TT-R125LW (2002) - Motorcycle YAMAHA - Free user manual and instructions

Product type	Off-road motorcycle
Brand	Yamaha
Model	TT-R125LW (2002)
Year	2002
Displacement	124 cc
Dry weight	Approximately 80 kg
Seat height	Approximately 750 mm
Fuel tank capacity	6 liters
Cooling	Air
Starting	Kick
Transmission	Chain
Front brake	Single disc
Rear brake	Drum
Front suspension	Telescopic fork
Rear suspension	Mono-shock
Fuel system	Gasoline
Routine maintenance	Engine oil change, air filter cleaning, chain lubrication
Safety	Mandatory helmet and protective gear
Spare parts	Available at Yamaha dealerships

Frequently Asked Questions - TT-R125LW (2002) YAMAHA

What type of engine oil to use for the Yamaha TT-R125LW 2002?

Use a 10W-40 oil for 4-stroke motorcycles, preferably JASO MA.

How to adjust the chain of the TT-R125LW?

Chain tension must be checked regularly: 30 to 40 mm slack in the middle. Lubricate with a specific chain lubricant.

What is the recommended tire pressure?

Front: 1.5 bar, rear: 1.7 bar (for off-road use). Adjust according to terrain.

How to clean the air filter?

Remove the filter, clean it with mild detergent and water, dry it, then oil it with air filter oil.

What to do if the motorcycle does not start?

Check fuel, spark plug, air filter, and make sure the fuel tap is open. Try with the choke.

What is the appropriate seat height for a child?

Seat height is approximately 750 mm, suitable for young riders from 1.40 m.

How to drain the engine oil?

Place a drain pan under the crankcase, remove the drain plug, let the warm oil drain, replace the gasket and fill with 1.2 L of new oil.

Are spare parts available?

Yes, the TT-R125LW is well supported by Yamaha and common parts are available at authorized dealers.

What fuel to use?

Use unleaded gasoline 95 or 98, preferably ethanol-free.

How to maintain the brakes?

Check the wear of the front brake pads and rear shoes. Replace if thickness is less than 3 mm.

USER MANUAL TT-R125LW (2002) YAMAHA

OWNER'S SERVICE MANUAL

MANUEL D'ATELIER DU

PROPRIETAIRE

FAHRER- UND

WARTUNGS-HANDBUCH

TT-R125(R)

TT-R125LW(R)

5HP-28199-84

EC010010

TT-R125(R)/TT-R125LW(R)

OWNER'S SERVICE MANUAL

©2002 by Yamaha Motor Co., Ltd.

1st Edition, April 2002

All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

is expressly prohibited.

Printed in Japan

TT-R125(R)/TT-R125LW(R)

MANUEL D'ATELIER

DU PROPRIETAIRE

©2002 Yamaha Motor Co., Ltd.

Congratulations on your purchase of a Yamaha TT-R125(R)/TT-R125LW(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 outdated. If you have any questions, please consult your Yamaha dealer.

WARNING

• READ THIS MANUAL CAREFULLY FOR INSTRUCTIONS ON HOW TO PROPERLY OPERATE THIS MACHINE.
  • ADULT INSTRUCTION AND SUPERVISION ARE REQUIRED.
  • WEIGHT OF THE RIDER SHOULD NOT EXCEED 68 kg (150 lb). (TT-R125 ONLY)
• ALWAYS WEAR A HELMET AND SUITABLE 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.

INTRODUCTION

This machine is designed for off-road use only by young operators under adult instruction and supervision. It is illegal for this machine to be operated on any public street, road, or highway.

Off-road use on public lands may be illegal.

Please check local regulations before riding.

SAFETY INFORMATION

1. GASOLINE IS HIGHLY FLAMMABLE:

* Always turn off the engine when refueling.
* Take care not to spill on the engine or exhaust pipe/muffler, when refueling.
* Never refuel while smoking or in the vicinity of an open flame.

1. If you should swallow some gasoline or inhale a lot of gasoline vapor, or allow some gasoline to get in your eye(s), see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash it with soap and water, and change your clothes.

2. Always turn off the engine before leaving the machine unattended. When parking the machine, note the following:

* The engine and exhaust pipe(s)/muffler(s) may be hot. Park the machine in a place where pedestrians or children are not likely to touch the machine.
* Do not park the machine on a slope or soft ground; the machine may overturn.

REMARQUE IMPORTANTE

Illustration of a motorcyclist crossing a circular obstacle with a dog nearby (no text or symbols)

Illustration of a person riding a bicycle under a circular barrier with smoke and clouds (no text or symbols)

Cartoon illustration of a person riding a motorcycle inside a circular frame (no text or symbols)

Illustration of a classroom scene with teacher, students, and a dog (no text or symbols present)

SAFETY INFORMATION

1. Do not ride it on the street.

2. Do not run the engine inside a building.

3. This is a one-seater motorbike. Do not give any person a ride.

4. Let's learn how to ride properly. Ask your parents for any question.

5. When riding the machine, be sure to wear the protective apparel as illustrated.

① Helmet
② Goggles
③ Mouth guard
④ Gloves
⑤ Boots
⑥ Motocross pants
⑦ Long sleeved trainer
⑧ Protector

⚠ INFORMATION DE SECURITE

Illustration of a person standing beside a motorcyclist, both gesturing with one hand (no text or symbols present)

Illustration of a man and child on a motorcycle with a dog nearby (no text or symbols)

Cartoon illustration of a group of people riding a wheeled cart inside a circular frame, with a starburst symbol in the corner (no text or symbols present)

Illustration of a person using a bicycle to interact with children, enclosed in a circular frame (no text or symbols)

Cartoon illustration of a motorcyclist riding a large tire, kicking up dust (no text or symbols)

This manual will provide you with a good basic understanding of features, operation, and basic maintenance and inspection items of this machine. Please read this manual carefully and completely before operating your new machine. If you have any questions regarding the operation or maintenance of your machine, please consult your Yamaha dealer.

NOTE:

This manual should be considered a permanent part of this machine and should remain with it even if the machine is subsequently sold.

EC060000

NOTICE

Some data in this manual may become outdated due to improvements made to this model in the future. If there is any question you have regarding this manual or your machine, please consult your Yamaha dealer.

AVIS AU NOUVEAU PRO- PRIÉTAIRE

HOW TO USE THIS MANUAL

EC081000

PARTICULARLY IMPORTANT INFORMATION

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid damage to the machine.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

FINDING THE REQUIRED PAGE

1. This manual consists of six chapters; "General Information", "Specifications", "Regular inspection and adjustments", "Engine", "Chassis" and "Electrical".
2. The table of contents is at the beginning of the manual. Look over the general layout of the book before finding then required chapter and item.
   Bend the book at its edge, as shown, to find the required fore edge symbol mark and go to a page for required item and description.

COMMENT UTILISER CE MANUEL

INFORMATIONS IMPORTANTES

All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.

In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g.

- Bearings

Pitting/damage → Replace.

EC084002

HOW TO READ DESCRIPTIONS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.

1. An easy-to-see exploded diagram ① is provided for removal and disassembly jobs.
2. Numbers ② are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks ③. The meanings of the symbol marks are given on the next page.
4. A job instruction chart ④ accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.
5. Extent of removal ⑤ is provided in the job instruction chart to save the trouble of an unnecessary removal job.
6. For jobs requiring more information, the step-by-step format supplements ⑥ are given in addition to the exploded diagram and job instruction chart.

FORMAT DU MANUEL

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 ⑭ are used to identify the specifications appearing in the text.

⑦ With engine mounted
⑧ Special tool
⑨ Filling fluid
⑩ Lubricant
⑪ Tightening
⑫ Specified value, Service limit
⑬ Engine speed
⑭ Resistance (Ω), Voltage (V), Electric current (A)

Illustrated symbols ⑮ to ⑱ in the exploded diagrams indicate grade of lubricant and location of lubrication point.

⑮ Apply engine oil
⑯ Apply molybdenum disulfide oil
⑰ Apply lightweight lithium-soap base grease
⑱ Apply molybdenum disulfide grease

Illustrated symbols ⑲ to ⑳ in the exploded diagrams indicate where to apply a locking agent and when to install new parts.

⑲ Apply locking agent (LOCTIT®)
⑳ Use new one

CHECKING OF CONNECTION 1-5

SPECIAL TOOLS 1-6

CONTROL FUNCTIONS 1-9

FUEL 1-12

STARTING AND BREAK-IN 1-13

TORQUE-CHECK POINTS 1-15

TT-R125 1-15

TT-R125LW 1-16

CLEANING AND STORAGE 1-17

CHAPTER 2

SPECIFICATIONS

GENERAL SPECIFICATIONS.... 2-1

TT-R125 2-1

TT-R125LW 2-4

MAINTENANCE SPECIFICATIONS ..... 2-7

ENGINE 2-7

CHASSIS 2-15

TT-R125 2-15

TT-R125LW 2-19

ELECTRICAL 2-23

GENERAL TORQUE

SPECIFICATIONS 2-24

DEFINITION OF UNITS 2-24

CABLE ROUTING DIAGRAM 2-25

CHAPTER 3

REGULAR INSPECTION AND

ADJUSTMENTS

MAINTENANCE INTERVALS 3-1

KICK AXLE AND SHIFT SHAFT 4-53

CDI MAGNETO 4-58

ENGINE REMOVAL 4-61

CRANKCASE, CRANKSHAFT

AND BALANCER 4-65

TRANSMISSION, SHIFT CAM

AND SHIFT FORK 4-73

CHAPTER 5 CHASSIS

FOURCHE AVANT.... 5-32

GUIDON 5-41

DIRECTION.... 5-49

BRAS OSCILLANT.... 5-55

COMBINÉ RESSORT-

AMORTISSEUR ARRIÈRE....5-62

CHAPITRE 6 PARTIE ÉLECTRIQUE

ÉQUIPEMENT ÉLECTRIQUE ET SCHÉMA

DE CÂBLAGE....6-1

SYSTÈME D'ALLUMAGE 6-2

KAPITEL 4 MOTOR

SITZ, KRAFTSTOFFTANK UND

SEITENDECKEL 4-1

SCHALLDÄMPFER 4-2

VERGASER 4-3

ZYLINDERKOPF 4-12

NOCKENWELLE UND KIPPHEBEL ..... 4-20

VENTILE UND VENTILFEDERN 4-24

ZYLINDER UND KOLBEN 4-32

KUPPLUNG UND

PRIMÄRABTRIEBSZAHNRAD 4-40

ÖLPUMPE 4-49

KICKSTARTERWELLE UND

SCHALTWELLE 4-53

LICHTMASCHINENROTOR 4-58

MOTOR AUSBAUEN 4-61

KURBELGEHÄUSE, KURBELWELLE

① Clutch lever
② Engine stop switch
③ Starter knob
④ Front brake lever
⑤ Throttle grip
⑥ Fuel tank cap
⑦ Air filter
⑧ Kickstarter crank
⑨ Fuel tank
⑩ Dipstick
⑪ Rear brake pedal
⑫ Fuel cock
⑬ Drive chain
⑭ Shift pedal
⑮ Front fork

NOTE:

• The machine you have purchased may differ slightly from those shown in the following.
• Designs and specifications are subject to change without notice.

*The illustration shows the TT-R125LW.

RENSEIGNEMENTS GÉNÉRAUX DESCRIPTION

There are two significant reasons for knowing the serial number of your machine:

1. When ordering parts, you can give the number to your Yamaha dealer for positive identification of the model you own.

2. If your machine is stolen, the authorities will need the number to search for and identify your machine.

EC121001

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number ① is stamped on the right of the steering head pipe.

Mechanical assembly diagram showing a clamping mechanism with no visible text or symbols

Technical diagram of a mechanical assembly with labeled components (no readable text or symbols)

EC123001

ENGINE SERIAL NUMBER

The engine serial number ① is stamped into the elevated part of the right-side of the engine.

EC124000

MODEL LABEL

The model label ① is affixed to the frame under the rider's seat. This information will be needed to order spare parts.

IDENTIFICATION DE LA MACHINE

Cartoon illustration of a person washing a motorcycle with buckets nearby (no text or symbols)

Line drawing of an insect head showing wing anatomy and appendages (no text or labels)

Cartoon illustration of a mechanic working on a motorcycle with tools (no text or symbols)

Cartoon illustration of a smiling worker using a power tool (no text or symbols)

Cartoon illustration of a man sitting on the floor surrounded by stacks of money and a question mark above his head (no text or symbols)

EC130000 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY

1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. When washing the machine with high pressured water, cover the part as follow.

2. Silencer exhaust port

3. Use proper tools and cleaning equipment. Refer to "SPECIAL TOOLS" section.

4. When disassembling the machine, keep mated parts together. They include gears, cylinders, pistons, and other mated parts that have been "mated" through normal wear. Mated parts must be reused as an assembly or replaced.

5. During the machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled.

6. Keep away from fire.

INFORMATIONS IMPORTANTES PRÉPARATION À LA DÉPOSE ET AU DÉMONTAGE

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 overhauled. 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 numbers 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 lightweight 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 piston pin clips after one use. Replace distorted 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.

④Shaft

PIÈCES DE RECHANGE

Two-panel line drawing showing a hand holding a tool, with no text or symbols present.

Diagram of electrical testing setup with wires, probes, and a multimeter (no text or symbols)

Diagram of a multimeter connected to a cable with wires, showing wiring and terminal connections (no text or symbols present)

EC1C0000 CHECKING OF CONNECTION

Dealing with stains, rust, moisture, etc. on the connector.

1. Disconnect:

- Connector

1. Dry each terminal with an air bower.

2. Connect and disconnect the connector two or three times.

3. Pull the lead to check that it will not come off.

4. If the terminal comes off, bend up the pin ① and reinsert the terminal into the connector.

5. Connect:

- Connector

NOTE: \_\_\_\_ The two connectors "click" together.

1. Check for continuity with a tester.

NOTE:

- If there in no continuity, clean the terminals.

- Be sure to perform the steps 1 to 7 listed above when checking the wireharness.

- For a field remedy, use a contact revitalizer available on the market.

- Use the tester on the connector as shown.

VÉRIFICATION DES CONNEXIONS

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-A90890-0108490890-01085	Small slide hammer setWeightSlide hammer boltThese tools are used when removing or installing the rocker arm shafts.	YU-1083-A 90890-01084
YU-1135-A, 90890-01135 Crankcase separating toolThese tools are used to split the crankcase as well as remove the crankshaft from either case.		YU-1135-A 90890-01135
YU-3097, 90890-01252YU-1256	Dial gauge & stand setStandThese tools are used to check each part for runout or bend.	YU-3097YU-125	90890-01252
YU-90050, 90890-01274YU-90050, 90890-01275YU-90063, 90890-01278YU-91044, 90890-04081	Crankcase installing toolCrankshaft installer potCrankshaft installer boltAdaptorSpacer (crankshaft installer)These tools are used to install the crankshaft.	YU-90050YU-91044YU-9	90890-0127490890-0127590890-90890-
YM-1326, 90890-01326YM-1300, 90890-01294	T-handleDamper rod holderThese tools are used for holding the damper rod holder when removing or installing the damper rod holder.	YM-1326YN	90890-0132690890-01324
YU-1304, 90890-01304 Piston pin puller setThis tool is used to remove the piston pin.		YU-1304 90890-01304
YM-8035, 90890-01311 Tappet adjusting toolThis tool is necessary for adjusting valve clearance.		YM-8035 90890-01311
YM-1312-A, 90890-01312 Fuel level gaugeThis gauge is used to measure the fuel level in the float chamber.		YM-1312-A 90890-01312
YU-33270-B, 90890-01362 Flywheel pullerThis tool is used to remove the rotor.		YU-33270-B 90890-01362
YM-33963, 90890-01367YM-33281, 90890-01400	Fork seal driver weightFork seal driver attachmentThese tools are used to installing the fork oil seal.	YM-33963YM-33281	90890-0136790890-01400
YU-33975, 90890-01403 Steering nut wrenchThis tool is used when tighten the steering ring nut to specification.		YU-33975 90890-01403
YS-1880-A, 90890-01701 Sheave holderThis tool is used for when loosening or tightening the flywheel magneto securing nut.		YS-1880-A 90890-01701
YU-3112-C, 90890-03112 Pocket testerUse this tool to inspect the coil resistance, output voltage and amperage.		YU-3112-C 90890-03112
YU-8036-B90890-03113	Inductive tachometerEngine tachometerThis tool is needed for observing engine rpm.	YU-8036-B 90890-03113
YM-4019, 90890-04019 Valve spring compressorThis tool is needed to remove and install the valve assemblies.		YM-4019 90890-04019
YM-91042, 90890-04086 Clutch holding toolThis tool is used to hold the clutch when removing or installing the clutch boss securing nut.		YM-91042 90890-04086
YM-4097, 90890-04097YM-4098, 90890-04098YM-04099, 90890-04099	Valve guide removerValve guide installerValve guide reamerThese tools are needed to rebore the new valve guide.	YM-4097YM-4098	90890-0409790890-04098
YM-3448790890-06754	Dynamic spark testerIgnition checkerThis instrument is necessary for checking the ignition system components.	YM-34487 90890-06754
ACC-QUICK-GS-KT90890-85505	Quick gasket®YAMAHA Bond No.1215This sealant (Bond) is used for crankcase mating surface, etc.	ACC-QUICK-GS-KT 90890-85505

OUTILS SPÉCIAUX

Technical line drawing of a mechanical assembly with a numbered component (1), no visible text or symbols

Technical line drawing of a mechanical assembly with no visible text or symbols

Mechanical assembly diagram showing a lever mechanism with labeled component (1), no text or symbols present

EC150000

CONTROL FUNCTIONS

ENGINE STOP SWITCH

The engine stop switch ① is located on the left handlebar. Continue pushing the engine stop switch till the engine comes to a stop.

EC152000

CLUTCH LEVER

The clutch lever ① is located on the left handlebar; it disengages or engages the clutch. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth starts.

EC153000

SHIFT PEDAL

The gear ratios of the constant-mesh 5 speed transmission are ideally spaced. The gears can be shifted by using the shift pedal ① on the left side of the engine.

KICKSTARTER CRANK

WARNING

Before starting the engine, be sure to shift the transmission into neutral.

Rotate the kickstarter crank ① away from the engine. Push the starter down lightly with your foot until the gears engage, then kick smoothly and forcefully to start the engine.

EC155001

THROTTLE GRIP

The throttle grip ① is located on the right handlebar; it accelerates or decelerates the engine. For acceleration, turn the grip toward you; for deceleration, turn it away from you.

FONCTIONS DES COMMANDES COUPE-CIRCUIT DU MOTEUR

Technical line drawing of a mechanical component with no visible text or symbols

EC156000

FRONT BRAKE LEVER

The front brake lever ① is located on the right handlebar. Pull it toward the handlebar to activate the front brake.

EC157000

REAR BRAKE PEDAL

The rear brake pedal ① is located on the right side of the machine. Press down on the brake pedal to activate the rear brake.

EC158010

FUEL COCK

The fuel cock supplies fuel from the tank to carburetor while filtering the fuel. The fuel cock has the three positions:

OFF: With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running.

ON: With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position.

RES: This indicates reserve. If you run out of fuel while riding, move the lever to this position. FILL THE TANK AT THE FIRST OPPORTUNITY. BE SURE TO SET THE LEVER TO "ON" AFTER REFUELING.

EC159000

STARTER KNOB (CHOKE)

When cold, the engine requires a richer air-fuel mixture for starting. A separate starter circuit, which is controlled by the starter knob ①, supplies this mixture. Pull the starter knob out to open the circuit for starting. When the engine has warmed up, push it in to close the circuit.

LEVIER DE FREIN AVANT

Mechanical assembly diagram showing a lever and base component (no text or symbols)

FUEL TANK CAP

Remove the fuel tank cap ① by turning counterclockwise.

WARNING

Do not overfill the fuel tank. Avoid spilling fuel on the hot engine.

SIDESTAND

This sidestand ① is used to support only the machine when standing or transporting it.

WARNING

- Never apply additional force to the side-stand.

- Hold up the sidestand before starting out.

BOUCHON DE RÉSERVOIR DE CARBURANT

FUEL

Use regular gasoline. Always use fresh, name brand gasoline.

WARNING

Do not overfill the fuel tank. Avoid spilling fuel on the hot engine. Do not fill the fuel tank above the bottom of the filler tube ① as shown in the illustration or it may overflow when the fuel heats up later and expands.

①Fuel level

Recommended fuel:

For USA, AUS and NZ: Unleaded gasoline only

For CDN and EUROPE: Regular unleaded gasoline only

For ZA: Regular gasoline

Fuel tank capacity:

Total: 6.6 L (1.45 Imp gal, 1.74 US gal)

Reserve: 1.9 L (0.42 Imp gal, 0.5 US gal)

CAUTION:

Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to the engine internal parts such as valves, piston rings, and exhaust system, etc.

CARBURANT

Before starting the machine, perform the checks in the pre-operation check list.

WARNING

Never start or run the engine in a closed area. The exhaust fumes are poisonous; they can cause loss of consciousness and death in a very short time. Always operate the machine in a well-ventilated area.

STARTING A COLD ENGINE

1. Shift the transmission into neutral.
2. Turn the fuel cock to "ON" and full open the starter knob (CHOKE).
3. With the throttle completely closed start the engine by kicking the kickstarter crank forcefully with firm stroke.
4. Run the engine at idle or slightly higher until it warms up: this usually takes about one or two minutes.
5. The engine is warmed up when it responds normally to the throttle with the starter knob (CHOKE) turned off.

CAUTION:

Do not warm up the engine for extended periods.

EC193001

STARTING A WARM ENGINE

Do not operate the starter knob (CHOKE). Open the throttle slightly and start the engine by kicking the kickstater forcefully with firm stroke.

CAUTION:

Observe the following break-in procedures during initial operation to ensure optimum performance and avoid engine damage.

DÉMARRAGE ET RODAGE

ATTENTION:

Break-in is important to better fit the moving and sliding parts as well as the installed parts. It is also important to accustom the rider to the machine better.

Avoid full-throttle run on a new machine for the first 5 hours.

After the trial run, check for loose parts, oil leakage and other problems.

Make full inspection and adjustment especially of slack cables and drive chain and loose spokes.

CAUTION:

After the break-in or before each ride, you must check the entire machine for loose fittings and fasteners as per "TORQUE-CHECK POINTS".

Tighten all such fasteners as required.

BREAKING IN AFTER REPLACEMENT

After a part is replaced with a new one, it is necessary to break it in as in a new machine.

This is required especially when the following engine-related parts are replaced.

•Cylinder
•Piston
•Piston ring
-Valve
•Camshaft
•Crankshaft
- Clutch
●Transmission gear
- Shift fork

* For warming up and inspection during break-in, refer to "GENERAL INSPECTION AND MAINTENANCE" and if there is any problem, stop the engine immediately and check.

RODAGE

graph TD
    A["Engine mounting"] --> B["Frame to engine"]
    A --> C["Frame to engine bracket"]
    A --> D["Engine bracket to engine"]
    E["Muffler"] --> F["Muffler to cylinder head"]
    E --> G["Muffler to rear fender bracket"]
    E --> H["Muffler to seat pillar tube"]
    I["Steering Steering stem to handlebar"] --> J["Steering stem to frame"]
    I --> K["Steering stem to upper bracket"]
    I --> L["Upper bracket to handlebar"]
    M["Suspension Front Steering stem to front fork"] --> N["Front fork to upper bracket"]
    M --> O["Front fork to lower bracket"]
    P["Rear For link type"] --> Q["Assembly of links"]
    P --> R["Link to frame"]
    P --> S["Link to shock absorber"]
    P --> T["Link to swingarm"]
    U["Rear Installation of shock absorber"] --> V["Shock absorber to frame"]
    U --> W["Tightening of pivot shaft"]
    X["Rear Installation of swing-arm"] --> Y["Tightening of wheel axle"]
    X --> Z["Rear"]
    Z --> AA["Tightening of wheel axle"]
    Z --> AB["Wheel to sprocket"]
    AC["Wheel Installation of wheel Front"] --> AD["Tightening of wheel axle"]
    AC --> AE["Rear"]
    AE --> AF["Tightening of wheel axle"]
    AE --> AG["Wheel to sprocket"]
    AH["Brake Front"] --> AI["Camshaft lever to camshaft"]
    AH --> AJ["Rear"]
    AJ --> AK["Camshaft lever to camshaft"]
    AL["Fuel system"] --> AM["Fuel tank to fuel cock"]

NOTE:

Concerning the tightening torque, refer to "MAINTENANCE SPECIFICATIONS" section in the CHAPTER 2.

TT-R125LW

graph TD
    A["Engine mounting"] --> B["Frame to engine"]
    A --> C["Frame to engine bracket"]
    A --> D["Engine bracket to engine"]
    E["Muffler"] --> F["Muffler to cylinder head"]
    E --> G["Muffler to rear fender bracket"]
    E --> H["Muffler to seat pillar tube"]
    I["Steering Steering stem to handlebar"] --> J["Steering stem to frame"]
    I --> K["Steering stem to upper bracket"]
    I --> L["Upper bracket to handlebar"]
    M["Suspension Front Steering stem to front fork"] --> N["Front fork to upper bracket"]
    M --> O["Front fork to lower bracket"]
    P["Rear For link type"] --> Q["Assembly of links"]
    P --> R["Link to frame"]
    P --> S["Link to shock absorber"]
    P --> T["Link to swingarm"]
    U["Rear Installation of shock absorber"] --> V["Shock absorber to frame"]
    U --> W["Tightening of pivot shaft"]
    X["Rear Installation of swing-arm"] --> Y["Tightening of wheel axle"]
    X --> Z["Tightening of wheel axle"]
    X --> AA["Wheel to sprocket"]
    AB["Wheel Installation of wheel Front"] --> AC["Rear"]
    AB --> AD["Tightening of wheel axle"]
    AB --> AE["Wheel to sprocket"]
    AF["Brake Front"] --> AG["Brake caliper to front fork"]
    AF --> AH["Brake disc to wheel"]
    AF --> AI["Tightening of union bolt"]
    AF --> AJ["Brake master cylinder to joint"]
    AF --> AK["Brake hose to joint"]
    AF --> AL["Brake master cylinder to handlebar"]
    AF --> AM["Tightening of bleed screw"]
    AN["Fuel system"] --> AO["Brake camshaft lever to brake camshaft"]
    AN --> AP["Fuel tank to fuel cock"]

NOTE: ____ Concerning the tightening torque, refer to "MAINTENANCE SPECIFICATIONS" section in the CHAPTER 2.

CONTRÔLE DU SERRAGE AU COUPLE

TT-R125

CLEANING AND STORAGE

EC1B1000

CLEANING

Frequent cleaning of your machine will enhance its appearance, maintain good overall performance, and extend the life of many components.

1. Before washing the machine, block off the end of the exhaust pipe to prevent water from entering. A plastic bag secured with a rubber band may be used for this purpose.
2. If the engine is excessively greasy, apply some degreaser to it with a paint brush. Do not apply degreaser to the chain, sprockets, or wheel axles.
3. Rinse the dirt and degreaser off with a garden hose; use only enough pressure to do the job.

