brake YAMAHA TTR125 2003 User Guide

SPEC
2 - 19
MAINTENANCE SPECIFICATIONS
TT-R125LWE
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 453.6 mm (17.86 in) 448.6 mm
(17.66 in)
Spring rate, STD K = 3.20 N/mm
(0.330 kg/mm, 18.5 lb/in)----
Optional spring/spacer No ----
Oil capacity 158 cm
3
(5.56 Imp oz, 5.34 US oz)----
Oil level 125 mm (4.92 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 170.5 mm (6.71 in) ----
Fitting length 160.5 mm (6.32 in) ----
Spring rate, STD K = 61.8 N/mm
(6.3 kg/mm, 352 lb/in)----
Optional spring No ----
Enclosed gas pressure 1,200 kPa
(12 kg/cm
2, 171 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

SPEC
2 - 21
MAINTENANCE SPECIFICATIONS
NOTE:
1. First, tighten the ring nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the ring nut
wrench and turn the steering right and left a few times; then loosen the ring nut one turn.
2. Retighten the ring nut 20 Nm (2.0 m • kg, 14 ft • lb). Part to be tightened Thread size Q’tyTightening torque
Nm m•kg ft•lb
Upper bracket and inner tube M8 × 1.25 2 25 2.5 18
Lower bracket and inner tube M10 × 1.25 2 60 6.0 43
Upper bracket and steering stem M22 × 1.0 1 110 11.0 80
Handlebar upper holder and upper bracket M8 × 1.25 4 23 2.3 17
Steering stem and ring nut M25 × 1.0 1 Refer to NOTE.
Front fork and cap bolt M25 × 1.0 2 23 2.3 17
Front fork and damper rod M10 × 1.0 2 23 2.3 17
Front fork and brake hose holder M6 × 1.0 2 7 0.7 5.1
Number plate M6 × 1.0 1 7 0.7 5.1
Starter knob M11 × 1.25 1 1 0.1 0.7
Starter knob stay M6 × 1.0 2 10 1.0 7.2
Grip cap upper and lower M5 × 0.8 2 4 0.4 2.9
Throttle cable cap M4 × 0.7 2 2 0.2 1.4
Front brake master cylinder M6 × 1.0 2 9 0.9 6.5
Front brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
Brake lever mounting (bolt) M6 × 1.0 1 7 0.7 5.1
Brake lever mounting (nut) M6 × 1.0 1 7 0.7 5.1
Brake lever adjuster and locknut M6 × 0.75 1 4 0.4 2.9
Clutch lever mounting (bolt) M6 × 1.0 1 7 0.7 5.1
Clutch lever mounting (nut) M6 × 1.0 1 7 0.7 5.1
Clutch lever holder M5 × 0.8 2 4 0.4 2.9
Front brake master cylinder and joint M10 × 1.25 1 26 2.6 19
Front brake hose and joint M10 × 1.25 1 14 1.4 10
Front brake hose union bolt M10 × 1.25 1 26 2.6 19
Front brake caliper and front fork M8 × 1.25 2 30 3.0 22
Brake caliper support bolt M8 × 1.25 1 22 2.2 16
Front brake caliper and bleed screw M7 × 1.0 1 6 0.6 4.3
Front wheel axle and axle nut M12 × 1.25 1 45 4.5 32
Front brake disc and wheel hub M6 × 1.0 4 12 1.2 8.7
Rear wheel axle and axle nut M12 × 1.25 1 60 6.0 43
Rear brake camshaft lever and camshaft M6 × 1.0 1 10 1.0 7.2
Brake pedal mounting M10 × 1.25 1 30 3.0 22
Brake pedal position locknut M6 × 1.0 1 7 0.7 5.1
Front wheel nipple (spoke)—36 2 0.2 1.4
Rear wheel nipple (spoke)—36 3 0.3 2.2

2 - 26
SPEC

CABLE ROUTING DIAGRAM
EC240000
CABLE ROUTING DIAGRAM
1
Ground lead
2
Primary coil lead
3
Clamp
4
Wire harness
5
Starter relay lead
6
Rectifier/regulator lead
7
CDI magneto lead
8
Air vent hose
9
Neutral switch lead
0
Rear shock absorber assembly
sub-tank hose (TT-R125LWE
only)
A
Starting circuit cut-off relay lead
B
CDI unit lead
C
Corrugated tube
D
Brake hose holder (Brake cable
holder for the TT-R125E)
E
Brake hose (Brake cable for the
TT-R125E)
F
Cable guide
G
Main switch lead
H
Engine stop switch lead
I
Clutch switch lead
J
Start switch lead
K
CDI unit band
L
CDI unit
M
Connector cover
N
Rubber cover
O
Starter cable
P
Throttle cable
Q
Rectifier/regulator
Å
Fasten the primary coil lead and
ground lead.
ı
Fasten the wire harness at its
tape.
Ç
Fasten the wire harness and
CDI magneto lead in front of the
rear shock absorber assembly
bracket at the protecting tube
for the CDI magneto lead.
30~35 mm
(1.18~1.38 in)
E
DD
A
C
B-B
D-D
E
B
BC
TT-R125EA
L
1
3
4 2
3
35
3
36
7
3
3
8
9 0 A 3 B C
DEFGHIJKOP
7
4
0
3 3M
N
3Q
3 F
E
DË
◊
„
Ù
AB
AA
Û
ÁAC
N
Ì
Ï ‰ Î
Ç ı Å
Ó
È
Ô

