clock YAMAHA TTR125 2001 Owners Manual

1 - 11
GEN
INFO
CONTROL FUNCTIONS
FUEL TANK CAP
Remove the fuel tank cap 1 by turning coun-
terclockwise.
WARNING
Do not overfill the fuel tank. Avoid spilling
fuel on the hot engine.
SIDESTAND
This sidestand 1 is used to support only the
machine when standing or transporting it.
WARNING
lNever apply additional force to the side-
stand.
lHold up the sidestand before starting out.

SPEC

2 - 9
MAINTENANCE SPECIFICATIONS
Stem runout limit----0.01 mm
(0.0004 in)
Valve seat width IN0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)1.6 mm
(0.0630 in)
EX 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)1.6 mm
(0.0630 in)
Valve spring:
Free length IN 32.55 mm (1.28 in) 31.2 mm
(1.23 in)
EX 32.55 mm (1.28 in) 31.2 mm
(1.23 in)
Set length (valve closed) IN 25.6 mm (1.01 in) ----
EX 25.6 mm (1.01 in) ----
Compressed pressure
(installed) IN 137.5 ~ 158.1 N
(14.0 ~ 16.1 kg, 30.86 ~ 35.49 lb)----
EX 137.5 ~ 158.1 N
(14.0 ~ 16.1 kg, 30.86 ~ 35.49 lb)----
Tilt limit * IN ----2.5˚/1.4 mm
(2.5˚/0.06 in)
EX ----2.5˚/1.4 mm
(2.5˚/0.06 in)
Direction of winding
(top view) IN Clockwise ----
EX Clockwise ---- Item Standard Limit

3 - 12
INSP
ADJ
VALVE CLEARANCE INSPECTION AND ADJUSTMENT
4. Check:
lValve 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:
lTurn the crankshaft counterclockwise with
a wrench.
lAlign the T.D.C. mark a on the rotor with
the align mark b on the crankcase cover
when piston is at T.D.C. on compression
stroke.
lMeasure the valve clearance using a
feeler gauge 1.
Out of specification ® Adjust clearance.
5. Adjust:
lValve clearance
Adjustment steps:
lLoosen the locknut 1.
lTurn the adjuster 3 in or out with the
valve adjusting tool 2 until specified clear-
ance is obtained.
Turning in ®
Valve clearance is decreased.
Turning out ®
Valve clearance is increased.
Tappet adjusting tool:
YM-8035/90890-01311
lHold the adjuster to prevent it from moving
and tighten the locknut.
T R..
Locknut:
8 Nm (0.8 m • kg, 5.8 ft • lb)

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)

4 - 14
ENG

CYLINDER HEAD
REMOVAL POINTS
Cylinder head
1. Align:
l
“I” mark
(with stationary pointer)
Checking steps:
l
Turn the crankshaft counterclockwise with
a wrench.
l
Align the “I” mark
a
on the rotor with the
stationary pointer
b
on the crankcase
cover. When the “I” mark is aligned with
the stationary pointer, the piston is at the
Top Dead Center (T.D.C.).
NOTE:

In order to be sure that the piston is at Top
Dead Center, the match mark
c
on the
camshaft sprocket must align with the sta-
tionary pointer
d
on the cylinder head as
shown in the illustration.
2. Loosen:
l
Camshaft sprocket bolt
1

NOTE:

Remove the bolt while holding the rotor nut
with a wrench.
3. Remove:
l
Bolt (timing chain tensioner cap)
1

l
Bolt (timing chain tensioner)
2

l
Timing chain tensioner
3

4 - 17
ENGCYLINDER HEAD
3. Install:
lTiming chain
lCamshaft sprocket
4. Install:
lWasher
lBolt (camshaft sprocket)
NOTE:
Temporarily tighten the bolt (camshaft sprocket)
at this point. Installation steps:
lTurn the crankshaft counterclockwise with
a wrench.
lAlign the “I” mark a on the rotor with the
stationary pointer b on the crankcase
cover.
lAlign the match mark c on the camshaft
sprocket with the stationary pointer d on
the cylinder head.
lFit the timing chain 1 onto camshaft
sprocket 2 and install the camshaft
sprocket on the camshaft.
NOTE:
When installing the camshaft sprocket, keep
the timing chain as tense as possible on the
exhaust side.
CAUTION:
Do not turn the crankshaft during instal-
lation of the camshaft. Damage or
improper valve timing will result.
lRemove the safety wire from the timing
chain.