CAUTION:

Excessive hose pressure may cause water seepage and contamination of wheel bearings, front forks, brakes and transmission seals. Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin-operated car washers.

1. After the majority of the dirt has been hosed off, wash all surfaces with warm water and a mild detergent. Use an old toothbrush to clean hard-to-reach places.
2. Rinse the machine off immediately with clean water, and dry all surfaces with a soft towel or cloth.
3. Immediately after washing, remove excess water from the chain with a paper towel and lubricate the chain to prevent rust.
4. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy.
5. Automotive wax may be applied to all painted or chromed surfaces. Avoid combination cleaner-waxes, as they may contain abrasives.
6. After completing the above, start the engine and allow it to idle for several minutes.

NETTOYAGE ET REMISAGE

NETTOYAGE

If your machine is to be stored for 60 days or more, some preventive measures must be taken to avoid deterioration. After cleaning the machine thoroughly, prepare it for storage as follows:

1. Drain the fuel tank, fuel lines, and the carburetor float bowl.
2. Remove the spark plug, pour a tablespoon of SAE 10W-30 motor oil in the spark plug hole, and reinstall the plug. With the engine stop switch pushed in, kick the engine over several times to coat the cylinder walls with oil.
3. Remove the drive chain, clean it thoroughly with solvent, and lubricate it. Reinstall the chain or store it in a plastic bag tied to the frame.
4. Lubricate all control cables.
5. Block the frame up to raise the wheels off the ground.
6. Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering.
7. If the machine is to be stored in a humid or salt-air environment, coat all exposed metal surfaces with a film of light oil. Do not apply oil to rubber parts or the seat cover.

NOTE:

Make any necessary repairs before the machine is stored.

REMISAGE

Model name: TT-R125R (USA, CDN, AUS, NZ)	TT-R125 (EUROPE, ZA)
Model code number: 5HPF (USA, AUS, NZ, EUROPE, ZA)5HPG (CDN)
Dimensions: USA, AUS, NZ,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)←		CDN
Basic weight:With oil and full fuel tank 83 kg (183 lb)
Engine:Engine type Air cooled 4-stroke, SOHCCylinder arrangement Single cylinder, forwardinclinedDisplacement 124 cmBore × strokeCompression ratio 10.0:1Starting system Kickstarter	^3 (7.57 cu.in) 54.0 × 54.0 mm ( 2.126 × 2.126 in)
Lubrication system: Wet sump
Oil type or grade:Engine oil	(For USA and CDN)At -10^ ( 10^ ) or higherAYamalube 4 (10W-30) or SAE 10W-30 typeSE motor oilAt 5^ ( 40^ ) or higherBYamalube 4 (20W-40) or SAE 20W-40 typeSE motor oil(Except for USA and CDN)API “SE” or higher grade
Oil capacity:Engine oilPeriodic oil change 1.0 L (0.88 Imp qt, 1.06 US qt)Total amount 1.2 L (1.06 Imp qt, 1.27 US qt)
Air filter: Wet type element
Fuel:Type Unleaded gasoline only (USA, AUS, NZ)Tank capacity 6.6 L (1.45 Imp gal, 1.74 US gal)Reserve amount 1.9 L (0.42 Imp gal, 0.5 US gal)	Regular unleaded gasoline only(CDN, EUROPE)Regular gasoline (ZA)
Carburetor:Type VM20SSManufacturer MIKUNI
Spark plug:Type CR7HSA/U22FSR-UManufacturer NGK/DENSOGap 0.6 ~ 0.7 mm (0.02 ~ 0.03 in)
Clutch type: Wet, multiple-disc
Transmission:Primary reduction system GearPrimary reduction ratio 68/19 (3.579)Secondary reduction system Chain driveSecondary reduction ratio 49/13 (3.769)Transmission type Constant mesh, 5-speedOperation Left foot operationGear ratio: 1st 37/14 (2.643)2nd 3rd 4th 5th	32/18 (1.778)25/19 (1.316)23/22 (1.045)21/24 (0.875)
Chassis:Frame typeCaster angleTrail	Diamond28.7°93 mm (3.66 in)
Tire:Type With tubeSize (front)Size (rear)Manufacturer (front and rear)Tire pressure (front and rear)	70/100-17 40M90/100-14 49MCHENG SHIN100 kPa (1.00 kgf/cm2, 15 psi)
Brake:Front brake type Drum brakeOperation Right hand operationRear brake type Drum brakeOperation Right foot operation
Suspension:Front suspension Telescopic forkRear suspension Swingarm (link type monocross suspension)
Shock absorber:Front shock absorber Coil spring/oil damperRear shock absorber Coil spring/gas, oil damper
Wheel travel:Front wheel travel 180 mm (7.09 in)Rear wheel travel 160 mm (6.30 in)
Electrical:Ignition system CDI magneto

TT-R125LW

Model name: TT-R125LWR (USA, CDN, AUS, NZ)
	TT-R125LW (EUROPE, ZA)
Model code number: 5HPH (USA, AUS, NZ, EUROPE, ZA)5HPJ (CDN)
Dimensions: USA, AUS, NZ,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 84 kg (185 lb)
Engine:Engine type Air cooled 4-stroke, SOHCCylinder arrangement Single cylinder, forwardinclinedDisplacement 124 cmBore × strokeCompression ratio 10.0:1Starting system Kickstarter	^3 (7.57 cu.in)54.0 × 54.0 mm (2.126 × 2.126 in)
Lubrication system: Wet sump
Oil type or grade:Engine oil	(For USA and CDN)At -10 °C (10 °F) or higher [A]Yamalube 4 (10W-30) or SAE 10W-30 typeSE motor oilAt 5 °C (40 °F) or higher [B]Yamalube 4 (20W-40) or SAE 20W-40 typeSE motor oil(Except for USA and CDN)API “SE” or higher grade
Oil capacity:Engine oilPeriodic oil change 1.0 L (0.88 Imp qt, 1.06 US qt)Total amount 1.2 L (1.06 Imp qt, 1.27 US qt)
Air filter: Wet type element
Fuel:Type Unleaded gasoline only (USA, AUS, NZ)Tank capacity 6.6 L (1.45 Imp gal, 1.74 US gal)Reserve amount 1.9 L (0.42 Imp gal, 0.5 US gal)	Regular unleaded gasoline only(CDN, EUROPE)Regular gasoline (ZA)
Carburetor:Type VM20SSManufacturer MIKUNI
Spark plug:Type CR7HSA/U22FSR-UManufacturer NGK/DENSOGap 0.6 ~ 0.7 mm (0.02 ~ 0.03 in)
Clutch type: Wet, multiple-disc
Transmission:Primary reduction system GearPrimary reduction ratio 68/19 (3.579)Secondary reduction system Chain driveSecondary reduction ratio 54/13 (4.154)Transmission type Constant mesh, 5-speedOperation Left foot operationGear ratio: 1st 37/14 (2.643)2nd 3rd 4th 5th	32/18 (1.778)25/19 (1.316)23/22 (1.045)21/24 (0.875)
Chassis:Frame typeCaster angleTrail	Diamond28.5°107 mm (4.21 in)
Tire:Type With tubeSize (front)Size (rear)Manufacturer (front and rear)Tire pressure (front and rear)	70/100-19 42M90/100-16 52MINOUE RUBBER100 kPa (1.00 kgf/cm2, 15 psi)
Brake:Front brake type Single disc brakeOperation Right hand operationRear brake type Drum brakeOperation Right foot operation
Suspension:Front suspension Telescopic forkRear suspension Swingarm (link type monocross suspension)
Shock absorber:Front shock absorber Coil spring/oil damperRear shock absorber Coil spring/gas, oil damper
Wheel travel:Front wheel travel 180 mm (7.09 in)Rear wheel travel 168 mm (6.61 in)
Electrical:Ignition system CDI magneto

EC212000

MAINTENANCE SPECIFICATIONS

EC212100

ENGINE

Item Standard Limit
Cylinder head:Warp limit ---- 0.03 mm			(0.0012 in)
Cylinder:Bore size 54.000 ~ 54.019 mmOut of round limit ---- 0.05 mm		(2.1260 ~ 2.1267 in)	----(0.0020 in)
Camshaft:Drive method Chain drive (left) ----Cam dimensionsIntake “A” 25.881 ~ 25.981 mm“B” 21.195Exhaust “A” 25.841 ~ 25.941 mm“B” 21.050Camshaft runout limit ---- 0.03 mm		(1.0189 ~ 1.0229 in)(0.8344 ~ 0.8384 in)(1.0174 ~ 1.0213 in)(0.8287 ~ 0.8327 in)	25.851 mm(1.0178 in)21.165 mm(0.8333 in)25.811 mm(1.0162 in)21.020 mm(0.8276 in)(0.0012 in)
Item		Standard	Limit
Cam chain:Cam chain type/No. of links DID25SD DHA/88Cam chain adjustment method Automatic ----		----
Rocker arm/rocker arm shaft:Shaft outside diameter 9.981 ~ 9.991 mm		(0.3930 ~ 0.3933 in)	9.95 mm(0.3917 in)
Rocker arm inside diameter 10.000 ~ 10.015 mm		(0.3937 ~ 0.3943 in)	10.03 mm(0.3949 in)
Valve, valve seat, valve guide:Valve clearance (cold) IN 0.08 ~ 0.12 mm		(0.0031 ~ 0.0047 in)	----
		EX 0.10 ~ 0.14 mm	----
		(0.0039 ~ 0.0055 in)
Valve dimensions:
Head diameter	Face width	Seat width	Margin thickness
“A” head diameter IN 25.9 ~ 26.1 mm		(1.0197 ~ 1.0276 in)	----
		EX 21.9 ~ 22.1 mm	----
“B” face width IN 1.1 ~ 3.0 mm		(0.8622 ~ 0.8701 in)	----
		EX 1.7 ~ 2.8 mm	----
“C” seat width IN 0.9 ~ 1.1 mm		(0.0669 ~ 0.1102 in)	1.6 mm(0.0630 in)
		EX 0.9 ~ 1.1 mm	1.6 mm(0.0630 in)
“D” margin thickness IN 0.4 ~ 0.8 mm		(0.0354 ~ 0.0433 in)	----
		EX 0.8 ~ 1.2 mm	----
Stem outside diameter IN 4.975 ~ 4.990 mm		(0.0315 ~ 0.0472 in)	4.950 mm(0.1949 in)
		EX 4.960 ~ 4.975 mm	4.935 mm(0.1943 in)
Guide inside diameter IN 5.000 ~ 5.012 mm		(0.1953 ~ 0.1959 in)	5.042 mm(0.1985 in)
		EX 5.000 ~ 5.012 mm	5.042 mm(0.1985 in)
Stem-to-guide clearance IN 0.010 ~ 0.037 mm		(0.1969 ~ 0.1973 in)	0.08 mm(0.0031 in)
		EX 0.025 ~ 0.052 mm	0.10 mm(0.0040 in)
Item Standard Limit
Stem runout limit ---- 0.01 mmValve seat width IN 0.9 ~ 1.1 mmEX 0.9 ~ 1.1 mm(0.0354 ~ 0.0433 in)1.6 mm(0.0630 in)1.6 mm(0.0630 in)		(0.0004 in)
Valve spring:Free length IN 32.55 mm (1.28 in) 31.2 mmEX 32.55 mm (1.28 in) 31.2 mm(1.23 in)Set length (valve closed) IN 25.6 mm (1.01 in) ----EX 25.6 mm (1.01 in) ----Compressed pressure(installed) IN 137.5 ~ 158.1 N(14.0 ~ 16.1 kg, 30.86 ~ 35.49 lb)----EX 137.5 ~ 158.1 N(14.0 ~ 16.1 kg, 30.86 ~ 35.49 lb)----Tilt limit * IN ---- 2.5°/1.4 mmEX ---- 2.5°/1.4 mm(2.5°/0.06 in)Direction of winding(top view) IN Clockwise ----EX Clockwise ----

Item		Standard	Limit
Piston:
Piston to cylinder clearance 0.020 ~ 0.026 mm		(0.0008 ~ 0.0010 in)	0.15 mm(0.0059 in)
Piston size “D” 53.977 ~ 53.996 mm		(2.1251 ~ 2.1258 in)	----
Piston over size (2nd) 54.5 mm (2.1457 in) ----(4th) 55.0 mm (2.1654 in) ----
Measuring point “H” 5 mm (0.20 in) ----
Piston off-set 0.5 mm (0.0197 in) ----
Piston pin bore inside diameter 15.002 ~ 15.013 mm		(0.5906 ~ 0.5911 in)	15.043 mm(0.5922 in)
Piston pin outside diameter 14.991 ~ 15.000 mm		(0.5902 ~ 0.5906 in)	14.971 mm(0.5894 in)
Piston rings:
Top ring
Type Barrel ----
Dimensions (B × T)		1.0 × 2.1 mm (0.04 × 0.08 in)	----
End gap (installed)		0.15 ~ 0.30 mm(0.006 ~ 0.012 in)	0.4 mm(0.016 in)
Side clearance (installed) 0.035 ~ 0.090 mm		(0.0014 ~ 0.0035 in)	0.12 mm(0.0047 in)
2nd ring
Type Taper ----
Dimensions (B × T)		1.0 × 2.1 mm (0.04 × 0.08 in)	----
End gap (installed)		0.30 ~ 0.45 mm(0.012 ~ 0.018 in)	0.55 mm(0.022 in)
Side clearance		0.020 ~ 0.060 mm(0.0008 ~ 0.0024 in)	0.12 mm(0.0047 in)
Oil ring
Dimensions (B × T)		2.0 × 2.2 mm (0.08 × 0.09 in)	----
End gap (installed)		0.20 ~ 0.70 mm (0.01 ~ 0.03 in)	----
Crankshaft:
Crank width “A” 46.95 ~ 47.00 n		(1.848 ~ 1.850 in)	----
Runout limit “C” ---- 0.03 mm			(0.0012 in)
Big end side clearance “D” 0.15		(0.0059 ~ 0.0177 in)	0.5 mm (0.02 in)
Clutch:
Friction plate thickness 2.92 ~ 3.08 mm		(0.115 ~ 0.121 in)	2.8 mm (0.110 in)
Quantity 5 ----
Clutch plate thickness 1.05 ~ 1.35 mm		(0.041 ~ 0.053 in)	----
Quantity 4 ----			(0.008 in)
Warp limit ---- 0.2 mm
Clutch spring free length 33 mm (1.30 in) 31 mm			(1.22 in)
Quantity 4 ----
Clutch release method Inner push, cam push ----
Push rod bending limit ---- 0.5 mm			(0.020 in)
Shifter:
Shifter type Cam drum and guide bar ----
Kick starter:
Type		Kick and mesh type	----
Kick clip friction force		6.4 ~ 13.2 N (0.65 ~ 1.35 kg, 1.4 ~ 3.0 lb)	----
Carburetor:
I.D. mark		5HP1 10	----
Main jet	(M.J)	#105	----
Main jet nozzle	(N.J)	N-6M	----
Main air jet	(M.A.J)	ø1.2	----
Jet needle-clip position	(J.N)	5HGM56-2	----
Cutaway	(C.A)	2.5	----
Pilot air jet 1	(P.A.J.1)	#80	----
Pilot air jet 2	(P.A.J.2)	#145	----
Pilot outlet	(P.O)	ø1.05	----
Pilot jet	(P.J)	#15	----
Pilot air screw (example)	(A.S)	(2-1/2 ~ 3-1/2 turns out)	----
Bypass	(B.P)	ø1.0	----
Needle valve seat size	(V.S)	1.8	----
Starter jet 1 (G.S.1) #22.5		----
Starter jet 2 (G.S.2) #1.2		----
Fuel level	(F.L)	6.0 ~ 7.0 mm (0.24 ~ 0.28 in)	----
Engine idle speed		1,300 ~ 1,500 r/min	----
Item Standard Limit
Lubrication system:Oil filter type Wire mesh type ----Oil pump type Trochoid type ----Tip clearance 0.15 mmSide clearance 0.06 ~ 0.10 mmHousing and rotor clearance 0.06 ~ 0.10 mm		(0.0059 in)(0.0024 ~ 0.0039 in)(0.0024 ~ 0.0039 in)	0.2 mm(0.0079 in)0.15 mm(0.0059 in)0.15 mm(0.0059 in)

Part to be tightened Thread size Qty			Tightening 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
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
Segment	M6 × 1.0 1	12 1.2 8.7
Stopper lever	M6 × 1.0 1	10 1.0 7.2

NOTE:

△- marked portion shall be checked for torque tightening after break-in or before each ride.

Cylinder head tightening sequence

EC212201

CHASSIS

TT-R125

Item Standard Limit
Steering system:Steering bearing type (upper) Angular bearing ----(lower) Taper roller bearing ----
Front suspension:Front fork travel 180 mm (7.09 in) ----Fork spring free length 327 mm (12.87 in) 322 mm (12.68 in)Spring rate, STD K = 3.00 N/mm(0.310 kg/mm, 17.4 lb/in)Optional spring/spacer No ----Oil capacity 159 cm3(5.60 Imp oz, 5.38 US oz)Oil level 122 mm (4.80 in) ----Oil grade Fork oil 10W or equivalent ----Inner tube outer diameter ----30 mm (1.18 in) ----Front fork top end Zero mm (Zero in) ----
Rear suspension:Shock absorber travel65 mm (2.56 in) ----Spring free length175 mm (6.89 in) ----Fitting length165 mm (6.50 in) ----Spring rate, STD K = 48.1 N/mm(4.9 kg/mm, 274 lb/in) ----Optional springNo ----1,500 kPa ----Enclosed gas pressure(15 kg/cm2, 213 psi) ----
Wheel:Front wheel typeSpoke wheel ----Rear wheel type Spoke wheel----Front rim size/material17 × 1.40/Steel ----Rear rim size/material14 × 1.60/Steel ----Rim runout limit:Radial ----2.0 mm (0.08 in)Lateral ----2.0 mm (0.08 in)	Spoke wheel ----17 × 1.40/Steel ----14 × 1.60/Steel ----2.0 mm (0.08 in)
Drive chain:Type/manufacturerDID428HD/DAIDO ----Number of links116 links ----Chain slack 35 ~ 50 mm (1.4 ~ 2.0 in) ----Chain length (10 links) ----121.4 mm (4.78 in)Item	Standard	Limit
Drum brake:Front drum brake type Leading, trailing ----Rear drum brake type Leading, trailing ----Front drum inside diameter 110 mm (4.33 in) 111 mm (4.37 in)Rear drum inside diameter 110 mm (4.33 in) 111 mm (4.37 in)Front lining thickness 4.0 mm (0.16 in) 2.0 mm (0.08 in)Rear lining thickness 4.0 mm (0.16 in) 2.0 mm (0.08 in)Front shoe spring free length 50.5 mm (1.99 in) ----Rear shoe spring free length 50.5 mm (1.99 in) ----
Brake lever and brake pedal:Brake lever free play (lever end) 10 ~ 15 mm (0.39 ~ 0.59 in) ----Brake pedal position (vertical height below footrest top) 1 mm (0.04 in) ----Brake pedal free play 20 ~ 30 mm (0.79 ~ 1.18 in) ----Clutch lever free play (lever end) 10 ~15 mm (0.39 ~ 0.59 in) ----Throttle grip free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----	----

Part to be tightened Thread size Q'ty			Tightening torque
			Nm m•kg ft•lb
Upper bracket and inner tube M8 × 1.25 2 25 2.5 18Lower bracket and inner tube M10 × 1.25 2 60 6.0 43Upper bracket and steering stem M22 × 1.0 1 110 11.0 80Handlebar upper holder and upper bracket M8 × 1.25 4 23 2.3 17Steering stem and ring nut M25 × 1.0 1 Refer to NOTE.
Front fork and cap bolt	M25 × 1.0 2	23 2.3 17
Front fork and damper rod	M10 × 1.0 2	23 2.3 17
Front fork and brake cable holder	M6 × 1.0	1	7	0.7	5.1
Number plate	M6 × 1.0	1	7	0.7	5.1
Starter knob	M11 × 1.25	1	1	0.1	0.7
Starter knob stay	M6 × 1.0	2	10	1.0	7.2
Grip cap upper and lower	M5 × 0.8	2	4	0.4	2.9
Throttle cable cap	M4 × 0.7	2	2	0.2	1.4
Brake lever mounting (bolt)	M6 × 1.0	1	7	0.7	5.1
Brake lever mounting (nut)	M6 × 1.0	1	7	0.7	5.1
Brake lever holder	M5 × 0.8	2	4	0.4	2.9
Clutch lever mounting (bolt)	M6 × 1.0	1	7	0.7	5.1
Clutch lever mounting (nut)	M6 × 1.0	1	7	0.7	5.1
Clutch lever holder	M5 × 0.8	2	4	0.4	2.9
Front wheel axle and axle nut	M12 × 1.25 1	45 4.5 32
Front brake camshaft lever and camshaft	M6 × 1.0	1	10	1.0	7.2
Rear wheel axle and axle nut	M12 × 1.25	1	60	6.0	43
Rear brake camshaft lever and camshaft	M6 × 1.0	1	10	1.0	7.2
Brake pedal mounting	M10 × 1.25 1	30 3.0 22
Brake pedal position locknut	M6 × 1.0	1	7	0.7	5.1
Front wheel nipple (spoke)	—	36	2	0.2	1.4
Rear wheel nipple (spoke)	—	36	3	0.3	2.2
Driven sprocket (nut)	M10 × 1.25 4	43 4.3 31
Driven sprocket (stud)	M10 × 1.25 4	30 3.0 22
Sidestand mounting (nut)	M10 × 1.25 1	44 4.4 32
Engine mounting:
Engine bracket (front) and frame	M8 × 1.25 2	40 4.0 29
Engine bracket (front) and engine	M8 × 1.25 2	40 4.0 29
Engine bracket (upper) and frame	M8 × 1.25 2	40 4.0 29
Engine bracket (upper) and cylinder head	M8 × 1.25	1	40	4.0	29
Engine and frame (rear)	M8 × 1.25 2	40 4.0 29
Pivot shaft and nut	M12 × 1.25 1	53 5.3 38
Relay arm and swingarm	M12 × 1.25 1	53 5.3 38

NOTE:
1. First, tighten the ring nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the ring nut wrench and turn the steering right and left a few times; then loosen the ring nut one turn.
2. Retighten the ring nut 20 Nm (2.0 m • kg, 14 ft • lb).

Part to be tightened Thread size Q'ty			Tightening torque
			Nm m•kg ft•lb
Relay arm and connecting arm M10 × 1.25 1 35 3.5 25Connecting arm and frame M10 × 1.25 1 35 3.5 25Rear shock absorber assembly and frame M12 × 1.25 1 53 5.3 38Rear shock absorber assembly and relay arm M10 × 1.25 1 35 3.5 25Rear shock absorber and locknut (preload) M46 × 1.5 1 42 4.2 30Drive chain tensioner (upper)	M8 × 1.25 1 23 2.3 17
Drive chain tensioner (lower)	M6 × 1.0	1	7	0.7	5.1
Drive chain support and swingarm	M6 × 1.0	2	7	0.7	5.1
Drive chain guide and swingarm	M6 × 1.0	2	7	0.7	5.1
Drive chain guard mounting	M6 × 1.0	2	7	0.7	5.1
Fuel tank mounting	M6 × 1.0	2	10	1.0	7.2
Fuel tank and fuel cock	M6 × 1.0	2	7	0.7	5.1
Fuel tank and fuel tank bracket	M6 × 1.0	4	7	0.7	5.1
Front fender mounting	M6 × 1.0	4	7	0.7	5.1
Rear fender mounting	M6 × 1.0	4	7	0.7	5.1
Flap guard mounting	M6 × 1.0	2	4	0.4	2.9
Left side cover mounting	M6 × 1.0	2	7	0.7	5.1
Seat mounting	M6 × 1.0	2	7	0.7	5.1

NOTE:
△- marked portion shall be checked for torque tightening after break-in or before each ride.

TT-R125LW

Item Standard Limit
Steering system:Steering bearing type (upper) Angular bearing ----(lower) Taper roller bearing ----
Front suspension:Front fork travel 180 mm (7.09 in) ----Fork spring free length 339 mm (13.35 in) 334 mm (13.15 in)Spring rate, STD K = 3.20 N/mm(0.330 kg/mm, 18.5 lb/in)Optional spring/spacer No ----Oil capacity 156 cm3(5.49 Imp oz, 5.27 US oz)Oil level 130 mm (5.12 in) ----Oil grade Fork oil 10W or equivalent ----Inner tube outer diameter 30 mm (1.18 in) ----Front fork top end Zero mm (Zero in) ----
Rear suspension:Shock absorber travel 65 mm (2.56 in) ----Spring free length 178 mm (7.01 in) ----Fitting length 165 mm (6.50 in) ----Spring rate, STD K = 58.9 N/mm(6.0 kg/mm, 336 lb/in) ----Optional spring No ----Enclosed gas pressure 1,500 kPa ----(15 kg/cm2, 213 psi) ----
Wheel:Front wheel type Spoke wheel ----Rear wheel type Spoke wheel----Front rim size/material 19 × 1.40/Steel ----Rear rim size/material 16 × 1.60/Steel ----Rim runout limit:Radial ----2.0 mm (0.08 in) 2.0 mm (0.08 in)Lateral ----2.0 mm (0.08 in)
Drive chain:Type/manufacturer DID428HD/DAIDO ----Number of links 122 links ----Chain slack 35 ~ 50 mm (1.4 ~ 2.0 in) ----Chain length (10 links) ----121.4 mm(4.78 in)
Front disc brake:Disc outside dia. × Thickness 220 × 3.0 mm (8.66 × 0.12 in) 220 × 2.5 mm(8.66 × 0.10 in)Deflection limit ----0.15 mm (0.006 in)Pad thickness 4.0 mm (0.16 in) 0.8 mm (0.03 in)Master cylinder inside dia. 11.0 mm (0.433 in) ----Caliper cylinder inside dia. 22.22 mm (0.875 in) × 2 ----Brake fluid type DOT #4 ----
Rear drum brake:Drum brake type Leading, trailing ----Drum inside diameter 110 mm (4.33 in) 111 mm (4.37 in)Lining thickness 4.0 mm (0.16 in) 2.0 mm (0.08 in)Shoe spring free length 50.5 mm (1.99 in) ----
Brake lever and brake pedal:Brake lever free play (lever end) 2 ~ 5 mm (0.08 ~ 0.20 in) ----Brake pedal position (vertical height below footrest top)Brake pedal free play 20 ~ 30 mm (0.79 ~ 1.18 in) ----Clutch lever free play (lever end) 10 ~ 15 mm (0.39 ~ 0.59 in) ----Throttle grip free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----

Part to be tightened Thread size Q'ty			Tightening torque
			Nm m•kg ft•lb
Upper bracket and inner tube M8 × 1.25 2 25 2 .5 18Lower bracket and inner tube M10 × 1.25 2 60 6.0 43Upper bracket and steering stem M22 × 1.0 1 110 11.0 80Handlebar upper holder and upper bracket M8 × 1.25 4 23 2 .3 17Steering stem and ring nut M25 × 1.0 1 Refer to NOTE.
Front fork and cap bolt	M25 × 1.0 2	23 2.3 17
Front fork and damper rod	M10 × 1.0 2	23 2.3 17
Front fork and brake hose holder	M6 × 1.0	2	7	0.7	5.1
Number plate	M6 × 1.0	1	7	0.7	5.1
Starter knob	M11 × 1.25	1	1	0.1	0.7
Starter knob stay	M6 × 1.0	2	10	1.0	7.2
Grip cap upper and lower	M5 × 0.8	2	4	0.4	2.9
Throttle cable cap	M4 × 0.7	2	2	0.2	1.4
Front brake master cylinder	M6 × 1.0	2	9	0.9	6.5
Front brake master cylinder cap	M4 × 0.7	2	2	0.2	1.4
Brake lever mounting (bolt)	M6 × 1.0	1	7	0.7	5.1
Brake lever mounting (nut)	M6 × 1.0	1	7	0.7	5.1
Brake lever adjuster and locknut	M6 × 0.75	1	4	0.4	2.9
Clutch lever mounting (bolt)	M6 × 1.0	1	7	0.7	5.1
Clutch lever mounting (nut)	M6 × 1.0	1	7	0.7	5.1
Clutch lever holder	M5 × 0.8	2	4	0.4	2.9
Front brake master cylinder and joint	M10 × 1.25 1	26 2.6 19
Front brake hose and joint	M10 × 1.25 1	14 1.4 10
Front brake hose union bolt	M10 × 1.25 1	26 2.6 19
Front brake caliper and front fork M8 × 1.25 2 30 3.0 22
Brake caliper support bolt	M8 × 1.25 1	22 2.2 16
Front brake caliper and bleed screw	M7 × 1.0	1	6	0.6	4.3
Front wheel axle and axle nut	M12 × 1.25	1	45	4.5	32
Front brake disc and wheel hub	M6 × 1.0	4	12	1.2	8.7
Rear wheel axle and axle nut	M12 × 1.25	1	60	6.0	43
Rear brake camshaft lever and camshaft	M6 × 1.0	1	10	1.0	7.2
Brake pedal mounting	M10 × 1.25 1	30 3.0 22
Brake pedal position locknut	M6 × 1.0	1	7	0.7	5.1
Front wheel nipple (spoke)	—	36	2	0.2	1.4
Rear wheel nipple (spoke)	—	36	3	0.3	2.2

NOTE:

1. First, tighten the ring nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the ring nut wrench and turn the steering right and left a few times; then loosen the ring nut one turn.