Ò ˜ ˆ Ø ∏
ŒÂÍ ÊÂ

2 - 27
SPEC

CABLE ROUTING DIAGRAM
Î
After fastening the starter relay
lead, pass it on the left of the
chassis.
‰
Fasten the CDI magneto lead
and starter relay lead.
Ï
Fasten the wire harness.
Ì
Pass the rectifier/regulator lead
between the frame and air filter
case.
Ó
Do not allow the CDI magneto
lead to slacken except between
the two plastic locking ties.
È
Fasten the CDI magneto lead
over the engine bracket (rear).
Ô
Fasten the CDI magneto lead.

Pass the air vent hoses between
the engine and swingarm.
Ò
Fit the neutral switch lead into
the groove in the crankcase
cover.
˜
Pass the starting circuit cut-off
relay lead under the frame and
at the right of the chassis.
ˆ
Fasten the rear shock absorber
assembly sub-tank.
(TT-R125LWE only)
Ø
Pass the CDI unit lead on the
outside of the main switch lead,
engine stop switch lead, clutch
switch lead and start switch
lead.
∏After fastening the start switch
lead, clutch switch lead, engine
stop switch lead and main
switch lead, push their corru-
gated tube against the CDI unit
coupler.
ŒFasten the brake hose between
the paint marks.
ÂPass the brake hose (brake
cable for the TT-R125E)
through the cable guide.
ÍFit the CDI unit band over the
CDI unit bracket till it stops.
ÊFasten the brake cable.
30~35 mm
(1.18~1.38 in)
E
DD
A
C
B-B
D-D
E
B
BC
TT-R125EA
L
1
3
4 2
3
35
3
36
7
3
3
8
9 0 A 3 B C
DEFGHIJKOP
7
4
0
3 3M
N
3Q
3 F
E
DË
◊
„
Ù
AB
AA
Û
ÁAC
N
Ì
Ï ‰ Î
Ç ı Å
Ó
È
Ô

Ò ˜ ˆ Ø ∏
ŒÂÍ ÊÂ

2 - 31
SPEC
1Clamp
2Clutch switch lead
3Engine stop switch lead
4Brake hose (Brake cable for the
TT-R125E)
5Clutch cable
6Throttle cable
7Main switch lead
8Start switch leadÅFasten the clutch switch lead
and engine stop switch lead to 3
clicks.
ıPass the brake hose (brake
cable for the TT-R125E) in front
of the number plate and through
the cable guide.
ÇPass the clutch cable in back of
the number plate.
ÎStarting at the forepart, pass the
main switch lead, clutch cable
and start switch lead in that
order.
‰Pass the start switch lead in
back of the starter cable.ÏPass the main switch lead on
the right of the number plate
stay.
ÌFasten the throttle cable
adjuster cover and start switch
lead with a plastic locking tie
ends downward.
ÓFasten the start switch lead to 3
clicks.
ÈPass the start switch lead in the
middle of the brake master cyl-
inder bracket. (TT-R125LWE
only)
ÔPass the engine stop switch
lead in the middle of the clutch
holder.
A
A
87
3
11
2
3
4
5 67 1 8ÓÅ
ı
ÇÎ ‰Ï ÌÔ È
CABLE ROUTING DIAGRAM

3 - 1
INSP
ADJ

MAINTENANCE INTERVALS
EC300000
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind
that such factors as weather, terrain, geographical location, and individual usage will alter the
required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in
maintaining and lubricating your machine, consult your Yamaha dealer.
Dealer
NoteItem Checks and maintenance jobsInitial Every
10 hours
(1 month)60 hours
(6 months)120 hours
(12 months)
*
Fuel lineCheck fuel hoses for cracks or damage.
Replace if necessary.
Spark plugCheck condition.
Clean, regap or replace if necessary.
*
ValvesCheck valve clearance.
Adjust if necessary.
Air filter Clean or replace element if necessary.
*
CarburetorCheck engine idling speed and starter operation.
Adjust if necessary.
Exhaust systemsCheck for leakage.
Retighten if necessary.
Replace gasket if necessary.
Engine oilCheck oil level and vehicle for oil leakage.
Correct if necessary.
Change. (Warm engine before draining.)
ClutchCheck operation.
Adjust or replace cable.
*
Front brakeCheck operation.
Adjust brake lever free play.
Check fluid level and leakage. (TT-R125LWE only)Every ride
*
Rear brakeCheck operation.
Adjust brake pedal free play and replace brake
shoes if necessary.Every ride
*
WheelsCheck balance, runout, spoke tightness and for
damage.
Tighten spokes and rebalance, replace if
necessary.
*
TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
*
Wheel bearingsCheck bearing for looseness or damage.
Replace if necessary.
*
SwingarmCheck swingarm pivoting point for play.
Correct if necessary.
Lubricate with molybdenum disulfide grease.
Drive chainCheck chain slack.
Adjust if necessary. Make sure that the rear wheel
is properly aligned.
Clean and lubricate.Every ride
*
Steering bearingsCheck bearing play and steering for roughness.
Correct accordingly.
Lubricate with lithium soap base grease every 120
hours.
SidestandCheck operation.
Lubricate and repair if necessary.

