length 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.

SPEC

2 - 1
GENERAL SPECIFICATIONS
EC200000
SPECIFICATIONS
EC211000
GENERAL SPECIFICATIONS
TT-R125
Model name: TT-R125P
(USA-except for California, CDN, AUS, NZ)
TT-R125PC (USA for California)
TT-R125 (EUROPE)
Model code number: 5HPB (USA, AUS, NZ, EUROPE)
5HPC (CDN)
Dimensions: USA, AUS, NZ,
EUROPECDN
Overall length 1,830 mm (72.0 in) 1,865 mm (73.4 in)
Overall width 785 mm (30.9 in)
¬
Overall height 1,055 mm (41.5 in)
¬
Seat height 775 mm (30.5 in)
¬
Wheelbase 1,250 mm (49.2 in)
¬
Minimum ground clearance 265 mm (10.4 in)
¬
Basic weight:
With oil and full fuel tank 83 kg (183 lb)
Engine:
Engine type Air cooled 4-stroke, SOHC
Cylinder arrangement Single cylinder, forward inclined
Displacement 124 cm
3

(7.57 cu.in)
Bore
´
stroke 54.0
´
54.0 mm (2.126
´
2.126 in)
Compression ratio 10.0:1
Starting system Kickstarter
Lubrication system: Wet sump
Oil type or grade:
Engine oil (For USA and CDN)
At –10 ˚C (10 ˚F) or higher

Yamalube 4 (10W-30) or SAE 10W-30 type
SE motor oil
At 5 ˚C (40 ˚F) or higher
õ

Yamalube 4 (20W-40) or SAE 20W-40 type
SE motor oil
(Except for USA and CDN)
API “SE” or higher grade
2

SPEC

2 - 4
GENERAL SPECIFICATIONS
TT-R125LW
Model name: TT-R125LWP
(USA-except for California, CDN, AUS, NZ)
TT-R125LWPC (USA for California)
TT-R125LW (EUROPE)
Model code number: 5HPD (USA, AUS, NZ, EUROPE)
5HPE (CDN)
Dimensions: USA, AUS, NZ,
EUROPECDN
Overall length 1,885 mm (74.2 in) 1,890 mm (74.4 in)
Overall width 795 mm (31.3 in)
¬
Overall height 1,085 mm (42.7 in)
¬
Seat height 805 mm (31.7 in)
¬
Wheelbase 1,270 mm (50.0 in)
¬
Minimum ground clearance 295 mm (11.6 in)
¬
Basic weight:
With oil and full fuel tank 84 kg (185 lb)
Engine:
Engine type Air cooled 4-stroke, SOHC
Cylinder arrangement Single cylinder, forward inclined
Displacement 124 cm
3

(7.57 cu.in)
Bore
´
stroke 54.0
´
54.0 mm (2.126
´
2.126 in)
Compression ratio 10.0:1
Starting system Kickstarter
Lubrication system: Wet sump
Oil type or grade:
Engine oil (For USA and CDN)
At –10 ˚C (10 ˚F) or higher

Yamalube 4 (10W-30) or SAE 10W-30 type
SE motor oil
At 5 ˚C (40 ˚F) or higher
õ

Yamalube 4 (20W-40) or SAE 20W-40 type
SE motor oil
(Except for USA and CDN)
API “SE” or higher grade

SPEC

2 - 9
MAINTENANCE SPECIFICATIONS
Stem runout limit----0.01 mm
(0.0004 in)
Valve seat width IN0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)1.6 mm
(0.0630 in)
EX 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)1.6 mm
(0.0630 in)
Valve spring:
Free length IN 32.55 mm (1.28 in) 31.2 mm
(1.23 in)
EX 32.55 mm (1.28 in) 31.2 mm
(1.23 in)
Set length (valve closed) IN 25.6 mm (1.01 in) ----
EX 25.6 mm (1.01 in) ----
Compressed pressure
(installed) IN 137.5 ~ 158.1 N
(14.0 ~ 16.1 kg, 30.86 ~ 35.49 lb)----
EX 137.5 ~ 158.1 N
(14.0 ~ 16.1 kg, 30.86 ~ 35.49 lb)----
Tilt limit * IN ----2.5˚/1.4 mm
(2.5˚/0.06 in)
EX ----2.5˚/1.4 mm
(2.5˚/0.06 in)
Direction of winding
(top view) IN Clockwise ----
EX Clockwise ---- Item Standard Limit

