clutch YAMAHA TTR125 2003 User Guide

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 - 17
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 cable holder M6 × 1.0 1 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
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 holder M5 × 0.8 2 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 wheel axle and axle nut M12 × 1.25 1 45 4.5 32
Front brake camshaft lever and camshaft M6 × 1.0 1 10 1.0 7.2
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
Driven sprocket (nut) M10 × 1.25 4 43 4.3 31
Driven sprocket (stud) M10 × 1.25 4 30 3.0 22
Sidestand mounting (nut) M10 × 1.25 1 44 4.4 32
Engine mounting:
Engine bracket (front) and frame M8 × 1.25 2 40 4.0 29
Engine bracket (front) and engine M8 × 1.25 2 40 4.0 29
Engine bracket (upper) and frame M8 × 1.25 2 40 4.0 29
Engine bracket (upper) and cylinder head M8 × 1.25 1 40 4.0 29
Engine and frame (rear) M8 × 1.25 2 40 4.0 29
Pivot shaft and nut M12 × 1.25 1 53 5.3 38
Relay arm and swingarm M12 × 1.25 1 70 7.0 50

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 - 28
SPECCABLE ROUTING DIAGRAM
ËAfter connecting the main
switch coupler, engine stop
switch coupler, clutch switch
coupler and start switch cou-
pler, put a connector cover on
the couplers and push them in
at the rubber cover end.
◊Pass the wire harness on the
outside of the main switch cou-
pler.
„Do not allow the primary coil
lead to slacken where it is bare
of the protecting tube.ÙFasten the CDI unit lead and
starting circuit cut-off relay lead
with a plastic locking tie at the
tape holding the main switch
lead, engine stop switch lead,
clutch switch lead, and start
switch lead together.
ÁPosition the starter cable, throt-
tle cable, CDI magneto lead,
wire harness and rear shock
absorber assembly sub-tank
hose (TT-R125LWE only) as
shown.ÛFasten the wire harness, throttle
cable, starter cable, CDI mag-
neto lead and rear shock
absorber assembly sub-tank
hose (TT-R125LWE only) at the
protecting tube for the CDI mag-
neto lead.
Fasten the rectifier/regulator
lead as shown.
Do not allow the CDI magneto
lead to slacken.
Position the plastic locking tie
ends as shown.
AA
AB
AC
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 - 29
SPEC
1Throttle cable
2Clutch cable
3Starter cable
4Fuel tank breather hose
5Hose guide
6Clamp
7Cable guide
8Starting circuit cut-off relay
9Spark plug lead
0Starter motor lead
ANegative battery leadBEngine oil breather hose
CPositive battery lead
DOverflow hose
EAir vent hose
FPrimary coil lead
GGround leadÅPass the clutch cable on the
inside of the throttle cable and
starter cable.
ıPass the fuel tank breather
hose through the hose guide.
ÇFasten the clutch cable with the
paint in the cable guide bottom
recess.
ÎPass the throttle cable and
starter cable through the cable
guide.
1
2
3
4
5
6
7
8
9
0
6 ABC6DEFGÅ
ı
Ç
Î
‰ Ï ÌÓÈÔÒ
CABLE ROUTING DIAGRAM

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.