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Yamaha TT-R125EY, Service Manual

The Yamaha TT-R125EY Service Manual is a comprehensive and essential resource for maintaining and repairing your motorcycle. This manual, available for free download at manualshive.com, provides detailed instructions and diagrams, making it easier to service your TT-R125EY and keep it running at its best.

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5-45

CHAS

HANDLEBAR

REMOVAL POINTS

Brake master cylinder

1. Remove:

• Brake master cylinder bracket 

1

• Brake master cylinder 

2

• Do not let the brake master cylinder hang

on the brake hose.

• Keep the brake master cylinder cap side

horizontal to prevent air from coming in.

Handlebar grip

1. Remove:

• Handlebar grip 

1

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.

Do not attempt to straighten a bent handle-
bar as this may dangerously weaken the
handlebar.

WARNING

NOTICE

TIP

Summary of Contents for TT-R125EY

Page 1: ...TT R125EY TT R125LEY 1B2 F8197 14 SERVICE MANUAL LIT 11626 22 26 ...

Page 2: ...y Yamaha Motor da Amazônia Ltda 1st Edition June 2008 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 22 26 EC010000 ...

Page 3: ...t infor mation available at the time of printing there may be minor discrepancies between your machine and this manual If you have any questions con cerning this manual please consult your Yamaha dealer READ 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 R125E ONLY ...

Page 4: ...UENTIAL DAMAGES SO THE ABOVE EXCLUSION MAY NOT APPLYTOYOU THISWARRANTY GIVESYOU SPECIFIC LEGAL RIGHTS ANDYOU MAY ALSO HAVE OTHERWHICHVARY FROM STATETO STATE YAMAHA MOTOR CORPORATION USA Post Office Box 6555 Cypress California 90630 WARRANTY QUESTIONS AND ANSWERS Q What costs are my responsibility during the warranty period A The customer s responsibility includes all costs of normal maintenance se...

Page 5: ... ma chine 3 ALWAYS MAINTAIN YOUR MACHINE IN PROPER WORKING ORDER For safety and reliability the machine must be properly maintained Always perform the pre operation checks in dicated in this manual Correcting a mechanical problem before you ride may prevent an accident 4 GASOLINE IS HIGHLY FLAMMABLE Always turn off the engine while refu eling Take care to not spill any gaso line on the engine or e...

Page 6: ...urn off the engine if you area going to leave the machine Do not park the machine on a slope or soft ground as it may fall over 8 THE ENGINE EXHAUST PIPE MUF FLER AND OIL TANK BE VERY HOT AFTER THE ENGINE HAS BEEN RUN Be careful not to touch them or to al low any clothing item to contact them during inspection or repair 9 PROPERLY SECURE THE MACHINE BEFORE TRANSPORTING IT When transporting the mac...

Page 7: ...ular in spection and adjustments Engine Chas sis and Electrical 2 The table of contents is at the beginning of the manual Look over the general layout of the book before finding then required chapter and item Bend the book at its edge as shown to find the required fore edge symbol mark and go to a page for required item and description ...

Page 8: ...e 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 ...

Page 9: ...pearing in the text 7 With engine mounted 8 Special tool 9 Filling fluid 0 Lubricant A Tightening B Specified value Service limit C Engine speed D Resistance Ω Voltage V Electric cur rent A Illustrated symbols E to I in the exploded dia grams indicate grade of lubricant and location of lubrication point E Apply engine oil F Apply molybdenum disulfide oil G Apply brake fluid H Lithium soap base gre...

Page 10: ...MEMO ...

Page 11: ...INDEX GEN INFO SPEC INSP ADJ CHAS GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS ELEC ELECTRICAL ENG 1 2 3 4 5 6 ...

Page 12: ...KING OF CONNECTION 1 4 SPECIAL TOOLS 1 5 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 TT R125E 2 1 TT R125LE 2 4 MAINTENANCE SPECIFICATIONS 2 7 ENGINE 2 7 CHASSIS 2 15 TT R125E 2 15 TT R125LE 2 19 ELECTRICAL 2 23 GENERAL TORQUE SPECIFICATIONS 2 25 DEFINITION OF UNITS 2 25 CABLE ROUTING DIAGRAM 2 26 ...

Page 13: ...FUEL TANK AND SIDE COVERS 4 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 39 OIL PUMP 4 48 KICK AXLE AND SHIFT SHAFT 4 52 CDI MAGNETO AND STARTER CLUTCH 4 57 ENGINE REMOVAL 4 62 CRANKCASE CRANKSHAFT AND BALANCER 4 66 TRANSMISSION SHIFT CAM AND SHIFT FORK 4 74 ...

Page 14: ...FRONT BRAKE TT R125LE 5 12 REAR WHEEL AND REAR BRAKE 5 24 FRONT FORK 5 32 HANDLEBAR 5 42 STEERING 5 50 SWINGARM 5 56 REAR SHOCK ABSORBER ASSEMBLY 5 63 CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM 6 1 IGNITION SYSTEM 6 2 ELECTRIC STARTING SYSTEM 6 7 CHARGING SYSTEM 6 16 ...

Page 15: ...ositive identi fication of the model you own 2 If your machine is stolen the authorities will need the number to search for and identify your machine KEY IDENTIFICATION NUMBER The key identification number 1 is stamped on the key as shown in the following illustration This number can be used for ordering a new key EC121001 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stampe...

Page 16: ... FOR REMOVAL AND DISASSEMBLY 1 Remove all dirt mud dust and foreign material before removal and disassembly When washing the machine with high pressured water cover the part as follow Silencer exhaust port 2 Use proper tools and cleaning equipment Refer to SPECIAL TOOLS section 3 When disassembling the machine keep mated parts together They include gears cylinders pistons and other mated parts tha...

Page 17: ...nt 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 numbers 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 lightweight lithium base grease to the seal lip s Oil the bear...

Page 18: ...field remedy use a contact revitalizer available on the market Use the tester on the connector as shown EC1C0000 CHECKING OF CONNECTION Dealing with stains rust moisture etc on the connector 1 Disconnect Connector 2 Dry each terminal with an air bower 3 Connect and disconnect the connector two or three times 4 Pull the lead to check that it will not come off 5 If the terminal comes off bend up the...

Page 19: ...084 90890 01085 Small slide hammer set Weight Slide hammer bolt These tools are used when removing or installing the rocker arm shafts YU 1083 A 90890 01084 90890 01085 YU 1135 A Crankcase separating tool YU 1135 A 90890 01135 90890 01135 These tools are used to split the crankcase as well as remove the crankshaft from either case YU 3097 90890 01252 YU 1256 YU 90050 90890 01274 YU 90050 90890 012...

Page 20: ... is necessary for adjusting valve clearance Fuel level gauge This gauge is used to measure the fuel level in the float chamber Flywheel puller This tool is used to remove the rotor Fork seal driver weight Fork seal driver attachment These tools are used to installing the fork oil seal Steering nut wrench This tool is used when tighten the steering ring nut to specification Sheave holder This tool ...

Page 21: ... 85505 Clutch holding tool This tool is used to hold the clutch when removing or installing the clutch boss securing nut Valve guide remover Valve guide installer Valve guide reamer These tools are needed to rebore the new valve guide Dynamic spark tester Ignition checker This instrument is necessary for checking the ignition system components Quick gasket YAMAHA Bond No 1215 This sealant Bond is ...

Page 22: ... mm 41 7 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 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 s x stroke 54 0 x 54 0 mm 2 126 x 2 126 in Compression ratio 10 0 1 Starting system Kick and electric s...

Page 23: ...acity 6 0 L 1 31 Imp gal 1 58 US gal Reserve amount 0 83 L 0 18 Imp gal 0 22 US gal Carburetor Type VM20x1 Manufacturer MIKUNI Spark plug Type CR7HSA U22FSR U Manufacturer NGK DENSO Gap 0 6 0 7 mm 0 02 0 03 in Clutch type Wet multiple disc Oil type or grade Engine oil At 10 C 10 F or higher A Yamalube 4 10W 30 or SAE 10W 30 type SE motor oil At 5 C 40 F or higher B Yamalube 4 20W 40 or SAE 20W 40 ...

Page 24: ... rear 90 100 14 49M 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 Re...

Page 25: ... 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 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 s x stroke 54 0 x 54 0 mm 2 126 x 2 126 in Compression ratio 10 0 1 Starting system Kick and electric starter Lubrication system W...

Page 26: ...acity 6 0 L 1 31 Imp gal 1 58 US gal Reserve amount 0 83 L 0 18 Imp gal 0 22 US gal Carburetor Type VM20x1 Manufacturer MIKUNI Spark plug Type CR7HSA U22FSR U Manufacturer NGK DENSO Gap 0 6 0 7 mm 0 02 0 03 in Clutch type Wet multiple disc Oil type or grade Engine oil At 10 C 10 F or higher A Yamalube 4 10W 30 or SAE 10W 30 type SE motor oil At 5 C 40 F or higher B Yamalube 4 20W 40 or SAE 20W 40 ...

Page 27: ...r 90 100 16 52M Manufacturer 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 damp...

Page 28: ...mm 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 25 851 mm 1 0189 1 0229 in 1 0178 in B 21 195 21 295 mm 21 165 mm 0 8344 0 8384 in 0 8333 in Exhaust A 25 841 25 941 mm 25 811 mm 1 0174 1 0213 in 1 0162 in B 21 050 21 150 mm 21 020 mm 0 8287 0 8327 in 0 8276 in Camshaft run out limit 0 03 mm 0 0012 in ...

Page 29: ...ameter IN 5 000 5 012 mm 5 042 mm 0 1969 0 1973 in 0 1985 in EX 5 000 5 012 mm 5 042 mm 0 1969 0 1973 in 0 1985 in Stem to guide clearance IN 0 010 0 037 mm 0 08 mm 0 0004 0 0015 in 0 0031 in EX 0 025 0 052 mm 0 10 mm 0 0010 0 0020 in 0 0040 in Valve valve seat valve guide Valve clearance cold IN 0 08 0 12 mm 0 0031 0 0047 in EX 0 10 0 14 mm 0 0039 0 0055 in Valve dimensions Cam chain Cam chain ty...

Page 30: ...pressed pressure installed IN 191 219 N 19 5 22 3 kgf 42 93 49 23 lbf EX 191 219 N 19 5 22 3 kgf 42 93 49 23 lbf Tilt limit IN 2 5 1 7 mm 2 5 0 07 in EX 2 5 1 7 mm 2 5 0 07 in Direction of winding top view IN Clockwise EX Clockwise Stem run out limit 0 01 mm 0 0004 in Valve seat width IN 0 9 1 1 mm 1 6 mm 0 0354 0 0433 in 0 0630 in EX 0 9 1 1 mm 1 6 mm 0 0354 0 0433 in 0 0630 in Item Standard Limi...

Page 31: ... 0 090 mm 0 12 mm 0 0014 0 0035 in 0 0047 in 2nd ring B T B T Dimensions B T 2 0 2 2 mm 0 08 0 09 in End gap installed 0 20 0 70 mm 0 01 0 03 in H D Piston Piston to cylinder clearance 0 020 0 026 mm 0 15 mm 0 0008 0 0010 in 0 0059 in Piston size D 53 977 53 996 mm 2 1251 2 1258 in Piston over size 2nd 54 5 mm 2 1457 in 4th 55 0 mm 2 1654 in Measuring point H 5 mm 0 20 in Piston off set 0 5 mm 0 0...

