brake YAMAHA TTR125 2001 Betriebsanleitungen (in German)

3 - 18
INSP
ADJ
BRAKE PEDAL HEIGHT ADJUSTMENT
1. Check:
lBrake pedal height a
Out of specification ® Adjust.
2. Adjust:
lBrake pedal height
FRONT BRAKE PAD INSPECTION AND
REPLACEMENT (TT-R125LW)
1. Remove:
lPlug
2. Inspect:
lBrake pad thickness a
Out of specification ® Replace as a set.
Brake pedal height a:
1 mm (0.04 in)
Pedal height adjustment steps:
lLoosen the locknut 1.
lTurn the adjusting bolt 2 until the pedal
height a is within specified height.
lTighten the locknut.
Brake pad thickness a:
Standard
4.0 mm
(0.16 in)0.8 mm
(0.03 in)
3. Replace:
lBrake pad
Brake pad replacement steps:
lRemove the brake caliper support bolt 1.
lTurn the brake caliper 2 counterclock-
wise a.
lReplace the brake pads 3.
BRAKE PEDAL HEIGHT ADJUSTMENT/FRONT BRAKE
PAD INSPECTION AND REPLACEMENT (TT-R125LW)

3 - 19
INSP
ADJ
4. Inspect:
lBrake fluid level
Refer to “BRAKE FLUID LEVEL
INSPECTION” section in the CHAP-
TER 3.
5. Check:
lBrake lever operation
A softy or spongy feeling ® Bleed
brake system.
Refer to “BRAKE SYSTEM AIR
BLEEDING” section.
FRONT BRAKE SHOE INSPECTION (TT-R125)
1. Inspect:
lBrake shoe lining wear limit
lConnect the transparent hose 4 to the
bleed screw 5 and place the suitable con-
tainer under its end.
lLoosen the bleed screw and push the
brake caliper piston in.
CAUTION:
Do not reuse the drained brake fluid.
lTighten the bleed screw.
T R..
Bleed screw:
6 Nm (0.6 m • kg, 4.3 ft • lb)
lInstall the brake caliper 6 and brake cali-
per support bolt 7.
NOTE:
Apply the lithium soap base grease on the
caliper support bolt.
T R..
Brake caliper support bolt:
22 Nm (2.2 m • kg, 16 ft • lb)
Brake shoe lining wear limit checking
steps:
lFully pull in the brake lever and hold it in
position.
lThen check the brake shoe wear indicator
1 is within the wear limit a.
Outside the limit ® Replace the brake
shoe.
Refer to “FRONT WHEEL AND FRONT
BRAKE” section in the CHAPTER 5.
FRONT BRAKE SHOE INSPECTION (TT-R125)

3 - 20
INSP
ADJ
REAR BRAKE SHOE INSPECTION
1. Inspect:
lBrake shoe lining wear limit
BRAKE FLUID LEVEL INSPECTION
(TT-R125LW)
1. Place the brake master cylinder so that
its top is in a horizontal position.
2. Inspect:
lBrake fluid level
Fluid at lower level ® Fill up.
aLower level
WARNING
lUse only designated quality brake fluid to
avoid poor brake performance.
lRefill with same type and brand of brake
fluid; mixing fluids could result in poor
brake performance.
lBe sure that water or other contaminants
do not enter brake master cylinder when
refilling.
lClean up spilled fluid immediately to
avoid erosion of painted surfaces or plas-
tic parts. Brake shoe lining wear limit checking
steps:
lFully push down the brake pedal and hold
it in position.
lThen check the brake shoe wear indicator
1 is within the wear limit a.
Outside the limit ® Replace the brake
shoe.
Refer to “REAR WHEEL AND REAR BRAKE”
section in the CHAPTER 5.
Recommended brake fluid:
DOT #4
SPROCKETS INSPECTION
1. Inspect:
lSprocket teeth a
Excessive wear ® Replace.
NOTE:
Replace the drive, driven sprockets and drive
chain as a set.
REAR BRAKE SHOE INSPECTION/BRAKE FLUID LEVEL
INSPECTION (TT-R125LW)/SPROCKETS INSPECTION

3 - 23
INSP
ADJFRONT FORK INSPECTION/
REAR SHOCK ABSORBER ASSEMBLY INSPECTION/
REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT
EC36C000
FRONT FORK INSPECTION
1. Inspect:
lFront fork smooth action
Operate the front brake and stroke the
front fork.
Unsmooth action/oil leakage ® Repair
or replace.
REAR SHOCK ABSORBER ASSEMBLY
INSPECTION
1. Inspect:
lSwingarm 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. Elevate the rear wheel by placing the
suitable stand under the engine.
2. Remove:
lLeft side cover
3. Loosen:
lLocknut 1
4. Adjust:
lSpring preload
By turning the adjuster 2.
Stiffer ®Increase the spring preload.
(Turn the adjuster 2 in.)
Softer ®Decrease the spring preload.
(Turn the adjuster 2 out.)
Spring length (installed) a:
Standard length Extent of adjustment
165 mm
(6.50 in)155 ~ 175 mm
(6.10 ~ 6.89 in)

