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Yamaha TT-R125EY Service Manual
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Yamaha TT-R125EY Service Manual

Yamaha TT-R125EY Service Manual

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TT-R125EY
TT-R125LEY
SERVICE MANUAL
LIT-11626-22-26
1B2-F8197-14

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Summary of Contents for Yamaha TT-R125EY

  • Page 1 TT-R125EY TT-R125LEY SERVICE MANUAL LIT-11626-22-26 1B2-F8197-14...
  • Page 2 EC010000 TT-R125EY/TT-R125LEY SERVICE MANUAL ©2008 by 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...
  • Page 3 Yamaha a leader. This manual explains operation, inspection, basic WARNING maintenance and tuning of your machine. If you...

  • Page 4: Customer Service

    CUSTOMER SERVICE Q. What costs are my responsibility during the warranty period? If your machine requires warranty service, you must take it to any authorized Yamaha Motor- cycle dealer within the continental United States. Be sure to bring your warrant registration A.
  • Page 5 SAFETY INFORMATION THIS MACHINE IS DESIGNED FOR OFF- ROAD USE ONLY. 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 ille- gal. Please check local regulations before riding. SAFETY INFORMATION 1.
  • Page 6 6. ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE VENTILA- TION. Never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes are poisonous. These fumes contain carbon monoxide, which by itself is odorless and colorless. Car- bon monoxide is a dangerous gas which can cause unconsciousness or can be lethal.
  • Page 7 EC080000 HOW TO USE THIS MANUAL FINDING THE REQUIRED PAGE 1. This manual consists of six chapters; "Gen- eral Information", "Specifications", "Regular in- spection and adjustments", "Engine", "Chas- sis" and "Electrical". 2. The table of contents is at the beginning of the manual.
  • Page 8 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 9: Chassis

    ILLUSTRATED SYMBOLS (Refer to the illustration) SPEC Illustrated symbols 1 to 6 are designed as 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 10 MEMO...
  • Page 11 INDEX GENERAL INFORMATION INFO SPECIFICATIONS SPEC REGULAR INSPECTION AND INSP ADJUSTMENTS ENGINE CHASSIS CHAS – ELECTRICAL ELEC...

  • Page 12: Table Of Contents

    EC0A0000 CONTENTS CHAPTER 1 GENERAL INFORMATION MACHINE IDENTIFICATION ....1-1 IMPORTANT INFORMATION ....1-2 CHECKING 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 ..........
  • Page 13 CHAPTER 3 REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS ....3-1 PRE-OPERATION INSPECTION AND MAINTENANCE ....... 3-4 ENGINE ............. 3-5 CHASSIS ..........3-16 ELECTRICAL .......... 3-33 CHAPTER 4 ENGINE SEAT, FUEL TANK AND SIDE COVERS ......... 4-1 MUFFLER ..........4-2 CARBURETOR ......... 4-3 CYLINDER HEAD ........
  • Page 14 CHAPTER 5 CHASSIS FRONT WHEEL AND FRONT BRAKE (TT-R125E) ..........5-1 FRONT WHEEL (TT-R125LE) ..........5-8 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 ..........

  • Page 15: Machine Identification

    There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the num- ber to your Yamaha dealer for positive 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.

  • Page 16: Important Information

    INFO IMPORTANT INFORMATION 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 2.
  • Page 17 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 overhauled.

  • Page 18: Checking Of Connection

    INFO CHECKING OF CONNECTION 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.

  • Page 19: Special Tools

    INFO SPECIAL TOOLS 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 20 INFO SPECIAL TOOLS Part number Tool name/How to use Illustration YM-8035, 90890-01311 Tappet adjusting tool YM-8035 90890-01311 This tool is necessary for adjusting valve clearance. YM-1312-A, Fuel level gauge YM-1312-A 90890-01312 90890-01312 This gauge is used to measure the fuel level in the float chamber.
  • Page 21 YM-34487 YM-34487 90890-06754 Dynamic spark tester 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.

  • Page 22: Specifications

    SPEC GENERAL SPECIFICATIONS EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS TT-R125E Model name: TT-R125EY Model code number: 39C1 Dimensions: Overall length 1,845 mm (72.6 in) Overall width 785 mm (30.9 in) Overall height 1,060 mm (41.7 in) Seat height 775 mm (30.5 in) Wheelbase 1,250 mm (49.2 in)
  • Page 23 SPEC GENERAL SPECIFICATIONS 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 type SE motor oil Oil capacity: Engine oil...
  • Page 24 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 25: Tt-R125Le

    SPEC GENERAL SPECIFICATIONS TT-R125LE Model name: TT-R125LEY Model code number: 19CA Dimensions: Overall length 1,885 mm (74.2 in) Overall width 795 mm (31.3 in) Overall height 1,085 mm (42.7 in) Seat height 805 mm (31.7 in) Wheelbase 1,270 mm (50.0 in) Minimum ground clearance 295 mm (11.6 in) Basic weight:...
  • Page 26 SPEC GENERAL SPECIFICATIONS 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 type SE motor oil Oil capacity: Engine oil...
  • Page 27 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 28: 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 29 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Cam chain: Cam chain type/No. of links SCR - 0404 SV/90 ---- 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...
  • Page 30 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Stem run out 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...
  • Page 31 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 32 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 33 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 34 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Spark plug M10 x 1.0 Cylinder head bolt M8 × 1.25 Cylinder head bolt M6 × 1.0 Oil pressure check bolt M6 × 1.0 Cylinder head side cover M6 ×...
  • Page 35 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Segment M6 × 1.0 Stopper lever M6 × 1.0 Î - marked portion shall be checked for torque tightening after break-in or before each ride. Cylinder head tightening sequence 2-14...