Page 32: ...ne idle speed 1 300 1 500 r min Clutch Friction plate thickness 2 92 3 08 mm 2 8 mm 0 115 0 121 in 0 110 in Quantity 5 Clutch plate thickness 1 05 1 35 mm 0 041 0 053 in Quantity 4 Warp limit 0 2 mm 0 008 in Clutch spring free length 33 mm 1 30 in 31 mm 1 22 in Quantity 4 Clutch release method Inner push cam push Push rod bending limit 0 5 mm 0 020 in Shifter Shifter type Shift drum and guide bar ...

Page 33: ...filter type Wire mesh type Oil pump type Trochoid type Tip clearance 0 15 mm 0 2 mm 0 0059 in 0 0079 in Side clearance 0 06 0 10 mm 0 15 mm 0 0024 0 0039 in 0 0059 in Housing and rotor clearance 0 06 0 10 mm 0 15 mm 0 0024 0 0039 in 0 0059 in Item Standard Limit ...

Page 34: ...er cover M4 0 7 2 2 0 2 1 4 Air filter case M6 1 0 3 7 0 7 5 1 Muffler M6 1 0 2 10 1 0 7 2 Muffler M10 1 25 1 60 6 0 43 Muffler M8 1 25 1 30 3 0 22 Muffler guard M6 1 0 7 10 1 0 7 2 Spark arrester M6 1 0 3 10 1 0 7 2 Crankcase M6 1 0 10 10 1 0 7 2 Left crankcase cover M6 1 0 7 10 1 0 7 2 Drive sprocket cover M6 1 0 2 12 1 2 8 7 Right crankcase cover M6 1 0 9 10 1 0 7 2 Lead guide CDI Magneto lead ...

Page 35: ...ad tightening sequence Tightening torque Part to be tightened Thread size Q ty Nm m kg ft lb Segment M6 1 0 1 12 1 2 8 7 Stopper lever M6 1 0 1 10 1 0 7 2 TIP Î marked portion shall be checked for torque tightening after break in or before each ride ...

Page 36: ...ameter 31 mm 1 22 in Front fork top end Zero mm Zero in EC212201 CHASSIS TT R125E Rear suspension Shock absorber travel 65 mm 2 56 in Spring free length 178 mm 7 01 in Fitting length 165 mm 6 50 in Spring rate STD 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 wheel type Spoke wheel Front rim size materia...

Page 37: ...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 1 mm 0 04 in vertical height below footrest top Brake pedal free play 20 30 mm 0 79 1 18 in Clutch lever free play lever end 10 15 mm 0 ...

Page 38: ...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 nut M12 1 25 1 60 6 0 43 Rear brake camshaft lever and camshaft M6 1 0 1 10 1 0 7 2 Brake pedal mounting M10 1 25 1 30 3 0 22 Brake pedal position locknut M6 1 0 1 7 0 7 5 1 Front wheel nipple spoke 36 2 0 2 1 4 Rear wheel nipple spoke 36 3 0 3 2 2 Dri...

Page 39: ...uide and swingarm M6 1 0 2 7 0 7 5 1 Drive chain guard mounting M6 1 0 2 7 0 7 5 1 Fuel tank mounting M6 1 0 2 10 1 0 7 2 Fuel tank and fuel cock M6 1 0 2 7 0 7 5 1 Fuel tank and fuel tank bracket M6 1 0 4 7 0 7 5 1 Front fender mounting M6 1 0 4 7 0 7 5 1 Rear fender mounting M6 1 0 4 7 0 7 5 1 Flap guard mounting M6 1 0 2 4 0 4 2 9 Left side cover mounting M6 1 0 2 7 0 7 5 1 Seat mounting M6 1 0...

Page 40: ... 180 mm 7 09 in Fork spring free length 469 4 mm 18 46 in 463 9 mm 18 23 in Spring rate STD K 3 20 N mm 0 330 kg mm 18 5 lb in Optional spring spacer No Oil capacity 164 cm3 5 77 Imp oz 5 54 US oz Oil level 134 mm 5 27 in Oil grade Fork oil 10W or equivalent Inner tube outer diameter 31 mm 1 22 in Front fork top end Zero mm Zero in TT R125LE Rear suspension Shock absorber travel 65 mm 2 56 in Spri...

Page 41: ...edal free play 20 30 mm 0 79 1 18 in Clutch lever free play lever end 10 15 mm 0 39 0 59 in Throttle grip free play 3 5 mm 0 12 0 20 in Item Standard Limit Drive chain Type manufacturer DID428HD DAIDO Number of links 122 links Chain slack 35 50 mm 1 4 2 0 in Chain length 15 links 194 3 mm 7 65 in Front disc brake Disc outside dia Thickness 220 3 0 mm 8 66 0 12 in 220 2 5 mm 8 66 0 10 in Deflection...

Page 42: ...nd 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 0 4 2 9 Front brake master cylinder and joint M10 1 25 1 26 2 6 19 Front brake hose and joint M10 1 25 1 14 1 4 10 Front brake hose union bolt M10 1 25 1 26 2 6 19 Front brake caliper and front fork M8 1 25 2 32 3 2 24 Brake caliper support bolt M...

Page 43: ... Rear shock absorber assembly and frame M12 1 25 1 53 5 3 38 Rear shock absorber assembly and relay arm M10 1 25 1 35 3 5 25 Rear shock absorber and locknut preload M46 1 5 1 42 4 2 30 Drive chain tensioner upper M8 1 25 1 23 2 3 17 Drive chain tensioner lower M6 1 0 1 7 0 7 5 1 Drive chain support and swingarm M6 1 0 2 7 0 7 5 1 Drive chain guide and swingarm M6 1 0 2 7 0 7 5 1 Drive chain guard ...

Page 44: ...at 20 C 68 F Charging system System type CDI magneto 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 Rectfier regulator Regulator type Semiconductor short circuit Model manufacture TWBA 11 DENSO No load regulated voltage 14 0 15 0 V Rectifier capacity 8 A Electric starting system Type Constant mesh Starter mot...

Page 45: ... Model manufacturer ACM33221 M06 Nais 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 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 Tightening torque Part to be tightened Thread size Q ty Nm m k...

Page 46: ...perature EC220001 GENERAL TORQUE SPECIFICATIONS A Distance between flats B Outside thread diameter A B Nm m kg ft lb A B Nut Bolt TORQUE SPECIFICATION 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 94 EC230000 DEFINITION OF UNITS Unit Read Definition Measure mm millimeter 10 3 meter Length cm centimeter 10 2 meter Leng...

Page 47: ...lead 6 Rectifier regulator lead 7 CDI magneto lead 8 Air vent hose 9 Neutral switch lead 0 Rear shock absorber assembly sub tank hose TT R125LE only A Starting circuit cut off relay lead B CDI unit lead C Corrugated tube P Frame Q Rectifier regulator A Fasten the primary coil lead and ground lead B Fasten the wire harness at its tape C Fasten the wire harness and CDI magneto lead in front of the r...

Page 48: ...crankcase cover M Pass the starting circuit cult off relay lead under the frame and at the right of the chassis N Fasten the rear shock absorber assemby sub tank TT R125LE only O Pass the CDI unit lead on the outside of the main switch lead engine stop switch lead clutch switch lead and start switch lead P After fastening the start switch lead clutch switch lead engine stop switch lead and main sw...

Page 49: ...ube X Fasten the CDI unit lead and starting circuit cut off relay lead with a plastic locking tie at the tape holding the main switch lead engine stop switch lead clutch switch lead and start switch lead together Y Position the CDI magneto lead wire harness and rear shock absorber assembly sub tank hose TT R125LE only as shown Z Fasten the wire harness CDI magneto lead and rear shock absorber asse...

Page 50: ...g circuit cut off relay 9 Spark plug lead 0 Starter motor lead A Negative battery lead B Engine oil breather hose C Positive battery lead D Overflow hose E Air vent hose F Primary coil lead G Ground lead A Tighten the starter choke nut while taking care not to twist the starter cable B Pass the clutch cable on the inside of the throttle cable and starter cable C Pass the starter cable so that it i...

Page 51: ... starter motor lead H Pass the air vent hose between the swingarm and the frame and the overflow hose between the engine and the swingarm I Pass the negative battery lead on the inside of the frame as shown J Fasten the overflow hose and air vent hoses to 2 clicks K After fastening the starter cable push it against the starter plunger L Put the tip of the air vent hose into the frame M Install the...

Page 52: ...h the cable guide C Pass the clutch cable in back of the number plate D Starting at the forepart pass the main switch lead clutch cable and start switch lead in that order E Pass the start switch lead in back of the starter cable F Pass the main switch lead on the right of the number plate stay G Fasten the throttle cable adjuster cover and start switch lead with a plastic locking tie ends downwar...

Page 53: ...isn t used for a long period of time the month maintenance intervals should be followed TIP Check fuel hoses for cracks or damage Replace if necessary Check condition Adjust gap and clean Check and adjust valve clearance when engine is cold Clean with solvent Replace if necessary Check ventilation hose for cracks or damage Replace if necessary Check engine idling speed an starter operation Adjust ...

Page 54: ...eck operation Adjust or replace cable Clean Check operation Adjust brake lever free play and replace brake shoes if necessary TT R125E Check operation fluid level and for fluid leakage Replace brake pads if necessary TT R125LE Replace brake fluid TT R125LE Check operation Adjust brake pedal free play and replace brake shoes if necessary Check for clacks or damage Replace Check runout spoke tightne...

Page 55: ... based grease lightly Check operation Apply lithium soap based grease lightly Check operation and for oil leakage Replace if necessary Check operation and for oil leakage Replace if necessary Apply Yamaha chain and cable lube or engine oil 10W 30 thoroughly Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable Check all chassis...

Page 56: ...chain is lubricated properly Check for excessive wear and tire pressure Check for loose spokes and have no excessive play Check that the handlebar can be turned smoothly and have no excessive play Check that they operate smoothly and there is no oil leakage Check that the clutch and throttle cables move smoothly Check that they are not caught when the handlebars are turned or when the front forks ...

Page 57: ... specified limits Tighten the locknut Clutch lever free play a 10 15 mm 0 39 0 59 in Make minute adjustment on the lever side After adjustment check proper operation of clutch lever 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 steps L...

Page 58: ...ICATION 1 Remove Grip cap lower 1 2 Apply Lithium soap base grease On the throttle cable end a and tube guide cable winding portion b 3 Install Grip cap lower 4 Nm 0 4 m kg 2 9 ft lb AIR FILTER CLEANING Proper air filter maintenance is the biggest key to preventing premature engine wear and damage Never run the engine without the air filter element in place this would allow dirt and dust to enter ...

Page 59: ...e Band 1 Air filter 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 it with solvent After cleaning remove the remaining solvent by squeezing the element Do not twist the element when squeezing the element 5 Inspect Air filter element Damage Replace TIP TIP NOTICE ...

Page 60: ...ght position by placing the suitable stand under the engine 6 Apply Yamaha foam air filter oil or other quality foam air filter oil Squeeze out the excess oil Element should be wet but not dripping 7 Install Air filter element 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 3 Remove Dipstick...

