Yamaha TT-R125EW Owners Service Manual

[Page 1] Yamaha TT-R125E(W)

R A TE MPO RY PRINTED IN BRASIL 00/2000 - 0000 - GYL (E) LIT-11626-20-01 1B2-F8199-12 TT-R125EW TT-R125LW TT-R125LEW TT-R125EW / TT-R125LW / TT-R125LEW ...

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EC010000 TT-R125EW/TT-R125LW TT-R125LEW OWNER’S SERVICE MANUAL ©2006 by Yamaha Motor da Amazônia Ltda. 1st Edition, 2006 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor da Amaz...

[Page 4] Yamaha TT-R125E(W)

The design and manufacture of this Yamaha ma- chine fully comply with the emissions standards for clean air applicable at the date of manufac- ture. Yamaha has met these standards without reducing the performance or economy of opera- tion of the mach...

[Page 5] Yamaha TT-R125E(W)

9 WARRANTY QUESTIONS AND ANSWERS Q. What costs are my responsibility during the warranty period? A. The customer’s responsibility includes all costs of normal maintenance services, no-warranty repairs, accident and collision damages, and oil, oil f...

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IMPORTANT NOTICE 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 high- way. Off-road use on public lands may b...

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4. When transporting the machine in another vehicle, be sure is kept upright and that the fuel cock is turned to the “OFF”. If it should lean over, gasoline may leak out of the car- buretor or fuel tank. 5. Never start your engine or let it run f...

[Page 8] Yamaha TT-R125E(W)

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. W...

[Page 9] Yamaha TT-R125E(W)

6. When going for riding, be sure to be with your family. Never go alone. 7. Before riding the machine, ask your par- ents to check the machine very carefully. 8. Do not touch the areas shown, or you will get burnt in the hand. 9. Do not touc...

[Page 10] Yamaha TT-R125E(W)

EC050000 TO THE NEW OWNER 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 ne...

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EC080000 HOW TO USE THIS MANUAL EC081000 PARTICULARLY IMPORTANT INFORMATION The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to th...

[Page 12] Yamaha TT-R125E(W)

EC083000 MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The informa- tion has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explan...

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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 El...

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MEMO ...

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GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS ELECTRICAL GEN INFO SPEC ENG CHAS CHÂS INSP ADJ 1 2 3 4 5 6 INDEX ...

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EC0A0000 CONTENTS CHAPTER 1 GENERAL INFORMATION DESCRIPTION .......................................... 1-1 MACHINE IDENTIFICATION .................... 1-2 IMPORTANT INFORMATION ................... 1-3 CHECKING OF CONNECTION ................ 1-5 S...

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CHAPTER 3 REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS ................... 3-1 PRE-OPERATION INSPECTION AND MAINTENANCE ............................... 3-4 ENGINE ..................................................... 3-5 CHASSIS ........

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CHAPTER 5 CHASSIS FRONT WHEEL AND FRONT BRAKE (TT-R125/TT-R125E) ................................. 5-1 FRONT WHEEL (TT-R125LW/TT-R125LWE) ..................... 5-8 FRONT BRAKE (TT-R125LW/TT-R125LWE) ................... 5-12 REAR WHEEL AND REAR B...

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1 - 1 GEN INFO DESCRIPTION EC100000 GENERAL INFORMATION EC110000 DESCRIPTION 1 Clutch lever 2 Engine stop switch 3 Main switch (TT-R125E/TT-R125LWE) 4 Starter knob 5 Start switch (TT-R125E/TT-R125LWE) 6 Front brake lever 7 Throttle grip 8 Fuel tank c...

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1 - 2 GEN INFO MACHINE IDENTIFICATION EC120001 MACHINE IDENTIFICATION 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 o...

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1 - 3 GEN INFO IMPORTANT INFORMATION 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...

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1 - 4 GEN INFO IMPORTANT INFORMATION EC132000 ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. EC133000 GASKETS, OIL SEALS AND O-RINGS 1. ...

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1 - 5 GEN INFO CHECKING OF CONNECTION EC1C0000 CHECKING OF CONNECTION Dealing with stains, rust, moisture, etc. on the connector. 1. Disconnect: ● Connector 2. Dry each terminal with an air bower. 3. Connect and disconnect the connector two or thre...

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1 - 6 GEN INFO SPECIAL TOOLS SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. Th...

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1 - 7 GEN INFO SPECIAL TOOLS YM-1312-A, 90890-01312 Fuel level gauge This gauge is used to measure the fuel level in the float chamber. YM-1312-A 90890-01312 YU-33270-B, 90890-01362 Flywheel puller This tool is used to remove the rotor. YU-33270-B 9...