  • Page 36: Chassis

    SPEC MAINTENANCE SPECIFICATIONS EC212201 CHASSIS 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 478.7 mm (18.82 in) 472,2mm (18.59 in) Spring rate, STD K = 3.00 N/mm...
  • Page 37 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 38 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Î Upper bracket and inner tube M8 × 1.25 Î Lower bracket and inner tube M10 × 1.25 Î Upper bracket and steering stem M22 × 1.0 11.0 Î...
  • Page 39 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Î Relay arm and connecting arm M10 × 1.25 Î Connecting arm and frame M10 × 1.25 Î Rear shock absorber assembly and frame M12 × 1.25 Î...

  • Page 40: Tt-R125Le

    SPEC MAINTENANCE SPECIFICATIONS TT-R125LE 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 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)
  • Page 41 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 (15 links) 194.3 mm (7.65 in) Front disc brake: Disc outside dia. × Thickness 220 ×...
  • Page 42 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Î Upper bracket and inner tube M8 × 1.25 Î Lower bracket and inner tube M10 × 1.25 Î Upper bracket and steering stem M22 × 1.0 11.0 Î...
  • Page 43 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Bead stopper M8 × 1.25 Î Driven sprocket (nut) M10 × 1.25 Driven sprocket (stud) M10 × 1.25 Sidestand mounting (nut) M10 × 1.25 Engine mounting: Î...

  • Page 44: Electrical

    SPEC MAINTENANCE SPECIFICATIONS EC212300 ELECTRICAL Item Standard Limit CDI: Magneto-model (stator)/manufacturer F1B2/MORIC 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 45 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 M06/Nais 75.69 ~ 92.51 Ω at 20 °C (68 °F) Coil winding resistance Fuse (amperage ×...

  • Page 46: General Torque Specifications

    GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS EC220001 GENERAL TORQUE SPECIFICATIONS This char t specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached.

  • Page 47: Cable Routing Diagram

    SPEC CABLE ROUTING DIAGRAM EC240000 CABLE ROUTING DIAGRAM 1 Ground lead D Brake hose holder P Frame 2 Primary coil lead Q Rectifier/regulator (Brake cable 3 Clamp holder for the TT-R125E) A Fasten the primary coil lead 4 Wire harness E Brake hose (Brake cable for and ground lead.
  • Page 48 SPEC CABLE ROUTING DIAGRAM L Fit the neutral switch lead E Fasten the CDI magneto lead P After fastening the start switch into the groove in the and starter relay lead. lead, clutch switch lead, crankcase cover. F Fasten the wire harness. engine stop switch lead and main M Pass the starting circuit cult- G Pass the rectifier/regulator lead...
  • Page 49 SPEC CABLE ROUTING DIAGRAM U After connecting the main switch X Fasten the CDI unit lead and Z Fasten the wire harness, CDI coupler, engine stop switch starting circuit cut-off relay lead magneto lead and rear shock coupler, clutch switch coupler with a plastic locking tie at the absorber assembly sub-tank and start switch coupler, put a...
  • Page 50 SPEC CABLE ROUTING DIAGRAM 1 Throttle cable B Engine oil breather hose A Tighten the starter choke nut 2 Clutch cable C Positive battery lead while taking care not to twist 3 Starter cable D Overflow hose the starter cable. 4 Fuel tank breather hose E Air vent hose B Pass the clutch cable on the...
  • Page 51 SPEC CABLE ROUTING DIAGRAM E Fasten the clutch cable with I Pass the negative battery lead M Install the primary coil the paint in the cable guide on the inside of the frame as terminal (orange) to the bottom recess. shown.
  • Page 52 SPEC CABLE ROUTING DIAGRAM 1 Clamp A Fasten the clutch switch lead and G Fasten the throttle cable 2 Clutch switch lead engine stop switch lead to 3 clicks. adjuster cover and start switch 3 Engine stop switch lead B Pass the brake hose (brake cable for lead with a plastic locking tie the TT-R125E) in front of the number 4 Brake hose (Brake cable...

  • Page 53: Regular Inspection And Adjustments

    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 54: 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 55 Check operation and for oil leakage. Replace if necessary. assembly 17 * Control cabes Apply Yamaha chain and cable lube or engine oil 10W-30 thoroughly. 18 * Throttle grip Check operation and free play. Adjust the throttle cable free play if necessary.

  • Page 56: 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 condition. 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 57: 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 Clutch lever free play adjustment steps: •...
  • Page 58 INSP THROTTLE LUBRICATION/AIR FILTER CLEANING 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 59 INSP AIR FILTER CLEANING 1. Remove: • Right side cover 1 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: •...
  • Page 60 INSP ENGINE OIL LEVEL INSPECTION 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.
  • Page 61 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. When inspecting the oil level, do not screw the dipstick into the oil tank.
  • Page 62 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. Wait a few minutes until the oil settles before inspecting the oil level.
  • Page 63 OIL PRESSURE INSPECTION / INSP ENGINE IDLING SPEED ADJUSTMENT OIL PRESSURE INSPECTION 1. Check: • Oil pressure Checking steps: • Slightly loosen the oil pressure check bolt 1. • Start the engine and keep it idling until oil starts to seep from the oil pressure check bolt.
  • Page 64 VALVE CLEARANCE INSPECTION AND INSP 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 65 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: •...
  • Page 66 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) •...
  • Page 67 INSP SPARK ARRESTER CLEANING SPARK ARRESTER CLEANING 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 2.

