Yamaha TT-R125E(W) Owner'S Service Manual Download Page 222 | Manualshive

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CHAS

4. Install:

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Diaphragm

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Brake master cylinder cap

1

●

Screw (brake 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 cylinder
and brake caliper.

T

R

.

.

2 Nm (0.2 m · kg, 1.4 ft · lb)

FRONT BRAKE (TT-R125LW/TT-R125LWE)

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Summary of Contents for TT-R125E(W)

Page 1: ...PRINTED IN BRASIL 00 2000 0000 GYL E LIT 11626 20 01 1B2 F8199 12 TT R125EW TT R125LW TT R125LEW TT R125EW TT R125LW TT R125LEW ...

Page 2: ......

Page 3: ... by Yamaha Motor da Amazônia Ltda 1st Edition 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor da Amazônia Ltda is expressly prohibited Printed in Brazil P N LIT 11626 1 1st Edition May 2006 P N LIT 11626 20 01 ...

Page 4: ...D THIS MANUAL CAREFULLY FOR INSTRUCTIONS ON HOW TO PROPERLY OPERATE THIS MACHINE ADULT INSTRUCTION AND SUPERVI SION ARE REQUIRED WEIGHT OF THE RIDER SHOULD NOT EXCEED 68 kg 150 lb TT R125 TT R125E ONLY ALWAYS WEAR A HELMET AND SUIT ABLE PROTECTIVE CLOTHING WHEN RIDING DO NOT TOUCH ANY MOVING PARTS OR HEATED AREAS ALWAYS PERFORM PRE OPERATION CHECKS REFER TO PAGE 3 3 THIS MACHINE IS DESIGNED TO CAR...

Page 5: ...AMAHA MOTOR CORPORATION U S A OFF ROAD MOTORCYCLE LIMITED WARRANTY Yamaha Motor Corporation USA hereby warrants that new Yamaha off road motorcycles purchased from an authorized Yamaha motorcycle dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein subject to certain stated limitations Covered off road motorcycles are th...

Page 6: ...l 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 any gasoline spills on your skin or clothing immediately wash it with soap and water and change your clothes 3 Always turn off the engine before leaving the machine unattended When parking the machine ...

Page 7: ...ak 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 within a short time Always operate your machine in an area with adequate ventilation 6 Always wear a helmet gloves boots trousers and jacket for motocross riding ...

Page 8: ...a 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 1 Helmet 2 Goggles 3 Mouth guard 4 Gloves 5 Boots 6 Motocross pants 7 Long sleeved trainer 8 Protector ...

Page 9: ...one 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 starting the engine be sure to shift the transmission into neutral ...

Page 10: ... 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 even if the machine is subsequently sold EC060000 NOTICE Some data in this manual may become out dated due to improvements made to this model in the future If there is any question you have regardin...

Page 11: ... 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 Specifications Regular inspection and adjustments Engine Chassis and Electrical 2 The table of contents is at the beginning of the manual Look over the general lay out of the book before finding then re...

Page 12: ... 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 number that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an easy to read way by the use of symbol marks 3 The meanings of the symbol marks a...

Page 13: ...ightening B Specified value Service limit C Engine speed D Resistance Ω Voltage V Electric current A Illustrated symbols E to H in the exploded diagrams indicate grade of lubricant and loca tion of lubrication point E Apply engine oil F Apply molybdenum disulfide oil G Apply lightweight lithium soap base grease H Apply molybdenum disulfide grease Illustrated symbols I to J in the exploded diagrams...

Page 14: ...MEMO ...

Page 15: ...GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS ELECTRICAL GEN INFO SPEC ENG CHAS CHÂS INSP ADJ 1 2 3 4 5 6 INDEX ...

Page 16: ...25E 1 16 TT R125LW TT R125LWE 1 17 CLEANING AND STORAGE 1 18 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 TT R125 TT R125E 2 1 TT R125LW TT R125LWE 2 4 MAINTENANCE SPECIFICATIONS 2 7 ENGINE 2 7 CHASSIS 2 15 TT R125 TT R125E 2 15 TT R125LW TT R125LWE 2 19 ELECTRICAL 2 23 TT R125 TT R125LW 2 23 TT R125E TT R125LWE 2 24 GENERAL TORQUE SPECIFICATIONS 2 26 DEFINITION OF UNITS 2 26 CABLE ROUTING ...

Page 17: ... 1 MUFFLER 4 2 CARBURETOR 4 3 CYLINDER HEAD 4 12 CAMSHAFT AND ROCKER ARMS 4 20 VALVES AND VALVE SPRINGS 4 24 CYLINDER AND PISTON 4 32 CLUTCH AND PRIMARY DRIVEN GEAR 4 40 OIL PUMP 4 49 KICK AXLE AND SHIFT SHAFT 4 53 CDI MAGNETO TT R125 TT R125LW 4 58 CDI MAGNETO AND STARTER CLUTCH TT R125E TT R125LWE 4 61 ENGINE REMOVAL 4 66 CRANKCASE CRANKSHAFT AND BALANCER 4 70 TRANSMISSION SHIFT CAM AND SHIFT FO...

Page 18: ...125LW TT R125LWE 5 12 REAR WHEEL AND REAR BRAKE 5 24 FRONT FORK 5 32 HANDLEBAR 5 42 STEERING 5 52 SWINGARM 5 58 REAR SHOCK ABSORBER ASSEMBLY 5 65 CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM 6 1 IGNITION SYSTEM 6 3 ELECTRIC STARTING SYSTEM TT R125E TT R125LWE 6 8 CHARGING SYSTEM TT R125E TT R125LWE 6 18 ...

Page 19: ...nt brake lever 7 Throttle 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 The machine you have purchased may differ slightly from those shown in the following Designs and specifications are subject to change without notice 9 0 A C B D F E G 1 2 3 4 5 6 7 8...

Page 20: ...EY IDENTIFICATION NUMBER TT R125E TT R125LWE 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 IDENTIFICATION NUMBER The vehicle identification number 1 is stamped on the right of the steering head pipe EC123001 ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the elevated par...

Page 21: ...oper tools and cleaning equip ment Refer to SPECIAL TOOLS sec tion 3 When disassembling the machine keep mated parts together They include gears cylinders pistons and other mated parts that have been mated through normal wear Mated parts must be reused as an assembly or replaced 4 During the machine disassembly clean all parts and place them in trays in the order of disassembly This will speed up ...

Page 22: ...t 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 facing outward In other words the stamped letters must be on the side exposed to view When installing oil seal s apply a light coating of light weight lithium base grease to the seal lip s Oil the bea...

Page 23: ...o 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 continuity with a tester NOTE If there in no continuity clean the terminals Be sure to perform the steps 1 to 7 listed above when checking the wireharness For a field remedy use a contact revitalizer ava...

Page 24: ...ese 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 each part for runout or bend YU 3097 YU 1256 90890 01252 YU 90050 90890 01274 YU 90050 90890 01275 YU 90063 90890 01278 YU 91044 90890 04081 Crankcase installing tool Crankshaft installer pot Crankshaf...

Page 25: ...n 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 Use this tool to inspect the coil resistance output voltage and amperage YU 3112 C 90890 03112 YU 8036 B 90890 03113 Inductive tachometer Engine tachometer This tool is needed for observing engine r...

Page 26: ... 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 90890 06754 ACC QUICK GS KT 90890 85505 Quick gasket YAMAHA Bond No 1215 This sealant Bond is used for crankcase mating surface etc ACC QUICK GS KT 90890 85505 Part number Tool name How to use Illustr...

Page 27: ... to a stop START SWITCH TT R125E TT R125LWE 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 dlebar it disengages or engages the clutch Pull the clutch lever to the handlebar to disen gage the clutch and release the lever to engage the clutch The lever should be pulled r...

Page 28: ... 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 from you EC156000 FRONT BRAKE LEVER The front brake lever 1 is located on the right handlebar Pull it toward the handlebar to acti vate the front brake EC157000 REAR BRAKE PEDAL The rear brake pedal 1 ...

Page 29: ...K 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 which is controlled by the starter knob 1 sup plies this mixture Pull the starter knob out to open the circuit for starting When the engine has warmed up push it in to close the circuit FUEL TANK CAP Re...

Page 30: ...ngine internal parts such as valves piston rings and exhaust system etc Recommended fuel For USA AUS and NZ Unleaded gasoline only For CDN and EUROPE Regular unleaded gasoline only For ZA Regular gasoline Fuel tank capacity Total 6 6 L 1 45 lmp gal 1 74 US gal Reserve 1 9 L 0 42 Imp gal 0 5 US gal FUEL Gasohol There are two types of gasohol gasohol con taining ethanol and that containing methanol ...

Page 31: ...e or slightly higher until it warms up this usually takes about one or two minutes 5 The engine is warmed up when it responds normally to the throttle with the starter knob CHOKE turned off CAUTION Do not warm up the engine for extended periods TT R125E TT R125LWE NOTE This model is equipped with an ignition circuit cut off system The engine can be started under the following conditions When the t...

Page 32: ...rate the starter knob CHOKE Open the throttle slightly and start the engine by kicking the kickstater forcefully 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 moving and sliding parts as well as the installed parts It is also important to accustom the...

Page 33: ...ine 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 inspection during break in refer to GENERAL INSPECTION AND MAINTENANCE section in the CHAPTER 3 and if there is any problem stop the engine immediately and check ...

Page 34: ...racket to engine Muffler to cylinder head Muffler to rear fender bracket Muffler to seat pillar tube Steering stem to upper bracket Upper bracket to handlebar Front fork to upper bracket Front fork to lower bracket Assembly of links Link to frame Link to shock absorber Link to swingarm Shock absorber to frame Tightening of pivot shaft Tightening of wheel axle Tightening of wheel axle Wheel to spro...

Page 35: ...ar tube Steering stem to upper bracket Upper bracket to handlebar Front fork to upper bracket Front fork to lower bracket Assembly of links Link to frame Link to shock absorber Link to swingarm Shock absorber to frame Tightening of pivot shaft Tightening of wheel axle Tightening of wheel axle Wheel to sprocket Brake caliper to front fork Brake disc to wheel Tightening of union bolt Brake master cy...

