brake YAMAHA TTR125 2001 Betriebsanleitungen (in German)

SPEC
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MAINTENANCE SPECIFICATIONS
TT-R125LWItem 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 339 mm (13.35 in) 334 mm (13.15 in)
Spring rate, STD K = 3.20 N/mm (0.330 kg/mm, 18.5 lb/in)----
Optional spring/spacer No ----
Oil capacity 156 cm
3
(5.49 Imp oz, 5.27 US oz) ----
Oil level 130 mm (5.12 in) ----
Oil grade Fork oil 10W or equivalent ----
Inner tube outer diameter 30 mm (1.18 in) ----
Front fork top end Zero mm (Zero in) ----
Rear suspension: Shock absorber travel 65 mm (2.56 in) ----
Spring free length 178 mm (7.01 in) ----
Fitting length 165 mm (6.50 in) ----
Spring rate, STD K = 58.9 N/mm
(6.0 kg/mm, 336 lb/in) ----
Optional spring No ----
Enclosed gas pressure 1,500 kPa (15 kg/cm
2, 213 psi)----
Wheel: Front wheel type Spoke wheel ----
Rear wheel type Spoke wheel ----
Front rim size/material 19 ´ 1.40/Steel ----
Rear rim size/material 16 ´ 1.60/Steel ----
Rim runout limit: Radial ---- 2.0 mm (0.08 in)
Lateral ---- 2.0 mm (0.08 in)
Drive chain: Type/manufacturer DID428 HG(I)/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. ´ Thickness 220 ´ 3.0 mm (8.66 ´ 0.12 in) 220 ´ 2.5 mm
(8.66 ´ 0.10 in)
Deflection limit ---- 0.15 mm (0.006 in)
Pad thickness 4.0 mm (0.16 in) 0.8 mm (0.03 in)
Master cylinder inside dia. 11.0 mm (0.433 in) ----
Caliper cylinder inside dia. 22.22 mm (0.875 in) ´ 2 ----
Brake fluid type DOT #4 ----

SPEC
2 - 20
MAINTENANCE SPECIFICATIONS
Rear drum brake:
Drum brake type Leading, trailing ----
Drum inside diameter 110 mm (4.33 in) 111 mm (4.37 in)
Lining thickness 4.0 mm (0.16 in) 2.0 mm (0.08 in)
Shoe spring free length 50.5 mm (1.99 in) ----
Brake lever and brake pedal:
Brake lever free play (lever end) 2 ~ 5 mm (0.08 ~ 0.20 in) ----
Brake pedal position
(vertical height below footrest top)1 mm (0.04 in) ----
Brake pedal free play 20 ~ 30 mm (0.79 ~ 1.18 in) ----
Clutch lever free play (lever end) 10 ~ 15 mm (0.39 ~ 0.59 in) ----
Throttle grip free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----Item Standard Limit

SPEC
2 - 21
MAINTENANCE SPECIFICATIONS
NOTE:
1. First, tighten the ring nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the ring nut
wrench and turn the steering right and left a few times; then loosen the ring nut one turn.
2. Retighten the ring nut 20 Nm (2.0 m • kg, 14 ft • lb).Part to be tightened Thread size Q’tyTightening torque
Nm m•kg ft•lb
Upper bracket and inner tube M8 ´ 1.25 2 25 2.5 18
Lower bracket and inner tube M10 ´ 1.25 2 60 6.0 43
Upper bracket and steering stem M22 ´ 1.0 1 110 11.0 80
Handlebar upper holder and upper bracket M8 ´ 1.25 4 23 2.3 17
Steering stem and ring nut M25 ´ 1.0 1 Refer to NOTE.
Front fork and cap bolt M25 ´ 1.0 2 23 2.3 17
Front fork and damper rod M10 ´ 1.0 2 23 2.3 17
Front fork and brake hose holder M6 ´ 1.0 2 7 0.7 5.1
Number plate M6 ´ 1.0 1 7 0.7 5.1
Starter knob M11 ´ 1.25 1 1 0.1 0.7
Starter knob stay M6 ´ 1.0 2 10 1.0 7.2
Grip cap upper and lower M5 ´ 0.8 2 4 0.4 2.9
Throttle cable cap M4 ´ 0.7 2 2 0.2 1.4
Front brake master cylinder M6 ´ 1.0 2 9 0.9 6.5
Front brake master cylinder cap M4 ´ 0.7 2 2 0.2 1.4
Brake lever mounting (bolt) M6 ´ 1.0 1 7 0.7 5.1
Brake lever mounting (nut) M6 ´ 1.0 1 7 0.7 5.1
Brake lever adjuster and locknut M6 ´ 0.75 1 4 0.4 2.9
Clutch lever mounting (bolt) M6 ´ 1.0 1 7 0.7 5.1
Clutch lever mounting (nut) M6 ´ 1.0 1 7 0.7 5.1
Clutch lever holder M5 ´ 0.8 2 4 0.4 2.9
Front brake master cylinder and joint M10 ´ 1.25 1 26 2.6 19
Front brake hose and joint M10 ´ 1.25 1 14 1.4 10
Front brake hose union bolt M10 ´ 1.25 1 26 2.6 19
Front brake caliper and front fork M8 ´ 1.25 2 30 3.0 22
Brake caliper support bolt M8 ´ 1.25 1 22 2.2 16
Front brake caliper and bleed screw M7 ´ 1.0 1 6 0.6 4.3
Front wheel axle and axle nutM12 ´ 1.25 1 45 4.5 32
Front brake disc and wheel hub M6 ´ 1.0 4 12 1.2 8.7
Rear wheel axle and axle nutM12 ´ 1.25 1 60 6.0 43
Rear brake camshaft lever and camshaft M6 ´ 1.0 1 10 1.0 7.2
Brake pedal mounting M10 ´ 1.25 1 30 3.0 22
Brake pedal position locknut M6 ´ 1.0 1 7 0.7 5.1
Front wheel nipple (spoke) — 36 2 0.2 1.4
Rear wheel nipple (spoke) — 36 3 0.3 2.2

