warning YAMAHA TTR125 2002 Owner's Guide

5 - 32
CHASFRONT FORK
EC550000
FRONT FORK
Extent of removal:1 Front fork removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalFRONT FORK 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 wheel Refer to “FRONT WHEEL AND FRONT
BRAKE” section.
(Refer to “FRONT WHEEL” section for
the TT-R125LW.)
Handlebar Refer to “HANDLEBAR” section.
1 Cap 1
2 Pinch bolt (upper bracket) 1 Only loosening.
3 Cap bolt 1Loosen when disassembling the front fork.
4 Pinch bolt (lower bracket) 1 Only loosening.
5Front fork
1
1

5 - 36
CHASFRONT FORK
Inner tube
1. Inspect:
lInner tube surface a
Score marks ® Repair or replace.
Use #1,000 grit wet sandpaper.
Damaged oil lock piece ® Replace.
lInner tube 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 inner
tube as this may dangerously weaken the
tube.
2. Inspect:
lPiston metal 1
Wear/damage ® Replace.
Inner tube bending limit:
0.2 mm (0.008 in)
Outer tube
1. Inspect:
lOuter tube 1
lSlide metal 2
Score marks/wear/damage ® Replace
outer tube assembly.
Cap bolt
1. Inspect:
lCap bolt 1
lO-ring 2
Wear/damage ® Replace.

5 - 45
CHAS
REMOVAL POINTS
Brake master cylinder (TT-R125LW)
1. Remove:
lBrake master cylinder bracket 1
lBrake master cylinder 2
CAUTION:
lDo not let the brake master cylinder hang
on the brake hose.
lKeep the brake master cylinder cap side
horizontal to prevent air from coming in.
Handlebar grip
1. Remove:
lHandlebar grip 1
NOTE:
Blow in air between the handlebar or tube
guide and the grip. Then remove the grip
which has become loose.
INSPECTION
Handlebar
1. Inspect:
lHandlebar 1
Bends/cracks/damage ® Replace.
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken the
handlebar.
HANDLEBAR

5 - 47
CHAS
2. Install:
lHandlebar grip (left) 1
Apply the adhesive to the handlebar 2.
NOTE:
Before applying the adhesive, wipe off grease
or oil on the handlebar surface a with a lac-
quer thinner.
3. Install:
lCollar 1
4. Install:
lThrottle grip assembly 1
lGrip cap (upper) 2
lThrottle cables 3
On tube guide 4.
NOTE:
Apply the lithium soap base grease on the
throttle cable end and tube guide cable wind-
ing portion.
5. Install:
lThrottle cable cap 1
lScrew (throttle cable cap) 2
lGrip cap (lower) 3
lScrew (grip cap) 4
lCover (grip cap) 5
WARNING
After tightening the screws, check that the
throttle grip 6 moves smoothly. If it does
not, retighten the bolts for adjustment.
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
HANDLEBAR

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

5 - 51
CHAS
EC563000
REMOVAL POINTS
EC563202
Ring nut
1. Remove:
lRing nut 1
Use the steering nut wrench 2.
WARNING
Support the steering shaft so that it may
not fall down.
Steering nut wrench:
YU-33975/90890-01403
Bearing race
1. Remove:
lBearing race 1
Remove the bearing race using long
rod 2 and the hammer.
EC563300
Bearing (lower)
1. Remove:
lBearing (lower) 1
Use the floor chisel 2.
CAUTION:
Take care not to damage the steering shaft
thread.
EC564000
INSPECTION
Steering stem
1. Inspect:
lSteering stem 1
Bend/damage ® Replace.
STEERING

5 - 55
CHASSWINGARM
EC570000
SWINGARM
Extent of removal:1 Swingarm removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalSWINGARM 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.
Rear wheel Refer to “REAR WHEEL AND REAR
BRAKE” section.
1 Drive chain tensioner (upper) 1
2 Drive chain tensioner (lower) 1
3 Bolt (connecting arm-frame) 1
4 Bolt (rear shock absorber-relay arm) 1Hold the swingarm.
5 Pivot shaft 1
6 Swingarm 1
1

5 - 62
CHASREAR SHOCK ABSORBER ASSEMBLY
EC580000
REAR SHOCK ABSORBER ASSEMBLY
Extent of removal:1 Rear shock absorber assembly removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalREAR SHOCK ABSORBER
ASSEMBLY 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.
Seat and side covers Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
1 Bolt (rear shock absorber assem-
bly-relay arm)1 Hold the swingarm.
2 Bolt (rear shock absorber assem-
bly-frame)1
3 Bushing 1 Refer to “REMOVAL POINTS”.
4 Rear shock absorber assembly 1
1

5 - 63
CHASREAR SHOCK ABSORBER ASSEMBLY
HANDLING NOTE
WARNING
This rear shock absorber contains high-
pressure nitrogen gas. To prevent the dan-
ger of explosion, read and understand the
following information before handling the
shock absorber.
The manufacturer can not be held responsi-
ble for property damage or personal injury
that may result from improper handling.
1. Never tamper or attempt to open the
rear shock absorber.
2. Never throw the rear shock absorber
into an open flame or other high heat.
The rear shock absorber may explode
as a result of nitrogen gas expansion
and/or damage to the hose.
3. Be careful not to damage any part of
the rear shock absorber. A damaged
rear shock absorber will impair the
damping performance or cause a mal-
function.
4. Take care not to scratch the contact
surface of the piston rod with the cyl-
inder; or oil could leak out.
5. When scrapping the rear shock
absorber, follow the instruction on
disposal.
NOTES ON DISPOSAL (YAMAHA DEALERS
ONLY)
Gas pressure must be released before dispos-
ing of a rear shock absorber and gas cylinder.
To release the gas pressure, drill a 2 ~ 3-mm
(0.08 ~ 0.12-in) hole through the gas cylinder
at a point 12 mm (0.5 in) a from its end as
shown.
WARNING
Wear eye protection to prevent eye damage
from released gas or metal chips.

5 - 65
CHAS
Installation
1. Install:
lRear shock absorber assembly
On frame.
NOTE:
Install the rear shock absorber assembly with
its warning label a facing left side of the
machine.
2. Install:
lBolt (rear shock absorber assembly -
frame)
lPlain washer 1
lNut (rear shock absorber assembly -
frame) 2
NOTE:
Apply the molybdenum disulfide grease on the
bolt (rear shock absorber assembly - frame).
T R..53 Nm (5.3 m · kg, 38 ft · lb)
3. Install:
lBolt (rear shock absorber assembly -
relay arm)
lPlain washer 1
lNut (rear shock absorber assembly -
relay arm) 2
NOTE:
Apply the molybdenum disulfide grease on the
bolt (rear shock absorber assembly - relay
arm).
T R..35 Nm (3.5 m · kg, 25 ft · lb)
REAR SHOCK ABSORBER ASSEMBLY