2. Retighten the ring nut 20 Nm (2.0 m • kg, 14 ft • lb).

Part to be tightened Thread size Q'ty			Tightening torque
			Nm m•kg ft•lb
Bead stopper M8 × 1.25 1 3 0.3 2.2
Driven sprocket (nut) M10 × 1.25 4 43 4.3 31
Driven sprocket (stud) M10 × 1.25 4 30 3.0 22
Sidestand mounting (nut) M10 × 1.25 1 44 4.4 32
Engine mounting:
Engine bracket (front) and frame M8 × 1.25 2 40 4.0 29
Engine bracket (front) and engine M8 × 1.25 2 40 4.0 29
Engine bracket (upper) and frame	M8 × 1.25 2 40 4.0 29
Engine bracket (upper) and cylinder head	M8 × 1.25 1 40 4.0 29		40	4.0	29
Engine and frame (rear)	M8 × 1.25 2 40 4.0 29
Pivot shaft and nut	M12 × 1.25 1 53 5.3 38
Relay arm and swingarm	M12 × 1.25 1 53 5.3 38
Relay arm and connecting arm	M10 × 1.25 1 35 3.5 25
Connecting arm and frame	M10 × 1.25 1 35 3.5 25
Rear shock absorber assembly and frame	M12 × 1.25 1 53 5.3 38		53	5.3	38
Rear shock absorber assembly and relay arm	M10 × 1.25 1 35 3.5 25		35	3.5	25
Rear shock absorber and locknut (preload)	M46 × 1.5 1 42 4.2 30		42	4.2	30
Drive chain tensioner (upper)	M8 × 1.25 1 23 2.3 17
Drive chain tensioner (lower)	M6 × 1.0 1 7 0.7 5.1		7	0.7	5.1
Drive chain support and swingarm	M6 × 1.0 2 7 0.7 5.1		7	0.7	5.1
Drive chain guide and swingarm	M6 × 1.0 2 7 0.7 5.1		7	0.7	5.1
Drive chain guard mounting	M6 × 1.0 2 7 0.7 5.1		7	0.7	5.1
Fuel tank mounting	M6 × 1.0 2 10 1.0 7.2		1.0	7.2
Fuel tank and fuel cock	M6 × 1.0 2 7 0.7 5.1		7	0.7	5.1
Fuel tank and fuel tank bracket	M6 × 1.0 4 7 0.7 5.1		7	0.7	5.1
Front fender mounting M6 × 1.0 4 7 0.7 5.1
Rear fender mounting	M6 × 1.0 4 7 0.7 5.1
Flap guard mounting	M6 × 1.0 2 4 0.4 2.9
Left side cover mounting	M6 × 1.0 2 7 0.7 5.1		7	0.7	5.1
Seat mounting	M6 × 1.0 2 7 0.7 5.1

NOTE:
△ - marked portion shall be checked for torque tightening after break-in or before each ride.

EC212300

ELECTRICAL

Item Standard Limit
CDI: Magneto-model (stator)/manufacturer 5HP-01/YAMAHA ---- Charging coil resistance (color)	688 ~ 1,032 Ω at 20 °C (68 °F) (Green-Brown)	----
Pickup coil resistance (color)	248 ~ 372 Ω at 20 °C (68 °F) (White-Red)	----
CDI unit-model/manufacturer 5HP-00/YAMAHA ----
Ignition coil: Model/manufacturer 4KJ-10/YAMAHA ---- Minimum spark gap 6 mm (0.24 in) ---- Primary coil resistance	0.18 ~ 0.28 Ω at 20 °C (68 °F)	----
Secondary coil resistance	6.3 ~ 9.5 kΩ at 20 °C (68 °F)	----

Part to be tightened Thread size	Q'ty		Tightening torque
			Nm	m•kg	ft•lb
Pickup coil	M6 × 1.0	2	10	1.0	7.2
Blind plug (neutral switch)	M10 × 1.25	1	20	2.0	14
Stator	M6 × 1.0	3	10	1.0	7.2
Rotor	M12 × 1.25	1	80	8.0	58
Ignition coil	M6 × 1.0	2	7	0.7	5.1

EC220001

GENERAL TORQUE SPECIFICATIONS

This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature.

A(Nut)	B(Bolt)	TORQUE SPECIFICATION
		Nm m•kg ft•lb
10 mm	6 mm	6	0.6	4.3
12 mm	8 mm	15	1.5	11
14 mm	10 mm	30	3.0	22
17 mm	12 mm	55	5.5	40
19 mm	14 mm	85	8.5	61
22 mm	16 mm	130	13	94

A: Distance between flats

B: Outside thread diameter

EC230000

DEFINITION OF UNITS

Unit Read Definition Measure
mmcm	millimetercentimeter	10^-3 meter 10^-2 meter	LengthLength
kg kilogram 10		^3 gram Weight
N Newton 1 kg		× m/sec^2	Force
Nm m • kg	Newton meterMeter kilogram	N × mm × kg	TorqueTorque
Pa Pascal N/m		^2	Pressure
N/mm Newton per	millimeter N/mm Spring rate
L cm^3	LiterCubic centimeter	——	Volume or capacityVolume or capacity
r/min	Revolution per minute	—	Engine speed

CARACTÉRISTIQUES

CARACTÉRISTIQUES GÉNÉRALES

TT-R125

PARTIE CYCLE

TT-R125

RAHMEN

TT-R125

①Fuel tank breather hose
②CDI unit
③CDI unit band
④Clamp
⑤CDI magneto lead
⑥Air vent hose
⑦Wire harness
⑧Engine stop switch lead
⑨Cable guide
⑩Brake cable

(Brake hose for the

TT-R125LW)

⑪Brake cable holder

(Brake hose holder for the

TT-R125LW)

AFit the CDI unit band over the CDI unit bracket till it stops.
B Clamp the ignition coil lead.
©Clamp the wire harness coupler.
D Clamp the CDI magneto lead, throttle cable and starter cable.
E Clamp the CDI magneto lead so that it does not contact the push lever.
FPass the air vent hoses between the engine and swingarm.
G Clamp the wire harness and engine stop switch lead.
HPass the brake cable (brake hose for the TT-R125LW) into the cable guide.
☐ Clamp the brake cable.
☐ Clamp the brake hose between the paint marks.

CHEMINEMENT DES CÂBLES

①Air vent hose
②Spark plug lead
③Starter cable
④Throttle cable
⑤Clutch cable
⑥Clamp
⑦Cable guide
⑧Engine oil breather hose
⑨Overflow hose

A After clamping the starter cable, push it against the starter plunger.
B Put the tip of the air vent hose into the main pipe.
Install the primary coil terminal (orange) to the ignition coil.
☐Fasten the ground lead together with the ignition coil.
EPass the clutch cable on the inside of the throttle and starter cable.
Clamp the clutch cable with the paint in the cable guide bottom recess.
GPass the throttle cable and starter cable into the cable guide.
HPass 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.

CHEMINEMENT DES CÂBLES KABELFÜHRUNG

①Engine stop switch lead
②Engine stop switch
③Fuel tank breather hose
④Clamp
⑤Brake cable
(Brake hose for the TT-R125LW)
⑥Clutch cable
⑦Throttle cable

A Pass the engine stop switch lead in the middle of the clutch holder.
B Clamp the engine stop switch lead to the handlebar to 3 clicks.
☐Pass the brake cable (brake hose for the TT-R125LW) in front of the number plate and through the cable guide.
☐Pass the clutch cable in back of the number plate.
EInsert the fuel tank breather hose into the hole in the starter knob stay more the 30 mm (1.18 in).
F Clamp the throttle cable adjuster cover to the handlebar with the clamp ends downward.

CHEMINEMENT DES CÂBLES KABELFÜHRUNG

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 Note	Item Checks	and maintenance jobs	Initial Every
			10 hours(1 month)	60 hours(6 months)	120 hours(12 months)
*	Fuel line	Check fuel hoses for cracks or damage.Replace if necessary.		○	○
	Spark plug	Check condition.Clean, regap or replace if necessary.		○	○
*	Valves	Check valve clearance.Adjust if necessary.			○
	Air filter Clean or replace element if necessary.			○	○
*	Carburetor	Check engine idling speed and starter operation.Adjust if necessary.	○	○	○
	Exhaust systems	Check for leakage.Retighten if necessary.Replace gasket if necessary.		○	○
	Engine oil	Check oil level and vehicle for oil leakage.Correct if necessary.Change. (Warm engine before draining.)	○	○	○
	Clutch	Check operation.Adjust or replace cable.	○	○	○
*	Front brake	Check operation.Adjust brake lever free play.Check fluid level and leakage. (TT-R125LW only)	Every ride
*	Rear brake	Check operation.Adjust brake pedal free play and replace brake shoes if necessary.	Every ride
*	Wheels	Check balance, runout, spoke tightness and for damage.Tighten spokes and rebalance, replace if necessary.	○	○	○
*	Tires	Check tread depth and for damage.Replace if necessary.Check air pressure.Correct if necessary.		○	○
*	Wheel bearings	Check bearing for looseness or damage.Replace if necessary.		○	○
*	Swingarm	Check swingarm pivoting point for play.Correct if necessary.Lubricate with molybdenum disulfide grease.	○	○	○
	Drive chain	Check chain slack.Adjust if necessary. Make sure that the rear wheel is properly aligned.Clean and lubricate.	Every ride
*	Steering bearings	Check bearing play and steering for roughness.Correct accordingly.Lubricate with lithium soap base grease every 120 hours.	○		○
	Sidestand	Check operation.Lubricate and repair if necessary.	○		○
*	Spark arrester*1	Clean.			○
*	Front fork	Check operation and for oil leakage.Correct accordingly.		○	○
*	Rear shock absorber assembly	Check operation and shock absorber for oil leakage.Replace shock absorber assembly if necessary.		○	○
*	Chassis fasteners	Make sure that all nuts, bolts and screws are properly tightened.Tighten if necessary.	○	○	○

* : Since these items requires special tools data and technical skills, they should be serviced.
*1 : For USA

CONTRÔLES ET RÉGLAGES PÉRIODIQUES

PROGRAMME D'ENTRETIEN

Before riding for break-in operation or practice, make sure the machine is in good operating condition.

Before using this machine, check the following points.

GENERAL INSPECTION AND MAINTENANCE

Item Routine Page
Fuel	Check that a fresh gasoline is filled in the fuel tank. Check the fuel line for leakage.	P.1-12
Engine oil	Check that the oil level is correct. Check the crankcase for leakage.	P.3-7 ~ 10
Gear shifter and clutch	Check that gears can be shifted correctly in order and that the clutch operates smoothly.	P.3-4
Throttle grip/housing	Check that the throttle grip operation and free play are correctly adjusted. Lubricate the throttle grip and housing, if necessary.	P.3-4 ~ 5
Brakes	Check the play of front and rear brake and effect of front and rear brake.Check fluid level and leakage. (TT-R125LW only)	P.3-15 ~ 20
Drive chain	Check chain slack and alignment. Check that the chain is lubricated properly.	P.3-21 ~ 22
Wheels	Check for excessive wear and tire pressure. Check for loose spokes and have no excessive play.	P.3-24 ~ 25
Steering	Check that the handlebar can be turned smoothly and have no excessive play.	P.3-25 ~ 27
Front forks and rear shock absorber assembly	Check that they operate smoothly and there is no oil leakage. P.3-23 ~ 24
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.3-28
Bolts and nuts Check the chassis and engine for loose bolts and nuts. —
Lead connectors	Check that the CDI magneto, CDI unit, and ignition coil are connected tightly.	P.1-5

CONTRÔLES ET ENTRETIENS AVANT UTILISATION

ENGINE/CLUTCH ADJUSTMENT/ THROTTLE CABLE ADJUSTMENT

INSP ADJ

EC350000

ENGINE

CLUTCH ADJUSTMENT

1. Check:

- Clutch lever free play @

Out of specification → Adjust.

Clutch lever free play ⓐ: 10 \~ 15 mm (0.39 \~ 0.59 in)

2. Adjust:

- Clutch lever free play

Clutch lever free play adjustment steps:

• Loosen the locknut ①.
• Turn the adjuster ② until free play ⓐ is within the specified limits.
  ●Tighten the locknut.

NOTE:

●Make minute adjustment on the lever side.
●After adjustment, check proper operation of clutch lever.

Line drawing of a hand gripping a motor with a handle and gear mechanism (no text or symbols)

EC35A001

THROTTLE CABLE ADJUSTMENT

1. Check:

- Throttle grip free play @

Out of specification → Adjust.

Throttle grip free play ⓐ: 3 \~ 5 mm (0.12 \~ 0.20 in)

2. Adjust:

- Throttle grip free play

Throttle grip free play adjustment steps:

• Loosen the locknut ①.
• Turn the adjuster ② until the specified free play is obtained.
  ●Tighten the locknut.

MOTEUR

RÉGLAGE DE L'EMBRAYAGE

1. Contrôler:

NOTE: ____ Before adjusting the throttle cable free play, the engine idle speed should be adjusted.

WARNING

After adjusting, turn the handlebar to right and left and make sure that the engine idling does not run faster.

THROTTLE LUBRICATION

1. Remove:

- Throttle cable cap ①

1. Apply:

- Lithium soap base grease On the throttle cable end ① and tube guide cable winding portion ②.

1. Install:

- Throttle cable cap

2 Nm (0.2 m · kg, 1.4 ft · lb)

AIR FILTER CLEANING

NOTE: ____

Proper air filter maintenance is the biggest key to preventing premature engine wear and damage.

CAUTION:

Never run the engine without the air filter element in place; this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage.

N.B.:

Illustration showing three steps of a hand holding a small object, with arrows indicating motion (no text or symbols)

1. Remove:

•Right side cover ①

NOTE:

Loosen the quick screw ② and remove the right side cover from the holding boss @.

2. Remove:

•Band ①
●Air filter case cover ②

3. Remove:

●Air filter assembly ①
•Wing nut ②
•Washer ③
●Air filter element ④
●Air filter guide ⑤

4. Clean:

●Air filter element

Clean them with solvent.

NOTE:

After cleaning, remove the remaining solvent by squeezing the element.

CAUTION:

Do not twist the element when squeezing the element.

5. Inspect:

●Air filter element

Damage → Replace.

1. Déposer:

- Foam-air-filter oil or engine mixing oil To the element.

NOTE:

Squeeze out the excess oil. Element should be wet but not dripping.

1. Install:

●Air filter element ① On air filter guide ②.

1. Apply:

- Lithium soap base grease On the matching surface ⓐ on air filter element.

1. 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.

Technical line drawing of a mechanical component with no visible text or symbols

1. Remove:

•Dipstick ①

CONTRÔLE DU NIVEAU D'HUILE DE MOTEUR MOTORÖLSTAND KONTROLLIEREN

INSP ADJ

6. Appliquer:

4. Check:

•Oil level

Oil level should be between maximum ① and minimum ② marks.

Oil level is low → Add oil to proper level.

NOTE:

When inspecting the oil level, do not screw the dipstick into the oil tank. Insert the gauge lightly.

(For USA and CDN)

Recommended oil:

At -10^ ( 10^ ) or higher A:

Yamalube 4 (10W-30) or SAE

10W-30 type SE motor oil

At 5 °C (40 °F) or higher ☐:

Yamalube 4 (20W-40) or SAE

20W-40 type SE motor oil

CAUTION:

•Do not add any chemical additives. Engine oil also lubricates the clutch and additives could cause clutch slippage.

- Do not allow foreign material to enter the crankcase.

(Except for USA and CDN)

Recommended oil:

Refer to the following chart for selection of oils which are suited to the atmospheric temperatures.

Recommended engine oil classification:

API STANDARD:

API "SE" or higher grade (Designed primarily for motorcycles)

CAUTION:

- Do not add any chemical additives or use oils with a grade of CD ⓐ or higher.

- Do not use oils labeled "ENERGY CONSERVING II" ⑥ or higher. Engine oil also lubricates the clutch and additives could cause clutch slippage.

- Do not allow foreign materials to enter the crankcase.

CONTRÔLE DU NIVEAU D'HUILE DE MOTEUR MOTORÖLSTAND KONTROLLIEREN

INSP ADJ

4. Contrôler:

•Niveau d'huile

1. Start the engine and let it warm up for several minutes.

2. Turn off the engine and inspect the oil level once again.

NOTE:

Wait a few minutes until the oil settles before inspecting the oil level.

ENGINE OIL REPLACEMENT

1. Start the engine and warm it up for several minutes and wait for five minute.
2. Place the machine on a level place and hold it on upright position by placing the suitable stand under the engine.
3. Place a suitable container under the engine.

4. Remove:

5. Oil drain bolt ①
   •Dipstick ②

Drain the engine oil.

1. Install:

•Copper washer
- Oil drain bolt ①

New

Technical line drawing of a mechanical assembly with no visible text or symbols

Technical line drawing of a mechanical component with no visible text or symbols

1. Fill:

-Engine oil

Oil capacity:

Periodic oil change:

1.0 L (0.88 Imp qt, 1.06 US qt)

1. Check:

- Oil leakage

1. Check:

-Engine oil level

1. Install:

•Dipstick ②

CHANGEMENT DE L'HUILE DE MOTEUR MOTORÖL WECHSELN

INSP ADJ

1. Installer:

OIL PRESSURE INSPECTION/PILOT AIR SCREW ADJUSTMENT/ENGINE IDLING SPEED ADJUSTMENT

INSP ADJ

Mechanical assembly diagram showing a bolted joint with rotating components and a numbered callout (no text or symbols present)

OIL PRESSURE INSPECTION

1. Check:

- Oil pressure

Checking steps:

• Slightly loosen the oil pressure check bolt ①.
• Start the engine and keep it idling until oil starts to seep from the oil pressure check bolt. If no oil comes out after one minute, turn the engine off so it will not seize.
• Check oil passages and oil pump for damage or leakage.
• Start the engine after solving the problem(s) and recheck the oil pressure.
  ●Tighten the oil pressure check bolt.

Oil pressure check bolt: 7 Nm (0.7 m • kg, 5.1 ft • lb)

Technical line drawing of a mechanical assembly with no visible text or symbols

PILOT AIR SCREW ADJUSTMENT

1. Adjust:

●Pilot air screw ①

Adjustment steps:

NOTE:

To optimize the fuel flow at a smaller throttle opening, each machine's pilot air screw has been individually set at the factory. Before adjusting the pilot air screw, turn it in fully and count the number of turns. Record this number as the factory-set number of turns out.

• Screw in the pilot air screw until it is lightly seated.
  ●Back out by the specified number of turns.

Pilot air screw: 2-1/2 \~ 3-1/2 turns out (example)

ENGINE IDLING SPEED ADJUSTMENT

1. Start the engine and thoroughly warm it up.
2. Attach:

- Inductive tachometer To spark plug lead.

1. Adjust:

-Engine idling speed

CONTRÔLE DE LA PRESSION D'HUILE DE MOTEUR

1. Contrôler:

- Pression d'huile

Étapes du contrôle:

Adjustment steps:•Adjust the pilot air screw.Refer to “PILOT AIR SCREW ADJUST-MENT” section.•Turn the throttle stop screw 1 until the specified engine idling speed.
To increase idling speed →Turn the throttle stop screw 1 in a.To decrease idling speed →Turn the throttle stop screw 1 out b.
	Inductive tachometer:YU-8036-B/90890-03113
	Engine idling speed:1,300 ~ 1,500 r/min

VALVE CLEARANCE INSPECTION AND ADJUSTMENT

NOTE:

• The valve clearance should be adjusted when the engine is cool to the touch.
• The piston must be at Top Dead Center (T.D.C.) on compression stroke to check or adjust the valve clearance.

1. Remove:

• Seat
  •Fuel tank

Refer to "SEAT, FUEL TANK AND SIDE COVERS" section in the CHAPTER 4.

2. Remove:

• Spark plug
• Intake tappet cover ①
• Exhaust tappet cover ②
  •O-ring

3. Remove:

• Timing mark accessing screw ①
  •Crankshaft end accessing screw ②
  •O-ring

Out of specification → Adjust.

Valve clearance (cold):

Intake valve:

0.08 \~ 0.12 mm

(0.0031 \~ 0.0047 in)

Exhaust valve:

0.10 \~ 0.14 mm

(0.0039 \~ 0.0055 in)

Mechanical assembly diagram showing a hand operating a wheel with bolts and a tool (no text or symbols visible)

Checking steps:

• Turn the crankshaft counterclockwise with a wrench.
• Align the T.D.C. mark ⓐ on the rotor with the align mark ⓑ on the crankcase cover when piston is at T.D.C. on compression stroke.
• Measure the valve clearance using a feeler gauge ①.
  Out of specification → Adjust clearance.

5. Adjust:

-Valve clearance

Adjustment steps:

• Loosen the locknut ①.
• Turn the adjuster ③ in or out with the valve adjusting tool ② until specified clearance is obtained.

Turning in →

Valve clearance is decreased.

Turning out →

Valve clearance is increased.

Tappet adjusting tool:

YM-8035/90890-01311

●Hold the adjuster to prevent it from moving and tighten the locknut.

Locknut:

8 Nm (0.8 m • kg, 5.8 ft • lb)

●Measure the valve clearance.
- If the clearance is incorrect, repeat above steps until specified clearance is obtained.

6. Install:

•O-ring ① New
•Crankshaft end accessing screw ②
7 Nm (0.7 m · kg, 5.1 ft · lb)
•Timing mark accessing screw ③
7 Nm (0.7 m · kg, 5.1 ft · lb)

NOTE: Apply the lithium soap base grease on the O-rings.

7. Install:

•O-ring ① New
- Exhaust tappet cover ②
18 Nm (1.8 m · kg, 13 ft · lb)
- Intake tappet cover ③
18 Nm (1.8 m · kg, 13 ft · lb)

NOTE: Apply the lithium soap base grease on the O-rings.

8. Install:

• Spark plug
  13 Nm (1.3 m · kg, 9.4 ft · lb)
  •Fuel tank
  10 Nm (1.0 m · kg, 7.2 ft · lb) 7 Nm (0.7 m · kg, 5.1 ft · lb)
• Seat

Refer to "SEAT, FUEL TANK AND SIDE COVERS" section in the CHAPTER 4.

- Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester.

- Do not start the engine when cleaning the exhaust system.

Technical illustration of a hand holding a mechanical component with a flanged shaft and bolt (no text or symbols)

1. Remove:

●Bolt (spark arrester) ①

1. Remove:

- Spark arrester ①

Pull the spark arrester out of the muffler.

1. Clean:

•Spark arrester

Tap the spark arrester lightly, then use a wire brush to remove any carbon deposits.

1. Install:

•Spark arrester

Insert the spark arrester into the muffler and align the bolt holes.

●Bolt (spark arrester)

10 Nm (1.0 m · kg, 7.2 ft · lb)

NETTOYAGE DU PARE-ÉTINCELLES

(pour les USA)

AVERTISSEMENT

Bleed the brake system if:

•The system has been disassembled.

•A brake hose has been loosened or removed.

•The brake fluid is very low.

•The brake operation is faulty.

A dangerous loss of braking performance may occur if the brake system is not properly bleed.

1. Remove:

●Brake master cylinder cap

•Diaphragm

1. Bleed:

-Brake fluid

Technical line drawing of a bicycle brake system with labeled components (no text or symbols present)

Air bleeding steps:

a. Add proper brake fluid to the reservoir.

b. Install the diaphragm. Be careful not to spill any fluid or allow the reservoir to overflow.

c. Connect the clear plastic tube ② tightly to the caliper bleed screw ①.

d. Place the other end of the tube into a container.

e. Slowly apply the brake lever several times.

f. Pull in the lever. Hold the lever in position.

g. Loosen the bleed screw and allow the lever to travel towards its limit.

h. Tighten the bleed screw when the lever limit has been reached; then release the lever.

Bleed screw:

6 Nm (0.6 m • kg, 4.3 ft • lb)

i. Repeat steps (e) to (h) until of the air bubbles have been removed from the system.

PARTIE CYCLE

PURGE DE L'AIR DU SYSTÈME DE FREINAGE (TT-R125LW)

AVERTISSEMENT

If bleeding is difficult, it may be necessary to let the brake fluid system stabilize for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disappeared.

j. Add brake fluid to the level line on the reservoir.

WARNING

Check the operation of the brake after bleeding the brake system.

1. Install:

•Diaphragm

●Brake master cylinder cap

Mechanical assembly diagram showing a linkage mechanism with no visible text or symbols

FRONT BRAKE ADJUSTMENT TT-R125

1. Check:

- Brake lever free play ⓐ

Out of specification → Adjust.

Brake lever free play ⓐ: 10 \~ 15 mm (0.39 \~ 0.59 in)

1. Adjust:

●Brake lever free play

Brake lever free play adjustment steps:

- Loosen the locknuts ①.

- Turn the locknuts until free play ⓐ is within the specified limits by changing their tightening position.

●Tighten the locknuts.

