TT-R125EY TT-R125LEY SERVICE MANUAL LIT-11626-22-26 1B2-F8197-14
EC010000 TT-R125EY/TT-R125LEY SERVICE MANUAL ©2008 by Yamaha Motor da Amazônia Ltda. 1st Edition, June 2008 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor da Amazônia Ltda. is expressly prohibited. Printed in Brazil P/N.
INTRODUCTION IMPORTANT MANUAL INFORMATION Congratulations on your purchase of a Yamaha TT-R125E/TT-R125LE. 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.
YAMAHA MOTOR CORPORATION, U.S.A. OFF-ROAD MOTORCYCLE LIMITED WARRANTY YAMAHA MOTOR CORPORATION, U.S.A. OFF-ROAD MOTORCYCLE LIMITED WARRANTY Yamaha Motor Corporation, USA hereby warrants that new Yamaha off-road motorcycles purchased from an authorized Yamaha motorcycle dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein, subject to certain stated limitations.
SAFETY INFORMATION THIS MACHINE IS DESIGNED FOR OFFROAD USE ONLY. 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. THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY. Do not carry passengers on this machine. 2. ALWAYS WEAR PROTECTIVE APPAREL. When operating this machine, always wear an approved helmet with goggles or a face shield.
. ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE VENTILATION. Never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes are poisonous. These fumes contain carbon monoxide, which by itself is odorless and colorless. Carbon monoxide is a dangerous gas which can cause unconsciousness or can be lethal. 7. PARK THE MACHINE CAREFULLY; TURN OFF THE ENGINE. Always turn off the engine if you area going to leave the machine.
EC080000 HOW TO USE THIS MANUAL 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.
EC083000 MANUAL FORMAT 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.
1 ILLUSTRATED SYMBOLS (Refer to the illustration) 2 GEN INFO SPEC Illustrated symbols 1 to 6 are designed as thumb tabs to indicate the chapter’s number and content. 4 3 INSP ADJ ENG 5 6 ELEC CHAS 7 – 0 A B General information Specifications Regular inspection and adjustments Engine Chassis Electrical Illustrated symbols 7 to D are used to identify the specifications appearing in the text.
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INDEX GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS GEN INFO 1 SPEC 2 INSP ADJ 3 ENG 4 CHAS 5 ENGINE CHASSIS – ELECTRICAL ELEC + 6
EC0A0000 CONTENTS CHAPTER 1 GENERAL INFORMATION MACHINE IDENTIFICATION .................... IMPORTANT INFORMATION ................... CHECKING OF CONNECTION ............... SPECIAL TOOLS ...................................... 1-1 1-2 1-4 1-5 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ................. 2-1 TT-R125E ............................................... 2-1 TT-R125LE ............................................. 2-4 MAINTENANCE SPECIFICATIONS ........ 2-7 ENGINE .............................
CHAPTER 3 REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS .................. 3-1 PRE-OPERATION INSPECTION AND MAINTENANCE ............................... 3-4 ENGINE ..................................................... 3-5 CHASSIS ................................................. 3-16 ELECTRICAL .......................................... 3-33 CHAPTER 4 ENGINE SEAT, FUEL TANK AND SIDE COVERS ................................. 4-1 MUFFLER ..................................................
CHAPTER 5 CHASSIS FRONT WHEEL AND FRONT BRAKE (TT-R125E) ................................................ 5-1 FRONT WHEEL (TT-R125LE) .............................................. 5-8 FRONT BRAKE (TT-R125LE) ............................................ 5-12 REAR WHEEL AND REAR BRAKE ...... 5-24 FRONT FORK ......................................... 5-32 HANDLEBAR .......................................... 5-42 STEERING .............................................. 5-50 SWINGARM .............................
MACHINE IDENTIFICATION GEN INFO 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 of the model you own. 2. If your machine is stolen, the authorities will need the number to search for and identify your machine. KEY IDENTIFICATION NUMBER The key identification number 1 is stamped on the key as shown in the following illustration.