SPEC

2 - 11
MAINTENANCE SPECIFICATIONS
Crankshaft:
Crank width “A” 46.95 ~ 47.00 mm
(1.848 ~ 1.850 in)----
Runout limit “C” ---- 0.03 mm
(0.0012 in)
Big end side clearance “D” 0.15 ~ 0.45 mm
(0.0059 ~ 0.0177 in)0.5 mm
(0.02 in)
Clutch:
Friction plate thickness 2.92 ~ 3.08 mm
(0.115 ~ 0.121 in)2.8 mm
(0.110 in)
Quantity 5 ----
Clutch plate thickness 1.05 ~ 1.35 mm
(0.041 ~ 0.053 in)----
Quantity 4 ----
Warp limit ---- 0.2 mm
(0.008 in)
Clutch spring free length 33 mm (1.30 in) 31 mm
(1.22 in)
Quantity 4 ----
Clutch release method Inner push, cam push ----
Push rod bending limit ---- 0.5 mm
(0.020 in)
Shifter:
Shifter type Cam drum and guide bar ----
Kick starter:
Type Kick and mesh type ----
Kick clip friction force 6.4 ~ 13.2 N
(0.65 ~ 1.35 kg, 1.4 ~ 3.0 lb)----
Carburetor:
I.D. mark 5HP1 10 ----
Main jet (M.J) #105 ----
Main jet nozzle (N.J) N-6M ----
Main air jet (M.A.J) ø1.2 ----
Jet needle-clip position (J.N) 5HGM56-2 ----
Cutaway (C.A) 2.5 ----
Pilot air jet 1 (P.A.J.1) #80 ----
Pilot air jet 2 (P.A.J.2) #145 ----
Pilot outlet (P.O) ø1.05 ----
Pilot jet (P.J) #15 ----
Pilot air screw (example) (A.S) (2-1/2 ~ 3-1/2 turns out) ----
Bypass (B.P)ø1.0----
Needle valve seat size (V.S) 1.8 ----
Starter jet 1 (G.S.1) #22.5 ----
Starter jet 2 (G.S.2) #1.2 ----
Fuel level (F.L) 6.0 ~ 7.0 mm (0.24 ~ 0.28 in) ----
Engine idle speed 1,300 ~ 1,500 r/min ----Item Standard Limit

SPEC
2 - 15
MAINTENANCE SPECIFICATIONS
EC212201
CHASSIS
TT-R125
Item Standard Limit
Steering system:
Steering bearing type (upper) Angular bearing ----
(lower) Taper roller bearing ----
Front suspension:
Front fork travel 180 mm (7.09 in) ----
Fork spring free length 327 mm (12.87 in) 322 mm (12.68 in)
Spring rate, STD K = 3.00 N/mm
(0.310 kg/mm, 17.4 lb/in)----
Optional spring/spacer No ----
Oil capacity 159 cm
3
(5.60 Imp oz, 5.38 US oz)----
Oil level 122 mm (4.80 in) ----
Oil grade Fork oil 10W or equivalent ----
Inner tube outer diameter 30 mm (1.18 in) ----
Front fork top end Zero mm (Zero in) ----
Rear suspension:
Shock absorber travel 65 mm (2.56 in) ----
Spring free length 175 mm (6.89 in) ----
Fitting length 165 mm (6.50 in) ----
Spring rate, STD K = 48.1 N/mm
(4.9 kg/mm, 274 lb/in)----
Optional spring No ----
Enclosed gas pressure 1,500 kPa
(15 kg/cm
2, 213 psi)----
Wheel:
Front wheel type Spoke wheel ----
Rear wheel type Spoke wheel ----
Front rim size/material 17 ´ 1.40/Steel ----
Rear rim size/material 14 ´ 1.60/Steel ----
Rim runout limit:
Radial ---- 2.0 mm (0.08 in)
Lateral ---- 2.0 mm (0.08 in)
Drive chain:
Type/manufacturer DID428HD/DAIDO ----
Number of links 116 links ----
Chain slack 35 ~ 50 mm (1.4 ~ 2.0 in) ----
Chain length (10 links) ----121.4 mm
(4.78 in)