Page 36: ...on 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 car washers 4 After the majority of the dirt has been hosed off wash all surfaces with warm water and a mild detergent Use an old toothbrush to clean hard to reach places 5 Rinse the machine off immedi...

Page 37: ...switch 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 plastic bag tied to the frame 4 Lubricate all control cables 5 Block the frame up to raise the wheels off the ground 6 Tie a plastic bag over the exhaust pipe outlet to prevent moisture from enterin...

Page 38: ... 72 0 in 1 865 mm 73 4 in Overall width 785 mm 30 9 in Overall height 1 055 mm 41 5 in Seat height 775 mm 30 5 in Wheelbase 1 250 mm 49 2 in Minimum ground clearance 265 mm 10 4 in Basic weight With oil and full fuel tank TT R125 83 kg 183 lb TT R125E 90 kg 198 4 lb Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Single cylinder forward inclined Displacement 124 cm3 7 57 cu in Bor...

Page 39: ...y Engine oil Periodic oil change 1 0 L 0 88 Imp qt 1 06 US qt Total amount 1 2 L 1 06 Imp qt 1 27 US qt Air filter Wet type element Fuel Type Unleaded gasoline only USA AUS NZ Regular unleaded gasoline only CDN EUROPE Regular gasoline ZA Tank capacity 6 6 L 1 45 Imp gal 1 74 US gal Reserve amount 1 9 L 0 42 Imp gal 0 5 US gal Carburetor Type VM20SS Manufacturer MIKUNI Spark plug Type CR7HSA U22FSR...

Page 40: ...M Manufacturer front and rear CHENG SHIN Tire pressure front and rear 100 kPa 1 00 kgf cm2 15 psi Brake Front brake type Drum brake Operation Right hand operation Rear brake type Drum brake Operation Right foot operation Suspension Front suspension Telescopic fork Rear suspension Swingarm link type monocross suspension Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber ...

Page 41: ... 890 mm 74 4 in Overall width 795 mm 31 3 in Overall height 1 085 mm 42 7 in Seat height 805 mm 31 7 in Wheelbase 1 270 mm 50 0 in Minimum ground clearance 295 mm 11 6 in Basic weight With oil and full fuel tank TT R125LW 84 kg 185 lb TT R125LWE 90 kg 198 4 lb Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement Single cylinder forward inclined Displacement 124 cm3 7 57 cu in Bore stro...

Page 42: ...ty Engine oil Periodic oil change 1 0 L 0 88 Imp qt 1 06 US qt Total amount 1 2 L 1 06 Imp qt 1 27 US qt Air filter Wet type element Fuel Type Unleaded gasoline only USA AUS NZ Regular unleaded gasoline only CDN EUROPE Regular gasoline ZA Tank capacity 6 6 L 1 45 Imp gal 1 74 US gal Reserve amount 1 9 L 0 42 Imp gal 0 5 US gal Carburetor Type VM20SS Manufacturer MIKUNI Spark plug Type CR7HSA U22FS...

Page 43: ...cturer front and rear INOUE RUBBER Tire pressure front and rear 100 kPa 1 00 kgf cm2 15 psi Brake Front brake type Single disc brake Operation Right hand operation Rear brake type Drum brake Operation Right foot operation Suspension Front suspension Telescopic fork Rear suspension Swingarm link type monocross suspension Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber...

Page 44: ... 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 8384 in 21 165 mm 0 8333 in Exhaust A 25 841 25 941 mm 1 0174 1 0213 in 25 811 mm 1 0162 in B 21 050 21 150 mm 0 8287 0 8327 in 21 020 mm 0 8276 in Camshaft runout limit 0 03 mm 0 0012 in ...

Page 45: ... 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 4 0 8 mm 0 0157 0 0315 in EX 0 8 1 2 mm 0 0315 0 0472 in Stem outside diameter IN 4 975 4 990 mm 0 1959 0 1965 in 4 950 mm 0 1949 in EX 4 960 4 975 mm 0 1953 0 1959 in 4 935 mm 0 1943 in Guide insid...

Page 46: ...ee 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 kg 30 86 35 49 lb EX 137 5 158 1 N 14 0 16 1 kg 30 86 35 49 lb Tilt limit IN 2 5 1 4 mm 2 5 0 06 in EX 2 5 1 4 mm 2 5 0 06 in Direction of winding top view IN Clockwise EX Clockwise Item Standard Lim...

Page 47: ...utside 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 in Side clearance installed 0 035 0 090 mm 0 0014 0 0035 in 0 12 mm 0 0047 in 2nd ring Type Taper Dimensions B T 1 0 2 1 mm 0 04 0 08 in End gap installed 0 30 0 45 mm 0 012 0 018 in 0 55 mm 0 022 i...

Page 48: ...am 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 I D mark 5HP1 20 Main jet M J 105 Main jet nozzle N J N 6M Main air jet M A J ø1 2 Jet needle clip position J N 5HGM77 1 Cutaway C A 2 5 Pilot air jet 1 P A J 1 80 Pilot air jet 2 P A J 2 145 Pilot out...

Page 49: ...filter 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 10 mm 0 0024 0 0039 in 0 15 mm 0 0059 in Item Standard Limit ...

Page 50: ...2 0 2 1 4 Air filter case M6 1 0 3 7 0 7 5 1 Muffler M6 1 0 2 10 1 0 7 2 Muffler M10 1 25 1 60 6 0 43 Muffler M8 1 25 1 30 3 0 22 Muffler guard M6 1 0 7 10 1 0 7 2 Spark arrester M6 1 0 3 10 1 0 7 2 Crankcase M6 1 0 10 10 1 0 7 2 Left crankcase cover M6 1 0 7 10 1 0 7 2 Drive sprocket cover M6 1 0 2 12 1 2 8 7 Right crankcase cover M6 1 0 9 10 1 0 7 2 Lead guide CDI magneto lead M6 1 0 1 7 0 7 5 1...

Page 51: ...d 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 Thread size Q ty Tightening torque Nm m kg ft lb ...

Page 52: ... 1 18 in Front fork top end Zero mm Zero in Rear suspension Shock absorber travel 65 mm 2 56 in Spring free length TT R125 175 mm 6 89 in TT R125E 178 mm 7 01 in Fitting length 165 mm 6 50 in Spring rate STD TT R125 K 48 1 N mm 4 9 kg mm 274 lb in TT R125E K 50 5 N mm 5 1 kg mm 286 lb in Optional spring No Enclosed gas pressure 1 500 kPa 15 kg cm2 213 psi Wheel Front wheel type Spoke wheel Rear wh...

Page 53: ...in 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 free play lever end 10 15 mm 0 39 0 59 in Brake pedal position vertical height below footrest top 1 mm 0 04 in Brake pedal free play 20 30 mm 0 79 1 18 in Clutch lever free play lever end 10 15 mm 0 ...

Page 54: ...2 1 4 Brake lever mounting bolt M6 1 0 1 3 0 3 2 2 Brake lever mounting nut M6 1 0 1 4 0 4 2 9 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 nut M6 1 0 1 7 0 7 5 1 Clutch lever holder M5 0 8 2 4 0 4 2 9 Front wheel axle and axle nut M12 1 25 1 45 4 5 32 Front brake camshaft lever and camshaft M6 1 0 1 10 1 0 7 2 Rear wheel axle and axle n...

Page 55: ... 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 M...

Page 56: ...25LWE 125 mm 4 92 in Oil grade Fork oil 10W or equivalent 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 TT R125LW 178 mm 7 01 in TT R125LWE 170 5 mm 6 71 in Fitting length TT R125LW 165 mm 6 50 in TT R125LWE 160 5 mm 6 32 in Spring rate STD TT R125LW K 58 9 N mm 6 0 kg mm 336 lb in TT R125LWE K 61 8...

Page 57: ... mm 0 433 in Caliper cylinder inside dia 22 22 mm 0 875 in 2 Brake fluid type DOT 4 Rear drum brake Drum brake type Leading trailing Drum inside diameter 110 mm 4 33 in 111 mm 4 37 in Lining thickness 4 0 mm 0 16 in 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 footre...

Page 58: ...Throttle 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 nut M6 1 0 1 7 0 7 5 1 Brake lever adjuster and locknut M6 0 75 1 4 0 4 2 9 Clutch lever mounting bolt M6 1 0 1 7 0 7 5 1 Clutch lever mounting nut M6 1 0 1 7 0 7 5 1 Clutch lever holder M5 0 8 2 4 ...

Page 59: ...lay 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 swi...

Page 60: ...F White Red CDI unit model manufacturer 5HP 00 YAMAHA Ignition coil Model manufacturer 4KJ 10 YAMAHA Minimum spark gap 6 mm 0 24 in Primary coil resistance 0 18 0 28 Ω at 20 C 68 F Secondary coil resistance 6 3 9 5 kΩ at 20 C 68 F Part to be tightened Thread size Q ty Tightening torque Nm m kg ft lb Pickup coil M6 1 0 2 10 1 0 7 2 Blind plug neutral switch M10 1 25 1 20 2 0 14 Stator M6 1 0 3 10 1...

Page 61: ...I 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 Ω at 20 C 68 F White Black Lighting coil resistance color 0 52 0 78 Ω at 20 C 68 F Yellow Black Rectifier regulator Regulator type Semiconductor short circuit Model manufacture SH620B 12 SHINDENGEN No load regulated voltage 14 0 15 0 V Rectifier capacity 8 A Electric starting...

Page 62: ...CM33221 MATSUSHITA Coil winding resistance 75 69 92 51 Ω 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 Pickup coil M6 1 0 2 10 1 0 7 2 Neutral switch M10 1 25 1 18 1 8 13 Stator M6 1 0 3 10 1 0 7 2 Rotor M12 1 25 1 80 8 0 58 Ignition coil M6 1 0 2 7 0 7 5 1 Starter motor M6 1 0 2 10 1 0 7 2 Item Standa...