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SPEC

CABLE ROUTING DIAGRAM
EC240000
CABLE ROUTING DIAGRAM
1
Fuel tank breather hose
2
CDI unit
3
CDI unit band
4
Clamp
5
CDI magneto lead
6
Air vent hose
7
Wire harness
8
Engine stop switch lead
9
Cable guide
0
Brake cable
(Brake hose for the
TT-R125LW)
A
Brake cable holder
(Brake hose holder for the
TT-R125LW)

Fit the CDI unit band over the CDI unit bracket till it stops.
õ
Clamp the ignition coil lead.
‚
Clamp the wire harness coupler.
ë
Clamp the CDI magneto lead, throttle cable and starter cable.
ä
Clamp the CDI magneto lead so that it does not contact the push lever.
ì
Pass the air vent hoses between the engine and swingarm.
í
Clamp the wire harness and engine stop switch lead.
î
Pass the brake cable (brake hose for the TT-R125LW) into the cable guide.
é
Clamp the brake cable.
ï
Clamp the brake hose between the paint marks.

2 - 27
SPEC

CABLE ROUTING DIAGRAM
1
Engine stop switch lead
2
Engine stop switch
3
Fuel tank breather hose
4
Clamp
5
Brake cable
(Brake hose for the TT-R125LW)
6
Clutch cable
7Throttle cablePass the engine stop switch lead in the middle of the clutch holder.
õClamp the engine stop switch lead to the handlebar to 3 clicks.
‚Pass the brake cable (brake hose for the TT-R125LW) in front of the
number plate and through the cable guide.
ëPass the clutch cable in back of the number plate.
äInsert the fuel tank breather hose into the hole in the starter knob stay
more the 30 mm (1.18 in).
ìClamp the throttle cable adjuster cover to the handlebar with the clamp
ends downward.

3 - 1
INSP
ADJ

MAINTENANCE INTERVALS
EC300000
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind
that such factors as weather, terrain, geographical location, and individual usage will alter the
required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in
maintaining and lubricating your machine, consult your Yamaha dealer.
Dealer
NoteItem Checks and maintenance jobsInitial Every
10 hours
(1 month)60 hours
(6 months)120 hours
(12 months)
*
Fuel lineCheck fuel hoses for cracks or damage.
Replace if necessary.
Spark plugCheck condition.
Clean, regap or replace if necessary.
*
ValvesCheck valve clearance.
Adjust if necessary.
Air filter Clean or replace element if necessary.
*
CarburetorCheck engine idling speed and starter operation.
Adjust if necessary.
Exhaust systemsCheck for leakage.
Retighten if necessary.
Replace gasket if necessary.
Engine oilCheck oil level and vehicle for oil leakage.
Correct if necessary.
Change. (Warm engine before draining.)
ClutchCheck operation.
Adjust or replace cable.
*
Front brakeCheck operation.
Adjust brake lever free play.
Check fluid level and leakage. (TT-R125LW only)Every ride
*
Rear brakeCheck operation.
Adjust brake pedal free play and replace brake
shoes if necessary.Every ride
*
WheelsCheck balance, runout, spoke tightness and for
damage.
Tighten spokes and rebalance, replace if
necessary.
*
TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
*
Wheel bearingsCheck bearing for looseness or damage.
Replace if necessary.
*
SwingarmCheck swingarm pivoting point for play.
Correct if necessary.
Lubricate with molybdenum disulfide grease.
Drive chainCheck chain slack.
Adjust if necessary. Make sure that the rear wheel
is properly aligned.
Clean and lubricate.Every ride
*
Steering bearingsCheck bearing play and steering for roughness.
Correct accordingly.
Lubricate with lithium soap base grease every 120
hours.
SidestandCheck operation.
Lubricate and repair if necessary.
3