Page 61: ...E motor oil At 5 C 40 F or higher B Yamalube 4 20W 40 or SAE 20W 40 type SE motor oil Do not add any chemical additives Engine oil also lubricates the clutch and additives could cause clutch slippage Do not allow foreign material to enter the crankcase Do not add any chemical additives or use oils with a grade of CD a or higher Do not use oils labeled ENERGY CONSERVING II b or higher Engine oil al...

Page 62: ...warm it up for several 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 6 Fill Engine oil New 20 Nm 2 0 m kg 14 ft lb 7 Check Oil leakage 8 Check Engine oi...

Page 63: ...re check bolt If no oil comes out after one minute turn the engine off so it will not seize Check oil passages and oil pump for damage or leakage Start the engine after solving the problem s and recheck the oil pressure Tighten the oil pressure check bolt Oil pressure check bolt 7 Nm 0 7 m kg 5 1 ft lb ENGINE IDLING SPEED ADJUSTMENT 1 Start the engine and thoroughly warm it up 2 Attach Inductive t...

Page 64: ... section in the CHAPTER 4 2 Remove Spark plug Intake tappet cover 1 Exhaust tappet cover 2 O ring 3 Remove Timing mark accessing screw 1 Crankshaft end accessing screw 2 O ring 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...

Page 65: ...n 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 clearance is obtained Turning in Valve clearance is decreased Turning out Valve clearance is increased...

Page 66: ...3 Apply the lithium soap base grease on the O rings 7 Install O ring 1 Exhaust tappet cover 2 Intake tappet cover 3 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 CHAPTER 4 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb 18 Nm 1 8 m kg 13 ft lb 18 Nm 1 8 m kg 13 ft lb 7 Nm 0 7 m kg 5 1 ft lb 10 Nm 1 0 m k...

Page 67: ... the exhaust system WARNING 3 Clean Spark arrester Tap the spark arrester lightly then use a wire brush to remove any carbon deposits 1 Remove Bolt spark arrester 1 2 Remove Cap 1 Spark arrester 2 Pull the spark arrester out of the muffler 4 Install Spark arrester Insert the spark arrester into the muffler cap and align the bolt holes Bolt spark arrester 10 Nm 1 0 m kg 7 2 ft lb ...

Page 68: ...Air bleeding steps a Add proper brake fluid to 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 position g Loosen the bleed screw and al...

Page 69: ...ster cylinder cap WARNING FRONT BRAKE ADJUSTMENT TT R125E 1 Check Brake lever free play a Out of specification Adjust 2 Adjust Brake lever free play Brake lever free play adjustment steps Loosen the locknuts 1 Turn the locknuts until free play a is within the specified limits by changing their tightening position Tighten the locknuts For minute adjustment loosen the locknut 2 on the lever side and...

Page 70: ... within the specified limits Tighten the locknut Make sure that there is no brake drag after adjusting the brake lever free play REAR BRAKE ADJUSTMENT 1 Check Brake pedal free play a Out of specification Adjust Brake pedal free play a 20 30 mm 0 79 1 18 in 2 Adjust Brake pedal free play Make sure that there is no brake drag after adjusting the brake pedal play Brake pedal free play adjustment step...

Page 71: ...g bolt 2until the pedal height a is within specified height Tighten the locknut Brake pedal height a 1 mm 0 04 in FRONT BRAKE PAD INSPECTION AND REPLACEMENT TT R125LE 1 Remove Plug 2 Inspect Brake pad thickness a Out of specification Replace as a set Brake pad thickness a Standard Limit 4 0 mm 0 8 mm 0 16 in 0 03 in 3 Replace Brake pad Brake pad replacement steps Remove the brake caliper support b...

Page 72: ...m kg 4 3 ft lb Brake caliper support bolt 22 Nm 2 2 m kg 16 ft lb 4 Inspect Brake fluid level Refer to BRAKE FLUID LEVEL INSPEC TION section 5 Check Brake lever operation A softy or spongy feeling Bleed brake system Refer to BRAKE SYSTEM AIR BLEED ING section FRONT BRAKE SHOE INSPECTION TT R125E 1 Inspect Brake shoe lining wear limit Brake shoe lining wear limit checking steps Fully pull in the br...

Page 73: ... brake fluid to avoid poor brake performance Refill with same type and brand of brake fluid mixing fluids could result in poor brake performance Be sure that water or other contaminants do not enter brake master cylinder when refilling Clean up spilled fluid immediately to avoid erosion of painted surfaces or plastic parts WARNING REAR BRAKE SHOE INSPECTION 1 Inspect Brake shoe lining wear limit B...

Page 74: ...chain from the kerosene and dry the chain 3 Measure Drive chain length 15 links a Out of specification Replace Drive chain length 15 links Limit 194 3 mm 7 65 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 Be sure to install the master link clip to the direction as shown a Turning direc...

Page 75: ...and or adjusting rotate the rear wheel through several revolutions and check the slack several times to find the tightest point Check and or adjust chain slack with rear wheel in this tight chain position 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 wit...

Page 76: ...ust Spring preload By turning the adjuster 1 Stiffer a Increase the spring preload Turn the adjuster 1 in Softer b Decrease the spring preload Turn the adjuster 1 out Extent of adjustment Maximum Minimum Position 1 Position 4 STANDARD POSITION Standard position 4 Grooves are provided to indicate the adjustment position Never go beyond the maximum or minimum adjustment positions Always adjust each ...

Page 77: ...r 3 Loosen Locknut 1 4 Adjust Spring preload By turning the adjuster 2 Stiffer Increase the spring preload Turn the adjuster 2 in Softer Decrease the spring preload Turn the adjuster 2 out Be sure to remove all dirt and mud from around the locknut and adjuster before adjustment The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster Never attempt to turn the adjuster bey...

Page 78: ...Softer b Decrease the rebound damping force Turn the adjuster 1 out 5 Tighten Locknut 6 Install Left side cover 7 Nm 0 7 m kg 5 1 ft lb 42 Nm 4 2 m kg 30 ft lb STANDARD POSITION This is the position which is back by the specific number of clicks from the fully turned in position Extent of adjustment Maximum Minimum Fully turned in position 20 clicks out from maximum position Standard position Abou...

Page 79: ... Maximum Minimum Fully turned in position 12 clicks out from maximum position STANDARD POSITION This is the position which is back by the specific number of clicks from the fully turned in position Standard position About 9 clicks out Never go beyond the maximum or minimum adjustment positions Stiffer a Increase the compression damping force Turn the adjuster 1 in Softer b Decrease the compression...

Page 80: ...d stoppers allow the tire to slip off its position on the rim when the tire pressure is low A tilted tire valve stem indicates that the tire slips off its position on the rim If the tire valve stem is found tilted the tire is considered to be slipping off its position Correct the tire position EC36T000 WHEEL INSPECTION 1 Inspect Wheel runout Elevate the wheel and turn it Abnormal runout Replace Fr...

Page 81: ... assembly back and forth Free play Adjust steering head 3 Check Steering smooth action Turn the handlebar lock to lock Unsmooth action Adjust steering ring nut 4 Adjust Steering ring nut Steering ring nut adjustment steps Remove the number plate and starter knob Remove the main switch handlebar and upper bracket Remove the special washer 1 Remove the upper ring nut 2 and rubber washer 3 Loosen the...

Page 82: ...er pawls into the slots If the slots are not aligned tighten the upper ring nut for alignment Lower ring nut initial tightening 38 Nm 3 8 m kg 27 ft lb Steering nut wrench YU 33975 90890 01403 Loosen the lower ring nut one turn Retighten the lower ring nut using the steering nut wrench WARNING Avoid over tightening Ring nut final tightening 20 Nm 2 0 m kg 14 ft lb Install the upper bracket A steer...

Page 83: ...de of the handlebar holder and then tighten the bolts on the rear side 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 NOTICE ...

Page 84: ...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 R125LE A Use Yamaha cable lube or equivalent on these areas B Use SAE 10W 30 motor oil or suitable chain lubricants C Lubricate the following areas with high quality lightweight lithium soap base grease LUBRICATION A A...

Page 85: ...s the spark plug insulator will become sooty even if the engine and carburetor are in good operating condition 3 Measure Plug gap a Use a wire gauge or thickness gauge Out of specification Regap 5 Tighten Spark plug Before installing a spark plug clean the gasket surface and plug surface Finger tighten a the spark plug before torquing to specification b Spark plug gap 0 6 0 7 mm 0 02 0 03 in Stand...

Page 86: ... OF REACH OF CHILDREN Avoid 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 followed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention Charging...

Page 87: ...he battery terminals First disconnect the negative battery lead 1 and then the positive battery lead 2 3 Remove Battery 4 Measure Battery charge Measurement steps Connect a pocket tester 1 to the battery terminals Tester positive probe battery positive terminal Tester negative probe battery negative terminal The charge state of an MF battery can be checked by measuring its open circuit voltage i e...

Page 88: ...the battery mounted on the machine disconnect the negative battery lead from the battery terminal To reduce the chance of sparks do not plug in the battery charger until the battery charger leads are connected to the battery Check the charge of the battery as shown in the charts and the following example Example Open circuit voltage 12 0 V Charging time 6 5 hours Charge of the battery 20 30 A Rela...

Page 89: ...d clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process disconnect the battery charger and let the battery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of an MF battery stabilizes about 30 minutes after charging has be...

Page 90: ... amperage for 3 5 minutes Is the standard charging amperage exceeded If the amperage does not exceed the standard charging amperage after 5 minutes replace the battery Adjust the voltage to obtain the standard charging amperage Set the timer to the charging time determined by the open circuit voltage Refer to BATTERY INSPECTION AND CHARGING section If the required charging time exceeds 5 hours it ...

Page 91: ...ging amperage written on the battery Charge the battery until the charging voltage reaches 15 V Set the charging time to a maximum of 20 hours This type of battery charger cannot charge an MF battery A variable voltage charger is recommended Leave the battery unused for more than 30 minutes before measuring its open circuit voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is required Und...

Page 92: ...ity Set the pocket tester selector to Ω 1 6 Install Battery 7 Check Battery terminals Dirt Clean with a wire brush Loose connection Connect properly 8 Lubricate Battery terminal Recommended lubricant Lithium soap base grease 9 Connect Battery leads to the battery terminals First connect the positive lead 1 then the negative lead 2 10 Install Battery cover If the pocket tester indicates replace the...

Page 93: ...amage to the electrical system cause the starting and ignition systems to malfunction and could possibly cause a fire FUSE INSPECTION WARNING Replacement steps Set the main switch to OFF Install a new fuse of the correct amperage Set on the switches to verify if the electrical circuit is operational If the fuse immediately blows again check the electrical circuit Items Amperage rating Qty Main fus...

Page 94: ...K AND SIDE COVERS Extent of removal 1 Seat removal 2 Fuel tank removal 3 Side covers removal 4 Number plate removal Extent of removal Order Part name Q ty Remarks SEAT FUEL TANK AND SIDE COVERS REMOVAL Turn the fuel cock to OFF Preparation for removal 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...

Page 95: ... lb 30 Nm 3 0 m kg 22 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 60 Nm 6 0 m kg 43 ft lb MUFFLER REMOVAL Right side cover Preparation for removal 1 Bolt spark arrester 3 2 Spark arrester 1 3 Nut muffler 2 4 Bolt muffler 1 5 Muffler 1 Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Extent of removal Order Part name Q ty Remarks ...