Page 63: ...e A Distance between flats B Outside thread diameter EC230000 DEFINITION OF UNITS 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 5 8 5 13 4 3 11 22 40 61 94 Unit Read Definition Measure mm cm millimeter centimeter 10 3 meter 10 2 meter Length Length kg kilogram 103 gram Weight N Newton 1 kg m sec...

Page 64: ......

Page 65: ...hten the starter choke nut while taking care not to twist the starter cable Ì Pass the clutch cable on the inside of the throttle and starter cable Ó Clamp the clutch cable with the paint in the cable guide bottom recess È Pass the throttle cable and starter cable into the cable guide Ô Pass the engine oil breather hose and overflow hose between the right half of the swingarm and pillar tube Clamp...

Page 66: ...er ı Clamp the engine stop switch lead to the handlebar to 3 clicks Ç Pass the brake cable brake hose for the TT R125LW in front of the number plate and through the cable guide Î Pass the clutch cable in back of the number plate Insert the fuel tank breather hose into the hole in the starter knob stay more the 30 mm 1 18 in Ï Clamp the throttle cable adjuster cover to the handlebar with the clamp ...

Page 67: ......

Page 68: ...F E G H I J K L D A B 3 C 0 1 2 3 3 3 3 3 3 3 4 5 6 6 6 6 6 6 7 8 9 A B C S R Q P O N M L K J I H G G G G G G F E D B A C 30 35 m 4 m 1 3 i 1 8 1 8 n ...

Page 69: ......

Page 70: ...1 2 3 4 5 6 7 8 9 0 6 6 C B D F G E A B C D E F G J K L M N H ...

Page 71: ...and overflow hose between the right half of the swingarm and frame È Pass the negative battery lead on the inside of the frame as shown Ô 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 Ò Put the tip of the air vent hose into the frame Install the primary coil terminal orange to the ignition coil...

Page 72: ... Î 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 Ï Pass the main switch lead on the right of the number plate stay Ì Fasten the throttle cable adjuster cover and start switch lead with a plastic locking tie ends downward Ó Fasten the start switch lead to 3 clicks È Pass the start switch le...

Page 73: ...aintenance intervals should be followed Nº ITEM CHECKS AND MAINTENANCE JOBS ODOMETERREADINGS INITIAL Fuel line Check fuel hoses for cracks or damage Replace if necessary 1 Whichever comer first month mi km hours 600 1 000 1 6 12 1 800 3 000 3 000 5 000 30 90 150 Spark plug Check condition Adjust gap and clean Carburetor Check engine idling speed an starter operation Adjust if necessary Exhaust sys...

Page 74: ...kage Replace brake pads if necessary Replace brake fluid every 1 year TT R125LW TT R125LWE Rear brake Check operation Adjustbrakepedalfreeplayandreplacebrakeshoesifnecessary Brake hose TT R125LW TT R125LWE Check for clack damage Replace Wheels Check runout spoke tightness and for damage Tighten spokes if necessary Tires Check tread depth and for damage Replace if necessary Check air pressure Corre...

Page 75: ...r damaged Control cabes ApplyYamaha chain and cable lube or engine oil 10W 30 thoroughly Throttle grip housing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable Chassis fasteners Check all chassis fitting and fasteners Correct if necessary Battery TT R125E TT R125LWE Check terminal for looseness and corrosion Nº I...

Page 76: ...ake Check fluid level and leakage TT R125LW TT R125LWE only P 3 16 21 Drive chain Check chain slack and alignment Check that the chain is lubri cated properly P 3 22 23 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P 3 28 29 Steering Check that the handlebar can be turned smoothly and have no excessive play P 3 29 33 Front forks and rear shock ...

Page 77: ...ck 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 THROTTLE CABLE ADJUSTMENT 1 Check Throttle grip free play a Out of specification Adjust Throttle grip free play a 3 5 mm 0 12 0 20 in 2 Adjust Throttle grip free play Throttle grip free play adjustment ste...

Page 78: ...e 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 FILTER CLEANING NOTE Proper air filter maintenance is the biggest key to preventing premature engine wear and damage CAUTION Never run the engine without the air filter element in place this would allow ...

Page 79: ...r 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 solvent by squeezing the element CAUTION Do not twist the element when squeezing the element 5 Inspect Air filter element Damage Replace AIR FILTER CLEANING ...

Page 80: ...ent 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 engine warm it up for several minutes and wait for five minutes 2 Place the machine on a level place and hold it up on upright position by placing the suitable stand under the engine 3 Remove Dipstick...

Page 81: ... 10 C 10 F or higher Å Yamalube 4 10W 30 or SAE 10W 30 type SE motor oil At 5 C 40 F or higher ı Yamalube 4 20W 40 or SAE 20W 40 type SE motor oil Except for USA and CDN CAUTION Do not add any chemical additives or use oils with a grade of CD a or higher Do not use oils labeled ENERGY CON SERVING II b or higher Engine oil also lubricates the clutch and additives could cause clutch slippage Do not ...

Page 82: ...d 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 container under the engine 4 Remove Oil drain bolt 1 Dipstick 2 Drain the engine oil 5 Install Copper washer Oil drain bolt 1 New T R 20 Nm 2 0 m kg 14 ft lb 6 Fill Engine oil 7 Check Oil leakage 8 Check En...

Page 83: ...il 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 opening each machine s pilot air screw has been individually set at the factory Before adjusting the pilot air screw turn it in fully and count the number of turns Record this number as the factory set...

Page 84: ...VERS 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 idling speed Turn the throttle stop screw 1 in a To decrease idling speed Turn the throttle stop screw 1 out b Inductive tachometer YU 8036 B 90890 03113 Engine idling speed 1 300 1 500 r min 2 Remo...

Page 85: ...the 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 Loosen the locknut 1 Turn the adjuster 3 in or out with the valve adjusting tool 2 until specified clear ance is obtained Turning in Valve clearance is decreased Turning out Valve clearance is increased ...

Page 86: ...e 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 grease on the O rings 8 Install Spark plug Fuel tank Seat Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAP TER 4 New T R 18 Nm 1 8 m kg 13 ft lb T R 18 Nm 1 8 m kg 13 ft lb T R 13 Nm 1 3 m k...

Page 87: ...ngine 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 use a wire brush to remove any carbon deposits 4 Install Spark arrester Insert the spark arrester into the muffler and align the bolt holes Bolt spark arrester T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 88: ... 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 of the tube into a container e Slowly apply the brake lever several times f Pull in the lever Hold the lever in posi tion g Loosen the bleed screw and allow the lever to travel towards its limit h T...

Page 89: ...em FRONT BRAKE ADJUSTMENT TT R125 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 adjust with the adjuster 3 CAUTION Make sure that there is no brake drag after adjusting the brake lever free play Brake lever free play a 10 15 mm 0 39 0 59 in Brake lever free play adjustment st...

Page 90: ...teps Loosen 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 Adjust Brake pedal free play CAUTION Make sure that there is no brake drag after adjusting the brake pedal play Brake pedal free play a 20 30 mm 0 79 1 18 in Brake pedal free play adjustment step T...

Page 91: ... 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 Standard Limit 4 0 mm 0 16 in 0 8 mm 0 03 in 3 Replace Brake pad Brake pad replacement steps Remove the brake caliper support bolt 1 Turn the brake caliper 2 counterclock wise a Replace the brake pads 3 BRA...

Page 92: ...ke 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 Apply the lithium soap base grease on the caliper support bolt T R Brake caliper support bolt 22 Nm 2 2 m kg 16 ft lb Brake shoe lining wear limit checking steps Fully pull in the brake lever and hold it...

Page 93: ... 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 Fully push down the brake pedal and hold it in position Then check the brake shoe wear indicator 1 is within the wear limit a Outside the limit Replace the brake shoe Refer to REAR WHEEL AND REAR BRAKE ...

Page 94: ...hain 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 and oil the chain and hold as illustrated Stiff Replace drive chain 5 Install Drive chain 1 Joint 2 Master link clip 3 CAUTION Be sure to install the master link clip to the direction as shown a Turnin...

Page 95: ...ons 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 slack Drive chain slack adjustment steps Loosen the axle nut 1 Turn both drive chain pullers 2 the same amount a and adjust them to the stopper in the same position so that the drive chain slack is ...

Page 96: ...ad By turning the adjuster 1 STANDARD POSITION NOTE Grooves are provided to indicate the adjust ment position CAUTION Never go beyond the maximum or mini mum adjustment positions WARNING Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability Stiffer a Increase the spring preload Turn the adjuster 1 in Softer b Decrease the spring pre load ...

Page 97: ... 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 adjuster beyond the maximum or minimum setting Stiffer Increase the spring preload Turn the adjuster 2 in Softer Decrease the spring preload Turn the adjuster 2 out Spring length installed a Standard length Extent of adjust...

Page 98: ...h 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 adjuster 1 in Softer b Decrease the rebound damping force Turn the adjuster 1 out Extent of adjustment Maximum Minimum Fully turned in position 20 clicks out from maximum position Standard position ...

Page 99: ...compression 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 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 Standard position About 9 clicks out REAR SHOCK ABSORBER...

Page 100: ...ion 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 INSPECTION AND TIGHTENING 1 Inspect Spokes 1 Bend damage Replace Loose spoke Retighten 2 Tighten Spokes NOTE Be sure to retighten these spokes before and after break in After a practice check spokes for loo...

Page 101: ...ssembly 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 TT R125 TT R125LW Steering ring nut Steering ring nut adjustment steps Remove the number plate and starter knob Remove the handlebar and upper bracket Remove the special washer 1 Remove the upper ring nut 2 and rubber washer 3 Loosen...

Page 102: ...ower ring nut using the steering nut wrench WARNING Avoid over tightening T R Ring nut final tightening 20 Nm 2 0 m kg 14 ft lb Check the steering stem by turning it lock to lock If there is any binding remove the steering stem 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 wa...