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1 - 8 GEN INFO SPECIAL TOOLS YM-4097, 90890-04097 YM-4098, 90890-04098 YM-04099, 90890-04099 Valve guide remover Valve guide installer Valve guide reamer These tools are needed to rebore the new valve guide. YM-4097 YM-4098 YM-04099 90890-04097 9089...

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1 - 9 GEN INFO CONTROL FUNCTIONS EC150000 CONTROL FUNCTIONS MAIN SWITCH (TT-R125E/TT-R125LWE) Functions of the respective switch positions are as follows: ON: The engine can be started only at this position. OFF: All electrical circuits are switched ...

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1 - 10 GEN INFO CONTROL FUNCTIONS 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 ...

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1 - 11 GEN INFO CONTROL FUNCTIONS 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 ...

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1 - 12 GEN INFO 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 illustrati...

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1 - 13 GEN INFO STARTING AND BREAK-IN EC190000 STARTING AND BREAK-IN CAUTION: 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; th...

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1 - 14 GEN INFO 5. Run the engine at idle or slightly higher until it warms up: this usually takes about one or two minutes. 6. The engine is warmed up when it responds normally to the throttle with the starter knob (CHOKE) turned off. NOTE: If the e...

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1 - 15 GEN INFO STARTING AND BREAK-IN 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. ● Cyl...

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1 - 16 GEN INFO TORQUE-CHECK POINTS TORQUE-CHECK POINTS TT-R125/TT-R125E Engine mounting Muffler Steering Steering stem to handlebar Suspension Front Steering stem to front fork Rear For link type Rear Installation of shock absorber Rear Installati...

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1 - 17 GEN INFO TORQUE-CHECK POINTS TT-R125LW/TT-R125LWE Engine mounting Muffler Steering Steering stem to handlebar Suspension Front Steering stem to front fork Rear For link type Rear Installation of shock absorber Rear Installation of swing- arm...

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1 - 18 GEN INFO CLEANING AND STORAGE EC1B0000 CLEANING AND STORAGE EC1B1000 CLEANING Frequent cleaning of your machine will enhance its appearance, maintain good overall performance, and extend the life of many com- ponents. 1. Before washing the mac...

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1 - 19 GEN INFO CLEANING AND STORAGE EC182001 STORAGE 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. Dra...

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SPEC 2 - 1 GENERAL SPECIFICATIONS EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS TT-R125/TT-R125E Model name: TT-R125W (CDN, AUS, NZ) TT-R125 (EUROPE, ZA) TT-R125EW (USA, CDN, AUS, NZ) TT-R125E (EUROPE, ZA) Model code number: TT-R125: 1B2H ...

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SPEC 2 - 2 GENERAL SPECIFICATIONS Oil type or grade: Engine oil (For USA and CDN) At –10 ˚C (10 ˚F) or higher Å Yamalube 4 (10W-30) or SAE 10W-30 type SE motor oil At 5 ˚C (40 ˚F) or higher ı Yamalube 4 (20W-40) or SAE 20W-40 type SE motor o...

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SPEC 2 - 3 GENERAL SPECIFICATIONS Transmission: Primary reduction system Gear Primary reduction ratio 68/19 (3.579) Secondary reduction system Chain drive Secondary reduction ratio 49/13 (3.769) Transmission type Constant mesh, 5-speed Operation Left...

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SPEC 2 - 4 GENERAL SPECIFICATIONS TT-R125LW/TT-R125LWE Model name: TT-R125LW (USA, CDN),TT-R125LWW( AUS, NZ) TT-R125LW (EUROPE, ZA) TT-R125LEW (USA, CDN),TT-R125LWEW(AUS, NZ) TT-R125LWE (EUROPE...

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SPEC 2 - 5 GENERAL SPECIFICATIONS Oil type or grade: Engine oil (For USA and CDN) At –10 ˚C (10 ˚F) or higher Å Yamalube 4 (10W-30) or SAE 10W-30 type SE motor oil At 5 ˚C (40 ˚F) or higher ı Yamalube 4 (20W-40) or SAE 20W-40 type SE motor o...

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SPEC 2 - 6 GENERAL SPECIFICATIONS Transmission: Primary reduction system Gear Primary reduction ratio 68/19 (3.579) Secondary reduction system Chain drive Secondary reduction ratio 54/13 (4.154) Transmission type Constant mesh, 5-speed Operation Left...