3 - 28
INSP
ADJ
LUBRICATION
LUBRICATION
To ensure smooth operation of all compo-
nents, lubricate your machine during setup,
after break-in, and after every ride.
1All control cable
2Brake and clutch lever pivots
3Shift pedal pivot
4Footrest pivot
5Throttle-to-handlebar contact
6Drive chain
7Tube guide cable winding portion
8Throttle cable end
9Brake and clutch cable ends
(Clutch cable end only for the TT-R125LW)Use Yamaha cable lube or equivalent on these
areas.
õUse SAE 10W-30 motor oil or suitable chain
lubricants.
‚Lubricate the following areas with high quality,
lightweight lithium-soap base grease.
AAA
AAB
CC

5 - 1
CHAS

FRONT WHEEL AND FRONT BRAKE (TT-R125)
EC500000
CHASSIS
FRONT WHEEL AND FRONT BRAKE (TT-R125)
Extent of removal:
1
Front wheel removal
2
Wheel bearing removal
3
Brake shoe plate assembly removal and disassembly
Extent of removal Order Part name Q’ty Remarks
Preparation for removal
FRONT WHEEL AND DRUM
BRAKE
Hold the machine by placing the
suitable stand under the engine.
WARNING

Support the machine securely so there is no
danger of it falling over.
1 Brake cable holder 1
2 Brake cable 1 Disconnect at the lever side, first.
3 Axle nut 1
4 Wheel axle 1
5 Front wheel 1
6 Collar set 1
7 Brake shoe plate assembly 1
8 Oil seal 1
9 Wheel bearing 2 Refer to “REMOVAL POINTS”.
10Spacer
1
2
3
1

5

5 - 2
CHAS

FRONT WHEEL AND FRONT BRAKE (TT-R125)
Extent of removal Order Part name Q’ty Remarks
11 Brake shoe 2
12 Spring 2
13 Brake camshaft lever 1
14 Wear indicator plate 1
15 Brake camshaft 1
16 Brake shoe plate 1
3

5 - 3
CHAS

FRONT WHEEL AND FRONT BRAKE (TT-R125)
REMOVAL POINTS
EC513201
Wheel bearing (if necessary)
1. Remove:
l
Bearing
1

NOTE:

Remove the bearing using a general bearing
puller
2
.
INSPECTION
EC514100
Wheel
1. Measure:
l
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. Inspect:
l
Bearing
Rotate inner race with a finger.
Rough spot/seizure
®
Replace.
NOTE:

Replace the bearings, oil seal and wheel collar
as a set.
EC514200
Wheel axle
1. Measure:
l
Wheel axle bends
Out of specification
®
Replace.
Use the dial gauge
1
.
NOTE:

The bending value is shown by one half of the
dial gauge reading.
WARNING

Do not attempt to straighten a bent axle.
Wheel axle bending limit:
0.5 mm (0.020 in)

5 - 4
CHAS

FRONT WHEEL AND FRONT BRAKE (TT-R125)
Drum brake
1. Inspect:
l
Brake shoe lining surface
Glazed areas
®
Polish.
Use coarse sand paper.
NOTE:

After polishing, wipe the polished particles with
a cloth.
2. Measure:
l
Brake shoe lining thickness
a

Out of specification
®
Replace.
NOTE:

Replace the brake shoes and springs as a set
if either is worn to the limit.
Brake shoe lining thickness:
Standard
40 mm
(0.16 in)2.0 mm
(0.08 in)
3. Measure:
l
Brake drum inside diameter
a

Out of specification
®
Replace.
Brake drum inside diameter:
Standard
110 mm
(4.33 in)111 mm
(4.37 in)
4. Inspect:
l
Brake drum inner surface
Oil/scratches
®
Remove.
OilUse a rag soaked in lac-
quer thinner or a solvent.
ScratchesUse a emery cloth (lightly
and evenly polishing).

5 - 5
CHAS

FRONT WHEEL AND FRONT BRAKE (TT-R125)
ASSEMBLY AND INSTALLATION
Brake shoe plate assembly
1. Install:
l
Brake camshaft
1

NOTE:

Apply the lithium soap base grease on the
brake camshaft.
2. Check:
l
Brake camshaft operation
Unsmooth operation
®
Repair.
3. Install:
l
Wear indicator plate
1

NOTE:

When installing the wear indicator plate to the
brake camshaft align the projection
a
on the
wear indicator plate with the slots
b
on the
brake camshaft.
4. Install:
l
Brake camshaft lever
1

NOTE:

Install the brake camshaft lever in relation to
the punch mark
a
as shown.
1
1a
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

5. Install:
l
Springs
1

lBrake shoes 2
NOTE:
Apply the lithium soap base grease on the
pivot pin.
WARNING
Do not apply grease to the brake shoe lin-
ings.
New