bolt pattern YAMAHA TTR125 2002 Owners Manual

4 - 16
ENGCYLINDER HEAD
Warpage limit:
0.03 mm (0.0012 in)
lIf the warpage is out of specification,
resurface the cylinder head.
lPlace #400 ~ 600 grit wet sandpaper on
the surface plate, and re-surface the head
using a figure-eight sanding pattern.
NOTE:
Rotate the cylinder head several times to
avoid removing too much material from one
side.
ASSEMBLY AND INSTALLATION
Cylinder head
1. Install:
lDowel pin 1
lGasket 2 New
2. Install:
lCylinder head
lCopper washer
lBolt (cylinder head)
NOTE:
lApply Quick gasket® (YAMAHA Bond
No.1215) on end of the cylinder head bolts
(M6), as shown.
lApply the engine oil on the contact surfaces of
the bolts (cylinder head) and copper washers.
lFollow the numerical order shown in the illus-
tration. Tighten the bolts in two stages.
Quick gasket®:
ACC-QUICK-GS-KT
YAMAHA Bond No.1215:
90890-85505
T R..M8 22 Nm (2.2 m · kg, 16 ft · lb)
M6 10 Nm (1.0 m · kg, 7.2 ft · lb)

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 - 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 - 60
ENGCDI MAGNETO
2. Install:
lWoodruff key 1
lRotor 2
NOTE:
lClean the tapered portions of the crankshaft
and rotor.
lWhen installing the woodruff key, make sure
that its flat surface a is in parallel with the
crankshaft center line b.
lWhen installing the rotor, align the keyway of
the rotor with the woodruff key.
3. Install:
lPlain washer 1
lNut (rotor) 2
Use the sheave holder 3.
Sheave holder:
YS-1880-A/90890-01701
T R..80 Nm (8.0 m · kg, 58 ft · lb)
4. Install:
lDowel pin
lGasket
lLeft crankcase cover
lBolt (left crankcase cover)
NOTE:
Tighten the screws in stage, using a crisscross
pattern.
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
5. Connect:
lCDI magneto lead
Refer to “CABLE ROUTING DIA-
GRAM” section in the CHAPTER 2.

4 - 72
ENGCRANKCASE, CRANKSHAFT AND BALANCER
3. Tighten:
lLead guide 1
lClutch cable holder 2
lBolt (crankcase) [45 mm (1.8 in)] 3
lBolt (crankcase) [55 mm (2.2 in)] 4
lBolt (crankcase) [30 mm (1.2 in)] 5
NOTE:
lApply Quick gasket® (YAMAHA Bond
No.1215) on end of the crankcase bolts [45
mm (1.8 in)] 3, as shown.
lTighten the crankcase bolts in stage, using a
crisscross pattern.
Quick gasket®:
ACC-QUICK-GS-KT
YAMAHA Bond No.1215:
90890-85505
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
4. Check:
lCrankshaft and transmission operation
Unsmooth operation ® Repair.
5. Install:
lTiming chain 1
lIntake timing chain guide 2
lBolt (intake timing chain guide)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)LT

5 - 11
CHASFRONT WHEEL (TT-R125LW)
2. Install:
lBrake disc 1
lBolt (brake disc) 2
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)LT
3. Install:
lCollar 1
NOTE:
lApply the lithium soap base grease on the oil
seal lips.
lInstall the longer collar on the brake disc 2
side.
4. Install:
lFront wheel
NOTE:
Install the brake disc 1 between the brake
pads 2 correctly.
5. Install:
lWheel axle 1
6. Install:
lWasher 1
lAxle nut 2
T R..45 Nm (4.5 m · kg, 32 ft · lb)