Page 103: ... 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 2 3 m kg 17 ft lb Starter knob nut 1 Nm 0 1 m kg 0 7 ft lb Number plate 7 Nm 0 7 m kg 5 1 ft lb TT R125E TT R125LWE Steering ring nut Steering ring nut adjustment steps Remove the number plate and starter knob Remove the m...

Page 104: ... 0 m kg 14 ft lb Check the steering stem by turning it lock to lock If there is any binding remove the steering stem 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 washer pawls into the slots If the slots are not aligned tighten the upper ring nut for...

Page 105: ... 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 2 3 m kg 17 ft lb Starter knob nut 1 Nm 0 1 m kg 0 7 ft lb Number plate 7 Nm 0 7 m kg 5 1 ft lb STEERING HEAD INSPECTION AND ADJUSTMENT ...

Page 106: ...al 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 R125LW TT R125LWE Å Use Yamaha cable lube or equivalent on these areas ı Use SAE 10W 30 motor oil or suitable chain lubricants Ç Lubricate the following areas with high quality lightweight lithium soap base gr...

Page 107: ...ds the spark plug insulator will become sooty even if the engine and carburetor are in good operating condition 3 Measure Plug gap a Use a wire gauge or thickness gauge Out of specification Regap 4 Clean the plug with a spark plug cleaner if necessary Spark plug gap 0 6 0 7 mm 0 02 0 03 in Standard spark plug CR7HSA NGK U22FSR U DENSO 5 Tighten Spark plug NOTE Before installing a spark plug clean ...

Page 108: ...d 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 immediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention CAUTION Charging time charging am...

Page 109: ...onnect 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 positive probe battery positive terminal Tester negative probe battery negative terminal NOTE The charge state of an MF battery can be checked by measuring its open circuit voltage i e the voltage when the posi...

Page 110: ...opriate 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 current into the battery quickly and can cause battery overheating and battery plate damage If it is impossible to regulate the charging current on the battery charger be careful not to overcharge the batt...

Page 111: ...ea 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 reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of an MF battery sta bilizes about 30 minutes after charging has been completed Therefore wait 30 minutes af...

Page 112: ...3 40 INSP ADJ Charging method using a variable voltage charger BATTERY INSPECTION AND CHARGING TT R125E TT R125LWE ...

Page 113: ...3 41 INSP ADJ Charging method using a constant voltage charger BATTERY INSPECTION AND CHARGING TT R125E TT R125LWE ...

Page 114: ...PECTION TT R125E TT R125LWE 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 lubricant Lithium soap base grease Checking steps Remove the fuse 1 Connect the pocket tester to the fuse and check the continuity NOTE Set the pocket tester selector to Ω 1 Pocket tester YU 03112 C 908...

Page 115: ...tem 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 correct amperage Set on the switches to verify if the electri cal circuit is operational If the fuse immediately blows again check the electrical circuit Items Amperage rating Q ty Main fuse 10 A 1 FUSE INSPECTION ...

Page 116: ...INSP ADJ FUSE INSPECTION TT R125E TT R125LWE ...

Page 117: ...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 fuel tank side 4 Fitting band 1 5 Bolt fuel tank 2 6 Fuel tank 1 7 Left side cover 1 8 Right side cover 1 9 Number plate 1 1 3 4 2 3 SEAT FUEL TANK AND SIDE COVERS 4 ...

Page 118: ...r 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 arrester 1 3 Nut muffler 2 4 Bolt muffler 1 5 Muffler 1 1 ...

Page 119: ...aration 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 Clamp air cleaner joint 1 Loosen the screw air cleaner joint 7 Clamp carburetor joint 1 Loosen the screws carburetor joint 8 Carburetor 1 1 ...

Page 120: ... 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 1 B Needle valve seat 1 C Main jet 1 D Main jet nozzle 1 E Pilot jet 1 F Pilot air jet 1 1 G Pilot air jet 2 1 H Pilot air screw 1 Refer to REMOVAL POINTS I Throttle stop screw 1 J Coasting enricher ...

Page 121: ...EMOVAL 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 Pilot air screw 1 Remove Pilot air screw 1 NOTE To optimize the fuel flow at a smaller throttle opening each machine s pilot air screw has been individually set at the factory Before removing the pilot ...

Page 122: ...jets 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 use a wire Needle valve 1 Inspect Needle valve 1 Needle valve seat 2 Grooved wear a Replace Dust b Clean NOTE Always replace the needle valve and needle valve seat as a set ...

Page 123: ...low 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 next to the float chamber mating surface Loosen the drain screw Measure the fuel level with the fuel level gauge NOTE Keep the carburetor and fuel level gauge vertically when measuring the fuel level I...

Page 124: ...uretor 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 installation points Turn in the pilot air screw until it is lightly seated Turn out the pilot air screw by the number of turns recorded before removing Pilot air screw 2 1 2 3 1 2 example ...

Page 125: ...r 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 On starter cable 3 8 Install Jet needle set 1 Needle holder 2 On throttle valve 3 NOTE Align the projections a on the throttle valve with the grooves b in the needle holder CARBURETOR ...

Page 126: ... 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 carburetor joint slots 2 Tighten Screw carburetor joint 1 Screw air cleaner joint 2 ...

Page 127: ...hose 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 for the starter plunger 4 Adjust Idle speed Refer to ENGINE IDLING SPEED ADJUSTMENT section in the CHAP TER 3 ...

Page 128: ...ks 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 CARBURETOR section CDI unit Remove from the frame 1 Engine bracket 1 2 Spark plug 1 3 Cylinder head side cover 1 4 Tappet cover 2 5 Crankshaft end accessing screw 1 6 Timing mark accessing screw 1 1 ...

Page 129: ...d 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 1 5 Camshaft sprocket 1 6 Cylinder head 1 7 Dowel pin 2 8 Gasket 1 1 ...

Page 130: ...ned 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 sta tionary pointer d on the cylinder head as shown in the illustration 2 Loosen Camshaft sprocket bolt 1 NOTE Remove the bolt while holding the rotor nut with a wrench 3 Remove Bolt timing chain tens...

Page 131: ... 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 aging or scratching Spark plug threads Valve seats 2 Inspect Cylinder head Scratches damage Replace 3 Inspect Cylinder head warpage Out of specification Re surface Warpage measurement and re surfacing ...

Page 132: ...e 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 cylinder head bolts M6 as shown Apply the engine oil on the contact surfaces of the bolts cylinder head and copper washers Follow the numerical order shown in the illus tration Tighten the bolts in two s...

Page 133: ...ointer 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 camshaft sprocket on the camshaft NOTE When installing the camshaft sprocket keep the timing chain as tense as possible on the exhaust side CAUTION Do not turn the crankshaft during instal lation of the ca...

Page 134: ...use 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 chain tensioner 10 Nm 1 0 m kg 7 2 ft lb Release the screwdriver check the ten sioner rod to come out and tighten the gasket 4 and the cap bolt 5 to the speci fied torque T R Cap bolt timing chain tensi...

Page 135: ...ly 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 screw 2 T R 7 Nm 0 7 m kg 5 1 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb 13 Install Spark plug Engine bracket T R 13 Nm 1 3 m kg 9 4 ft lb T R 40 Nm 4 0 m kg 29 ft lb ...

Page 136: ...Extent 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 shaft 1 Refer to REMOVAL POINTS 3 Exhaust rocker arm shaft 1 4 Camshaft 1 5 Intake rocker arm 1 6 Exhaust rocker arm 1 1 2 ...

Page 137: ...0890 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 Cam lobes Pitting scratches blue discoloration Replace 2 Measure Cam lobes length a and b Out of specification Replace Cam lobes length limit Intake a 25 851 mm 1 0178 in b 21 165 mm 0 8333 in Exhaust...

Page 138: ... 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 mm 0 3930 0 3933 in Limit 9 95 mm 0 3917 in ASSEMBLY AND INSTALLATION 1 Apply Molybdenum disulfide oil onto the camshaft cam lobe and rocker arm hole Engine oil onto the camshaft bearing 2 Install R...

Page 139: ...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 140: ...e 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 Refer to REMOVAL POINTS 2 Valve spring retainer 2 3 Valve spring 2 4 Intake valve 1 5 Exhaust valve 2 6 Valve stem seal 2 7 Valve spring seat 2 1 ...

Page 141: ...eals 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 cotters Valve spring compressor YM 4019 90890 04019 3 Remove Valve spring retainer 1 Valve spring 2 Valve 3 Valve stem seal 4 Valve spring seat 5 NOTE Identify the position of each part very careful...

Page 142: ...de 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 the new valve guide using a valve guide remover and valve guide installer After installing the valve guide bore the valve guide using a valve guide reamer 2 to obtain proper stem to guide clearance Val...

Page 143: ...ace 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 Intake 0 4 0 8 mm 0 0157 0 0315 in Exhaust 0 8 1 2 mm 0 0315 0 0472 in Runout limit 0 01 mm 0 0004 in 6 Eliminate Carbon deposits from the valve face and valve seat 7 Inspect Valve seats Pitting wear ...

Page 144: ...to 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 seat is not centered the valve seat must be refaced 9 Lap Valve face Valve seat NOTE After refacing the valve seat or replacing the valve and valve guide the valve seat and valve face should be lapped ...

Page 145: ... 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 valve through the valve guide and onto the valve seat to make a clear pattern Measure the valve seat width again If the valve seat width is out of specification reface and re lap the valve seat Valve s...

Page 146: ... 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 and valve stem seal 2 Install Valve spring seats 1 Valve stem seals 2 Valves 3 Valve springs 4 Valve spring retainers 5 NOTE Make sure that each valve is installed in its original place Install the val...

Page 147: ... 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 piece of wood CAUTION Hitting the valve tip with excessive force could damage the valve ...

Page 148: ...t 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 pin 2 4 Gasket 1 5 Piston pin clip 2 Refer to REMOVAL POINTS 6 Piston pin 1 7 Piston 1 8 Piston ring set 1 1 2 ...