NOTE:

For minute adjustment, loosen the locknut ② on the lever side and adjust with the adjuster ③.

CAUTION:

Make sure that there is no brake drag after adjusting the brake lever free play.

N.B.:

TT-R125LW

1. Check:

- Brake lever free play ⓐ

Out of specification → Adjust.

Brake lever free play ⓐ: 2 \~ 5 mm (0.08 \~ 0.20 in)

1. Adjust:

●Brake lever free play

Brake lever free play adjustment steps:

• Loosen the locknut ①.
• Turn the adjuster ② until the free play ④ is within the specified limits.
• Tighten the locknut.

CAUTION:

Make sure that there is no brake drag after adjusting the brake lever free play.

Out of specification → Adjust.

Brake pedal free play ⓐ: 20 \~ 30 mm (0.79 \~ 1.18 in)

1. Adjust:

●Brake pedal free play

Brake pedal free play adjustment step:

Turn the adjuster ① until the free play ⓐ is within the specified limits.

CAUTION:

Make sure that there is no brake drag after adjusting the brake pedal play.

TT-R125LW

1. Contrôler:

BRAKE PEDAL HEIGHT ADJUSTMENT

1. Check:

-Brake pedal height @

Out of specification → Adjust.

Brake pedal height ⓐ: 1 mm (0.04 in)

1. Adjust:

●Brake pedal height

Pedal height adjustment steps:

• Loosen the locknut ①.
• Turn the adjusting bolt ② until the pedal height @ is within specified height.
  ●Tighten the locknut.

FRONT BRAKE PAD INSPECTION AND REPLACEMENT (TT-R125LW)

1. Remove:

•Plug

1. Inspect:

-Brake pad thickness ⓐ

Out of specification → Replace as a set.

	Brake pad thickness ⓐ:
Standard
4.0 mm(0.16 in)		0.8 mm(0.03 in)

1. Replace:

-Brake pad

Brake pad replacement steps:

• Remove the brake caliper support bolt ①.
• Turn the brake caliper ② counterclockwise a.
  -Replace the brake pads ③.

Technical line drawing of a mechanical assembly with a hand adjusting a component (no text or symbols present)

RÉGLAGE DE LA HAUTEUR DE LA PÉDALE DE FREIN

1. Contrôler:

Technical line drawing of a bicycle brake system with labeled components (no text or symbols present)

• Connect the transparent hose ④ to the bleed screw ⑤ and place the suitable container under its end.
• Loosen the bleed screw and push the brake caliper piston in.

CAUTION:

Do not reuse the drained brake fluid.

●Tighten the bleed screw.

Bleed screw: 6 Nm (0.6 m • kg, 4.3 ft • lb)

- Install the brake caliper ⑥ and brake caliper support bolt ⑦.

NOTE:

Apply the lithium soap base grease on the caliper support bolt.

Brake caliper support bolt: 22 Nm (2.2 m • kg, 16 ft • lb)

4. Inspect:

-Brake fluid level

Refer to "BRAKE FLUID LEVEL INSPECTION" section in the CHAPTER 3.

5. Check:

●Brake lever operation

A softly or spongy feeling → Bleed brake system.

Refer to "BRAKE SYSTEM AIR BLEEDING" section.

●Brake shoe lining wear limit

Brake shoe lining wear limit checking steps:

• Fully pull in the brake lever and hold it in position.
• Then check the brake shoe wear indicator ① is within the wear limit ⓐ.

Outside the limit → Replace the brake shoe.

Refer to "FRONT WHEEL AND FRONT BRAKE" section in the CHAPTER 5.

●Brake shoe lining wear limit

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 ⓐ.

Outside the limit → Replace the brake shoe.

Refer to "REAR WHEEL AND REAR BRAKE" section in the CHAPTER 5.

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.

ⒶLower level

Recommended brake fluid: DOT #4

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 plastic parts.

SPROCKETS INSPECTION

1. Inspect:

- Sprocket teeth ⓐ

Excessive wear → Replace.

NOTE: Replace the drive, driven sprockets and drive chain as a set.

CONTRÔLE DES MÂCHOIRES DE FREIN

1. Examiner:

Illustration showing hands using a tool to clean material from chains, with no text or symbols present.

EC369002 DRIVE CHAIN INSPECTION

1. Remove:

• Master link clip
  •Joint ①
  -Drive chain ②

2. Clean:

-Drive chain

Place it in kerosene, and brush off as much dirt as possible. Then remove the chain from the kerosene and dry the chain.

3. Measure:

-Drive chain length (10 links) @ Out of specification Replace.

Drive chain length (10 links): : 121.4 mm (4.78 in)

4. Check:

- Drive chain stiffness @ Clean and oil the chain and hold as illustrated. Stiff → Replace drive chain.

5. Install:

-Drive chain ①
•Joint ②
- Master link clip ③

New

CAUTION:

Be sure to install the master link clip to the direction as shown.

ⒶTurning direction

CONTRÔLE DE LA CHAÎNE DE TRANSMISSION

1. Déposer:

Illustration of a hand using a tool to adjust a chain gear mechanism (no text or symbols present)

Mechanical diagram showing a chain with rotating components and motion arrows (no text or symbols)

1. Lubricate:

-Drive chain

Drive chain lubricant: SAE 10W-30 motor oil or suitable chain lubricants

DRIVE CHAIN SLACK ADJUSTMENT

1. Elevate the rear wheel by placing the suitable stand under the engine.

2. Check:

-Drive chain slack ⓐ

In the center between the drive axle and rear wheel axle.

Out of specification → Adjust.

Drive chain slack: 35 \~ 50 mm (1.4 \~ 2.0 in)

NOTE:

Before checking and/or adjusting, rotate the rear wheel through several revolutions and check the slack several times to find the tightest point. Check and/or adjust chain slack with rear wheel in this "tight chain" position.

1. Adjust:

-Drive chain slack

Drive chain slack adjustment steps:

• Loosen the axle nut ①.
• Turn both drive chain pullers ② the same amount @ and adjust them to the stopper in the same position so that the drive chain slack is within the specified limits.

CAUTION:

Too small chain slack will overload the engine and other vital parts; keep the slack within the specified limits.

●Tighten the axle nut while pushing down the drive chain.

Axle nut: 60 Nm (6.0 m • kg, 43 ft • lb)

1. Lubrifier:

Mechanical diagram showing a gear and chain assembly on a bicycle wheel (no text or labels)

Technical line drawing of a motorcycle's front wheel and side-mounted gear assembly (no text or symbols)

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.

REAR SHOCK ABSORBER ASSEMBLY INSPECTION

1. Inspect:

●Swingarm smooth action

Abnormal noise/unsmooth action → Grease the pivoting points or repair the pivoting points.

Damage/oil leakage → Replace.

REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT

1. Elevate the rear wheel by placing the suitable stand under the engine.

2. Remove:

- Left side cover

1. Loosen:

- Locknut ①

1. Adjust:

- Spring preload

By turning the adjuster ②.

Stiffer → Increase the spring preload.

(Turn the adjuster ② in.)

Softer → Decrease the spring preload.

(Turn the adjuster ② out.)

Technical line drawing of a mechanical spring assembly with dimension label 'a' (no text or symbols beyond the label)

	Spring length (installed) a:
Standard length Extent of adjustment
165 mm(6.50 in)		155 ~ 175 mm(6.10 ~ 6.89 in)

INSPECTION DE LA FOURCHE AVANT

1. Examiner:

• Be sure to remove all dirt and mud from around the locknut and adjuster before adjustment.
  ●The length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the adjuster.

CAUTION:

Never attempt to turn the adjuster beyond the maximum or minimum setting.

1. Tighten:

- Locknut

42 Nm (4.2 m · kg, 30 ft · lb)

1. Install:

- Left side cover

7 Nm (0.7 m · kg, 5.1 ft · lb)

Line drawing of hands holding a pressure gauge with a tool, no text or symbols present

EC36Q000

TIRE PRESSURE CHECK

1. Measure:

●Tire pressure

Out of specification → Adjust.

Standard tire pressure: 100 kPa (1.00 kgf/cm ^2 , 15 psi)

NOTE:

• Check the tire while it is cold.
• Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low.
  ●A tilted tire valve stem indicates that the tire slips off its position on the rim.
• If the tire valve stem is found tilted, the tire is considered to be slipping off its position. Correct the tire position.

CONTRÔLE DE LA PRESSION DE GONFLAGE DE PNEU REIFENDRUCK PRÜFEN

INSP ADJ

N.B.:

Bend/damage → Replace.

Loose spoke → Retighten.

2. Tighten:

•Spokes

	Front 2 Nm (0.2 m · kg, 1.4 ft · lb)
	Rear 3 Nm (0.3 m · kg, 2.2 ft · lb)

NOTE:

Be sure to retighten these spokes before and after break-in. After a practice check spokes for looseness.

Diagram of a bicycle wheel assembly with gear and chain, showing mechanical components (no text or labels)

EC36T000

WHEEL INSPECTION

1. Inspect:

- Wheel runout

Elevate the wheel and turn it.

Abnormal runout → Replace.

Diagram of hands operating a bicycle gear mechanism with rotating wheels and a wheel (no text or symbols)

2. Inspect:

●Bearing free play

Exist play → Replace.

Illustration showing a hand using a tool to lift a bicycle wheel, with no text or symbols present.

STEERING HEAD INSPECTION AND ADJUSTMENT

1. Elevate the front wheel by placing a suitable stand under the engine.

2. Check:

•Steering shaft

Grasp the bottom of the forks and gently rock the fork assembly back and forth.

Free play → Adjust steering head.

INSPECTION ET SERRAGE DES RAYONS

1. Examiner:

●Rayons ①

Déformation/endommagement → Remplacer.

Diagram of a mechanical device with rotating arms and housing, no text or symbols present

3. Check:

- Steering smooth action Turn the handlebar lock to lock. Unsmooth action → Adjust steering ring nut.

4. Adjust:

•Steering ring nut

Steering ring nut adjustment steps:

• Remove the number plate and starter knob.
• Remove the handlebar and upper bracket.
• Remove the special washer ①
• Remove the upper ring nut ②, and rubber washer ③.
• Loosen the lower ring nut ④ using the steering nut wrench ⑤.

Steering nut wrench: YU-33975/90890-01403

- Tighten the lower ring nut ⑥ using steering nut wrench ⑦ and turn the steering right and left a few times.

NOTE: Set the torque wrench to the steering nut wrench so that they form a right angle.

Steering nut wrench: YU-33975/90890-01403

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.

WARNING

Avoid over-tightening.

Hakenschlüssel YU-33975/90890-01403

Hakenschlüssel YU-33975/90890-01403

Technical line drawing of a mechanical assembly with no visible text or symbols

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 ⑩.

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 ⑪, steering stem nut ⑫, cap ⑬, handlebar ⑭, upper handlebar holder ⑮, starter knob nut ⑯ and number plate ⑰.

NOTE:

• The upper handlebar holder should be installed with the punched mark ⓐ forward.
• Insert the end of fuel breather hose ⑱ into the hole of the starter knob stay.

CAUTION:

First tighten the bolts on the front side of the handlebar holder, and then tighten the bolts on the rear side.

Pinch bolt (upper bracket):

25 Nm (2.5 m • kg, 18 ft • lb)

Steering stem nut:

110 Nm (11.0 m • kg, 80 ft • lb)

Handlebar upper holder:

23 Nm (2.3 m • kg, 17 ft • lb)

Starter knob nut:

1 Nm (0.1 m • kg, 0.7 ft • lb)

Number plate:

7 Nm (0.7 m • kg, 5.1 ft • lb)

Écrou annulaire (serrage final): 20 Nm (2,0 m • kg, 14 ft • lb)

To ensure smooth operation of all components, 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-R125LW)

A Use Yamaha cable lube or equivalent on these areas.
B Use SAE 10W-30 motor oil or suitable chain lubricants.
☐ Lubricate the following areas with high quality, lightweight lithium-soap base grease.

LUBRIFICATION

EC370000

ELECTRICAL

EC371001

SPARK PLUG INSPECTION

1. Remove:

- Spark plug

1. Inspect:

- Electrode ①

Wear/damage → Replace.

•Insulator color ②

Normal condition is a medium to light tan color.

Distinctly different color → Check the engine condition.

NOTE:

When the engine runs for many hours at low speeds, the spark plug insulator will become sooty, even if the engine and carburetor are in good operating condition.

1. Measure:

- Plug gap ⓐ

Use a wire gauge or thickness gauge.

Out of specification → Regap.

Spark plug gap:

0.6 \~ 0.7 mm (0.02 \~ 0.03 in)

Standard spark plug:

CR7HSA (NGK)

U22FSR-U (DENSO)

1. Clean the plug with a spark plug cleaner if necessary.

1. Tighten:

- Spark plug

13 Nm (1.3 m · kg, 9.4 ft · lb)

NOTE:

• Before installing a spark plug, clean the gas- ket surface and plug surface.
• Finger-tighten ⓐ the spark plug before torquing to specification ⓑ.

PARTIE ÉLECTRIQUE INSPECTION DE LA BOUGIE

1. Déposer:

•Bougie

1. Examiner:

- Électrodes ①

③ Side covers removal

④ Number plate removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		SEAT, FUEL TANK AND SIDE COVERS REMOVALTurn the fuel cock to “OFF”.
1↑ 2↓ 3↓ 4↑	1 Seat 12 Air scoop (left and right) 23 Fuel hose 1 Remove on fuel tank side.4 Fitting band 15 Bolt (fuel tank) 26 Fuel tank 17 Left side cover 18 Right side cover 19 Number plate	1

MOTEUR

SELLE, RÉSERVOIR DE CARBURANT ET CACHES LATÉRAUX

Extent of removal:
① Muffler removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		MUFFLER REMOVALRight side cover		Refer to “SEAT, FUEL TANK AND SIDE COVERS” section.
1	1 Bolt (spark arrester) 32 Spark arrester 13 Nut (muffler) 24 Bolt (muffler) 15 Muffler		1

POT D'ÉCHAPPEMENT

Extent of removal:
① Carburetor removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal	Fuel tank	CARBURETOR REMOVALRefer to “SEAT, FUEL TANK AND SIDE	SIDE	COVERS” section.
1	1 Fuel hose 12 Over flow hose 13 Air vent hose 24 Starter plunger 15 Carburetor top cover 16 Clamp (air cleaner joint) 1 Loosen the screw (air cleaner joint).7 Clamp (carburetor joint) 1 Loosen the screws (carburetor joint).8 Carburetor		1

CARBURATEUR

① Carburetor disassembly

Extent of removal Order Part name Q'ty Remarks
1	CARBURETOR DISASSEMBLYThrottle cable 1Throttle valve 1 Refer to “REMOVAL POINTS”.
	Jet needle set 1Carburetor top cover 1Starter plunger 1Float chamber 1Float pivot pin 1Float 1Needle valve 1Main jet washer 1Needle valve seat holder 1Needle valve seat 1Main jet Main jet nozzle Pilot jet Pilot air jet 1 Pilot air jet 2 Pilot air screw 1 Refer to “REMOVAL POINTS”.
	Throttle stop screw 1Coasting enricher 1

DÉMONTAGE DU CARBURATEUR

Technical line drawing of a mechanical assembly with no visible text or symbols

HANDLING NOTE

At high altitudes, the atmospheric pressure is lower. This can make the fuel mixture too rich, leading to such problems as fouled.

Spark plugs and slow response at high engine speeds. A special part, High Altitude Main Jet ① #102.5 (620-1423A-71-A0) is available to correct this.

EC463000

REMOVAL POINTS

Throttle valve

1. Remove:

2. Throttle valve ①

3. Spring (throttle valve) ②
   • Carburetor top cover ③
4. Throttle cable ④

NOTE:

While compressing the spring (throttle valve), disconnect the throttle cable.

Technical line drawing of a mechanical component with no visible text or symbols

Pilot air screw

1. Remove:

- Pilot air screw ①

NOTE:

To optimize the fuel flow at a smaller throttle opening, each machine's pilot air screw has been individually set at the factory. Before removing the pilot air screw, turn it in fully and count the number of turns. Record this number as the factory-set number of turns out.

REMARQUE

Line drawing of a hand using a gun to interact with a device (no text or symbols)

EC464000

INSPECTION

Carburetor

1. Inspect:

•Carburetor body

Contamination → Clean.

NOTE:

- Use a petroleum based solvent for cleaning. Blow out all passages and jets with compressed air.

●Never use a wire.

1. Inspect:

2. Main jet ①

3. Main jet nozzle ②
   •Pilot jet ③

NOTE:

• Use a petroleum based solvent for cleaning. Blow out all passages and jets with compressed air.
  ●Never use a wire.

Needle valve

1. Inspect:

-Needle valve ①
-Needle valve seat ②

Grooved wear ⓐ → Replace.

Dust ⓑ → Clean.

NOTE:

Always replace the needle valve and needle valve seat as a set.

INSPECTION

Carburateur

1. Examiner:

Technical line drawing of a mechanical clamp or bracket assembly (no text or symbols)

EC464301

Throttle valve

1. Check:

•Free movement

Stick → Repair or replace.

NOTE:

Insert the throttle valve ① into the carburetor body, and check for free movement.

EC464401

Jet needle

1. Inspect:

Jet needle ①

Bends/wear → Replace.

- Clip groove

Free play exists/wear → Replace.

- Clip position

Standard clip position: No. 2 Groove

Fuel level

1. Measure:

●Fuel level ⓐ

Out of specification → Adjust.

Fuel level:

6.0 \~ 7.0 mm (0.24 \~ 0.28 in)

Below the float chamber mat- ing surface

Measurement and adjustment steps:●Connect the fuel level gauge 1 to the float chamber.
	Fuel level gauge:YM-1312-A/90890-01312

●Hold the fuel level gauge vertically next to the float chamber mating surface.
- Loosen the drain screw.
●Measure the fuel level with the fuel level gauge.

NOTE:

Keep the carburetor and fuel level gauge vertically when measuring the fuel level.

• If the fuel level is not within specification, inspect the needle valve seat and needle valve.
• If either is worn, replace them both.
• If both are fine, adjust the fuel level by bending the float tab ⑥ on the float.
  ●Recheck the fuel level.

Boisseau

1. Contrôler:

Technical line drawing of a mechanical assembly with two bearing parts and a numbered component (no text or symbols)

EC464600 Float

1. Inspect:

-Float ① Damage Replace.

Coasting enricher

1. Inspect:

- Diaphragm ① - Spring ② - Cover ③ Tears (diaphragm)/damage → Replace.

ASSEMBLY AND INSTALLATION Carburetor

1. Install:

- Diaphragm ① - Spring ② - Cover ③ - Screw ④

2 Nm (0.2 m · kg, 1.4 ft · lb)

2. Install:

- Throttle stop screw ① - Pilot air screw ②

• Turn in the pilot air screw until it is lightly seated.
  ●Turn out the pilot air screw by the number of turns recorded before removing.

Note the following installation points:

Pilot air screw: 2-1/2 \~ 3-1/2 (example)

3. Install:

- Pilot air jet 1 ① - Pilot air jet 2 ②

Flotteur

1. Examiner:

- Flotteur ①

4. Install:

•Pilot jet ①
- Main jet nozzle ②
●Main jet ③
-Needle valve seat ④
- Needle valve seat holder ⑤
- Main jet washer ⑥

5. Install:

-Needle valve ①
-Float ②
-Float pivot pin ③

NOTE:

●After installing the needle valve to the float, install them to the carburetor.
- Check the float for smooth movement.

6. Install:

•Gasket
-Float chamber ①
●Screw (float chamber) ②

7. Install:

•Spring ①
- Starter plunger ②
On starter cable ③.

8. Install:

• Jet needle set ①
  -Needle holder ②
  On throttle valve ③.

NOTE:

Align the projections ⓐ on the throttle valve with the grooves ⓑ in the needle holder.

Technical line drawing of a mechanical assembly with no visible text or symbols

9. Install:

•Carburetor top cover ①
- Spring (throttle valve) ②
- Throttle valve ③
On throttle cable ④.

NOTE:

While compressing the spring, connect the throttle cable.

Carburetor installation

1. Install:

•Carburetor assembly ①

NOTE:

Install the projection between the carburetor joint slots.

2. Tighten:

●Screw (carburetor joint) ①
●Screw (air cleaner joint) ②

Technical illustration of a hand holding a mechanical spring assembly (no text or symbols present)

3. Install:

•Carburetor top cover ①
- Starter plunger ②
●Air vent hose ③
•Over flow hose ④
•Fuel hose ⑤

NOTE:

Align the slit ⓐ of the throttle valve with the tab ⓑ of the carburetor body.

4. Adjust:

-Idle speed

Refer to "ENGINE IDLING SPEED ADJUSTMENT" section in the CHAPTER 3.

Extent of removal: ① Cylinder head side cover and tappet cover removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		CYLINDER HEAD SIDE COVER AND TAPPET COVER REMOVALSeat and fuel tankMufflerCarburetor Refer to “CARBURETOR” section.CDI unit Remove from the frame.		Refer to “SEAT, FUEL TANK AND SIDE COVERS” section.Refer
	1 Engine bracket 12 Spark plug 13 Cylinder head side cover 14 Tappet cover 25 Crankshaft end accessing screw6 Timing mark accessing screw	1

to

CULASSE

CACHE LATÉRAL DE CULASSE ET COUVRE-POUSSOIRS

Extent of removal: ① Cylinder head removal

Extent of removal Order Part name Q'ty Remarks
		CYLINDER HEAD REMOVAL1 Bolt (camshaft sprocket) 12 Bolt (timing chain tensioner cap) 13 Timing chain tensioner 14 Gasket5 Camshaft sprocket 16 Cylinder head 17 Dowel pin 28 Gasket	1	Refer to “REMOVAL _1 POINTS”.

CULASSE

REMOVAL POINTS

Cylinder head

1. Align:

• "l" mark

(with stationary pointer)

Checking steps:

• Turn the crankshaft counterclockwise with a wrench.
• Align the "l" mark ⓐ on the rotor with the stationary pointer ⓑ on the crankcase cover. When the "l" mark is aligned with the stationary pointer, the piston is at the Top Dead Center (T.D.C.).

NOTE:

In order to be sure that the piston is at Top Dead Center, the match mark © on the camshaft sprocket must align with the stationary pointer ⓐ on the cylinder head as shown in the illustration.

Mechanical assembly diagram showing a hand using a wrench to adjust a gear mechanism (no text or labels)

2. Loosen:

•Camshaft sprocket bolt ①

NOTE:

Remove the bolt while holding the rotor nut with a wrench.

3. Remove:

●Bolt (timing chain tensioner cap) ①
●Bolt (timing chain tensioner) ②
- Timing chain tensioner ③

PIÈCES À DÉPOSER

Culasse

1. Aligner:

Line drawing of a hand using a screwdriver to adjust or install a mechanical component (no text or symbols present)

Technical line drawing of hands using a tool to adjust or install a mechanical component (no text or symbols present)

4. Remove:

●Bolt (camshaft sprocket) ①
- Camshaft sprocket ②

NOTE:

Attach a wire ⓐ to the timing chain to prevent it from falling into the crankcase.

5. Remove:

• Bolts (cylinder head)
  •Cylinder head

NOTE:

• Loosen the bolts 1/4 turn each and remove then after all are loosened.
• Loosen the bolts starting with the lowest number one.

INSPECTION

Cylinder head

1. Eliminate:

●Carbon deposits (from the combustion chambers)

Use a rounded scraper.

NOTE:

Do not use a sharp instrument to avoid damaging or scratching:

• Spark plug threads
• Valve seats

2. Inspect:

•Cylinder head

Scratches/damage → Replace.

3. Inspect:

•Cylinder head warpage

Out of specification → Re-surface.

Warpage measurement and re-surfacing steps:

• Attach a straightedge and a thickness gauge on the cylinder head.
  ●Measure the warpage.

4. Déposer:

Technical line drawing of a mechanical component with concentric rings and mounting holes (no text or symbols)

Warpage limit: 0.03 mm (0.0012 in)

• If the warpage is out of specification, resurface the cylinder head.
• Place #400 \~ 600 grit wet sandpaper on the surface plate, and re-surface the head using a figure-eight sanding pattern.

NOTE:

Rotate the cylinder head several times to avoid removing too much material from one side.

ASSEMBLY AND INSTALLATION Cylinder head

1. Install:

- Dowel pin ①

•Gasket ②

New

1. Install:

•Cylinder head

•Copper washer

●Bolt (cylinder head)

	M8 22 Nm (2.2 m · kg, 16 ft · lb)
	M6 10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:

• Apply Quick gasket ^® (YAMAHA Bond No.1215) on end of the cylinder head bolts (M6), as shown.
• Apply the engine oil on the contact surfaces of the bolts (cylinder head) and copper washers.
• Follow the numerical order shown in the illustration. Tighten the bolts in two stages.

Quick gasket®: ACC-QUICK-GS-KT YAMAHA Bond No.1215: 90890-85505

3. Install:

• Timing chain
• Camshaft sprocket

Installation steps:

• Turn the crankshaft counterclockwise with a wrench.
• Align the "I" mark ⓐ on the rotor with the stationary pointer ⓑ on the crankcase cover.
• Align the match mark Ⓒ on the camshaft sprocket with the stationary pointer ⓓ on the cylinder head.
• Fit the timing chain ① onto camshaft sprocket ② and install the camshaft sprocket on the camshaft.

NOTE:

When installing the camshaft sprocket, keep the timing chain as tense as possible on the exhaust side.

CAUTION:

Do not turn the crankshaft during installation of the camshaft. Damage or improper valve timing will result.

- Remove the safety wire from the timing chain.

4. Install:

•Washer
●Bolt (camshaft sprocket)

NOTE:

Temporarily tighten the bolt (camshaft sprocket) at this point.

3. Installer:

Illustration of hands using a tool to adjust a mechanical component (no text or symbols present)

5. Install:

- Timing chain tensioner

Installation steps:

• While pressing the tensioner rod lightly with fingers, use a thin screwdriver and wind the tensioner rod up fully clockwise.
• With the rod fully wound, install the gasket ① and the chain tensioner ②, and tighten the bolts ③ to the specified torque.

Bolt (chain tensioner): 10 Nm (1.0 m • kg, 7.2 ft • lb)

- Release the screwdriver, check the tensioner rod to come out and tighten the gasket ④ and the cap bolt ⑤ to the specified torque.

Cap bolt (timing chain tensioner): 8 Nm (0.8 m • kg, 5.8 ft • lb)

6. Turn:

•Crankshaft Counterclockwise several turns

7. Check:

•Rotor "I" mark
Align with the crankcase stationary pointer.
•Camshaft match mark
Align with the cylinder head stationary pointer.
Out of alignment → Adjust.

Technical line drawing of a mechanical assembly with a hand operating a wrench (no text or symbols present)

8. Tighten:

●Bolt ① 20 Nm (2.0 m · kg, 14 ft · lb)

NOTE:

Tighten the bolt while holding the rotor nut with a wrench.

5. Installer:

Out of specification → Adjust.

Refer to "VALVE CLEARANCE

INSPECTION AND ADJUSTMENT"

section in the CHAPTER 3.

