weight YAMAHA TTR125 2003 Owners Manual

INTRODUCTION
Congratulations on your purchase of a
Yamaha TT-R125E(R)/TT-R125LWE(R). This
model is the culmination of Yamaha’s vast
experience in the production of pacesetting
racing machines. It represents the highest
grade of craftsmanship and reliability that have
made Yamaha a leader.
This manual explains operation, inspection,
basic maintenance and tuning of your
machine. If you have any questions about this
manual or your machine, please contact your
Yamaha dealer.
NOTE:

As improvements are made on this model,
some data in this manual may become out-
dated. If you have any questions, please con-
sult your Yamaha dealer.
WARNING


READ THIS MANUAL CAREFULLY FOR
INSTRUCTIONS ON HOW TO PROPERLY
OPERATE THIS MACHINE.

ADULT INSTRUCTION AND SUPERVI-
SION ARE REQUIRED.

WEIGHT OF THE RIDER SHOULD NOT
EXCEED 68 kg (150 lb). (TT-R125E ONLY)

ALWAYS WEAR A HELMET AND SUIT-
ABLE PROTECTIVE CLOTHING WHEN
RIDING.

DO NOT TOUCH ANY MOVING PARTS OR
HEATED AREAS.

ALWAYS PERFORM PRE-OPERATION
CHECKS. REFER TO PAGE 3-3.

THIS MACHINE IS DESIGNED TO CARRY
THE OPERATOR ONLY.
NO PASSENGERS.

THIS MACHINE IS DESIGNED OFF-ROAD
USE ONLY.
IT IS NOT SUITABLE FOR ON-ROAD USE.

ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols
1
to
6
are designed as
thumb tabs to indicate the chapter’s number
and content.
1
General information
2
Specifications
3
Regular inspection and adjustments
4
Engine
5
Chassis
6
Electrical
Illustrated symbols
7
to
D
are used to identify
the specifications appearing in the text.
7
With engine mounted
8
Special tool
9
Filling fluid
0
Lubricant
ATightening
BSpecified value, Service limit
CEngine speed
DResistance (Ω), Voltage (V), Electric current (A)
Illustrated symbols E to H in the exploded
diagrams indicate grade of lubricant and loca-
tion of lubrication point.
EApply engine oil
FApply molybdenum disulfide oil
GApply lightweight lithium-soap base grease
HApply molybdenum disulfide grease
Illustrated symbols I to J in the exploded
diagrams indicate where to apply a locking
agent and when to install new parts.
IApply locking agent (LOCTITE®)
JUse new one 12
34
56
78
90
AB
CD
EF
GH
IJ
GEN
INFOSPEC
INSP
ADJENG
CHAS–+ELEC
T R..
EM
LSM
LTNew

1 - 4
GEN
INFO

IMPORTANT INFORMATION
EC132000
ALL REPLACEMENT PARTS
1. We recommend to use Yamaha genuine
parts for all replacements. Use oil and/or
grease recommended by Yamaha for
assembly and adjustment.
EC133000
GASKETS, OIL SEALS AND O-RINGS
1. All gaskets, oil seals, and O-rings should
be replaced when an engine is over-
hauled. All gasket surfaces, oil seal lips,
and O-rings must be cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the
oil seal lips.
EC134000
LOCK WASHERS/PLATES AND COTTER
PINS
1. All lock washers/plates
1
and cotter pins
must be replaced when they are
removed. Lock tab(s) should be bent
along the bolt or nut flat(s) after the bolt
or nut has been properly tightened.
EC135001
BEARINGS AND OIL SEALS
1. Install the bearing(s)
1
and oil seal(s)
2
with their manufacturer’s marks or num-
bers facing outward. (In other words, the
stamped letters must be on the side
exposed to view.) When installing oil
seal(s), apply a light coating of light-
weight lithium base grease to the seal
lip(s). Oil the bearings liberally when
installing.
CAUTION:

Do not use compressed air to spin the
bearings dry. This causes damage to the
bearing surfaces.
EC136000
CIRCLIPS
1. All circlips should be inspected carefully
before reassembly. Always replace pis-
ton pin clips after one use. Replace dis-
torted circlips. When installing a circlip
1
,
make sure that the sharp-edged corner
2
is positioned opposite to the thrust
3
it
receives. See the sectional view.
4
Shaft

1 - 6
GEN
INFO
SPECIAL TOOLS
SPECIAL TOOLS
The proper special tools are necessary for complete and accurate tune-up and assembly. Using the
correct special tool will help prevent damage caused by the use of improper tools or improvised
techniques. The shape and part number used for the special tool differ by country, so two types are
provided. Refer to the list provided to avoid errors when placing an order.
NOTE:
For U.S.A. and CDN, use part number starting with “YM-”, “YU-”, “YS-” or “ACC-”.
For others, use part number starting with “90890-”.
Part number Tool name/How to use Illustration
YU-1083-A
90890-01084
90890-01085Small slide hammer set
Weight
Slide hammer bolt
These tools are used when removing or installing the
rocker arm shafts.YU-1083-A 90890-01084
90890-01085
YU-1135-A, 90890-01135 Crankcase separating tool
These tools are used to split the crankcase as well as
remove the crankshaft from either case.YU-1135-A 90890-01135
YU-3097, 90890-01252
YU-1256Dial gauge & stand set
Stand
These tools are used to check each part for runout or
bend.YU-3097
YU-125690890-01252
YU-90050, 90890-01274
YU-90050, 90890-01275
YU-90063, 90890-01278
YU-91044, 90890-04081Crankcase installing tool
Crankshaft installer pot
Crankshaft installer bolt
Adaptor
Spacer (crankshaft installer)
These tools are used to install the crankshaft.YU-90050
YU-91044
YU-9006390890-01274
90890-01275
90890-01278
90890-04081
YM-1326, 90890-01326
YM-1300, 90890-01294T-handle
Damper rod holder
These tools are used for holding the damper rod
holder when removing or installing the damper rod
holder.YM-1326
YM-130090890-01326
90890-01294
YU-1304, 90890-01304 Piston pin puller set
This tool is used to remove the piston pin.YU-1304 90890-01304
YM-8035, 90890-01311 Tappet adjusting tool
This tool is necessary for adjusting valve clearance.YM-8035 90890-01311

