engine oil YAMAHA TTR125 2004 User Guide

SPEC
2 - 13
MAINTENANCE SPECIFICATIONS
Part to be tightened Thread size Q’tyTightening torque
Nm m•kg ft•lb
Spark plug M10 × 1.0 1 13 1.3 9.4
Cylinder head bolt M8 × 1.25 4 22 2.2 16
Cylinder head bolt M6 × 1.0 2 10 1.0 7.2
Oil pressure check bolt M6 × 1.0 1 7 0.7 5.1
Cylinder head side cover M6 × 1.0 2 10 1.0 7.2
Tappet cover M45 × 1.5 2 18 1.8 13
Timing chain guide M6 × 1.0 1 10 1.0 7.2
Adjusting screw (valve) and locknut M5 × 0.5 2 8 0.8 5.8
Camshaft sprocket M8 × 1.25 1 20 2.0 14
Bearing plate cover (camshaft) M6 × 1.0 1 10 1.0 7.2
Timing chain tensioner cap bolt M6 × 1.0 1 8 0.8 5.8
Timing chain tensioner M6 × 1.0 2 10 1.0 7.2
Oil pump assembly M6 × 1.0 2 7 0.7 5.1
Oil pump cover M5 × 0.8 1 5 0.5 3.6
Engine oil drain bolt M12 × 1.5 1 20 2.0 14
Carburetor joint M6 × 1.0 2 10 1.0 7.2
Carburetor joint clamp (air filter) M4 × 0.7 1 2 0.2 1.4
Coasting enricher cover M4 × 0.7 2 2 0.2 1.4
Air filter case M6 × 1.0 3 7 0.7 5.1
Muffler M6 × 1.0 2 10 1.0 7.2
Muffler M10 × 1.25 1 60 6.0 43
Muffler M8 × 1.25 1 30 3.0 22
Muffler guard M6 × 1.0 7 10 1.0 7.2
Spark arrester M6 × 1.0 3 10 1.0 7.2
Crankcase M6 × 1.0 10 10 1.0 7.2
Left crankcase cover M6 × 1.0 7 10 1.0 7.2
Drive sprocket cover M6 × 1.0 2 12 1.2 8.7
Right crankcase cover M6 × 1.0 9 10 1.0 7.2
Lead guide (CDI magneto lead) M6 × 1.0 1 7 0.7 5.1
Timing mark accessing screw M14 × 1.5 1 7 0.7 5.1
Crankshaft end accessing screw M32 × 1.5 1 7 0.7 5.1
Kickstarter crank M12 × 1.0 1 50 5.0 36
Starter clutch (TT-R125E/TT-R125LWE) M8 × 1.25 3 30 3.0 22
Plate (starter idle gear) (TT-R125E/TT-R125LWE) M6 × 1.0 2 7 0.7 5.1
Primary drive gear M12 × 1.0 1 70 7.0 50
Clutch spring M5 × 0.8 4 6 0.6 4.3
Clutch boss M12 × 1.0 1 60 6.0 43
Adjusting screw (push rod) and locknut M6 × 1.0 1 8 0.8 5.8
Bearing plate cover (main axle) M6 × 1.0 2 7 0.7 5.1
Drive sprocket M5 × 0.8 2 6 0.6 4.3
Shift arm M6 × 1.0 1 10 1.0 7.2
Shift rod and shift pedal M6 × 1.0 1 7 0.7 5.1
Shift rod and shift arm M6 × 1.0 1 7 0.7 5.1
Shift pedal M6 × 1.0 1 12 1.2 8.7

2 - 27
SPEC
EC240000
CABLE ROUTING DIAGRAM
TT-R125/TT-R125LW
1Fuel tank breather hose
2CDI unit
3CDI unit band
4Clamp
5CDI magneto lead
6Air vent hose
7Wire harness
8Engine stop switch lead
9Cable guide
0Brake cable
(Brake hose for the TT-R125LW)
ABrake cable holder
(Brake hose holder for the
TT-R125LW)ÅFit the CDI unit band over the CDI unit bracket till it stops.
ıClamp the ignition coil lead.
ÇClamp the wire harness coupler.
ÎClamp the CDI magneto lead, throttle cable and starter cable.
‰Clamp the CDI magneto lead so that it does not contact the push
lever.
ÏPass the air vent hoses between the engine and swingarm.
ÌClamp the wire harness and engine stop switch lead.
ÓPass the brake cable (brake hose for the TT-R125LW) into the cable
guide.
ÈClamp the brake cable.
ÔClamp the brake hose between the paint marks.
CABLE ROUTING DIAGRAM

