clutch YAMAHA TTR125 2003 Service Manual

4 - 63
ENG

ENGINE REMOVAL
ENGINE REMOVAL
Extent of removal:
1
Engine removal
Extent of removal Order Part name Q’ty Remarks
ENGINE REMOVAL
Preparation for removal Hold the machine by placing the
suitable stand under the frame.
Seat, fuel tank and side covers Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Carburetor Refer to “CARBURETOR” section.
Muffler Refer to “MUFFLER” section.
Clutch cable Disconnect at engine side.
Spark plug cap
Disconnect the CDI magneto
lead.
Disconnect the neutral switch
lead.
Starter motor Refer to “ELECTRIC STARTING SYS-
TEM” section in the CHAPTER 6.
Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT”
section in the CHAPTER 3.

4 - 67
ENGCRANKCASE, CRANKSHAFT AND BALANCER
CRANKCASE, CRANKSHAFT AND BALANCER
Extent of removal:1 Crankcase separation2 Balancer removal
3 Crankshaft removal
Extent of removal Order Part name Q’ty Remarks
CRANKCASE, CRANKSHAFT
AND BALANCER REMOVAL
Preparation for removal Engine Refer to “ENGINE REMOVAL” section.
Piston Refer to “CYLINDER AND PISTON” sec-
tion.
Primary drive gear Refer to “CLUTCH AND PRIMARY
DRIVEN GEAR” section.
Kick axle assembly
Refer to “KICK AXLE AND SHIFT
SHAFT” section.
Segment
Rotor and stator Refer to “CDI MAGNETO AND
STARTER CLUTCH” section.

4 - 68
ENGCRANKCASE, CRANKSHAFT AND BALANCER
Extent of removal Order Part name Q’ty Remarks
1 Intake timing chain guide 1
2 Timing chain 1
3 Bolt [45 mm (1.8 in)] 7
4 Bolt [55 mm (2.2 in)] 1
5 Bolt [30 mm (1.2 in)] 2
6 Lead guide 1
7 Clutch cable holder 1
8 Right crankcase 1
Use special tool.
Refer to “REMOVAL POINTS”.
9 Left crankcase 1
10 Balancer 1
11 Crankshaft 1 Use special tool.
Refer to “REMOVAL POINTS”.
12 Bearing 3 Refer to “REMOVAL POINTS”.
3
21

4 - 69
ENGCRANKCASE, CRANKSHAFT AND BALANCER
REMOVAL POINTS
Crankcase
1. Remove:
Bolt (crankcase)
Lead guide 1
Clutch cable holder 2
NOTE:
Loosen each bolt 1/4 of a turn at a time and
after all the bolts are loosened, remove them.
2. Remove:
Right crankcase 1
Use the crankcase separating tool 2.
NOTE:
Fully tighten the tool holding bolts, but make
sure the tool body is parallel with the case. If
necessary, one screw may be backed out
slightly to level tool body.
As pressure is applied, alternately tap on the
front engine mounting boss and transmission
shafts.
CAUTION:
Use soft hammer to tap on the case half.
Tap only on reinforced portions of case. Do
not tap on gasket mating surface. Work
slowly and carefully. Make sure the case
halves separate evenly. If one end “hangs
up”, take pressure off the push screw, re-
align, and start over. If the cases do not
separate, check for a remaining case screw
or fitting. Do not force.
Crankcase separating tool:
YU-1135-A/90890-01135

4 - 74
ENGCRANKCASE, CRANKSHAFT AND BALANCER
3. Tighten:
Lead guide 1
Clutch cable holder 2
Bolt (crankcase) [45 mm (1.8 in)] 3
Bolt (crankcase) [55 mm (2.2 in)] 4
Bolt (crankcase) [30 mm (1.2 in)] 5
NOTE:
Apply Quick gasket® (YAMAHA Bond
No.1215) on end of the crankcase bolts [45
mm (1.8 in)] 3, as shown.
Tighten the crankcase bolts in stage, using a
crisscross pattern.
Quick gasket®:
ACC-QUICK-GS-KT
YAMAHA Bond No.1215:
90890-85505
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
4. Check:
Crankshaft and transmission operation
Unsmooth operation → Repair.
5. Install:
Timing chain 1
Intake timing chain guide 2
Bolt (intake timing chain guide)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)LT

5 - 41
CHASHANDLEBAR
EC5B0000
HANDLEBAR
TT-R125E
Extent of removal:1 Handlebar removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalHANDLEBAR REMOVAL
Number plate
1 Clutch cable 1
2 Clutch lever 1
3 Engine stop switch 1
4 Front brake cable 1
5 Start switch 1
6 Front brake lever 1
7 Grip cap (lower) 1
8 Grip cap (upper) 1
9 Throttle cable 1
10 Throttle grip assembly 1
11 Collar 1
12 Handlebar grip (left) 1 Refer to “REMOVAL POINTS”.
13 Main switch 1
14 Handlebar holder 2
15 Handlebar 1
1