Page 149: ...d 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 Remove Piston rings NOTE Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown as shown in the illustration Piston pin puller set YU 1304 90890 01304...

Page 150: ... 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 the piston skirt diameter P with a micrometer a 5 mm 0 20 in from the piston bottom edge Piston size P Standard 53 977 53 996 mm 2 1251 2 1258 in If out of specification replace the piston and piston ...

Page 151: ...ication 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 15 000 mm 0 5902 0 5906 in Limit 14 971 mm 0 5894 in Measure the piston inside diameter b If out of specification replace the piston Inside diameter piston 15 002 15 013 mm 0 5906 0 5911 in Limit 15 043...

Page 152: ...ston 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 the cylinder bore a 40 mm 1 57 in 3 Measure Ring end gap Out of specification Replace NOTE You cannot measure the end gap on the expander spacer of the oil control ring If the oil control ring rails sh...

Page 153: ...der 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 mark a color Piston size A red 53 977 53 980 mm 2 1251 2 1252 in B orange 53 981 53 984 mm 2 1252 2 1254 in C green 53 985 53 988 mm 2 1254 2 1255 in D purple 53 989 53 992 mm 2 1255 2 1257 in E blue 53...

Page 154: ...hown 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 that the arrow mark a on the piston points to the exhaust side of the engine Before installing the piston pin clip cover the crankcase with a clean rag to prevent the piston pin clip from falling in...

Page 155: ...st 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 damage the timing chain guide during installation NOTE After installing check the smooth movement of the piston New ...

Page 156: ...ngine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Engine skidplate Refer to ENGINE REMOVAL section Starter motor for the TT R125E TT R125LWE 1 Refer to ELECTRIC STARTING SYS TEM section in the CHAPTER 6 for the TT R125E TT R125LWE 1 Kickstarter crank 1 2 Starter motor lead holder 2 TT R125E TT R125LWE 3 Negative battery lead 1 TT R125E TT R125LWE 4 Gasket 1 5 Dowel pin 2 6 Pressur...

Page 157: ...Extent 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 gear 1 6 Thrust plate 1 7 Conical spring washer 1 8 Nut primary drive gear 1 Refer to REMOVAL POINTS 9 Primary drive gear 1 10 Straight key 1 2 1 ...

Page 158: ...TCH 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 Oil seal 1 1 ...

Page 159: ...86 Å ı 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 to damage the gear teeth EC494000 INSPECTION EC484100 Clutch housing and boss 1 Inspect Clutch housing 1 Cracks wear damage Replace Clutch boss 2 Scoring wear damage Replace EC484201 Primary driv...

Page 160: ... 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 Replace clutch plate as a set Use a surface plate 1 and thickness gauge 2 Push lever 1 Inspect Push lever 1 Wear damage Replace Friction plate thickness 2 92 3 08 mm 0 115 0 121 in Limit 2 8 mm 0 110 in W...

Page 161: ...Push 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 gear 3 Primary driven gear 4 NOTE Install the primary drive gear with the stamp a facing out Place a folded rag or aluminum plate 5 between the teeth of the primary drive gear and primary driven gea...

Page 162: ...h holding tool YM 91042 90890 04086 New T R 60 Nm 6 0 m kg 43 ft lb Å ı 4 Install Friction plate 1 Clutch plate 2 NOTE Install the clutch plates and friction plates alternately on the clutch boss starting with a friction plate and ending with a friction plate Apply the engine oil on the friction plates and clutch plates Be sure to install a clutch plate with projec tion a offset approximately 90 f...

Page 163: ... 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 Check Push lever position Push the push lever assembly in the arrow direction and make sure that the mach mark are aligned adjust a Match mark on the push lever assembly b Match mark on the crankcase ...

Page 164: ... cross pattern Adjustment steps Loosen the locknut 1 Turn the push rod 1 2 clockwise or coun terclockwise to match alignment marks Hold the push rod 1 to prevent it from moving and tighten the locknut to specifi cation Tighten the locknut 1 T R Locknut 8 Nm 0 8 m kg 5 8 ft lb Quick gasket ACC QUICK GS KT YAMAHA Bond No 1215 90890 85505 New T R 10 Nm 1 0 m kg 7 2 ft lb 11 Install Kickstarter crank ...

Page 165: ...al 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 drive gear 1 3 Oil pump assembly 1 4 Gasket 1 5 Oil strainer 1 1 ...

Page 166: ...sassembly 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 shaft 1 9 Pin 1 0 Inner rotor 1 A Outer rotor 1 B Oil pump housing 1 1 ...

Page 167: ...he oil pump housing 3 Out of specification Replace the oil pump assembly Housing and rotor clearance Ç between the pump housing 3 and the rotors 1 2 Out of specification Replace the oil pump assembly Tip clearance Å 0 15 mm 0 0059 in Limit 0 20 mm 0 0079 in Side clearance ı 0 06 0 10 mm 0 0024 0 0039 in Limit 0 15 mm 0 0059 in Housing and rotor clearance Ç 0 06 0 10 mm 0 0024 0 0039 in Limit 0 15 ...

Page 168: ...to 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 oil onto the crankcase oil pas sage and oil pump assembly New New T R 5 Nm 0 5 m kg 3 6 ft lb New T R 7 Nm 0 7 m kg 5 1 ft lb 3 Install Oil pump drive gear 1 Rotary filter 2 NOTE Install the oil pum...

Page 169: ...AND 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 Circlip 1 3 Washer 1 4 Kick idle gear 1 5 Washer 1 6 Circlip 1 7 Shift shaft 1 8 Circlip 1 9 Torsion spring 1 10 Bolt stopper lever 1 11 Stopper lever 1 12 Spring 1 13 Segment 1 Refer to REMOVAL POIN...

Page 170: ...xle 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 Inspect Kickstarter segment gear 1 Kick idle gear 2 Gear teeth a Wear damage Replace Kick axle clip 1 Measure Kick axle clip friction force torsion spring Out of specification Replace Use a spring gauge 1...

Page 171: ...ng 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 bit Stopper lever 1 Install Stopper lever 1 Bolt stopper lever 2 Torsion spring 3 NOTE Align the stopper lever roller with the slot on segment T R 12 Nm 1 2 m kg 8 7 ft lb LT T R 10 Nm 1 0 m kg 7 2 f...

Page 172: ... 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 the torsion spring 3 Install Kick axle assembly 1 NOTE Apply the engine oil on the kick axle Slide the kick axle assembly into the crank case make sure the clip 2 and kick axle stopper b fit into their...

Page 173: ...IFT 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 depressed side toward you New New ...

Page 174: ...fuel tank Refer to SAET FUEL TANK AND SIDE COVERS section Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Drive sprocket cover Refer to ENGINE REMOVAL section 1 CDI magneto lead 1 2 Left crankcase cover 1 3 Nut rotor 1 Use special tool Refer to REMOVAL POINTS 4 Rotor 1 5 Woodruff key 1 6 Pickup coil 1 7 Lead guide 1 8 Stator 1 1 CDI MAGNETO TT R125 TT R125LW ...

Page 175: ...ner surface a Stator outer surface b Damage Inspect the crankshaft runout and crankshaft bearing If necessary replace CDI magneto and or stator EC4L4200 Woodruff key 1 Inspect Woodruff key 1 Damage Replace EC4L5000 ASSEMBLY AND INSTALLATION CDI magneto 1 Install Stator 1 Bolt stator Lead guide Screw lead guide 2 Pickup coil 3 Bolt pickup coil T R 10 Nm 1 0 m kg 7 2 ft lb LT T R 7 Nm 0 7 m kg 5 1 f...

Page 176: ... the keyway of the rotor with the woodruff key 3 Install Plain washer 1 Nut rotor 2 Use the sheave holder 3 Sheave holder YS 1880 A 90890 01701 T R 80 Nm 8 0 m kg 58 ft lb 4 Install Dowel pin Gasket Left crankcase cover Bolt left crankcase cover NOTE Tighten the screws in stage using a crisscross pattern New T R 10 Nm 1 0 m kg 7 2 ft lb 5 Connect CDI magneto lead Refer to CABLE ROUTING DIAGRAM sec...

Page 177: ...Order Part name Q ty 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 Rotor 1 6 Starter clutch 1 7 Woodruff key 1 8 Starter wheel gear 1 9 Plain washer 1 10 Plate starter idle gear 1 11 Starter idle gear 1 12 Lead guide 1 13 Pickup coil stator assem...

Page 178: ...3270 B 90890 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 or stator EC4L4200 Woodruff key 1 Inspect Woodruff key 1 Damage Replace Starter clutch 1 Check Starter clutch Damage wear Replace 2 Check Idle gear Starter clutch gear Pitting burrs chips ...

Page 179: ...lty and must be replaced When turning the starter clutch drive gear clockwise Å it should turn freely If the starter clutch drive gear does not turn freely the starter clutch is faulty and must be replaced Å ı 1 2 EC4L5000 ASSEMBLY AND INSTALLATION CDI magneto 1 Install Stator 1 Bolt stator Lead guide Screw lead guide 2 Pickup coil 3 Bolt pickup coil T R 10 Nm 1 0 m kg 7 2 ft lb LT T R 7 Nm 0 7 m ...

Page 180: ...p 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 rotor make sure the woodruff key is properly seated in the key way of the crankshaft Apply the engine oil on the starter wheel gear inner circumference 6 Install Plain washer 1 Nut magneto 2 NOTE Tighten the nut m...

Page 181: ...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 CDI MAGNETO AND STARTER CLUTCH TT R125E TT R125LWE ...

Page 182: ...EAT FUEL TANK AND SIDE COVERS section Carburetor Refer to CARBURETOR section Muffler Refer to MUFFLER section Clutch cable Disconnect at engine side Spark plug cap Disconnect the CDI magneto lead Disconnect the neutral switch lead for the TT R125E TT R125LWE Starter motor for the TT R125E TT R125LWE Refer to ELECTRIC STARTING SYS TEM section in the CHAPTER 6 for the TT R125E TT R125LWE Drain the e...