2 - 28
SPEC
1Air vent hose
2Spark plug lead
3Starter cable
4Throttle cable
5Clutch cable
6Clamp
7Cable guide
8Engine oil breather hose
9Overflow hoseÅAfter clamping the starter cable, push it against the starter plunger.
ıPut the tip of the air vent hose into the main pipe.
ÇInstall the primary coil terminal (orange) to the ignition coil.
ÎFasten the ground lead together with the ignition coil.
‰Pass the starter cable so that it is not twisted.
ÏTighten the starter choke nut while taking care not to twist the starter cable.
ÌPass the clutch cable on the inside of the throttle and starter cable.
ÓClamp the clutch cable with the paint in the cable guide bottom recess.
ÈPass the throttle cable and starter cable into the cable guide.
ÔPass the engine oil breather hose and overflow hose between the right
half of the swingarm and pillar tube.
Clamp the engine oil breather hose, overflow hose and air vent hose to 2 clicks.
CABLE ROUTING DIAGRAM

2 - 30
SPECCABLE ROUTING DIAGRAM
TT-R125E/TT-R125LWE
1Ground lead
2Primary coil lead
3Clamp
4Wire harness
5Starter relay lead
6Rectifier/regulator lead
7CDI magneto lead
8Air vent hose
9Neutral switch lead
0Rear shock absorber assembly
sub-tank hose (TT-R125LWE
only)
AStarting circuit cut-off relay lead
BCDI unit lead
CCorrugated tubeDBrake hose holder (Brake cable
holder for the TT-R125E)
EBrake hose (Brake cable for the
TT-R125E)
FCable guide
GMain switch lead
HEngine stop switch lead
IClutch switch lead
JStart switch lead
KCDI unit band
LCDI unit
MConnector cover
NRubber cover
OStarter cable
PThrottle cableQRectifier/regulator
ÅFasten the primary coil lead and
ground lead.
ıFasten the wire harness at its
tape.
ÇFasten 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 - 32
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 - 33
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 leadÅTighten the starter choke nut
while taking care not to twist the
starter cable.
ıPass the clutch cable on the
inside of the throttle cable and
starter cable.
ÇPass the starter cable so that it
is not twisted.
ÎPass the fuel tank breather
hose through the hose guide.
1
2
3
4
5
6
7
8
9
0
6 ABC6DEFGı
Î
‰
Ï
Ì Ó ÈÔÒ˜ˆ
Ç
Å
CABLE ROUTING DIAGRAM

2 - 34
SPEC
‰Fasten the clutch cable with the
paint in the cable guide bottom
recess.
ÏPass the throttle cable and
starter cable through the cable
guide.
ÌFasten the starter motor lead.
ÓPass the engine oil breather
hose and overflow hose
between the right half of the
swingarm and frame.ÈPass the negative battery lead
on the inside of the frame as
shown.
ÔFasten the engine oil breather
hose, overflow hose and air
vent hoses to 2 clicks.
After fastening the starter cable,
push it against the starter
plunger.
ÒPut the tip of the air vent hose
into the frame.˜Install the primary coil terminal
(orange) to the ignition coil.
ˆFasten the ground lead together
with the ignition coil.
1
2
3
4
5
6
7
8
9
0
6 ABC6DEFGı
Î
‰
Ï
Ì Ó ÈÔÒ˜ˆ
Ç
Å
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-R125LW/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.

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-R125LW/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 ~ 32
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.3-33
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 - 7
INSP
ADJ
ENGINE OIL LEVEL INSPECTION
6. Apply:
Foam-air-filter oil or engine mixing oil
To the element.
NOTE:
Squeeze out the excess oil. Element should be
wet but not dripping.
7. Install:
Air filter element 1
On air filter guide 2.
8. Apply:
Lithium soap base grease
On the matching surface a on air filter
element.
9. Install:
Air filter element 1
Washer 2
Wing nut 3
ENGINE OIL LEVEL INSPECTION
1. Start the engine, warm it up for several
minutes and wait for five minutes.
2. Place the machine on a level place and
hold it up on upright position by placing
the suitable stand under the engine.
3. Remove:
Dipstick 1