3 - 3
INSP
ADJ

PRE-OPERATION INSPECTION AND MAINTENANCE
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation or practice, make sure the machine is in good operating condi-
tion.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
FuelCheck that a fresh gasoline is filled in the fuel tank. Check the
fuel line for leakage.P.1-12
Engine oilCheck that the oil level is correct. Check the crankcase for leak-
age.P.3-7 ~ 10
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-4
Throttle grip/housingCheck that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.P.3-4 ~ 5
BrakesCheck the play of front and rear brake and effect of front and
rear brake.
Check fluid level and leakage. (TT-R125LWE only)P.3-15 ~ 20
Drive chainCheck chain slack and alignment. Check that the chain is lubri-
cated properly.P.3-21 ~ 22
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-27 ~ 28
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-28 ~ 30
Front forks and rear shock
absorber assemblyCheck that they operate smoothly and there is no oil leakage. P.3-23 ~ 26
Cables (wires)Check that the clutch and throttle cables move smoothly. Check
that they are not caught when the handlebars are turned or
when the front forks travel up and down.—
Muffler Check that the muffler is tightly mounted and has no cracks. P.4-2
Sprocket Check that the driven sprocket tightening nut is not loose. P.3-20
Lubrication Check for smooth operation. Lubricate if necessary. P.3-31
Bolts and nuts Check the chassis and engine for loose bolts and nuts. —
Lead connectorsCheck that the CDI magneto, CDI unit, and ignition coil are con-
nected tightly.P.1-5

3 - 15
INSP
ADJ
EC360000
CHASSIS
EC361012
BRAKE SYSTEM AIR BLEEDING
(TT-R125LWE)
WARNING
Bleed the brake system if:
The system has been disassembled.
A brake hose has been loosened or
removed.
The brake fluid is very low.
The brake operation is faulty.
A dangerous loss of braking performance
may occur if the brake system is not prop-
erly bleed.
1. Remove:
Brake master cylinder cap
Diaphragm
2. Bleed:
Brake fluid
Air bleeding steps:
a. Add proper brake fluid to the reservoir.
b. Install the diaphragm. Be careful not to
spill any fluid or allow the reservoir to
overflow.
c. Connect the clear plastic tube 2 tightly
to the caliper bleed screw 1.
d. Place the other end of the tube into a
container.
e. Slowly apply the brake lever several
times.
f. Pull in the lever. Hold the lever in posi-
tion.
g. Loosen the bleed screw and allow the
lever to travel towards its limit.
h. Tighten the bleed screw when the lever
limit has been reached; then release the
lever.
T R..
Bleed screw:
6 Nm (0.6 m • kg, 4.3 ft • lb)
i. Repeat steps (e) to (h) until of the air
bubbles have been removed from the
system.
CHASSIS/
BRAKE SYSTEM AIR BLEEDING (TT-R125LWE)

3 - 16
INSP
ADJ
3. Install:
Diaphragm
Brake master cylinder cap
NOTE:
If bleeding is difficult, it may be necessary to
let the brake fluid system stabilize for a few
hours. Repeat the bleeding procedure when
the tiny bubbles in the system have disap-
peared.
j. Add brake fluid to the level line on the
reservoir.
WARNING
Check the operation of the brake after
bleeding the brake system.
FRONT BRAKE ADJUSTMENT
TT-R125E
1. Check:
Brake lever free play a
Out of specification → Adjust.
2. Adjust:
Brake lever free play
NOTE:
For minute adjustment, loosen the locknut 2
on the lever side and adjust with the adjuster
3.
CAUTION:
Make sure that there is no brake drag after
adjusting the brake lever free play.
Brake lever free play a:
10 ~ 15 mm (0.39 ~ 0.59 in)
Brake lever free play adjustment steps:
Loosen the locknuts 1.
Turn the locknuts until free play a is
within the specified limits by changing their
tightening position.
Tighten the locknuts.
FRONT BRAKE ADJUSTMENT