Page 183: ...cover 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 Engine bracket front 1 10 Engine mounting bolt rear 2 11 Engine 1 Refer to REMOVAL POINTS 1 ...

Page 184: ...bles 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 mounting bolt lower 5 Engine mounting bolt front 6 Engine bracket upper 7 Engine mounting bolt upper 8 Bolt engine bracket 9 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...

Page 185: ...Bolt 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 Drive chain 2 NOTE Install the drive sprocket together with the drive chain 2 Install Drive sprocket holder 1 Bolt drive sprocket T R 6 Nm 0 6 m kg 4 3 ft lb 3 Install Drive sprocket cover 1 Bolt driv...

Page 186: ...ation for removal Engine Refer to ENGINE REMOVAL section Piston Refer to CYLINDER AND PISTON sec tion Primary drive gear Refer to CLUTCH AND PRIMARY DRIVEN GEAR section Kick axle assembly Refer to KICK AXLE AND SHIFT SHAFT section Segment Rotor for the TT R125 TT R125LW Refer to CDI MAGNETO section for the TT R125 TT R125LW Rotor and starter clutch for the TT R125E TT R125LWE Refer to CDI MAGNETO ...

Page 187: ... 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 crankcase 1 10 Balancer 1 11 Crankshaft 1 Use special tool Refer to REMOVAL POINTS 12 Bearing 3 Refer to REMOVAL POINTS 3 2 1 ...

Page 188: ...e 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 tap on the case half Tap only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If one end hangs up take pressure o...

Page 189: ...nkcase 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 Timing chain and timing chain guide 1 Inspect Timing chain Cracks stiff Replace the timing chain and camshaft sprocket as a set 2 Inspect Timing chain guide Wear damage Replace ...

Page 190: ...e 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 gauge Dial gauge stand set YU 3097 90890 01252 Standard Limit Runout limit 0 03 mm 0 0012 in Side clearance 0 15 0 45 mm 0 0059 0 0177 in 0 50 mm 0 02 in Crack width 46 95 47 00 mm 1 848 1 850 in ...

Page 191: ...xcept 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 against the bearing Before installing the crankshaft clean the contacting surface of crankcase CAUTION Do not use a hammer to drive in the crank shaft Crankshaft installing tool Crankshaft installer ...

Page 192: ...t 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 crankcase On left crankcase NOTE Fit the right crankcase onto the left crank case Tap lightly on the case with soft ham mer When installing the crankcase the connect ing rod should be positioned at TDC top d...

Page 193: ...rankcase 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 Nm 1 0 m kg 7 2 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 4 Check Crankshaft and transmission operation Unsmooth operation Repair 5 Install Timing chain 1 Intake timing chain guide 2 Bolt intake timing chain...

Page 194: ...y 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 fork guide bar 1 short 1 2 Shift fork guide bar 2 long 1 3 Shift cam 1 4 Shift fork 2 C 1 5 Shift fork 3 R 1 6 Shift fork 1 L 1 7 Main axle 1 Refer to REMOVAL POINTS 8 Drive axle 1 9 Push rod 2 1 10 W...

Page 195: ...ammer 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 a Gear teeth b Shift fork groove c Wear damage Replace 2 Check Gears movement Unsmooth movement Repair or replace Push rod 1 Inspect Push rod 2 1 Wear damage bend Replace ...

Page 196: ...shift 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 Replace shift fork and or guide bar NOTE For a malfunctioning shift fork replace not only the shift fork itself but the two gears each adja cent to the shift fork ...

Page 197: ...axle 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 wheel gear 21T 2 3rd wheel gear 25T 3 4th wheel gear 23T 4 1st wheel gear 37T 5 On drive axle 6 NOTE Apply the molybdenum disulfide oil on the gears inner circumference ...

Page 198: ...p 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 these in the left crankcase at the same time NOTE Apply the lithium soap base grease on the oil seal lip When installing the drive axle into the crank case pay careful attention to the crankcase oil s...

Page 199: ...the 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 guide bar 2 long 2 NOTE Apply the engine oil on the guide bars Be sure the long bar is inserted into the shift forks 1 and 3 and the short one into 2 4 Check Shifter operation Transmission operation Uns...

Page 200: ...er Part name 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 falling over 1 Brake cable holder 1 2 Brake cable 1 Disconnect at the lever side first 3 Axle nut 1 4 Wheel axle 1 5 Front wheel 1 6 Collar set 1 7 Brake shoe plate assembly 1 8 Oil seal 1 9 Whe...

Page 201: ...NT WHEEL AND FRONT BRAKE TT R125 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 plate 1 3 5 ...

Page 202: ...heel 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 EC514200 Wheel axle 1 Measure Wheel axle bends Out of specification Replace Use the dial gauge 1 NOTE The bending value is shown by one half of the dial gauge reading WARNING Do not attempt to st...

Page 203: ...Replace 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 of specification Replace Brake drum inside diameter Standard Limit 110 mm 4 33 in 111 mm 4 37 in 4 Inspect Brake drum inner surface Oil scratches Remove Oil Use a rag soaked in lac quer thinner or...

Page 204: ...ndicator 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 1 NOTE Install the brake camshaft lever in relation to the punch mark a as shown 1 1 a T R 10 Nm 1 0 m kg 7 2 ft lb 5 Install Springs 1 Brake shoes 2 NOTE Apply the lithium soap base grease on t...

Page 205: ...de diam 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 of the bearing Contact should be made only with the outer race 2 Install Brake shoe plate assembly Collar set 1 NOTE Apply the lithium soap base grease on the oil seal lip New 3 Install Front whe...

Page 206: ...t 1 T 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 free play Refer to FRONT BRAKE ADJUST MENT section in the CHAPTER 3 ...

Page 207: ... 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 Washer 1 3 Wheel axle 1 4 Front wheel 1 5 Collar 2 6 Oil seal 2 7 Wheel bearing 2 Refer to REMOVAL POINTS 8 Spacer 1 9 Brake disk 1 2 3 1 3 FRONT WHEEL TT R125LW TT R125LWE ...

Page 208: ...ct Bearing Rotate inner race with a finger Rough spot seizure Replace NOTE Replace the bearings oil seal and wheel collar as a set Wheel runout limit Radial 1 2 0 mm 0 08 in Lateral 2 2 0 mm 0 08 in EC514200 Wheel axle 1 Measure Wheel axle bends Out of specification Replace Use the dial gauge 1 NOTE The bending value is shown by one half of the dial gauge reading WARNING Do not attempt to straight...

Page 209: ...EMBLY 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 wheel bearing so that the enclosed side is facing outward Use a socket that matches the outside diam eter of the race of the bearing Left side of wheel bearing shall be installed first Install the ...

Page 210: ...attern 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 the brake disc 1 between the brake pads 2 correctly 5 Install Wheel axle 1 6 Install Washer 1 Axle nut 2 T R 45 Nm 4 5 m kg 32 ft lb ...

Page 211: ...the 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 holder 2 2 Union bolt 1 3 Brake hose 1 4 Joint 1 5 Brake caliper support bolt 1 6 Brake caliper 1 Refer to REMOVAL POINTS 7 Brake lever 1 8 Brake master cylinder bracket 1 9 Brake master cylinder 1 3 1 2 ...

Page 212: ...STER CYLINDER 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 1 3 Brake caliper piston 2 Refer to REMOVAL POINTS 4 Brake caliper dust seal 2 5 Brake caliper piston seal 2 6 Pin boot 1 7 Sleeve boot 1 8 Brake master cylinder cap 1 9 Diaphragm 1 0 Brake mas...

Page 213: ...lastic 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 Brake caliper piston 1 Remove Brake caliper piston Use compressed air and proceed care fully WARNING Cover piston with rag and use extreme caution when expelling piston from cylin der Never attem...

Page 214: ...RNING 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 Wear scratches Replace brake mas ter cylinder assembly Stains Clean WARNING Use only new brake fluid 2 Inspect Diaphragm 1 Crack damage Replace 3 Inspect Brake master cylinder piston 1 Brake master cylind...

Page 215: ...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 damage Replace the brake cal iper assembly Sleeve boot 3 Pin boot 4 Wear damage Replace 4 Inspect Brake caliper support bolt 1 Scorches rust damage Replace Brake hose 1 Inspect Brake hose 1 Crack damage Repl...

Page 216: ...ust seal 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 Fit the brake caliper piston seals and brake caliper dust seals onto the slot on brake cali per correctly New New 3 Install Brake caliper piston 1 NOTE Apply the brake fluid on the brake caliper...

Page 217: ...T R 30 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 support bolt 1 NOTE Apply the lithium soap base grease on the brake caliper support bolt T R 22 Nm 2 2 m kg 16 ft lb Brake master cylinder kit 1 Clean Brake master cylinder Brake master cylinder k...

Page 218: ...ng cylinder 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 diameter side 4 Install Brake master cylinder kit 1 Washer 2 Circlip 3 Brake master cylinder boot 4 On brake master cylinder 5 NOTE Apply the brake fluid on the brake master cylinder kit When installi...

Page 219: ...ing 2 Bolt brake lever 3 Nut brake lever 4 NOTE Apply the lithium soap base grease on the bolt and brake lever sliding surface Apply the molybdenum disulfide grease on the tip of the adjuster bolt T R 9 Nm 0 9 m kg 6 5 ft lb Å U P 2 1 3 3 a ı T R 7 Nm 0 7 m kg 5 1 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb Brake hose 1 Install Copper washer 1 Brake hose 2 Union bolt 3 WARNING Always use new copper washers ...

Page 220: ...NING 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 Install Brake hose holder 1 Bolt brake hose holder 2 T R 7 Nm 0 7 m kg 5 1 ft lb FRONT BRAKE TT R125LW TT R125LWE ...

Page 221: ...ormance 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 may erode painted surfaces or plastic parts Always clean up spilled fluid immediately Recommended brake fluid DOT 4 2 Air bleed Brake system Refer to BRAKE SYSTEM AIR BLEEDING section in the CHAPTER 3 3 ...

