olbenlaufspiel 0 020 0 026 mm 0 0008 0 0010 in Grenzwert 0 15 mm 0 006 in 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 m...

Page 314: ...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 315: ...Kolbenbol zenauge 15 002 15 013 mm 0 5906 0 5911 in Grenzwert 15 043 mm 0 5922 in Si la valeur obtenue ne correspond pas aux sp cifications remplacer le cylindre et rempla cer la fois le piston et se...

Page 316: ...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 317: ...4 mm 0 016 in 2 Kom pressi onsring 0 30 0 45 mm 0 012 0 018 in 0 55 mm 0 022 in lab streifring 0 20 0 70 mm 0 01 0 03 in Segment de piston 1 Mesurer Jeu lat ral de segment Utiliser une cale d paisseur...

Page 318: ...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 319: ...1257 2 1258 in Zylinder Markierung Kolbenmarkierung Farbe A A rot B B orange C C gr n 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 su...

Page 320: ...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 321: ...hmieren Kolben Kolbenringe Zylinderlauffl che HINWEIS Reichlich Motor l auftragen New ASSEMBLAGE ET REPOSE Segments et piston 1 Monter Segments de piston sur le piston N B S assurer d installer le seg...

Page 322: ...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 323: ...darf bei der Montage nicht besch digt werden HINWEIS Nach der Montage die Leichtg ngigkeit des Kolbens pr fen New Cylindre 1 Monter Goujons 1 Joint cylindre 2 New 2 Monter Joint torique Cylindre 1 Pa...

Page 324: ...ION 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 section Starter motor 1 Refer to ELECTR...

Page 325: ...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 Organisation de la d pose 1 D pose des di...

Page 326: ...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 327: ...1 Se reporter la section PI CES D PO SER 9 Pignon menant primaire 1 10 Clavette droite 1 2 1 EMBRAYAGE ET PIGNON MEN PRIMAIRE KUPPLUNG UND PRIM RABTRIEBSZAHNRAD PRIM RABTRIEBSZAHNRAD Demontage Arbeit...

Page 328: ...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 329: ...l 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 Organisation de la d pose 1 D pose du levier de pouss e Org...

Page 330: ...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 331: ...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 c...

Page 332: ...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 333: ...21 in Grenzwert 2 8 mm 0 110 in Verzugsgrenze 0 2 mm 0 008 in Ressort d embrayage 1 Mesurer Longueur libre de ressort d embrayage a Hors sp cifications Remplacer tous les ressorts Longueur libre de re...

Page 334: ...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 335: ...platte 5 zwischen die Z hne des Prim rantriebszahnrades und des Pri m rabtriebszahnrades stecken T R 70 Nm 7 0 m kg 50 ft lb Tige de commande 1 Contr ler Tige de commande 1 1 Bille 2 Usure endommageme...

Page 336: ...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 337: ...m Ver satz von etwa 90 zur Nase der vorhergehen den Scheibe montieren Im Uhrzeigersinn vorgehen bis alle Kupplungsscheiben mon tiert sind Embrayage 1 Monter Rondelle lastique conique 1 Plaque de pouss...

Page 338: ...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 339: ...sgerichtet sind Einstellen a Markierung auf dem Ausr ckhebel b Markierung auf dem Kurbelgeh use 5 Monter Bille N B Enduire la bille d huile de moteur 6 Monter Tige de commande 1 1 Plaque de pouss e 2...

Page 340: ...crankcase cover Right crankcase cover Battery negative lead 1 Lead holder 2 Bolts right crankcase cover NOTE Apply Quick gasket YAMAHA Bond No 1215 to end of the right crankcase cover bolts as shown...

Page 341: ...sedeckel besteht Quick gasket ACC QUICK GS KT YAMAHA Dichtmasse Nr 1215 90890 85505 New T R 10 Nm 1 0 m kg 7 2 ft lb T R 50 Nm 5 0 m kg 36 ft lb 9 R gler Position du levier de pouss e tapes du r glage...

Page 342: ...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 343: ...1 2 lpumpe Antriebsrad 1 3 lpumpe komplett 1 4 Dichtung 1 5 lpumpensieb 1 1 POMPE HUILE Organisation de la d pose 1 D pose de la pompe huile Organisation de la d pose Ordre Nom de pi ce Qt Remarques D...

Page 344: ...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 345: ...tift 1 0 Innenrotor 1 A Au enrotor 1 B lpumpengeh use 1 1 D MONTAGE DE LA POMPE HUILE Organisation de la d pose 1 D montage de la pompe huile Organisation de la d pose Ordre Nom de pi ce Qt Remarques...

Page 346: ...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 347: ...5 mm 0 0059 in Zentrifugalfilter 1 Kontrollieren Zentrifugalfilter Risse Besch digung Erneuern INSPECTION Pompe huile 1 Contr ler Pignon menant de pompe huile Pignon men de pompe huile Logement de la...

Page 348: ...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 349: ...3 6 ft lb New T R 7 Nm 0 7 m kg 5 1 ft lb Cr pine huile 1 Contr ler Cr pine huile Craquelures endommagement Rempla cer Crasses obstructions Nettoyer ASSEMBLAGE ET REPOSE Pompe huile 1 Monter Logement...

Page 350: ...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 351: ...ckstarter 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 ARBRE DE S LECTEUR Organisation...

Page 352: ...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 353: ...rritzel Clip 1 Messen Kickstarterritzel Clip Friktionskraft R ckholfeder Nicht vorschriftsm ig Erneuern Dynamometer 1 verwenden Kickstarterritzel Clip Friktionskraft 0 65 1 35 kg 1 4 3 0 lb PI CES D P...

