fuse YAMAHA TTR125 2004 Owners Manual

SPEC
2 - 25
MAINTENANCE SPECIFICATIONS
Starter relay:
Model/manufacturer MS5F-751/JIDECO ----
Amperage rating 180 A ----
Coil winding resistance 4.2 ~ 4.6 Ω at 20 ˚C (68 ˚F) ----
Starting circuit cut-off relay:
Model/manufacturer ACM33221/MATSUSHITA ----
Coil winding resistance 75.69 ~ 92.51 Ω at 20 ˚C (68 ˚F) ----
Fuse (amperage × quantity):
Main fuse 10 A × 1 ----
Reserve fuse 10 A × 1 ----
Part to be tightened Thread size Q’tyTightening torque
Nm m•kg ft•lb
Pickup coil M6 × 1.0 2 10 1.0 7.2
Neutral switch M10 × 1.25 1 18 1.8 13
Stator M6 × 1.0 3 10 1.0 7.2
Rotor M12 × 1.25 1 80 8.0 58
Ignition coil M6 × 1.0 2 7 0.7 5.1
Starter motor M6 × 1.0 2 10 1.0 7.2 Item Standard Limit

SPEC
2 - 10 Piston:
Jeu piston-cylindre 0,020 à 0,026 mm
(0,0008 à 0,0010 in)0,15 mm
(0,0059 in)
Taille de piston “D” 53,977 à 53,996 mm
(2,1251 à 2,1258 in)----
Cote réparation de piston (2e) 54,5 mm (2,1457 in) ----
(4e) 55,0 mm (2,1654 in) ----
Point de mesure “H” 5 mm (0,20 in) ----
Décalage du piston 0,5 mm (0,0197 in) ----
Diamètre intérieur d’alésage d’axe de piston 15,002 à 15,013 mm
(0,5906 à 0,5911 in)15,043 mm
(0,5922 in)
Diamètre extérieur d’axe de piston 14,991 à 15,000 mm
(0,5902 à 0,5906 in)14,971 mm
(0,5894 in)
Segments:
Segment de feu
Type Cylindrique ----
Dimensions (B × T) 1,0 × 2,1 mm (0,04 × 0,08 in) ----
Écartement des becs (segment monté) 0,15 à 0,30 mm
(0,006 à 0,012 in)0,4 mm
(0,016 in)
Jeu latéral (monté) 0,035 à 0,090 mm
(0,0014 à 0,0035 in)0,12 mm
(0,0047 in)
Segment d’étanchéité
Type Fuselé----
Dimensions (B × T) 1,0 × 2,1 mm (0,04 × 0,08 in) ----
Écartement des becs (segment monté) 0,30 à 0,45 mm
(0,012 à 0,018 in)0,55 mm
(0,022 in)
Jeu latéral 0,020 à 0,060 mm
(0,0008 à 0,0024 in)0,12 mm
(0,0047 in)
Segment racleur d’huile
Dimensions (B × T) 2,0 × 2,2 mm (0,08 × 0,09 in) ----
Écartement des becs (segment monté) 0,20 à 0,70 mm (0,01 à 0,03 in) ---- Désignation Standard Limite
H
D
T
B
B
T
B
T
CARACTÉRISTIQUES D’ENTRETIEN

3 - 41
INSP
ADJ
6. Install:
Battery
7. Check:
Battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
8. Lubricate:
Battery terminal
9. Connect:
Battery leads
(to the battery terminals)
CAUTION:
First, connect the positive lead 1, then the
negative lead 2.
10. Install:
Battery cover
FUSE INSPECTION
(TT-R125E/TT-R125LWE)
CAUTION:
To avoid a short circuit, always set the
main switch to “OFF” when checking or
replacing a fuse.
1. Remove:
Battery cover
2. Check:
Continuity
2Reserve fuse
Recommended lubricant:
Lithium soap base grease
Checking steps:
Remove the fuse 1.
Connect the pocket tester to the fuse and
check the continuity.
NOTE:
Set the pocket tester selector to “Ω × 1”.
Pocket tester:
YU-03112-C/90890-03112
If the pocket tester indicates “∞”, replace
the fuse.
1
2
1
2
FUSE INSPECTION (TT-R125E/TT-R125LWE)

3 - 42
INSP
ADJ
3. Replace:
Blown fuse
WARNING
Never use a fuse with an amperage rating
other than that specified. Improvising or
using a fuse with the wrong amperage rat-
ing may cause extensive damage to the
electrical system, cause the starting and
ignition systems to malfunction and could
possibly cause a fire.
4. Install:
Battery cover Replacement steps:
Set the main switch to “OFF”.
Install a new fuse of the correct amperage.
Set on the switches to verify if the electri-
cal circuit is operational.
If the fuse immediately blows again, check
the electrical circuit.
ItemsAmperage
ratingQ’ty
Main fuse 10 A 1
FUSE INSPECTION (TT-R125E/TT-R125LWE)