Page 96: ... 1 2 Over flow hose 1 3 Air vent hose 2 4 Starter plunger starter knob 1 5 Trottle main cable 1 6 Trottle return cable 1 7 Clamp air cleaner joint 1 8 Clamp carburetor joint 1 9 Carburetor 1 Refer to SEAT FUEL TANK AND SIDE COVERS section Loosen the screw air cleaner joint Loosen the screws carburetor joint 1 Extent of removal Order Part name Q ty Remarks ...

Page 97: ... 7 Float pivot pin 1 8 Float 1 9 Needle valve 1 10 Main jet washer 1 11 Needle valve seat holder 1 12 Needle valve seat 1 13 Main jet 1 14 Main jet nozzle 1 15 Pilot jet 1 16 Pilot air jet 1 1 17 Pilot air jet 2 1 18 Pilot air screw 1 19 Throttle stop screw 1 20 Coasting enricher 1 CARBURETOR DISASSEMBLY Refer to REMOVAL POINTS Refer to REMOVAL POINTS 1 Extent of removal Order Part name Q ty Remar...

Page 98: ...NSPECTION Carburetor 1 Inspect Carburetor body Contamination Clean Use a petroleum based solvent for cleaning Blow out all passages and jets with com pressed air Never use a wire 2 Inspect Main jet 1 Main jet nozzle 2 Pilot jet 3 Use a petroleum based solvent for cleaning Blow out all passages and jets with compressed air Never use a wire Needle valve 1 Inspect Needle valve 1 Needle valve seat 2 G...

Page 99: ...uge Keep the carburetor and fuel level gauge vertically when measuring the fuel level If the fuel level is not within specification inspect the needle valve seat and needle valve If either is worn replace them both If both are fine adjust the fuel level by bending the float tab b on the float Recheck the fuel level Fuel level 1 Measure Fuel level a Out of specification Adjust Fuel level 6 0 7 0 mm...

Page 100: ...gm 1 Spring 2 Cover 3 Tears diaphragm damage Replace EC464600 Float 1 Inspect Float 1 Damage Replace Starter plunger 1 Inspect Cold starter plunger 1 Hot starter plunger 2 Wear damage Replace 2 Inspect Throttle shaft 1 Spring 2 Lever 1 3 Spring 1 4 Dirt Clean ...

Page 101: ...ottle valve 4 ASSEMBLY AND INSTALLATION Carburetor 1 Install Diaphragm 1 Spring 2 Cover 3 Screw 4 2 Nm 0 2 m kg 1 4 ft lb LT 3 Install Spring 1 1 To lever 1 2 4 Install Spring 1 To throttle shaft 2 Install the bigger hook a of the spring fits on the stopper b of the throttle shaft pulley TIP ...

Page 102: ...the recess in the carburetor 6 Install O ring Valve lever housing cover Bolt valve lever housing cover 7 Install Pilot jet 1 Main jet nozzle 2 Main jet 3 Needle valve seat 4 Needle valve seat holder 5 Main jet washer 6 8 Install Needle valve 1 Float 2 Float pivot pin 3 After installing the needle valve to the float install them to the carburetor Check the float for smooth movement TIP TIP ...

Page 103: ...er plunger 2 On starter cable 3 9 Install Gasket Float chamber 1 Screw float chamber 2 2 Install Throttle cable pull 1 Throttle cable return 2 3 Install Carburetor assembly Install the projection between the carburetor joint slots 4 Nm 0 4 m kg 2 9 ft lb 11 Nm 1 1 m kg 8 0 ft lb TIP ...

Page 104: ...able cover 2 5 Tighten Screw carburetor joint 1 Screw air carburetor joint 2 4 Nm 0 4 m kg 2 9 ft lb 6 Adjust Throttle grip free play Refer to THROTTLE CABLE ADJUST MENT section in the CHAPTER 3 7 Adjust Idle speed Refer to ENGINE IDLING SPEED ADJUST MENT section in the CHAPTER 3 ...

Page 105: ...MOVAL Seat and fuel tank Preparation for removal 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 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 Extent of removal Order Part name Q ty Remarks 1 ...

Page 106: ...NDER HEAD REMOVAL 1 Bolt camshaft sprocket 1 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 Refer to REMOVAL POINTS CYLINDER HEAD Extent of removal Order Part name Q ty Remarks 1 ...

Page 107: ...gned with the stationary pointer the piston is at the Top Dead Center T D C 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 stationary pointer d on the cylinder head as shown in the illustration 2 Loosen Camshaft sprocket bolt 1 Remove the bolt while holding the rotor nut with a wrench 3 Remove Bolt timing chain tensioner cap ...

Page 108: ...ts starting with the lowest number one INSPECTION Cylinder head 1 Eliminate Carbon deposits from the combustion chambers Use a rounded scraper Do not use a sharp instrument to avoid damaging 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 steps Attach a...

Page 109: ...12 in 2 Install Cylinder head Copper washer Bolt cylinder head 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 illustration Tighten the bolts in two stages M8 22 Nm 2 2 m kg 16 ft lb M6 10 Nm 1 0 m kg 7 2 ft lb Quick gasket ACC QUIC...

Page 110: ...ter d on the cylinder head Fit the timing chain 1 onto camshaft sprocket 2 and install the camshaft sprocket on the camshaft When installing the camshaft sprocket keep the timing chain as tense as possible on the exhaust side Do not turn the crankshaft during installation of the camshaft Damage or improper valve timing will result Remove the safety wire from the timing chain 4 Install Washer Bolt ...

Page 111: ...e screwdriver check the tensioner rod to come out and tighten the gasket 4 and the cap bolt 5 to the specified torque Bolt chain tensioner 10 Nm 1 0 m kg 7 2 ft lb 6 Turn Crankshaft Counterclockwise several turns 7 Check Rotor I mark Align with the crankcase stationary pointer Camshaft match mark Align with the cylinder head stationary pointer Out of alignment Adjust Cap bolt timing chain tensione...

Page 112: ...TER 3 12 Install Timing mark accessing screw 1 Crankshaft end accessing screw 2 10 Apply Engine oil On camshaft 11 Install Tappet cover 1 Cylinder head side cover 2 18 Nm 1 8 m kg 13 ft lb 10 Nm 1 0 m kg 7 2 ft lb 13 Install Spark plug Engine bracket 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb 13 Nm 1 3 m kg 9 4 ft lb 40 Nm 4 0 m kg 29 ft lb ...

Page 113: ...CAMSHAFT AND ROCKER ARMS REMOVAL Cylinder head Preparation for removal 1 Camshaft bearing holder 1 2 Intake rocker arm shaft 1 3 Exhaust rocker arm shaft 1 4 Camshaft 1 5 Intake rocker arm 1 6 Exhaust rocker arm 1 Refer to CYLINDER HEAD section 2 1 Refer to REMOVAL POINTS Extent of removal Order Part name Q ty Remarks ...

Page 114: ...Use a slide hammer bolt 1 and weight 2 to slide out the rocker arm shafts Small slide hammer set YU 1083 A Slide hammer bolt 90890 01085 Weight 90890 01084 Camshaft 1 Remove Camshaft 1 Camshaft bearing 2 Screw in a suitable length of 8 mm bolt 3 into the threaded end of the camshaft and pull out the camshaft Cam lobes length limit Intake a 25 851 mm 1 0178 in b 21 165 mm 0 8333 in Exhaust a 25 811...

Page 115: ...ms and rocker arm shafts 1 Inspect Cam lobe contact surface a Adjuster surface 1 Wear pitting scratches blue discoloration Replace Measurement steps Measure the inside diameter a of the rocker arm holes Out of specification Replace Measure the outside diameter b of the rocker arm shafts Out of specification Replace Inside diameter rocker arm 10 000 10 015 mm 0 3937 0 3943 in Limit 10 03 mm 0 3949 ...

Page 116: ...4 23 ENG 5 Install Camshaft bearing holder 1 Bolt 2 CAMSHAFT AND ROCKER ARMS 10 Nm 1 0 m kg 7 2 ft lb LT ...

Page 117: ...Cylinder head Camshaft and rocker arms Preparation for removal 1 Valve cotter 4 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 Refer to CYLINDER HEAD section Refer to CAMSHAFT AND ROCKER ARMS section Refer to REMOVAL POINTS 1 Extent of removal Order Part name Q ty Remarks ...

Page 118: ...eals properly There should be no leakage at the valve seat 2 2 Remove Valve cotters 1 Attach a valve spring compressor 2 between the valve spring retainer and the cylinder head to remove the valve cotters 3 Remove Valve spring retainer 1 Valve spring 2 Valve 3 Valve stem seal 4 Valve spring seat 5 Identify the position of each part very carefully so that it can be reinstalled in its original place...

Page 119: ...using a valve guide reamer 2 to obtain proper stem to guide clearance INSPECTION Valve 1 Measure Stem to guide clearance Stem to guide clearance valve guide inside diameter a valve stem diameter b Out of specification Replace the valve guide Clearance stem to guide Intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 08 mm 0 0031 in Exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 10 mm 0 0040 in Valve g...

Page 120: ...ce 4 Measure Margin thickness a Out of specification Replace Margin thickness Intake 0 4 0 8 mm 0 0157 0 0315 in Exhaust 0 8 1 2 mm 0 0315 0 0472 in When installing a new valve always replace the guide If the valve is removed or replaced always replace the oil seal 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 Refac...

Page 121: ...m b 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 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 VALVES ANDVALVE SPRINGS 8 Measure Valve ...

Page 122: ...orth between your hands Apply a fine lapping compound to the valve face and repeat the above steps After every 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 v...

Page 123: ... 3 kgf at 25 6 mm 42 93 49 23 lbf at 1 01 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 Make sure that each valve is installed in its original place Install the valve springs with the larger pitch a facing upwards b Smaller pitch Spring t...

Page 124: ...ve spring with a valve spring compressor 2 install the valve cotters 4 To secure the valve cotters onto the valve stem lightly tap the valve tip with a piece of wood Hitting the valve tip with excessive force could damage the valve Valve spring compressor YM 4019 90890 04019 TIP NOTICE ...

Page 125: ...l pin 2 4 Gasket 1 5 Piston pin clip 2 6 Piston pin 1 7 Piston 1 8 Piston ring set 1 Extent of removal 1 Cylinder removal 2 Piston removal CYLINDER AND PISTON REMOVAL Cylinder head Preparation for removal Refer to CYLINDER HEAD section Refer to REMOVAL POINTS Extent of removal Order Part name Q ty Remarks 1 1 ...

Page 126: ...ston 3 Before removing the piston pin clip cover the crankcase opening with a clean towel or rag to prevent the clip from falling into the crankcase cavity Before removing each piston pin deburr the clip groove and 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 Piston pin puller set YU 1304 90890 01304 INSPECTION Cylin...

Page 127: ...ximum 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 rings...

Page 128: ...rings as a set 2 Measure Piston pin to piston clearance Measurement steps Measure the piston pin outside diameter a If out of specification replace the piston pin Measure the piston inside diameter b If out of specification replace the piston Outside diameter piston pin 14 991 15 000 mm 0 5902 0 5906 in Limit 14 971 mm 0 5894 in Inside diameter piston 15 002 15 013 mm 0 5906 0 5911 in Limit 15 043...