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SPEC 2 - 7 MAINTENANCE SPECIFICATIONS 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 mm (2.1260 ~ 2.1267 in) ---- Out of round limit ----...

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SPEC 2 - 8 MAINTENANCE SPECIFICATIONS Cam chain: Cam chain type/No. of links DID25SD DHA/88 ---- Cam 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)...

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SPEC 2 - 9 MAINTENANCE SPECIFICATIONS Stem runout limit ---- 0.01 mm (0.0004 in) Valve seat width IN 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.6 mm (0.0630 in) EX 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.6 mm (0.0630 in) Valve spring: Free length IN 32.55 mm...

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SPEC 2 - 10 MAINTENANCE SPECIFICATIONS 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) ---- (4...

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SPEC 2 - 11 MAINTENANCE SPECIFICATIONS Crankshaft: Crank width “A” 46.95 ~ 47.00 mm (1.848 ~ 1.850 in) ---- Runout limit “C” ---- 0.03 mm (0.0012 in) Big end side clearance “D” 0.15 ~ 0.45 mm (0.0059 ~ 0.0177 in) 0.5 mm (0.02 in) Clutch...

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SPEC 2 - 12 MAINTENANCE SPECIFICATIONS Lubrication system: Oil filter type Wire mesh type ---- Oil pump type Trochoid type ---- Tip clearance 0.15 mm (0.0059 in) 0.2 mm (0.0079 in) Side clearance 0.06 ~ 0.10 mm (0.0024 ~ 0.0039 in) 0.15 mm (0.0059 ...

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SPEC 2 - 13 MAINTENANCE SPECIFICATIONS Part to be tightened Thread size Q’ty 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 che...

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SPEC 2 - 14 MAINTENANCE SPECIFICATIONS NOTE: - marked portion shall be checked for torque tightening after break-in or before each ride. Cylinder head tightening sequence Segment M6 × 1.0 1 12 1.2 8.7 Stopper lever M6 × 1.0 1 10 1.0 7.2 Part to be ...

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SPEC 2 - 15 MAINTENANCE SPECIFICATIONS EC212201 CHASSIS TT-R125/TT-R125E 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) --...

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SPEC 2 - 16 MAINTENANCE SPECIFICATIONS 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 m...

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SPEC 2 - 17 MAINTENANCE SPECIFICATIONS 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. Retighte...

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SPEC 2 - 18 MAINTENANCE SPECIFICATIONS NOTE: - marked portion shall be checked for torque tightening after break-in or before each ride. Part to be tightened Thread size Q’ty Tightening torque Nm m•kg ft•lb Relay arm and connecting arm M10 × 1...

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SPEC 2 - 19 MAINTENANCE SPECIFICATIONS TT-R125LW/TT-R125LWE 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 sprin...

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SPEC 2 - 20 MAINTENANCE SPECIFICATIONS 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. �...

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SPEC 2 - 21 MAINTENANCE SPECIFICATIONS 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. Retighte...

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SPEC 2 - 22 MAINTENANCE SPECIFICATIONS NOTE: - marked portion shall be checked for torque tightening after break-in or before each ride. 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 D...

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SPEC 2 - 23 MAINTENANCE SPECIFICATIONS EC212300 ELECTRICAL TT-R125/TT-R125LW 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...

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SPEC 2 - 24 MAINTENANCE SPECIFICATIONS TT-R125E/TT-R125LWE Item Standard Limit CDI: Magneto-model/manufacturer 5HP-10/YAMAHA ---- Source coil resistance (color) 688 ~ 1,032 Ω at 20 ˚C (68 ˚F) (Brown – Green) ---- Pickup coil resistance (color) ...

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SPEC 2 - 25 MAINTENANCE SPECIFICATIONS Starter relay: Model/manufacturer MS5F-751/JIDECO ---- Amperage rating 180 A ---- Coil winding resistance 4.2 ~ 4.6 Ω at 20 ˚C (68 ˚F) ---- Starting circuit cut-off relay: Model/manufacturer ACM33221/MATSUSH...

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SPEC 2 - 26 EC220001 GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasten- ers with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sec- tions of this b...

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2 - 28 SPEC 1 Air vent hose 2 Spark plug lead 3 Starter cable 4 Throttle cable 5 Clutch cable 6 Clamp 7 Cable guide 8 Engine oil breather hose 9 Overflow hose Å After clamping the starter cable, push it against the starter plunger. ı Put the tip of...