6 - 2
–+ELEC
The illustration shows the TT-R125LWE
12345 7 6890A
EDCB
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
TT-R125E/TT-R125LWE
EC611000
ELECTRICAL COMPONENTS
1CDI unit
2Main switch
3Start switch
4Clutch switch
5Engine stop switch
6Starting circuit cut-off
relay
7Ignition coil
8Battery
9Starter relay
0Fuse
ARectifier/regulator
BNeutral switch
CCDI magneto
DStarter motor
ESpark plugCOLOR CODE
B ...................... Black
Br ..................... Brown
G...................... Green
O...................... Orange
R ...................... Red
Sb .................... Sky blueW ..................... White
Y ...................... Yellow
B/W.................. Black/White
L/Y ................... Blue/Yellow
R/W ................. Red/White
EC612000
WIRING DIAGRAM
B
R/W
WB
RYW
BR Y
10A
R
BR/W
ON
OFFR
BrRB/WBB/WBr B
ON OFF
R/WBr BB
R/WSbR/W
BB BL/Y
OFF RUN
BBBB/W
W
YWSbBSbY B
G
WBrRG
WBrRB
B/WR
W Br
GO
R
SbR/WR/WR/WR/W
R/W
B
R
B/WBrBr
B
L/Y
BSb
YW
RWBrG
RWBrG
B/W
B/W
BOO
B
B
1
2
3
45 67
8
90 A
BC
DE

6 - 8
–+ELEC
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
switch is closed).
The clutch lever is pulled to the handlebar
(the clutch switch is closed).
The starting circuit cut-off relay prevents the
starter motor from operating when neither of
these conditions has been met. In this
instance, the starting circuit cut-off relay is
open so current cannot reach the starter
motor. When at least one of the above condi-
tions has been met the starting circuit cut-off
relay is closed and the engine can be started
by pressing the start switch.
WHEN THE TRANSMISSION IS
IN NEUTRAL
WHEN THE CLUTCH LEVER IS
PULLED TO THE HANDLEBAR
1Battery
2Main fuse
3Main switch
4Start switch
5Starting circuit cut-off relay
6Neutral switch
7Clutch switch
8Starter relay
9Starter motor
12
M
3
8
54
6 9
7
ELECTRIC STARTING SYSTEM (TT-R125E/TT-R125LWE)

–+ELEC
6 - 9 INSPECTION STEPS
If the starter motor will not operate, use the following inspection steps.
*1 marked: Refer to “FUSE INSPECTION” section in the CHAPTER 3.
*2 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3.
*3 marked: Refer to “MAIN SWITCH INSPECTION” section.
NOTE:
Remove the following parts before inspection.
1) Seat
2) Rear fender
3) Fuel tank
Use 12 V battery in this inspection.
Use the following special tools in this inspection.
Pocket tester:
YU-3112-C/90890-03112
*1 Check fuseReplace fuse and
check wire harness.
*2 Check battery Recharge or replace.
Check each coupler and
wire connection.Repair or replace.
*3 Check main switch. Replace.
Check starter motor
operation.Repair or replace.
Check starting circuit
cut-off relay.Replace.
Check starter relay. Replace.
Check neutral switch. Replace.
Check clutch switch. Replace.
Check start switch. Replace.
OK
OK
OK
OK
OK
OK
OK
OK
OK
No good
No good
No good
No good
No good
No good
No good
No good
No good
No good
ELECTRIC STARTING SYSTEM (TT-R125E/TT-R125LWE)

–+ELEC
6 - 18
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.
*1 marked: Refer to “FUSE INSPECTION” section in the CHAPTER 3.
*2 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3.
NOTE:
Remove the following parts before inspection.
1) Seat
2) Rear fender
3) Fuel tank
Use the following special tool in this inspection.
Pocket tester:
YU-3112-C/90890-03112Inductive tachometer:
YU-8036-B
Engine tachometer:
90890-03113
*1 Check fuse.Replace fuse and
check wire harness.
*2 Check battery. Recharge or replace.
Check each coupler and
wire connection.Repair or replace.
Check charging voltage.Charging system is
good.
Check CDI magneto. Charging coil Replace.
Replace rectifier/regulator.
OK
OK
OK
No good
OK
No good
No good
No good
No good
OK