Page 354: ...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 355: ...INWEIS Kickstarter Anschlag Rolle auf den Schlitz im Kickstarter Zahnsegment ausrichten T R 12 Nm 1 2 m kg 8 7 ft lb LT T R 10 Nm 1 0 m kg 7 2 ft lb LT Arbre de s lecteur 1 Contr ler Arbre de s lecteu...

Page 356: ...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 357: ...den 4 Einhaken 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 Monter Arbre de s lecteur 1 N B Enduire l...

Page 358: ...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 359: ...S Motor l auf das gesamte Kickstarterritzel auftragen Kickstarterritzel mit der flachen Seite nach au en montieren New New Pignon libre de kick 1 Monter Circlip 1 Rondelle 2 Pignon libre de kick 3 Ron...

Page 360: ...Remarks CDI MAGNETO AND STATOR REMOVAL Preparation for removal Fuel tank 1 CDI magneto lead 1 2 Neutral switch lead 1 3 Left crankcase cover 1 4 Nut rotor 1 Use special tool Refer to REMOVAL POINTS 5...

Page 361: ...terleerlaufrad 1 11 Starterleerlaufrad 1 12 Kabelf hrung 1 13 Aufnehmerspule St nder Bau gruppe 1 2 1 1 MAGNETO CDI ET ROCHET DE DEMARRAGE Organisation de la d pose 1 D pose de la bobine d excitation...

Page 362: ...0 01362 EC4L4000 INSPECTION EC4L4101 CDI magneto 1 Inspect Rotor inner surface a Stator outer surface b Damage Inspect the crankshaft runout and crankshaft bearing If necessary replace CDI magneto and...

Page 363: ...keit Ver schlei Die defekten Teile erneuern MAGNETO CDI ET ROCHET DE DEMARRAGE CDI MAGNETZ NDER UND STARTERKUPPLUNG PI CES D POSER Rotor 1 D poser crou rotor 1 Rondelle plate 2 Se servir d une cl sang...

Page 364: ...ust be replaced When turning the starter clutch drive gear clockwise it should turn freely If the starter clutch drive gear does not turn freely the starter clutch is faulty and must be replaced 1 2 E...

Page 365: ...ad 1 Scheibe 2 Schraube 3 Unterlegscheibe 4 HINWEIS Das Motor l auf den Innenumfang des Starter leerlaufrads und auf den Au enumfang der Welle auftragen T R 7 Nm 0 7 m kg 5 1 ft lb 3 Contr ler Fonctio...

Page 366: ...serve as a stop per a T R 30 Nm 3 0 m kg 22 ft lb 5 Install Starter wheel gear 1 Woodruff key 2 Rotor 3 NOTE Clean the tapered portion of the crankshaft and the magneto hub When installing the magneto...

Page 367: ...gehalten wird Kupplungskorb Halter YS 1880 A 90890 01701 T R 80 Nm 8 0 m kg 58 ft lb MAGNETO CDI ET ROCHET DE DEMARRAGE CDI MAGNETZ NDER UND STARTERKUPPLUNG 3 Installer l embrayage de d marreur 1 sur...

Page 368: ...ver left 8 Connect Neutral switch lead 1 NOTE Pass the neutral switch lead into the crank case cover groove as shown 9 Connect CDI magneto lead Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2...

Page 369: ...rotor Kabel Siehe unter KABELF HRUNG in KAPITEL 2 MAGNETO CDI ET ROCHET DE DEMARRAGE CDI MAGNETZ NDER UND STARTERKUPPLUNG 7 Monter Couvercle de carter gauche 8 Connecter Fil de contacteur de point mor...

Page 370: ...Seat fuel tank and side covers Refer to SEAT FUEL TANK AND SIDE COVERS section Carburetor Refer to CARBURETOR section Muffler Refer to MUFFLER section Clutch cable Disconnect at engine side Spark plug...

Page 371: ...M in KAPITEL 6 Motor l ablassen Siehe unter MOTOR L WECHSELN in KAPITEL 3 D POSE DU MOTEUR Organisation de la d pose 1 D pose du moteur Organisation de la d pose Ordre Nom de pi ce Qt Remarques D POSE...

Page 372: ...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 373: ...orhalterung vorne 1 10 Motorbefestigungsschraube hinten 2 11 Motor 1 Siehe unter DEMONTAGEPUNKTE 1 Organisation de la d pose Ordre Nom de pi ce Qt Remarques 1 Cache de pignon menant 1 2 Boulon pignon...

Page 374: ...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 375: ...29 ft lb T R 40 Nm 4 0 m kg 29 ft lb T R 40 Nm 4 0 m kg 29 ft lb T R 40 Nm 4 0 m kg 29 ft lb T R 40 Nm 4 0 m kg 29 ft lb PI CES D POSER Pignon menant 1 D poser Boulon pignon menant Support de pignon m...

Page 376: ...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 377: ...bsritzel Deckel 1 Schraube Antriebsritzel Deckel 2 T R 12 Nm 1 2 m kg 8 7 ft lb N B Enduire le filet des boulons de montage du moteur 2 de graisse base de savon au lithium Serrer le boulon de montage...

Page 378: ...der 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 gear Refe...

Page 379: ...he unter KICKSTARTERWELLE UND SCHALTWELLE Kickstarter Zahnsegment Rotor und Stator Siehe unter CDI MAGNETZ NDER UND STARTERKUPPLUNG CARTER MOTEUR VILEBREQUIN ET BALANCIER Organisation de la d pose 1 S...

