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Yamaha TT-R125EW Owner's Service Manual

Lit-11626-20-01; 1b2-f8199-12.
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TT-R125EW
TT-R125LW
TT-R125LEW
LIT-11626-20-01
1B2-F8199-12

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Table of Contents

   Also See for Yamaha TT-R125EW

   Summary of Contents for Yamaha TT-R125EW

  • Page 1 TT-R125EW TT-R125LW TT-R125LEW LIT-11626-20-01 1B2-F8199-12...
  • Page 3 EC010000 TT-R125EW/TT-R125LW TT-R125LEW OWNER’S SERVICE MANUAL ©2006 by Yamaha Motor da Amazônia Ltda. 1st Edition, May 2006 1st Edition, 2006 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor da Amazônia Ltda. is expressly prohibited.
  • Page 4 Yamaha has met these standards without reducing the performance or economy of opera- tion of the machine. To maintain these high stan- dards, it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instruc- tions contained within this manual.
  • Page 5 If your machine requires warranty service, you must take it to any authorized The customer’s responsibility includes all costs of normal maintenance Yamaha Motorcycle dealer within the continental United States. Be sure to services, no-warranty repairs, accident and collision damages, and oil, bring your warrant registration card or other valid proof of the original date of oil filters, air filters, spark plugs and brake shoes.
  • Page 6: Important Notice

    IMPORTANT NOTICE This machine is designed for off-road use only by young operators under adult instruction and supervision. It is illegal for this machine to be operated on any public street, road, or high- way. Off-road use on public lands may be illegal. Please check local regulations before riding.
  • Page 7 4. When transporting the machine in another vehicle, be sure is kept upright and that the fuel cock is turned to the “OFF”. If it should lean over, gasoline may leak out of the car- buretor or fuel tank. 5. Never start your engine or let it run for any length of time in a closed area.
  • Page 8 SAFETY INFORMATION 1. Do not ride it on the street. 2. Do not run the engine inside a building. 3. This is a one-seater motorbike. Do not give any person a ride. 4. Let’s learn how to ride properly. Ask your parents for any question.
  • Page 9 6. When going for riding, be sure to be with your family. Never go alone. 7. Before riding the machine, ask your par- ents to check the machine very carefully. 8. Do not touch the areas shown, or you will get burnt in the hand.
  • Page 10 If you have any questions regarding the operation or maintenance of your machine, please consult your Yamaha dealer. NOTE: This manual should be considered a perma- nent part of this machine and should remain with it even if the machine is subsequently sold.
  • Page 11: Regular Inspection And

    EC080000 HOW TO USE THIS MANUAL EC081000 PARTICULARLY IMPORTANT INFORMATION The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine.
  • Page 12 EC083000 MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The informa- tion has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g.
  • Page 13 ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols 1 to 6 are designed as SPEC INFO thumb tabs to indicate the chapter’s number and content. 1 General information INSP 2 Specifications 3 Regular inspection and adjustments 4 Engine 5 Chassis 6 Electrical –...
  • Page 14 MEMO...
  • Page 15 INDEX GENERAL INFORMATION INFO SPECIFICATIONS SPEC REGULAR INSPECTION AND ADJUSTMENTS INSP ENGINE CHASSIS CHAS ELECTRICAL CHÂS...
  • Page 16: Table Of Contents

    EC0A0000 CONTENTS CHAPTER 1 GENERAL INFORMATION DESCRIPTION .......... 1-1 MACHINE IDENTIFICATION ....1-2 IMPORTANT INFORMATION ....1-3 CHECKING OF CONNECTION ....1-5 SPECIAL TOOLS ........1-6 CONTROL FUNCTIONS ......1-9 FUEL ............1-12 STARTING AND BREAK-IN ....1-13 TORQUE-CHECK POINTS ..... 1-16 TT-R125/TT-R125E ......
  • Page 17 CHAPTER 3 REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS ....3-1 PRE-OPERATION INSPECTION AND MAINTENANCE ....... 3-4 ENGINE ............. 3-5 CHASSIS ..........3-16 ELECTRICAL .......... 3-35 CHAPTER 4 ENGINE SEAT, FUEL TANK AND SIDE COVERS ......... 4-1 MUFFLER ..........4-2 CARBURETOR ......... 4-3 CYLINDER HEAD ........
  • Page 18 CHAPTER 5 CHASSIS FRONT WHEEL AND FRONT BRAKE (TT-R125/TT-R125E) ......... 5-1 FRONT WHEEL (TT-R125LW/TT-R125LWE) ..... 5-8 FRONT BRAKE (TT-R125LW/TT-R125LWE) ....5-12 REAR WHEEL AND REAR BRAKE ..5-24 FRONT FORK ......... 5-32 HANDLEBAR .......... 5-42 STEERING ..........5-52 SWINGARM ..........5-58 REAR SHOCK ABSORBER ASSEMBLY ..........
  • Page 19: General Information

    DESCRIPTION INFO EC100000 GENERAL INFORMATION EC110000 DESCRIPTION 1 Clutch lever NOTE: 2 Engine stop switch The machine you have purchased may differ ● 3 Main switch (TT-R125E/TT-R125LWE) slightly from those shown in the following. 4 Starter knob 5 Start switch (TT-R125E/TT-R125LWE) Designs and specifications are subject to ●...
  • Page 20: Machine Identification

    There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the number to your Yamaha dealer for positive identification of the model you own. 2. If your machine is stolen, the authorities will need the number to search for and identify your machine.
  • Page 21: Important Information

    IMPORTANT INFORMATION INFO EC130000 IMPORTANT INFORMATION PREPARATION 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 ●...
  • Page 22 IMPORTANT INFORMATION INFO EC132000 ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. EC133000 GASKETS, OIL SEALS AND O-RINGS 1. All gaskets, oil seals, and O-rings should be replaced when an engine is over- hauled.
  • Page 23: Checking Of Connection

    CHECKING OF CONNECTION INFO 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.
  • Page 24: Special Tools

    SPECIAL TOOLS INFO SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided.
  • Page 25 SPECIAL TOOLS INFO Part number Tool name/How to use Illustration YM-1312-A, 90890-01312 Fuel level gauge YM-1312-A 90890-01312 This gauge is used to measure the fuel level in the float chamber. YU-33270-B, 90890-01362 Flywheel puller YU-33270-B 90890-01362 This tool is used to remove the rotor. YM-33963, 90890-01367 Fork seal driver weight YM-33963...
  • Page 26 Dynamic spark tester YM-34487 90890-06754 90890-06754 Ignition checker This instrument is necessary for checking the ignition system components. ACC-QUICK-GS-KT Quick gasket ® ACC-QUICK-GS-KT 90890-85505 90890-85505 YAMAHA Bond No.1215 This sealant (Bond) is used for crankcase mating surface, etc. 1 - 8...
  • Page 27: Control Functions

    CONTROL FUNCTIONS INFO EC150000 CONTROL FUNCTIONS MAIN SWITCH (TT-R125E/TT-R125LWE) Functions of the respective switch positions are as follows: The engine can be started only at this position. OFF: All electrical circuits are switched off. The key can be removed in this position. ENGINE STOP SWITCH The engine stop switch 1 is located on the left handlebar.
  • Page 28 CONTROL FUNCTIONS INFO KICKSTARTER CRANK WARNING Before starting the engine, be sure to shift the transmission into neutral. Rotate the kickstarter crank 1 away from the engine. Push the starter down lightly with your foot until the gears engage, then kick smoothly and forcefully to start the engine.
  • Page 29 CONTROL FUNCTIONS INFO EC158010 FUEL COCK The fuel cock supplies fuel from the tank to carburetor while filtering the fuel. The fuel cock has the three positions: OFF: With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running.
  • Page 30: Fuel

    Gasohol containing ethanol can be used it the ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems. 1 - 12...
  • Page 31: Starting And Break-in

    STARTING AND BREAK-IN INFO EC190000 STARTING AND BREAK-IN CAUTION: Before starting the machine, perform the checks in the pre-operation check list. WARNING Never start or run the engine in a closed area. The exhaust fumes are poisonous; they can cause loss of consciousness and death in a very short time.
  • Page 32 STARTING AND BREAK-IN INFO 5. Run the engine at idle or slightly higher until it warms up: this usually takes about one or two minutes. 6. The engine is warmed up when it responds normally to the throttle with the starter knob (CHOKE) turned off.
  • Page 33 STARTING AND BREAK-IN INFO BREAKING IN AFTER REPLACEMENT After a part is replaced with a new one, it is necessary to break it in as in a new machine. This is required especially when the following engine-related parts are replaced. Cylinder ●...
  • Page 34: Torque-check Points

    TORQUE-CHECK POINTS INFO TORQUE-CHECK POINTS TT-R125/TT-R125E Engine mounting Frame to engine Frame to engine bracket Engine bracket to engine Muffler Muffler to cylinder head Muffler to rear fender bracket Muffler to seat pillar tube Steering Steering stem to Steering stem to upper bracket Upper bracket to handlebar handlebar Suspension...
  • Page 35: Tt-r125lw/tt-r125lwe

    TORQUE-CHECK POINTS INFO TT-R125LW/TT-R125LWE Engine mounting Frame to engine Frame to engine bracket Engine bracket to engine Muffler Muffler to cylinder head Muffler to rear fender bracket Muffler to seat pillar tube Steering Steering stem to Steering stem to upper bracket Upper bracket to handlebar handlebar Suspension...
  • Page 36: Cleaning And Storage

    CLEANING AND STORAGE INFO EC1B0000 CLEANING AND STORAGE EC1B1000 CLEANING Frequent cleaning of your machine will enhance its appearance, maintain good overall performance, and extend the life of many com- ponents. 1. Before washing the machine, block off the end of the exhaust pipe to prevent water from entering.
  • Page 37 CLEANING AND STORAGE INFO EC182001 STORAGE If your machine is to be stored for 60 days or more, some preventive measures must be taken to avoid deterioration. After cleaning the machine thoroughly, prepare it for storage as follows: 1. Drain the fuel tank, fuel lines, and the car- buretor float bowl.
  • Page 38: Specifications

    SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS TT-R125/TT-R125E Model name: TT-R125W (CDN, AUS, NZ) TT-R125 (EUROPE, ZA) TT-R125EW (USA, CDN, AUS, NZ) TT-R125E (EUROPE, ZA) Model code number: TT-R125: 1B2H (AUS, NZ, EUROPE, ZA) 1B2J (CDN) TT-R125E: 1B2K (USA, AUS, NZ, EUROPE, ZA)
  • Page 39 SPEC GENERAL SPECIFICATIONS Oil type or grade: Engine oil (For USA and CDN) At –10 ˚C (10 ˚F) or higher Å Yamalube 4 (10W-30) or SAE 10W-30 type SE motor oil At 5 ˚C (40 ˚F) or higher ı Yamalube 4 (20W-40) or SAE 20W-40 type SE motor oil (Except for USA and CDN) API “SE”...
  • Page 40 SPEC GENERAL SPECIFICATIONS Transmission: Primary reduction system Gear Primary reduction ratio 68/19 (3.579) Secondary reduction system Chain drive Secondary reduction ratio 49/13 (3.769) Transmission type Constant mesh, 5-speed Operation Left foot operation Gear ratio: 37/14 (2.643) 32/18 (1.778) 25/19 (1.316) 23/22 (1.045) 21/24 (0.875) Chassis:...
  • Page 41: Tt-r125lw/tt-r125lwe