Line drawing of a hand using a tool to adjust or install a mechanical component (no text or symbols visible)

10. Apply:

•Engine oil

On camshaft.

11. Install:

•Tappet cover ①

18 Nm (1.8 m · kg, 13 ft · lb)

•Cylinder head side cover ②

10 Nm (1.0 m · kg, 7.2 ft · lb)

12. Install:

- Timing mark accessing screw ①

7 Nm (0.7 m · kg, 5.1 ft · lb)

•Crankshaft end accessing screw ②

7 Nm (0.7 m · kg, 5.1 ft · lb)

13. Install:

- Spark plug

13 Nm (1.3 m · kg, 9.4 ft · lb)

-Engine bracket

Extent of removal: ① Camshaft removal ② Rocker arm removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		CAMSHAFT AND ROCKER ARMS REMOVALCylinder head
	1 Camshaft bearing holder 12 Intake rocker arm shaft 13 Exhaust rocker arm shaft 14Camshaft5 Intake rocker arm 16 Exhaust rocker arm 1		Refer to “CYLINDER HEAD” section.

Refer

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:

2. Camshaft ①

3. 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.

Two diagrams showing hand positioning of a mechanical clamp or spring, labeled (a) and (b), with no text or symbols present.

INSPECTION

Camshaft

1. Inspect:

- Cam lobes

Pitting/scratches/blue discoloration → Replace.

1. Measure:

- Cam lobes length ⓐ and ⓑ

Out of specification → Replace.

Cam lobes length limit:

Intake:

① 25.851 mm (1.0178 in)
⑥ 21.165 mm (0.8333 in)

Exhaust:

① 25.811 mm (1.0162 in)
⑥ 21.020 mm (0.8276 in)

Dimensions limites de came:

Admission:

① 25,851 mm (1,0178 in)

⑥ 21,165 mm (0,8333 in)

Échappement:

① 25,811 mm (1,0162 in)
⑥ 21,020 mm (0,8276 in)

Nockenwelle

1. Demontieren:

① 25,811 mm
⑥ 21,020 mm

Illustration of hands using a micrometer to measure a cylindrical tool (no text or symbols visible)

Technical line drawing of a mechanical assembly with a hand operating a shaft and a labeled component (E) attached to a housing (no text or symbols present)

Rocker arms and rocker arm shafts

1. Inspect:

•Cam lobe contact surface ⓐ
-Adjuster surface ①

Wear/pitting/scratches/blue discoloration → Replace.

Measurement steps:

- Measure the inside diameter ⓐ of the rocker arm holes. Out of specification → Replace.

Inside diameter (rocker arm):

10.000 \~ 10.015 mm

(0.3937 \~ 0.3943 in)

: 10.03 mm (0.3949 in)

- Measure the outside diameter ⑥ of the rocker arm shafts. Out of specification → Replace.

Outside diameter

(rocker arm shaft):

9.981 \~ 9.991 mm

(0.3930 \~ 0.3933 in)

: 9.95 mm (0.3917 in)

ASSEMBLY AND INSTALLATION

1. Apply:

- Molybdenum disulfide oil (onto the camshaft cam lobe and rocker arm hole) - Engine oil (onto the camshaft bearing)

2. Install:

•Rocker arms
- Camshaft ①

3. Apply:

- Engine oil (onto the rocker arm shaft)

4. Install:

•Rocker arm shaft

5. Install:

•Camshaft bearing holder ①

•Bolt ②

10 Nm (1.0 m · kg, 7.2 ft · lb)

Extent of removal: ① Valves and valve springs removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		VALVES AND VALVE SPRINGS REMOVALCylinder headCamshaft and rocker arms Refer to “CAMSHAFT AND ROCKER ARMS” section.		Refer to “CYLINDER HEAD” section.
1	1 Valve cotter 42 Valve spring retainer 23 Valve spring 24 Intake valve 15 Exhaust valve 26 Valve stem seal 27 Valve spring seat	2	-Refer to “REMOVAL POINTS”.

SOUPAPES ET RESSORTS DE SOUPAPE

REMOVAL POINTS

Valve

1. Check:

- Valve sealing

Leakage at the valve seat → Inspect the valve face, valve seat and valve seat width.

Checking steps:

• Pour a clean solvent ① into the intake and exhaust ports.
• Check that the valve seals properly.
  There should be no leakage at the valve seat ②.

2. Remove:

-Valve cotters ①

NOTE:

Attach a valve spring compressor ② between the valve spring retainer and the cylinder head to remove the valve cotters.

Valve spring compressor: YM-4019/90890-04019

3. Remove:

• Valve spring retainer ①
  -Valve spring ②
  -Valve ③
• Valve stem seal ④
• Valve spring seat ⑤

NOTE:

Identify the position of each part very carefully so that it can be reinstalled in its original place.

PIÈCES À DÉPOSER

Valve

1. Contrôler:

Technical line drawing of a micrometer caliper (no text or symbols present)

INSPECTION

Valve

1. Measure:

- Stem-to-guide clearance

Stem-to-guide clearance = valve guide inside diameter ① - valve stem diameter ②

Out of specification → Replace the valve guide.

Clearance (stem to guide):

Intake:

0.010 \~ 0.037 mm

(0.0004 \~ 0.0015 in)

: 0.08 mm (0.0031 in)

Exhaust:

0.025 \~ 0.052 mm

(0.0010 \~ 0.0020 in)

: 0.10 mm (0.0040 in)

1. Replace:

-Valve guide

Replacement steps:

NOTE:

To ease guide removal, installation and to maintain correct fit heat the cylinder head in an over to 100 ^ (212 ^ ).

• Remove the valve guide using a valve guide remover ①.
  • Install the new valve guide using a valve guide remover and valve guide installer.
• After installing the valve guide, bore the valve guide using a valve guide reamer ② to obtain proper stem-to-guide clearance.

Valve guide remover:

YM-4097/90890-04097

Valve guide installer:

YM-4098/90890-04098

Valve guide reamer:

YM-04099/90890-04099

NOTE:

After replacing the valve guide reface the valve seat.

INSPECTION

Soupape

1. Mesurer:

Pitting/wear → Grind the face.

- Valve stem end

Mushroom shape or diameter larger than the body of the stem → Replace.

Technical diagram of a mechanical testing setup with a dial indicator and rotating component (no text or symbols)

4. Measure:

- Margin thickness ⓐ

Out of specification → Replace.

Margin thickness:

Intake:

0.4 \~ 0.8 mm

(0.0157 \~ 0.0315 in)

Exhaust:

0.8 \~ 1.2 mm

(0.0315 \~ 0.0472 in)

5. Measure:

Out of specification → Replace.

Runout limit:

0.01 mm (0.0004 in)

NOTE:

• When installing a new valve always replace the guide.
• If the valve is removed or replaced always replace the oil seal.

6. Eliminate:

- Carbon deposits

(from the valve face and valve seat)

7. Inspect:

- Valve seats

Pitting/wear → Reface the valve seat.

SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN

ENG

3. Examiner:

Out of specification → Reface the valve seat.

Valve seat width:

Intake:

0.9 \~ 1.1 mm (0.0354 \~ 0.0433 in)

: 1.6 mm (0.0630 in)

Exhaust:

0.9 \~ 1.1 mm (0.0354 \~ 0.0433 in)

: 1.6 mm (0.0630 in)

Measurement steps:

• Apply Mechanic's blueing dye (Dykem) ⑥ to the valve face.
  ●Install the valve into the cylinder head.
• Press the valve through the valve guide and onto the valve seat to make a clear pattern.
  ●Measure the valve seat width. Where the valve seat and valve face made contact, blueing will have been removed.
• If the valve seat is too wide, too narrow, or the seat is not centered, the valve seat must be refaced.

9. Lap:

-Valve face
-Valve seat

NOTE:

After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped.

Simple line drawing of a circular object with a shaded inner ring and two vertical lines above it, labeled '11171601' at the bottom (no text or symbols on the object itself)

Lapping steps:

- Apply a coarse lapping compound to the valve face.

CAUTION:

Do not let the compound enter the gap between the valve stem and the valve guide.

- Apply molybdenum disulfide oil to the valve stem.

SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN

ENG

8. Mesurer:

• Install the valve into the cylinder head.
• Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the compound.

NOTE:

For best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands.

- Apply a fine lapping compound to the valve face and repeat the above steps.

NOTE:

After every lapping operation be sure to clean off all of the compound from the valve face and valve seat.

• Apply Mechanic's blueing dye (Dykem) to the valve face.
• Install the valve into the cylinder head.
• Press the valve through the valve guide and onto the valve seat to make a clear pattern.
• Measure the valve seat width again. If the valve seat width is out of specification, reface and re-lap the valve seat.

Valve spring

1. Measure:

- Valve spring free length ⓐ

Out of specification → Replace.

Free length (valve spring):

Intake:

32.55 mm (1.28 in)

: 31.2 mm (1.23 in)

Exhaust:

32.55 mm (1.28 in)

: 31.2 mm (1.23 in)

•Compressed spring force ⓐ

Out of specification → Replace.

⑥Installed length

Compressed spring force:

Intake:

14.0 \~ 16.1 kg at 25.6 mm

(30.86 \~ 35.49 lb at 1.01 in)

Exhaust:

14.0 \~ 16.1 kg at 25.6 mm

(30.86 \~ 35.49 lb at 1.01 in)

3. Measure:

•Spring tilt ⓐ

Out of specification → Replace.

Spring tilt limit:

Intake:

2.5°/1.4 mm (0.06 in)

Exhaust:

2.5°/1.4 mm (0.06 in)

ASSEMBLY AND INSTALLATION

Valve

1. Apply:

•Molybdenum disulfide oil (onto the valve stem and valve stem seal)

2. Install:

-Valve spring seats ①
-Valve stem seals ②
-Valves ③
-Valve springs ④
-Valve spring retainers ⑤

New

NOTE:

• Make sure that each valve is installed in its original place.
• Install the valve springs with the larger pitch a) facing upwards.

⑥Smaller pitch

SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN

ENG

2. Mesurer:

-Force de ressort comprimé ⓐ

Technical line drawing of a mechanical assembly with a cylindrical component inserted into a housing (no text or symbols)

1. Install:

-Valve cotters ①

NOTE:

While compressing the valve spring with a valve spring compressor ②, install the valve cotters.

Valve spring compressor: YM-4019/90890-04019

1. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood.

CAUTION:

Hitting the valve tip with excessive force could damage the valve.

SOUPAPES ET RESSORTS DE SOUPAPE VENTILE UND VENTILFEDERN

ENG

3. Installer:

Extent of removal: ① Cylinder removal ② Piston removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal				CYLINDER AND PISTON REMOVALCylinder head
			1 Exhaust timing chain guide 12 Cylinder/O-ring3 Dowel pin 24 Gasket5 Piston pin clip 27 Piston ring set8		Refer to “CYLINDER HEAD” section.1/11Refer to “REMOVAL POINTS”.6 Piston pin 1Refer to “REMOVAL POINTS”.

CYLINDRE ET PISTON

Illustration of hands holding a small container with arrows indicating rotation or movement (no text or symbols)

REMOVAL POINTS

Piston

1. Remove:

2. Piston pin clips ①
   •Piston pin ②
   •Piston ③

NOTE:

• Before removing the piston pin clip, cover the crankcase opening with a clean towel or rag to prevent the clip from falling into the crank-case cavity.
• Before removing each piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller ④.

Piston pin puller set: YU-1304/90890-01304

CAUTION:

Do not use a hammer to drive the piston pin out.

Piston ring

1. Remove:

•Piston rings

NOTE:

Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown, as shown in the illustration.

INSPECTION

Cylinder and piston

1. Inspect:

- Cylinder and piston walls Vertical scratches → Replace cylinder and piston.

PIÈCES À DÉPOSER

Piston

1. Déposer:

●Piston-to-cylinder clearance

Piston-to-cylinder clearance measurement steps:1st step:Measure the cylinder bore “C” with the cylinder bore gauge.NOTE:Measure the cylinder bore “C” in parallel to and at right angles to the crankshaft. Then, find the average of the measurements.
Cylinder bore “C”	54.000 ~ 54.019 mm(2.126 ~ 2.127 in)
Taper limit “T” 0.05 mm (0.002 in)
Out of round “R” 0.05 mm (0.002 in)
“C” = maximum of D1 ~ D6
“T” = maximum of D1, or D2 – maximum of D5 or D6
“R” = maximum of D1, D3 or D5 – minimum of D2, D4 or D6
·If out of specification, replace the cylinder, and replace the piston and piston rings as set.2nd step:Measure the piston skirt diameter “P” with a micrometer.@5 mm (0.20 in) from the piston bottom edge.
	Piston size P
Standard	53.977 ~ 53.996 mm(2.1251 ~ 2.1258 in)
·If out of specification, replace the piston and piston rings as a set.3rd step:Calculate the piston-to-cylinder clearance with following formula.
Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P”
	Piston-to-cylinder clearance:0.020 ~ 0.026 mm(0.0008 ~ 0.0010 in): 0.15 mm (0.006 in)

2. Mesurer:

- If out of specification, replace the cylinder, and replace the piston and piston rings as a set.

Piston pin

1. Inspect:

•Piston pin

Blue discoloration/grooves → Replace, then inspect the lubrication system.

Illustration of a hand using a micrometer to measure a tool, with no visible text or symbols

2. Measure:

●Piston pin-to-piston clearance

Measurement steps:●Measure the piston pin outside diameter a).If out of specification, replace the piston pin.
	Outside diameter (piston pin):14.991 ~ 15.000 mm(0.5902 ~ 0.5906 in):14.971 mm (0.5894 in)
●Measure the piston inside diameter b).If out of specification, replace the piston.
	Inside diameter (piston):15.002 ~ 15.013 mm(0.5906 ~ 0.5911 in):15.043 mm (0.5922 in)

Line drawing of two hands holding a circular object, no text or symbols present

Piston ring

1. Measure:

●Ring side clearance

Use a feeler gauge.

Out of specification → Replace the piston and rings as a set.

NOTE:

Clean carbon from the piston ring grooves and rings before measuring the side clearance.

	Side clearance:
	Standard
Top ring	0.035 ~ 0.090 mm(0.0014 ~ 0.0035 in)	0.12 mm(0.0047 in)
2nd ring	0.020 ~ 0.060 mm(0.0008 ~ 0.0024 in)	0.12 mm(0.0047 in)

2. Position:

•Piston ring

(in cylinder)

NOTE:

Insert a ring into the cylinder and push it approximately 40 mm (1.57 in) into the cylinder. Push the ring with the piston crown so that the ring will be at a right angle to the cylinder bore.

Ⓐ40 mm (1.57 in)

1. Measure:

•Ring end gap

Out of specification → Replace.

NOTE:

You cannot measure the end gap on the expander spacer of the oil control ring. If the oil control ring rails show excessive gap, replace all three rings.

	End gap:
	Standard
Top ring	0.15 ~ 0.30 mm(0.006 ~ 0.012 in)	0.4 mm(0.016 in)
2nd ring	0.30 ~ 0.45 mm(0.012 ~ 0.018 in)	0.55 mm(0.022 in)
Oil ring	0.20 ~ 0.70 mm(0.01 ~ 0.03 in)	—

Segment de piston

1. Mesurer:

Technical line drawing of a multi-tiered mechanical component with labeled point 'a' and circular feature 'C' (no text or symbols beyond labels)

Combination of piston and cylinder

1. Check:

•Cylinder mark ⓐ

Cylinder mark ⓐCylinder size
A	54.000 ~ 54.003 mm(2.1260 ~ 2.1261 in)
B	54.004 ~ 54.007 mm(2.1261 ~ 2.1263 in)
C	54.008 ~ 54.011 mm(2.1263 ~ 2.1264 in)
D	54.012 ~ 54.015 mm(2.1265 ~ 2.1266 in)
E	54.016 ~ 54.019 mm(2.1266 ~ 2.1267 in)

1. Check:

•Piston mark ⓐ

Cylinder mark ⓐ (color)	Piston size
A (red)	53.977 ~ 53.980 mm(2.1251 ~ 2.1252 in)
B (orange)	53.981 ~ 53.984 mm(2.1252 ~ 2.1254 in)
C (green)	53.985 ~ 53.988 mm(2.1254 ~ 2.1255 in)
D (purple)	53.989 ~ 53.992 mm(2.1255 ~ 2.1257 in)
E (blue)	53.993 ~ 53.996 mm(2.1257 ~ 2.1258 in)

1. Combination:

- Combine the piston and cylinder by the following chart.

Cylinder mark Piston mark (color)
A A (red)
B B (orange)
C C (green)
D D (purple)
E E (blue)

NOTE:

When you purchase a cylinder, you cannot designate its size. Choose the piston that matches the above chart.

Zylinder-Markierung a	Zylindergröße
A 54,000–54,003 mm
B 54,004–54,007 mm
C 54,008–54,011 mm
D 54,012–54,015 mm
E 54,016–54,019 mm

2. Kontrollieren:

•Kolbenmarkierung ⓐ

Zylinder-Markierung@ (Farbe)	Kolbengröße
A (rot) 53,977–	53,980 mm
B (orange) 53,981–	53,984 mm
C (grün) 53,985–	53,988 mm
D (violett) 53,989–	53,992 mm
E (blau) 53,993–	53,996 mm

3. Kombinieren:

Simple line drawing of a loop with an upward arrow labeled 'UP' pointing to it (no text or symbols beyond the label)

ASSEMBLY AND INSTALLATION

Piston ring and piston

1. Install:

•Piston rings

(onto the piston)

NOTE:

- Be sure to install the 2nd piston ring so that the manufacturer's mark or number are located on the upper side of the ring.

●Lubricate the piston and piston rings liberally with engine oil.

2. Position:

• Top ring
  -2nd ring
  •Oil ring

Offset the piston ring end gaps as shown.

①: Top ring end
⑥: 2nd ring end
©: Oil ring end (upper)
(d): Oil ring end (lower)

3. Install:

Piston ①
•Piston pin ②
- Piston pin clips ③

New

NOTE:

• Apply engine oil onto the piston pin, piston rings and piston.
• Be sure that the arrow mark ⓐ on the piston points to the exhaust side of the engine.
  ●Before installing the piston pin clip, cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase.
• When removing the piston pin clip, pop it out using the small opening ⓑ.

4. Lubricate:

Piston
•Piston rings
●Inside of cylinder

NOTE:

Apply a liberal coating of engine oil.

ASSEMBLAGE ET REPOSE

Segments et piston

1. Installer:

Cylinder

1. Install:

•Dowel pins ①

●Gasket (cylinder) ②

New

1. Install:

•O-ring New

•Cylinder ①

●Exhaust timing chain guide

CAUTION:

• Install the cylinder with one hand while compressing the piston rings with the other hand.

•Pass the timing chain through the cylinder timing chain cavity.

- Be careful not to damage the timing chain guide during installation.

NOTE:

After installing, check the smooth movement of the piston.

Cylindre

1. Installer:

•Goujons ①

●Joint (cylindre) ②

New

Zylinder

1. Montieren:

•Paßhülsen ①

CLUTCH AND PRIMARY DRIVEN GEAR

EC498000

CLUTCH PLATE AND FRICTION PLATE

Extent of removal: ① Clutch plate and friction plate removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		CLUCTH PLATE AND FRIC-TION PLATE REMOVALDrain the engine oil.Engine skidplate Refer to “ENGINE REMOVAL” section.		Refer to “ENGINE OIL REPLACEMENT”section in the CHAPTER 3.
1	1 Kickstarter crank 12 Right crankcase cover 13 Gasket 14 Dowel pin 25 Clutch spring 46 Pressure plate 17 Ball 18 Friction plate9 Clutch plate10 Nut/washer11 Push rod 112 Push plate 1	541/11

EMBRAYAGE ET PIGNON MENÉ PRIMAIRE

DISQUES D'EMBRAYAGE ET DE FRICTION

① Primary driven gear removal

② Primary drive gear removal

Extent of removal Order Part name Q'ty Remarks
	[5504]	PRIMARY DRIVEN GEAR REMOVAL1 Nut (clutch boss) 12 Lock washer 13 Clutch boss 14 Thrust plate 15 Primary driven gear 16 Thrust plate 17 Conical spring washer 18 Nut (primary drive gear) 19 Primary drive gear 110 Straight key	1	Use special tool.Refer to “REMOVAL POINTS”.Refer to “REMOVAL POINTS”.

EMBRAYAGE ET PIGNON MENÉ PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD

ENG

PIGNON MENÉ PRIMAIRE

Extent of removal: ① Push lever removal

Extent of removal Order Part name Q'ty Remarks
		PUSH LEVER REMOVAL
	1 Clutch cable 12 Push lever 13 Spring 14 Circlip 15 Oil seal

EMBRAYAGE ET PIGNON MENÉ PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD

ENG

LEVIER DE POUSSÉE

Two technical line drawings of metal clamps, labeled A and B, showing different angles and configurations (no text or symbols present)

EC493000

REMOVAL POINTS

Clutch boss

1. Remove:

•Nut ①
- Lock washer
- Clutch boss ②

NOTE:

Straighten the lock washer tab and use the clutch holding tool ③ to hold the clutch boss.

Clutch holding tool: YM-91042/90890-04086

AFor USA and CDN
B Except for USA and CDN

Primary drive gear

1. Remove:

•Nut (primary drive gear) ①
•Primary drive gear ②

NOTE:

• Place a folded rag or aluminum plate between the teeth of the primary drive gear and primary driven gear.
  ●Take care not to damage the gear teeth.

EC494000

INSPECTION

EC484100

Clutch housing and boss

1. Inspect:

2. Clutch housing ①
   Cracks/wear/damage → Replace.

3. Clutch boss ②
   Scoring/wear/damage → Replace.

EC484201

Primary driven gear

1. Check:

•Circumferential play

Free play exists → Replace.

•Gear teeth ⓐ

Wear/damage → Replace.

EMBRAYAGE ET PIGNON MENÉ PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD

ENG

PIÈCES À DÉPOSER

Noix d'embrayage

1. Déposer:

Line drawing of a hand using a caliper to adjust a spring (no text or symbols present)

EC484400

Clutch spring

1. Measure:

- Clutch spring free length ⓐ

Out of specification → Replace springs as a set.

Clutch spring free length:

33 mm (1.30 in)

: 31 mm (1.22 in)

Line drawing of hands using a tool to cut a gear (no text or symbols)

EC484500

Friction plate

1. Measure:

●Friction plate thickness

Out of specification → Replace friction plate as a set.

Measure at all four points.

Friction plate thickness:

2.92 \~ 3.08 mm

(0.115 \~ 0.121 in)

: 2.8 mm (0.110 in)

EC484600

Clutch plate

1. Measure:

- Clutch plate warpage

Out of specification → Replace clutch plate as a set.

Use a surface plate ① and thickness gauge ②.

Technical line drawing of a mechanical lever or support device with labeled part (1), no text or symbols present

Warp limit:

0.2 mm (0.008 in)

Push lever

1. Inspect:

- Push lever ①

Wear/damage → Replace.

EMBRAYAGE ET PIGNON MENÉ PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD

ENG

Ressort d'embrayage

1. Mesurer:

Technical line drawing of a gear with evenly spaced teeth (no text or symbols)

Technical line drawing of a mechanical assembly with labeled component (no text or symbols present)

Technical line drawing of a gear with labeled point 'a' (no text or symbols beyond label)

Push rod

1. Inspect:

2. Push rod 1 ①
   •Ball ②

Wear/damage/bend → Replace.

Primary drive gear

1. Inspect:

•Primary drive gear

Wear/damage → Replace.

EC495000

ASSEMBLY AND INSTALLATION

Push lever

1. Install:

- Push lever ①

NOTE:

- Apply the lithium soap base grease on the oil seal lip.

- Apply the engine oil on the push lever.

Primary drive gear

1. Install:

•Straight key
•Primary drive gear ①
•Washer ②
●Nut (primary drive gear) ③

70 Nm (7.0 m · kg, 50 ft · lb)

•Primary driven gear ④

NOTE:

• Install the primary drive gear with the stamp a) facing out.
• Place a folded rag or aluminum plate ⑤ between the teeth of the primary drive gear and primary driven gear.

EMBRAYAGE ET PIGNON MENÉ PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD

ENG

Tige de commande

1. Examiner:

-Druckstange 1 ①
•Kugel ②

Two technical line drawings of metal clamps, labeled A and B, showing different clamp configurations (no text or symbols present)

Clutch

1. Install:

•Conical spring washer ①
-Thrust plate ②
•Primary driven gear ③
-Thrust plate ④
- Clutch boss ⑤

2. Install:

• Lock washer
  New
  ●Nut (clutch boss) ①

60 Nm (6.0 m · kg, 43 ft · lb)

NOTE:

Use the clutch holding tool ② to hold the clutch boss.

Clutch holding tool: YM-91042/90890-04086

AFor USA and CDN

B Except for USA and CDN

3. Bend:

- Lock washer tab

4. Install:

- Friction plate ①

- Clutch plate ②

NOTE:

• Install the clutch plates and friction plates alternately on the clutch boss, starting with a friction plate and ending with a friction plate.
- Apply the engine oil on the friction plates and clutch plates.
- Be sure to install a clutch plate with projection ⓐ offset approximately 90° from previous plates projection. Continue this procedure in a clockwise direction until all clutch plates are installed.

EMBRAYAGE ET PIGNON MENÉ PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD

ENG

Embrayage

1. Installer:

CLUTCH AND PRIMARY DRIVEN GEAR

ENG

Mechanical assembly diagram showing a hand turning a gear into a mechanical component (no text or symbols visible)

1. Install:

•Ball

NOTE:

Apply the engine oil on the ball.

1. Install:

2. Push rod 1 ①

3. Push plate ②
   •Washer ③
   ●Nut (push rod 1) ④

4. Install:

-Pressure plate ①
- Clutch spring ②
●Bolt (clutch spring) ③

6 Nm (0.6 m · kg, 4.3 ft · lb)

NOTE:

• Align the arrow mark ⓐ on the pressure plate with the punched mark ⓑ on the clutch boss.

• Tighten the bolts in stage, using a crisscross pattern.

• Check:

- Push lever position

Push the push lever assembly in the arrow direction and make sure that the mach mark are aligned → adjust.

① Match mark on the push lever assembly
⑥ Match mark on the crankcase

EMBRAYAGE ET PIGNON MENÉ PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD

ENG

5. Installer:

•Bille

N.B.:

9. Adjust:

- Push lever position

Adjustment steps:

• Loosen the locknut ①.
• Turn the push rod 1 ② clockwise or counterclockwise to match alignment marks.
• Hold the push rod 1 to prevent it from moving and tighten the locknut to specification.
  •Tighten the locknut ①.

Locknut: 8 Nm (0.8 m • kg, 5.8 ft • lb)

10. Install:

•Dowel pins
●Gasket (right crankcase cover)
New
•Right crankcase cover
●Bolts (right crankcase cover)

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:

• Apply Quick gasket ^® (YAMAHA Bond No.1215) to end of the right crankcase cover bolts, as shown.
• Tighten the bolts in stages, using a criss-cross pattern.