Page 380: ...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 381: ...1 11 Kurbelwelle 1 Spezialwerkzeug verwenden Siehe unter DEMONTAGEPUNKTE 12 Lager 3 Siehe unter DEMONTAGEPUNKTE 3 2 1 Organisation de la d pose Ordre Nom de pi ce Qt Remarques 1 Patin de cha ne de dis...

Page 382: ...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 383: ...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 384: ...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 385: ...ifheit 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 d...

Page 386: ...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 387: ...Axial spiel 0 15 0 45 mm 0 0059 0 0177 in 0 50 mm 0 02 in Kurbel breite 46 95 47 00 mm 1 848 1 850 in Carter moteur 1 Contr ler Plan de joint a Rayures Remplacer Noix de montage du moteur b carter mo...

Page 388: ...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 389: ...g 3 YU 90050 90890 01275 Adapter 4 YU 90063 90890 01278 Distanzh lse 5 YM 91044 90890 04081 Balancier 1 Contr ler Balancier Craquelures endommagement Rempla cer ASSEMBLAGE ET REPOSE Roulement 1 Monter...

Page 390: ...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 391: ...fte 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 Monter Balancier N B...

Page 392: ...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 393: ...rkettenf hrung Einla seite 2 Schraube Steuerkettenf hrung Ein la seite T R 10 Nm 1 0 m kg 7 2 ft lb LT 3 Serrer Guide de fil 1 Support de c ble d embrayage 2 Boulon carter moteur 45 mm 1 8 in 3 Boulon...

Page 394: ...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 395: ...NTAGEPUNKTE 8 Ausgangswelle 1 9 Druckstange 2 1 10 Anlaufscheibe 1 1 2 BO TE DE VITESSES TAMBOUR ET FOURCHETTES DE S LECTION Organisation de la d pose 1 D pose du tambour et des fourchettes de s lecti...

Page 396: ...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 397: ...e 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 g...

Page 398: ...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 399: ...e sich neben der Schaltgabel befinden Roulement 1 Contr ler Roulement 1 Faire tourner la cage interne avec un doigt Duret grippage Remplacer Fourchette de s lection et tambour 1 Contr ler Fourchette d...

Page 400: ...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 401: ...auf den Innenring der Zahn r der auftragen Bo te de vitesses 1 Monter 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 402: ...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 403: ...geachtet werden da die Dichtlippe des Kurbelge h use Dichtrings nicht besch digt wird 3 Monter Rondelle plate 1 Circlip 2 N B S assurer de diriger le c t ouvert a du circlip du c t oppos de la rondell...

Page 404: ...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 405: ...parieren Tambour et fourchette de s lection 1 Monter 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...

Page 406: ...ame 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 fal...

Page 407: ...Distanzst ck 1 2 3 1 ROUE AVANT ET FREIN AVANT TT R125E VORDERRAD UND VORDERRADBREMSE TT R125E PARTIE CYCLE ROUE AVANT ET FREIN AVANT TT R125E Organisation de la d pose 1 D pose de la roue avant 2 D p...

Page 408: ...FRONT WHEEL AND FRONT BRAKE TT R125E 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 p...

Page 409: ...1 14 Verschlei anzeige 1 15 Bremsnocken 1 16 Bremsankerplatte 1 3 ROUE AVANT ET FREIN AVANT TT R125E VORDERRAD UND VORDERRADBREMSE TT R125E Organisation de la d pose Ordre Nom de pi ce Qt Remarques 11...

Page 410: ...runout 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...

Page 411: ...biegung 0 5 mm 0 020 in ROUE AVANT ET FREIN AVANT TT R125E VORDERRAD UND VORDERRADBREMSE TT R125E PI CES D POSER Roulement de roue si n cessaire 1 D poser Roulement 1 N B D poser le roulement l aide d...

Page 412: ...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 413: ...chtig und gleichm ig polieren ROUE AVANT ET FREIN AVANT TT R125E VORDERRAD UND VORDERRADBREMSE TT R125E Frein tambour 1 Contr ler Surface de garniture de m choire de frein Zones brillantes Poncer Util...

Page 414: ...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 415: ...emsbel ge auftra gen T R 10 Nm 1 0 m kg 7 2 ft lb New ROUE AVANT ET FREIN AVANT TT R125E VORDERRAD UND VORDERRADBREMSE TT R125E REMONTAGE ET INSTALLATION Flasque de frein complet 1 Monter Came de frei...

Page 416: ...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 417: ...NT TT R125E VORDERRAD UND VORDERRADBREMSE TT R125E Roue avant 1 Monter 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...

Page 418: ...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 419: ...Siehe unter VORDERRADBREMSE EINSTELLEN IN KAPITEL 3 ROUE AVANT ET FREIN AVANT TT R125E VORDERRAD UND VORDERRADBREMSE TT R125E 5 Monter crou d axe 1 T R 45 Nm 4 5 m kg 32 ft lb 6 Monter C ble de frein...

Page 420: ...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 421: ...ter DEMONTAGEPUNKTE 8 Distanzst ck 1 9 Bremsscheibe 1 2 3 1 3 ROUE AVANT TT R125LWE VORDERRAD TT R125LWE ROUE AVANT TT R125LWE Organisation de la d pose 1 D pose de la roue avant 2 D pose des roulemen...

Page 422: ...ring 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 EC51420...

Page 423: ...in Max Seitenschlag 2 2 0 mm 0 08 in Maximal zul ssige Achsbiegung 0 5 mm 0 020 in 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...

Page 424: ...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 425: ...0 in New Disque 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 lim...