    SPEC GENERAL SPECIFICATIONS TT-R125LW/TT-R125LWE Model name: TT-R125LW (USA, CDN),TT-R125LWW( AUS, NZ) TT-R125LW (EUROPE, ZA) TT-R125LEW (USA, CDN),TT-R125LWEW(AUS, NZ) TT-R125LWE (EUROPE, ZA) Model code number: TT-R125LW: 1B2M (USA, AUS, NZ, EUROPE, ZA) 1B2N (CDN) TT-R125LWE: 1B2P (USA, AUS, NZ, EUROPE, ZA) 1B2R (CDN) Dimensions: USA, AUS, NZ,...
  • Page 42 SPEC GENERAL SPECIFICATIONS Oil type or grade: Engine oil (For USA and CDN) At –10 ˚C (10 ˚F) or higher Å Yamalube 4 (10W-30) or SAE 10W-30 type SE motor oil At 5 ˚C (40 ˚F) or higher ı Yamalube 4 (20W-40) or SAE 20W-40 type SE motor oil (Except for USA and CDN) API “SE”...
  • Page 43 SPEC GENERAL SPECIFICATIONS Transmission: Primary reduction system Gear Primary reduction ratio 68/19 (3.579) Secondary reduction system Chain drive Secondary reduction ratio 54/13 (4.154) Transmission type Constant mesh, 5-speed Operation Left foot operation Gear ratio: 37/14 (2.643) 32/18 (1.778) 25/19 (1.316) 23/22 (1.045) 21/24 (0.875) Chassis:...
  • Page 44: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS EC212000 MAINTENANCE SPECIFICATIONS EC212100 ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.03 mm (0.0012 in) Cylinder: Bore size 54.000 ~ 54.019 mm ---- (2.1260 ~ 2.1267 in) Out of round limit ---- 0.05 mm (0.0020 in) Camshaft: Drive method Chain drive (left)
  • Page 45 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Cam chain: Cam chain type/No. of links DID25SD DHA/88 ---- Cam chain adjustment method Automatic ---- Rocker arm/rocker arm shaft: Shaft outside diameter 9.981 ~ 9.991 mm 9.95 mm (0.3930 ~ 0.3933 in) (0.3917 in) Rocker arm inside diameter 10.000 ~ 10.015 mm 10.03 mm...
  • Page 46 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Stem runout limit ---- 0.01 mm (0.0004 in) Valve seat width 0.9 ~ 1.1 mm 1.6 mm (0.0354 ~ 0.0433 in) (0.0630 in) 0.9 ~ 1.1 mm 1.6 mm (0.0354 ~ 0.0433 in) (0.0630 in) Valve spring: Free length 32.55 mm (1.28 in)
  • Page 47 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit 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)
  • Page 48 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Crankshaft: Crank width “A” 46.95 ~ 47.00 mm ---- (1.848 ~ 1.850 in) Runout limit “C” ---- 0.03 mm (0.0012 in) Big end side clearance “D” 0.15 ~ 0.45 mm 0.5 mm (0.0059 ~ 0.0177 in) (0.02 in) Clutch: Friction plate thickness...
  • Page 49 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Lubrication system: Oil 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...
  • Page 50 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m•kg ft•lb M10 × 1.0 Spark plug M8 × 1.25 Cylinder head bolt M6 × 1.0 Cylinder head bolt M6 × 1.0 Oil pressure check bolt M6 × 1.0 Cylinder head side cover M45 ×...
  • Page 51 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m•kg ft•lb M6 × 1.0 Segment M6 × 1.0 Stopper lever NOTE: - marked portion shall be checked for torque tightening after break-in or before each ride. Cylinder head tightening sequence 2 - 14...
  • Page 52: Chassis

    SPEC MAINTENANCE SPECIFICATIONS EC212201 CHASSIS TT-R125/TT-R125E Item Standard Limit Steering system: Steering bearing type (upper) Angular bearing ---- (lower) Taper roller bearing ---- Front suspension: Front fork travel 180 mm (7.09 in) ---- Fork spring free length 327 mm (12.87 in) 322 mm (12.68 in) Spring rate, STD K = 3.00 N/mm...
  • Page 53 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Drum brake: Front drum brake type Leading, trailing ---- Rear drum brake type Leading, trailing ---- Front drum inside diameter 110 mm (4.33 in) 111 mm (4.37 in) Rear drum inside diameter 110 mm (4.33 in) 111 mm (4.37 in) Front lining thickness 4.0 mm (0.16 in)
  • Page 54 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m•kg ft•lb M8 × 1.25 Upper bracket and inner tube M10 × 1.25 Lower bracket and inner tube M22 × 1.0 Upper bracket and steering stem 11.0 M8 × 1.25 Handlebar upper holder and upper bracket M25 ×...
  • Page 55 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m•kg ft•lb M10 × 1.25 Relay arm and connecting arm M10 × 1.25 Connecting arm and frame M12 × 1.25 Rear shock absorber assembly and frame Rear shock absorber assembly and relay arm M10 × 1.25 M46 ×...
  • Page 56: Tt-r125lw/tt-r125lwe

    SPEC MAINTENANCE SPECIFICATIONS TT-R125LW/TT-R125LWE Item Standard Limit Steering system: Steering bearing type (upper) Angular bearing ---- (lower) Taper roller bearing ---- Front suspension: Front fork travel 180 mm (7.09 in) ---- Fork spring free length (TT-R125LW) 339 mm (13.35 in) 334 mm (13.15 in) (TT-R125LWE) 453.6 mm (17.86 in)
  • Page 57 SPEC MAINTENANCE SPECIFICATIONS 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 (10 links) ---- 121.4 mm (4.78 in) Front disc brake: Disc outside dia.
  • Page 58 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m•kg ft•lb M8 × 1.25 Upper bracket and inner tube M10 × 1.25 Lower bracket and inner tube M22 × 1.0 Upper bracket and steering stem 11.0 M8 × 1.25 Handlebar upper holder and upper bracket M25 ×...
  • Page 59 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m•kg ft•lb M8 × 1.25 Bead stopper M10 × 1.25 Driven sprocket (nut) M10 × 1.25 Driven sprocket (stud) M10 × 1.25 Sidestand mounting (nut) Engine mounting: M8 × 1.25 Engine bracket (front) and frame M8 ×...
  • Page 60: Electrical

    EC212300 ELECTRICAL TT-R125/TT-R125LW Item Standard Limit CDI: Magneto-model (stator)/manufacturer 5HP-01/YAMAHA ---- 688 ~ 1,032 Ω at 20 ˚C (68 ˚F) Charging coil resistance (color) ---- (Green-Brown) 248 ~ 372 Ω at 20 ˚C (68 ˚F) Pickup coil resistance (color) ----...
  • Page 61: Tt-r125e/tt-r125lwe

    MAINTENANCE SPECIFICATIONS TT-R125E/TT-R125LWE Item Standard Limit CDI: Magneto-model/manufacturer 5HP-10/YAMAHA ---- 688 ~ 1,032 Ω at 20 ˚C (68 ˚F) Source coil resistance (color) ---- (Brown – Green) 248 ~ 372 Ω at 20 ˚C (68 ˚F) Pickup coil resistance (color) ---- (Red –...
  • Page 62 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Starter relay: Model/manufacturer MS5F-751/JIDECO ---- Amperage rating 180 A ---- 4.2 ~ 4.6 Ω at 20 ˚C (68 ˚F) Coil winding resistance ---- Starting circuit cut-off relay: Model/manufacturer ACM33221/MATSUSHITA ---- 75.69 ~ 92.51 Ω at 20 ˚C (68 ˚F) Coil winding resistance ---- Fuse (amperage ×...
  • Page 63: General Torque Specifications

    GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS EC220001 GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasten- ers with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sec- tions of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fash- ion, in progressive stages, until full torque is reached.
  • Page 65: Cable Routing Diagram

    SPEC CABLE ROUTING DIAGRAM 1 Air vent hose Å After clamping the starter cable, push it against the starter plunger. ı Put the tip of the air vent hose into the main pipe. 2 Spark plug lead Ç Install the primary coil terminal (orange) to the ignition coil. 3 Starter cable Î...
  • Page 66 SPEC CABLE ROUTING DIAGRAM 1 Engine stop switch lead Å Pass the engine stop switch lead in the middle of the clutch holder. 2 Engine stop switch ı Clamp the engine stop switch lead to the handlebar to 3 clicks. 3 Fuel tank breather hose Ç...
  • Page 68 6 6 6 6 6 6 G G G G G G...
  • Page 71 SPEC CABLE ROUTING DIAGRAM ‰ Fasten the clutch cable with the È Pass the negative battery lead ˜ Install the primary coil terminal paint in the cable guide bottom on the inside of the frame as (orange) to the ignition coil. ˆ...
  • Page 72 SPEC CABLE ROUTING DIAGRAM 1 Clamp Å Fasten the clutch switch lead Ï Pass the main switch lead on 2 Clutch switch lead and engine stop switch lead to 3 the right of the number plate 3 Engine stop switch lead clicks.
  • Page 73: Maintenance Intervals

    From 18 months or 4,200 mi (7,000 km) or 210 hours, repeat the maintenance intervals starting from 6 months or 1,800 mi (3,000 km) or 90 hours. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 74: General Maintenance And Lubrication Chart

    From 18 months or 4,200 mi (7,000 km) or 210 hours, repeat the maintenance intervals starting from 6 months or 1,800 mi (3,000 km) or 90 hours. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 75 Shock absorber Check operation and for oil leakage. √ √ assembly Replace if necessary. 17 * Control cabes Apply Yamaha chain and cable lube or engine oil 10W-30 thoroughly. √ √ √ Check operation and free play. Throttle grip √ √...
  • Page 76: Pre-operation Inspection And Maintenance

    INSP PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation or practice, make sure the machine is in good operating condi- tion. Before using this machine, check the following points. GENERAL INSPECTION AND MAINTENANCE Item Routine Page Check that a fresh gasoline is filled in the fuel tank.
  • Page 77: Engine

    ENGINE/CLUTCH ADJUSTMENT/ INSP THROTTLE CABLE ADJUSTMENT EC350000 ENGINE CLUTCH ADJUSTMENT 1. Check: Clutch lever free play a ● Out of specification → Adjust. Clutch lever free play a: 10 ~ 15 mm (0.39 ~ 0.59 in) 2. Adjust: Clutch lever free play ●...
  • Page 78 INSP THROTTLE LUBRICATION/AIR FILTER CLEANING NOTE: Before adjusting the throttle cable free play, the engine idle speed should be adjusted. WARNING After adjusting, turn the handlebar to right and left and make sure that the engine idling does not run faster. THROTTLE LUBRICATION 1.
  • Page 79 INSP AIR FILTER CLEANING 1. Remove: Right side cover 1 ● NOTE: Loosen the quick screw 2 and remove the right side cover from the holding boss a. 2. Remove: Band 1 ● Air filter case cover 2 ● 3. Remove: Air filter assembly 1 ●...
  • Page 80 INSP ENGINE OIL LEVEL INSPECTION 6. Apply: Foam-air-filter oil or engine mixing oil ● To the element. NOTE: Squeeze out the excess oil. Element should be wet but not dripping. 7. Install: Air filter element 1 ● On air filter guide 2. 8.
  • Page 81 INSP ENGINE OIL LEVEL INSPECTION 4. Check: Oil level ● Oil level should be between maximum a and minimum b marks. Oil level is low → Add oil to proper level. NOTE: When inspecting the oil level, do not screw the dipstick into the oil tank.
  • Page 82 INSP ENGINE OIL REPLACEMENT 5. Install: Dipstick ● 6. Start the engine and let it warm up for several minutes. 7. Turn off the engine and inspect the oil level once again. NOTE: Wait a few minutes until the oil settles before inspecting the oil level.
  • Page 83 OIL PRESSURE INSPECTION/PILOT AIR SCREW INSP ADJUSTMENT/ENGINE IDLING SPEED ADJUSTMENT OIL PRESSURE INSPECTION 1. Check: Oil pressure ● Checking steps: Slightly loosen the oil pressure check bolt ● Start the engine and keep it idling until oil ● starts to seep from the oil pressure check bolt.
  • Page 84 INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT 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.
  • Page 85 INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT 4. Check: Valve clearance ● Out of specification → Adjust. Valve clearance (cold): Intake valve: 0.08 ~ 0.12 mm (0.0031 ~ 0.0047 in) Exhaust valve: 0.10 ~ 0.14 mm (0.0039 ~ 0.0055 in) Checking steps: Turn the crankshaft counterclockwise with ●...
  • Page 86: Valve Clearance Inspection And Adjustment

    INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT Measure the valve clearance. ● If the clearance is incorrect, repeat above ● steps until specified clearance is obtained. 6. Install: O-ring 1 ● Crankshaft end accessing screw 2 ● 7 Nm (0.7 m · kg, 5.1 ft · lb) Timing mark accessing screw 3 ●...
  • Page 87 INSP SPARK ARRESTER CLEANING (For USA) SPARK ARRESTER CLEANING (For USA) WARNING Be sure the exhaust pipe and muffler are ● cool before cleaning the spark arrester. Do not start the engine when cleaning the ● exhaust system. 1. Remove: Bolt (spark arrester) 1 ●...
  • Page 88: Chassis

    CHASSIS/BRAKE SYSTEM AIR BLEEDING INSP (TT-R125LW/TT-R125LWE) EC360000 CHASSIS EC361012 BRAKE SYSTEM AIR BLEEDING (TT-R125LW/TT-R125LWE) WARNING Bleed the brake system if: The system has been disassembled. ● A brake hose has been loosened or ● removed. The brake fluid is very low. ●...
  • Page 89 INSP FRONT BRAKE ADJUSTMENT NOTE: If bleeding is difficult, it may be necessary to let the brake fluid system stabilize for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disap- peared. j. Add brake fluid to the level line on the reservoir.
  • Page 90 INSP REAR BRAKE ADJUSTMENT TT-R125LW/TT-R125LWE 1. Check: Brake lever free play a ● Out of specification → Adjust. Brake lever free play a: 2 ~ 5 mm (0.08 ~ 0.20 in) 2. Adjust: Brake lever free play ● Brake lever free play adjustment steps: Loosen the locknut 1.
  • Page 91 INSP BRAKE PEDAL HEIGHT ADJUSTMENT/FRONT BRAKE PAD INSPECTION AND REPLACEMENT (TT-R125LW/TT-R125LWE) BRAKE PEDAL HEIGHT ADJUSTMENT 1. Check: Brake pedal height a ● Out of specification → Adjust. Brake pedal height a: 1 mm (0.04 in) 2. Adjust: Brake pedal height ●...
  • Page 92 INSP FRONT BRAKE SHOE INSPECTION (TT-R125/TT-R125E) Connect the transparent hose 4 to the ● bleed screw 5 and place the suitable con- tainer under its end. Loosen the bleed screw and push the ● brake caliper piston in. CAUTION: Do not reuse the drained brake fluid. Tighten the bleed screw.
  • Page 93 INSP REAR BRAKE SHOE INSPECTION/BRAKE FLUID LEVEL INSPECTION (TT-R125LW/TT-R125LWE)/SPROCKETS INSPECTION REAR BRAKE SHOE INSPECTION 1. Inspect: Brake shoe lining wear limit ● Brake shoe lining wear limit checking steps: Fully push down the brake pedal and hold ● it in position. Then check the brake shoe wear indicator ●...
  • Page 94 INSP DRIVE CHAIN INSPECTION EC369002 DRIVE CHAIN INSPECTION 1. Remove: Master link clip ● Joint 1 ● Drive chain 2 ● 2. Clean: Drive chain ● Place it in kerosene, and brush off as much dirt as possible. Then remove the chain from the kerosene and dry the chain.
  • Page 95 INSP DRIVE CHAIN SLACK ADJUSTMENT 6. Lubricate: Drive chain ● Drive chain lubricant: SAE 10W-30 motor oil or suit- able chain lubricants DRIVE CHAIN SLACK ADJUSTMENT 1. Elevate the rear wheel by placing the suitable stand under the engine. 2. Check: Drive chain slack a ●...
  • Page 96 FRONT FORK INSPECTION/FRONT FORK SPRING INSP PRELOAD ADJUSTMENT (TT-R125LWE) EC36C000 FRONT FORK INSPECTION 1. Inspect: Front fork smooth action ● Operate the front brake and stroke the front fork. Unsmooth action/oil leakage → Repair or replace. FRONT FORK SPRING PRELOAD ADJUSTMENT (TT-R125LWE) 1.
  • Page 97 INSP REAR SHOCK ABSORBER ASSEMBLY INSPECTION/ REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT REAR SHOCK ABSORBER ASSEMBLY INSPECTION 1. Inspect: Swingarm smooth action ● Abnormal noise/unsmooth action → Grease the pivoting points or repair the pivoting points. Damage/oil leakage → Replace. REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 1.
  • Page 98 REAR SHOCK ABSORBER REBOUND DAMPING FORCE INSP ADJUSTMENT (TT-R125LWE) 5. Tighten: Locknut 42 Nm (4.2 m · kg, 30 ft · lb) ● 6. Install: Left side cover ● 7 Nm (0.7 m · kg, 5.1 ft · lb) EC36N014 REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT (TT-R125LWE)
  • Page 99 REAR SHOCK ABSORBER COMPRESSION DAMPING INSP FORCE ADJUSTMENT (TT-R125LWE) EC36c000 REAR SHOCK ABSORBER COMPRESSION DAMPING FORCE ADJUSTMENT (TT-R125LWE) 1. Adjust: Compression damping force ● By turning the adjuster 1. Stiffer a → Increase the compression damping force. (Turn the adjuster 1 in.) Softer b →...
  • Page 100 TIRE PRESSURE CHECK/SPOKES INSPECTION AND INSP TIGHTENING/WHEEL INSPECTION EC36Q000 TIRE PRESSURE CHECK 1. Measure: Tire pressure ● Out of specification → Adjust. Standard tire pressure: 100 kPa (1.00 kgf/cm , 15 psi) NOTE: Check the tire while it is cold. ●...
  • Page 101: Tt-r125/tt-r125lw

    INSP STEERING HEAD INSPECTION AND ADJUSTMENT 2. Inspect: Bearing free play ● Exist play → Replace. STEERING HEAD INSPECTION AND ADJUSTMENT 1. Elevate the front wheel by placing a suit- able stand under the engine. 2. Check: Steering shaft ● Grasp the bottom of the forks and gen- tly rock the fork assembly back and forth.
  • Page 102 INSP STEERING HEAD INSPECTION AND ADJUSTMENT Tighten the lower ring nut 6 using steer- ● ing nut wrench 7 and turn the steering right and left a few times. NOTE: Set the torque wrench to the steering nut wrench so that they form a right angle. Steering nut wrench: YU-33975/90890-01403 Lower ring nut (initial tightening):...
  • Page 103 INSP STEERING HEAD INSPECTION AND ADJUSTMENT Install the upper bracket A, steering stem ● nut B, cap C, handlebar D, upper han- dlebar holder E, starter knob nut F and number plate G. NOTE: The upper handlebar holder should be ●...
  • Page 104 INSP STEERING HEAD INSPECTION AND ADJUSTMENT Tighten the lower ring nut 6 using steer- ● ing nut wrench 7 and turn the steering right and left a few times. NOTE: Set the torque wrench to the steering nut wrench so that they form a right angle. Steering nut wrench: YU-33975/90890-01403 Lower ring nut (initial tightening):...
  • Page 105 INSP STEERING HEAD INSPECTION AND ADJUSTMENT CAUTION: First tighten the bolts on the front side 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 •...
  • Page 106 INSP LUBRICATION Å Use Yamaha cable lube or equivalent on these LUBRICATION areas. To ensure smooth operation of all compo- ı Use SAE 10W-30 motor oil or suitable chain nents, lubricate your machine during setup, lubricants. after break-in, and after every ride.
  • Page 107: Electrical

    INSP ELECTRICAL/SPARK PLUG INSPECTION EC370000 ELECTRICAL EC371001 SPARK PLUG INSPECTION 1. Remove: Spark plug ● 2. Inspect: Electrode 1 ● Wear/damage → Replace. Insulator color 2 ● Normal condition is a medium to light tan color. Distinctly different color → Check the engine condition.
  • Page 108 BATTERY INSPECTION AND CHARGING INSP (TT-R125E/TT-R125LWE) BATTERY INSPECTION AND CHARGING (TT-R125E/TT-R125LWE) WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: Wear protective eye gear when handling ●...
  • Page 109: Tt-r125e/tt-r125lwe

    BATTERY INSPECTION AND CHARGING INSP (TT-R125E/TT-R125LWE) NOTE: Since MF batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
  • Page 110 BATTERY INSPECTION AND CHARGING INSP (TT-R125E/TT-R125LWE) Å 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% Å...
  • Page 111 BATTERY INSPECTION AND CHARGING INSP (TT-R125E/TT-R125LWE) Before removing the battery charger lead ● clips from the battery terminals, be sure to turn off the battery charger. Make sure the battery charger lead clips ● are in full contact with the battery termi- nal and that they are not shorted.
  • Page 112 BATTERY INSPECTION AND CHARGING INSP (TT-R125E/TT-R125LWE) Charging method using a variable voltage charger 3 - 40...
  • Page 113 BATTERY INSPECTION AND CHARGING INSP (TT-R125E/TT-R125LWE) Charging method using a constant voltage charger 3 - 41...
  • Page 114 INSP FUSE INSPECTION (TT-R125E/TT-R125LWE) 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 ●...
  • Page 115 INSP FUSE INSPECTION (TT-R125E/TT-R125LWE) 3. Replace: Blown fuse ● Replacement steps: Set the main switch to “OFF”. ● Install a new fuse of the correct amperage. ● Set on the switches to verify if the electri- ● cal circuit is operational. If the fuse immediately blows again, check ●...
  • Page 116 INSP FUSE INSPECTION (TT-R125E/TT-R125LWE)
  • Page 117: Engine

    SEAT, FUEL TANK AND SIDE COVERS EC400000 ENGINE EC4R0000 SEAT, FUEL TANK AND SIDE COVERS 1 Seat removal 2 Fuel tank removal Extent of 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...
  • Page 118: Muffler

    MUFFLER MUFFLER 1 Muffler removal Extent of removal: Extent of removal Order Part name Q’ty Remarks MUFFLER REMOVAL Preparation for removal Right side cover Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Bolt (spark arrester) Spark arrester Nut (muffler) Bolt (muffler) Muffler 4 - 2...
  • Page 119: Carburetor