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2 - 29 SPEC 1 Engine stop switch lead 2 Engine stop switch 3 Fuel tank breather hose 4 Clamp 5 Brake cable (Brake hose for the TT-R125LW) 6 Clutch cable 7 Throttle cable Å Pass the engine stop switch lead in the middle of the clutch holder. ı Clamp...

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F E G H I J K L D A B 3 C 0 1 2 3 3 3 3 3 3 3 4 5 666666 7 8 9 A B C S R Q P O N M L K J I H GGGGGG F E D B A C 30~35 m4 m (1 3i1. 8~1. 8 n) ...

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1 2 3 4 5 6 7 8 9 0 6 6 C B D F G E A B C D E F G J K L M N H ...

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1 2 3 4 5 6 7 8 9 0 6 6 C B D F G E A B C D E F G J K L M N H 2 - 34 SPEC ‰ Fasten the clutch cable with the paint in the cable guide bottom recess. Ï Pass the throttle cable and starter cable through the cable guide. Ì Fasten the starter motor l...

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2 - 35 SPEC 1 Clamp 2 Clutch switch lead 3 Engine stop switch lead 4 Brake hose (Brake cable for the TT-R125E) 5 Clutch cable 6 Throttle cable 7 Main switch lead 8 Start switch lead Å Fasten the clutch switch lead and engine stop switch lead to 3 cl...

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PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM NOTE: From 18 months or 4,200 mi (7,000 km) or 210 hours, repeat the maintenance intervals starting from 6 months or 1,800 mi (3,000 km) or 90 hours. Items marked with an asterisk should be p...

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GENERAL MAINTENANCE AND LUBRICATION CHART NOTE: From 18 months or 4,200 mi (7,000 km) or 210 hours, repeat the maintenance intervals starting from 6 months or 1,800 mi (3,000 km) or 90 hours. Items marked with an asterisk should be performed by a Yam...

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NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake service (TT-R125LW / TT-R125LWE) After disassembling the brake master cylinders and calipers, always change the fluid. Regulary check ...

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3 -4 INSP ADJ PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation or practice, make sure the machine is in good operating condi- tion. Before using this machine, check the following p...

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3 - 5 INSP ADJ ENGINE/CLUTCH ADJUSTMENT/ THROTTLE CABLE ADJUSTMENT EC350000 ENGINE CLUTCH ADJUSTMENT 1. Check: ● Clutch lever free play a Out of specification → Adjust. Clutch lever free play a: 10 ~ 15 mm (0.39 ~ 0.59 in) 2. Adjust: ● Clutch ...

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3 - 6 INSP ADJ THROTTLE LUBRICATION/AIR FILTER CLEANING THROTTLE LUBRICATION 1. Remove: ● Throttle cable cap 1 NOTE: Before adjusting the throttle cable free play, the engine idle speed should be adjusted. WARNING After adjusting, turn the handleb...

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3 - 7 INSP ADJ 1. Remove: ● Right side cover 1 NOTE: Loosen the quick screw 2 and remove the right side cover from the holding boss a. 2. Remove: ● Band 1 ● Air filter case cover 2 3. Remove: ● Air filter assembly 1 ● Wing nut 2 ● Wa...

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3 - 8 INSP ADJ ENGINE OIL LEVEL INSPECTION 6. Apply: ● Foam-air-filter oil or engine mixing oil To the element. NOTE: Squeeze out the excess oil. Element should be wet but not dripping. 7. Install: ● Air filter element 1 On air filter guide 2. 8...

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3 - 9 INSP ADJ ENGINE OIL LEVEL INSPECTION 4. Check: ● Oil level Oil level should be between maximum a and minimum b marks. Oil level is low → Add oil to proper level. NOTE: When inspecting the oil level, do not screw the dipstick into the oil ta...

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3 - 10 INSP ADJ ENGINE OIL REPLACEMENT 5. Install: ● Dipstick 6. Start the engine and let it warm up for several minutes. 7. Turn off the engine and inspect the oil level once again. NOTE: Wait a few minutes until the oil settles before inspecting ...

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3 - 11 INSP ADJ OIL PRESSURE INSPECTION/PILOT AIR SCREW ADJUSTMENT/ENGINE IDLING SPEED ADJUSTMENT OIL PRESSURE INSPECTION 1. Check: ● Oil pressure Checking steps: ● Slightly loosen the oil pressure check bolt 1. ● Start the engine and keep it i...

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3 - 12 INSP ADJ VALVE CLEARANCE INSPECTION AND ADJUSTMENT 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 compress...

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3 - 13 INSP ADJ VALVE CLEARANCE INSPECTION AND ADJUSTMENT 4. Check: ● Valve clearance 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) C...