Page 426: ...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 427: ...l ge 2 f hren 5 Montieren Radachse 1 6 Montieren Unterlegscheibe 1 Achsmutter 2 T R 45 Nm 4 5 m kg 32 ft lb 2 Monter Disque de frein 1 Boulon disque de frein 2 N B Serrer les boulons par tapes et dan...

Page 428: ...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 429: ...USBAU 7 Handbremshebel 1 8 Hauptbremszylinder Halterung 1 9 Hauptbremszylinder 1 2 3 1 3 2 FREIN AVANT TT R125LWE Organisation de la d pose 1 D pose du flexible de frein 2 D pose de l trier de frein 3...

Page 430: ...YLINDER DISAS 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...

Page 431: ...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 Organisation de la d pose 1 D montage de l trier...

Page 432: ...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 433: ...Bremssattelkolben vorsichtig mit Druckluft aus dem Bremssattel heraus pressen FREIN AVANT TT R125LWE VORDERRADBREMSE TT R125LWE PI CES D POSER Liquide de frein 1 D poser Couvercle de ma tre cylindre d...

Page 434: ...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 435: ...tbremszylinder 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 j...

Page 436: ...ake 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 dam...

Page 437: ...EIN AVANT TT R125LWE VORDERRADBREMSE TT R125LWE trier de frein 1 Contr ler Surface int rieure du cylindre d trier de frein a Endommagement striation par usage Remplacer l trier de frein complet 2 Cont...

Page 438: ...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 439: ...Auf Bremssattel Halterung 2 aufset zen New New FREIN AVANT TT R125LWE VORDERRADBREMSE TT R125LWE REMONTAGE ET INSTALLATION AVERTISSEMENT Nettoyer les pi ces internes exclusivement avec du liquide de f...

Page 440: ...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 su...

Page 441: ...ile Mit Bremsfl ssigkeit reinigen FREIN AVANT TT R125LWE VORDERRADBREMSE TT R125LWE 2 Monter Manchon sup rieur 1 sur l trier de frein 2 N B Enduire la surface interne du manchon sup rieur de graisse b...

Page 442: ...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 443: ...Montage des Sicherungsrings eine Zange mit langen Backen verwenden FREIN AVANT TT R125LWE VORDERRADBREMSE TT R125LWE 2 Monter Coupelle primaire de ma tre cylindre de frein 1 Coupelle secondaire de ma...

Page 444: ...olt 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 R 9 Nm 0...

Page 445: ...ft lb FREIN AVANT TT R125LWE VORDERRADBREMSE TT R125LWE Ma tre cylindre de frein 1 Monter Ma tre cylindre de frein 1 Demi palier de fixation de ma tre cylindre de frein 2 Boulon demi palier de fixati...

Page 446: ...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 447: ...rung 1 Schrauben Bremsschlauch Halterung 2 T R 7 Nm 0 7 m kg 5 1 ft lb FREIN AVANT TT R125LWE VORDERRADBREMSE TT R125LWE 2 Faire passer le flexible de frein par le guide de c ble 1 3 Monter Rondelle e...

Page 448: ...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 449: ...I TEL 3 FREIN AVANT TT R125LWE VORDERRADBREMSE TT R125LWE Liquide de frein 1 Remplir Liquide de frein jusqu ce que le niveau du liquide atteigne la ligne LOWER a AVERTISSEMENT Utiliser exclusivement l...

Page 450: ...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 451: ...Bremssattel Bremsfl ssigkeit austritt T R 2 Nm 0 2 m kg 1 4 ft lb FREIN AVANT TT R125LWE VORDERRADBREMSE TT R125LWE 4 Monter Diaphragme Couvercle de ma tre cylindre de frein 1 Vis couvercle de ma tre...

Page 452: ...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 453: ...e 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 Organisation de la d pose 1 D pose de la roue arri re 2 D pose des roulement...

Page 454: ...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 455: ...Feder 2 18 Bremsnocken Bet tigungshebel 1 19 Verschlei anzeiger 1 20 Bremsnocken 1 21 Bremsankerplatte 1 3 2 Organisation de la d pose Ordre Nom de pi ce Qt Remarques 11 crou pignon de roue arri re 4...

Page 456: ...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 457: ...m 0 08 in Max Seitenschlag 2 2 0 mm 0 08 in Maximal zul ssige Achsbiegung 0 5 mm 0 020 in 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 transmis...

Page 458: ...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 459: ...ftsm ig Erneuern Bremstrommel Innendurchmes ser Standard Grenzwert 110 mm 4 33 in 111 mm 4 37 in N B Pour obtenir la d formation il faut diviser en deux la valeur affich e sur le comparateur cadran AV...

Page 460: ...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 461: ...ung a montieren wie in der Abbildung gezeigt T R 10 Nm 1 0 m kg 7 2 ft lb ROUE ARRI RE ET FREIN ARRI RE HINTERRAD UND HINTERRADBREMSE 4 Contr ler Surface int rieure du tambour de frein Taches d huile...

Page 462: ...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 463: ...ET FREIN ARRI RE HINTERRAD UND HINTERRADBREMSE 5 Monter 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 464: ...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 465: ...er linken Seite aus montie ren ROUE ARRI RE ET FREIN ARRI RE HINTERRAD UND HINTERRADBREMSE 2 Monter Pignon de roue arri re 1 Rondelles d arr t 2 crou pignon de roue arri re 3 N B Serrer les crous par...

Page 466: ...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 467: ...ter HINTERRADBREMSE EINSTELLEN in KAPITEL 3 ROUE ARRI RE ET FREIN ARRI RE HINTERRAD UND HINTERRADBREMSE 7 Monter Tendeur de cha ne de transmission droit 1 Rondelle plate 2 crou d axe 3 N B Serrer l cr...

