engine oil YAMAHA TTR125 2007 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

152 - A - V
2 - 27
SPEC
EC240000
CABLE ROUTING DIAGRAM
TT-R125/TT-R125LW
1 CDI unit
2 CDI unit band
3 Clamp
4 CDI magneto lead
5 Air vent hose
6 Wire harness
7 Engine stop switch lead
8 Cable guide
9 Brake cable
(Brake hose for the TT-R125LW)
0 Brake cable holder
(Brake hose holder for the
TT-R125LW) Å
Fit the CDI unit band over the CDI unit bracket till it stops.
ı Clamp the ignition coil lead.
Ç Clamp the wire harness coupler.
Î Clamp the CDI magneto lead, throttle cable and starter cable.
‰ Clamp the CDI magneto lead so that it does not contact the push
lever.
Ï Pass the air vent hoses between the engine and swingarm.
Ì Clamp the wire harness and engine stop switch lead.
Ó Pass the brake cable (brake hose for the TT-R125LW) into the cable
guide.
È Clamp the brake cable.
Ô Clamp the brake hose between the paint marks.
CABLE ROUTING DIAGRAM
1
2
3
3
3
7
6
8
9
0 3
3
4
5
Î È
É
Ê
Ë
Ì
Í
Ï
Ð

6 - B - V
2 - 30
SPECCABLE ROUTING DIAGRAM
TT-R125E/TT-R125LWE
1Ground 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.
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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.
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AB
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12 - B - V
2 - 33
SPEC
1Throttle cable
2 Clutch cable
3 Starter cable
4 Fuel tank breather hose
5 Hose guide
6 Clamp
7 Cable guide
8 Starting circuit cut-off relay
9 Spark plug lead
0 Starter motor lead
A Negative battery lead B
Engine oil breather hose
C Positive battery lead
D Overflow hose
E Air vent hose
F Primary coil lead
G Ground lead Å
Tighten the starter choke nut
while taking care not to twist the
starter cable.
ı Pass the clutch cable on the
inside of the throttle cable and
starter cable.
Ç Pass the starter cable so that it
is not twisted.
Î Pass the fuel tank breather
hose through the hose guide.
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14 - B - V
2 - 34
SPEC
‰Fasten the clutch cable with the
paint in the cable guide bottom
recess.
Ï Pass the throttle cable and
starter cable through the cable
guide.
Ì Fasten the starter motor lead.
Ó Pass the engine oil breather
hose and overflow hose
between the right half of the
swingarm and frame. È
Pass the negative battery lead
on the inside of the frame as
shown.
Ô Fasten 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.
Ò Put the tip of the air vent hose
into the frame. ˜
Install the primary coil terminal
(orange) to the ignition coil.
ˆ Fasten the ground lead together
with the ignition coil.
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Pass the overflow hose
between the right half of the
swingarm and frame.
Fasten the overflow hose and
air vent hoses to 2 clicks.
KAfter fastening the starter
cable, push it against the
starter plunger.
LPut the tip of the air vent hose
into the frame.

PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM
NOTE:
From 18 months or 7,000 km (4,200 mi) or 210 hours, repeat the maintenance intervals starting from 6 months
or 3,000 km (1,800 mi) or 90 hours.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
For TT-Rs not equipped with an odometer or an hour meter, follow the month maintenance intervals.
For TT-Rs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals.
Hovewer, keep in mind that if the TT-R isn´t used for a long period of time, the month maintenance intervals
should be followed.
Nº ITEM CHECKS AND MAINTENANCE JOBS
ODOMETER READINGSINITIAL
Fuel lineCheck fuel hoses for cracks or damage.
Replace if necessary. 1
*
Whichever
comer firstmonth
km
(mi)
hours1,000
(600)1612
3,000
(1,800)5,000
(3,000)
30 90 150
Spark plug
Check condition
Adjust gap and clean.
CarburetorCheck engine idling speed an starter operation.
Adjust if necessary.
Exhaust system
Engine oilChange (warm engine before draining).2
*3
*5
7
8
√√
√
√√√
√√
√√√√√
Valve clearenceCheck and adjust valve clearance when engine is cold.
Air filter elementClean with solvent.
Replace if necessary. 4
*
Breather systemCheck ventilation hose for cracks or damage.
Replace if necessary.
*6
Check for leakage.
Tighten if necessary.
Replace gasket if necessary.
√√
√√√
3
INSP
ADJ
MAINTENANCE INTERVALS
ONLY FOR CANADA
REGULAR INSPECTION AND ADJUSTMENTS
3 - 0 - 1

NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake service (TT-R125LW / TT-R125LWE)
After disassembling the brake master cylinders and calipers, always change the fluid. Regulary check the
brake fluid levels and fill the reservoirs as required.
Every two years replace the internal components of the brake master cylinders and calipers, and change
the brake fluid.
Replace the brake hoses every four years and if cracked or damaged.
Control cabesApply Yamaha chain and cable lube or engine oil 10W-30 thoroughly.
Throttle grip
housing and cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.
Chassis
fastenersCheck all chassis fitting and fasteners.
Correct if necessary.
Battery (TT-R125E
/ TT-R125LWE)Check terminal for looseness and corrosion.
Nº ITEM CHECKS AND MAINTENANCE JOBS
ODOMETER READINGSINITIAL
16
Whichever
comer firstmonth
km
(mi)
hours1,000
(600)1612
3,000
(1,800)5,000
3,000)
30 90 150
Shock absorber
assemblyCheck operation and for oil leakage.
Replace if necessary.*
17
*
18 *
19 *
20
√√
√√√
√√√
√√√
√
INSP
ADJ
MAINTENANCE INTERVALS
3 - 0 - 3

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