    CARBURETOR CARBURETOR 1 Carburetor removal Extent of removal: Extent of removal Order Part name Q’ty Remarks CARBURETOR REMOVAL Preparation for removal Fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Number plate Fuel hose Over flow hose Air vent hose Starter plunger/starter knob Carburetor top cover Clamp (air cleaner joint)
  • Page 120 CARBURETOR EC468000 CARBURETOR DISASSEMBLY 1 Carburetor disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks CARBURETOR DISASSEMBLY Throttle cable Throttle valve Refer to “REMOVAL POINTS”. Jet needle set Carburetor top cover Starter plunger Float chamber Float pivot pin Float Needle valve Main jet washer...
  • Page 121 CARBURETOR HANDLING NOTE At high altitudes, the atmospheric pressure is lower. This can make the fuel mixture too rich, leading to such problems as fouled. Spark plugs and slow response at high engine speeds. A special part, High Altitude Main Jet 1 #102.5 (620-1423A-71-A0) is available to correct this.
  • Page 122 CARBURETOR EC464000 INSPECTION Carburetor 1. Inspect: Carburetor body ● Contamination → Clean. NOTE: 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 ●...
  • Page 123 CARBURETOR EC464301 Throttle valve 1. Check: Free movement ● Stick → Repair or replace. NOTE: Insert the throttle valve 1 into the carburetor body, and check for free movement. EC464401 Jet needle 1. Inspect: Jet needle 1 ● Bends/wear → Replace. Clip groove ●...
  • Page 124 CARBURETOR EC464600 Float 1. Inspect: Float 1 ● Damage → Replace. Coasting enricher 1. Inspect: Diaphragm 1 ● Spring 2 ● Cover 3 ● Tears (diaphragm)/damage → Replace. ASSEMBLY AND INSTALLATION Carburetor 1. Install: Diaphragm 1 ● Spring 2 ● Cover 3 ●...
  • Page 125 CARBURETOR 4. Install: Pilot jet 1 ● Main jet nozzle 2 ● Main jet 3 ● Needle valve seat 4 ● Needle valve seat holder 5 ● Main jet washer 6 ● 5. Install: Needle valve 1 ● Float 2 ●...
  • Page 126 CARBURETOR 9. Install: Carburetor top cover 1 ● Spring (throttle valve) 2 ● Throttle valve 3 ● On throttle cable 4. NOTE: While compressing the spring, connect the throttle cable. Carburetor installation 1. Install: Carburetor assembly 1 ● NOTE: Install the projection between the carburetor joint slots.
  • Page 127 CARBURETOR 3. Install: Carburetor top cover 1 ● Starter plunger 2 ● Air vent hose 3 ● Over flow hose 4 ● Fuel hose 5 ● NOTE: Align the slit a of the throttle valve with the tab b of the carburetor body. CAUTION: In order to release the starter cable from the twist, install the starter knob after tight-...
  • Page 128: Cylinder Head

    CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD SIDE COVER AND TAPPET COVER 1 Cylinder head side cover and tappet cover removal Extent of removal: Extent of removal Order Part name Q’ty Remarks CYLINDER HEAD SIDE COVER AND TAPPET COVER REMOVAL Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS”...
  • Page 129 CYLINDER HEAD CYLINDER HEAD 1 Cylinder head removal Extent of removal: Extent of removal Order Part name Q’ty Remarks CYLINDER HEAD REMOVAL Bolt (camshaft sprocket) Bolt (timing chain tensioner cap) Timing chain tensioner Refer to “REMOVAL POINTS”. Gasket Camshaft sprocket Cylinder head Dowel pin Gasket...
  • Page 130 CYLINDER HEAD REMOVAL POINTS Cylinder head 1. Align: “I” mark ● (with stationary pointer) Checking steps: Turn the crankshaft counterclockwise with ● a wrench. Align the “I” mark a on the rotor with the ● stationary pointer b on the crankcase cover.
  • Page 131 CYLINDER HEAD 4. Remove: Bolt (camshaft sprocket) 1 ● Camshaft sprocket 2 ● NOTE: Attach a wire a to the timing chain to prevent it from falling into the crankcase. 5. Remove: Bolts (cylinder head) ● Cylinder head ● NOTE: Loosen the bolts 1/4 turn each and remove ●...
  • Page 132 Apply the engine oil on the contact surfaces of ● the bolts (cylinder head) and copper washers. Follow the numerical order shown in the illus- ● tration. Tighten the bolts in two stages. ® Quick gasket ACC-QUICK-GS-KT YAMAHA Bond No.1215: 90890-85505 4 - 16...
  • Page 133 CYLINDER HEAD 3. Install: Timing chain ● Camshaft sprocket ● Installation steps: Turn the crankshaft counterclockwise with ● a wrench. Align the “I” mark a on the rotor with the ● stationary pointer b on the crankcase cover. Align the match mark c on the camshaft ●...
  • Page 134 CYLINDER HEAD 5. Install: Timing chain tensioner ● Installation steps: While pressing the tensioner rod lightly ● with fingers, use a thin screwdriver and wind the tensioner rod up fully clockwise. With the rod fully wound, install the gasket ● 1 and the chain tensioner 2, and tighten the bolts 3 to the specified torque.
  • Page 135 CYLINDER HEAD 9. Check: Valve clearance ● Out of specification → Adjust. Refer “VALVE CLEARANCE INSPECTION ADJUSTMENT” section in the CHAPTER 3. 10. Apply: Engine oil ● On camshaft. 11. Install: Tappet cover 1 ● 18 Nm (1.8 m · kg, 13 ft · lb) Cylinder head side cover 2 ●...
  • Page 136: Camshaft And Rocker Arms

    CAMSHAFT AND ROCKER ARMS CAMSHAFT AND ROCKER ARMS 1 Camshaft removal 2 Rocker arm removal Extent of removal: Extent of removal Order Part name Q’ty Remarks CAMSHAFT AND ROCKER ARMS REMOVAL Preparation for removal Cylinder head Refer to “CYLINDER HEAD” section. Camshaft bearing holder Intake rocker arm shaft Exhaust rocker arm shaft...
  • Page 137 CAMSHAFT AND ROCKER ARMS REMOVAL POINTS Rocker arm shaft 1. Remove: Rocker arm shafts ● NOTE: 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...
  • Page 138 CAMSHAFT AND ROCKER ARMS Rocker arms and rocker arm shafts 1. Inspect: Cam lobe contact surface a ● Adjuster surface 1 ● Wear/pitting/scratches/blue discolora- tion → Replace. Measurement steps: Measure the inside diameter a of the ● rocker arm holes. Out of specification →...
  • Page 139 CAMSHAFT AND ROCKER ARMS 5. Install: Camshaft bearing holder 1 ● Bolt 2 ● 10 Nm (1.0 m · kg, 7.2 ft · lb) 4 - 23...
  • Page 140: Valves And Valve Springs

    VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS 1 Valves and valve springs removal Extent of removal: Extent of removal Order Part name Q’ty Remarks VALVES AND VALVE SPRINGS REMOVAL Preparation for removal Cylinder head Refer to “CYLINDER HEAD” section. Camshaft and rocker arms Refer to “CAMSHAFT AND ROCKER ARMS”...
  • Page 141 VALVES AND VALVE SPRINGS REMOVAL POINTS Valve 1. Check: Valve sealing ● Leakage at the valve seat → Inspect the valve face, valve seat and valve seat width. Checking steps: Pour a clean solvent 1 into the intake and ● exhaust ports.
  • Page 142 VALVES AND VALVE SPRINGS 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:...
  • Page 143 VALVES AND VALVE SPRINGS 3. Inspect: Valve face ● Pitting/wear → Grind the face. Valve stem end ● Mushroom shape or diameter larger than the body of the stem → Replace. 4. Measure: Margin thickness a ● Out of specification → Replace. Margin thickness: Intake: 0.4 ~ 0.8 mm...
  • Page 144 VALVES AND VALVE SPRINGS 8. Measure: Valve seat width a ● Out of specification → Reface the valve seat. Valve seat width: Intake: 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) <Limit>: 1.6 mm (0.0630 in) Exhaust: 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) <Limit>: 1.6 mm (0.0630 in) Measurement steps: Apply Mechanic’s blueing dye (Dykem) b...
  • Page 145 VALVES AND VALVE SPRINGS Install the valve into the cylinder head. ● Turn the valve until the valve face and ● valve seat are evenly polished, then clean off all of the compound. NOTE: For best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands.
  • Page 146 VALVES AND VALVE SPRINGS 2. Measure: Compressed spring force a ● Out of specification → Replace. b Installed length Compressed spring force: Intake: 14.0 ~ 16.1 kg at 25.6 mm (30.86 ~ 35.49 lb at 1.01 in) Exhaust: 14.0 ~ 16.1 kg at 25.6 mm (30.86 ~ 35.49 lb at 1.01 in) 3.
  • Page 147 VALVES AND VALVE SPRINGS 3. Install: Valve cotters 1 ● NOTE: While compressing the valve spring with a valve spring compressor 2, install the valve cotters. Valve spring compressor: YM-4019/90890-04019 4. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood.
  • Page 148: Cylinder And Piston

    CYLINDER AND PISTON CYLINDER AND PISTON 1 Cylinder removal 2 Piston removal Extent of removal: Extent of removal Order Part name Q’ty Remarks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to “CYLINDER HEAD” section. Exhaust timing chain guide Cylinder/O-ring Dowel pin Gasket...
  • Page 149 CYLINDER AND PISTON REMOVAL POINTS Piston 1. Remove: Piston pin clips 1 ● Piston pin 2 ● Piston 3 ● NOTE: Before removing the piston pin clip, cover the ● crankcase opening with a clean towel or rag to prevent the clip from falling into the crank- case cavity.
  • Page 150 CYLINDER AND PISTON 2. Measure: Piston-to-cylinder clearance ● Piston-to-cylinder clearance measure- ment steps: 1st step: Measure the cylinder bore “C” with the cyl- ● inder bore gauge. NOTE: Measure the cylinder bore “C” in parallel to and at right angles to the crankshaft. Then, find the average of the measurements.
  • Page 151 CYLINDER AND PISTON If out of specification, replace the cylinder, ● and replace the piston and piston rings as a set. Piston pin 1. Inspect: Piston pin ● Blue discoloration/grooves → Replace, then inspect the lubrication system. 2. Measure: Piston pin-to-piston clearance ●...
  • Page 152 CYLINDER AND PISTON Piston ring 1. Measure: Ring side clearance ● Use a feeler gauge. Out of specification → Replace the pis- ton and rings as a set. NOTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance. Side clearance: Standard <Limit>...
  • Page 153 CYLINDER AND PISTON Combination of piston and cylinder 1. Check: Cylinder mark a ● Cylinder mark a Cylinder size 54.000 ~ 54.003 mm (2.1260 ~ 2.1261 in) 54.004 ~ 54.007 mm (2.1261 ~ 2.1263 in) 54.008 ~ 54.011 mm (2.1263 ~ 2.1264 in) 54.012 ~ 54.015 mm (2.1265 ~ 2.1266 in) 54.016 ~ 54.019 mm...
  • Page 154 CYLINDER AND PISTON ASSEMBLY AND INSTALLATION Piston ring and piston 1. Install: Piston rings ● (onto the piston) NOTE: Be sure to install the 2nd piston ring so that ● the manufacturer’s mark or number are located on the upper side of the ring. Lubricate the piston and piston rings liberally ●...
  • Page 155 CYLINDER AND PISTON Cylinder 1. Install: Dowel pins 1 ● Gasket (cylinder) 2 ● 2. Install: O-ring ● Cylinder 1 ● Exhaust timing chain guide ● CAUTION: Install the cylinder with one hand while ● compressing the piston rings with the other hand.
  • Page 156: Clutch And Primary Driven Gear

