warning YAMAHA TTR125 2003 User Guide

3 - 20
INSP
ADJ
REAR BRAKE SHOE INSPECTION
1. Inspect:
Brake shoe lining wear limit
BRAKE FLUID LEVEL INSPECTION
(TT-R125LWE)
1. Place the brake master cylinder so that
its top is in a horizontal position.
2. Inspect:
Brake fluid level
Fluid at lower level → Fill up.
aLower level
WARNING
Use only designated quality brake fluid to
avoid poor brake performance.
Refill with same type and brand of brake
fluid; mixing fluids could result in poor
brake performance.
Be sure that water or other contaminants
do not enter brake master cylinder when
refilling.
Clean up spilled fluid immediately to
avoid erosion of painted surfaces or plas-
tic parts. Brake shoe lining wear limit checking
steps:
Fully push down the brake pedal and hold
it in position.
Then check the brake shoe wear indicator
1 is within the wear limit a.
Outside the limit → Replace the brake
shoe.
Refer to “REAR WHEEL AND REAR BRAKE”
section in the CHAPTER 5.
Recommended brake fluid:
DOT #4
SPROCKETS INSPECTION
1. Inspect:
Sprocket teeth a
Excessive wear → Replace.
NOTE:
Replace the drive, driven sprockets and drive
chain as a set.
REAR BRAKE SHOE INSPECTION/BRAKE FLUID LEVEL
INSPECTION (TT-R125LWE)/SPROCKETS INSPECTION

3 - 23
INSP
ADJFRONT FORK INSPECTION/FRONT FORK SPRING
PRELOAD ADJUSTMENT (TT-R125LWE)
EC36C000
FRONT FORK INSPECTION
1. Inspect:
Front fork smooth action
Operate the front brake and stroke the
front fork.
Unsmooth action/oil leakage → Repair
or replace.
FRONT FORK SPRING PRELOAD
ADJUSTMENT (TT-R125LWE)
1. Adjust:
Spring preload
By turning the adjuster 1.
STANDARD POSITION:
CAUTION:
Grooves are provided to indicate the
adjustment position.
Never go beyond the maximum or mini-
mum adjustment positions.
WARNING
Always adjust each front fork to the same
setting. Uneven adjustment can cause poor
handling and loss of stability.Stiffer a →Increase the spring preload.
(Turn the adjuster 1 in.)
Softer b →Decrease the spring pre-
load. (Turn the adjuster 1
out.)
Extent of adjustment:
Maximum Minimum
Position 1 Position 4
Standard position:
4
1
a
b1234

3 - 29
INSP
ADJ
STEERING HEAD INSPECTION AND ADJUSTMENT
Tighten the lower ring nut 6 using steer-
ing nut wrench 7 and turn the steering
right and left a few times.
Steering nut wrench:
YU-33975/90890-01403
T R..
Lower ring nut (initial tightening):
38 Nm (3.8 m • kg, 27 ft • lb)
Loosen the lower ring nut one turn.
Retighten the lower ring nut using the
steering nut wrench.
T R..
Ring nut (final tightening):
20 Nm (2.0 m • kg, 14 ft • lb)
Check the steering stem by turning it lock
to lock. If there is any binding, remove the
steering stem assembly and inspect the
steering bearings.
Install the rubber washer 8, upper ring
nut 9 and special washer 0.
NOTE:
Tighten the upper ring nut until it contacts
the rubber washer.
Insert the special washer pawls into the
slots. If the slots are not aligned, tighten
the upper ring nut for alignment.
Install the upper bracket A, steering stem
nut B, cap C, handlebar D, upper han-
dlebar holder E, main switch F, starter
knob nut G and number plate H.
NOTE:
The upper handlebar holder should be
installed with the punched mark a for-
ward.
Insert the end of fuel breather hose I into
the hose clamp.
NOTE:
Set the torque wrench to the steering nut
wrench so that they form a right angle.
WARNING
Avoid over-tightening.
H
DF
B
C
I
A

3 - 33
INSP
ADJ
BATTERY INSPECTION AND CHARGING
WARNING
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of
poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
Wear protective eye gear when handling
or working near batteries.
Charge batteries in a well-ventilated area.
Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
Skin — Wash with water.
Eyes — Flush with water for 15 minutes
and get immediate medical attention.
INTERNAL
Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.
CAUTION:
Charging time, charging amperage and
charging voltage for an MF battery are dif-
ferent from those of conventional batteries.
The MF battery should be charged as
explained in the charging method illustra-
tions. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charging
the battery.
BATTERY INSPECTION AND CHARGING