Page 222: ...er 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 cylinder and brake caliper T R 2 Nm 0 2 m kg 1 4 ft lb FRONT BRAKE TT R125LW TT R125LWE ...

Page 223: ...al 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 Drive chain puller right 1 4 Wheel axle 1 5 Drive chain puller left 1 6 Drive chain 1 7 Rear wheel 1 Refer to REMOVAL POINTS 8 Collar right 1 9 Brake shoe plate assembly 1 10 Collar left 1 2 3 1 REAR ...

Page 224: ...Nut 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 camshaft 1 21 Brake shoe plate 1 3 2 REAR WHEEL AND REAR BRAKE ...

Page 225: ...puller 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 wheel collar wheel sprocket side as a set Wheel runout limit Radial 1 2 0 mm 0 08 in Lateral 2 2 0 mm 0 08 in EC514200 Wheel axle 1 Measure Wheel axle bends Out of specification Replace Use the dial...

Page 226: ...sand 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 is worn to the limit Brake shoe lining thickness Standard Limit 4 0 mm 0 16 in 2 0 mm 0 08 in 3 Measure Brake drum inside diameter a Out of specification Replace Brake drum inside diameter Standard ...

Page 227: ...rake 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 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 1 NOTE Install the brake camshaft lever i...

Page 228: ...he 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 seal facing outward Use a socket that matches the outside diam eter of the race of the bearing Right side of bearing shall be installed first Install the oil seal with its manufacture s marks or numb...

Page 229: ...shoe 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 swingarm 5 Install Drive chain 1 NOTE Push the wheel 2 forward and install the drive chain 6 Install Drive chain puller left 1 Plain washer 2 Wheel axle 3 NOTE Apply the lithium soap base grease on the whe...

Page 230: ...oint 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 Spring 1 Brake rod 2 Pin 3 Wing nut 4 On brake camshaft lever 5 11 Adjust Brake pedal free play Refer to REAR BRAKE ADJUST MENT section in the CHAPTER 3 ...

Page 231: ...tand 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 for the TT R125 TT R125E Refer to FRONT WHEEL section for the TT R125LW TT R125LWE Handlebar Refer to HANDLEBAR section A B 1 Cap 1 2 Pinch bolt upper bracket 1 1 Only loosening 3 Cap bolt 1 1 Loosen when disassembling the front fork 4 Pinch b...

Page 232: ...r Part name 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 REMOVAL POINTS 7 Stopper ring 1 1 8 Bolt damper rod 1 1 9 Damper rod 1 1 0 Inner tube 1 1 A Oil flow stopper 1 1 B Piston metal 1 1 C Oil seal 1 1 D Outer tube 1 1 2 1 ...

Page 233: ...are 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 the inner tube NOTE Before removing the front fork from the machine loosen the cap bolt Å TT R125 TT R125E TT R125LW ı TT R125LWE Inner tube 1 Remove Dust seal 1 Stopper ring 2 Using slotted head screwdriver CAUTI...

Page 234: ...ter tube EC554000 INSPECTION Damper rod 1 Inspect Damper rod Bend damage Replace damper rod CAUTION The front fork with a built in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disassembled and reassembled ...

Page 235: ... 1 in TT R125LWE 448 6 mm 17 66 in Inner tube 1 Inspect Inner tube surface a Score marks Repair or replace Use 1 000 grit wet sandpaper Damaged oil lock piece Replace Inner tube bends Out of specification Replace Use the dial gauge 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...

Page 236: ...5000 ASSEMBLY AND INSTALLATION Front fork assembly 1 Wash the all parts in a clean solvent 2 Install Piston metal 1 Damper rod 2 Oil flow stopper 3 On inner tube 4 CAUTION To install the damper 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 FRONT FORK ...

Page 237: ...on the inner tube When installing the oil seal use vinyl seat a with fork oil applied to protect the oil seal lip Install the oil seal with its manufacturer s marks or number facing upside Press the oil seal into the outer tube with fork seal driver attachment ø30 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 Ins...

Page 238: ...ommended fork oil If other oils are used they may have an excessively adverse effect on the front fork performance Never allow foreign materials to enter the front fork 11 After filling pump the inner tube slowly up and down more than 10 times to dis tribute the fork oil Recommended oil Fork oil 10W or equivalent Quantity each front fork leg TT R125 TT R125E 159 cm3 5 60 Imp oz 5 38 US oz TT R125L...

Page 239: ...2 mm 4 80 in TT R125LW 130 mm 5 12 in TT R125LWE 125 mm 4 92 in From the top of the inner tube with the inner tube fully com pressed and without the fork spring 1 Å ı Installation 1 Install Front fork NOTE Temporarily tighten the pinch bolt lower bracket Do not tighten the pinch bolt upper bracket yet 2 Tighten Cap bolt 1 3 Adjust Front fork top end a Å TT R125 TT R125E TT R125LW ı TT R125LWE Fron...

Page 240: ...ew dust boot 3 NOTE Make sure that the dust boot holes a are positioned outward Tighten the screw dust boot until the top of the dust boot is touching the lower bracket T R 60 Nm 6 0 m kg 43 ft lb T R 25 Nm 2 5 m kg 18 ft lb 5 Install TT R125 TT R125E TT R125LW Cap 1 FRONT FORK ...

Page 241: ...paration for removal HANDLEBAR REMOVAL Number plate 1 Clutch cable 1 2 Clutch lever 1 3 Engine stop switch 1 4 Front brake cable 1 5 Front brake lever 1 6 Grip cap lower 1 7 Grip cap upper 1 8 Throttle cable 1 9 Throttle grip assembly 1 10 Collar 1 11 Handlebar grip left 1 Refer to REMOVAL POINTS 12 Handlebar holder 2 13 Handlebar 1 1 ...

Page 242: ...EBAR 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 cable 1 10 Throttle grip assembly 1 11 Collar 1 12 Handlebar grip left 1 Refer to REMOVAL POINTS 13 Main switch 1 14 Handlebar holder 2 15 Handlebar 1 1 ...

Page 243: ...DLEBAR 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 Grip cap lower 1 6 Grip cap upper 1 7 Throttle cable 1 8 Throttle grip assembly 1 9 Collar 1 10 Handlebar grip left 1 Refer to REMOVAL POINTS 11 Upper handlebar holder 2 12 Handlebar 1 1 HANDLEBAR ...

Page 244: ...LEBAR 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 cable 1 9 Throttle grip assembly 1 10 Handlebar grip left 1 Refer to REMOVAL POINTS 11 Main switch 1 12 Upper handlebar holder 2 13 Handlebar 1 1 ...

Page 245: ... 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 POINTS 2 Collar 2 3 Tube guide 1 1 ...

Page 246: ...ylinder cap side horizontal to prevent air from coming in Å TT R125LW ı TT R125LWE Å U P 1 2 ı Handlebar grip 1 Remove Handlebar grip 1 NOTE Blow in air between the handlebar or tube guide and the grip Then remove the grip which has become loose INSPECTION Handlebar 1 Inspect Handlebar 1 Bends cracks damage Replace WARNING Do not attempt to straighten a bent handle bar as this may dangerously weak...

Page 247: ...ndlebar 1 Handlebar holder 2 Main switch TT R125E TT R125LWE 3 Main switch holder TT R125E TT R125LWE 4 Bolt handlebar holder 5 NOTE Align the punched mark a on the handlebar with the upper surface of the handlebar holder on the upper bracket The handlebar holder should be installed with the punched mark b forward First tighten the bolts on the front side of the handlebar holder and then tighten t...

Page 248: ...ly 1 Grip 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 cap 2 Grip cap lower 3 Screw grip cap 4 Cover grip cap 5 WARNING After tightening the screws check that the throttle grip 6 moves smoothly If it does not retighten the bolts for adjustment ...

Page 249: ...Install the bracket so that the arrow mark a face upward First tighten the bolts on the upper side of the brake master cylinder bracket and then tighten the bolts on the lower side TT R125LWE Start switch 1 Brake master cylinder 2 Brake master cylinder bracket 3 Bolt brake master cylinder bracket 4 NOTE Install the bracket so that the arrow mark a face upward First tighten the bolts on the upper s...

Page 250: ...Pass the engine stop switch lead in the mid dle of the clutch lever holder Å TT R125 TT R125LW ı TT R125E TT R125LWE 1 2 3 3 Å ı T R 4 Nm 0 4 m kg 2 9 ft lb 8 Install Clutch cable 1 Clamp NOTE Apply the lithium soap base grease on the clutch cable end 9 Adjust Brake lever free play Refer to FRONT BRAKE ADJUST MENT section in the CHAPTER 3 Clutch lever free play Refer to CLUTCH ADJUSTMENT section i...

Page 251: ...placing 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 Front fender 1 Steering stem nut 1 2 Upper bracket 1 3 Special washer 1 4 Upper ring nut 1 Use special tool Refer to REMOVAL POINTS 5 Rubber washer 1 6 Lower ring nut 1 7 Lower bracket 1 8 Bearing cove...

Page 252: ...S 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 lower 1 2 ...

Page 253: ...ll 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 floor chisel 2 CAUTION Take care not to damage the steering shaft thread EC564000 INSPECTION Steering stem 1 Inspect Steering stem 1 Bend damage Replace STEERING ...

Page 254: ... 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 soap base grease on the dust seal lip and bearing inner circumference 2 Install Bearing outer race lower Bearing outer race upper 3 Install Bearing upper Bearing inner race 1 Bearing cover 2 NOTE Apply ...

Page 255: ...NG 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 bearings T R 20 Nm 2 0 m kg 14 ft lb 7 Install Upper bracket 1 Steering stem nut 2 Starter knob bracket 3 NOTE Do not tighten the steering stem nut yet T R 10 Nm 1 0 m kg 7 2 ft lb 8 Install Front forks...