  • Page 68: Chassis

    CHASSIS / BRAKE SYSTEM AIR BLEEDING INSP (TT-R125LE) EC360000 CHASSIS EC361012 BRAKE SYSTEM AIR BLEEDING (TT-R125LE) 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 69 INSP FRONT BRAKE ADJUSTMENT 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 disappeared. j. Add brake fluid to the level line on the reservoir.
  • Page 70 INSP REAR BRAKE ADJUSTMENT TT-R125LE 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: •...
  • Page 71 INSP BRAKE PEDAL HEIGHT ADJUSTMENT/FRONT BRAKE PAD INSPECTION AND REPLACEMENT (TT-R125LE) 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 Pedal height adjustment steps: •...
  • Page 72 INSP FRONT BRAKE SHOE INSPECTION (TT-R125E) • Connect the transparent hose 4 to the bleed screw 5 and place the suitable container under its end. • Loosen the bleed screw and push the brake caliper piston in. NOTICE Do not reuse the drained brake fluid. •...
  • Page 73 INSP REAR BRAKE SHOE INSPECTION / BRAKE FLUID LEVEL INSPECTION (TT-R125LE) / 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.
  • Page 74 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 75 INSP DRIVE CHAIN SLACK ADJUSTMENT 6. Lubricate: • Drive chain Drive chain lubricant: SAE 10W-30 motor oil or suitable chain lubricants DRIVE CHAIN SLACK ADJUSTMENT 1. Elevate the rear wheel by placing the suitable stand under the engine. 2. Check: •...
  • Page 76 FRONT FORK INSPECTION/FRONT FORK INSP SPRING PRELOAD ADJUSTMENT (TT-R125LE) 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-R125LE) 1.
  • Page 77 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 78 REAR SHOCK ABSORBER REBOUND DAMPING INSP FORCE ADJUSTMENT (TT-R125LE) 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-R125LE)
  • Page 79 INSP REAR SHOCK ABSORBER COMPRESSION DAMPING FORCE ADJUSTMENT (TT-R125LE) EC36c000 REAR SHOCK ABSORBER COMPRESSION DAMPING FORCE ADJUSTMENT (TT-R125LE) 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 80 TIRE PRESSURE CHECK/SPOKES INSPECTION INSP AND TIGHTENING/WHEEL INSPECTION EC36Q000 TIRE PRESSURE CHECK 1. Measure: • Tire pressure Out of specification → Adjust. Standard tire pressure: 100 kPa (1.00 kgf/cm2, 15 psi) • Check the tire while it is cold. • Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low.
  • Page 81 STEERING HEAD INSPECTION AND INSP ADJUSTMENT 2. Inspect: • Bearing free play Exist play → Replace. STEERING HEAD INSPECTION AND ADJUSTMENT 1. Elevate the front wheel by placing a suitable stand under the engine. 2. Check: • Steering shaft Grasp the bottom of the forks and gently rock the fork assembly back and forth.
  • Page 82 STEERING HEAD INSPECTION AND INSP ADJUSTMENT • Tighten the lower ring nut 6 using steering nut wrench 7 and turn the steering right and left a few times. 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 83 STEERING HEAD INSPECTION AND INSP ADJUSTMENT NOTICE 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 84 INSP LUBRICATION LUBRICATION To ensure smooth operation of all components, A Use Yamaha cable lube or equivalent on lubricate your machine during setup, after break- these areas. in, and after every ride. B Use SAE 10W-30 motor oil or suitable chain lubricants.

  • Page 85: 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 86 INSP BATTERY INSPECTION AND CHARGING BATTERY INSPECTION AND CHARGING 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 or working near batteries.
  • Page 87 INSP BATTERY INSPECTION AND CHARGING Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
  • Page 88 INSP BATTERY INSPECTION AND CHARGING • 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 Relationship between the open-circuit voltage and the charging time at 20 °C (68 °F) (These values vary with the temperature, the...
  • Page 89 INSP BATTERY INSPECTION AND CHARGING • 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 terminal and that they are not shorted.
  • Page 90 INSP BATTERY INSPECTION AND CHARGING Charging method using a variable voltage charger Leave the battery unused for Measure the open- more than 30 minutes before circuit voltage prior to measuring its open-circuit Charger voltage. charging. Ammeter Set the charging voltage to Connect a charger and 16-17 V.
  • Page 91 INSP BATTERY INSPECTION AND CHARGING Charging method using a constant voltage charger Measure the open- Leave the battery unused for more circuit voltage prior to than 30 minutes before measuring charging. its open-circuit voltage. Connect a charger and ammeter to the battery and start charging.
  • Page 92 INSP FUSE INSPECTION 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) NOTICE First, connect the positive lead 1, then the...
  • Page 93 INSP FUSE INSPECTION 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 electrical circuit is operational. • If the fuse immediately blows again, check the electrical circuit.

  • Page 94: Engine

    SEAT, FUEL TANK AND SIDE COVERS EC400000 ENGINE EC4R0000 SEAT, FUEL TANK AND SIDE COVERS 7 Nm (0.7 m kg, 5.1 ft lb) • • 7 Nm (0.7 m kg, 5.1 ft lb) • • 7 Nm (0.7 m kg, 5.1 ft lb) •...