IMPORTANT INFORMATION GEN INFO 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. • Silencer exhaust port 2. Use proper tools and cleaning equipment. Refer to "SPECIAL TOOLS" section. 3. When disassembling the machine, keep mated parts together.
IMPORTANT INFORMATION GEN INFO 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.
CHECKING OF CONNECTION GEN INFO 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 three times. 4. Pull the lead to check that it will not come off. 5. If the terminal comes off, bend up the pin 1 and reinsert the terminal into the connector. 6. Connect: • Connector TIP The two connectors "click" together. 7. Check for continuity with a tester.
SPECIAL TOOLS GEN INFO SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an order. TIP • For U.S.A. and CDN, use part number starting with "YM-", "YU-", "YS-" or "ACC-".
SPECIAL TOOLS Part number YM-8035, 90890-01311 Tool name/How to use Tappet adjusting tool GEN INFO Illustration YM-8035 90890-01311 YM-1312-A 90890-01312 YU-33270-B 90890-01362 YM-33963 YM-33281 90890-01367 90890-01400 YU-33975 90890-01403 YS-1880-A 90890-01701 YU-3112-C 90890-03112 YU-8036-B 90890-03113 YM-4019 90890-04019 This tool is necessary for adjusting valve clearance. YM-1312-A, 90890-01312 Fuel level gauge This gauge is used to measure the fuel level in the float chamber.
SPECIAL TOOLS Part number Tool name/How to use YM-91042, 90890-04086 Clutch holding tool GEN INFO Illustration YM-91042 90890-04086 YM-4097 YM-4098 YM-04099 90890-04097 90890-04098 90890-04099 YM-34487 90890-06754 This tool is used to hold the clutch when removing or installing the clutch boss securing nut.
GENERAL SPECIFICATIONS SPEC EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS TT-R125E Model name: TT-R125EY Model code number: 39C1 Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Basic weight: With oil and full fuel tank 1,845 mm (72.6 in) 785 mm (30.9 in) 1,060 mm (41.7 in) 775 mm (30.5 in) 1,250 mm (49.2 in) 265 mm (10.4 in) 90 kg (198.
GENERAL SPECIFICATIONS SPEC Oil type or grade: Engine oil At -10 °C (10 °F) or higher A Yamalube 4 (10W-30) or SAE 10W-30 type SE motor oil At 5 °C (40 °F) or higher B Yamalube 4 (20W-40) or SAE 20W-40 type SE motor oil Oil capacity: Engine oil Periodic oil change Total amount 1.0 L (0.88 Imp qt, 1.06 US qt) 1.2 L (1.06 Imp qt, 1.27 US qt) Air filter: Wet type element Fuel: Type Tank capacity Reserve amount Unleaded gasoline only 6.0 L (1.31 Imp gal, 1.58 US gal) 0.83 L (0.18 Imp gal, 0.
GENERAL SPECIFICATIONS SPEC Transmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio: 1st 2nd 3rd 4th 5th Gear 68/19 (3.579) Chain drive 49/13 (3.769) Constant mesh, 5-speed Left foot operation 37/14 (2.643) 32/18 (1.778) 25/19 (1.316) 23/22 (1.045) 21/24 (0.875) Chassis: Frame type Caster angle Trail Diamond 28.7° 93 mm (3.
GENERAL SPECIFICATIONS SPEC TT-R125LE Model name: TT-R125LEY Model code number: 19CA Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance 1,885 mm (74.2 in) 795 mm (31.3 in) 1,085 mm (42.7 in) 805 mm (31.7 in) 1,270 mm (50.0 in) 295 mm (11.6 in) Basic weight: With oil and full fuel tank 90 kg (198.