Quick gasket®: ACC-QUICK-GS-KT YAMAHA Bond No.1215: 90890-85505

11. Install:

• Kickstarter crank ①
  ●Nut (kickstarter crank) ②

50 Nm (5.0 m · kg, 36 ft · lb)

NOTE:

Install the kickstarter crank so that there is 5 \~ 10 mm (0.2 \~ 0.4 in) @ between the kickstarter crank and the right crankcase cover.

EMBRAYAGE ET PIGNON MENÉ PRIMAIRE KUPPLUNG UND PRIMÄRABTRIEBSZAHNRAD

ENG

9. Régler:

50 Nm (5,0 m·kg, 36 ft·lb)

N.B.:

Extent of removal: ① Oil pump removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		OIL PUMP REMOVALClutch and primary drive gear		Refer to “CLUTCH AND PRIMARY DRIVEN GEAR” section.
1	1 Rotary filter 12 Oil pump drive gear 13 Oil pump assembly 14 Gasket 15 Oil strainer

POMPE À HUILE

Extent of removal: ① Oil pump disassembly

Extent of removal Order Part name Q'ty Remarks
1	OIL PUMP DISASSEMBLY1Circlip 12Oil pump driven gear 13Conical spring washer 14Circlip 15Washer 16Oil pump cover 17Pin 28Oil pump shaft 19Pin 110Inner rotor 111Outer rotor 112Oil pump housing 1

DÉMONTAGE DE LA POMPE À HUILE

• Oil pump drive gear
• Oil pump driven gear
• Oil pump housing
• Oil pump cover

Cracks/wear/damage → Replace.

2. Measure:

• Tip clearance A
  (between the inner rotor ① and the outer rotor ②)
• Side clearance B
  (between the outer rotor ② and the oil pump housing ③)
  Out of specification → Replace the oil pump assembly.
  ●Housing and rotor clearance C
  (between the pump housing ③ and the rotors ① ②)
  Out of specification → Replace the oil pump assembly.

Tip clearance A:

0.15 mm (0.0059 in)

: 0.20 mm (0.0079 in)

Side clearance B:

0.06 \~ 0.10 mm

(0.0024 \~ 0.0039 in)

: 0.15 mm (0.0059 in)

Housing and rotor clearance C:

0.06 \~ 0.10 mm

(0.0024 \~ 0.0039 in)

: 0.15 mm (0.0059 in)

Simple concentric circle diagram with a central hole, no text or symbols present

Rotary filter

1. Inspect:

- Rotary filter

Cracks/damage → Replace.

INSPECTION

Pompe à huile

1. Examiner:

Simple line drawing of a square frame with a grid pattern on the front face (no text or symbols)

Oil strainer

1. Inspect:

- Oil strainer Cracks/damage → Replace.

Contamination → Clean the flushing oil.

ASSEMBLY AND INSTALLATION Oil pump

1. Install:

- Oil pump housing ①

-Outer rotor ②

•Inner rotor ③

•Pin ④

- Oil pump shaft ⑤

•Pin ⑥

- Oil pump cover ⑦

•Washer ⑧

•Circlip ⑨ New

•Conical spring washer ⑩

- Oil pump driven gear ⑪

• Circlip ⑫

•Screws ⑬

5 Nm (0.5 m · kg, 3.6 ft · lb)

NOTE:

- Apply engine oil onto the outer rotor, inner rotor and oil pump shaft.

- Install the conical spring washer in the direction as shown.

2. Install:

- Oil strainer

•Gasket New

- Oil pump assembly

●Screws (oil pump assembly)

7 Nm (0.7 m · kg, 5.1 ft · lb)

NOTE:

Apply engine oil onto the crankcase oil passage and oil pump assembly.

3. Install:

- Oil pump drive gear ①

- Rotary filter ②

NOTE:

• Install the oil pump drive gear with its groove @ facing the engine.

- Install the rotary filter with the dog ⓑ facing out.

- Align the rotary filter dog ⓑ with groove Ⓒ of the crankshaft.

Crépine à huile

1. Examiner:

• Crépine à huile
  Craquelures/endommagement → Remplacer.
  Crasses/obstructions → Nettoyer.

Ölpumpensieb

1. Kontrollieren:

KICK AXLE AND SHIFT SHAFT

KICK AXLE AND SHIFT SHAFT

Extent of removal: ① Kick axle removal ② Shift shaft removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		KICK AXLE AND SHIFT SHAFT REMOVALShift pedal linkClutch Refer to “CLUTCH AND PRIMARYDRIVEN GEAR” section.		Refer to “ENGINE REMOVAL” section.
[73/9]	scam1	1 Kick axle assembly 1 Refer to “REMOVAL POINTS”.2 Circlip 13 Washer 14 Kick idle gear 15 Washer 16 Circlip 17 Shift shaft 18 Circlip 19 Torsion spring 110 Bolt (stopper lever) 111 Stopper lever12 Spring13 Segment	1	Refer to “REMOVAL POINTS”.

AXE DE KICK ET ARBRE DE SÉLECTEUR

AXE DE KICK ET ARBRE DE SÉLECTEUR

Illustration of a hand holding a mechanical spring and connecting a spring to a measuring tool (no text or symbols present)

REMOVAL POINTS

Kick axle

1. Remove:

- Kick axle assembly ①

NOTE:

Unhook the torsion spring ② from the hole in the crankcase.

Segment

1. Remove:

- Screw (segment)

•Segment ①

NOTE:

Loosen the screw using the T30 bit.

INSPECTION

Kick axle and kickstarter segment gear

1. Check:

- Kickstarter segment gear smooth movement Unsmooth movement → Replace.

1. Inspect:

- Kick axle ① Wear/damage → Replace.

Kickstarter segment gear and kick idle gear

1. Inspect:

●Kickstarter segment gear ①

●Kick idle gear ②

- Gear teeth ⓐ Wear/damage → Replace.

Kick axle clip

1. Measure:

- Kick axle clip friction force (torsion spring) Out of specification → Replace. Use a spring gauge ①.

Kick axle clip friction force: 0.65 \~ 1.35 kg (1.4 \~ 3.0 lb)

EC4B4400

Shift shaft

1. Inspect:

• Shift shaft ① Bend/damage → Replace.
• Spring ② Broken → Replace.

EC4B4500

Stopper lever

1. Inspect:

-Stopper lever ① Wear/damage → Replace.
- Torsion spring ② Broken → Replace.

EC4C5000

ASSEMBLY AND INSTALLATION

Segment

1. Install:

- Segment ① - Screw (segment) ②

12 Nm (1.2 m · kg, 8.7 ft · lb)

NOTE:

• Align the notch ⓐ on the segment with the pin ⓑ on the shift cam.
  ●Tighten the screw using the T30 bit.

Stopper lever

1. Install:

-Stopper lever ①
●Bolt (stopper lever) ②
•Torsion spring ③

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:

Align the stopper lever roller with the slot on segment.

Shift shaft

1. Install:

-Shift shaft ①

NOTE:

• Apply the lithium soap base grease on the oil seal lip of the left crankcase side.
• Hook the spring ends onto the stopper ②.

Kick axle assembly

1. Install:

●Kickstarter segment gear ①
- Plain washer ②
•Torsion spring ③

On kick axle ④.

NOTE: ____

Make sure the stopper ⓐ of the torsion spring fits into the hole ⓑ on the kick axle.

1. Install:

- Spring guide ①

NOTE:

Slide the spring guide into the kick axle, make sure the groove ⓐ in the spring guide fits on the stopper of the torsion spring.

1. Install:

- Kick axle assembly ①

NOTE:

• Apply the engine oil on the kick axle.

• Slide the kick axle assembly into the crank-case, make sure the clip ② and kick axle stopper ⑥ fit into their home positions a, c.

• Hook:

•Torsion spring ①

NOTE: ____

Turn the torsion spring clockwise and hook into the proper hole ⓐ in the crankcase.

Kick idle gear

1. Install:

• Circlip ①

New

•Washer ②

●Kick idle gear ③

•Washer ④

• Circlip ⑤

New

NOTE:

- Apply the engine oil on the kick idle gear inner circumference.

- Install the kick idle gear with its depressed side toward you.

Extent of removal: ① CDI magneto removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		CDI MAGNETO REMOVALSeat and fuel tankDrain the engine oilDrive sprocket cover Refer to “ENGINE REMOVAL” section.		Refer to “SAET, FUEL TANK AND SIDE COVERS” section.Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3.
1	1 CDI magneto lead 12 Left crankcase cover 13 Nut (rotor) 14 Rotor 15 Woodruff key 16 Pickup coil 17 Lead guide8 Stator		1	Use special tool.Refer to “REMOVAL POINTS”.

MAGNÉTO CDI

Technical line drawing of a mechanical assembly with two views: one showing a gear-like component and the other showing a circular housing (no text or symbols)

Technical line drawing of a mechanical assembly with no visible text or symbols

REMOVAL POINTS

Rotor

1. Remove:

•Nut (rotor) ①
- Plain washer ②

Use the sheave holder ③.

Sheave holder: YS-1880-A/90890-01701

2. Remove:

- Rotor ①

Use the flywheel puller ②.

Flywheel puller: YU-33270-B/90890-01362

EC4L4000

INSPECTION

EC4L4101

CDI magneto

1. Inspect:

• Rotor inner surface ⓐ
• Stator outer surface ⑥

Damage → Inspect the crankshaft runout and crankshaft bearing.

If necessary, replace CDI magneto and/or stator.

EC4L4200

Woodruff key

1. Inspect:

- Woodruff key ①

Damage → Replace.

EC4L5000

ASSEMBLY AND INSTALLATION

CDI magneto

1. Install:

• Stator ①
  •Bolt (stator)

• Lead guide
  ●Screw (lead guide) ②

10 Nm (1.0 m · kg, 7.2 ft · lb)
7 Nm (0.7 m · kg, 5.1 ft · lb)
7 Nm (0.7 m · kg, 5.1 ft · lb)
7 Nm (0.7 m · kg, 5.1 ft · lb)
7 Nm (0.7 m · kg, 5.1 ft · lb)
7 Nm (0.7 m · kg, 5.1 ft · lb)
7 Nm (0.7 m · kg, 5.1 ft · lb)
7 Nm (0.7 m · kg, 5.1 ft · lb)
7 Nm (0.7 m · kg, 5.1 ft · lb)
7 Nm (0.7 m · kg, 5.1 ft · lb)
7 Nm (0.7 m · kg, 5.1 ft · lb)

- Pickup coil ③

- Pickup coil ③

- Pickup coil ③

- Pickup coil ③

- Pickup coil ③

- Pickup coil ③

- Pickup coil ③

- Pickup coil ③

●Bolt (pickup coil)

10 Nm (1.0 m · kg, 7.2 ft · lb)

PIÈCES À DÉPOSER

Rotor

1. Déposer:

-Écrou (rotor) ①
●Rondelle plate ②

1. Installer:

2. Stator ①
   •Boulon (stator)

●Guide de fil

-Vis (guide de fil) ②

•Stator ①
•Schraube (Stator)

2. Install:

- Woodruff key ①

•Rotor ②

NOTE:

- Clean the tapered portions of the crankshaft and rotor.

- When installing the woodruff key, make sure that its flat surface ⓐ is in parallel with the crankshaft center line ⓑ.

- When installing the rotor, align the keyway of the rotor with the woodruff key.

3. Install:

- Plain washer ①

•Nut (rotor) ②

80 Nm (8.0 m · kg, 58 ft · lb)

Use the sheave holder ③.

Sheave holder: YS-1880-A/90890-01701

Technical line drawing of a mechanical gear assembly with no visible text or symbols

4. Install:

•Dowel pin

•Gasket New

●Left crankcase cover

●Bolt (left crankcase cover)

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:

Tighten the screws in stage, using a crisscross pattern.

5. Connect:

- CDI magneto lead

Refer to "CABLE ROUTING DIAGRAM" section in the CHAPTER 2.

MAGNÉTO CDI LICHTMASCHINENROTOR

ENG

2. Installer:

-Clavette demi-lune ①
- Rotor ②

N.B.:

Extent of removal: ① Engine removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal	Hold the	ENGINE REMOVALmachine 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 capDisconnect the CDI magneto lead.Drain the engine oil.		Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3.

DÉPOSE DU MOTEUR

Extent of removal Order Part name Q'ty Remarks
1	1 Drive sprocket cover 12 Bolt (drive sprocket) 24 Drive sprocket 15 Shift pedal link 16 Crankcase breather hose 17 Engine bracket (upper) 18 Engine skidplate 19 Engine bracket (front) 110 Engine mounting bolt (rear)Engine	21	Refer to “REMOVAL POINTS”.3 Drive sprocket holder 1Refer to “REMOVAL POINTS”.

Technical line drawing of a mechanical gear assembly with no visible text or symbols

Technical line drawing of a mechanical assembly with hands and components (no visible text or symbols)

REMOVAL POINTS

Drive sprocket

1. Remove:

●Bolt (drive sprocket)
-Drive sprocket holder ①
-Drive sprocket ②
-Drive chain ③

NOTE:

Remove the drive sprocket together with the drive chain.

Engine removal

1. Remove:

-Engine ①
From left side.

NOTE:

Make sure that the couplers, hoses and cables are disconnected.

ASSEMBLY AND INSTALLATION

Engine installation

1. Install:

-Engine ①
Install the engine from left side.

●Engine mounting bolt (rear) ②

●Engine bracket (front) ③

●Bolt (engine bracket) ④

●Engine mounting bolt (lower) ⑤

●Engine mounting bolt (front) ⑥

●Engine mounting bolt (upper) ⑧

• Apply the lithium soap base grease on the thread of the engine mounting bolts (rear) ②.
• Tighten the engine mounting bolt (upper) ⑧, and then tighten the bolts (engine bracket) ⑨.

Technical line drawing of a mechanical gear assembly with no visible text or symbols

Shift pedal link

1. Install:

• Shift pedal link ①
  ●Bolt (shift pedal link) ②

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:

Adjust the center ⓐ of the front end of the shift pedal to match the highest point of the foot-rest.

Drive sprocket

1. Install:

-Drive sprocket ①
-Drive chain ②

NOTE:

Install the drive sprocket together with the drive chain.

2. Install:

-Drive sprocket holder ①
●Bolt (drive sprocket)

6 Nm (0.6 m · kg, 4.3 ft · lb)

3. Install:

-Drive sprocket cover ①
●Bolt (drive sprocket cover) ②

12 Nm (1.2 m · kg, 8.7 ft · lb)

N.B.:

Extent of removal: ① Crankcase separation ② Balancer removal
③ Crankshaft removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal	Engine R	CRANKCASE, CRANKSHAFT AND BALANCER REMOVALRefer to “ENGINE REMOVAL” section.Piston Refer to “CYLINDER AND PISTON” Primary drive gear Refer to “CLUTCH AND PRIMARYDRIVEN GEAR” section.Kick axle assembly SegmentRotor and stator Refer to “CDI MAGNETO”	sec-tion.Refer to “KICK AXLE AND SHIFT SHAFT” section.section.

CARTER-MOTEUR, VILEBREQUIN ET BALANCIER KURBELGEHÄUSE, KURBELWELLE UND AUSGLEICHSWELLE

ENG

CARTER-MOTEUR, VILEBREQUIN ET BALANCIER

Extent of removal Order Part name Q'ty Remarks
↓	1 Intake timing chain guide 12 Timing chain 13 Bolt [45 mm (1.8 in)] 74 Bolt [55 mm (2.2 in)] 15 Bolt [30 mm (1.2 in)] 26 Lead guide 17 Clutch cable holder 18 Right crankcase 19 Left crankcase 110 Balancer 111 Crankshaft 1 Use special tool.12 Bearing 3 Refer to “REMOVAL POINTS”.		Use special tool.Refer to “REMOVAL POINTS”.Refer to “REMOVAL POINTS”.

CARTER-MOTEUR, VILEBREQUIN ET BALANCIER KURBELGEHÄUSE, KURBELWELLE UND AUSGLEICHSWELLE

ENG

Technical line drawing of a mechanical assembly with gears and springs (no text or labels)

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.

Crankcase separating tool: YU-1135-A/90890-01135

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, realign, and start over. If the cases do not separate, check for a remaining case screw or fitting. Do not force.

CARTER-MOTEUR, VILEBREQUIN ET BALANCIER KURBELGEHÄUSE, KURBELWELLE UND AUSGLEICHSWELLE

ENG

PIÈCES À DÉPOSER

Carter-moteur

1. Déposer:

Crankshaft

1. Remove:

•Crankshaft ①

Use the crankcase separating tool ②.

Crankcase separating tool: YU-1135-A/90890-01135

CAUTION:

Do not use a hammer to drive out the crankshaft.

Bearing

1. Remove:

•Bearing ①

NOTE:

- Remove the bearing from the crankcase by pressing its inner race as shown in.

- Do not use the removed bearing.

INSPECTION

Timing chain and timing chain guide

1. Inspect:

- Timing chain

Cracks/stiff → Replace the timing chain and camshaft sprocket as a set.

1. Inspect:

- Timing chain guide

Wear/damage → Replace.

CARTER-MOTEUR, VILEBREQUIN ET BALANCIER KURBELGEHÄUSE, KURBELWELLE UND AUSGLEICHSWELLE

ENG

Vilebrequin

1. Déposer:

•Vilebrequin ①

Technical line drawings of two mechanical components (a and b) showing internal gears and housing (no text or symbols)

Crankcase

1. Inspect:

- Contacting surface ⓐ

Scratches → Replace.

●Engine mounting boss ⓑ, crankcase

Cracks/damage → Replace.

2. Inspect:

•Bearing

Rotate inner race with a finger.

Rough spot/seizure → Replace.

Crankshaft

1. Measure:

-Runout limit ⓐ
- Connecting rod big end side clearance ⑥
•Crank width ©

Out of specification → Replace.

Use the dial gauge and a thickness gauge.

Dial gauge & stand set: YU-3097/90890-01252

	Standard
Runout limit:	—	0.03 mm (0.0012 in)
Side clearance:	0.15 ~ 0.45 mm (0.0059 ~ 0.0177 in)	0.50 mm (0.02 in)
Crack width:	46.95 ~ 47.00 mm (1.848 ~ 1.850 in)	—

CARTER-MOTEUR, VILEBREQUIN ET BALANCIER KURBELGEHÄUSE, KURBELWELLE UND AUSGLEICHSWELLE

ENG

Carter-moteur

1. Examiner:

Technical line drawing of a mechanical component with no visible text or symbols

Balancer

1. Inspect:

•Balancer

Cracks/damage → Replace.

ASSEMBLY AND INSTALLATION Bearing

1. Install:

•Bearing ①

New

On crankcase (left and right).

NOTE: Install the bearing by pressing its outer race parallel.

Crankshaft

1. Install:

•Crankshaft ①

Use the crankshaft installing tool ②, ③, ④, ⑤.

Crankshaft installing tool:

Crankshaft installer pot ②:

YU-90050/90890-01274

Crankshaft installer bolt ③:

YU-90050/90890-01275

Adapter ④:

YU-90063/90890-01278

Spacer ⑤:

YM-91044/90890-04081

AFor USA and CDN

B Except for USA and CDN

NOTE:

- Hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other. Operate the installing tool until the crankshaft bottoms against the bearing.

●Before installing the crankshaft, clean the contacting surface of crankcase.

CAUTION:

Do not use a hammer to drive in the crankshaft.

CARTER-MOTEUR, VILEBREQUIN ET BALANCIER KURBELGEHÄUSE, KURBELWELLE UND AUSGLEICHSWELLE

ENG

Balancier

1. Examiner:

•Balancier

Technical line drawing of an internal combustion engine component (no text or labels)

1. Install:

•Balancer

NOTE:

Align the punched mark ⓐ on the balancer drive gear with the punched mark ⓑ on the balancer driven gear.

Crankcase

1. Apply:

- Sealant

On the right crankcase ①.

Quick gasket®:

ACC-QUICK-GS-KT

YAMAHA Bond No.1215:

90890-85505

NOTE:

Clean the contacting surface of crankcase (left and right) before applying the sealant.

1. Install:

- Dowel pin ①

•Right crankcase

On left crankcase.

NOTE:

- Fit the right crankcase onto the left crank-case. Tap lightly on the case with soft hammer.

- When installing the crankcase, the connecting rod should be positioned at TDC (top dead center).

CARTER-MOTEUR, VILEBREQUIN ET BALANCIER KURBELGEHÄUSE, KURBELWELLE UND AUSGLEICHSWELLE

ENG

2. Installer:

•Balancier

N.B.:

Technical line drawing of a mechanical gear assembly (no text or symbols)

3. Tighten:

• Lead guide ①
• Clutch cable holder ②
  ●Bolt (crankcase) [45 mm (1.8 in)] ③

10 Nm (1.0 m · kg, 7.2 ft · lb)

●Bolt (crankcase) [55 mm (2.2 in)] ④

10 Nm (1.0 m · kg, 7.2 ft · lb)

●Bolt (crankcase) [30 mm (1.2 in)] ⑤

10 Nm (1.0 m · kg, 7.2 ft · lb)

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

4. Check:

•Crankshaft and transmission operation Unsmooth operation → Repair.

5. Install:

• Timing chain ①
• Intake timing chain guide ②
  ●Bolt (intake timing chain guide)

10 Nm (1.0 m · kg, 7.2 ft · lb)

CARTER-MOTEUR, VILEBREQUIN ET BALANCIER KURBELGEHÄUSE, KURBELWELLE UND AUSGLEICHSWELLE

ENG

3. Serrer:

TRANSMISSION, SHIFT CAM AND SHIFT FORK

Extent of removal:
① Shift cam and shift fork removal
② Main axle and drive axle removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal Engine R		TRANSMISSION, SHIFTCAM AND SHIFT FORK REMOVALRefer to “ENGINE REMOVAL” section.Separate the crankcase. Refer to “CRANKCASE, CRANKSHAFT AND BALANCER” section.
↓	1 Shift fork guide bar 1 (short) 12 Shift fork guide bar 2 (long) 13 Shift cam 14 Shift fork 2 (C) 15 Shift fork 3 (R) 16 Shift fork 1 (L) 17 Main axle8 Drive axle9 Push rod 210 Washer			Refer to “REMOVAL POINTS”.
			1
			1
			1
			1

BOÎTE DE VITESSES, TAMBOUR ET FOURCHETTES DE SÉLECTION

REMOVAL POINTS

Transmission

1. Remove:

2. Main axle ①
   -Drive axle ②

NOTE:

• Tap lightly on the transmission drive axle with a soft hammer to remove.
• Remove assembly carefully. Note the position of each part. Pay particular attention to the location and direction of shift forks.

EC4H4000

INSPECTION

EC4H4200

Gears

1. Inspect:

2. Matching dog ⓐ
   •Gear teeth ⓑ

3. Shift fork groove ©

Wear/damage → Replace.

Technical line drawing of a mechanical gear assembly (no text or symbols)

1. Check:

•Gears movement

Unsmooth movement → Repair or replace.

Line drawing of a cylindrical mechanical part with a labeled end (1), no text or symbols present.

Push rod

1. Inspect:

- Push rod 2 ①

Wear/damage/bend → Replace.

PIÈCES À DÉPOSER

Boîte de vitesses

1. Déposer:

Diagram of a hand gripping a cylindrical object with a striped pattern below, no text or symbols present

EC4H4600

Bearing

1. Inspect:

- Bearing ① Rotate inner race with a finger. Rough spot/seizure → Replace.

Shift fork and shift cam

1. Inspect:

- Shift fork ① Wear/damage/scratches → Replace.

1. Inspect:

- Shift cam ① - Shift fork guide bar ② Bend/wear/damage → Replace.

1. Check:

- Shift fork movement On its guide bar. Unsmooth operation → Replace shift fork and/or guide bar.

NOTE:

For a malfunctioning shift fork, replace not only the shift fork itself but the two gears each adjacent to the shift fork.

Roulement

1. Examiner:

- Roulement ①

Transmission

1. Install:

2. 4th pinion gear (22T) ①
   -3rd pinion gear (19T) ②
   -2nd pinion gear (18T) ③
   -5th pinion gear (24T) ④

On main axle ⑤.

NOTE:

• Apply the molybdenum disulfide oil on the gears' inner circumference.
  • Install the 5th pinion gear so that measurement @ is 83.25 \~ 83.45 mm (3.278 \~ 3.285 in).

• Install:

-2nd wheel gear (32T) ①
- 5th wheel gear (21T) ②
-3rd wheel gear (25T) ③
- 4th wheel gear (23T) ④
- 1st wheel gear (37T) ⑤

On drive axle ⑥.

NOTE:

Apply the molybdenum disulfide oil on the gears' inner circumference.

Boîte de vitesses

1. Installer:

Mechanical assembly diagram showing a shaft and gear mechanism with a labeled component (E), no text or symbols present.

Mechanical assembly diagram showing gear and shaft components with a labeled part (①), no text or symbols present.

3. Install:

-Plain washer ①
•Circlip ② New

NOTE:

• Be sure the circlip sharp-edged corner ⓐ is positioned opposite side to the plain washer and gear ⓑ.
• Be sure the circlip end © is positioned at axle spline groove ⓐ.

4. Install:

- Push rod 2

On main axle.

NOTE:

Apply the engine oil on the push rod 2.

5. Install:

- Washer ①

On drive axle.

6. Install:

• Main axle
  -Drive axle

Install these in the left crankcase at the same time.

NOTE:

• Apply the lithium soap base grease on the oil seal lip.
• When installing the drive axle into the crank-case, pay careful attention to the crankcase oil seal lip.

BOÎTE DE VITESSES, TAMBOUR ET FOURCHETTES DE SÉLECTION GETRIEBE, SCHALTNOCKE UND SCHALTGABEL

ENG

3. Installer:

●Rondelle plate ①
- Circlip ② New

N.B.:

Shift cam and shift fork

1. Install:

-Shift fork 1 (L) ①
-Shift fork 2 (C) ②
-Shift fork 3 (R) ③

NOTE:

• Mesh the shift fork #1 (L) with the 2nd wheel gear and #3 (R) with the 4th wheel gear on the drive axle.
• Mesh the shift fork #2 (C) with the 3rd pinion gear on the main axle.

1. Install:

-Shift cam ①

NOTE:

Apply the engine oil on the shift cam.

1. Install:

-Shift fork guide bar 1 (short) ①
- Shift fork guide bar 2 (long) ②

NOTE:

• Apply the engine oil on the guide bars.
• Be sure the long bar is inserted into the shift forks #1 and #3 and the short one into #2.

Technical line drawing of a mechanical assembly with gears and shafts (no text or symbols)

1. Check:

●Shifter operation
●Transmission operation

Unsmooth operation → Repair.

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 BRAKEHold the machine by placing the suitable stand under the engine.		WARNINGSupport the machine securely so there is no danger of it falling over.
↓	1 Brake cable holder 12 Brake cable 1 Disconnect at the lever side, first.3 Axle nut 14 Wheel axle 15 Front wheel 16 Collar set 17 Brake shoe plate assembly 18 Oil seal 19 Wheel bearing 2 Refer to “REMOVAL POINTS”.10 Spacer

PARTIE CYCLE

ROUE AVANT ET FREIN AVANT (TT-R125)

Extent of removal Order Part name Q'ty Remarks
3	11 Brake shoe 212 Spring 213 Brake camshaft lever 114 Wear indicator plate 115 Brake camshaft 116 Brake shoe plate 1

Technical line drawing of two mechanical components with dimension arrows (no text or symbols)

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)

1. 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.