    CLUTCH AND PRIMARY DRIVEN GEAR EC490000 CLUTCH AND PRIMARY DRIVEN GEAR EC498000 CLUTCH PLATE AND FRICTION PLATE 1 Clutch plate and friction plate removal Extent of removal: Extent of removal Order Part name Q’ty Remarks CLUCTH PLATE AND FRIC- TION PLATE REMOVAL Preparation for removal Drain the engine oil.
  • Page 157 CLUTCH AND PRIMARY DRIVEN GEAR EC498100 PRIMARY DRIVEN GEAR 1 Primary driven gear removal 2 Primary drive gear removal Extent of removal: Extent of removal Order Part name Q’ty Remarks PRIMARY DRIVEN GEAR REMOVAL Nut (clutch boss) Use special tool. Lock washer Refer to “REMOVAL POINTS”.
  • Page 158 CLUTCH AND PRIMARY DRIVEN GEAR PUSH LEVER 1 Push lever removal Extent of removal: Extent of removal Order Part name Q’ty Remarks PUSH LEVER REMOVAL Clutch cable Push lever Spring Circlip Oil seal 4 - 42...
  • Page 159 CLUTCH AND PRIMARY DRIVEN GEAR EC493000 REMOVAL POINTS Clutch boss 1. Remove: Nut 1 ● Lock washer ● Clutch boss 2 ● NOTE: Straighten the lock washer tab and use the clutch holding tool 3 to hold the clutch boss. Å...
  • Page 160 CLUTCH AND PRIMARY DRIVEN GEAR EC484400 Clutch spring 1. Measure: Clutch spring 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) EC484500 Friction plate 1.
  • Page 161 CLUTCH 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. EC495000 ASSEMBLY AND INSTALLATION Push lever 1. Install: Push lever 1 ●...
  • Page 162 CLUTCH AND PRIMARY DRIVEN GEAR Clutch 1. Install: Conical spring washer 1 ● Thrust plate 2 ● Primary driven gear 3 ● Thrust plate 4 ● Clutch boss 5 ● 2. Install: Lock washer ● Nut (clutch boss) 1 ● 60 Nm (6.0 m ·...
  • Page 163 CLUTCH AND PRIMARY DRIVEN GEAR 5. Install: Ball ● NOTE: Apply the engine oil on the ball. 6. Install: Push rod 1 1 ● Push plate 2 ● Washer 3 ● Nut (push rod 1) 4 ● 7. Install: Pressure plate 1 ●...
  • Page 164 Tighten the bolts in stages, using a criss- ● cross pattern. ® Quick gasket ACC-QUICK-GS-KT YAMAHA Bond No.1215: 90890-85505 11. Install: Kickstarter crank 1 ● Nut (kickstarter crank) 2 ● 50 Nm (5.0 m · kg, 36 ft · lb)
  • Page 165: Oil Pump

    OIL PUMP OIL PUMP 1 Oil pump removal Extent of removal: Extent of removal Order Part name Q’ty Remarks OIL PUMP REMOVAL Preparation for removal Clutch and primary drive gear Refer to “CLUTCH AND PRIMARY DRIVEN GEAR” section. Rotary filter Oil pump drive gear Oil pump assembly Gasket...
  • Page 166 OIL PUMP OIL PUMP DISASSEMBLY 1 Oil pump disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks OIL PUMP DISASSEMBLY Circlip Oil pump driven gear Conical spring washer Circlip Washer Oil pump cover Oil pump shaft Inner rotor Outer rotor Oil pump housing 4 - 50...
  • Page 167 OIL PUMP INSPECTION Oil pump 1. Inspect: Oil pump drive gear ● Oil pump driven gear ● Oil pump housing ● Oil pump cover ● Cracks/wear/damage → Replace. 2. Measure: Tip clearance Å ● (between the inner rotor 1 and the outer rotor 2) Side clearance ı...
  • Page 168 OIL PUMP Oil strainer 1. Inspect: Oil strainer ● Cracks/damage → Replace. Contamination → Clean the flushing oil. ASSEMBLY AND INSTALLATION Oil pump 1. Install: Oil pump housing 1 ● Outer rotor 2 ● Inner rotor 3 ● Pin 4 ●...
  • Page 169: Kick Axle And Shift Shaft

    KICK AXLE AND SHIFT SHAFT KICK AXLE AND SHIFT SHAFT KICK AXLE AND SHIFT SHAFT 1 Kick axle removal 2 Shift shaft removal Extent of removal: Extent of removal Order Part name Q’ty Remarks KICK AXLE AND SHIFT SHAFT REMOVAL Preparation for removal Shift pedal link Refer to “ENGINE REMOVAL”...
  • Page 170 KICK AXLE AND SHIFT SHAFT REMOVAL POINTS Kick axle 1. Remove: Kick axle assembly 1 ● NOTE: Unhook the torsion spring 2 from the hole in the crankcase. Segment 1. Remove: Screw (segment) ● Segment 1 ● NOTE: Loosen the screw using the T30 bit. INSPECTION Kick axle and kickstarter segment gear 1.
  • Page 171 KICK AXLE AND SHIFT SHAFT 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. EC4C5000 ASSEMBLY AND INSTALLATION Segment...
  • Page 172 KICK AXLE AND SHIFT SHAFT Shift shaft 1. Install: Shift shaft 1 ● NOTE: Apply the lithium soap base grease on the oil ● seal lip of the left crankcase side. Hook the spring ends onto the stopper 2. ● Kick axle assembly 1.
  • Page 173: Kick Axle And Shift Shaft

    KICK AXLE AND SHIFT SHAFT Kick idle gear 1. Install: Circlip 1 ● Washer 2 ● Kick idle gear 3 ● Washer 4 ● Circlip 5 ● NOTE: Apply the engine oil on the kick idle gear ● inner circumference. Install the kick idle gear with its depressed ●...
  • Page 174: Cdi Magneto (tt-r125/tt-r125lw)

    CDI MAGNETO (TT-R125/TT-R125LW) EC4L0000 CDI MAGNETO (TT-R125/TT-R125LW) 1 CDI magneto removal Extent of removal: Extent of removal Order Part name Q’ty Remarks CDI MAGNETO REMOVAL Preparation for removal Seat and fuel tank Refer to “SAET, FUEL TANK AND SIDE COVERS” section. Drain the engine oil Refer to “ENGINE OIL REPLACEMENT”...
  • Page 175 CDI MAGNETO (TT-R125/TT-R125LW) REMOVAL POINTS Rotor 1. Remove: Nut (rotor) 1 ● Plain washer 2 ● Use the sheave holder 3. Sheave holder: YS-1880-A/90890-01701 2. Remove: Rotor 1 ● Use the flywheel puller 2. Flywheel puller: YU-33270-B/90890-01362 EC4L4000 INSPECTION EC4L4101 CDI magneto 1.
  • Page 176 CDI MAGNETO (TT-R125/TT-R125LW) 2. Install: Woodruff key 1 ● Rotor 2 ● NOTE: Clean the tapered portions of the crankshaft ● and rotor. When installing the woodruff key, make sure ● that its flat surface a is in parallel with the crankshaft center line b.
  • Page 177: Cdi Magneto And Starter Clutch (tt-r125e/tt-r125lwe)

    CDI MAGNETO AND STARTER CLUTCH (TT-R125E/TT-R125LWE) CDI MAGNETO AND STARTER CLUTCH (TT-R125E/TT-R125LWE) 1 Pickup coil/stator removal 2 Starter clutch/wheel gear removal Extent of removal: Extent of removal Order Part name Q’ty Remarks CDI MAGNETO AND STATOR REMOVAL Preparation for removal Fuel tank CDI magneto lead Neutral switch lead...
  • Page 178 CDI MAGNETO AND STARTER CLUTCH (TT-R125E/TT-R125LWE) REMOVAL POINTS Rotor 1. Remove: Nut (rotor) 1 ● Plain washer 2 ● Use the sheave holder 3. Sheave holder: YS-1880-A/90890-01701 2. Remove: Rotor 1 ● Use the flywheel puller 2. Flywheel puller: YU-33270-B/90890-01362 EC4L4000 INSPECTION EC4L4101...
  • Page 179 CDI MAGNETO AND STARTER CLUTCH (TT-R125E/TT-R125LWE) 3. Check: Å Starter clutch operation ● Install the starter clutch drive gear 1 onto ● the starter clutch 2 and hold the starter ı clutch. When turning the starter clutch drive gear ● counterclockwise ı, the starter clutch and the starter clutch drive gear should engage.
  • Page 180 CDI MAGNETO AND STARTER CLUTCH (TT-R125E/TT-R125LWE) 3. Install the starter clutch 1 on the rotor 2. NOTE: 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.
  • Page 181 CDI MAGNETO AND STARTER CLUTCH (TT-R125E/TT-R125LWE) 7. Install: Crankcase cover (left) ● 8. Connect: Neutral switch lead 1 ● NOTE: Pass the neutral switch lead into the crank- case cover groove as shown. 9. Connect: CDI magneto lead ● Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2.
  • Page 182: Engine Removal

    ENGINE REMOVAL ENGINE REMOVAL 1 Engine removal Extent of removal: Extent of removal Order Part name Q’ty Remarks ENGINE REMOVAL Preparation for removal Hold the machine by placing the suitable stand under the frame. Seat, fuel tank and side covers Refer to “SEAT, FUEL TANK AND SIDE COVERS”...
  • Page 183 ENGINE REMOVAL Extent of removal Order Part name Q’ty Remarks Drive sprocket cover Bolt (drive sprocket) Drive sprocket holder Refer to “REMOVAL POINTS”. Drive sprocket Shift pedal link Crankcase breather hose Engine bracket (upper) Engine skidplate Engine bracket (front) Engine mounting bolt (rear) Engine Refer to “REMOVAL POINTS”.
  • Page 184 ENGINE REMOVAL REMOVAL POINTS Drive sprocket 1. Remove: Bolt (drive sprocket) ● Drive sprocket holder 1 ● Drive sprocket 2 ● Drive chain 3 ● NOTE: Remove the drive sprocket together with the drive chain. Engine removal 1. Remove: Engine 1 ●...
  • Page 185 ENGINE REMOVAL NOTE: Apply the lithium soap base grease on the ● thread of the engine mounting bolts (rear) 2. Tighten the engine mounting bolt (upper) 8, ● and then tighten the bolts (engine bracket) Shift pedal link 1. Install: Shift pedal link 1 ●...
  • Page 186: Crankcase, Crankshaft And Balancer