  • Page 95: Muffler

    MUFFLER MUFFLER 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) • • 10 Nm (1.0 m kg, 7.2 ft lb) •...

  • Page 96: Carburetor

    CARBURETOR CARBURETOR 1 Carburetor removal Extent of removal: Extent of removal Order Part name Q’ty Remarks CARBURETOR REMOVAL Preparation for Fuel tank Refer to SEAT, FUEL TANK AND removal SIDE COVERS section. Fuel hose Over flow hose Air vent hose Starter plunger/starter knob Trottle main cable Trottle return cable...

  • Page 97: Carburetor Disassembly

    CARBURETOR EC468000 CARBURETOR DISASSEMBLY 1 Carburetor disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks CARBURETOR DISASSEMBLY Throttle shaft Throttle valve Refer to REMOVAL POINTS Jet needle set Lever 1 Starter plunger Float chamber Float pivot pin Float Needle valve Main jet washer...
  • Page 98 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 #100 (620-14231-20) is available to correct this.
  • Page 99 CARBURETOR EC464301 Throttle valve 1. Check: • Free movement Stick → Repair or replace. 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. Fuel level 1.
  • Page 100 CARBURETOR EC464600 Float 1. Inspect: • Float 1 Damage → Replace. Starter plunger 1. Inspect: • Cold starter plunger 1 • Hot starter plunger 2 Wear/damage → Replace. Coasting enricher 1. Inspect: • Diaphragm 1 • Spring 2 • Cover 3 Tears (diaphragm)/damage →...
  • Page 101 CARBURETOR ASSEMBLY AND INSTALLATION Carburetor 1. Install: • Diaphragm 1 • Spring 2 • Cover 3 • Screw 4 2 Nm (0.2 m • kg, 1.4 ft • lb) 2. Install: • Jet needle 1 • Spring 2 • Holder 3 •...
  • Page 102 CARBURETOR 5. Install: • Throttle shaft assembly • Plain washer (resin) 1 • Valve lever 2 • Apply the fluorchemical grease on the bearings. • Make sure the stopper of the TPS spring fits into the recess in the carburetor. 6.
  • Page 103 CARBURETOR 9. Install: • Gasket • Float chamber 1 • Screw (float chamber) 2 Carburetor installation 1. Install: • Spring 1 • Starter plunger 2 • On starter cable 3 2. Install: • Throttle cable (pull) 1 4 Nm (0.4 m • kg, 2.9 ft • lb •...
  • Page 104 CARBURETOR 4. Install: • Throttle ca ble cover 1 • Screw (throttle cable cover) 2 4 Nm (0.4 m • kg, 2.9 ft • lb) 5. Tighten • Screw (carburetor joint) 1 • Screw (air carburetor joint) 2 6. Adjust: •...

  • Page 105: 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 Refer to SEAT, FUEL TANK AND Seat and fuel tank removal...
  • Page 106 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 107 CYLINDER HEAD REMOVAL POINTS Cylinder head 1. Align: • I mark (with stationary pointer) Checking steps: • Turn the crankshaft counterclockwise with wrench. • Align the I mark a on the rotor with the stationary pointer b on the crankcase cover.
  • Page 108 CYLINDER HEAD 4. Remove: • Bolt (camshaft sprocket) 1 • Camshaft sprocket 2 Attach a wire a to the timing chain to prevent it from falling into the crankcase. 5. Remove: • Bolts (cylinder head) • Cylinder head • Loosen the bolts 1/4 turn each and remove then after all are loosened.
  • Page 109 • 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. Quick gasket ® ACC-QUICK-GS-KT YAMAHA Bond No.1215: 90890-85505 4-16...
  • Page 110 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 sprocket with the stationary pointer d on the cylinder head.
  • Page 111 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 112 CYLINDER HEAD 9. Check: • Valve clearance Out of specification → Adjust. Refer to VALVE CLEARANCE INSPEC- TION AND 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) •...

  • Page 113: 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 114 CAMSHAFT AND ROCKER ARMS REMOVAL POINTS Rocker arm shaft 1. Remove: • Rocker arm shafts 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...
  • Page 115 CAMSHAFT AND ROCKER ARMS Rocker arms 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. Inside diameter (rocker arm): 10.000 ~ 10.015 mm (0.3937 ~ 0.3943 in)
  • Page 116 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 117: 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 Cylinder head Refer to CYLINDER HEAD section. Preparation for Camshaft and rocker arms Refer to CAMSHAFT AND removal ROCKER ARMS section.
  • Page 118 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 119 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 120 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 121 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: •...
  • Page 122 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. For best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands.
  • Page 123 VALVES AND VALVE SPRINGS 2. Measure: • Compressed spring force a Out of specification → Replace. b Installed length Compressed spring force: Intake: 19.5 ~ 22.3 kgf at 25.6 mm (42.93 ~ 49.23 lbf at 1.01 in) Exhaust: 19.5 ~ 22.3 kgf at 25.6 mm (42.93 ~ 49.23 lbf at 1.01 in) 3.
  • Page 124 VALVES AND VALVE SPRINGS 3. Install: • Valve cotters 1 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 125: 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 Cylinder head Refer to CYLINDER HEAD section. removal Exhaust timing chain guide Cylinder/O-ring Dowel pin Gasket...
  • Page 126 CYLINDER AND PISTON REMOVAL POINTS Piston 1. Remove: • Piston pin clips 1 • Piston pin 2 • Piston 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.
  • Page 127 CYLINDER AND PISTON 2. Measure: • Piston-to-cylinder clearance Piston-to-cylinder clearance measurement steps: 1st step: • Measure the cylinder bore C with the cylin- der bore gauge. Measure the cylinder bore C in parallel to and at right angles to the crankshaft. Then, find the average of the measurements.
  • Page 128 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 Measurement steps: •...
  • Page 129 CYLINDER AND PISTON 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>...
  • Page 130 CYLINDER AND PISTON ASSEMBLY AND INSTALLATION Piston ring and piston 1. Install: • Piston rings (onto the piston) • 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. •...
  • Page 131 CYLINDER AND PISTON Cylinder 1. Install: • Dowel pins 1 • Gasket (cylinder) 2 2. Install: • O-ring • Cylinder 1 • Exhaust timing chain guide NOTICE • Install the cylinder with one hand while compressing the piston rings with the other hand.