Wheel axle bending limit:

0.5 mm (0.020 in)

NOTE:

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

WARNING

Do not attempt to straighten a bent axle.

ROUE AVANT ET FREIN AVANT (TT-R125) VORDERRAD UND VORDERRADBREMSE (TT-R125)

PIÈCES À DÉPOSER

Illustration of hands using a tool to clean or fabric the surface (no text or symbols)

Drum brake

1. Inspect:

- Brake shoe lining surface Glazed areas → Polish. Use coarse sand paper.

NOTE:

After polishing, wipe the polished particles with a cloth.

2. Measure:

- Brake shoe lining thickness ⓐ

Out of specification → Replace.

	Brake shoe lining thickness:
Standard
40 mm(0.16 in)		2.0 mm(0.08 in)

NOTE:

Replace the brake shoes and springs as a set if either is worn to the limit.

3. Measure:

- Brake drum inside diameter ⓐ Out of specification → Replace.

	Brake drum inside diameter:
Standard
110 mm(4.33 in)		111 mm(4.37 in)

4. Inspect:

- Brake drum inner surface Oil/scratches → Remove.

Oil	Use a rag soaked in lac-quer thinner or a solvent.
Scratches	Use a emery cloth (lightly and evenly polishing).

ROUE AVANT ET FREIN AVANT (TT-R125) VORDERRAD UND VORDERRADBREMSE (TT-R125)

Frein à tambour

1. Examiner:

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 ⓐ on the wear indicator plate with the slots ⓑ on the brake camshaft.

4. Install:

- Brake camshaft lever ①

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:

Install the brake camshaft lever in relation to the punch mark ⓐ as shown.

5. Install:

- Springs ①

New

- Brake shoes ②

NOTE:

Apply the lithium soap base grease on the pivot pin.

WARNING

Do not apply grease to the brake shoe linings.

ROUE AVANT ET FREIN AVANT (TT-R125) VORDERRAD UND VORDERRADBREMSE (TT-R125)

REMONTAGE ET INSTALLATION

Technical line drawing of a mechanical assembly with a central shaft and flanged components (no text or symbols)

Front wheel

1. Install:

2. Wheel bearing ①

3. Spacer ②
4. Wheel bearing ③
5. Oil seal ④ New

NOTE:

• Apply the lithium soap base grease on the wheel bearing and oil seal lip when installing.
  •Install the wheel bearing so that the enclosed side is facing outward.
• Use a socket that matches the outside diameter of the race of the bearing.
  ●Left side of wheel bearing shall be installed first.
  •Install the oil seal with its manufacture's marks or numbers facing outward.

CAUTION:

Do not strike the inner race of the bearing. Contact should be made only with the outer race.

1. Install:

●Brake shoe plate assembly
- Collar set ①

NOTE:

Apply the lithium soap base grease on the oil seal lip.

1. Install:

- Front wheel

NOTE:

Make sure that the slot ⓐ on the brake shoe plate with the stopper ⓑ on the front fork outer tube.

1. Install:

- Wheel axle ①

Roue avant

1. Installer:

Technical line drawing of a mechanical assembly with no visible text or symbols

Technical line drawing of a mechanical assembly with no visible text or symbols

Technical line drawing of a mechanical assembly with no visible text or symbols

5. Install:

- Axle nut ①

NOTE: ____ Brake camshaft lever side of brake cable shall be installed first.

7. Install:

●Brake cable holder ①

7 Nm (0.7 m · kg, 5.1 ft · lb)

8. Adjust:

- Brake lever free play Refer to "FRONT BRAKE ADJUSTMENT" section in the CHAPTER 3.

ROUE AVANT ET FREIN AVANT (TT-R125) VORDERRAD UND VORDERRADBREMSE (TT-R125)

5. Installer:

- Écrou d'axe ①

45 Nm (4,5 m · kg, 32 ft · lb)

5. Montieren:

- Achsmutter ①

45 Nm (4,5 m · kg)

6. Installer:

•Câble de frein

N.B.:

Extent of removal: ① Front wheel removal ② Wheel bearing removal
③ Brake disc removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal			FRONT WHEEL REMOVALHold the machine by placing the suitable stand under the engine.		WARNINGSupport the machine securely so there is no danger of it falling over.
		1 Axle nut 12 Washer 13 Wheel axle 14 Front wheel 15 Collar 26 Oil seal 27 Wheel bearing 2 Refer to “REMOVAL POINTS”.8 Spacer 19 Brake disk

ROUE AVANT (TT-R125LW)

Technical line drawing of two mechanical components with dimension arrows (no text or symbols)

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)

1. 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.

Wheel axle bending limit:

0.5 mm (0.020 in)

NOTE:

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

WARNING

Do not attempt to straighten a bent axle.

PIÈCES À DÉPOSER

- Brake disc deflection Use the dial gauge ①.

Out of specification → Inspect wheel runout. If wheel runout is in good condition, replace the brake disc.

Disc deflection limit: 0.15 mm (0.006 in)

2. Measure:

●Brake disc thickness ⓐ Out of limit → Replace.

	Disc wear limit:
Standard
3.0 mm(0.12 in)		2.5 mm(0.10 in)

ASSEMBLY AND INSTALLATION Front wheel

1. Install:

• Wheel bearing ①
• Spacer ②
• Wheel bearing ③
• Oil seal ④
  New

NOTE:

• Apply the lithium soap base grease on the wheel bearing and oil seal lip when installing.
• Install the wheel bearing so that the enclosed side is facing outward.
• Use a socket that matches the outside diameter of the race of the bearing.
  ●Left side of wheel bearing shall be installed first.
  •Install the oil seal with its manufacture's marks or numbers facing outward.

CAUTION:

Do not strike the inner race of the bearing. Contact should be made only with the outer race.

Disque de frein

1. Mesurer:

Technical line drawing of a mechanical assembly with a central shaft and flange (no text or symbols)

2. Install:

-Brake disc ①

●Bolt (brake disc) ②

12 Nm (1.2 m · kg, 8.7 ft · lb)

NOTE:

Tighten the bolts in stage, using a crisscross pattern.

3. Install:

•Collar ①

NOTE:

- Apply the lithium soap base grease on the oil seal lips.

- Install the longer collar on the brake disc ② side.

4. Install:

- Front wheel

NOTE:

Install the brake disc ① between the brake pads ② correctly.

5. Install:

- Wheel axle ①

6. Install:

•Washer ①

- Axle nut ②

Extent of removal: ① Brake hose removal ② Brake caliper removal
③ Brake master cylinder removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		FRONT BRAKE REMOVALHold the machine by placing the suitable stand under the engine.Drain the brake fluid.
			WARNINGSupport the machine securely so there is no danger of it falling over.Refer to “REMOVAL POINTS”.
	1 Brake hose holder 22 Union bolt 13 Brake hose 14 Joint 15 Brake caliper support bolt 16 Brake caliper 1 Refer to “REMOVAL POINTS”.7 Brake lever 18 Brake master cylinder bracket 19 Brake master cylinder	1

FREIN AVANT (TT-R125LW)

Extent of removal:
① Brake caliper disassembly
② Brake master cylinder disassembly

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		BRAKE CALIPER AND BRAKE MASTER CYLINDER DISASSEMBLYHold the machine by placing the suitable stand under the engine.
	1Brake pad 22Brake caliper bracket 13 Brake caliper piston4Brake caliper dust seal 25Brake caliper piston seal 26Pin boot 17Sleeve boot 18Brake master cylinder cap 19Diaphragm10Brake master cylinder boot11Circlip12Washer13Brake master cylinder kit	2	Refer to “REMOVAL POINTS”.Refer to “REMOVAL POINTS”.

Technical line drawing of a bicycle brake system with labeled components (no text or symbols present)

Line drawing of a hand holding a small mechanical component (no text or symbols)

REMOVAL POINTS

Brake fluid

1. Remove:

●Brake master cylinder cap ①

NOTE:

Do not remove the diaphragm.

1. Connect the transparent hose ② to the bleed screw ① and place a suitable container under its end.
2. Loosen the bleed screw and drain the brake fluid while pulling in the lever.

CAUTION:

•Do not reuse the drained brake fluid.
- Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately.

Brake caliper

1. Remove:

-Brake caliper ①

NOTE:

Turn the brake caliper counterclockwise and pull out it from the guide pin ② on the brake caliper bracket.

Brake caliper piston

1. Remove:

●Brake caliper piston

Use compressed air and proceed carefully.

WARNING

•Cover piston with rag and use extreme caution when expelling piston from cylinder.

●Never attempt to pry out piston.

Brake caliper piston removal steps:

• Insert a piece of rag into the brake caliper to lock one brake caliper.
• Carefully force the piston out of the brake caliper cylinder with compressed air.

PIÈCES À DÉPOSER

Liquide de frein

1. Déposer:

Brake caliper piston seal kit

1. Remove:

●Brake caliper dust seal ①
●Brake caliper piston seal ②

NOTE:

Remove the brake caliper piston seals and brake caliper dust seals by pushing them with a finger.

CAUTION:

Never attempt to pry out brake caliper piston seals and brake caliper dust seals.

WARNING

Replace the brake caliper piston seals and brake caliper dust seals whenever a brake caliper is disassembled.

Technical line drawing of a mechanical component with a labeled section (a), no readable text or symbols present.

INSPECTION

Brake master cylinder

1. Inspect:

- Brake master cylinder inner surface @ Wear/scratches → Replace brake master cylinder assembly. Stains → Clean.

Simple line drawing of a tray with a handle and label (1) pointing to the top surface, no text or symbols present.

WARNING

Use only new brake fluid.

2. Inspect:

- Diaphragm ① Crack/damage → Replace.

3. Inspect:

- Brake master cylinder piston ① - Brake master cylinder cup ② Wear/damage/score marks → Replace brake master cylinder kit.

Technical line drawing of a mechanical component with internal springs and mounting holes (no text or symbols)

graph TD
    A["Component 1"] --> C["Node 2"]
    B["Component 1"] --> C
    D["Component 2"] --> E["Node 2"]
    D --> F["Node 3"]
    D --> G["Node 4"]

Technical line drawing of a bolt with threaded shaft and hexagonal end (no text or symbols)

Line drawing of a curved mechanical or electrical component with labeled parts (1), no text or symbols present.

Brake caliper

1. Inspect:

- Brake caliper cylinder inner surface @ Wear/score marks → Replace brake caliper assembly.

2. Inspect:

- Brake caliper piston ① Wear/score marks → Replace brake caliper piston assembly.

WARNING

Replace the brake caliper piston seals and brake caliper dust seals ② whenever a brake caliper is disassembled.

3. Inspect:

- Brake caliper bracket ① Cracks/damage → Replace the brake caliper assembly. - Guide pin ② Rust/damage → Replace the brake caliper assembly. - Sleeve boot ③ - Pin boot ④ Wear/damage → Replace.

4. Inspect:

- Brake caliper support bolt ① Scorches/rust/damage → Replace.

Brake hose

1. Inspect:

- Brake hose ① Crack/damage → Replace.

Étrier de frein

1. Examiner:

ASSEMBLY AND INSTALLATION

WARNING

• All internal parts should be cleaned in new brake fluid only.
• Internal parts should be lubricated with brake fluid when installed.
  -Replace the brake caliper piston seals and brake caliper dust seals whenever a brake caliper is disassembled.

Brake caliper piston

1. Clean:

-Brake caliper
●Brake caliper piston seal
●Brake caliper dust seal
●Brake caliper piston
Clean them with brake fluid.

1. Install:

●Brake caliper piston seal ①
New
●Brake caliper dust seal ②
New

WARNING

Always use new brake caliper piston seals and brake caliper dust seals.

NOTE:

Fit the brake caliper piston seals and brake caliper dust seals onto the slot on brake caliper correctly.

1. Install:

●Brake caliper piston ①

NOTE:

Apply the brake fluid on the brake caliper piston wall.

CAUTION:

•Install the brake caliper piston with its shallow depressed side @ facing the brake caliper.

- Never force to insert.

Brake caliper

1. Install:

2. Sleeve boot ①.
   On brake caliper bracket ②.

REMONTAGE ET INSTALLATION

AVERTISSEMENT

2. Install:

- Pin boot ①

On brake caliper ②.

NOTE:

Apply the lithium soap base grease on the pin boot inner surface.

3. Install:

-Brake caliper bracket ①

●Bolt (brake caliper bracket) ②

30 Nm (3.0 m · kg, 22 ft · lb)

-Brake pad ③

4. Install:

-Brake caliper ①

NOTE:

- Apply the lithium soap base grease on the guide pin ②.

- Install the brake caliper into the guide pin and turn it clockwise.

5. Install:

●Brake caliper support bolt ①

22 Nm (2.2 m · kg, 16 ft · lb)

NOTE:

Apply the lithium soap base grease on the brake caliper support bolt.

Brake master cylinder kit

1. Clean:

●Brake master cylinder

●Brake master cylinder kit

Clean them with brake fluid.

FREIN AVANT (TT-R125LW) VORDERRADBREMSE (TT-R125LW)

2. Installer:

2. Install:

-Brake master cylinder cup (primary) ①

- Brake master cylinder cup (secondary) ②

On brake master cylinder piston ③.

NOTE:

Apply the brake fluid on the brake master cylinder cup.

WARNING

After installing, cylinder cup should be installed as shown direction. Wrong installation cause improper brake performance.

3. Install:

•Spring ①

On brake master cylinder piston ②.

NOTE:

Install the spring at the smaller diameter side.

4. Install:

●Brake master cylinder kit ①

- Washer ②

• Circlip ③

●Brake master cylinder boot ④

On brake master cylinder ⑤

NOTE:

- Apply the brake fluid on the brake master cylinder kit.

- When installing the circlip, use a long nose circlip pliers.

FREIN AVANT (TT-R125LW) VORDERRADBREMSE (TT-R125LW)

2. Installer:

Brake master cylinder

1. Install:

• Brake master cylinder ①
  ●Brake master cylinder bracket ②
  ●Bolt (brake master cylinder bracket) ③

9 Nm (0.9 m · kg, 6.5 ft · lb)

NOTE:

• Install the brake master cylinder bracket so that the arrow mark @ 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.

2. Install:

-Brake lever ①
- Spring ②
●Bolt (brake lever) ③

7 Nm (0.7 m · kg, 5.1 ft · lb)

- Nut (brake lever) ④

7 Nm (0.7 m · kg, 5.1 ft · lb)

NOTE:

• Apply the lithium soap base grease on the bolt and brake lever sliding surface.
• Apply the molybdenum disulfide grease on the tip of the adjuster bolt.

Brake hose

1. Install:

New

•Copper washer ①
-Brake hose ②
- Union bolt ③

26 Nm (2.6 m · kg, 19 ft · lb)

WARNING

Always use new copper washers.

CAUTION:

Install the brake hose so that its pipe portion ⓐ directs as show and lightly touches the projection Ⓑ on the brake caliper.

Technical line drawing of a car suspension system with no visible text or symbols

1. Pass the brake hose through the cable guide ①.

2. Install:

•Copper washer ①
New
●Joint ② 26 Nm (2.6 m · kg, 19 ft · lb)
-Brake hose ③
14 Nm (1.4 m · kg, 10 ft · lb)

WARNING

Always use a new copper washer.

NOTE:

When turning the joint over the brake hose, hold the brake hose so that it may not be twisted.

1. Install:

●Brake hose holder ①

●Bolt (brake hose holder) ②

7 Nm (0.7 m · kg, 5.1 ft · lb)

FREIN AVANT (TT-R125LW) VORDERRADBREMSE (TT-R125LW)

Until the fluid level reaches "LOWER" level line @.

Recommended brake fluid: DOT #4

WARNING

- Use only the designated quality brake fluid: otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance.

- Refill with the same type of brake fluid; mixing fluids may result in a harmful chemical reaction and lead to poor performance.

- Be careful that water does not enter the brake master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock.

CAUTION:

Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately.

1. Air bleed:

-Brake system

Refer to "BRAKE SYSTEM AIR BLEEDING" section in the CHAPTER 3.

1. Inspect:

-Brake fluid level

Fluid at lower level → Fill up.

Refer to "BRAKE FLUID LEVEL INSPECTION" section in the CHAPTER 3.

Liquide de frein

1. Verser:

4. Install:

•Diaphragm
●Brake master cylinder cap ①
●Screw (brake master cylinder cap) ②

2 Nm (0.2 m · kg, 1.4 ft · lb)

CAUTION:

After installation, while pulling in the lever, check whether there is any brake fluid leaking where the union bolts are installed respectively at the brake master cylinder and brake caliper.

4. Installer:

Extent of removal: ① Rear 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			REAR WHEEL AND DRUM BRAKEHold the machine by placing the suitable stand under the engine.		WARNINGSupport the machine securely so there is no danger of it falling over.
		1 Brake rod 12 Axle nut 13 Drive chain puller (right) 14 Wheel axle 15 Drive chain puller (left) 16 Drive chain 17 Rear wheel 1 Refer to “REMOVAL POINTS”.8 Collar (right) 19 Brake shoe plate assembly 110 Collar (left)

ROUE ARRIÈRE ET FREIN ARRIÈRE HINTERRAD UND HINTERRADBREMSE

ROUE ARRIÈRE ET FREIN ARRIÈRE

Extent of removal Order	Part name Q'ty Remarks
	11 Nut (wheel sprocket) 412 Wheel sprocket 113 Oil seal 114 Wheel bearing 2 Refer to “REMOVAL15 Spacer 116 Brake shoe 217 Spring 218 Brake camshaft lever 119 Wear indicator plate 120 Brake camshaft 121 Brake shoe plate	POINTS".1

ROUE ARRIÈRE ET FREIN ARRIÈRE HINTERRAD UND HINTERRADBREMSE

Technical line drawing of two mechanical bearing components with alignment arrows (no text or symbols)

REMOVAL POINTS

EC523101

Rear wheel

1. Remove:

- Wheel ①

NOTE:

Push the wheel forward and remove the drive chain ②.

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)

1. Inspect:

•Bearing

Rotate inner race with a finger.

Rough spot/seizure → Replace.

NOTE:

Replace the bearings, oil seal and wheel collar (wheel sprocket side) as a set.

EC514200

Wheel axle

1. Measure:

- Wheel axle bends

Out of specification → Replace.

Use the dial gauge ①.

Wheel axle bending limit:

0.5 mm (0.020 in)

ROUE ARRIÈRE ET FREIN ARRIÈRE HINTERRAD UND HINTERRADBREMSE

CHAS

PIÈCES À DÉPOSER

Roue arrière

1. Déposer:

- Roue ①

N.B.:

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

WARNING

Do not attempt to straighten a bent axle.

Illustration of hands using a tool to clean or store items, no text or symbols present

Drum brake

1. Inspect:

●Brake shoe lining surface Glazed areas → Polish. Use coarse sand paper.

NOTE: After polishing, wipe the polished particles with a cloth.

2. Measure:

- Brake shoe lining thickness ⓐ Out of specification → Replace.

	Brake shoe lining thickness:
Standard
4.0 mm(0.16 in)		2.0 mm(0.08 in)

NOTE: Replace the brake shoes and springs as a set if either is worn to the limit.

Technical line drawing of a mechanical component with concentric rings and a central hub (no text or symbols)

3. Measure:

- Brake drum inside diameter @ Out of specification → Replace.

	Brake drum inside diameter:
Standard
110 mm(4.33 in)		111 mm(4.37 in)

ROUE ARRIÈRE ET FREIN ARRIÈRE HINTERRAD UND HINTERRADBREMSE

N.B.:

- Brake drum inner surface. Oil/scratches → Remove.

Oil	Use a rag soaked in lac-quer thinner or a solvent.
Scratches	Use a emery cloth (lightly and evenly polishing).

ASSEMBLY AND INSTALLATION

Brake shoe plate assembly

1. Install:

-Brake camshaft ①

NOTE: Apply the lithium soap base grease on the brake camshaft.

1. Check:

●Brake camshaft operation Unsmooth operation → Repair.

1. Install:

●Wear indicator plate ①

NOTE: When installing the wear indicator plate to the brake camshaft align the projection ⓐ on the wear indicator plate with the slots Ⓑ on the brake camshaft.

1. Install:

●Brake camshaft lever ①

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE: Install the brake camshaft lever in relation to the punch mark @ as shown.

ROUE ARRIÈRE ET FREIN ARRIÈRE HINTERRAD UND HINTERRADBREMSE

4. Examiner:

5. Install:

•Springs ①

New

-Brake shoes ②

On brake shoe plate ③

NOTE:

- Apply the lithium soap base grease on the pivot pin.

- When installing the springs and brake shoes, take care not to damage the springs.

- When replacing the brake shoes, replace the springs as a set.

WARNING

Do not apply grease to the brake shoe linings.

Rear wheel

1. Install:

- Wheel bearing ①

- Spacer ②

- Wheel bearing ③

- Oil seal ④

New

NOTE:

- Apply the lithium soap base grease on the oil seal lip when installing.

•Install the bearing with seal facing outward.

- Use a socket that matches the outside diameter of the race of the bearing.

●Right side of bearing shall be installed first.

- Install the oil seal with its manufacture's marks or numbers facing outward.

CAUTION:

Do not strike the inner race of the bearing. Contact should be made only with the outer race.

ROUE ARRIÈRE ET FREIN ARRIÈRE HINTERRAD UND HINTERRADBREMSE

5. Installer:

2. Install:

- Wheel sprocket ①

- Lock washers ② New

●Nut (wheel sprocket) ③

●Tighten the nuts in stage, using a crisscross pattern.

●Bend the lock washer tab.

3. Install:

•Collar (left)
●Brake shoe plate assembly
•Collar (right)

NOTE:

Apply the lithium soap base grease on the oil seal lip.

4. Install:

•Rear wheel

NOTE:

Make sure that the slot ⓐ on the brake shoe plate with the stopper ⓑ on the swingarm.

5. Install:

-Drive chain ①

NOTE:

Push the wheel ② forward and install the drive chain.

6. Install:

-Drive chain puller (left) ①
- Plain washer ②
- Wheel axle ③

NOTE:

- Apply the lithium soap base grease on the wheel axle.

- Insert the wheel axle from left side.

ROUE ARRIÈRE ET FREIN ARRIÈRE HINTERRAD UND HINTERRADBREMSE

2. Installer:

Mechanical diagram of a chain drive system with gear and pulley components (no text or labels)

Technical line drawing of a mechanical assembly with no visible text or symbols

7. Install:

-Drive chain puller (right) ①
- Plain washer ②
- Axle nut ③

NOTE:

Temporarily tighten the axle nut at this point.

8. Adjust:

-Drive chain slack ⓐ

Drive chain slack: 35 \~ 50 mm (1.4 \~ 2.0 in)

Refer to "DRIVE CHAIN SLACK ADJUSTMENT" section in the CHAPTER 3.

9. Tighten:

- Axle nut ①

60 Nm (6.0 m · kg, 43 ft · lb)

10. Install:

•Spring ①
-Brake rod ②
•Pin ③
•Wing nut ④

On brake camshaft lever ⑤.

11. Adjust:

●Brake pedal free play

Refer to "REAR BRAKE ADJUSTMENT" section in the CHAPTER 3.

ROUE ARRIÈRE ET FREIN ARRIÈRE HINTERRAD UND HINTERRADBREMSE

CHAS

7. Installer:

Extent of removal: ① Front fork removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		FRONT FORK REMOVALHold the machine by placing the suitable stand under the engine.Front wheel Refer to “FRONT WHEEL AND FRONTBRAKE” section.Handlebar Refer to “HANDLEBAR” section.	WARNINGSupport the machine securely so there is no danger of it falling over.
	1 Cap 12 Pinch bolt (upper bracket) 1 Only loosening.3 Cap bolt 1 Loosen when disassembling the front fork.4 Pinch bolt (lower bracket) 1 Only loosening.5 Front fork	1

FOURCHE AVANT

Extent of removal: ① Oil seal removal ② Damper rod removal

Extent of removal Order Part name Q'ty Remarks
↓	FRONT FORK DISASSEMBLY1Dust boot 12Cap bolt 1 Refer to “REMOVAL POINTS”.3Spacer 14Washer 15Fork spring 1 Drain the fork oil.6Dust seal 17Stopper ring 18Bolt (damper rod) 19Damper rod10Inner tube11Oil flow stopper12Piston metal13Oil seal14Outer tube	1111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111	Use special tool.Refer to “REMOVAL POINTS”.

DÉMONTAGE DE LA FOURCHE AVANT

The front fork requires careful attention. So it is recommended that the front fork be maintained at the dealers.

CAUTION:

To prevent an accidental explosion of air, the following instructions should be observed:

The front fork with a built-in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material.

Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disassembled and reassembled.

Simple line drawing of a cylindrical object with a labeled section (①), no text or symbols present.

EC553000

REMOVAL POINTS

Cap bolt

1. Remove:

- Cap bolt ①

From the inner tube.

NOTE:

Before removing the front fork from the machine, loosen the cap bolt.

Inner tube

1. Remove:

•Dust seal ①

-Stopper ring ②

Using slotted-head screwdriver.

CAUTION:

Take care not to scratch the inner tube.

1. Remove:

●Bolt (damper rod)
•Damper rod
•Inner tube
- Oil flow stopper
•Piston metal

NOTE:

Use the damper rod holder ① and the T-handle ② to lock the damper rod.

REMARQUE CONCERNANT LA MANIPULATION

N.B.:

Simple line drawing of a cylindrical mechanical component with threaded end (no text or symbols)

Diagram of a coiled spring with labeled dimension 'a' (no text or symbols beyond label)

3. Remove:

- Oil seal ①

Using slotted-hand screwdriver.

CAUTION:

Take care not to scratch the outer tube.

EC554000

INSPECTION

Damper rod

1. Inspect:

- Damper rod

Bend/damage → Replace damper rod.

CAUTION:

The front fork with a built-in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material.

Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disassembled and reassembled.

EC554400

Fork spring

1. Measure:

●Fork spring free length ⓐ

Out of specification → Replace.

	Fork spring free length:
Standard
TT-R125: 327 mm(12.9 in)TT-R125LW:339 mm(13.3 in)		TT-R125: 322 mm(12.7 in)TT-R125LW:334 mm(13.1 in)

- Inner tube surface ⓐ Score marks → Repair or replace. Use #1,000 grit wet sandpaper. Damaged oil lock piece → Replace.

- Inner tube bends Out of specification → Replace. Use the dial gauge ①.

Inner tube bending limit: 0.2 mm (0.008 in)

NOTE:

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

WARNING

Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube.

2. Inspect:

- Piston metal ① Wear/damage → Replace.

Technical line drawing of a mechanical component with a labeled part (1), no text or symbols present.

Outer tube

1. Inspect:

- Outer tube ① - Slide metal ② Score marks/wear/damage → Replace outer tube assembly.

Cap bolt

1. Inspect:

- Cap bolt ① - O-ring ② Wear/damage → Replace.

Tube plongeur

1. Examiner:

ASSEMBLY AND INSTALLATION

Front fork assembly

1. Wash the all parts in a clean solvent.

1. Install:

•Piston metal ①
- Damper rod ②
- Oil flow stopper ③

On inner tube ④.