    CRANKCASE, CRANKSHAFT AND BALANCER CRANKCASE, CRANKSHAFT AND BALANCER 1 Crankcase separation 2 Balancer removal Extent of removal: 3 Crankshaft removal Extent of removal Order Part name Q’ty Remarks CRANKCASE, CRANKSHAFT AND BALANCER REMOVAL Preparation for removal Engine Refer to “ENGINE REMOVAL” section. Piston Refer to “CYLINDER AND PISTON”...
  • Page 187 CRANKCASE, CRANKSHAFT AND BALANCER Extent of removal Order Part name Q’ty Remarks Intake timing chain guide Timing chain Bolt [45 mm (1.8 in)] Bolt [55 mm (2.2 in)] Bolt [30 mm (1.2 in)] Lead guide Clutch cable holder Right crankcase Use special tool.
  • Page 188 CRANKCASE, CRANKSHAFT AND BALANCER REMOVAL POINTS Crankcase 1. Remove: Bolt (crankcase) ● Lead guide 1 ● Clutch cable holder 2 ● NOTE: Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them. 2.
  • Page 189 CRANKCASE, CRANKSHAFT AND BALANCER Crankshaft 1. Remove: Crankshaft 1 ● Use the crankcase separating tool 2. Crankcase separating tool: YU-1135-A/90890-01135 CAUTION: Do not use a hammer to drive out the crankshaft. Bearing 1. Remove: Bearing 1 ● NOTE: Remove the bearing from the crankcase by ●...
  • Page 190 CRANKCASE, CRANKSHAFT AND BALANCER Crankcase 1. Inspect: Contacting surface a ● Scratches → Replace. Engine mounting boss b, crankcase ● Cracks/damage → Replace. 2. Inspect: Bearing ● Rotate inner race with a finger. Rough spot/seizure → Replace. Crankshaft 1. Measure: Runout limit a ●...
  • Page 191 CRANKCASE, CRANKSHAFT AND BALANCER Balancer 1. Inspect: Balancer ● Cracks/damage → Replace. ASSEMBLY AND INSTALLATION Bearing 1. Install: Bearing 1 ● On crankcase (left and right). NOTE: Install the bearing by pressing its outer race parallel. Crankshaft 1. Install: Crankshaft 1 ●...
  • Page 192 Crankcase 1. Apply: Sealant ● On the right crankcase 1. ® Quick gasket ACC-QUICK-GS-KT YAMAHA Bond No.1215: 90890-85505 NOTE: Clean the contacting surface of crankcase (left and right) before applying the sealant. 2. Install: Dowel pin 1 ● Right crankcase ●...
  • Page 193 [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 4. Check: Crankshaft and transmission operation ● Unsmooth operation → Repair. 5. Install: Timing chain 1 ●...
  • Page 194: Transmission, Shift Cam And Shift Fork

    TRANSMISSION, SHIFT CAM AND SHIFT FORK TRANSMISSION, SHIFT CAM AND SHIFT FORK 1 Shift cam and shift fork removal 2 Main axle and drive axle removal Extent of removal: Extent of removal Order Part name Q’ty Remarks TRANSMISSION, SHIFTCAM AND SHIFT FORK REMOVAL Preparation for removal Engine Refer to “ENGINE REMOVAL”...
  • Page 195 TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVAL POINTS Transmission 1. Remove: Main axle 1 ● Drive axle 2 ● NOTE: Tap lightly on the transmission drive axle ● with a soft hammer to remove. Remove assembly carefully. Note the posi- ●...
  • Page 196 TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H4600 Bearing 1. Inspect: Bearing 1 ● Rotate inner race with a finger. Rough spot/seizure → Replace. Shift fork and shift cam 1. Inspect: Shift fork 1 ● Wear/damage/scratches → Replace. 2. Inspect: Shift cam 1 ●...
  • Page 197 TRANSMISSION, SHIFT CAM AND SHIFT FORK Transmission 1. Install: 4th pinion gear (22T) 1 ● 3rd pinion gear (19T) 2 ● 2nd pinion gear (18T) 3 ● 5th pinion gear (24T) 4 ● On main axle 5. NOTE: Apply the molybdenum disulfide oil on the ●...
  • Page 198 TRANSMISSION, SHIFT CAM AND SHIFT FORK 3. Install: Plain washer 1 ● Circlip 2 ● NOTE: 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 ●...
  • Page 199 TRANSMISSION, SHIFT CAM AND SHIFT FORK Shift cam and shift fork 1. Install: Shift fork 1 (L) 1 ● Shift fork 2 (C) 2 ● Shift fork 3 (R) 3 ● NOTE: Mesh the shift fork #1 (L) with the 2nd wheel ●...
  • Page 200 CHAS FRONT WHEEL AND FRONT BRAKE (TT-R125/TT-R125E) EC500000 CHASSIS FRONT WHEEL AND FRONT BRAKE (TT-R125/TT-R125E) 1 Front wheel removal 2 Wheel bearing removal Extent of removal: 3 Brake shoe plate assembly removal and disassembly Extent of removal Order Part name Q’ty Remarks FRONT WHEEL AND DRUM...
  • Page 201: Front Wheel And Front Brake

    CHAS FRONT WHEEL AND FRONT BRAKE (TT-R125/TT-R125E) Extent of removal Order Part name Q’ty Remarks Brake shoe Spring Brake camshaft lever Wear indicator plate Brake camshaft Brake shoe plate 5 - 2...
  • Page 202 CHAS FRONT WHEEL AND FRONT BRAKE (TT-R125/TT-R125E) REMOVAL POINTS EC513201 Wheel bearing (if necessary) 1. Remove: Bearing 1 ● NOTE: Remove the bearing using a general bearing puller 2. INSPECTION EC514100 Wheel 1. Measure: Wheel runout ● Out of limit → Repair/replace. Wheel runout limit: Radial 1: 2.0 mm (0.08 in) Lateral 2: 2.0 mm (0.08 in)
  • Page 203 CHAS FRONT WHEEL AND FRONT BRAKE (TT-R125/TT-R125E) Drum brake 1. Inspect: Brake shoe lining surface ● Glazed areas → Polish. Use coarse sand paper. NOTE: After polishing, wipe the polished particles with a cloth. 2. Measure: Brake shoe lining thickness a ●...
  • Page 204 CHAS FRONT WHEEL AND FRONT BRAKE (TT-R125/TT-R125E) ASSEMBLY AND INSTALLATION Brake shoe plate assembly 1. Install: Brake camshaft 1 ● NOTE: Apply the lithium soap base grease on the brake camshaft. 2. Check: Brake camshaft operation ● Unsmooth operation → Repair. 3.
  • Page 205 CHAS FRONT WHEEL AND FRONT BRAKE (TT-R125/TT-R125E) Front wheel 1. Install: Wheel bearing 1 ● Spacer 2 ● Wheel bearing 3 ● Oil seal 4 ● NOTE: Apply the lithium soap base grease on the ● wheel bearing and oil seal lip when installing. Install the wheel bearing so that the enclosed ●...
  • Page 206 CHAS FRONT WHEEL AND FRONT BRAKE (TT-R125/TT-R125E) 5. Install: Axle nut 1 ● 45 Nm (4.5 m · kg, 32 ft · lb) 6. Install: Brake cable ● NOTE: Brake camshaft lever side of brake cable shall be installed first. 7.
  • Page 207: Front Wheel (tt-r125lw/tt-r125lwe)

    CHAS FRONT WHEEL (TT-R125LW/TT-R125LWE) FRONT WHEEL (TT-R125LW/TT-R125LWE) 1 Front wheel removal 2 Wheel bearing removal Extent of removal: 3 Brake disc removal Extent of removal Order Part name Q’ty Remarks FRONT WHEEL REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine.
  • Page 208 CHAS FRONT WHEEL (TT-R125LW/TT-R125LWE) REMOVAL POINTS EC513201 Wheel bearing (if necessary) 1. Remove: Bearing 1 ● NOTE: Remove the bearing using a general bearing puller 2. INSPECTION EC514100 Wheel 1. Measure: Wheel runout ● Out of limit → Repair/replace. Wheel runout limit: Radial 1: 2.0 mm (0.08 in) Lateral 2: 2.0 mm (0.08 in) 2.
  • Page 209 CHAS FRONT WHEEL (TT-R125LW/TT-R125LWE) Brake disc 1. Measure: Brake disc deflection ● Use the dial gauge 1. Out of specification → Inspect wheel runout. If wheel runout is in good condition, replace the brake disc. Disc deflection limit: 0.15 mm (0.006 in) 2.
  • Page 210 CHAS FRONT WHEEL (TT-R125LW/TT-R125LWE) 2. Install: Brake disc 1 ● Bolt (brake disc) 2 ● 12 Nm (1.2 m · kg, 8.7 ft · lb) NOTE: Tighten the bolts in stage, using a crisscross pattern. 3. Install: Collar 1 ● NOTE: Apply the lithium soap base grease on the oil ●...
  • Page 211: Front Brake (tt-r125lw/tt-r125lwe)

    CHAS FRONT BRAKE (TT-R125LW/TT-R125LWE) FRONT BRAKE (TT-R125LW/TT-R125LWE) 1 Brake hose removal 2 Brake caliper removal Extent of removal: 3 Brake master cylinder removal Extent of removal Order Part name Q’ty Remarks FRONT BRAKE REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine.
  • Page 212 CHAS FRONT BRAKE (TT-R125LW/TT-R125LWE) BRAKE CALIPER AND BRAKE MASTER CYLINDER DISASSEMBLY 1 Brake caliper disassembly 2 Brake master cylinder disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks BRAKE CALIPER AND BRAKE MASTER CYLINDER DISAS- WARNING SEMBLY Support the machine securely so there is no Preparation for removal Hold the machine by placing the...
  • Page 213 CHAS FRONT BRAKE (TT-R125LW/TT-R125LWE) REMOVAL POINTS Brake fluid 1. Remove: Brake master cylinder cap 1 ● NOTE: Do not remove the diaphragm. 2. Connect the transparent hose 2 to the bleed screw 1 and place a suitable con- tainer under its end. 3.
  • Page 214 CHAS FRONT BRAKE (TT-R125LW/TT-R125LWE) Brake caliper piston seal kit 1. Remove: Brake caliper dust seal 1 ● Brake caliper piston seal 2 ● NOTE: Remove the brake caliper piston seals and brake caliper dust seals by pushing them with a finger. CAUTION: Never attempt to pry out brake caliper pis- ton seals and brake caliper dust seals.
  • Page 215 CHAS FRONT BRAKE (TT-R125LW/TT-R125LWE) Brake caliper 1. Inspect: Brake caliper cylinder inner surface a ● Wear/score marks → Replace brake caliper assembly. 2. Inspect: Brake caliper piston 1 ● Wear/score marks → Replace brake caliper piston assembly. WARNING Replace the brake caliper piston seals and brake caliper dust seals 2 whenever a brake caliper is disassembled.
  • Page 216 CHAS FRONT BRAKE (TT-R125LW/TT-R125LWE) ASSEMBLY AND INSTALLATION WARNING All internal parts should be cleaned in ● new brake fluid only. Internal parts should be lubricated with ● brake fluid when installed. Replace the brake caliper piston seals ● and brake caliper dust seals whenever a brake caliper is disassembled.
  • Page 217 CHAS FRONT BRAKE (TT-R125LW/TT-R125LWE) 2. Install: Pin boot 1 ● On brake caliper 2. NOTE: Apply the lithium soap base grease on the pin boot inner surface. 3. Install: Brake caliper bracket 1 ● Bolt (brake caliper bracket) 2 ● 30 Nm (3.0 m ·...
  • Page 218 CHAS FRONT BRAKE (TT-R125LW/TT-R125LWE) 2. Install: Brake master cylinder cup (primary) 1 ● Brake master cylinder cup (secondary) 2 ● On brake master cylinder piston 3. NOTE: Apply the brake fluid on the brake master cyl- inder cup. WARNING After installing, cylinder cup should be installed as shown direction.
  • Page 219 CHAS FRONT BRAKE (TT-R125LW/TT-R125LWE) Å Brake master cylinder 1. Install: Brake master cylinder 1 ● Brake master cylinder bracket 2 ● Bolt (brake master cylinder bracket) 3 ● 9 Nm (0.9 m · kg, 6.5 ft · lb) NOTE: Install the brake master cylinder bracket so ●...
  • Page 220 CHAS FRONT BRAKE (TT-R125LW/TT-R125LWE) 2. Pass the brake hose through the cable guide 1. 3. Install: Copper washer 1 ● Joint 2 26 Nm (2.6 m · kg, 19 ft · lb) ● Brake hose 3 ● 14 Nm (1.4 m · kg, 10 ft · lb) WARNING Always use a new copper washer.
  • Page 221 CHAS FRONT BRAKE (TT-R125LW/TT-R125LWE) Brake fluid 1. Fill: Brake fluid ● Until the fluid level reaches “LOWER” level line a. Recommended brake fluid: DOT #4 WARNING Use only the designated quality brake ● fluid: otherwise, the rubber seals may deterio- rate, causing leakage and poor brake per- formance.
  • Page 222 CHAS FRONT BRAKE (TT-R125LW/TT-R125LWE) 4. Install: Diaphragm ● Brake master cylinder cap 1 ● Screw (brake master cylinder cap) 2 ● 2 Nm (0.2 m · kg, 1.4 ft · lb) CAUTION: After installation, while pulling in the lever, check whether there is any brake fluid leak- ing where the union bolts are installed respectively at the brake master cylinder and brake caliper.
  • Page 223 CHAS REAR WHEEL AND REAR BRAKE REAR WHEEL AND REAR BRAKE 1 Rear wheel removal 2 Wheel bearing removal Extent of removal: 3 Brake shoe plate assembly removal and disassembly Extent of removal Order Part name Q’ty Remarks REAR WHEEL AND DRUM WARNING BRAKE Support the machine securely so there is no...
  • Page 224 CHAS REAR WHEEL AND REAR BRAKE Extent of removal Order Part name Q’ty Remarks Nut (wheel sprocket) Wheel sprocket Oil seal Wheel bearing Refer to “REMOVAL POINTS”. Spacer Brake shoe Spring Brake camshaft lever Wear indicator plate Brake camshaft Brake shoe plate 5 - 25...
  • Page 225: Rear Wheel And Rear Brake