Page 468: ...able 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...

Page 469: ...Klemmschraube untere Gabelbr cke 1 1 Nur lockern 5 Teleskopgabel 1 1 1 FOURCHE AVANT TELESKOPGABEL FOURCHE AVANT TT R125E TT R125LWE Organisation de la d pose 1 D pose de la fourche avant Organisatio...

Page 470: ...Q ty Remarks FRONT FORK DISASSEMBLY A B 1 Dust boot 1 1 2 Cap bolt 1 1 Refer to REMOVAL POINTS 3 Spacer 1 4 Washer 1 1 5 Fork spring 1 1 Drain the fork oil 6 Dust seal 1 1 Use special tool Refer to RE...

Page 471: ...htring 1 1 D Tauchrohr 1 1 2 1 FOURCHE AVANT TELESKOPGABEL D MONTAGE DE LA FOURCHE AVANT TT R125E TT R125LWE Organisation de la d pose 1 D pose de la bague d tanch it 2 D pose de la tige d amortisseur...

Page 472: ...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 bolt 1 From t...

Page 473: ...ferrohrbuchse Metallh lse 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 474: ...ith 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 oil is...

Page 475: ...6 mm 17 66 in FOURCHE 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...

Page 476: ...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 477: ...O Ring 2 Verschlei Besch digung Erneuern FOURCHE AVANT TELESKOPGABEL Tube plongeur 1 Contr ler Surface du tube plongeur a Striation par usage R parer ou rempla cer Utiliser du papier de verre humide...

Page 478: ...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 479: ...90 01294 T Griff YM 01326 90890 01326 New T R 23 Nm 2 3 m kg 17 ft lb LT FOURCHE AVANT TELESKOPGABEL REMONTAGE ET INSTALLATION Fourche avant 1 Nettoyer toutes les pi ces dans du dissolvant propre 2 Mo...

Page 480: ...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 481: ...AVANT TELESKOPGABEL 5 Monter 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 e...

Page 482: ...ork leg TT R125E 159 cm3 5 60 Imp oz 5 38 US oz TT R125LWE 158 cm3 5 56 Imp oz 5 34 US oz 11 After filling pump the inner tube slowly up and down more than 10 times to dis tribute the fork oil 12 Meas...

Page 483: ...ante des Standrohrs bei vollst ndig eingetauchtem Standrohr und ohne Gabelfeder FOURCHE AVANT TELESKOPGABEL 9 Comprimer fond la fourche avant 10 Remplir Huile de fourche avant 1 ATTENTION Utiliser san...

Page 484: ...R125E TT R125LWE Front fork top end standard a Zero mm Zero in a 1 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...

Page 485: ...m 6 0 m kg 43 ft lb T R 25 Nm 2 5 m kg 18 ft lb 5 Montieren TT R125E Schutzkappe 1 FOURCHE AVANT TELESKOPGABEL Installation 1 Monter Fourche avant N B Serrer le boulon de pincement du t inf rieur de q...

Page 486: ...al HANDLEBAR REMOVAL Number plate 1 Clutch cable 1 2 Clutch lever 1 3 Engine stop switch 1 4 Front brake cable 1 5 Start switch 1 6 Front brake lever 1 7 Grip cap lower 1 8 Grip cap upper 1 9 Throttle...

Page 487: ...schalter 1 14 Lenkerhalter 2 15 Lenker 1 1 GUIDON LENKER GUIDON TT R125E Organisation de la d pose 1 D pose du guidon Organisation de la d pose Ordre Nom de pi ce Qt Remarques Pr paration la d pose D...

Page 488: ...EBAR 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 Start switch 1 6 Grip cap lower 1 7 Grip cap upper 1 8 Throttle c...

Page 489: ...er 1 12 Lenkerhalter 2 13 Lenker 1 1 GUIDON LENKER TT R125LWE Organisation de la d pose 1 D pose du guidon Organisation de la d pose Ordre Nom de pi ce Qt Remarques Pr paration la d pose D POSE DU GUI...

Page 490: ...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 491: ...I GN E DES GAZ 1 Poign e de guidon droite 1 Se reporter la section L MENTS D POSER 2 Entretoise paul e 2 3 Tube de commande des gaz 1 1 GASDREHGRIFF ZERLEGEN Demontage Arbeiten 1 Gasdrehgriff zerlegen...

Page 492: ...master cylinder cap side horizontal to prevent air from coming in U P 1 2 Handlebar grip 1 Remove Handlebar grip 1 NOTE Blow in air between the handlebar or tube guide and the grip Then remove the gri...

Page 493: ...en ker zu richten weil dadurch seine Stabilit t verloren geht GUIDON LENKER PI CES D POSER Ma tre cylindre de frein TT R125LWE 1 D poser Demi palier de fixation de ma tre cylindre de frein 1 Ma tre cy...

Page 494: ...dlebar 1 Install Handlebar 1 Handlebar holder 2 Main switch 3 Main switch holder 4 Bolt handlebar holder 5 NOTE Align the punched mark a on the handlebar with the upper surface of the handlebar holder...

Page 495: ...e hinteren Schrauben festziehen T R 23 Nm 2 3 m kg 17 ft lb GUIDON LENKER REMONTAGE ET INSTALLATION Poign e des gaz compl te 1 Monter Entretoise paul e 1 Poign e de guidon droite 2 Enduire le tube de...

Page 496: ...cap upper 2 Throttle cable 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...