CAUTION:

To install the damper rod into the inner tube, hold the inner tube aslant. If the inner tube is held vertically, the damper rod may fall into it and be damaged.

1. Install:

•Inner tube

On outer tube.

1. Install:

•Copper washer

New

●Bolt (damper rod)

23 Nm (2.3 m · kg, 17 ft · lb)

NOTE:

Use the damper rod holder ① and the T-handle ② to lock the damper rod.

Damper rod holder:

YM-1300/90890-01294

T-handle:

YM-01326/90890-01326

REMONTAGE ET INSTALLATION

Fourche avant

Technical line drawing of a mechanical tool with two opposing arrows indicating motion (no text or symbols)

5. Install:

- Oil seal ①

New

NOTE:

• Apply the fork oil on the inner tube.
• When installing the oil seal, use vinyl seat ⓐ with fork oil applied to protect the oil seal lip.
• Install the oil seal with its manufacturer's marks or number facing upside.
• Press the oil seal into the outer tube with fork seal driver attachment (ø30) ② and fork seal driver weight ③.

Fork seal driver weight:

YM-33963/90890-01367

Fork seal driver attachment:

YM-33281/90890-01400

6. Install:

-Stopper ring ①

NOTE:

Fit the stopper ring correctly in the groove in the outer tube.

7. Install:

•Dust seal ①

NOTE:

Apply the lithium soap base grease on the inner tube.

8. Check:

- Inner tube smooth movement Tightness/binding/rough spots → Repeat the steps 2 to 7.

5. Installer:

1. Compress the front fork fully.

2. Fill:

- Front fork oil ①

Recommended oil: Fork oil 10W or equivalent Quantity (each front fork leg): TT-R125: 159 cm ^3 (5.60 Imp oz, 5.38 US oz) TT-R125LW: 156 cm ^3 (5.49 Imp oz, 5.27 US oz)

CAUTION:

- Be sure to use recommended fork oil. If other oils are used, they may have an excessively adverse effect on the front fork performance.

●Never allow foreign materials to enter the front fork.

1. After filling, pump the inner tube slowly up and down more than 10 times to distribute the fork oil.

1. Measure:

•Oil level ⓐ

Out of specification → Adjust.

Standard oil level: TT-R125: 122 mm (4.80 in) TT-R125LW: 130 mm (5.12 in) From the top of the inner tube, with the inner tube fully compressed, and without the fork spring.

Simple line drawing of a cylindrical object with a labeled section (①), no text or symbols present.

1. Install:

•Fork spring
•Washer
•Spacer
- Cap bolt ①
•Dust boot

NOTE:

Temporarily tighten the cap bolt.

- Temporarily tighten the pinch bolt (lower bracket).

- Do not tighten the pinch bolt (upper bracket) yet.

1. Tighten:

- Cap bolt ①

23 Nm (2.3 m · kg, 17 ft · lb)

1. Adjust:

- Front fork top end ⓐ

Front fork top end (standard) ⓐ: Zero mm (Zero in)

1. Tighten:

•Pinch bolt (lower bracket) ①

60 Nm (6.0 m · kg, 43 ft · lb)

- Pinch bolt (upper bracket) ②

25 Nm (2.5 m · kg, 18 ft · lb)

●Screw (dust boot) ③

NOTE:

- Make sure that the dust boot holes ⓐ are positioned outward.

●Tighten the screw (dust boot) until the top of the dust boot is touching the lower bracket.

Technical line drawing of a mechanical assembly with labeled component (1), no readable text or symbols present

1. Install:

- Cap ①

Installation

1. Installer:

- Fourche avant

N.B.:

Extent of removal: ① Handlebar removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		HANDLEBAR REMOVALNumber plate
1	1 Clutch cable 12 Clutch lever 13 Engine stop switch 14 Front brake cable 15 Front brake lever 16 Grip cap (lower) 17 Grip cap (upper) 18 Throttle cable 19 Throttle grip assembly 110 Collar11 Handlebar grip (left)12 Handlebar holder13 Handlebar	1121	Refer to “REMOVAL POINTS”.

GUIDON

TT-R125

Extent of removal: ① Handlebar removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		HANDLEBAR REMOVALNumber plate
1	1 Clutch cable 12 Clutch lever 13 Engine stop switch 14 Brake master cylinder 1 Refer to “REMOVAL POINTS”.5 Grip cap (lower) 16 Grip cap (upper) 17 Throttle cable 18 Throttle grip assembly 1

TT-R125LW

Extent of removal Order Part name Q'ty Remarks
1	9 Collar 110 Handlebar grip (left) 1 Refer to “REMOVAL POINTS”.11 Upper handlebar holder 212 Handlebar		1

Extent of removal: ① Throttle grip assembly disassembly

Extent of removal Order Part name Q'ty Remarks
[XX-37]	12Collar 23	THROTTLE GRIP ASSEMBLYDISASSEMBLYHandlebar grip (right)Tube guide	11	Refer to “REMOVAL POINTS”.

DÉMONTAGE DE LA POIGNÉE DES GAZ

REMOVAL POINTS

Brake master cylinder (TT-R125LW)

1. Remove:

●Brake master cylinder bracket ①
●Brake master cylinder ②

CAUTION:

• Do not let the brake master cylinder hang on the brake hose.
• Keep the brake master cylinder cap side horizontal to prevent air from coming in.

Illustration of a hand using a tool to adjust or install a mechanical component, no text or symbols present

Line drawing of a bent tool or tool with a labeled component (no text or symbols present)

Handlebar grip

1. Remove:

- Handlebar grip ①

NOTE:

Blow in air between the handlebar or tube guide and the grip. Then remove the grip which has become loose.

INSPECTION

Handlebar

1. Inspect:

- Handlebar ①

Bends/cracks/damage → Replace.

WARNING

Do not attempt to straighten a bent handlebar as this may dangerously weaken the handlebar.

PIÈCES À DÉPOSER

ASSEMBLY AND INSTALLATION

Throttle grip assembly

1. Install:

•Collar ①
●Handlebar grip (right) ②

Apply the adhesive on the tube guide ③.

NOTE:

Before applying the adhesive, wipe off grease or oil on the tube guide surface ⓐ with a lacquer thinner.

Handlebar

1. Install:

•Handlebar ①
- Handlebar holder ②
●Bolt (handlebar holder) ③

23 Nm (2.3 m · kg, 17 ft · lb)

NOTE:

• Align the punched mark ⓐ on the handlebar with the upper surface of the handlebar holder on the upper bracket.
• The handlebar holder should be installed with the punched mark ⑥ forward.
• First tighten the bolts on the front side of the handlebar holder, and then tighten the bolts on the rear side.

REMONTAGE ET INSTALLATION

Technical line drawing of a mechanical lever assembly with a handle and nut (no text or symbols)

Technical diagram of a mechanical clamp or connector assembly with labeled parts (no text or symbols present)

2. Install:

- Handlebar grip (left) ①

Apply the adhesive to the handlebar ②.

NOTE: ____ Before applying the adhesive, wipe off grease or oil on the handlebar surface @ with a lacquer thinner.

3. Install:

•Collar ①

4. Install:

•Throttle grip assembly ①
•Grip cap (upper) ②
- Throttle cables ③

On tube guide ④.

NOTE: ____ Apply the lithium soap base grease on the throttle cable end and tube guide cable winding portion.

5. Install:

• Throttle cable cap ①
  ●Screw (throttle cable cap) ②

2 Nm (0.2 m · kg, 1.4 ft · lb)

●Grip cap (lower) ③
- Screw (grip cap) ④

4 Nm (0.4 m · kg, 2.9 ft · lb)
4 Nm (0.4 m · kg, 2.9 ft · lb)
- Cover (grip cap) ⑤

WARNING

After tightening the screws, check that the throttle grip ⑥ moves smoothly. If it does not, retighten the bolts for adjustment.

2. Installer:

6. Install:

TT-R125

• Front brake lever holder ①
  ●Bolts (front brake lever holder) ②

4 Nm (0.4 m · kg, 2.9 ft · lb)

• Front brake cable ③
  -Clamp

NOTE: ____ Apply the lithium soap base grease on the front brake cable end.

TT-R125LW

●Brake master cylinder ①
●Brake master cylinder bracket ②
●Bolt (brake master cylinder bracket) ③

9 Nm (0.9 m · kg, 6.5 ft · lb)

NOTE:

• Install the bracket so that the arrow mark @ 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
●Bolts (clutch lever holder) ③

4 Nm (0.4 m · kg, 2.9 ft · lb)

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 middle 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 ADJUSTMENT" section in the CHAPTER 3.

- Clutch lever free play

Refer to "CLUTCH ADJUSTMENT" section in the CHAPTER 3.

6. Installer:

TT-R125

Extent of removal: ① Lower bracket removal ② Bearing removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		STEERING REMOVALHold the machine by placing the suitable stand under the engine.Front forks Refer to “FRONT FORK” section.Handlebar Refer to “HANDLEBAR” sectionFront fender		WARNINGSupport the machine securely so there is no danger of it falling over.
	1 Steering stem nut 12 Upper bracket 13 Special washer 14 Upper ring nut 15 Rubber washer 16 Lower ring nut 17 Lower bracket 18 Bearing cover			Use special tool.Refer to “REMOVAL POINTS”.

DIRECTION

Extent of removal Order Part name Q'ty Remarks
2	9 Bearing inner race (upper) 110 Bearing (upper) 111 Bearing outer race (upper) 112 Bearing outer race (lower) 113 Bearing (lower)	1	Refer to “REMOVAL POINTS”.Refer to “REMOVAL POINTS”.

EC563000

REMOVAL POINTS

EC563202

Ring nut

1. Remove:

- Ring nut ①

Use the steering nut wrench ②.

Steering nut wrench: YU-33975/90890-01403

WARNING

Support the steering shaft so that it may not fall down.

Bearing race

1. Remove:

●Bearing race ①

Remove the bearing race using long rod ② and the hammer.

EC563300

Bearing (lower)

1. Remove:

●Bearing (lower) ①

Use the floor chisel ②.

CAUTION:

Take care not to damage the steering shaft thread.

Technical line drawing of a mechanical assembly with a shaft and flange (no text or symbols)

EC564000

INSPECTION

Steering stem

1. Inspect:

•Steering stem ①

Bend/damage → Replace.

PIÈCES À DÉPOSER

Écrou crénelé

1. Déposer:

- Écrou crénelé ①

Bearing and bearing race

1. Wash the bearings and bearing races with a solvent.
2. Inspect:

•Bearing
•Bearing race

Pitting/damage → Replace bearings and bearing races as a set.

Install the bearing in the bearing races. Spin the bearings by hand. If the bearings hang up or are not smooth in their operation in the bearing races, replace bearings and bearing races as a set.

EC565000

ASSEMBLY AND INSTALLATION

Lower bracket

1. Install:

●Bearing (lower) ①

NOTE:

Apply the lithium soap base grease on the dust seal lip and bearing inner circumference.

1. Install:

●Bearing outer race (lower)
●Bearing outer race (upper)

1. Install:

●Bearing (upper)
●Bearing inner race ①
●Bearing cover ②

NOTE:

Apply the lithium soap base grease on the bearing and bearing cover lip.

Line drawing of hands using a tool to adjust or install a mechanical component (no text or symbols present)

4. Install:

●Lower bracket ①

NOTE: Apply the lithium soap base grease on the bearing.

5. Install:

●Lower ring nut ①

•Rubber washer
• Upper ring nut
•Special washer

Tighten the ring nut using the steering nut wrench ②.

NOTE: Install the lower ring nut with its larger chamfered portion @ facing downward.

Refer to "STEERING HEAD INSPECTION AND ADJUSTMENT" section in the CHAPTER 3.

1. Check the steering shaft by turning it lock to lock. If there is any binding, remove the steering shaft assembly and inspect the steering bearings.

7. Install:

•Upper bracket ①
•Steering stem nut ②
- Starter knob bracket ③

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE: ____ Do not tighten the steering stem nut yet.

8. Install:

- Front forks ①

NOTE: ____

• Temporarily tighten the pinch bolts (lower bracket) ②.
• Do not tighten the pinch bolts (upper bracket) yet.

4. Installer:

- Té inférieur ①

N.B.:

Technical line drawing of a mechanical assembly with no visible text or symbols

9. Tighten:

•Steering stem nut ①

110 Nm (11.0 m · kg, 80 ft · lb)

10. Install:

•Cap ②

1. After tightening the nut, check the steering for smooth movement. If not, adjust the steering by loosening the ring nut little by little.

12. Adjust:

- Front fork top end ⓐ

Front fork top end (standard) ⓐ: Zero mm (Zero in)

13. Tighten:

•Pinch bolts (lower bracket) ①

60 Nm (6.0 m · kg, 43 ft · lb)

- Pinch bolts (upper bracket) ②

25 Nm (2.5 m · kg, 18 ft · lb)

9. Serrer:

Extent of removal: ① Swingarm removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		SWINGARM REMOVALHold the machine by placing the suitable stand under the engine.Rear wheel Refer to “REAR WHEEL AND REARBRAKE” section.
	1 Drive chain tensioner (upper) 12 Drive chain tensioner (lower) 13 Bolt (connecting arm-frame) 14 Bolt (rear shock absorber-relay arm) 1 Hold the swingarm.5 Pivot shaft 16 Swingarm 1

BRAS OSCILLANT

② Connecting arm removal and disassembly

③ Relay arm removal and disassembly

Extent of removal Order Part name Q'ty Remarks
↓	SWINGARM DISASSEMBLY1Drive chain guard 12Drive chain support 13Drive chain guide 14Dust cover 45Collar 16Connecting arm 17Oil seal 28Collar 29Dust cover 210Bushing 111Relay arm 112Dust cover 213Bushing 114Swingarm	1

DÉMONTAGE DU BRAS OSCILLANT

REMOVAL POINTS

Bushing

1. Remove:

• Bushing ①

NOTE:

Remove the bushing by pressing.

INSPECTION

Wash the bushings, collars, and covers in a solvent.

Swingarm

1. Inspect:

• Bushing ①
●Bushing ②

Damage/pitting → Replace bushings as a set.

1. Inspect:

•Dust cover

Damage → Replace.

1. Inspect:

•Swingarm

Damage/bends/cracks → Replace.

Relay arm

1. Inspect:

•Collar ①
• Bushing ②

Damage/pitting → Replace collar and bushing as a set.

• Bushing ③
• Bushing ④

Damage/pitting → Replace bushings as a set.

•Collar ⑤
• Bushing ⑥
• Bushing ⑦

Damage/pitting → Replace collars and bushing as a set.

1. Inspect:

2. Oil seal ⑧
   •Dust cover ⑨

Damage → Replace.

1. Inspect:

-Relay arm ⑩

Damage/bends/cracks → Replace.

PIÈCES À DÉPOSER

Bague

1. Déposer:

•Bague ①

N.B.:

Connecting arm

1. Inspect:

•Collar ①
• Bushing ②

Damage/pitting → Replace collar and bushings as a set.

1. Inspect:

•Dust cover ③

Damage → Replace.

1. Inspect:

- Connecting arm ④

Damage/bends/cracks → Replace.

Pure electrical circuit lines without any symbols

EC575000

ASSEMBLY AND INSTALLATION

Bushing

1. Install:

• Bushing

NOTE:

Make sure to press in the bushing so that they are flush with the surface of the connecting arm and relay arm.

Swingarm assembly

1. Install:

• Bushing ①
•Dust covers ②

On swingarm.

NOTE:

Apply the molybdenum disulfide grease on the bushing and dust cover lip.

Bras de raccordement

•Bague ①
- Caches antipoussière ②

2. Install:

• Oil seals ①
  •Collars ②
  • Bushing ③
  •Dust covers ④
  •Dust covers ⑤
  •Rubber boot ⑥

On relay arm.

NOTE:

Apply the molybdenum disulfide grease on the bushing, collar, oil seal lip and dust cover lip.

3. Install:

•Collar ①
•Dust covers ②

On connecting arm.

NOTE: ____

Apply the molybdenum disulfide grease on the collar and dust cover lip.

4. Install:

-Relay arm ①
•Bolt (relay arm)
- Plain washer
•Nut (relay arm)

53 Nm (5.3 m · kg, 38 ft · lb)

On swingarm.

NOTE:

Apply the molybdenum disulfide grease on the bolt (relay arm).

5. Install:

• Connecting arm ①
  ●Bolt (connecting arm)
  -Plain washer
  ●Nut (connecting arm)

35 Nm (3.5 m · kg, 25 ft · lb)

On relay arm.

NOTE: ____

Apply the molybdenum disulfide grease on the bolt (connecting arm).

2. Installer:

6. Install:

-Drive chain guide ①
•Collars
●Bolts (drive chain guide) ②

7 Nm (0.7 m · kg, 5.1 ft · lb)

7. Install:

-Drive chain support ①
•Collars
- Bolts (drive chain support) ②

7 Nm (0.7 m · kg, 5.1 ft · lb)

-Drive chain guard ③
●Bolts (drive chain guide) ④

7 Nm (0.7 m · kg, 5.1 ft · lb)

Installation

1. Install:

•Swingarm
- Pivot shaft ①
- Plain washer
●Nut (pivot shaft)

53 Nm (5.3 m · kg, 38 ft · lb)

NOTE:

Apply the molybdenum disulfide grease on the pivot shaft.

2. Check:

• Swingarm side play ⓐ
  Free play exists → Replace bushing.
  ●Swingarm up and down movement ⑥

Unsmooth movement/binding/rough

spots → Grease or replace bushing.

3. Install:

●Bolt (rear shock absorber - relay arm) ①
- Plain washer
●Nut (rear shock absorber-relay arm)

35 Nm (3.5 m · kg, 25 ft · lb)

NOTE:

Apply the molybdenum disulfide grease on the bolt (rear shock absorber - relay arm).

6. Installer:

Technical line drawing of a mechanical assembly with bolts and a central component (no text or symbols)

4. Install:

●Bolt (connecting arm-frame) ①
- Plain washer
●Nut (connecting arm-frame)

35 Nm (3.5 m · kg, 25 ft · lb)

NOTE:

Apply the molybdenum disulfide grease on the bolt (connecting arm - frame).

5. Install:

-Drive chain tensioner (lower) ①
•Collar
●Bolt [drive chain tensioner (lower)]

7 Nm (0.7 m · kg, 5.1 ft · lb)

6. Install:

• Bushing ①
-Drive chain tensioner (upper) ②
- Plain washer ③

●Bolt [drive chain tensioner (upper)] ④

23 Nm (2.3m · kg, 17 ft · lb)

NOTE:

Apply the lithium soap base grease on the bushing inner surface.

4. Installer:

•Boulon (bras de raccordement – cadre) ①
•Rondelle plate
- Écrou (bras de raccordement – cadre)

Extent of removal: ① Rear shock absorber assembly removal

Extent of removal Order Part name Q'ty Remarks
Preparation for removal		REAR SHOCK ABSORBER ASSEMBLY REMOVALHold the machine by placing the suitable stand under the engine.Seat and side covers Refer to “SEAT, FUEL TANK AND SIDE COVERS” section.
	1 Bolt (rear shock absorber assembly-relay arm)2 Bolt (rear shock absorber assembly-frame)3 Bushing 1 Refer to “REMOVAL POINTS”.4 Rear shock absorber assembly 1	1 Hold the swingarm.1

COMBINÉ RESSORT-AMORTISSEUR ARRIÈRE

This rear shock absorber contains high-pressure nitrogen gas. To prevent the danger of explosion, read and understand the following information before handling the shock absorber.

The manufacturer can not be held responsible for property damage or personal injury that may result from improper handling.

1. Never tamper or attempt to open the rear shock absorber.
2. Never throw the rear shock absorber into an open flame or other high heat. The rear shock absorber may explode as a result of nitrogen gas expansion and/or damage to the hose.
3. Be careful not to damage any part of the rear shock absorber. A damaged rear shock absorber will impair the damping performance or cause a malfunction.
4. Take care not to scratch the contact surface of the piston rod with the cylinder; or oil could leak out.
5. When scrapping the rear shock absorber, follow the instruction on disposal.

NOTES ON DISPOSAL (YAMAHA DEALERS ONLY)

Gas pressure must be released before disposing of a rear shock absorber and gas cylinder. To release the gas pressure, drill a 2 \~ 3-mm (0.08 \~ 0.12-in) hole through the gas cylinder at a point 12 mm (0.5 in) @ from its end as shown.

WARNING

Wear eye protection to prevent eye damage from released gas or metal chips.

REMARQUE CONCERNANT LA MANIPULATION

AVERTISSEMENT

EC583000

REMOVAL POINTS

Bushing

1. Remove:

• Bushing ①

NOTE:

Remove the bushing by pressing.

EC584000

INSPECTION

Rear shock absorber assembly

1. Inspect:

- Damper rod ① Bends/damage → Replace rear shock absorber assembly.

- Shock absorber ② Oil leaks → Replace rear shock absorber assembly. Gas leaks → Replace rear shock absorber assembly.

- Spring ③ Damage → Replace rear shock absorber assembly. Fatigue → Replace rear shock absorber assembly. Move spring up and down.

EC585000

ASSEMBLY AND INSTALLATION

Bushing

1. Install:

• Bushing ①

NOTE:

Install the bushing by pressing.

COMBINÉ RESSORT-AMORTISSEUR ARRIÈRE HINTERRAD-STOSSDÄMPFER

PIÈCES À DÉPOSER

Bague

1. Déposer:

•Bague ①

N.B.:

Installation

1. Install:

- Rear shock absorber assembly On frame.

NOTE:

Install the rear shock absorber assembly with its warning label ⓐ facing left side of the machine.

2. Install:

●Bolt (rear shock absorber assembly - frame)

- Plain washer ①

- Nut (rear shock absorber assembly - frame) ②

53 Nm (5.3 m · kg, 38 ft · lb)

NOTE:

Apply the molybdenum disulfide grease on the bolt (rear shock absorber assembly - frame).

3. Install:

●Bolt (rear shock absorber assembly - relay arm)

- Plain washer ①

- Nut (rear shock absorber assembly - relay arm) ②

35 Nm (3.5 m · kg, 25 ft · lb)

NOTE:

Apply the molybdenum disulfide grease on the bolt (rear shock absorber assembly - relay arm).

COMBINÉ RESSORT-AMORTISSEUR ARRIÈRE HINTERRAD-STOSSDÄMPFER

CHAS

Installation

1. Installer:

①CDI unit
②Engine stop switch
③Ignition coil
④CDI magneto
⑤Spark plug

COLOR CODE

B......	Black	B/R......	Black/Red
Br......	Brown	B/W......	Black/White
G......	Green	G/L......	Green/Blue
O......	Orange	G/W......	Green/White
R......	Red	W/L......	White/Blue
W......	White	W/R......	White/Red

* The illustration shows the TT-R125LW

EC612000

WIRING DIAGRAM

graph TD
    A["①"] --> B["B/R G/W"]
    A --> C["O B B/W"]
    A --> D["W/R W/L"]
    B --> E["G/W B/R"]
    C --> F["O B/W B"]
    D --> G["W/L W/R"]
    E --> H["G/W B/R"]
    F --> I["W/L W/R"]
    H --> J["Br G"]
    I --> K["R W"]
    J --> L["Br"]
    K --> M["G"]
    L --> N["R"]
    M --> O["W"]
    N --> P["②"]
    O --> Q["③"]
    P --> R["⑤"]
    Q --> S["③"]
    R --> T["⑤"]

PARTIE ÉLECTRIQUE ÉQUIPEMENT ÉLECTRIQUE ET SCHÉMA DE CÂBLAGE COMPOSANTS ÉLECTRIQUES

Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark.

graph TD
    A["Spark gap test"] -->|No Spark| B["Check entire ignition system for connection."]
    B -->|OK| C["Check engine stop switch. Replace."]
    C -->|No good| D["Repair or replace."]
    C -->|No good| E["Check ignition coil. Primary coil Replace."]
    E -->|No good| F["Secondary coil Replace."]
    E -->|No good| G["Check CDI magneto. Pickup coil Replace."]
    G -->|No good| H["Charging coil Replace."]
    G -->|No good| I["Replace CDI unit."]
    D --> J["*Clean or replace spark plug."]
    C --> K["Replace CDI unit."]

*marked: Only when the ignition checker is used.

NOTE:

- Remove the following parts before inspection.

1) Seat
2) Fuel tank

- Use the following special tools in this inspection.

Dynamic spark tester: YM-34487

Ignition checker: 90890-06754

Pocket tester: YU-3112-C/90890-03112

SYSTÈME D'ALLUMAGE

ÉTAPES DU CONTRÔLE

SPARK GAP TEST

1. Disconnect the spark plug cap from spark plug.

2. Connect the dynamic spark tester ① (ignition checker ②) as shown.

3. Spark plug cap ③

4. Spark plug ④

AFor USA and CDN

B Except for USA and CDN

1. Kick the kickstarter crank.
2. Check the ignition spark gap.
3. Start engine, and increase spark gap until misfire occurs. (for USA and CDN only)

Minimum spark gap: 6.0 mm (0.24 in)

EC624000

COUPLERS AND LEADS CONNECTION INSPECTION

1. Check:

- Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace.

ENGINE STOP SWITCH INSPECTION

1. Inspect:

●Engine stop switch conduct.

Tester (+) lead → Black/White lead 1

Tester (−) lead → Black lead 2

		B/W1	B2	Tester selec-tor position
	PUSH IN	○	○	Ω×1
	FREE

Not continuous while being pushed → Replace.

Continuous while being freed → Replace.

TEST DE LA LONGUEUR D'ÉTINCELLE

EC626002

IGNITION COIL INSPECTION

1. Inspect:

•Primary coil resistance

Out of specification → Replace.

Tester (+) lead → Orange lead 1

Tester (−) lead → Black lead 2

	Primary coil resistance	Tester selector position
	0.18 ~ 0.28 Ω at 20 °C (68 °F)	Ω × 1

2. Inspect:

•Secondary coil resistance

Out of specification → Replace.

Tester (+) lead → Spark plug lead 1

Tester (−) lead → Orange lead 2

	Secondary coil resistance	Tester selector position
	6.3 ~ 9.5 kΩ at 20 °C (68 °F)	kΩ × 1

NOTE:

When inspecting the secondary coil resistance, remove the spark plug cap.

CONTRÔLE DE LA BOBINE D'ALLUMAGE

1. Examiner:

CDI MAGNETO INSPECTION

1. Inspect:

- Pickup coil resistance

Out of specification → Replace.

Tester (+) lead → Red lead 1

Tester (−) lead → White lead 2

	Pickup coil resistance	Tester selector position
	248 ~ 372 Ω at 20 °C (68 °F)	Ω × 100

2. Inspect:

●Charging coil resistance

Out of specification → Replace.

Tester (+) lead → Brown lead 1

Tester (−) lead → Green lead 2

	Charging coil resistance	Tester selector position
	688 ~ 1,032 Ω at 20 °C (68 °F)	Ω × 100

EC628000

CDI UNIT INSPECTION

Check all electrical components. If no fault is found, replace the CDI unit. Then check the electrical components again.

CONTRÔLE DE LA MAGNÉTO CDI

1. Examiner: