boot YAMAHA TTR125 2002 Owners Manual

4. When transporting the machine in
another vehicle, be sure is kept
upright and that the fuel cock is
turned to the “OFF”. If it should lean
over, gasoline may leak out of the car-
buretor or fuel tank.
5. Never start your engine or let it run for
any length of time in a closed area.
The exhaust fumes are poisonous and
may cause loss of consciousness and
death within a short time. Always
operate your machine in an area with
adequate ventilation.
6. Always wear a helmet, gloves, boots,
trousers, and jacket for motocross
riding.

SAFETY INFORMATION

1. Do not ride it on the street.
2. Do not run the engine inside a building.
3. This is a one-seater motorbike. Do not give
any person a ride.
4. Let’s learn how to ride properly. Ask your
parents for any question.
5. When riding the machine, be sure to wear
the protective apparel as illustrated.
1
Helmet
2
Goggles
3
Mouth guard
4
Gloves
5
Boots
6
Motocross pants
7
Long sleeved trainer
8
Protector

5 - 13
CHASFRONT BRAKE (TT-R125LW)
BRAKE CALIPER AND BRAKE MASTER CYLINDER DISASSEMBLY
Extent of removal:1 Brake caliper disassembly2 Brake master cylinder disassembly
Extent of removal Order Part name Q’ty Remarks
Preparation for removalBRAKE CALIPER AND BRAKE
MASTER CYLINDER DISAS-
SEMBLY
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is nodanger of it falling over.
1Brake pad 2
2Brake caliper bracket 1
3Brake caliper piston 2 Refer to “REMOVAL POINTS”.
4Brake caliper dust seal 2
Refer to “REMOVAL POINTS”.
5Brake caliper piston seal 2
6Pin boot 1
7Sleeve boot 1
8Brake master cylinder cap 1
9Diaphragm 1
0Brake master cylinder boot 1
ACirclip 1
BWasher 1
CBrake master cylinder kit 1
2
1

5 - 16
CHAS
Brake caliper
1. Inspect:
lBrake caliper cylinder inner surface a
Wear/score marks ® Replace brake
caliper assembly.
2. Inspect:
lBrake caliper piston 1
Wear/score marks ® Replace brake
caliper piston assembly.
WARNING
Replace the brake caliper piston seals and
brake caliper dust seals 2 whenever a
brake caliper is disassembled.
3. Inspect:
lBrake caliper bracket 1
Cracks/damage ® Replace the brake
caliper assembly.
lGuide pin 2
Rust/damage ® Replace the brake cal-
iper assembly.
lSleeve boot 3
lPin boot 4
Wear/damage ® Replace.
4. Inspect:
lBrake caliper support bolt 1
Scorches/rust/damage ® Replace.
Brake hose
1. Inspect:
lBrake hose 1
Crack/damage ® Replace.
FRONT BRAKE (TT-R125LW)

5 - 17
CHASFRONT BRAKE (TT-R125LW)
ASSEMBLY AND INSTALLATION
WARNING
lAll internal parts should be cleaned in
new brake fluid only.
lInternal parts should be lubricated with
brake fluid when installed.
lReplace the brake caliper piston seals
and brake caliper dust seals whenever a
brake caliper is disassembled.
Brake caliper piston
1. Clean:
lBrake caliper
lBrake caliper piston seal
lBrake caliper dust seal
lBrake caliper piston
Clean them with brake fluid.
2. Install:
lBrake caliper piston seal 1
lBrake caliper dust seal 2
WARNING
Always use new brake caliper piston seals
and brake caliper dust seals.
NOTE:
Fit the brake caliper piston seals and brake
caliper dust seals onto the slot on brake cali-
per correctly.
New
New
3. Install:
lBrake caliper piston 1
NOTE:
Apply the brake fluid on the brake caliper pis-
ton wall.
CAUTION:
lInstall the brake caliper piston with its
shallow depressed side a facing the
brake caliper.
lNever force to insert.
Brake caliper
1. Install:
lSleeve boot 1.
On brake caliper bracket 2.

5 - 18
CHASFRONT BRAKE (TT-R125LW)
2. Install:
lPin boot 1
On brake caliper 2.
NOTE:
Apply the lithium soap base grease on the pin
boot inner surface.
3. Install:
lBrake caliper bracket 1
lBolt (brake caliper bracket) 2
lBrake pad 3
T R..30 Nm (3.0 m · kg, 22 ft · lb)
4. Install:
lBrake caliper 1
NOTE:
lApply the lithium soap base grease on the
guide pin 2.
lInstall the brake caliper into the guide pin
and turn it clockwise.
5. Install:
lBrake caliper support bolt 1
NOTE:
Apply the lithium soap base grease on the
brake caliper support bolt.
T R..22 Nm (2.2 m · kg, 16 ft · lb)
Brake master cylinder kit
1. Clean:
lBrake master cylinder
lBrake master cylinder kit
Clean them with brake fluid.

5 - 19
CHASFRONT BRAKE (TT-R125LW)
2. Install:
lBrake master cylinder cup (primary) 1
lBrake master cylinder cup (secondary) 2
On brake master cylinder piston 3.
NOTE:
Apply the brake fluid on the brake master cyl-
inder cup.
WARNING
After installing, cylinder cup should be
installed as shown direction. Wrong instal-
lation cause improper brake performance.
3. Install:
lSpring 1
On brake master cylinder piston 2.
NOTE:
Install the spring at the smaller diameter side.
4. Install:
lBrake master cylinder kit 1
lWasher 2
lCirclip 3
lBrake master cylinder boot 4
On brake master cylinder 5
NOTE:
lApply the brake fluid on the brake master
cylinder kit.
lWhen installing the circlip, use a long nose
circlip pliers.

5 - 33
CHASFRONT FORK
EC558000
FRONT FORK DISASSEMBLY
Extent of removal:1 Oil seal removal2 Damper rod removal
Extent of removal Order Part name Q’ty Remarks
FRONT FORK DISASSEMBLY
1Dust boot 1
2Cap bolt 1 Refer to “REMOVAL POINTS”.
3Spacer 1
4Washer 1
5Fork spring 1 Drain the fork oil.
6Dust seal 1
Use special tool.
Refer to “REMOVAL POINTS”. 7Stopper ring 1
8Bolt (damper rod) 1
9Damper rod 1
0Inner tube 1
AOil flow stopper 1
BPiston metal 1
COil seal 1
DOuter tube
1
2
1

5 - 39
CHASFRONT FORK
9. Compress the front fork fully.
10. Fill:
lFront fork oil 1
CAUTION:
lBe sure to use recommended fork oil. If
other oils are used, they may have an
excessively adverse effect on the front
fork performance.
lNever allow foreign materials to enter the
front fork.
Recommended oil:
Fork oil 10W or equivalent
Quantity (each front fork leg):
TT-R125: 159 cm
3
(5.60 Imp oz, 5.38 US oz)
TT-R125LW: 156 cm
3
(5.49 lmp oz, 5.27 US oz)
11. After filling, pump the inner tube slowly
up and down more than 10 times to dis-
tribute the fork oil.
12. Measure:
lOil level a
Out of specification ® Adjust.
13. Install:
lFork spring
lWasher
lSpacer
lCap bolt 1
lDust boot
NOTE:
Temporarily tighten the cap bolt.
Standard oil level:
TT-R125: 122 mm (4.80 in)
TT-R125LW: 130 mm (5.12 in)
From the top of the inner tube,
with the inner tube fully com-
pressed, and without the fork
spring.

5 - 40
CHASFRONT FORK
Installation
1. Install:
lFront fork
NOTE:
lTemporarily tighten the pinch bolt (lower
bracket).
lDo not tighten the pinch bolt (upper bracket)
yet.
2. Tighten:
lCap bolt 1
3. Adjust:
lFront fork top end a
Front fork top end (standard) a:
Zero mm (Zero in)
T R..23 Nm (2.3 m · kg, 17 ft · lb)
4. Tighten:
lPinch bolt (lower bracket) 1
lPinch bolt (upper bracket) 2
lScrew (dust boot) 3
NOTE:
lMake sure that the dust boot holes a are
positioned outward.
lTighten the screw (dust boot) until the top of
the dust boot is touching the lower bracket.
T R..60 Nm (6.0 m · kg, 43 ft · lb)
T R..25 Nm (2.5 m · kg, 18 ft · lb)
5. Install:
lCap 1