  • Page 132: 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 FRICTION PLATE REMOVAL Preparation for Drain the engine oil Refer to ENGINE OIL REPLACEMENT...
  • Page 133 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 134 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 4-41...
  • Page 135 CLUTCH AND PRIMARY DRIVEN GEAR EC493000 REMOVAL POINTS Clutch 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...
  • Page 136 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 137 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: •...
  • Page 138 CLUTCH AND PRIMARY DRIVEN GEAR Clutch 1. Install: • Primary driven gear 1 • Thrust plate 2 • Clutch boss 3 2. Install: • Lock washer • Nut (clutch boss) 1 60 Nm (6.0 m • kg, 43 ft • lb) Use the clutch holding tool 2 to hold the clutch boss.
  • Page 139 CLUTCH AND PRIMARY DRIVEN GEAR 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 7. Install: • Pressure plate 1 •...
  • Page 140 • Tighten the bolts in stages, using a crisscross 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) Install the kickstarter crank so that there is 5 ~ 10 mm (0.2 ~ 0.4 in) a between the kickstarter...

  • Page 141: 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 Clutch and primary drive gear Refer to CLUTCH AND PRIMARY removal DRIVEN GEAR section. Rotary filter Oil pump drive gear Oil pump assembly Gasket...

  • Page 142: Oil Pump Disassembly

    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 4-49...
  • Page 143 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 A (between the inner rotor 1 and the outer rotor 2) •...
  • Page 144 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 145: 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 Refer to ENGINE REMOVAL section.
  • Page 146 KICK AXLE AND SHIFT SHAFT REMOVAL POINTS Kick axle 1. Remove: • Kick axle assembly 1 Unhook the torsion spring 2 from the hole in the crankcase. Segment 1. Remove: • Screw (segment) • Segment 1 Loosen the screw using the T30 bit. INSPECTION Kick axle and ratchet wheel 1.
  • Page 147 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 148 KICK AXLE AND SHIFT SHAFT Shift shaft 1. Install: • Shift shaft 1 • 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 149 KICK AXLE 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.

  • Page 150: Cdi Magneto And Starter Clutch

    CDI MAGNETO AND STARTER CLUTCH CDI MAGNETO AND STARTER CLUTCH Extent of removal: 1 Pickup coil/stator removal 2 Starter clutch/wheel gear 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 Left crankcase cover...
  • Page 151 CDI MAGNETO AND STARTER CLUTCH 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...
  • Page 152 CDI MAGNETO AND STARTER CLUTCH 3. Check: • Starter clutch operation • Install the starter clutch drive gear 1 onto the starter clutch 2 and hold the starter clutch. • When turning the starter clutch drive gear counterclockwise B, the starter clutch and the starter clutch drive gear should engage.
  • Page 153 CDI MAGNETO AND STARTER CLUTCH 3. Install 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.
  • Page 154 CDI MAGNETO AND STARTER 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.

  • Page 155: Engine Removal

    ENGINE REMOVAL ENGINE REMOVAL Extent of removal: 1 Engine removal Extent of removal Order Part name Q’ty Remarks ENGINE REMOVAL Preparation for Hold the machine by placing the removal suitable stand under the frame. Seat, fuel tank and side covers Refer to SEAT, FUEL TANK AND SIDE COVERS section.
  • Page 156 ENGINE REMOVAL Extent of removal Order Part name Q’ty Remarks Drive sprocket cover Bolt (drive sprocket) Refer to REMOVAL POINTS Drive sprocket holder 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 4-63...
  • Page 157 ENGINE REMOVAL REMOVAL POINTS Drive sprocket 1. Remove: • Bolt (drive sprocket) • Drive sprocket holder 1 • Drive sprocket 2 • Drive chain 3 Remove the drive sprocket together with the drive chain. Engine removal 1. Remove: • Engine 1 From left side.
  • Page 158 ENGINE REMOVAL • 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) 9. Shift pedal link 1. Install: •...