4 - 18
ENGCYLINDER HEAD
5. Install:
lTiming chain tensioner
6. Turn:
lCrankshaft
Counterclockwise several turns
7. Check:
lRotor “I” mark
Align with the crankcase stationary
pointer.
lCamshaft match mark
Align with the cylinder head stationary
pointer.
Out of alignment ® Adjust. Installation steps:
lWhile pressing the tensioner rod lightly
with fingers, use a thin screwdriver and
wind the tensioner rod up fully clockwise.
lWith the rod fully wound, install the gasket
1 and the chain tensioner 2, and tighten
the bolts 3 to the specified torque.
T R..
Bolt (chain tensioner):
10 Nm (1.0 m • kg, 7.2 ft • lb)
lRelease the screwdriver, check the ten-
sioner rod to come out and tighten the
gasket 4 and the cap bolt 5 to the speci-
fied torque.
T R..
Cap bolt (timing chain tensioner):
8 Nm (0.8 m • kg, 5.8 ft • lb)
8. Tighten:
lBolt 1
NOTE:
Tighten the bolt while holding the rotor nut with
a wrench.
T R..20 Nm (2.0 m · kg, 14 ft · lb)

4 - 46
ENGCLUTCH AND PRIMARY DRIVEN GEAR
Clutch
1. Install:
lConical spring washer 1
lThrust plate 2
lPrimary driven gear 3
lThrust plate 4
lClutch boss 5
2. Install:
lLock washer
lNut (clutch boss) 1
NOTE:
Use the clutch holding tool 2 to hold the clutch
boss.
For USA and CDN
õExcept for USA and CDN
3. Bend:
lLock washer tab
Clutch holding tool:
YM-91042/90890-04086
New
T R..60 Nm (6.0 m · kg, 43 ft · lb)

õ
4. Install:
lFriction plate 1
lClutch plate 2
NOTE:
lInstall the clutch plates and friction plates
alternately on the clutch boss, starting with a
friction plate and ending with a friction plate.
lApply the engine oil on the friction plates and
clutch plates.
lBe sure to install a clutch plate with projec-
tion a offset approximately 90˚ from previ-
ous plates projection. Continue this
procedure in a clockwise direction until all
clutch plates are installed.

4 - 48
ENGCLUTCH AND PRIMARY DRIVEN GEAR
9. Adjust:
lPush lever position
Adjustment steps:
lLoosen the locknut 1.
lTurn the push rod 1 2 clockwise or coun-
terclockwise to match alignment marks.
lHold the push rod 1 to prevent it from
moving and tighten the locknut to specifi-
cation.
lTighten the locknut 1.
T R..
Locknut:
8 Nm (0.8 m • kg, 5.8 ft • lb)
10. Install:
lDowel pins
lGasket (right crankcase cover)
lRight crankcase cover
lBolts (right crankcase cover)
NOTE:
lApply Quick gasket® (YAMAHA Bond
No.1215) to end of the right crankcase cover
bolts, as shown.
lTighten the bolts in stages, using a criss-
cross pattern.
Quick gasket®:
ACC-QUICK-GS-KT
YAMAHA Bond No.1215:
90890-85505
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
11. Install:
lKickstarter crank 1
lNut (kickstarter crank) 2
NOTE:
Install the kickstarter crank so that there is 5 ~
10 mm (0.2 ~ 0.4 in) a between the kickstarter
crank and the right crankcase cover.
T R..50 Nm (5.0 m · kg, 36 ft · lb)

4 - 56
ENGKICK AXLE AND SHIFT SHAFT
Shift shaft
1. Install:
lShift shaft 1
NOTE:
lApply the lithium soap base grease on the oil
seal lips.
lHook the spring ends onto the stopper 2.
Kick axle assembly
1. Install:
lKickstarter segment gear 1
lPlain washer 2
lTorsion spring 3
On kick axle 4.
NOTE:
Make sure the stopper a of the torsion spring
fits into the hole b on the kick axle.
2. Install:
lSpring guide 1
NOTE:
Slide the spring guide into the kick axle, make
sure the groove a in the spring guide fits on
the stopper of the torsion spring.
3. Install:
lKick axle assembly 1
NOTE:
lApply the engine oil on the kick axle.
lSlide the kick axle assembly into the crank-
case, make sure the clip 2 and kick axle
stopper b fit into their home positions a, c.
4. Hook:
lTorsion spring 1
NOTE:
Turn the torsion spring clockwise and hook
into the proper hole a in the crankcase.