Page 497: ...g 2 9 ft lb GUIDON LENKER 2 Monter 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 diluant pour pe...

Page 498: ...er side 7 Install Engine stop switch 1 Clutch lever holder 2 Screws clutch lever holder 3 NOTE The engine stop switch and clutch lever holder should be installed according to the dimensions shown Pass...

Page 499: ...ntacteur de d marrage 1 Boulons contacteur de d marrage 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 R125LWE Contacteur de d marrage 1...

Page 500: ...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 501: ...mutter unten 1 7 Untere Gabelbr cke 1 8 Lager Schutzkappe 1 1 2 DIRECTION LENKUNG DIRECTION Organisation de la d pose 1 D pose du t inf rieur 2 D pose de la tige d amortisseur ETAPES DE SERRAGE Serrer...

Page 502: ...STEERING Extent 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...

Page 503: ...he unter DEMONTAGEPUNKTE 12 u erer Lager Laufring unten 1 13 Lager unten 1 2 DIRECTION LENKUNG Organisation de la d pose Ordre Nom de pi ce Qt Remarques 9 Cage interne haut de roulement 1 10 Roulement...

Page 504: ...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 505: ...en 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 dire...

Page 506: ...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 507: ...ger und 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 Contr ler Billes de roulement Cag...

Page 508: ...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 509: ...Die Klemmschrauben der oberen Gabel br cke noch nicht festziehen DIRECTION LENKUNG 4 Monter T inf rieur 1 N B Enduire le roulement de graisse base de savon au lithium 5 Monter crou cr nel inf rieur 1...

Page 510: ...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 TT R125E TT R125LWE Front fork top end standard a Zero mm Zero in a 13 T...

Page 511: ...abelbr cke 1 Klemmschrauben obere Gabelbr cke 2 T R 60 Nm 6 0 m kg 43 ft lb T R 25 Nm 2 5 m kg 18 ft lb DIRECTION LENKUNG 9 Serrer crou de colonne de direction 1 10 Monter Capuchon 2 11 Apr s avoir se...

Page 512: ...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 513: ...dre 1 4 Boulon amortisseur 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...

Page 514: ...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 515: ...Buchse 1 D Schwinge 1 3 1 2 BRAS OSCILLANT SCHWINGE D MONTAGE DU BRAS OSCILLANT Organisation de la d pose 1 D montage du bras oscillant 2 D pose et d montage du bras de raccordement 3 D pose et d mon...

Page 516: ...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 517: ...bschutz 9 Besch digung Erneuern 3 Kontrollieren 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 en la poussan...

Page 518: ...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 519: ...hwinge HINWEIS Lagerbuchsen und Dichtlippen der Staub schutzabdeckungen mit Molybd ndisulfid bestreichen BRAS OSCILLANT SCHWINGE Bras de raccordement 1 Contr ler Entretoise paul e 1 Bague 2 Endommagem...

Page 520: ...al lip and dust cover lip 3 Install Collar 1 Dust covers 2 On connecting arm NOTE Apply the molybdenum disulfide grease on the collar and dust cover lip 4 Install Relay arm 1 Bolt relay arm Plain wash...

Page 521: ...streichen T R 70 Nm 7 0 m kg 50 ft lb T R 53 Nm 5 3 m kg 38 ft lb BRAS OSCILLANT SCHWINGE 2 Monter Bagues d tanch it 1 Entretoises paul es 2 Bague 3 Caches antipoussi re 4 Caches antipoussi re 5 Manch...

Page 522: ...lb 7 Install Drive chain support 1 Collars Bolts drive chain support 2 Drive chain guard 3 Bolts drive chain guide 4 T R 7 Nm 0 7 m kg 5 1 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb LT Installation 1 Install S...

Page 523: ...en oder erneu ern T R 53 Nm 5 3 m kg 38 ft lb BRAS OSCILLANT SCHWINGE 5 Monter Bras de raccordement 1 Boulon bras de raccordement Rondelle plate crou bras de raccordement sur le bras relais N B Enduir...

Page 524: ...Plain washer Nut connecting arm frame NOTE Apply the molybdenum disulfide grease on the bolt connecting arm frame T R 35 Nm 3 5 m kg 25 ft lb 5 Install Drive chain tensioner lower 1 Collar Bolt drive...

Page 525: ...erbuchse mit Lithiumfett bestreichen T R 23 Nm 2 3 m kg 17 ft lb BRAS OSCILLANT SCHWINGE 3 Monter Boulon amortisseur arri re basculeur 1 Rondelle plate crou amortisseur arri re bras relais N B Enduire...

Page 526: ...SSEMBLY 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 FUEL TA...

Page 527: ...E 4 Hinterrad Sto d mpfer 1 1 COMBIN RESSORT AMORTISSEUR ARRI RE HINTERRAD STOSSD MPFER COMBIN RESSORT AMORTISSEUR ARRI RE Organisation de la d pose 1 D pose du combin ressort amortisseur arri re Orga...

Page 528: ...ever tamper or attempt to open the rear shock absorber 2 Never throw the rear shock absorber into an open flame or other high heat The rear shock absorber may explode as a result of nitrogen gas expan...

Page 529: ...en 5 Beim Entsorgen des Hinterradsto d mpfers m ssen die Anweisungen f r die Entsorgung befolgt werden COMBIN RESSORT AMORTISSEUR ARRI RE HINTERRAD STOSSD MPFER REMARQUE CONCERNANT LA MANIPULATION AVE...