  • Page 159: Crankcase, Crankshaft And Balancer

    CRANKCASE, CRANKSHAFT AND BALANCER CRANKCASE, CRANKSHAFT AND BALANCER Extent of removal: 1 Crankcase separation 2 Balancer removal 3 Crankshaft removal Extent of removal Order Part name Q’ty Remarks CRANKCASE, CRANKSHAFT AND BALANCER REMOVAL Preparation for Engine Refer to ENGINE REMOVAL section. removal Piston Refer to CYLINDER AND PISTON...
  • Page 160 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 161 CRANKCASE, CRANKSHAFT AND BALANCER REMOVAL POINTS Crankcase 1. Remove: • Bolt (crankcase) • Lead guide 1 • Clutch cable holder 2 Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them. 2.
  • Page 162 CRANKCASE, CRANKSHAFT AND BALANCER Crankshaft 1. Remove: • Crankshaft 1 Use the crankcase separating tool 2. Crankcase separating tool: YU-1135-A/90890-01135 NOTICE Do not use a hammer to drive out the crank- shaft. Bearing 1. Remove: • Bearing 1 • Remove the bearing from the crankcase by pressing its inner race as shown in.
  • Page 163 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: •...
  • Page 164 CRANKCASE, CRANKSHAFT AND BALANCER 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.
  • Page 165 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. 2. Install: • Dowel pin 1 • Right crankcase On left crankcase.
  • Page 166 (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 167: Transmission, Shift Cam And Shift Fork

    TRANSMISSION, SHIFT CAM AND SHIFT FORK TRANSMISSION, SHIFT CAM AND SHIFT FORK Extent of removal: 1 Shift cam and shift fork removal 2 Main axle and drive axle removal Extent of removal Order Part name Q’ty Remarks TRANSMISSION, SHIFTCAM AND SHIFT FORK REMOVAL Preparação para Engine...
  • Page 168 TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVAL POINTS Transmission 1. Remove: • Main axle 1 • Drive axle 2 • Tap lightly on the transmission drive axle with a soft hammer to remove. • Remove assembly carefully. Note the position of each part.
  • Page 169 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 170 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. • Apply the molybdenum disulfide oil on the gears inner circumference.
  • Page 171 TRANSMISSION, SHIFT CAM AND SHIFT FORK 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.
  • Page 172 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 • Mesh the shift fork #1 (L) with the 2nd wheel gear and #3 (R) with the 4th wheel gear on the drive axle.

  • Page 173: Front Wheel And Front Brake (Tt-R125E)

    CHAS FRONT WHEEL AND FRONT BRAKE (TT-R125E) EC500000 CHASSIS FRONT WHEEL AND FRONT BRAKE (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 BRAKE...
  • Page 174 CHAS FRONT WHEEL AND FRONT BRAKE (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...
  • Page 175 CHAS FRONT WHEEL AND FRONT BRAKE (TT-R125E) REMOVAL POINTS EC513201 Wheel bearing (if necessary) 1. Remove: • Bearing 1 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 176 CHAS FRONT WHEEL AND FRONT BRAKE (TT-R125E) Drum brake 1. Inspect: • 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 →...
  • Page 177 CHAS FRONT WHEEL AND FRONT BRAKE (TT-R125E) ASSEMBLY AND INSTALLATION 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. 3.
  • Page 178 CHAS FRONT WHEEL AND FRONT BRAKE (TT-R125E) 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. •...
  • Page 179 CHAS FRONT WHEEL AND FRONT BRAKE (TT-R125E) 5. Install: • Axle nut 1 45 Nm (4.5 m · kg, 32 ft · lb) 6. Install: • Brake cable Brake camshaft lever side of brake cable shall be installed first. 7. Install: •...

  • Page 180: Front Wheel (Tt-R125Le)

    CHAS FRONT WHEEL (TT-R125LE) FRONT WHEEL (TT-R125LE) 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 Hold the machine by placing the Support the machine securely so removal suitable stand under the engine.
  • Page 181 CHAS FRONT WHEEL (TT-R125LE) REMOVAL POINTS EC513201 Wheel bearing (if necessary) 1. Remove: • Bearing 1 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 182 CHAS FRONT WHEEL (TT-R125LE) 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 183 CHAS FRONT WHEEL (TT-R125LE) 2. Install: • Brake disc 1 • Bolt (brake disc) 2 12 Nm (1.2 m · kg, 8.7 ft · lb) Tighten the bolts in stage, using a crisscross pattern. 3. Install: • Collar 1 • Apply the lithium soap base grease on the oil seal lips.

  • Page 184: Front Brake (Tt-R125Le)

    CHAS FRONT BRAKE (TT-R125LE) FRONT BRAKE (TT-R125LE) 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 Hold the machine by placing the Support the machine securely so removal suitable stand under the engine.
  • Page 185 CHAS FRONT BRAKE (TT-R125LE) 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 DISASSEMBLY WARNING Support the machine securely so Preparation for Hold the machine by placing the there is no danger of it falling over.
  • Page 186 CHAS FRONT BRAKE (TT-R125LE) REMOVAL POINTS Brake fluid 1. Remove: • Brake master cylinder cap 1 Do not remove the diaphragm. 2. Connect the transparent hose 2 to the bleed screw 1 and place a suitable container under its end. 3.
  • Page 187 CHAS FRONT BRAKE (TT-R125LE) Brake caliper piston seal kit 1. Remove: • Brake caliper dust seal 1 • Brake caliper piston seal 2 Remove the brake caliper piston seals and brake caliper dust seals by pushing them with a finger. NOTICE Never attempt to pry out brake caliper piston seals and brake caliper dust seals.
  • Page 188 CHAS FRONT BRAKE (TT-R125LE) 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 189 CHAS FRONT BRAKE (TT-R125LE) 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 190 CHAS FRONT BRAKE (TT-R125LE) 2. Install: • Pin boot 1 On brake caliper 2. 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 · kg, 22 ft · lb) •...
  • Page 191 CHAS FRONT BRAKE (TT-R125LE) 2. Install: • Brake master cylinder cup (primary) 1 • Brake master cylinder cup (secondary) 2 On brake master cylinder piston 3. Apply the brake fluid on the brake master cylinder cup. WARNING After installing, cylinder cup should be in- stalled as shown direction.
  • Page 192 CHAS FRONT BRAKE (TT-R125LE) 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) • Install the brake master cylinder bracket so that the arrow mark a face upward.
  • Page 193 CHAS FRONT BRAKE (TT-R125LE) 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 194 CHAS FRONT BRAKE (TT-R125LE) Brake fluid 1. Fill: • Brake fluid Until the fluid level reaches "LOWER" level ......
  • Page 195 CHAS FRONT BRAKE (TT-R125LE) 4. Install: • Diaphragm • Brake master cylinder cap 1 • Screw (brake master cylinder cap) 2 2 Nm (0.2 m · kg, 1.4 ft · lb) NOTICE 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.