Page 129: ... the oil control ring rails show excessive gap replace all three rings Piston ring 1 Measure Ring side clearance Use a feeler gauge Out of specification Replace the piston and rings as a set Clean carbon from the piston ring grooves and rings before measuring the side clearance Side clearance Standard Limit Top 0 035 0 090 mm 0 12 mm Ring 0 0014 0 0035 in 0 0047 in 2nd 0 020 0 060 mm 0 12 mm Ring ...

Page 130: ... 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 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 into the cr...

Page 131: ...hand while compressing the piston rings with the other hand Pass the timing chain through the cylinder timing chain cavity Be careful not to damage the timing chain guide during installation After installing check the smooth movement of the piston Cylinder 1 Install Dowel pins 1 Gasket cylinder 2 New New NOTICE TIP ...

Page 132: ...riction plate 5 9 Clutch plate 4 10 Nut washer 1 1 11 Push rod 1 1 12 Push plate 1 Extent of removal 1 Clutch plate and friction plate removal CLUCTH PLATE AND FRICTION PLATE REMOVAL Preparation for removal Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Refer to ENGINE REMOVAL section Refer to ELECTRIC STARTING SYSTEM section in the CHAPTER 6 Drain the engine oil Engine skidplate Starter...

Page 133: ...hrust plate 1 5 Primary driven gear 1 6 Nut primary drive gear 1 7 Primary drive gear 1 8 Straight key 1 Extent of removal 1 Primary driven gear removal 2 Primary drive gear removal PRIMARY DRIVEN GEAR REMOVAL Extent of removal Order Part name Q ty Remarks 2 1 Refer to REMOVAL POINTS Use special tool Refer to REMOVAL POINTS ...

Page 134: ...H LEVER Extent of removal 1 Push lever removal 1 Clutch cable 1 2 Push lever 1 3 Spring 1 4 Circlip 1 5 Oil seal 1 PUSH LEVER REMOVAL 1 Extent of removal Order Part name Q ty Remarks CLUTCH AND PRIMARY DRIVEN GEAR ...

Page 135: ...h boss 1 Remove Nut 1 Lock washer Clutch boss 2 Straighten the lock washer tab and use the clutch holding tool 3 to hold the clutch boss Clutch holding tool YM 91042 90890 04086 A For USA and CDN B Except for USA and CDN 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 driven gear 1...

Page 136: ...g free length a Out of specification Replace springs as a set Clutch spring free length 33 mm 1 30 in Limit 31 mm 1 22 in 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 137: ...nstall Straight key Primary drive gear 1 Washer 2 Nut primary drive gear 3 Primary driven gear 4 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 gear Push rod 1 Inspect Push rod 1 1 Ball 2 Wear damage bend Replace Primary drive gear 1 Inspect Primary drive gear Wear damage Replace 70 Nm...

Page 138: ...h 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 projection a offset approximately 90 from previous plates projection Continue this procedure in a clockwise direction until all clutch plates are installed Clutch holding tool...

Page 139: ...ghten the bolts in stage using a crisscross pattern 5 Install Ball Apply the engine oil on the ball 6 Install Push rod 1 1 Push plate 2 Washer 3 Nut push rod 1 4 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 6 Nm 0 6 m kg 4 3 ft lb TIP TIP ...

Page 140: ...the kickstarter crank so that there is 5 10 mm 0 2 0 4 in a between the kickstarter crank and the right crankcase cover 50 Nm 5 0 m kg 36 ft lb 10 Install Dowel pins Gasket right crankcase cover Right crankcase cover Negative battery lead 1 Lead holder 2 Bolts right crankcase cover Apply Quick gasket YAMAHA Bond No 1215 to end of the right crankcase cover bolts as shown Tighten the bolts in stages...

Page 141: ... gear 1 3 Oil pump assembly 1 4 Gasket 1 5 Oil strainer 1 Extent of removal 1 Oil pump removal OIL PUMP REMOVAL Preparation for removal Clutch and primary drive gear Refer to CLUTCH AND PRIMARY DRIVEN GEAR section Extent of removal Order Part name Q ty Remarks 1 ...

Page 142: ...r 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 10 Inner rotor 1 11 Outer rotor 1 12 Oil pump housing 1 Extent of removal 1 Oil pump disassembly OIL PUMP DISASSEMBLY Extent of removal Order Part name Q ty Remarks 1 ...

Page 143: ...and the rotors 1 2 Out of specification Replace the oil pump assembly INSPECTION Oil pump 1 Inspect Oil pump drive gear Oil pump driven gear Oil pump housing Oil pump cover Cracks wear damage Replace Rotary filter 1 Inspect Rotary filter Cracks damage Replace Tip clearance A 0 15 mm 0 0059 in Limit 0 20 mm 0 0079 in Side clearance B 0 06 0 10 mm 0 0024 0 0039 in Limit 0 15 mm 0 0059 in Housing and...

Page 144: ...e conical spring washer in the direction as shown 2 Install Oil strainer Gasket Oil pump assembly Screws oil pump assembly Apply engine oil onto the crankcase oil passage and oil pump assembly 3 Install Oil pump drive gear 1 Rotary filter 2 Install the rotary filter with the dog a facing out Align the rotary filter dog a with groove b of the crankshaft Oil strainer 1 Inspect Oil strainer Cracks da...

Page 145: ...rclip 1 3 Washer 1 4 Kick idle gear 1 5 Washer 1 6 Shift shaft 1 7 Circlip 1 8 Torsion spring 1 9 Bolt stopper lever 1 10 Stopper lever 1 11 Spring 1 12 Segment 1 Refer to REMOVAL POINTS KICK AXLE AND SHIFT SHAFT REMOVAL Preparation for removal Refer to ENGINE REMOVAL section Shift pedal link Clutch Refer to CLUTCH AND PRIMARY DRIVEN GEAR section Extent of removal Order Part name Q ty Remarks 2 1 ...

Page 146: ...sure Kick axle clip friction force torsion spring Out of specification Replace Use a spring gauge 1 INSPECTION Kick axle and ratchet wheel 1 Check Ratchet wheel smooth movement Unsmooth movement Replace 2 Inspect Kick axle 1 Wear damage Replace Kickstarter segment gear and kick idle gear 1 Inspect Ratchet idle gear 1 Kickstarter segment gear 2 Kick idle gear 3 Gear teeth a Wear damage Replace Kick...

Page 147: ...sing the T30 bit EC4B4400 Shift shaft 1 Inspect Shift shaft 1 Bend damage Replace Spring 2 Broken Replace EC4B4500 Stopper lever 1 Inspect Stopper lever 1 Wear damage Replace Torsion spring 2 Broken Replace Stopper lever 1 Install Stopper lever 1 Bolt stopper lever 2 Torsion spring 3 Align the stopper lever roller with the slot on segment 12 Nm 1 2 m kg 8 7 ft lb LT 10 Nm 1 0 m kg 7 2 ft lb LT TIP...

Page 148: ...of the left crankcase side Hook the spring ends onto the stopper 2 Kick axle assembly 1 Install Ratchet idle gear 1 Kickstarter segment gear 3 Plain washer 2 Torsion spring 4 On kick axle 5 Make sure the stopper a of the torsion spring fits into the hole b on the kick axle 2 Install Spring guide 1 Slide the spring guide into the kick axle make sure the groove a in the spring guide fits on the stop...

Page 149: ... AND SHIFT SHAFT Kick idle gear 1 Install Washer 1 Kick idle gear 2 Washer 3 Circlip 4 Apply the engine oil on the kick idle gear inner circumference Install the kick idle gear with its depressed side toward you New TIP ...

Page 150: ...uff 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 assembly 1 Extent of removal 1 Pickup coil stator removal 2 Starter clutch wheel gear removal CDI MAGNETO AND STATOR REMOVAL Preparation for removal Fuel tank Use special tool Refer to REMOVAL POINTS 2 Extent of removal Order Part name Q ty Remarks 1 1 ...

Page 151: ...tor 1 Use the flywheel puller 2 Flywheel puller YU 33270 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 Starter clutch 1 Check Starter clutch Damage wear Replace 2 Check Idle gear Starter clutch gear Pitting burrs chips roughness ...

Page 152: ...er clutch is faulty and must be replaced When turning the starter clutch drive gear clockwise A it should turn freely If the starter clutch drive gear does not turn freely the starter clutch is faulty and must be replaced EC4L5000 ASSEMBLY AND INSTALLATION CDI magneto 1 Install Stator 1 Bolt stator Lead guide Screw lead guide 2 Pickup coil 3 Bolt pickup coil 10 Nm 1 0 m kg 7 2 ft lb LT 7 Nm 0 7 m ...

Page 153: ...tall the starter clutch 1 on the rotor 2 Install the starter clutch with its plate portion a facing the rotor Insert the plate portion of the starter clutch so that it is flush with the surface of contact b with the rotor 4 Tighten Bolt starter clutch Caulk a the end of the starter clutch holding bolt near its outer diameter to serve as a stopper 30 Nm 3 0 m kg 22 ft lb 6 Install Plain washer 1 Nu...

Page 154: ...TER CLUTCH 7 Install Crankcase cover left 8 Connect Neutral switch lead 1 Pass the neutral switch lead into the crankcase cover groove as shown 9 Connect CDI magneto lead Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 TIP ...

Page 155: ...lead Disconnect the neutral switch lead Starter motor Drain the engine oil Extent of removal 1 Engine removal Preparation for removal Refer to SEAT FUEL TANK AND SIDE COVERS section Refer to CARBURETOR section Refer to MUFFLER section Disconnect at engine side Refer to ELECTRIC STARTING SYSTEM section in the CHAPTER 6 Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Extent of removal Order...

Page 156: ...rocket 2 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 Extent of removal Order Part name Q ty Remarks 1 ...

Page 157: ... cables 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 40 Nm 4 0 m kg 29 ft lb 40 Nm 4 0 m kg 29 ft lb 40 Nm 4 0 m kg 29 ft lb...

Page 158: ... bracket 9 Shift pedal link 1 Install Shift pedal link 1 Bolt shift pedal link 2 Adjust the center a of the front end of the shift pedal to match the highest point of the footrest Drive sprocket 1 Install Drive sprocket 1 Drive chain 2 Install the drive sprocket together with the drive chain 3 Install Drive sprocket cover 1 Bolt drive sprocket cover 2 12 Nm 1 2 m kg 8 7 ft lb 6 Nm 0 6 m kg 4 3 ft ...

Page 159: ...tor and starter clutch Extent of removal 1 Crankcase separation 2 Balancer removal 3 Crankshaft removal Preparation for removal Refer to ENGINE REMOVAL section Refer to CYLINDER AND PISTON section Refer to CLUTCH AND PRIMARY DRIVEN GEAR section Refer to KICK AXLE AND SHIFT SHAFT section Refer to CDI MAGNETO AND STARTER CLUTCH section Extent of removal Order Part name Q ty Remarks ...

Page 160: ...t 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 9 Left crankcase 1 10 Balancer 1 11 Crankshaft 1 12 Bearing 3 Use special tool Refer to REMOVAL POINTS Use special tool Refer to REMOVAL POINTS Refer to REMOVAL POINTS Extent of removal Order Part name Q ty Remarks 1 2 3 ...