Page 530: ...the gas valve needle with a suitable tool as shown until all of the gas is released the hissing has stopped TT R125E TT R125LWE EC583000 REMOVAL POINTS Bushing 1 Remove Bushing 1 NOTE Remove the bushi...

Page 531: ...eder auf und ab bewegen COMBIN RESSORT AMORTISSEUR ARRI RE HINTERRAD STOSSD MPFER REMARQUES SUR LA MISE AU REBUT CONCESSIONNAIRES YAMAHA UNIQUEMENT Il est indispensable d liminer la pression du gaz av...

Page 532: ...Install Bolt rear shock absorber assembly frame Plain washer 1 Nut rear shock absorber assembly frame 2 NOTE Apply the molybdenum disulfide grease on the bolt rear shock absorber assembly frame T R 5...

Page 533: ...g 25 ft lb COMBIN RESSORT AMORTISSEUR ARRI RE HINTERRAD STOSSD MPFER REMONTAGE ET INSTALLATION Bague 1 Monter Bague 1 N B Remettre la bague en place en la poussant Installation 1 Monter Combin ressort...

Page 534: ...ottom portion directs as shown and lightly touches the projection a on the frame Install the rear shock absorber assembly sub tank with a clearance b between the sub tank and frame Fasten the sub tank...

Page 535: ...TEL 2 T R 4 Nm 0 4 m kg 2 9 ft lb COMBIN RESSORT AMORTISSEUR ARRI RE HINTERRAD STOSSD MPFER 4 Monter TT R125LWE Sous r servoir de l ensemble de l amortis seur arri re 1 Crampon de vis 2 Attache 3 N B...

Page 536: ...y 9 Starter relay 0 Fuse A Rectifier regulator B Neutral switch C CDI magneto D Starter motor E Spark plug COLOR CODE B Black Br Brown G Green O Orange R Red Sb Sky blue W White Y Yellow B W Black Whi...

Page 537: ...u W wei Y gelb B W schwarz wei L Y blau gelb R W rot wei Die Abbildung zeigt die TT R125LWE SCHALTPLAN PARTIE LECTRIQUE QUIPEMENT LECTRIQUE ET SCH MA DE C BLAGE COMPOSANTS LECTRIQUES 1 Bloc CDI 2 Coup...

Page 538: ...at 2 Fuel tank Use the following special tools in this inspection Dynamic spark tester YM 34487 Ignition checker 90890 06754 Pocket tester YU 3112 C 90890 03112 Spark gap test Clean or replace spark p...

Page 539: ...dans ce d pistage des pannes Test de longueur d tincelle Nettoyer ou remplacer la bougie Contr ler les connexions du sys t me entier d allumage R parer ou remplacer Contr ler le coupe circuit principa...

Page 540: ...Z ndenlage kon trollieren Erneuern oder instand setzen Z ndschalter kontrollieren Erneuern Motorstoppschalter kontrollieren Erneuern Z ndspule kontrollieren Prim rspule Erneuern Sekund r spule Erneue...

Page 541: ...ELEC MEMO...

Page 542: ...rk 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 looseness short circ...

Page 543: ...wei 3 Me kabel Kabel schwarz 4 Durchgang R 1 Br 2 B W 3 B 4 Me ger t Einstellung ON 1 OFF TEST DE LONGUEUR D ETINCELLE D ALLUMAGE 1 D connecter le capuchon de bougie de la bougie 2 Connecter le teste...

Page 544: ...GNITION COIL INSPECTION 1 Inspect Primary coil resistance Out of specification Replace 2 Inspect Secondary coil resistance Out of specification Replace NOTE When inspecting the secondary coil resis ta...

Page 545: ...re Hors sp cification Remplacer N B Pour contr ler la r sistance de la bobine secon daire enlever le capuchon de bougie Fil de multim tre Fil orange 1 Fil de multim tre Fil noir 2 R sistance de bobine...

Page 546: ...Red lead 1 Tester lead White lead 2 Pickup coil resistance Tester selector position 248 372 at 20 C 68 F 100 Br G R W 1 2 2 Inspect Source coil resistance Out of specification Replace Tester lead Brow...

Page 547: ...gr n 2 Erregerspule Widerstand Me ger t Einstellung 688 1 032 bei 20 C 68 F 100 CONTROLE DE LA MAGNETO CDI 1 Contr ler R sistance de bobine d excitation Hors sp cification Remplacer Fil de multim tre...

Page 548: ...erating when neither of these conditions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above condi tions h...

Page 549: ...artermotor SYSTEM DE DEMARRAGE ELECTRIQUE FONCTIONNEMENT DU SYSTEME DE COUPURE DU CIRCUIT DE DEMARRAGE Lorsque le contacteur cl est sur ON le d mar reur ne fonctionne que si au moins une des deux cond...

Page 550: ...ion Use the following special tools in this inspection Pocket tester YU 3112 C 90890 03112 1 Check fuse Replace fuse and check wire harness 2 Check battery Recharge or replace Check each coupler and w...

Page 551: ...re YU 3112 C 90890 03112 1 Contr ler le fusible Remplacer le fusible et v rifier le faisceau de fils 2 Contr ler la batterie Recharger ou remplacer Contr ler la connexion de chaque raccord et fil R pa...

Page 552: ...herung erneuern und Kabelbaum pr fen 2 Batterie kontrollieren Neu aufladen oder erneuern Alle Leitungsstecker und Kabelverbindungen kontrollieren Erneuern order instand setzen 3 Z ndschalter kontrolli...

Page 553: ...ELEC MEMO...

Page 554: ...the same capacity or more as that of the a battery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure nothing flammable is in the vicinity STARTING CIR...