    CHAS REAR WHEEL AND REAR BRAKE REMOVAL POINTS EC523101 Rear wheel 1. Remove: Wheel 1 ● NOTE: Push the wheel forward and remove the drive chain 2. EC513201 Wheel bearing (if necessary) 1. Remove: Bearing 1 ● NOTE: Remove the bearing using a general bearing puller 2.
  • Page 226 CHAS REAR WHEEL AND REAR BRAKE NOTE: The bending value is shown by one half of the dial gauge reading. WARNING Do not attempt to straighten a bent axle. Drum brake 1. Inspect: Brake shoe lining surface ● Glazed areas → Polish. Use coarse sand paper.
  • Page 227 CHAS REAR WHEEL AND REAR BRAKE 4. Inspect: Brake drum inner surface. ● Oil/scratches → Remove. Use a rag soaked in lac- quer thinner or a solvent. Use a emery cloth (lightly Scratches and evenly polishing). ASSEMBLY AND INSTALLATION Brake shoe plate assembly 1.
  • Page 228 CHAS REAR WHEEL AND REAR BRAKE 5. Install: Springs 1 ● Brake shoes 2 ● On brake shoe plate 3 NOTE: Apply the lithium soap base grease on the ● pivot pin. When installing the springs and brake shoes, ● take care not to damage the springs.
  • Page 229 CHAS REAR WHEEL AND REAR BRAKE 2. Install: Wheel sprocket 1 ● Lock washers 2 ● Nut (wheel sprocket) 3 ● 43 Nm (4.3 m · kg, 31 ft · lb) NOTE: Tighten the nuts in stage, using a crisscross ●...
  • Page 230 CHAS REAR WHEEL AND REAR BRAKE 7. Install: Drive chain puller (right) 1 ● Plain washer 2 ● Axle nut 3 ● NOTE: Temporarily tighten the axle nut at this point. 8. Adjust: Drive chain slack a ● Drive chain slack: 35 ~ 50 mm (1.4 ~ 2.0 in) Refer “DRIVE...
  • Page 231 CHAS FRONT FORK EC550000 FRONT FORK Å TT-R125/TT-R125E/TT-R125LW ı TT-R125LWE 1 Front fork removal Extent of removal: Extent of removal Order Part name Q’ty Remarks FRONT FORK REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine.
  • Page 232 CHAS FRONT FORK EC558000 FRONT FORK DISASSEMBLY Å TT-R125/TT-R125E/TT-R125LW ı TT-R125LWE 1 Oil seal removal 2 Damper rod removal Extent of removal: Extent of removal Order Part name Q’ty Remarks FRONT FORK DISASSEMBLY Dust boot Cap bolt Refer to “REMOVAL POINTS”. Spacer –...
  • Page 233 CHAS FRONT FORK HANDLING NOTE NOTE: The front fork requires careful attention. So it is recommended that the front fork be main- tained at the dealers. CAUTION: To prevent an accidental explosion of air, following instructions should observed: The front fork with a built-in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material.
  • Page 234 CHAS FRONT FORK Damper rod holder: YM-1300/90890-01294 T-handle: YM-1326/90890-01326 3. Remove: Oil seal 1 ● Using slotted-hand screwdriver. CAUTION: Take care not to scratch the outer tube. EC554000 INSPECTION Damper rod 1. Inspect: Damper rod ● Bend/damage → Replace damper rod. CAUTION: The front fork with a built-in piston rod has a very sophisticated internal construction...
  • Page 235 CHAS FRONT FORK EC554400 Fork spring 1. Measure: Fork spring free length a ● Out of specification → Replace. Fork spring free length: Standard <Limit> TT-R125/TT-R125E: TT-R125/TT-R125E: 327 mm (12.9 in) 322 mm (12.7 in) TT-R125LW: TT-R125LW: 339 mm (13.3 in) 334 mm (13.1 in) TT-R125LWE: TT-R125LWE:...
  • Page 236: Front Fork

    CHAS FRONT FORK 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. EC555000 ASSEMBLY AND INSTALLATION Front fork assembly 1.
  • Page 237 CHAS FRONT FORK 4. Install: Copper washer ● Bolt (damper rod) ● 23 Nm (2.3 m · kg, 17 ft · lb) NOTE: Use the damper rod holder 1 and the T-han- dle 2 to lock the damper rod. Damper rod holder: YM-1300/90890-01294 T-handle: YM-01326/90890-01326...
  • Page 238 CHAS FRONT FORK 7. Install: Dust seal 1 ● NOTE: Apply the lithium soap base grease on the inner tube. 8. Check: Inner tube smooth movement ● Tightness/binding/rough spots → Repeat the steps 2 to 7. 9. Compress the front fork fully. 10.
  • Page 239 CHAS FRONT FORK 12. Measure: Oil level a ● Out of specification → Adjust. Standard oil level: TT-R125/TT-R125E: 122 mm (4.80 in) TT-R125LW: 130 mm (5.12 in) TT-R125LWE: 125 mm (4.92 in) From the top of the inner tube, with the inner tube fully com- pressed, and without the fork spring.
  • Page 240 CHAS FRONT FORK 4. Tighten: Pinch bolt (lower bracket) 1 ● 60 Nm (6.0 m · kg, 43 ft · lb) Pinch bolt (upper bracket) 2 ● 25 Nm (2.5 m · kg, 18 ft · lb) Screw (dust boot) 3 ●...
  • Page 241: Handlebar

    CHAS HANDLEBAR EC5B0000 HANDLEBAR TT-R125 1 Handlebar removal Extent of removal: Extent of removal Order Part name Q’ty Remarks HANDLEBAR REMOVAL Preparation for removal Number plate Clutch cable Clutch lever Engine stop switch Front brake cable Front brake lever Grip cap (lower) Grip cap (upper) Throttle cable Throttle grip assembly...
  • Page 242 CHAS HANDLEBAR TT-R125E 1 Handlebar removal Extent of removal: Extent of removal Order Part name Q’ty Remarks HANDLEBAR REMOVAL Preparation for removal Number plate Clutch cable Clutch lever Engine stop switch Front brake cable Start switch Front brake lever Grip cap (lower) Grip cap (upper) Throttle cable Throttle grip assembly...
  • Page 243 CHAS HANDLEBAR TT-R125LW 1 Handlebar removal Extent of removal: Extent of removal Order Part name Q’ty Remarks HANDLEBAR REMOVAL Preparation for removal Number plate Clutch cable Clutch lever Engine stop switch Brake master cylinder Refer to “REMOVAL POINTS”. Grip cap (lower) Grip cap (upper) Throttle cable Throttle grip assembly...
  • Page 244 CHAS HANDLEBAR TT-R125LWE 1 Handlebar removal Extent of removal: Extent of removal Order Part name Q’ty Remarks HANDLEBAR REMOVAL Preparation for removal Number plate Clutch cable Clutch lever Engine stop switch Brake master cylinder Refer to “REMOVAL POINTS”. Start switch Grip cap (lower) Grip cap (upper) Throttle cable...
  • Page 245 CHAS HANDLEBAR THROTTLE GRIP ASSEMBLY DISASSEMBLY 1 Throttle grip assembly disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks THROTTLE GRIP ASSEMBLY DISASSEMBLY Handlebar grip (right) Refer to “REMOVAL POINTS”. Collar Tube guide 5 - 46...
  • Page 246 CHAS HANDLEBAR Å REMOVAL POINTS Brake master cylinder (TT-R125LW/TT-R125LWE) 1. Remove: Brake master cylinder bracket 1 ● Brake master cylinder 2 ● CAUTION: Do not let the brake master cylinder hang ● on the brake hose. Keep the brake master cylinder cap side ●...
  • Page 247 CHAS HANDLEBAR ASSEMBLY AND INSTALLATION Throttle grip assembly 1. Install: Collar 1 ● Handlebar grip (right) 2 ● Apply the adhesive on the tube guide NOTE: Before applying the adhesive, wipe off grease or oil on the tube guide surface a with a lac- quer thinner.
  • Page 248 CHAS HANDLEBAR 2. Install: Handlebar grip (left) 1 ● Apply the adhesive to the handlebar 2. NOTE: Before applying the adhesive, wipe off grease or oil on the handlebar surface a with a lac- quer thinner. 3. Install: TT-R125/TT-R125E/TT-R125LW Collar 1 ●...
  • Page 249 CHAS HANDLEBAR 6. Install: TT-R125 Front brake lever holder 1 ● Bolts (front brake lever holder) 2 ● 4 Nm (0.4 m · kg, 2.9 ft · lb) Front brake cable 3 ● Clamp ● NOTE: Apply the lithium soap base grease on the front brake cable end.
  • Page 250 CHAS HANDLEBAR Å ı 7. Install: Engine stop switch 1 ● Clutch lever holder 2 ● Bolts (TT-R125/TT-R125LW) 3 ● Screws (TT-R125E/TT-R125LWE) 3 ● 4 Nm (0.4 m · kg, 2.9 ft · lb) NOTE: The engine stop switch and clutch lever ●...
  • Page 251: Steering