Page 256: ...he 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 Å TT R125 TT R125E TT R125LW ı TT R125LWE Front fork top end standard a Zero mm Zero in a Å ı 13 Tighten Pinch bolts lower bracket 1 Pinch bolts upper bracket 2 T R 60 Nm 6 0 m kg 43 ft lb T R 25 Nm 2 5 m kg 18 ft lb STEERING ...

Page 257: ...e 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 chain tensioner upper 1 2 Drive chain tensioner lower 1 3 Bolt connecting arm frame 1 4 Bolt rear shock absorber relay arm 1 Hold the swingarm 5 Pivot shaft 1 6 Swingarm 1 1 ...

Page 258: ...ly 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 6 Connecting arm 1 7 Oil seal 2 8 Collar 2 9 Dust cover 2 0 Bushing 1 A Relay arm 1 B Dust cover 2 C Bushing 1 D Swingarm 1 3 1 2 ...

Page 259: ...ngs 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 Bushing 4 Damage pitting Replace bushings as a set Collar 5 Bushing 6 Bushing 7 Damage pitting Replace collars and bushing as a set 2 Inspect Oil seal 8 Dust cover 9 Damage Replace 3 Inspect Relay arm 0 D...

Page 260: ...ing 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 and relay arm Swingarm assembly 1 Install Bushing 1 Dust covers 2 On swingarm NOTE Apply the molybdenum disulfide grease on the bushing and dust cover lip SWINGARM ...

Page 261: ...nd 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 washer Nut relay arm TT R125 TT R125E TT R125LW TT R125LWE On swingarm NOTE Apply the molybdenum disulfide grease on the bolt relay arm T R 70 Nm 7 0 m kg 50 ft lb T R 53 Nm 5 3 m kg 38 ft lb SWINGARM ...

Page 262: ... 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 Swingarm Pivot shaft 1 Plain washer Nut pivot shaft NOTE Apply the molybdenum disulfide grease on the pivot shaft 2 Check Swingarm side play a Free play exists Replace bushing Swingarm up and down mov...

Page 263: ... 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 chain tensioner lower T R 7 Nm 0 7 m kg 5 1 ft lb 6 Install Bushing 1 Drive chain tensioner upper 2 Plain washer 3 Bolt drive chain tensioner upper 4 NOTE Apply the lithium soap base grease on the bu...

Page 264: ...ASSEMBLY REMOVAL Hold the machine by placing the suitable stand under the engine WARNING Support the machine securely so there is no danger of it falling over Seat and side covers Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 1 Bolt rear shock absorber assem bly relay arm 1 Hold the swingarm 2 Bolt rear shock absorber assem bly frame 1 3 Bushing 1 Refer to REMOVAL POINTS 4 Rear ...

Page 265: ...Never 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 expansion and or damage to the hose 3 Be careful not to damage any part of the rear shock absorber A damaged rear shock absorber will impair the damping performance or cause a mal function 4 Take care not...

Page 266: ... gas valve needle with a suitable tool as shown until all of the gas is released the hissing has stopped Å TT R125 TT R125E TT R125LW ı TT R125LWE Å ı EC583000 REMOVAL POINTS Bushing 1 Remove Bushing 1 NOTE Remove the bushing by pressing EC584000 INSPECTION Rear shock absorber assembly 1 Inspect Damper rod 1 Bends damage Replace rear shock absorber assembly Shock absorber 2 Oil leaks Replace rear ...

Page 267: ...T R125LW 2 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 53 Nm 5 3 m kg 38 ft lb 3 Install Bolt rear shock absorber assembly relay arm Plain washer 1 Nut rear shock absorber assembly relay arm 2 NOTE Apply the molybdenum disulfide grease on the bol...

Page 268: ...bottom 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 hose with the locking tie Refer to CABLE ROUTING DIAGRAM sec tion in the CHAPTER 2 1 3 a T R 4 Nm 0 4 m kg 2 9 ft lb b 0 2 mm 0 0 08 in 2 REAR SHOCK ABSORBER ASSEMBLY ...

Page 269: ... COMPONENTS AND WIRING DIAGRAM TT R125 TT R125LW EC611000 ELECTRICAL COMPONENTS 1 CDI unit 2 Engine stop switch 3 Ignition coil 4 CDI magneto 5 Spark plug COLOR CODE B Black Br Brown G Green O Orange R Red W White B R Black Red B W Black White G L Green Blue G W Green White W L White Blue W R White Red EC612000 WIRING DIAGRAM 6 ...

Page 270: ... 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 White L Y Blue Yellow R W Red White EC612000 WIRING DIAGRAM B R W W B R Y W B R Y 10A R B R W ON OFF R Br R B W B B W Br B ON OFF R W Br B B R W Sb R W B B B L Y OFF RUN B B B B W W Y W Sb B Sb Y B G W Br R G W Br R B B W R W B...

Page 271: ...nk 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 plug Check entire ignition system for connection Repair or replace Check main switch TT R125E TT R125LWE only Replace Check engine stop switch Replace Check ignition coil Primary coil Replace Secondary coil Replac...

Page 272: ...il misfire occurs for USA and CDN only Minimum spark gap 6 0 mm 0 24 in Å ı EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1 Check Couplers and leads connection Rust dust looseness short circuit Repair or replace MAIN SWITCH INSPECTION TT R125E TT R125LWE 1 Inspect Main switch continuity Check for continuity as follows Incorrect continuity Replace Tester Red lead 1 Tester Brown lead 2 Continuou...

Page 273: ...ace Continuous while being freed Replace Tester lead Black White lead 1 Tester lead Black lead 2 B W 1 B 2 Tester selec tor position PUSH IN Ω 1 FREE Tester lead Black lead 1 Tester lead Black lead 2 B 1 B 2 Tester selec tor position PUSH IN Ω 1 FREE B B 1 2 EC626002 IGNITION COIL INSPECTION 1 Inspect Primary coil resistance Out of specification Replace Tester lead Orange lead 1 Tester lead Black ...

Page 274: ... plug lead 1 Tester lead Orange lead 2 Secondary coil resistance Tester selector position 6 3 9 5 kΩ at 20 C 68 F kΩ 1 CDI MAGNETO INSPECTION 1 Inspect Pickup coil resistance Out of specification Replace Å TT R125 TT R125LW ı TT R125E TT R125LWE Tester lead Red lead 1 Tester lead White lead 2 Pickup coil resistance Tester selector position 248 372 Ω at 20 C 68 F Ω 100 Å Br G R W 1 2 ı ...

Page 275: ...tance Out of specification Replace Å TT R125 TT R125LW ı TT R125E TT R125LWE Tester lead Brown lead 1 Tester lead Green lead 2 Source coil resistance Tester selector position 688 1 032 Ω at 20 C 68 F Ω 100 Å Br G R W 1 2 ı IGNITION SYSTEM ...

Page 276: ...perating 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 has been met the starting circuit cut off relay is closed and the engine can be started by pressing the start switch WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE CLUTCH LEVER IS PULLED TO THE HANDLEBA...

Page 277: ...he 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 wire connection Repair or replace 3 Check main switch Replace Check starter motor operation Repair or replace Check starting circuit cut off relay Replace Check starter relay Replace Check neutral switch Replac...

Page 278: ... 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 CIRCUIT CUT OFF RELAY INSPECTION 1 Remove Starting circuit cut off relay 2 Inspect Starting circuit cut off relay conduct Use 12 V battery Battery lead Sky blue lead 1 Battery lead Red White lead 2 Tester lead Re...

Page 279: ...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 Ω 1 Not connected to battery NEUTRAL SWITCH INSPECTION 1 Inspect Neutral switch conduct No continuous while in neutral Replace Continuous while in gear Replace Tester lead Sky blue lead 1 Tester lead Black lead 2 Sb 1 B 2 Tester selec tor posit...

Page 280: ... 1 Tester lead Black lead 2 B 1 B 2 Tester selec tor position PULL Ω 1 FREE B B 1 2 START SWITCH INSPECTION 1 Inspect Start switch continuity No continuous while being pushed Replace Continuous while being freed Replace Tester lead Black lead 1 Tester lead Black lead 2 B 1 B 2 Tester selec tor position PUSH IN Ω 1 FREE B B 1 2 ELECTRIC STARTING SYSTEM TT R125E TT R125LWE ...

Page 281: ... 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 Starter motor front cover 1 2 Washer starter motor front cover 1 3 Plain washer 1 4 Circlip 1 5 O ring 3 1 ELECTRIC STARTING SYSTEM TT R125E TT R125LWE ...

Page 282: ...RTING SYSTEM TT R125E TT R125LWE 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 Brush spring 2 1 ...

Page 283: ...e 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 Replace the starter motor Measurement steps Measure the armature assembly resis tances with the pocket tester Pocket tester YU 3112 C 90890 03112 Armature coil Commutator resistance 1 0 017 0 021 Ω at 20 C 68 F I...

Page 284: ... 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 holding down the brush using a thin screw driver CAUTION Be careful not to damage the brush during installation ELECTRIC STARTING SYSTEM TT R125E TT R125LWE ...

Page 285: ...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 starter motor yoke with the match mark b on the starter motor front cover 1 2 a b New 3 4 New 5 Install Bolt 1 O ring 2 NOTE Apply the lithium soap base grease on the O ring 2 1 New LS New ELECTRIC STARTING SYSTEM T...

Page 286: ... the following parts 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 Check fuse Replace fuse and check wire harness 2 Check battery Recharge or replace Check each coupler and wire connection Repair or replace Check charging voltage Charging system ...

Page 287: ...e Out of 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 14 0 15 0 V at 5 000 r min DCV 20 W B R Y 2 1 3 Inspect Charging coil resistance Out of specification Replace Tester lead White lead 1 Tester lead Black lead 2 Charging coil resistance Tester ...

Page 288: ......

Page 289: ...PRINTED IN BRASIL 00 2000 0000 GYL E LIT 11626 20 01 1B2 F8199 12 TT R125EW TT R125LW TT R125LEW TT R125EW TT R125LW TT R125LEW ...

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