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3 - 14 INSP ADJ VALVE CLEARANCE INSPECTION AND ADJUSTMENT ● Measure the valve clearance. ● If the clearance is incorrect, repeat above steps until specified clearance is obtained. 6. Install: ● O-ring 1 ● Crankshaft end accessing screw 2 �...

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3 - 15 INSP ADJ SPARK ARRESTER CLEANING (For USA) SPARK ARRESTER CLEANING (For USA) WARNING ● Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. ● Do not start the engine when cleaning the exhaust system. 1. Remove:...

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3 - 16 INSP ADJ EC360000 CHASSIS EC361012 BRAKE SYSTEM AIR BLEEDING (TT-R125LW/TT-R125LWE) WARNING Bleed the brake system if: ● The system has been disassembled. ● A brake hose has been loosened or removed. ● The brake fluid is very low. ● T...

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3 - 17 INSP ADJ 3. Install: ● Diaphragm ● Brake master cylinder cap NOTE: 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 hav...

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3 - 18 INSP ADJ TT-R125LW/TT-R125LWE 1. Check: ● Brake lever free play a Out of specification → Adjust. 2. Adjust: ● Brake lever free play CAUTION: Make sure that there is no brake drag after adjusting the brake lever free play. Brake lever fr...

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3 - 19 INSP ADJ BRAKE PEDAL HEIGHT ADJUSTMENT 1. Check: ● Brake pedal height a Out of specification → Adjust. 2. Adjust: ● Brake pedal height FRONT BRAKE PAD INSPECTION AND REPLACEMENT (TT-R125LW/TT-R125LWE) 1. Remove: ● Plug 2. Inspect: �...

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3 - 20 INSP ADJ 4. Inspect: ● Brake fluid level Refer to “BRAKE FLUID LEVEL INSPECTION” section. 5. Check: ● Brake lever operation A softy or spongy feeling → Bleed brake system. Refer to “BRAKE SYSTEM AIR BLEEDING” section. FRONT BRAKE...

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3 - 21 INSP ADJ REAR BRAKE SHOE INSPECTION 1. Inspect: ● Brake shoe lining wear limit BRAKE FLUID LEVEL INSPECTION (TT-R125LW/TT-R125LWE) 1. Place the brake master cylinder so that its top is in a horizontal position. 2. Inspect: ● Brake fluid le...

[Page 94] Yamaha TT-R125E(W)

3 - 22 INSP ADJ DRIVE CHAIN INSPECTION 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 ...

[Page 95] Yamaha TT-R125E(W)

3 - 23 INSP ADJ DRIVE CHAIN SLACK ADJUSTMENT 6. Lubricate: ● Drive chain Drive chain lubricant: SAE 10W-30 motor oil or suit- able chain lubricants DRIVE CHAIN SLACK ADJUSTMENT 1. Elevate the rear wheel by placing the suitable stand under the engin...

[Page 96] Yamaha TT-R125E(W)

3 - 24 INSP ADJ FRONT FORK INSPECTION/FRONT FORK SPRING PRELOAD ADJUSTMENT (TT-R125LWE) EC36C000 FRONT FORK INSPECTION 1. Inspect: ● Front fork smooth action Operate the front brake and stroke the front fork. Unsmooth action/oil leakage → Repair ...

[Page 97] Yamaha TT-R125E(W)

3 - 25 INSP ADJ 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 P...

[Page 98] Yamaha TT-R125E(W)

3 - 26 INSP ADJ 5. Tighten: ● Locknut 6. Install: ● Left side cover T R . . 42 Nm (4.2 m · kg, 30 ft · lb) T R . . 7 Nm (0.7 m · kg, 5.1 ft · lb) EC36N014 REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT (TT-R125LWE) 1. Adjust: ● ...

[Page 99] Yamaha TT-R125E(W)

3 - 27 INSP ADJ EC36c000 REAR SHOCK ABSORBER COMPRESSION DAMPING FORCE ADJUSTMENT (TT-R125LWE) 1. Adjust: ● Compression damping force By turning the adjuster 1. Stiffer a → Increase the compression damping force. (Turn the adjuster 1 in.) Softe...

[Page 100] Yamaha TT-R125E(W)

3 - 28 INSP ADJ TIRE PRESSURE CHECK/SPOKES INSPECTION AND TIGHTENING/WHEEL INSPECTION EC36Q000 TIRE PRESSURE CHECK 1. Measure: ● Tire pressure Out of specification → Adjust. NOTE: ● Check the tire while it is cold. ● Loose bead stoppers allow...