5 - 42
CHASHANDLEBAR
TT-R125LWE
Extent of removal:1 Handlebar removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalHANDLEBAR REMOVAL
Number plate
1 Clutch cable 1
2 Clutch lever 1
3 Engine stop switch 1
4 Brake master cylinder 1 Refer to “REMOVAL POINTS”.
5 Start switch 1
6 Grip cap (lower) 1
7 Grip cap (upper) 1
8 Throttle cable 1
9 Throttle grip assembly 1
10 Handlebar grip (left) 1 Refer to “REMOVAL POINTS”.
11 Main switch 1
12 Upper handlebar holder 2
13 Handlebar 1
1

5 - 47
CHAS
6. Install:
TT-R125E
Start switch 1
Bolts (start switch) 2
Front brake cable 3
Clamp
NOTE:
Apply the lithium soap base grease on the
front brake cable end.
TT-R125LWE
Start switch 1
Brake master cylinder 2
Brake master cylinder bracket 3
Bolt (brake master cylinder bracket) 4
NOTE:
Install the bracket so that the arrow mark a
face upward.
First tighten the bolts on the upper side of the
brake master cylinder bracket, and then
tighten the bolts on the lower side.
7. Install:
Engine stop switch 1
Clutch lever holder 2
Screws (clutch lever holder) 3
NOTE:
The engine stop switch and clutch lever
holder should be installed according to the
dimensions shown.
Pass the engine stop switch lead in the mid-
dle of the clutch lever holder.
8. Install:
Clutch cable 1
Clamp
NOTE:
Apply the lithium soap base grease on the
clutch cable end.
9. Adjust:
Brake lever free play
Refer to “FRONT BRAKE ADJUST-
MENT” section in the CHAPTER 3.
Clutch lever free play
Refer to “CLUTCH ADJUSTMENT”
section in the CHAPTER 3.
3
1
2
LS
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
U P3 2
4 4
a1
T R..9 Nm (0.9 m · kg, 6.5 ft · lb)
12 3
3T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
HANDLEBAR

6 - 1
–+ELEC

* The illustration shows the TT-R125LWE
12345 7 6890A
EDCB

ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC600000
ELECTRICAL
EC610000
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC611000
ELECTRICAL COMPONENTS
1
CDI unit
2
Main switch
3
Start switch
4
Clutch switch
5
Engine stop switch
6
Starting circuit cut-off
relay
7
Ignition coil
8
Battery
9
Starter relay
0
Fuse
A
Rectifier/regulator
B
Neutral switch
C
CDI magneto
D
Starter motor
E
Spark plug
COLOR CODE
B ...................... Black
Br ..................... Brown
G...................... Green
O...................... Orange
R ...................... Red
Sb .................... Sky blueW ..................... White
Y ...................... Yellow
B/W.................. Black/White
L/Y ................... Blue/Yellow
R/W ................. Red/White
EC612000
WIRING DIAGRAM
B
R/W
WB
RYW
BR Y
10A
R
BR/W
ON
OFFR
BrRB/WBB/WBr B
ON OFF
R/WBr BB
R/WSbR/W
BB BL/Y
OFF RUN
BBBB/W
W
YWSbBSbY B
G
WBrRG
WBrRB
B/WR
W Br
GO
R
SbR/WR/WR/WR/W
R/W
B
R
B/WBrBr
B
L/Y
BSb
YW
RWBrG
RWBrG
B/W
B/W
BOO
B
B
1
2
3
45 67
8
90 A
BC
DE

6 - 6
–+ELEC
ELECTRIC STARTING SYSTEM
STARTING CIRCUIT CUT-OFF SYSTEM
OPERATION
If the main switch is set to “ON”, the starter
motor can only operate if at least one of the
following conditions is met:
The transmission is in neutral (the neutral
switch is closed).
The clutch lever is pulled to the handlebar
(the clutch switch is closed).
The starting circuit cut-off relay prevents the
starter motor from operating when neither of
these conditions has been met. In this
instance, the starting circuit cut-off relay is
open so current cannot reach the starter
motor. When at least one of the above condi-
tions has been met the starting circuit cut-off
relay is closed and the engine can be started
by pressing the start switch.
WHEN THE TRANSMISSION IS
IN NEUTRAL
WHEN THE CLUTCH LEVER IS
PULLED TO THE HANDLEBAR
1Battery
2Main fuse
3Main switch
4Start switch
5Starting circuit cut-off relay
6Neutral switch
7Clutch switch
8Starter relay
9Starter motor
12
M
3
8
54
6 9
7
ELECTRIC STARTING SYSTEM