ad blue YAMAHA TTR125 2002 Betriebsanleitungen (in German)

4 - 21
ENGCAMSHAFT AND ROCKER ARMS
REMOVAL POINTS
Rocker arm shaft
1. Remove:
lRocker arm shafts
NOTE:
Use a slide hammer bolt 1 and weight 2 to
slide out the rocker arm shafts.
Small slide hammer set:
YU-1083-A
Slide hammer bolt:
90890-01085
Weight:
90890-01084
Camshaft
1. Remove:
lCamshaft 1
lCamshaft bearing 2
NOTE:
Screw in a suitable length of 8 mm bolt 3 into
the threaded end of the camshaft and pull out
the camshaft.
INSPECTION
Camshaft
1. Inspect:
lCam lobes
Pitting/scratches/blue discoloration ®
Replace.
2. Measure:
lCam lobes length a and b
Out of specification ® Replace.
Cam lobes length limit:
Intake:
a 25.851 mm (1.0178 in)
b 21.165 mm (0.8333 in)
Exhaust:
a 25.811 mm (1.0162 in)
b 21.020 mm (0.8276 in)

4 - 22
ENGCAMSHAFT AND ROCKER ARMS
Rocker arms and rocker arm shafts
1. Inspect:
lCam lobe contact surface a
lAdjuster surface 1
Wear/pitting/scratches/blue discolora-
tion ® Replace.
Measurement steps:
lMeasure the inside diameter a of the
rocker arm holes.
Out of specification ® Replace.
Inside diameter (rocker arm):
10.000 ~ 10.015 mm
(0.3937 ~ 0.3943 in)
: 10.03 mm (0.3949 in)
lMeasure the outside diameter b of the
rocker arm shafts.
Out of specification ® Replace.
Outside diameter
(rocker arm shaft):
9.981 ~ 9.991 mm
(0.3930 ~ 0.3933 in)
: 9.95 mm (0.3917 in)
ASSEMBLY AND INSTALLATION
1. Apply:
lMolybdenum disulfide oil
(onto the camshaft cam lobe and rocker
arm hole)
lEngine oil
(onto the camshaft bearing)
2. Install:
lRocker arms
lCamshaft 1
3. Apply:
lEngine oil
(onto the rocker arm shaft)
4. Install:
lRocker arm shaft

4 - 28
ENGVALVES AND VALVE SPRINGS
8. Measure:
lValve seat width a
Out of specification ® Reface the valve
seat.
Valve seat width:
Intake:
0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)
: 1.6 mm (0.0630 in)
Exhaust:
0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)
: 1.6 mm (0.0630 in)
Measurement steps:
lApply Mechanic’s blueing dye (Dykem) b
to the valve face.
lInstall the valve into the cylinder head.
lPress the valve through the valve guide
and onto the valve seat to make a clear
pattern.
lMeasure the valve seat width. Where the
valve seat and valve face made contact,
blueing will have been removed.
lIf the valve seat is too wide, too narrow, or
the seat is not centered, the valve seat
must be refaced.
9. Lap:
lValve face
lValve seat
NOTE:
After refacing the valve seat or replacing the
valve and valve guide, the valve seat and
valve face should be lapped.
Lapping steps:
lApply a coarse lapping compound to the
valve face.
CAUTION:
Do not let the compound enter the gap
between the valve stem and the valve
guide.
lApply molybdenum disulfide oil to the
valve stem.

4 - 29
ENGVALVES AND VALVE SPRINGS
lInstall the valve into the cylinder head.
lTurn the valve until the valve face and
valve seat are evenly polished, then clean
off all of the compound.
NOTE:
For best lapping results, lightly tap the valve
seat while rotating the valve back and forth
between your hands.
lApply a fine lapping compound to the
valve face and repeat the above steps.
NOTE:
After every lapping operation be sure to
clean off all of the compound from the valve
face and valve seat.
lApply Mechanic’s blueing dye (Dykem) to
the valve face.
lInstall the valve into the cylinder head.
lPress the valve through the valve guide
and onto the valve seat to make a clear
pattern.
lMeasure the valve seat width again. If the
valve seat width is out of specification,
reface and re-lap the valve seat.
Valve spring
1. Measure:
lValve spring free length a
Out of specification ® Replace.
Free length (valve spring):
Intake:
32.55 mm (1.28 in)
: 31.2 mm (1.23 in)
Exhaust:
32.55 mm (1.28 in)
: 31.2 mm (1.23 in)

4 - 35
ENGCYLINDER AND PISTON
lIf out of specification, replace the cylinder,
and replace the piston and piston rings as
a set.
Piston pin
1. Inspect:
lPiston pin
Blue discoloration/grooves ® Replace,
then inspect the lubrication system.
2. Measure:
lPiston pin-to-piston clearance
Measurement steps:
lMeasure the piston pin outside diameter
a.
If out of specification, replace the piston
pin.
Outside diameter (piston pin):
14.991 ~ 15.000 mm
(0.5902 ~ 0.5906 in)
: 14.971 mm (0.5894 in)
lMeasure the piston inside diameter b.
If out of specification, replace the piston.
Inside diameter (piston):
15.002 ~ 15.013 mm
(0.5906 ~ 0.5911 in)
: 15.043 mm (0.5922 in)

4 - 37
ENGCYLINDER AND PISTON
Combination of piston and cylinder
1. Check:
lCylinder mark a
2. Check:
lPiston mark a
3. Combination:
lCombine the piston and cylinder by the
following chart.
NOTE:
When you purchase a cylinder, you cannot
designate its size. Choose the piston that
matches the above chart.Cylinder mark aCylinder size
A54.000 ~ 54.003 mm
(2.1260 ~ 2.1261 in)
B54.004 ~ 54.007 mm
(2.1261 ~ 2.1263 in)
C54.008 ~ 54.011 mm
(2.1263 ~ 2.1264 in)
D54.012 ~ 54.015 mm
(2.1265 ~ 2.1266 in)
E54.016 ~ 54.019 mm
(2.1266 ~ 2.1267 in)
Cylinder mark a
(color)Piston size
A (red)53.977 ~ 53.980 mm
(2.1251 ~ 2.1252 in)
B (orange)53.981 ~ 53.984 mm
(2.1252 ~ 2.1254 in)
C (green)53.985 ~ 53.988 mm
(2.1254 ~ 2.1255 in)
D (purple)53.989 ~ 53.992 mm
(2.1255 ~ 2.1257 in)
E (blue)53.993 ~ 53.996 mm
(2.1257 ~ 2.1258 in)
Cylinder mark Piston mark (color)
A A (red)
B B (orange)
C C (green)
D D (purple)
E E (blue)

6 - 1
–+ELEC

* The illustration shows the TT-R125LW
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC600000
ELECTRICAL
EC610000
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC611000
ELECTRICAL COMPONENTS
1
CDI unit
2
Engine stop switch
3
Ignition coil
4
CDI magneto
5
Spark plug
COLOR CODE
B...................... Black
Br .................... Brown
G ..................... Green
O ..................... Orange
R ..................... Red
W..................... WhiteB/R .................. Black/Red
B/W ................. Black/White
G/L .................. Green/Blue
G/W ................. Green/White
W/L .................. White/Blue
W/R ................. White/Red
EC612000
WIRING DIAGRAM
6