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INSP
ADJ

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
FuelCheck that a fresh gasoline is filled in the fuel tank. Check the
fuel line for leakage.P.1-12
Engine oilCheck that the oil level is correct. Check the crankcase for leak-
age.P.3-7 ~ 10
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-4
Throttle grip/housingCheck that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.P.3-4 ~ 5
BrakesCheck the play of front and rear brake and effect of front and
rear brake.
Check fluid level and leakage. (TT-R125LW only)P.3-15 ~ 20
Drive chainCheck chain slack and alignment. Check that the chain is lubri-
cated properly.P.3-21 ~ 22
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-24 ~ 25
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-25 ~ 27
Front forks and rear shock
absorber assemblyCheck that they operate smoothly and there is no oil leakage. P.3-23 ~ 24
Cables (wires)Check that the clutch and throttle cables move smoothly. Check
that they are not caught when the handlebars are turned or
when the front forks travel up and down.—
Muffler Check that the muffler is tightly mounted and has no cracks. P.4-2
Sprocket Check that the driven sprocket tightening nut is not loose. P.3-20
Lubrication Check for smooth operation. Lubricate if necessary. P.3-28
Bolts and nuts Check the chassis and engine for loose bolts and nuts. —
Lead connectorsCheck that the CDI magneto, CDI unit, and ignition coil are con-
nected tightly.P.1-5

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INSP
ADJ
EC360000
CHASSIS
EC361012
BRAKE SYSTEM AIR BLEEDING (TT-R125LW)
WARNING
Bleed the brake system if:
lThe system has been disassembled.
lA brake hose has been loosened or
removed.
lThe brake fluid is very low.
lThe brake operation is faulty.
A dangerous loss of braking performance
may occur if the brake system is not prop-
erly bleed.
1. Remove:
lBrake master cylinder cap
lDiaphragm
2. Bleed:
lBrake fluid
Air bleeding steps:
a. Add proper brake fluid to the reservoir.
b. Install the diaphragm. Be careful not to
spill any fluid or allow the reservoir to
overflow.
c. Connect the clear plastic tube 2 tightly
to the caliper bleed screw 1.
d. Place the other end of the tube into a
container.
e. Slowly apply the brake lever several
times.
f. Pull in the lever. Hold the lever in posi-
tion.
g. Loosen the bleed screw and allow the
lever to travel towards its limit.
h. Tighten the bleed screw when the lever
limit has been reached; then release the
lever.
T R..
Bleed screw:
6 Nm (0.6 m • kg, 4.3 ft • lb)
i. Repeat steps (e) to (h) until of the air
bubbles have been removed from the
system.
CHASSIS/BRAKE SYSTEM AIR BLEEDING (TT-R125LW)

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INSP
ADJ
3. Install:
lDiaphragm
lBrake master cylinder cap
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.
WARNING
Check the operation of the brake after
bleeding the brake system.
FRONT BRAKE ADJUSTMENT
TT-R125
1. Check:
lBrake lever free play a
Out of specification ® Adjust.
2. Adjust:
lBrake lever free play
NOTE:
For minute adjustment, loosen the locknut 2
on the lever side and adjust with the adjuster
3.
CAUTION:
Make sure that there is no brake drag after
adjusting the brake lever free play.
Brake lever free play a:
10 ~ 15 mm (0.39 ~ 0.59 in)
Brake lever free play adjustment steps:
lLoosen the locknuts 1.
lTurn the locknuts until free play a is
within the specified limits by changing their
tightening position.
lTighten the locknuts.
FRONT BRAKE ADJUSTMENT

3 - 17
INSP
ADJ
TT-R125LW
1. Check:
lBrake lever free play a
Out of specification ® Adjust.
2. Adjust:
lBrake lever free play
CAUTION:
Make sure that there is no brake drag after
adjusting the brake lever free play.
Brake lever free play a:
2 ~ 5 mm (0.08 ~ 0.20 in)
Brake lever free play adjustment steps:
lLoosen the locknut 1.
lTurn the adjuster 2 until the free play a
is within the specified limits.
lTighten the locknut.
REAR BRAKE ADJUSTMENT
1. Check:
lBrake pedal free play a
Out of specification ® Adjust.
2. Adjust:
lBrake pedal free play
CAUTION:
Make sure that there is no brake drag after
adjusting the brake pedal play.
Brake pedal free play a:
20 ~ 30 mm (0.79 ~ 1.18 in)
Brake pedal free play adjustment step:
Turn the adjuster 1 until the free play a is
within the specified limits.
REAR BRAKE ADJUSTMENT