GENERAL SPECIFICATIONS SPEC Oil type or grade: Engine oil At -10 °C (10 °F) or higher A Yamalube 4 (10W-30) or SAE 10W-30 type SE motor oil At 5 °C (40 °F) or higher B Yamalube 4 (20W-40) or SAE 20W-40 type SE motor oil Oil capacity: Engine oil Periodic oil change Total amount 1.0 L (0.88 Imp qt, 1.06 US qt) 1.2 L (1.06 Imp qt, 1.27 US qt) Air filter: Wet type element Fuel: Type Unleaded gasoline only Tank capacity Reserve amount 6.0 L (1.31 Imp gal, 1.58 US gal) 0.83 L (0.18 Imp gal, 0.
GENERAL SPECIFICATIONS SPEC Transmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio: 1st 2nd 3rd 4th 5th Gear 68/19 (3.579) Chain drive 54/13 (4.154) Constant mesh, 5-speed Left foot operation 37/14 (2.643) 32/18 (1.778) 25/19 (1.316) 23/22 (1.045) 21/24 (0.875) Chassis: Frame type Caster angle Trail Diamond 28.5° 107 mm (4.
MAINTENANCE SPECIFICATIONS SPEC EC212000 MAINTENANCE SPECIFICATIONS EC212100 ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.03 mm (0.0012 in) 54.000 ~ 54.019 mm (2.1260 ~ 2.1267 in) ---- ---- Chain drive (left) ---- 25.881 ~ 25.981 mm (1.0189 ~ 1.0229 in) 21.195 ~ 21.295 mm (0.8344 ~ 0.8384 in) 25.841 ~ 25.941 mm (1.0174 ~ 1.0213 in) 21.050 ~ 21.150 mm (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) 0.03 mm (0.
MAINTENANCE SPECIFICATIONS SPEC Item Standard Cam chain: Cam chain type/No. of links Cam chain adjustment method Rocker arm/rocker arm shaft: Shaft outside diameter Rocker arm inside diameter Valve, valve seat, valve guide: Valve clearance (cold) IN SCR - 0404 SV/90 Automatic ------- 9.981 ~ 9.991 mm (0.3930 ~ 0.3933 in) 10.000 ~ 10.015 mm (0.3937 ~ 0.3943 in 9.95 mm (0.3917 in) 10.03 mm (0.3949 in) 0.08 ~ 0.12 mm (0.0031 ~ 0.0047 in) 0.10 ~ 0.14 mm (0.0039 ~ 0.
MAINTENANCE SPECIFICATIONS SPEC Item Standard Stem run out limit Valve seat width ---- 0.01 mm (0.0004 in) 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.6 mm (0.0630 in) 1.6 mm (0.0630 in) IN 38.78 mm (1.52 in) EX 38.78 mm (1.52 in) IN EX 25.6 mm (1.01 in) 25.6 mm (1.01 in) 36.84 mm (1.45 in) 36.84 mm (1.45 in) ------- IN 191 ~ 219 N ---(19.5 ~ 22.3 kgf, 42.93 ~ 49.23 lbf) 191 ~ 219 N ---(19.5 ~ 22.3 kgf, 42.93 ~ 49.23 lbf) ---2.5°/1.7 mm 2.5°/0.07 in ---2.5°/1.
MAINTENANCE SPECIFICATIONS SPEC Item Standard Piston: Piston to cylinder clearance Piston size "D" Limit 0.020 ~ 0.026 mm (0.0008 ~ 0.0010 in) 53.977 ~ 53.996 mm (2.1251 ~ 2.1258 in) 0.15 mm (0.0059 in) ---- 54.5 mm (2.1457 in) 55.0 mm (2.1654 in) 5 mm (0.20 in) 0.5 mm (0.0197 in) 15.002 ~ 15.013 mm (0.5906 ~ 0.5911 in) 14.991 ~ 15.000 mm (0.5902 ~ 0.5906 in) ------------15.043 mm (0.5922 in) 14.971 mm (0.5894 in) Barrel 1.0 × 2.1 mm (0.04 × 0.08 in) 0.15 ~ 0.30 mm (0.006 ~ 0.012 in) 0.035 ~ 0.