Page 555: ...rot wei 3 Me kabel Kabel rot wei 4 R W 3 R W 4 Me ger t Einstellung An Batterie angeschlos sen 1 Nicht an Batterie angeschlos sen INSPECTION DE LA CONNEXION DES RACCORDS ET DES FILS 1 Contr ler Connex...

Page 556: ...ter relay terminal 2 Tester lead Starter relay terminal 3 Tester lead Starter relay terminal 4 Ter minal 3 Ter minal 4 Tester selec tor position Connected to battery 1 Not connected to battery NEUTRAL...

Page 557: ...Sb 1 B 2 Me ger t Einstellung LEERLAUF 1 GANG EIN GELEGT INSPECTION DU RELAIS DE DEMARREUR 1 D poser Relais de d marreur 2 Contr ler Conducteur de relais de d marreur Utiliser une batterie de 12 V Co...

Page 558: ...Black lead 1 Tester lead Black lead 2 B 1 B 2 Tester selec tor position PULL 1 FREE B B 1 2 START SWITCH INSPECTION 1 Inspect Start switch continuity No continuous while being pushed Replace Continuou...

Page 559: ...Kabel schwarz 1 Me kabel Kabel schwarz 2 B 1 B 2 Me ger t Einstellung GE DR CKT 1 FREI INSPECTION DU CONTACTEUR D EMBRAYAGE 1 Contr ler Continuit du contacteur d embrayage Discontinuit quand tir Remp...

Page 560: ...rder Part name Q ty Remarks STARTER MOTOR REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 1 Starter motor 1 STARTER MOTOR DISASSEM BLY 1 S...

Page 561: ...t de d marreur 1 2 Rondelle couvercle avant de d mar reur 1 3 Rondelle bomb e 1 4 Circlip 1 5 Joint torique 3 1 STARTERMOTOR Demontage Arbeiten 1 Startermotor zerlegen Demontage Arbeiten Reihen folge...

Page 562: ...CTRIC STARTING SYSTEM 7 4 3 5 2 1 5 8 0 9 0 9 5 6 1 New New New Extent of removal Order Part name Q ty Remarks 6 Starter motor yoke 1 7 Armature assembly 1 8 Starter motor rear cover 1 9 Brush 2 0 Bru...

Page 563: ...e l armature 1 8 Couvercle arri re de d marreur 1 9 Balais 2 0 Ressort de balais 2 1 Demontage Arbeiten Reihen folge Bauteil Anz Bemerkungen 6 Startermotorjoch 1 7 Anker Baugruppe 1 8 Starterrotor R c...

Page 564: ...ut to ensure proper operation of com mutator Commutator wear limit 21 0 mm 0 83 in Mica undercut 1 5 mm 0 06 in 4 Measure Armature assembly resistance com mutator and insulation Out of specification R...

Page 565: ...nktion des Kommutators sicherzustellen Kommutatorverschlei grenze 21 0 mm 0 83 in Glimmerunterschneidung 1 5 mm 0 06 in INSPECTION ET REPARATION 1 Contr ler Commutateur Sale Nettoyer avec du papier de...

Page 566: ...e Fatigue out of specification Replace as a set Brush spring force 5 52 8 28 N 560 840 g 19 8 29 7 oz ASSEMBLY 1 Install Brush spring 1 Brush 2 2 1 2 2 Install Armature assembly 1 Install while holdin...

Page 567: ...e mit einem d nnen Schraubenzieher einge dr ckt wird ACHTUNG Darauf achten nicht die B rste beim Ein bau zu besch digen 5 Mesurer Longueur des balais a Hors sp cification Remplacer Limite d usure des...

Page 568: ...washer 2 Washer starter motor front cover 3 Starter motor front cover 4 NOTE For installation align the projections on the washer with the slots in the front cover Align the match mark a on the starte...

Page 569: ...5 Montieren Schraube 1 O Ring 2 HINWEIS Lithiumfett auf den O Rinmg auftragen New SYSTEM DE DEMARRAGE ELECTRIQUE ELEKTROSTARTERSYSTEM 3 Monter Joint torique 1 Stator de d marreur 2 N B Faire co ncider...

Page 570: ...before inspection 1 Seat 2 Rear fender 3 Fuel tank Use the following special tool in this inspection Pocket tester YU 3112 C 90890 03112 Inductive tachometer YU 8036 B Engine tachometer 90890 03113 1...

Page 571: ...outil sp cial suivant pour le contr le Multim tre YU 3112 C 90890 03112 Compte tours inductif YU 8036 B Compte tours moteur 90890 03113 1 Contr ler le fusible Remplacer le fusible et contr ler le fais...

Page 572: ...nden Taschen Multimeter YU 3112 C 90890 03112 Induktivdrehzahlmesser YU 8036 B Drehzahlmesser 90890 03113 1 Sicherung kontrollieren Sicherung erneuern und Kabelbaum pr fen 2 Batterie kontrollieren Neu...

Page 573: ...ELEC MEMO...

Page 574: ...specification If no failure is found in checking the source coil resis tance replace the rectifier regulator Tester lead Red lead 1 Tester lead Black lead 2 Charging voltage Tester selector position 1...

Page 575: ...rz 2 Ladespulen Widerstand Me ger t Einstellung 0 64 0 96 bei 20 C 68 F 1 INSPECTION DE LA CONNEXION DES RACCORDS ET DES FILS 1 Contr ler Connexion des raccords et des fils Rouille poussi re desserrag...

Page 576: ......

Page 577: ......

Page 578: ...PRINTED IN JAPAN 2002 11 0 7 1 CR E F G PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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