    CHAS STEERING EC560000 STEERING 1 Lower bracket removal 2 Bearing removal Extent of removal: Extent of removal Order Part name Q’ty Remarks STEERING REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine.
  • Page 252 CHAS STEERING Extent of removal Order Part name Q’ty Remarks Bearing inner race (upper) Bearing (upper) Bearing outer race (upper) Bearing outer race (lower) Refer to “REMOVAL POINTS”. Bearing (lower) 5 - 53...
  • Page 253 CHAS STEERING EC563000 REMOVAL POINTS EC563202 Ring nut 1. Remove: Ring nut 1 ● Use the steering nut wrench 2. Steering nut wrench: YU-33975/90890-01403 WARNING Support the steering shaft so that it may not fall down. Bearing race 1. Remove: Bearing race 1 ●...
  • Page 254 CHAS STEERING Bearing and bearing race 1. Wash the bearings and bearing races with a solvent. 2. Inspect: Bearing ● Bearing race ● Pitting/damage → Replace bearings and bearing races as a set. Install the bearing in the bearing races. Spin the bearings by hand.
  • Page 255 CHAS STEERING 4. Install: Lower bracket 1 ● NOTE: Apply the lithium soap base grease on the bearing. 5. Install: Lower ring nut 1 ● 20 Nm (2.0 m · kg, 14 ft · lb) Rubber washer ● Upper ring nut ●...
  • Page 256 CHAS STEERING 9. Tighten: Steering stem nut 1 ● 110 Nm (11.0 m · kg, 80 ft · lb) 10. Install: Cap 2 ● 11. After tightening the nut, check the steer- ing for smooth movement. If not, adjust the steering by loosening the ring nut little by little.
  • Page 257: Swingarm

    CHAS SWINGARM EC570000 SWINGARM 1 Swingarm removal Extent of removal: Extent of removal Order Part name Q’ty Remarks SWINGARM REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine. danger of it falling over.
  • Page 258 CHAS SWINGARM EC578000 SWINGARM DISASSEMBLY 1 Swingarm disassembly 2 Connecting arm removal and disassembly Extent of removal: 3 Relay arm removal and disassembly Extent of removal Order Part name Q’ty Remarks SWINGARM DISASSEMBLY Drive chain guard Drive chain support Drive chain guide Dust cover Collar Connecting arm...
  • Page 259 CHAS SWINGARM REMOVAL POINTS Bushing 1. Remove: Bushing 1 ● NOTE: Remove the bushing by pressing. INSPECTION Wash the bushings, collars, and covers in a solvent. Swingarm 1. Inspect: Bushing 1 ● Bushing 2 ● Damage/pitting → Replace bushings as a set.
  • Page 260 CHAS SWINGARM 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. EC575000 ASSEMBLY AND INSTALLATION Bushing 1.
  • Page 261 CHAS SWINGARM 2. Install: Oil seals 1 ● Collars 2 ● Bushing 3 ● Dust covers 4 ● Dust covers 5 ● Rubber boot 6 ● On relay arm. NOTE: Apply the molybdenum disulfide grease on the bushing, collar, oil seal lip and dust cover lip. 3.
  • Page 262 CHAS SWINGARM 5. Install: Connecting arm 1 ● Bolt (connecting arm) ● Plain washer ● Nut (connecting arm) ● 35 Nm (3.5 m · kg, 25 ft · lb) On relay arm. NOTE: Apply the molybdenum disulfide grease on the bolt (connecting arm).
  • Page 263 CHAS SWINGARM 3. Install: Bolt (rear shock absorber - relay arm) 1 ● Plain washer ● Nut (rear shock absorber-relay arm) ● 35 Nm (3.5 m · kg, 25 ft · lb) NOTE: Apply the molybdenum disulfide grease on the bolt (rear shock absorber - relay arm).
  • Page 264: Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY EC580000 REAR SHOCK ABSORBER ASSEMBLY 1 Rear shock absorber assembly removal Extent of removal: Extent of removal Order Part name Q’ty Remarks REAR SHOCK ABSORBER WARNING ASSEMBLY REMOVAL Support the machine securely so there is no Preparation for removal Hold the machine by placing the danger of it falling over.
  • Page 265 CHAS REAR SHOCK ABSORBER ASSEMBLY HANDLING NOTE WARNING This rear shock absorber contains high- pressure nitrogen gas. To prevent the dan- ger of explosion, read and understand the following information before handling the shock absorber. The manufacturer can not be held responsi- ble for property damage or personal injury that may result from improper handling.
  • Page 266 CHAS REAR SHOCK ABSORBER ASSEMBLY NOTES ON DISPOSAL (YAMAHA DEALERS Å ONLY) Gas pressure must be released before dispos- ing of a rear shock absorber and gas cylinder. TT-R125/TT-R125E/TT-R125LW 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.
  • Page 267 CHAS REAR SHOCK ABSORBER ASSEMBLY EC585000 ASSEMBLY AND INSTALLATION Bushing 1. Install: Bushing 1 ● NOTE: Install the bushing by pressing. Installation 1. Install: Rear shock absorber assembly ● On frame. NOTE: Install the rear shock absorber assembly with its warning label a facing left side of the machine (for TT-R125/TT-R125E/TT-R125LW).
  • Page 268 CHAS REAR SHOCK ABSORBER ASSEMBLY 4. Install: TT-R125LWE Rear shock absorber assembly sub- ● tank 1 Screw clamp 2 ● 4 Nm (0.4 m · kg, 2.9 ft · lb) Locking tie 3 ● NOTE: Install the rear shock absorber assembly ●...
  • Page 269: Electrical

    – ELEC ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC600000 ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM TT-R125/TT-R125LW EC611000 ELECTRICAL COMPONENTS 1 CDI unit COLOR CODE 2 Engine stop switch B ....Black W ....White W/L ..... White/Blue 3 Ignition coil Br ....
  • Page 270 – ELEC ELECTRICAL COMPONENTS AND WIRING DIAGRAM TT-R125E/TT-R125LWE EC611000 ELECTRICAL COMPONENTS 1 CDI unit COLOR CODE 2 Main switch B ...... Black W ..... White 3 Start switch Br..... Brown Y ...... Yellow 4 Clutch switch G...... Green B/W....Black/White 5 Engine stop switch O......
  • Page 271: Ignition System

    – ELEC IGNITION SYSTEM EC620000 IGNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. Spark *Clean or replace Spark gap test spark plug.
  • Page 272 – ELEC IGNITION SYSTEM EC622001 Å SPARK GAP TEST 1. Disconnect the spark plug cap from spark plug. 2. Connect the dynamic spark tester 1 (ignition checker 2) as shown. Spark plug cap 3 ● Spark plug 4 ● Å For USA and CDN ı...
  • Page 273 – ELEC IGNITION SYSTEM ENGINE STOP SWITCH INSPECTION TT-R125/TT-R125LW 1. Inspect: Engine stop switch conduct ● Tester (+) lead → Black/White lead 1 Tester (–) lead → Black lead 2 Tester selec- tor position PUSH IN Ω × 1 FREE Not continuous while being pushed →...
  • Page 274 – ELEC IGNITION SYSTEM 2. Inspect: Secondary coil resistance ● Out of specification → Replace. Tester (+) lead → Spark plug lead 1 Tester (–) lead → Orange lead 2 Secondary coil Tester selector resistance position 6.3 ~ 9.5 kΩ at kΩ...
  • Page 275 – ELEC IGNITION SYSTEM Å 2. Inspect: Source coil resistance ● Out of specification → Replace. Tester (+) lead → Brown lead 1 Tester (–) lead → Green lead 2 Source coil Tester selector resistance position 688 ~ 1,032 Ω Ω...
  • Page 276: Electric Starting System (tt-r125e/tt-r125lwe)

    – ELEC ELECTRIC STARTING SYSTEM (TT-R125E/TT-R125LWE) ELECTRIC STARTING SYSTEM (TT-R125E/TT-R125LWE) STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is set to “ON”, the starter motor can only operate if at least one of the following conditions is met: The transmission is in neutral (the neutral ●...
  • Page 277 – ELEC ELECTRIC STARTING SYSTEM (TT-R125E/TT-R125LWE) INSPECTION STEPS If the starter motor will not operate, use the following inspection steps. No good Replace fuse and *1 Check fuse check wire harness. No good *2 Check battery Recharge or replace. No good Check each coupler and Repair or replace.
  • Page 278 – ELEC ELECTRIC STARTING SYSTEM (TT-R125E/TT-R125LWE) EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: Couplers and leads connection ● Rust/dust/looseness/short-circuit → Repair or replace. STARTER MOTOR OPERATION 1. Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3.
  • Page 279 – ELEC ELECTRIC STARTING SYSTEM (TT-R125E/TT-R125LWE) STARTER RELAY INSPECTION 1. Remove: Starter relay ● 2. Inspect: Starter relay conduct ● Use 12 V battery. Battery (+) lead → Starter relay terminal 1 Battery (–) lead → Starter relay terminal 2 Tester (+) lead →...
  • Page 280 – ELEC ELECTRIC STARTING SYSTEM (TT-R125E/TT-R125LWE) CLUTCH SWITCH INSPECTION 1. Inspect: Clutch switch continuity ● Tester (+) lead → Black lead 1 Tester (–) lead → Black lead 2 Tester selec- tor position PULL Ω × 1 FREE No continuous while being pulled → Replace. Continuous while being freed →...
  • Page 281 – ELEC ELECTRIC STARTING SYSTEM (TT-R125E/TT-R125LWE) STARTER MOTOR 1 Starter motor disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks STARTER MOTOR REMOVAL Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3. Starter motor STARTER MOTOR DISASSEM- Starter motor front cover...
  • Page 282 – ELEC ELECTRIC STARTING SYSTEM (TT-R125E/TT-R125LWE) Extent of removal Order Part name Q’ty Remarks Starter motor yoke Armature assembly Starter motor rear cover Brush Brush spring 6 - 14...
  • Page 283 – ELEC ELECTRIC STARTING SYSTEM (TT-R125E/TT-R125LWE) INSPECTION AND REPAIR 1. Inspect: Commutator ● Dirt → Clean it with #600 grit sandpaper. 2. Measure: Commutator diameter a ● Commutator wear limit: 21.0 mm (0.83 in) Out of specification → Replace the starter motor.
  • Page 284 – ELEC ELECTRIC STARTING SYSTEM (TT-R125E/TT-R125LWE) 5. Measure: Brush length a ● Out of specification → Replace. Brush length wear limit: 3.5 mm (0.14 in) 6. Measure: Brush spring force ● Fatigue/out of specification → Replace as a set. Brush spring force: 5.52 ~ 8.28 N (560 ~ 840 g, 19.8 ~ 29.7 oz) ASSEMBLY...
  • Page 285 – ELEC ELECTRIC STARTING SYSTEM (TT-R125E/TT-R125LWE) 3. Install: O-ring 1 ● Starter motor yoke 2 ● NOTE: Align the match mark on the starter motor yoke with the match mark b on the starter motor rear cover. 4. Install: O-ring 1 ●...
  • Page 286: Charging System (tt-r125e/tt-r125lwe)

    – ELEC CHARGING SYSTEM (TT-R125E/TT-R125LWE) EC680000 CHARGING SYSTEM (TT-R125E/TT-R125LWE) EC681001 INSPECTION STEPS If the battery is not charged, use the following inspection steps. No good Replace fuse and *1 Check fuse. check wire harness. No good *2 Check battery. Recharge or replace. Check each coupler and No good Repair or replace.
  • Page 287 – ELEC CHARGING SYSTEM (TT-R125E/TT-R125LWE) EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: Couplers and leads connection ● Rust/dust/looseness/short-circuit → Repair or replace. CHARGING VOLTAGE INSPECTION 1. Start the engine. 2. Inspect: Charging voltage ● Out of specification → If no failure is found in checking the source coil resis- tance, replace the rectifier/regulator.
  • Page 289 PRINTED IN BRASIL 00/2000 - 0000 - GYL...

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