Page 161: ... 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 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 sepa rate evenly If one end hangs up take pres sure off the push scr...

Page 162: ...bearing Crankshaft 1 Remove Crankshaft 1 Use the crankcase separating tool 2 Do not use a hammer to drive out the crank shaft 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 Crankcase separating tool YU 1135 A 90890 01135 NOTICE TIP ...

Page 163: ...ce 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 0 03mm limit 0 0012 in Side 0 15 0 45 mm 0 50 mm clearance 0 0059 0 0177 in 0 02 in Crack 46 95 47 00 mm width 1 848 1 850 in ...

Page 164: ... surface of crankcase Do not use a hammer to drive in the crank shaft Balancer 1 Inspect Balancer Cracks damage Replace ASSEMBLY AND INSTALLATION Bearing 1 Install Bearing 1 On crankcase left and right Install the bearing by pressing its outer race parallel Crankshaft 1 Install Crankshaft 1 Use the crankshaft installing tool 2 3 4 5 Crankshaft installing tool Crankshaft installer pot 2 YU 90050 90...

Page 165: ...he crankcase the connect ing rod should be positioned atTDC top dead center 2 Install Balancer Align the punched mark a on the balancer drive gear with the punched mark b on the balancer driven gear Crankcase 1 Apply Sealant On the right crankcase 1 Quick gasket ACC QUICK GS KT YAMAHA Bond No 1215 90890 85505 Clean the contacting surface of crankcase left and right before applying the sealant TIP ...

Page 166: ...nkcase 30 mm 1 2 in 5 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb Apply Quick gasket YAMAHA Bond No 1215 on end of the crankcase 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 5 Install Timing chain 1 Intake timing chain guide 2 Bolt intake timing chain guide 1...

Page 167: ...fork 1 L 1 7 Main axle 1 8 Drive axle 1 9 Push rod 2 1 10 Washer 1 Extent of removal 1 Shift cam and shift fork removal 2 Main axle and drive axle removal Preparação para remoção TRANSMISSION SHIFTCAM AND SHIFT FORK REMOVAL Engine Separate the crankcase Refer to REMOVAL POINTS Refer to ENGINE REMOVAL section Refer to CRANKCASE CRANKSHAFT AND BALANCER section Extent of removal Order Part name Q ty ...

Page 168: ...ap lightly on the transmission drive axle with a soft hammer to remove Remove assembly carefully Note the position 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 Push rod 1 Inspect Push rod 2 1 Wear damage bend Replace TIP ...

Page 169: ...ate inner race with a finger Rough spot seizure Replace Shift fork and shift cam 1 Inspect Shift fork 1 Wear damage scratches Replace 3 Check Shift fork movement On its guide bar Unsmooth operation Replace shift fork and or guide bar For a malfunctioning shift fork replace not only the shift fork itself but the two gears each adja cent to the shift fork TIP ...

Page 170: ...n axle 5 Apply the molybdenum disulfide oil on the gears inner circumference Install the 5th pinion gear so that measurement 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 Apply the molybdenum disulfide oil on the gears inner circumference TIP TIP ...

Page 171: ... Apply the lithium soap base grease on the oil seal lip When installing the drive axle into the crankcase pay careful attention to the crankcase oil seal lip 5 Install Washer 1 On drive axle 3 Install Plain washer 1 Circlip 2 Be sure the circlip sharp edged corner a is positioned opposite side to the plain washer and gear b Be sure the circlip end c is positioned at axle spline groove d New TIP TI...

Page 172: ...and the short one into 2 Shift cam and shift fork 1 Install Shift fork 1 L 1 Shift fork 2 C 2 Shift fork 3 R 3 Mesh the shift fork 1 L with the 2nd wheel gear and 3 R with the 4th wheel gear on the drive axle Mesh the shift fork 2 C with the 3rd pinion gear on the main axle 2 Install Shift cam 1 Apply the engine oil on the shift cam 4 Check Shifter operation Transmission operation Unsmooth operati...

Page 173: ...e cable 1 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 Wheel bearing 2 10 Spacer 1 Extent of removal Order Part name Q ty Remarks FRONT WHEEL AND DRUM BRAKE Hold the machine by placing the suitable stand under the engine Preparation for removal Support the machine securely so there is no danger of it falling over Disconnect at the lever si...

Page 174: ...S 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 FRONTWHEEL AND FRONT BRAKE TT R125E Extent of removal Order Part name Q ty Remarks 1 ...

Page 175: ...g 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 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 The bending value is shown by one half of the dial gauge reading Do not attempt to straighten a bent axle WARNI...

Page 176: ...kness a Out of specification Replace Drum brake 1 Inspect Brake shoe lining surface Glazed areas Polish Use coarse sand paper After polishing wipe the polished particles with a cloth Replace the brake shoes and springs as a set if either is worn to the limit 3 Measure Brake drum inside diameter a Out of specification Replace Brake drum inside diameter Standard Limit 110 mm 111 mm 4 33 in 4 37 in 4...

Page 177: ...N Brake shoe plate assembly 1 Install Brake camshaft 1 Apply the lithium soap base grease on the brake camshaft 2 Check Brake camshaft operation Unsmooth operation Repair 4 Install Brake camshaft lever 1 Install the brake camshaft lever in relation to the punch mark a as shown 5 Install Springs 1 Brake shoes 2 Apply the lithium soap base grease on the pivot pin Do not apply grease to the brake sho...

Page 178: ...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 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 Apply the lithium soap base grease on the oil seal lip New 3 Install Front wheel Make sure that the...

Page 179: ...cable holder 1 5 Install Axle nut 1 6 Install Brake cable Brake camshaft lever side of brake cable shall be installed first 8 Adjust Brake lever free play Refer to FRONT BRAKE ADJUSTMENT section in the CHAPTER 3 45 Nm 4 5 m kg 32 ft lb 7 Nm 0 7 m kg 5 1 ft lb TIP ...

Page 180: ...3 Wheel axle 1 4 Front wheel 1 5 Collar 2 6 Oil seal 2 7 Wheel bearing 2 8 Spacer 1 9 Brake disk 1 FRONTWHEEL REMOVAL Hold the machine by placing the suitable stand under the engine Preparation for removal Refer to REMOVAL POINTS 2 1 3 3 Extent of removal Order Part name Q ty Remarks Support the machine securely so there is no danger of it falling over WARNING ...

Page 181: ... 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 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 The bending value is shown by one half of the dial gauge reading Do not attempt to straighten a bent axle WARNING Wheel...

Page 182: ...Y AND INSTALLATION Front wheel 1 Install Wheel bearing 1 Spacer 2 Wheel bearing 3 Oil seal 4 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 diameter of the race of the bearing Left side of wheel bearing shall be installed first Install the oil seal w...

Page 183: ...rake disc 1 Bolt brake disc 2 Tighten the bolts in stage using a crisscross pattern 3 Install Collar 1 Apply the lithium soap base grease on the oil seal lips Install the longer collar on the brake disc 2 side 5 Install Wheel axle 1 6 Install Washer 1 Axle nut 2 45 Nm 4 5 m kg 32 ft lb 12 Nm 1 2 m kg 8 7 ft lb LT TIP TIP TIP ...

Page 184: ...master cylinder 1 Extent of removal 1 Brake hose removal 2 Brake caliper removal 3 Brake master cylinder removal FRONT BRAKE REMOVAL Hold the machine by placing the suitable stand under the engine Drain the brake fluid Preparation for removal Refer to REMOVAL POINTS Refer to REMOVAL POINTS 3 2 1 2 3 Extent of removal Order Part name Q ty Remarks Support the machine securely so there is no danger o...

Page 185: ...ter cylinder boot 1 11 Circlip 1 12 Washer 1 13 Brake master cylinder kit 1 Extent of removal 1 Brake caliper disassembly 2 Brake master cylinder disassembly BRAKE CALIPER AND BRAKE MASTER CYLINDER DISASSEMBLY Hold the machine by placing the suitable stand under the engine Preparation for removal Refer to REMOVAL POINTS 1 2 FRONT BRAKE TT R125LE Extent of removal Order Part name Q ty Remarks Suppo...

Page 186: ...uitable container under its end 3 Loosen the bleed screw and drain the brake fluid while pulling in the lever Do not reuse the drained brake fluid Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately Brake caliper 1 Remove Brake caliper 1 Turn the brake caliper counterclockwise and pull out it from the guide pin 2 on the brake caliper bracket WARNING Br...

Page 187: ...r dust seals Replace the brake caliper piston seals and brake caliper dust seals whenever a brake caliper is disassembled WARNING INSPECTION Brake master cylinder 1 Inspect Brake master cylinder inner surface a Wear scratches Replace brake master cylinder assembly Stains Clean Use only new brake fluid 2 Inspect Diaphragm 1 Crack damage Replace WARNING 3 Inspect Brake master cylinder piston 1 Brake...

Page 188: ...d Brake caliper 1 Inspect Brake caliper cylinder inner surface a Wear score marks Replace brake caliper assembly Brake hose 1 Inspect Brake hose 1 Crack damage Replace 4 Inspect Brake caliper support bolt 1 Scorches rust damage Replace 3 Inspect Brake caliper bracket 1 Cracks damage Replace the brake caliper assembly Guide pin 2 Rust damage Replace the brake caliper assembly Sleeve boot 3 Pin boot...

Page 189: ...hem with brake fluid 2 Install Brake caliper piston seal 1 Brake caliper dust seal 2 Always use new brake caliper piston seals and brake caliper dust seals Fit the brake caliper piston seals and brake caliper dust seals onto the slot on brake caliper correctly 3 Install Brake caliper piston 1 Apply the brake fluid on the brake caliper piston wall Install the brake caliper piston with its shallow d...

Page 190: ... the pin boot inner surface 3 Install Brake caliper bracket 1 Bolt brake caliper bracket 2 Brake pad 3 4 Install Brake caliper 1 Apply the lithium soap base grease on the guide pin 2 Install the brake caliper into the guide pin and turn it clockwise Brake master cylinder kit 1 Clean Brake master cylinder Brake master cylinder kit Clean them with brake fluid 30 Nm 3 0 m kg 22 ft lb 22 Nm 2 2 m kg 1...

Page 191: ...nder piston 3 Apply the brake fluid on the brake master cylinder cup After installing cylinder cup should be in stalled as shown direction Wrong installa tion cause improper brake performance 4 Install Brake master cylinder kit 1 Washer 2 Circlip 3 Brake master cylinder boot 4 On brake master cylinder 5 Apply the brake fluid on the brake master cylinder kit When installing the circlip use a long n...

Page 192: ... 2 Install Brake lever 1 Spring 2 Bolt brake lever 3 Nut brake lever 4 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 Brake hose 1 Install Copper washer 1 Brake hose 2 Union bolt 3 Always use new copper washers Install the brake hose so that its pipe por tion a directs as show and lightly touches ...

Page 193: ... copper washer When turning the joint over the brake hose hold the brake hose so that it may not be twisted 4 Install Brake hose holder 1 Bolt brake hose holder 2 WARNING 7 Nm 0 7 m kg 5 1 ft lb 3 Install Copper washer 1 Joint 2 Brake hose 3 26 Nm 2 6 m kg 19 ft lb 14 Nm 1 4 m kg 10 ft lb New TIP ...