1 - 7
GEN
INFO
SPECIAL TOOLS
YM-1312-A, 90890-01312Fuel level gauge
This gauge is used to measure the fuel level in the
float chamber.YM-1312-A 90890-01312
YU-33270-B, 90890-01362 Flywheel puller
This tool is used to remove the rotor.YU-33270-B 90890-01362
YM-33963, 90890-01367
YM-33281, 90890-01400Fork seal driver weight
Fork seal driver attachment
These tools are used to installing the fork oil seal.YM-33963
YM-3328190890-01367
90890-01400
YU-33975, 90890-01403 Steering nut wrench
This tool is used when tighten the steering ring nut to
specification.YU-33975 90890-01403
YS-1880-A, 90890-01701 Sheave holder
This tool is used for when loosening or tightening the
flywheel magneto securing nut.YS-1880-A 90890-01701
YU-3112-C, 90890-03112 Pocket tester
Use this tool to inspect the coil resistance, output
voltage and amperage.YU-3112-C 90890-03112
YU-8036-B
90890-03113Inductive tachometer
Engine tachometer
This tool is needed for observing engine rpm.YU-8036-B 90890-03113
YM-4019, 90890-04019 Valve spring compressor
This tool is needed to remove and install the valve
assemblies.YM-4019 90890-04019
YM-91042, 90890-04086 Clutch holding tool
This tool is used to hold the clutch when removing or
installing the clutch boss securing nut.YM-91042 90890-04086
Part number Tool name/How to use Illustration

SPEC

2 - 1
GENERAL SPECIFICATIONS
EC200000
SPECIFICATIONS
EC211000
GENERAL SPECIFICATIONS
TT-R125E
Model name: TT-R125ER (USA, CDN, AUS, NZ)
TT-R125E (EUROPE, ZA)
Model code number: 5HPK (USA, AUS, NZ, EUROPE, ZA)
5HPL (CDN)
Dimensions: USA, AUS, NZ,
ZA, 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 90 kg (198.4 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 Kick and electric starter
Lubrication system: Wet sump
Oil type or grade:
Engine oil (For USA and CDN)
At –10 ˚C (10 ˚F) or higher
Å
Yamalube 4 (10W-30) or SAE 10W-30 type
SE motor oil
At 5 ˚C (40 ˚F) or higher
ı

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

SPEC

2 - 4
GENERAL SPECIFICATIONS
TT-R125LWE
Model name: TT-R125LWER (USA, CDN, AUS, NZ)
TT-R125LWE (EUROPE, ZA)
Model code number: 5HPM (USA, AUS, NZ, EUROPE, ZA)
5HPN (CDN)
Dimensions: USA, AUS, NZ,
ZA, 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 90 kg (198.4 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 Kick and electric starter
Lubrication system: Wet sump
Oil type or grade:
Engine oil (For USA and CDN)
At –10 ˚C (10 ˚F) or higher
Å
Yamalube 4 (10W-30) or SAE 10W-30 type
SE motor oil
At 5 ˚C (40 ˚F) or higher
ı

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

2 - 25
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

3 - 31
INSP
ADJ
LUBRICATION
LUBRICATION
To ensure smooth operation of all compo-
nents, lubricate your machine during setup,
after break-in, and after every ride.
1All control cable
2Brake and clutch lever pivots
3Shift pedal pivot
4Footrest pivot
5Throttle-to-handlebar contact
6Drive chain
7Tube guide cable winding portion
8Throttle cable end
9Brake and clutch cable ends
(Clutch cable end only for the TT-R125LWE)ÅUse Yamaha cable lube or equivalent on these
areas.
ıUse SAE 10W-30 motor oil or suitable chain
lubricants.
ÇLubricate the following areas with high quality,
lightweight lithium-soap base grease.
AAA
AAB
CC

4 - 21
ENGCAMSHAFT AND ROCKER ARMS
REMOVAL POINTS
Rocker arm shaft
1. Remove:
Rocker arm shafts
NOTE:
Use a slide hammer bolt 1 and weight 2 to
slide out the rocker arm shafts.
Small slide hammer set:
YU-1083-A
Slide hammer bolt:
90890-01085
Weight:
90890-01084
Camshaft
1. Remove:
Camshaft 1
Camshaft bearing 2
NOTE:
Screw in a suitable length of 8 mm bolt 3 into
the threaded end of the camshaft and pull out
the camshaft.
INSPECTION
Camshaft
1. Inspect:
Cam lobes
Pitting/scratches/blue discoloration →
Replace.
2. Measure:
Cam lobes length a and b
Out of specification → Replace.
Cam lobes length limit:
Intake:
a 25.851 mm (1.0178 in)
b 21.165 mm (0.8333 in)
Exhaust:
a 25.811 mm (1.0162 in)
b 21.020 mm (0.8276 in)