3 - 35
INSP
ADJ
ÅRelationship between the open-circuit voltage
and the charging time at 20 ˚C (68 ˚F)
(These values vary with the temperature, the
condition of the battery plates, and the electro-
lyte level.)
ıOpen-circuit voltage
ÇCharging time (hours)
ÎTime (minutes)
‰Charging condition of the battery
ÏAmbient temperature 20 ˚C (68 ˚F)
aCharging
bCheck the open-circuit voltage.
Check the charge of the battery, as shown
in the charts and the following example.
Example
Open-circuit voltage = 12.0 V
Charging time = 6.5 hours
Charge of the battery = 20 ~ 30% Å
5. Charge:
Battery
(refer to the appropriate charging
method illustration)
WARNING
Do not quick charge a battery.
CAUTION:
Never remove the MF battery sealing
caps.
Do not use a high-rate battery charger
since it forces a high-amperage current
into the battery quickly and can cause
battery overheating and battery plate
damage.
If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
When charging a battery, be sure to
remove it from the machine. (If charging
has to be done with the battery mounted
on the machine, disconnect the negative
battery lead from the battery terminal.)
To reduce the chance of sparks, do not
plug in the battery charger until the bat-
tery charger leads are connected to the
battery.
BATTERY INSPECTION AND CHARGING

3 - 40
INSP
ADJ
3. Replace:
Blown fuse
WARNING
Never use a fuse with an amperage rating
other than that specified. Improvising or
using a fuse with the wrong amperage rat-
ing may cause extensive damage to the
electrical system, cause the starting and
ignition systems to malfunction and could
possibly cause a fire.
4. Install:
Battery cover Replacement steps:
Set the main switch to “OFF”.
Install a new fuse of the correct amperage.
Set on the switches to verify if the electri-
cal circuit is operational.
If the fuse immediately blows again, check
the electrical circuit.
ItemsAmperage
ratingQ’ty
Main fuse 10 A 1
FUSE INSPECTION

5 - 1
CHAS

FRONT WHEEL AND FRONT BRAKE (TT-R125E)
EC500000
CHASSIS
FRONT WHEEL AND FRONT BRAKE (TT-R125E)
Extent of removal:
1
Front wheel removal
2
Wheel bearing removal
3
Brake shoe plate assembly removal and disassembly
Extent of removal Order Part name Q’ty Remarks
Preparation for removal
FRONT WHEEL AND DRUM
BRAKE
Hold the machine by placing the
suitable stand under the engine.
WARNING

Support the machine securely so there is no
danger of it falling over.
1 Brake cable holder 1
2 Brake cable 1 Disconnect at the lever side, first.
3 Axle nut 1
4 Wheel axle 1
5 Front wheel 1
6 Collar set 1
7 Brake shoe plate assembly 1
8 Oil seal 1
9 Wheel bearing 2 Refer to “REMOVAL POINTS”.
10Spacer
1
2
3
1

5 - 3
CHAS

FRONT WHEEL AND FRONT BRAKE (TT-R125E)
REMOVAL POINTS
EC513201
Wheel bearing (if necessary)
1. Remove:

Bearing
1

NOTE:

Remove the bearing using a general bearing
puller
2
.
INSPECTION
EC514100
Wheel
1. Measure:

Wheel runout
Out of limit
→
Repair/replace.
Wheel runout limit:
Radial
1
: 2.0 mm (0.08 in)
Lateral
2
: 2.0 mm (0.08 in)
2. Inspect:

Bearing
Rotate inner race with a finger.
Rough spot/seizure
→
Replace.
NOTE:

Replace the bearings, oil seal and wheel collar
as a set.
EC514200
Wheel axle
1. Measure:

Wheel axle bends
Out of specification
→
Replace.
Use the dial gauge
1
.
NOTE:

The bending value is shown by one half of the
dial gauge reading.
WARNING

Do not attempt to straighten a bent axle.
Wheel axle bending limit:
0.5 mm (0.020 in)

5 - 5
CHAS

FRONT WHEEL AND FRONT BRAKE (TT-R125E)
ASSEMBLY AND INSTALLATION
Brake shoe plate assembly
1. Install:

Brake camshaft
1

NOTE:

Apply the lithium soap base grease on the
brake camshaft.
2. Check:

Brake camshaft operation
Unsmooth operation
→
Repair.
3. Install:

Wear indicator plate
1

NOTE:

When installing the wear indicator plate to the
brake camshaft align the projection
a
on the
wear indicator plate with the slots
b
on the
brake camshaft.
4. Install:

Brake camshaft lever
1

NOTE:

Install the brake camshaft lever in relation to
the punch mark
a
as shown.
1
1a
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

5. Install:

Springs
1


Brake shoes 2
NOTE:
Apply the lithium soap base grease on the
pivot pin.
WARNING
Do not apply grease to the brake shoe lin-
ings.
New

5 - 8
CHAS
FRONT WHEEL (TT-R125LWE)
Extent of removal:1 Front wheel removal2 Wheel bearing removal
3 Brake disc removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalFRONT WHEEL REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is nodanger of it falling over.
1 Axle nut 1
2 Washer 1
3 Wheel axle 1
4 Front wheel 1
5 Collar 2
6 Oil seal 2
7 Wheel bearing 2 Refer to “REMOVAL POINTS”.
8 Spacer 1
9Brake disk
1
2
31
3
FRONT WHEEL (TT-R125LWE)