  • Page 196: Rear Wheel And Rear Brake

    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 BRAKE WARNING Support the machine securely so Hold the machine by placing the...
  • Page 197 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 198 CHAS REAR WHEEL AND REAR BRAKE REMOVAL POINTS EC523101 Rear wheel 1. Remove: • Wheel 1 Push the wheel forward and remove the drive chain 2. EC513201 Wheel bearing (if necessary) 1. Remove: • Bearing 1 Remove the bearing using a general bearing puller2.
  • Page 199 CHAS REAR WHEEL AND REAR BRAKE 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 200 CHAS REAR WHEEL AND REAR BRAKE 4. Inspect: • Brake drum inner surface. Oil/scratches → Remove. Use a rag soaked in lacquer thinner or a solvent. Use a emery cloth (lightly Scratches and evenly polishing). ASSEMBLY AND INSTALLATION Brake shoe plate assembly 1.
  • Page 201 CHAS REAR WHEEL AND REAR BRAKE 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. •...
  • Page 202 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) • Tighten the nuts in stage, using a crisscross pattern.
  • Page 203 CHAS REAR WHEEL AND REAR BRAKE 7. Install: • Drive chain puller (right) 1 • Plain washer 2 • Axle nut 3 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 to "DRIVE CHAIN SLACK ADJUST- MENT"...

  • Page 204: Front Fork

    CHAS FRONT FORK EC550000 FRONT FORK 23 Nm (2.3 m kg, 17 ft lb) • • 60 Nm (6.0 m kg, 43 ft lb) • • 25 Nm (2.5 m kg, 18 ft lb) • • TT-R125E TT-R125LE A TT-R125E B TT-R125LE 1 Front fork removal Extent of removal:...

  • Page 205: Front Fork Disassembly

    CHAS FRONT FORK EC558000 FRONT FORK DISASSEMBLY A TT-R125E B TT-R125LE 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 Washer Fork spring...
  • Page 206 CHAS FRONT FORK HANDLING NOTE The front fork requires careful attention. So it is recommended that the front fork be maintained at the dealers. NOTICE 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.
  • Page 207 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. NOTICE Take care not to scratch the outer tube. EC554000 INSPECTION Damper rod 1. Inspect: • Damper rod Bend/damage → Replace damper rod. NOTICE The front fork with a built-in piston rod has a very sophisticated internal construction...
  • Page 208 CHAS FRONT FORK EC554400 Fork spring 1. Measure: • Fork spring free length a Out of specification → Replace. Fork spring free length: Standard <Limit> TT-R125E: TT-R125E: 478.7 mm (18.82 in) 472.2 mm (18.59 in) TT-R125LE: TT-R125LE: 469.4 mm (18.46 in) 463.9 mm (18.23 in) Inner tube 1.
  • Page 209 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 210 CHAS FRONT FORK 4. Install: • Copper washer • Bolt (damper rod) 23 Nm (2.3 m · kg, 17 ft · lb) Use the damper rod holder 1 and the T-handle 2 to lock the damper rod. Damper rod holder: YM-1300/90890-01294 T-handle: YM-01326/90890-01326.
  • Page 211 CHAS FRONT FORK 7. Install: • Dust seal 1 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 212 CHAS FRONT FORK 12. Measure: • Oil level a Out of specification → 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.
  • Page 213 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 214: Handlebar

    CHAS HANDLEBAR EC5B0000 HANDLEBAR TT-R125E 1 Handlebar removal Extent of removal: Extent of removal Order Part name Q’ty Remarks Preparation for HANDLEBAR REMOVAL 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...
  • Page 215 CHAS HANDLEBAR TT-R125LE 1 Handlebar removal Extent of removal: Extent of removal Order Part name Q’ty Remarks Preparation for HANDLEBAR REMOVAL 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 216 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 5-44...
  • Page 217 CHAS HANDLEBAR REMOVAL POINTS Brake master cylinder 1. Remove: • Brake master cylinder bracket 1 • Brake master cylinder 2 NOTICE • 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.
  • Page 218 CHAS HANDLEBAR 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 lacquer thinner.
  • Page 219 CHAS HANDLEBAR 2. Install: • Handlebar grip (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 4.
  • Page 220 CHAS HANDLEBAR 6. Install: TT-R125E • Start switch 1 • Bolts (start switch) 2 4 Nm (0.4 m · kg, 2.9 ft · lb) • Front brake cable 3 • Clamp Apply the lithium soap base grease on the front brake cable end.
  • Page 221 CHAS HANDLEBAR 7. Install: • Engine stop switch 1 • Clutch lever holder 2 • Screws 3 4 Nm (0.4 m · kg, 2.9 ft · lb) • The engine stop switch and clutch lever holder should be installed according to the dimensions shown.

