torque YAMAHA TTR125 2002 User Guide

SPEC
2 - 23
MAINTENANCE SPECIFICATIONS
EC212300
ELECTRICAL
Item Standard Limit
CDI:
Magneto-model (stator)/manufacturer 5HP-01/YAMAHA ----
Charging coil resistance (color) 688 ~ 1,032 W at 20 ˚C (68 ˚F)
(Green-Brown)----
Pickup coil resistance (color) 248 ~ 372 W at 20 ˚C (68 ˚F)
(White-Red)----
CDI unit-model/manufacturer 5HP-00/YAMAHA ----
Ignition coil:
Model/manufacturer 4KJ-10/YAMAHA ----
Minimum spark gap 6 mm (0.24 in) ----
Primary coil resistance 0.18 ~ 0.28 W at 20 ˚C (68 ˚F) ----
Secondary coil resistance 6.3 ~ 9.5 kW at 20 ˚C (68 ˚F) ----
Part to be tightened Thread size Q’tyTightening torque
Nm m•kg ft•lb
Pickup coil M6 ´ 1.0 2 10 1.0 7.2
Blind plug (neutral switch) M10 ´ 1.25 1 20 2.0 14
Stator M6 ´ 1.0 3 10 1.0 7.2
Rotor M12 ´ 1.25 1 80 8.0 58
Ignition coil M6 ´ 1.0 2 7 0.7 5.1

2 - 24
SPEC

GENERAL TORQUE SPECIFICATIONS/
DEFINITION OF UNITS
EC220001
GENERAL TORQUE SPECIFICATIONS
This chart specifies torque for standard fasten-
ers with standard I.S.O. pitch threads. Torque
specifications for special components or
assemblies are included in the applicable sec-
tions of this book. To avoid warpage, tighten
multi-fastener assemblies in a crisscross fash-
ion, in progressive stages, until full torque is
reached. Unless otherwise specified, torque
specifications call for clean, dry threads. Com-
ponents should be at room temperature.
A
(Nut)B
(Bolt)TORQUE
SPECIFICATION
Nm m•kg ft•lb
10 mm
12 mm
14 mm
17 mm
19 mm
22 mm6 mm
8 mm
10 mm
12 mm
14 mm
16 mm6
15
30
55
85
1300.6
1.5
3.0
5.5
8.5
134.3
11
22
40
61
94
A: Distance between flats
B: Outside thread diameter
EC230000
DEFINITION OF UNITS
Unit Read Definition Measure
mm
cmmillimeter
centimeter10
-3

meter
10
-2

meterLength
Length
kg kilogram 10
3

gram Weight
N Newton 1 kg
´
m/sec
2

Force
Nm
m • kgNewton meter
Meter kilogramN
´
m
m
´
kgTorque
Torque
Pa Pascal N/m
2

Pressure
N/mm Newton per millimeter N/mm Spring rate
L
cm
3

Liter
Cubic centimeter—
—Volume or capacity
Volume or capacity
r/min Revolution per minute — Engine speed

3 - 26
INSP
ADJ
STEERING HEAD INSPECTION AND ADJUSTMENT
3. Check:
lSteering smooth action
Turn the handlebar lock to lock.
Unsmooth action ® Adjust steering ring
nut.
4. Adjust:
lSteering ring nut
Steering ring nut adjustment steps:
lRemove the number plate and starter
knob.
lRemove the handlebar and upper bracket.
lRemove the special washer 1
lRemove the upper ring nut 2, and rubber
washer 3.
lLoosen the lower ring nut 4 using the
steering nut wrench 5.
Steering nut wrench:
YU-33975/90890-01403
lTighten the lower ring nut 6 using steer-
ing nut wrench 7 and turn the steering
right and left a few times.
Steering nut wrench:
YU-33975/90890-01403
T R..
Lower ring nut (initial tightening):
38 Nm (3.8 m • kg, 27 ft • lb)
lLoosen the lower ring nut one turn.
lRetighten the lower ring nut using the
steering nut wrench.
NOTE:
Set the torque wrench to the steering nut
wrench so that they form a right angle.
WARNING
Avoid over-tightening.

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)