Page 194: ...d poor brake performance Refill with the same type of brake fluid mixing fluids may result in a harmful chemical reaction and lead to poor performance Be careful that water does not enter the brake master cylinder when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may erode painted surfaces or plastic parts Always clean up spilled ...

Page 195: ...linder cap 1 Screw brake master cylinder cap 2 After installation while pulling in the lever check whether there is any brake fluid leak ing where the union bolts are installed re spectively at the brake master cylinder and brake caliper 2 Nm 0 2 m kg 1 4 ft lb NOTICE ...

Page 196: ...oe plate assembly 1 10 Collar left 1 Extent of removal 1 Rear wheel removal 2 Wheel bearing removal 3 Brake shoe plate assembly removal and disassembly REAR WHEEL AND DRUM BRAKE Hold the machine by placing the suitable stand under the engine Preparation for removal Refer to REMOVAL POINTS 1 2 3 Extent of removal Order Part name Q ty Remarks Support the machine securely so there is no danger of it ...

Page 197: ...l seal 1 14 Wheel bearing 2 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 Refer to REMOVAL POINTS 2 3 Extent of removal Order Part name Q ty Remarks REARWHEEL AND REAR BRAKE ...

Page 198: ...essary 1 Remove Bearing 1 Remove the bearing using a general bearing puller2 2 Inspect Bearing Rotate inner race with a finger Rough spot seizure Replace 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 gauge 1 Wheel...

Page 199: ...nspect Brake shoe lining surface Glazed areas Polish Use coarse sand paper After polishing wipe the polished particles with a cloth 2 Measure Brake shoe lining thickness a Out of specification Replace Brake shoe lining thickness Standard Limit 4 0 mm 2 0 mm 0 16 in 0 08 in Replace the brake shoes and springs as a set if either is worn to the limit Brake drum inside diameter Standard Limit 110 mm 1...

Page 200: ...SEMBLY AND INSTALLATION Brake shoe plate assembly 1 Install Brake camshaft 1 Apply the lithium soap base grease on the brake camshaft 3 Install Wear indicator plate 1 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 Install the brake camshaft lever in relation to...

Page 201: ...g shall be installed first Install the oil seal with its manufacture s marks or numbers facing outward Do not strike the inner race of the bearing Contact should be made only with the outer race 5 Install Springs 1 Brake shoes 2 On brake shoe plate 3 Apply the lithium soap base grease on the pivot pin When installing the springs and brake shoes take care not to damage the springs When replacing th...

Page 202: ... crisscross pattern Bend the lock washer tab New 43 Nm 4 3 m kg 31 ft lb 3 Install Collar left Brake shoe plate assembly Collar right Apply the lithium soap base grease on the oil seal lip 5 Install Drive chain 1 Push the wheel 1 forward and install the drive chain 6 Install Drive chain puller left 1 Plain washer 2 Wheel axle 3 Apply the lithium soap base grease on the wheel axle Insert the wheel ...

Page 203: ...ten the axle nut at this point 9 Tighten Axle nut 1 Refer to DRIVE CHAIN SLACK ADJUST MENT section in the CHAPTER 3 Drive chain slack 35 50 mm 1 4 2 0 in 10 Install Spring 1 Brake rod 2 Pin 3 Wing nut 4 On brake camshaft lever 5 60 Nm 6 0 m kg 43 ft lb 11 Adjust Brake pedal free play Refer to REAR BRAKE ADJUST MENT section in the CHAPTER 3 TIP ...

Page 204: ... Part name Q ty Remarks FRONT FORK REMOVAL Hold the machine by placing the suitable stand under the engine Preparation for removal Front wheel Refer to FRONT WHEEL AND FRONT BRAKE section for the TT R125E Refer to FRONT WHEEL section for the TT R125LE Handlebar Refer to HANDLEBAR section 1 A TT R125E B TT R125LE Support the machine securely so there is no danger of it falling over WARNING 23 Nm 2 ...

Page 205: ... 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 7 Stopper ring 1 1 8 Bolt damper rod 1 1 9 Damper rod 1 1 Use special tool 10 Inner tube 1 1 Refer to REMOVAL POINTS 11 Oil flow stopper 1 1 12 Piston metal 1 1 13 Oil seal 1 1 14 Outer tube 1 1 Extent of removal Order Part name Q ty Remarks FRONT FORK DISASSEMBLY 1 2 ...

Page 206: ...that the front fork be maintained at the dealers To prevent an accidental explosion of air the following instructions should be observed The front fork with a built in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign mate rial Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disassemble...

Page 207: ...e EC554000 INSPECTION Damper rod 1 Inspect Damper rod Bend damage Replace damper rod The front fork with a built in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign mate rial 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 NOTICE NOTICE ...

Page 208: ...Fork spring free length a Out of specification Replace The bending value is shown by one half of the dial gauge reading Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube 2 Inspect Piston metal 1 Wear damage Replace Inner tube bending limit 0 2 mm 0 008 in WARNING Fork spring free length Standard Limit TT R125E 472 2 mm 18 59 in TT R125LE 463 9 mm 18 23 in TT R1...

Page 209: ... On inner tube 4 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 Outer tube 1 Inspect Outer tube 1 Slide metal 2 Score marks wear damage Replace outer tube assembly Cap bolt 1 Inspect Cap bolt 1 O ring 2 Wear damage Replace NOTICE ...

Page 210: ...er tube with fork seal driver attachment ø30 2 and fork seal driver weight 3 4 Install Copper washer Bolt damper rod Use the damper rod holder 1 and the T handle 2 to lock the damper rod New 23 Nm 2 3 m kg 17 ft lb LT Damper rod holder YM 1300 90890 01294 T handle YM 01326 90890 01326 6 Install Stopper ring 1 Fit the stopper ring correctly in the groove in the outer tube New Fork seal driver weigh...

Page 211: ...ure to use recommended 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 distribute the fork oil Recommended oil Fork oil 10W or equivalent Quantity each front fork leg TT R125E 171 cm3 6 02 Imp oz 5 78 US oz TT ...

Page 212: ...tion Adjust Standard oil level TT R125E 120 mm 4 72 in TT R125LE 134 mm 5 27 in From the top of the inner tube with the inner tube fully compressed and without the fork spring 13 Install Fork spring Washer Spacer TT R125E Cap bolt 1 Dust boot Temporarily tighten the cap bolt A TT R125E B TT R125LE 23 Nm 2 3 m kg 17 ft lb 3 Adjust Front fork top end a Front fork top end standard a Zero mm Zero in A...

Page 213: ... bolt upper bracket 2 Screw dust boot 3 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 5 Install TT R125E Cap 1 60 Nm 6 0 m kg 43 ft lb 25 Nm 2 5 m kg 18 ft lb TIP ...

Page 214: ...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 2 10 Throttle grip assembly 1 11 Collar 1 12 Handlebar grip left 1 13 Main switch 1 14 Handlebar holder 2 15 Handlebar 1 Refer to REMOVAL POINTS HANDLEBAR REMOVAL Number plate Preparation for removal 1 EC5B0000 HANDLEBAR TT R125E ...

Page 215: ...ver 1 3 Engine stop switch 1 4 Brake master cylinder 1 5 Start switch 1 6 Grip cap lower 1 7 Grip cap upper 1 8 Throttle cable 2 9 Throttle grip assembly 1 10 Handlebar grip left 1 11 Main switch 1 12 Upper handlebar holder 2 13 Handlebar 1 Refer to REMOVAL POINTS HANDLEBAR REMOVAL Number plate Preparation for removal 1 Refer to REMOVAL POINTS ...

Page 216: ...DISASSEMBLY 1 Handlebar grip right 1 2 Collar 1 3 Tube guide 1 Extent of removal 1 Throttle grip assembly disassembly THROTTLE GRIP ASSEMBLY DISASSEMBLY Refer to REMOVAL POINTS 1 HANDLEBAR Extent of removal Order Part name Q ty Remarks ...

Page 217: ...ke master cylinder cap side horizontal to prevent air from coming in Handlebar grip 1 Remove Handlebar grip 1 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 Do not attempt to straighten a bent handle bar as this may dangerously weaken the handlebar WARNING NOTICE TIP ...

Page 218: ... 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 the bolts on the rear side ASSEMBLY AND INSTALLATION Throttle grip assembly 1 Install Collar 1 Handlebar grip right 2 Apply the adhesive on the tube guide 3 Before applying the adhesive wipe off grease or oil on the tube guide surface a with a lac...

Page 219: ...p left 1 Apply the adhesive to the handlebar 2 Before applying the adhesive wipe off grease or oil on the handlebar surface a with a lacquer thinner 3 Install TT R125E Collar 1 5 Install Grip cap lower 1 Grip cap upper Screw grip cap Cover grip cap 2 After tightening the screws check that the throttle grip 1 moves smoothly If it does not retighten the bolts for adjustment 4 Nm 0 4 m kg 2 9 ft lb W...

Page 220: ...ake cable end TT R125LE Start switch 1 Brake master cylinder 2 Brake master cylinder bracket 3 Bolt brake master cylinder bracket 4 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 4 Nm 0 4 m kg 2 9 ft lb 9 Nm 0 9 m kg 6 5 ft lb TIP TIP ...

Page 221: ...STMENT section in the CHAPTER 3 Clutch lever free play Refer to CLUTCH ADJUSTMENT section in the CHAPTER 3 7 Install Engine stop switch 1 Clutch lever holder 2 Screws 3 The engine stop switch and clutch lever holder should be installed according to the dimensions shown Pass the engine stop switch lead in the middle of the clutch lever holder 4 Nm 0 4 m kg 2 9 ft lb TIP TIP ...

Page 222: ... REMOVAL Hold the machine by placing the suitable stand under the engine Preparation for removal Use special tool Refer to REMOVAL POINTS Front forks Refer to FRONT FORK section Handlebar Refer to HANDLEBAR section Front fender 2 1 Support the machine securely so there is no danger of it falling over WARNING 110 Nm 11 0 m kg 80 ft lb 10 Nm 1 0 m kg 7 2 ft lb 25 Nm 2 5 m kg 18 ft lb 60 Nm 6 0 m kg ...

Page 223: ...ace lower 1 13 Bearing lower 1 Refer to REMOVAL POINTS 2 STEERING Extent of removal Order Part name Q ty Remarks 110 Nm 11 0 m kg 80 ft lb 10 Nm 1 0 m kg 7 2 ft lb 25 Nm 2 5 m kg 18 ft lb 60 Nm 6 0 m kg 43 ft lb Tighten ring nut 38 Nm 3 8 m kg 27 ft lb Loosen it one turn Retighten it 20 Nm 2 0 m kg 14 ft lb ...

Page 224: ...3000 REMOVAL POINTS EC563202 Ring nut 1 Remove Ring nut 1 Use the steering nut wrench 2 Support the steering shaft so that it may not fall down WARNING EC563300 Bearing lower 1 Remove Bearing lower 1 Use the floor chisel 2 Take care not to damage the steering shaft thread EC564000 INSPECTION Steering stem 1 Inspect Steering stem 1 Bend damage Replace NOTICE ...

Page 225: ...ang up or 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 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 Apply t...