SPEC
2 - 16
MAINTENANCE SPECIFICATIONS
Drum brake:
Front drum brake type Leading, trailing ----
Rear drum brake type Leading, trailing ----
Front drum inside diameter 110 mm (4.33 in) 111 mm (4.37 in)
Rear drum inside diameter 110 mm (4.33 in) 111 mm (4.37 in)
Front lining thickness 4.0 mm (0.16 in) 2.0 mm (0.08 in)
Rear lining thickness 4.0 mm (0.16 in) 2.0 mm (0.08 in)
Front shoe spring free length 50.5 mm (1.99 in) ----
Rear shoe spring free length 50.5 mm (1.99 in) ----
Brake lever and brake pedal:
Brake lever free play (lever end) 10 ~ 15 mm (0.39 ~ 0.59 in) ----
Brake pedal position
(vertical height below footrest top)1 mm (0.04 in) ----
Brake pedal free play 20 ~ 30 mm (0.79 ~ 1.18 in) ----
Clutch lever free play (lever end) 10 ~15 mm (0.39 ~ 0.59 in) ----
Throttle grip free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----Item Standard Limit

SPEC
2 - 19
MAINTENANCE SPECIFICATIONS
TT-R125LW
Item Standard Limit
Steering system:
Steering bearing type (upper) Angular bearing ----
(lower) Taper roller bearing ----
Front suspension:
Front fork travel 180 mm (7.09 in) ----
Fork spring free length 339 mm (13.35 in) 334 mm (13.15 in)
Spring rate, STD K = 3.20 N/mm
(0.330 kg/mm, 18.5 lb/in)----
Optional spring/spacer No ----
Oil capacity 156 cm
3
(5.49 Imp oz, 5.27 US oz)----
Oil level 130 mm (5.12 in) ----
Oil grade Fork oil 10W or equivalent ----
Inner tube outer diameter 30 mm (1.18 in) ----
Front fork top end Zero mm (Zero in) ----
Rear suspension:
Shock absorber travel 65 mm (2.56 in) ----
Spring free length 178 mm (7.01 in) ----
Fitting length 165 mm (6.50 in) ----
Spring rate, STD K = 58.9 N/mm
(6.0 kg/mm, 336 lb/in)----
Optional spring No ----
Enclosed gas pressure 1,500 kPa
(15 kg/cm
2, 213 psi)----
Wheel:
Front wheel type Spoke wheel ----
Rear wheel type Spoke wheel ----
Front rim size/material 19 ´ 1.40/Steel ----
Rear rim size/material 16 ´ 1.60/Steel ----
Rim runout limit:
Radial ---- 2.0 mm (0.08 in)
Lateral ---- 2.0 mm (0.08 in)
Drive chain:
Type/manufacturer DID428HD/DAIDO ----
Number of links 122 links ----
Chain slack 35 ~ 50 mm (1.4 ~ 2.0 in) ----
Chain length (10 links) ----121.4 mm
(4.78 in)
Front disc brake:
Disc outside dia. ´ Thickness 220 ´ 3.0 mm (8.66 ´ 0.12 in)220 ´ 2.5 mm
(8.66 ´ 0.10 in)
Deflection limit ----0.15 mm (0.006 in)
Pad thickness 4.0 mm (0.16 in)0.8 mm (0.03 in)
Master cylinder inside dia. 11.0 mm (0.433 in) ----
Caliper cylinder inside dia. 22.22 mm (0.875 in) ´ 2 ----
Brake fluid type DOT #4 ----

SPEC
2 - 20
MAINTENANCE SPECIFICATIONS
Rear drum brake:
Drum brake type Leading, trailing ----
Drum inside diameter 110 mm (4.33 in) 111 mm (4.37 in)
Lining thickness 4.0 mm (0.16 in) 2.0 mm (0.08 in)
Shoe spring free length 50.5 mm (1.99 in) ----
Brake lever and brake pedal:
Brake lever free play (lever end) 2 ~ 5 mm (0.08 ~ 0.20 in) ----
Brake pedal position
(vertical height below footrest top)1 mm (0.04 in) ----
Brake pedal free play 20 ~ 30 mm (0.79 ~ 1.18 in) ----
Clutch lever free play (lever end) 10 ~ 15 mm (0.39 ~ 0.59 in) ----
Throttle grip free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----Item Standard Limit

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