engine YAMAHA TTR125 2002 Repair Manual

4 - 45
ENGCLUTCH AND PRIMARY DRIVEN GEAR
Push rod
1. Inspect:
lPush rod 1 1
lBall 2
Wear/damage/bend ® Replace.
Primary drive gear
1. Inspect:
lPrimary drive gear
Wear/damage ® Replace.
EC495000
ASSEMBLY AND INSTALLATION
Push lever
1. Install:
lPush lever 1
NOTE:
lApply the lithium soap base grease on the oil
seal lip.
lApply the engine oil on the push lever.
Primary drive gear
1. Install:
lStraight key
lPrimary drive gear 1
lWasher 2
lNut (primary drive gear) 3
lPrimary driven gear 4
NOTE:
lInstall the primary drive gear with the stamp
a facing out.
lPlace a folded rag or aluminum plate 5
between the teeth of the primary drive gear
and primary driven gear.
T R..70 Nm (7.0 m · kg, 50 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 - 47
ENGCLUTCH AND PRIMARY DRIVEN GEAR
5. Install:
lBall
NOTE:
Apply the engine oil on the ball.
6. Install:
lPush rod 1 1
lPush plate 2
lWasher 3
lNut (push rod 1) 4
7. Install:
lPressure plate 1
lClutch spring 2
lBolt (clutch spring) 3
NOTE:
lAlign the arrow mark a on the pressure
plate with the punched mark b on the clutch
boss.
lTighten the bolts in stage, using a crisscross
pattern.
T R..6 Nm (0.6 m · kg, 4.3 ft · lb)
8. Check:
lPush lever position
Push the push lever assembly in the
arrow direction and make sure that the
mach mark are aligned ® adjust.
aMatch mark on the push lever assembly
bMatch mark on the crankcase

4 - 52
ENGOIL PUMP
Oil strainer
1. Inspect:
lOil strainer
Cracks/damage ® Replace.
Contamination ® Clean the flushing oil.
ASSEMBLY AND INSTALLATION
Oil pump
1. Install:
lOil pump housing 1
lOuter rotor 2
lInner rotor 3
lPin 4
lOil pump shaft 5
lPin 6
lOil pump cover 7
lWasher 8
lCirclip 9
lConical spring washer 0
lOil pump driven gear A
lCirclip B
lScrews C
NOTE:
lApply engine oil onto the outer rotor, inner
rotor and oil pump shaft.
lInstall the conical spring washer in the direc-
tion as shown.
2. Install:
lOil strainer
lGasket
lOil pump assembly
lScrews (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:
lOil 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 - 53
ENGKICK AXLE AND SHIFT SHAFT
KICK AXLE AND SHIFT SHAFT
KICK AXLE AND SHIFT SHAFT
Extent of removal:1 Kick axle removal2 Shift shaft removal
Extent of removal Order Part name Q’ty Remarks
KICK AXLE AND SHIFT SHAFT
REMOVAL
Preparation for removal Shift pedal link Refer to “ENGINE REMOVAL” section.
Clutch Refer to “CLUTCH AND PRIMARY
DRIVEN GEAR” section.
1 Kick axle assembly 1 Refer to “REMOVAL POINTS”.
2 Circlip 1
3 Washer 1
4 Kick idle gear 1
5 Washer 1
6 Circlip 1
7 Shift shaft 1
8 Circlip 1
9 Torsion spring 1
10 Bolt (stopper lever) 1
11 Stopper lever 1
12 Spring 1
13 Segment 1 Refer to “REMOVAL POINTS”.
1
2

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 lip of the left crankcase side.
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.

4 - 57
ENGKICK AXLE AND SHIFT SHAFT
Kick idle gear
1. Install:
lCirclip 1
lWasher 2
lKick idle gear 3
lWasher 4
lCirclip 5
NOTE:
lApply the engine oil on the kick idle gear
inner circumference.
lInstall the kick idle gear with its depressed
side toward you.
New
New

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 - 61
ENGENGINE REMOVAL
ENGINE REMOVAL
Extent of removal:1 Engine removal
Extent of removal Order Part name Q’ty Remarks
ENGINE REMOVAL
Preparation for removal Hold the machine by placing the
suitable stand under the frame.
Seat, fuel tank and side covers Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Carburetor Refer to “CARBURETOR” section.
Muffler Refer to “MUFFLER” section.
Clutch cable Disconnect at engine side.
Spark plug cap
Disconnect the CDI magneto
lead.
Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT”
section in the CHAPTER 3.

4 - 62
ENGENGINE REMOVAL
Extent of removal Order Part name Q’ty Remarks
1 Drive sprocket cover 1
2 Bolt (drive sprocket) 2
Refer to “REMOVAL POINTS”. 3 Drive sprocket holder 1
4 Drive sprocket 1
5 Shift pedal link 1
6 Crankcase breather hose 1
7 Engine bracket (upper) 1
8 Engine skidplate 1
9 Engine bracket (front) 1
10 Engine mounting bolt (rear) 2
11Engine
1Refer to “REMOVAL POINTS”.
1