Page 226: ...steering shaft by turning it lock to lock If there is any binding remove the steering shaft assembly and inspect the steering bearings 7 Install Upper bracket 1 Steering stem nut 2 Starter knob bracket 3 Do not tighten the steering stem nut yet 4 Install Lower bracket 1 Apply the lithium soap base grease on the bearing 20 Nm 2 0 m kg 14 ft lb 10 Nm 1 0 m kg 7 2 ft lb 8 Install Front forks 1 Tempor...

Page 227: ...After tightening the nut check the steering for smooth movement If not adjust the steering by loosening the ring nut little by little 12 Adjust Front fork top end a Front fork top end standard a Zero mm Zero in 13 Tighten Pinch bolts lower bracket 1 Pinch bolts upper bracket 2 60 Nm 6 0 m kg 43 ft lb 25 Nm 2 5 m kg 18 ft lb ...

Page 228: ... Bolt rear shock absorber relay arm 1 5 Pivot shaft 1 6 Swingarm 1 Extent of removal Order Part name Q ty Remarks SWINGARM REMOVAL Hold the machine by placing the suitable stand under the engine Preparation for removal Rear wheel Refer to REAR WHEEL AND REAR BRAKE section Hold the swingarm 1 Support the machine securely so there is no danger of it falling over WARNING ...

Page 229: ...rive 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 10 Bushing 1 11 Relay arm 1 12 Dust cover 2 13 Bushing 1 14 Swingarm 1 SWINGARM DISASSEMBLY EC578000 SWINGARM DISASSEMBLY SWINGARM Extent of removal Order Part name Q ty Remarks 1 2 3 ...

Page 230: ...nds cracks Replace REMOVAL POINTS Bushing 1 Remove Bushing 1 Remove the bushing by pressing 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 Damag...

Page 231: ... connecting arm and relay arm Swingarm assembly 1 Install Bushing 1 Dust covers 2 On swingarm Apply the molybdenum disulfide grease on the bushing and dust cover lip Connecting arm 1 Inspect Collar 1 Bushing 2 Damage pitting Replace collar and bushings as a set 2 Inspect Dust cover 3 Damage Replace 3 Inspect Connecting arm 4 Damage bends cracks Replace TIP TIP ...

Page 232: ...2 Bushing 3 Dust covers 4 Dust covers 5 Rubber boot 6 On relay arm Apply the molybdenum disulfide grease on the bushing collar oil seal lip and dust cover lip 4 Install Relay arm 1 Bolt relay arm Plain washer Nut relay arm TT R125E TT R125LE On swingarm Apply the molybdenum disulfide grease on the bolt relay arm 53 Nm 5 3 m kg 38 ft lb 70 Nm 7 0 m kg 50 ft lb TIP TIP TIP ...

Page 233: ...ease or replace bushing 5 Install Connecting arm 1 Bolt connecting arm Plain washer Nut connecting arm On relay arm Apply the molybdenum disulfide grease on the bolt connecting arm 6 Install Drive chain guide 1 Collars Bolts drive chain guide 2 35 Nm 3 5 m kg 25 ft lb 7 Nm 0 7 m kg 5 1 ft lb 7 Install Drive chain support 1 Collars Bolts drive chain support 2 Drive chain guard 3 Bolts drive chain g...

Page 234: ...ar shock absorber relay arm 35 Nm 3 5 m kg 25 ft lb 4 Install Bolt connecting arm frame 1 Plain washer Nut connecting arm frame Apply the molybdenum disulfide grease on the bolt connecting arm frame 35 Nm 3 5 m kg 25 ft lb 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 Apply the lithium soap base grease on the bushing inn...

Page 235: ...e 3 Bushing 1 4 Rear shock absorber assembly 1 Extent of removal Order Part name Q ty Remarks REAR SHOCK ABSORBER ASSEMBLY REMOVAL Hold the machine by placing the suitable stand under the engine Preparation for removal Seat and side covers Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 1 Hold the swingarm Refer to REMOVAL POINTS Support the machine securely so there is no danger ...

Page 236: ...amper 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 malfunction 4 Take care not to scra...

Page 237: ... down NOTES ON DISPOSAL YAMAHA DEALERS ONLY Gas pressure must be released before dispos ing of a rear shock absorber and gas cylinder TT R125E To release the gas pressure drill a 2 3 mm 0 08 0 12 in hole through the gas cylinder at a point a from its end as shown Wear eye protection to prevent eye damage from released gas or metal chips TT R125LE To release the gas pressure press on the gas valve ...

Page 238: ...ear shock absorber assembly frame 2 Apply the molybdenum disulfide grease on the bolt rear shock absorber assembly frame EC585000 ASSEMBLY AND INSTALLATION Bushing 1 Install Bushing 1 Install the bushing by pressing 3 Install Bolt rear shock absorber assembly relay arm Plain washer 1 Nut rear shock absorber assembly relay arm 2 Apply the molybdenum disulfide grease on the bolt rear shock absorber ...

Page 239: ...ar shock absorber assembly sub tank so that its 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 section in the CHAPTER 2 4 Nm 0 4 m kg 2 9 ft lb TIP ...

Page 240: ... 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 1 2 345 7 6 890 A E D C B The illustration shows the TT R125LE 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 241: ...ction Spark Clean or replace spark plug Repair or replace Replace OK No good Replace Replace Replace Replace Replace No good No good No good No good No good No good No Spark OK OK OK OK Check main switch Check engine stop switch Check ignition coil Replace CDI unit Check CDI magneto Primary coil Pickup coil Source coil Secondary coil Remove the following parts before inspection 1 Seat 2 Fuel tank ...

Page 242: ... 2 Connect the dynamic spark tester 1 ignition checker 2 as shown Spark plug cap 3 Spark plug 4 3 Kick the kick starter 4 Check the ignition spark gap 5 Start engine and increase spark gap until misfire occurs MAIN SWITCH INSPECTION 1 Inspect Main switch continuity Check for continuity as follows Incorrect continuity Replace R Br B W B 1 2 3 4 Tester selector position ON OFF Ω x 1 Tester Red lead ...

Page 243: ... 1 2 Tester selector position PUSH IN FREE Ω x 1 No continuous while being pushed Replace Continuous while being freed Replace EC626002 IGNITION COIL INSPECTION 1 Inspect Primary coil resistance Out of specification Replace Tester lead Orange lead 1 Tester _ lead Black lead 2 Tester selector position Primary coil resistance Ω x 1 0 18 0 28 Ω at 20 C 68 F ...

Page 244: ... plug cap CDI MAGNETO INSPECTION 1 Inspect Pickup coil resistance Out of specification Replace Tester lead Spark plug lead 1 Tester _ lead Orange lead 2 Tester selector position Secondary coil resistance kΩ x 1 6 3 9 5 kΩ at 20 C 68 F Tester lead Red lead 1 Tester _ lead White lead 2 Tester selector position Pickup coil resistance Ω x 100 248 372 Ω at 20 C 68 F TIP ...

Page 245: ...ect Source coil resistance Out of specification Replace IGNITION SYSTEM Br G R W 1 2 Tester lead Brown lead 1 Tester _ lead Green lead 2 Tester selector position Source coil resistance Ω x 100 688 1 032 Ω at 20 C 68 F ...

Page 246: ...rating 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 conditions has been met the starting circuit cut off relay is closed and the engine can be started by pressing the start switch 1 Battery 2 Main fuse 3 Main switch 4 Start switch 5 Starting circuit cut off relay 6 ...

Page 247: ...3 3 marked Refer to MAIN SWITCH INSPECTION section TIP Pocket tester YU 3112 C 90890 03112 ELECTRIC STARTING SYSTEM 1 Check fuse 2 Check battery No good Replace fuse and check wire harness Recharge or replace Repair or replace OK No good Replace Repair or replace Replace Replace Replace No good No good OK OK OK OK OK Check each coupler and wire connection 3 Check main switch Check starter motor op...

Page 248: ... produce sparks therefore make sure nothing flammable is in the vicinity EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1 Check Couplers and leads connection Rust dust looseness short circuit Repair or replace WARNING 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 Ba...

Page 249: ...4 Tester selector position Connected to battery Not connected to battery Ω x 1 No continuous while in neutral Replace Continuous while in gear Replace NEUTRAL SWITCH INSPECTION 1 Inspect Neutral switch conduct Tester lead Sky blue lead 1 1 1 1 1 Tester lead Black lead 2 2 2 2 2 Sb B 1 2 Tester selector position NEUTRAL IN GEAR Ω x 1 W Sb Y B 1 2 ELECTRIC STARTING SYSTEM Continuous while not connec...

Page 250: ...STEM Tester lead Black lead 1 Tester _ lead Black lead 2 B B 1 2 Tester selector position PULL FREE Ω x 1 No continuous while being pulled Replace Continuous while being freed Replace Tester lead Black lead 1 Tester _ lead Black lead 2 B B 1 2 Tester selector position PUSH IN FREE Ω x 1 No continuous while being pushed Replace Continuous while being freed Replace ...

Page 251: ...4 Starter motor yoke 1 5 Armature assembly 1 6 Starter motor rear cover 1 7 Brush 2 8 Brush spring 2 Extent of removal Order Part name Q ty Remarks STARTER MOTOR REMOVAL Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Preparation for removal 1 Starter motor 1 STARTER MOTOR DISASSEMBLY 1 5 2 3 6 8 7 8 7 4 1 3 New 1 3 New New ...

Page 252: ...o fit The mica insulation of the commutator must be undercut to ensure proper operation of commutator Mica undercut 1 5 mm 0 06 in 4 Measure Armature assembly resistance commuta tor and insulation Out of specification Replace the starter motor Pocket tester YU 3112 C 90890 03112 Measurement steps Measure the armature assembly resis tances with the pocket tester Armature coil Commutator resistance ...

Page 253: ...he brush during installation 5 Measure Brush length a Out of specification Replace 6 Measure Brush spring force Fatigue out of specification Replace as a set ASSEMBLY 1 Install Brush spring 1 Brush 2 Brush length wear limit 3 5 mm 0 14 in Brush spring force 5 52 8 28 N 560 840 g 19 8 29 7 oz 2 1 2 ELECTRIC STARTING SYSTEM NOTICE ...

Page 254: ...r cover New 4 Install O ring 1 Plain washer 2 Starter motor front cover 3 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 New 5 Install Bolt 1 O ring 2 Apply the lithium soap base grease on the O ring New ELECTRIC STARTING SYSTEM TIP TIP TIP ...

Page 255: ...re inspection 1 Seat 2 Rear fender 3 Fuel tank Use the following special tool in this inspection TIP Inductive tachometer YU 8036 B Engine tachometer 90890 03113 Pocket tester YU 3112 C 90890 03112 1 Check fuse 2 Check battery No good Replace fuse and check wire harness Recharge or replace Repair or replace OK No good Charging system is good Replace Charging coil No good OK OK OK No good OK Check ...

Page 256: ...Charging voltage Out of specification If no failure is found in checking the source coil resistance replace the rectifier regulator Tester selector position Charging voltage DCV 20 14 0 15 0 V at 5 000 r min Tester lead Red lead 1 Tester lead Black lead 2 3 Inspect Charging coil resistance Out of specification Replace Tester selector position Charging coil resistance Ω x 1 0 64 0 96 Ω at 20 C 68 F...

Page 257: ......

Page 258: ...YAMAHA MOTOR DA AMAZÔNIA LTDA ...

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