engine spec YAMAHA TTR125 2001 Service Manual

4 - 52
ENG

OIL PUMP
Oil strainer
1. Inspect:
l
Oil strainer
Cracks/damage
®
Replace.
Contamination
®
Clean the flushing oil.
ASSEMBLY AND INSTALLATION
Oil pump
1. Install:
l
Oil pump housing
1

l
Outer rotor
2

l
Inner rotor
3

l
Pin
4

l
Oil pump shaft
5

l
Pin
6

l
Oil pump cover
7

l
Washer
8

l
Circlip
9

l
Conical spring washer
0

l
Oil pump driven gear
A

l
Circlip
B

l
Screws
C

NOTE:

l
Apply engine oil onto the outer rotor, inner
rotor and oil pump shaft.
l
Install the conical spring washer in the direc-
tion as shown.
2. Install:
l
Oil strainer
l
Gasket
l
Oil pump assembly
l
Screws (oil pump assembly)
NOTE:

Apply engine oil onto the crankcase oil pas-
sage and oil pump assembly.
New
New
T R..5 Nm (0.5 m · kg, 3.6 ft · lb)
New
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)

3. Install:
l
Oil pump drive gear
1
lRotary filter 2
NOTE:
lInstall the oil pump drive gear with its groove
a facing the engine.
lInstall the rotary filter with the dog b facing
out.
lAlign the rotary filter dog b with groove c of
the crankshaft.

4 - 58
ENGCDI MAGNETO
EC4L0000
CDI MAGNETO
Extent of removal:1 CDI magneto removal
Extent of removal Order Part name Q’ty Remarks
CDI MAGNETO REMOVAL
Preparation for removal Seat and fuel tank Refer to “SAET, FUEL TANK AND SIDE
COVERS” section.
Drain the engine oil Refer to “ENGINE OIL REPLACEMENT”
section in the CHAPTER 3.
Drive sprocket cover Refer to “ENGINE REMOVAL” section.
1 CDI magneto lead 1
2 Left crankcase cover 1
3 Nut (rotor) 1
Use special tool.
Refer to “REMOVAL POINTS”.
4 Rotor 1
5 Woodruff key 1
6 Pickup coil 1
7 Lead guide 1
8Stator
1
1

4 - 69
ENGCRANKCASE, CRANKSHAFT AND BALANCER
Crankcase
1. Inspect:
lContacting surface a
Scratches ® Replace.
lEngine mounting boss b, crankcase
Cracks/damage ® Replace.
2. Inspect:
lBearing
Rotate inner race with a finger.
Rough spot/seizure ® Replace.
Crankshaft
1. Measure:
lRunout limit a
lConnecting rod big end side clearance
b
lCrank width c
Out of specification ® Replace.
Use the dial gauge and a thickness
gauge.
Dial gauge & stand set:
YU-3097/90890-01252
Standard
Runout
limit:—0.03 mm
(0.0012 in)
Side clear-
ance:0.15 ~ 0.45 mm
(0.0059 ~ 0.0177 in)0.50 mm
(0.02 in)
Crack
width:46.95 ~ 47.00 mm
(1.848 ~ 1.850 in)—

5 - 49
CHASSTEERING
EC560000
STEERING
Extent of removal:1 Lower bracket removal2 Bearing removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalSTEERING REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is nodanger of it falling over.
Front forks Refer to “FRONT FORK” section.
Handlebar Refer to “HANDLEBAR” section.
Front fender
1 Steering stem nut 1
2 Upper bracket 1
3 Special washer 1
4 Upper ring nut 1
Use special tool.
Refer to “REMOVAL POINTS”. 5 Rubber washer 1
6 Lower ring nut 1
7 Lower bracket 1
8Bearing cover
1
21

6 - 2
–+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.
*marked: Only when the ignition checker is used.
NOTE:

l
Remove the following parts before inspection.
1) Seat
2) Fuel tank
l
Use the following special tools in this inspection.
Spark gap test*Clean or replace
spark plug.
Check entire ignition
system for connection.Repair or replace.
Check engine stop switch. Replace.
Check ignition coil. Primary coil Replace.
Secondary coilReplace.
Check CDI magneto. Pickup coil Replace.
Charging coil Replace.
Replace CDI unit.
Dynamic spark tester:
YM-34487
Ignition checker:
90890-06754
Pocket tester:
YU-3112-C/90890-03112
No Spark
OK
OK
OK
OK
Spark
No good
No good
No good
No good
No good
No good

6 - 3
–+ELEC

IGNITION SYSTEM
SPARK GAP TEST
1. Disconnect the spark plug cap from spark
plug.
2. Connect the dynamic spark tester
1
(ignition checker
2
) as shown.
l
Spark plug cap
3

l
Spark plug
4


For USA and CDN
õ
Except for USA and CDN
3. Kick the kickstarter crank.
4. Check the ignition spark gap.
5. Start engine, and increase spark gap
until misfire occurs. (for USA and CDN
only)
Minimum spark gap:
6.0 mm (0.24 in)

õ

EC624000
COUPLERS AND LEADS CONNECTION
INSPECTION
1. Check:
l
Couplers and leads connection
Rust/dust/looseness/short-circuit
®

Repair or replace.
ENGINE STOP SWITCH INSPECTION
1. Inspect:
l
Engine stop switch conduct.
Not continuous while being pushed
®

Replace.
Continuous while being freed
®
Replace.
Tester (+) lead
®
Black/White lead
1

Tester (–) lead
®
Black lead
2

B/W
1
B
2
Tester selec-
tor position
PUSH IN
W

´
1
FREE