  • Page 222: Steering

    CHAS STEERING EC560000 STEERING 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) • • • Tighten ring nut. 38 Nm (3.8 m kg, 27 ft lb) •...
  • Page 223 CHAS STEERING 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) • • • Tighten ring nut. 38 Nm (3.8 m kg, 27 ft lb) •...
  • Page 224 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: •...
  • Page 225 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 226 CHAS STEERING 4. Install: • Lower bracket 1 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 227 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 steering for smooth movement. If not, adjust the steering by loosening the ring nut little by little.

  • Page 228: 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 Hold the machine by placing the Support the machine securely so removal suitable stand under the engine. there is no danger of it falling over.
  • Page 229 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 230 CHAS SWINGARM REMOVAL POINTS Bushing 1. Remove: • Bushing 1 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 231 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 232 CHAS SWINGARM 2. Install: • Oil seals 1 • Collars 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. 3.
  • Page 233 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. Apply the molybdenum disulfide grease on the bolt (connecting arm). 6.
  • Page 234 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) Apply the molybdenum disulfide grease on the bolt (rear shock absorber - relay arm). 4.

  • Page 235: 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 Preparation for Hold the machine by placing the suitable there is no danger of it falling over.
  • Page 236 CHAS REAR SHOCK ABSORBER ASSEMBLY HANDLING NOTE WARNING This rear shock absorber contains high- pressure nitrogen gas. To prevent the danger of explosion, read and understand the following information before handling the shock absorber. The manufacturer can not be held respon- sible for property damage or personal injury that may result from improper handling.
  • Page 237 CHAS REAR SHOCK ABSORBER ASSEMBLY A A A A A 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...
  • Page 238 CHAS REAR SHOCK ABSORBER ASSEMBLY EC585000 ASSEMBLY AND INSTALLATION Bushing 1. Install: • Bushing 1 Install the bushing by pressing. Installation 1. Install: • Rear shock absorber assembly On frame. Install the rear shock absorber assembly with its warning label a facing left side of the machine (for TT-R125E).
  • Page 239 CHAS REAR SHOCK ABSORBER ASSEMBLY 4. Install: TT-R125LE • Rear shock absorber assembly sub-tank 1 • Screw clamp 2 4 Nm (0.4 m · kg, 2.9 ft · lb) • Locking tie 3 • Install the rear shock absorber assembly sub-tank so that its bottom portion directs as shown and lightly touches the projection a = 0~2 mm...

  • Page 240: Electrical

    ELECTRICAL COMPONENTS AND – ELEC WIRING DIAGRAM EC600000 ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM 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....

  • Page 241: 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 242 – ELEC IGNITION SYSTEM EC622001 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 3. Kick the kick starter. 4.
  • Page 243 – ELEC IGNITION SYSTEM ENGINE STOP SWITCH INSPECTION 1. Inspect: • Engine stop switch conduct Tester (+) lead → Black lead 1 Tester ( _ ) lead → Black lead 2 Tester selector position PUSH IN Ω FREE No continuous while being pushed → Replace. Continuous while being freed →...
  • Page 244 – 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 245 – ELEC IGNITION SYSTEM 2. Inspect: • Source coil resistance Out of specification → Replace. Br G Tester (+) lead → Brown lead 1 Tester ( _ ) lead → Green lead 2 Source coil Tester selector resistance position Ω 688 ~ 1,032 Ω...

  • Page 246: Electric Starting System

    – ELEC ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM 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 switch is closed).
  • Page 247 – ELEC ELECTRIC STARTING SYSTEM 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. Check each coupler and No good Repair or replace.
  • Page 248 – ELEC ELECTRIC STARTING SYSTEM 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. Not operate →...
  • Page 249 – ELEC ELECTRIC STARTING SYSTEM STARTER RELAY INSPECTION 1. Remove: • Starter relay 2. Inspect: • Starter relay conduct Use 12 V battery. → Starter relay terminal 1 Battery (+) lead → Starter relay terminal 2 Battery (–) lead → Starter relay terminal 3 Tester (+) lead →...
  • Page 250 – ELEC ELECTRIC STARTING SYSTEM CLUTCH SWITCH INSPECTION 1. Inspect: • Clutch switch continuity Tester (+) lead → Black lead 1 Tester ( _ ) lead → Black lead 2 Tester selector position PULL Ω FREE No continuous while being pulled → Replace. Continuous while being freed →...
  • Page 251 – ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR 1 Starter motor disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks STARTER MOTOR REMOVAL Preparation for Drain the engine oil. Refer to "ENGINE OIL removal REPLACEMENT" section in the CHAPTER 3.
  • Page 252 – ELEC ELECTRIC STARTING SYSTEM 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 253 – ELEC ELECTRIC STARTING SYSTEM 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 254 – ELEC ELECTRIC STARTING SYSTEM 3. Install: • O-ring 1 • Starter motor yoke 2 Align the match mark a on the starter motor yoke with the match mark b on the starter motor rear cover. 4. Install: • O-ring 1 •...

  • Page 255: Charging System

    – ELEC CHARGING SYSTEM EC680000 CHARGING SYSTEM 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 Recharge or replace. *2 Check battery. Check each coupler and No good Repair or replace.
  • Page 256 – ELEC CHARGING SYSTEM 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 resistance, replace the rectifier/regulator.
  • Page 258 YAMAHA MOTOR DA AMAZÔNIA LTDA.

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