MAINTENANCE SPECIFICATIONS SPEC Item Standard Crankshaft: Crank width "A" 46.95 ~ 47.00 mm (1.848 ~ 1.850 in) Runout limit "C" Big end side clearance "D" 0.15 ~ 0.45 mm (0.0059 ~ 0.0177 in) Clutch: Friction plate thickness 2.92 ~ 3.08 mm (0.115 ~ 0.121 in) 5 1.05 ~ 1.35 mm (0.041 ~ 0.053 in) 4 ---- Quantity Clutch plate thickness Quantity Warp limit Clutch spring free length 33 mm (1.30 in) Quantity Clutch release method Push rod bending limit 4 Inner push, cam push ---- Limit ---0.03 mm (0.
MAINTENANCE SPECIFICATIONS SPEC Item Standard Limit Lubrication system: Oil filter type Oil pump type Tip clearance Side clearance Housing and rotor clearance Wire mesh type Trochoid type 0.15 mm (0.0059 in) 0.06 ~ 0.10 mm (0.0024 ~ 0.0039 in) 0.06 ~ 0.10 mm (0.0024 ~ 0.0039 in) 2-12 ------0.2 mm (0.0079 in) 0.15 mm (0.0059 in) 0.15 mm (0.
MAINTENANCE SPECIFICATIONS SPEC Part to be tightened Î Î Î Spark plug Cylinder head bolt Cylinder head bolt Oil pressure check bolt Cylinder head side cover Tappet cover Timing chain guide Adjusting screw (valve) and locknut Camshaft sprocket Bearing plate cover (camshaft) Timing chain tensioner cap bolt Timing chain tensioner Oil pump assembly Oil pump cover Engine oil drain bolt Carburetor joint Carburetor joint clamp (air filter) Coasting enricher cover Air filter case Muffler Muffler Muffler Muffler g
MAINTENANCE SPECIFICATIONS SPEC Part to be tightened Segment Stopper lever Thread size M6 × 1.0 M6 × 1.0 Q'ty 1 1 Tightening torque Nm m•kg ft•lb 12 10 1.2 1.0 TIP - marked portion shall be checked for torque tightening after break-in or before each ride. Î Cylinder head tightening sequence 2-14 8.7 7.
MAINTENANCE SPECIFICATIONS SPEC EC212201 CHASSIS TT-R125E Item Steering system: Steering bearing type Standard (upper) (lower) Limit Angular bearing Taper roller bearing ------- 180 mm (7.09 in) 478.7 mm (18.82 in) K = 3.00 N/mm (0.310 kg/mm, 17.4 lb/in) No 171 cm3 (6.02 Imp oz, 5.78 US oz) 120 mm (4.72 in) Fork oil 10W or equivalent 31 mm (1.22 in) Zero mm (Zero in) --472,2mm (18.59 in) --- 65 mm (2.56 in) 178 mm (7.01 in) 165 mm (6.50 in) K = 50.5 N/mm (5.
MAINTENANCE SPECIFICATIONS SPEC Item Drum brake: Front drum brake type Rear drum brake type Front drum inside diameter Rear drum inside diameter Front lining thickness Rear lining thickness Front shoe spring free length Rear shoe spring free length Brake lever and brake pedal: Brake lever free play (lever end) Brake pedal position (vertical height below footrest top) Brake pedal free play Clutch lever free play (lever end) Throttle grip free play Standard Leading, trailing Leading, trailing 110 mm (4.
MAINTENANCE SPECIFICATIONS SPEC Part to be tightened Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Upper bracket and inner tube Lower bracket and inner tube Upper bracket and steering stem Handlebar upper holder and upper bracket Steering stem and ring nut Front fork and cap bolt Front fork and damper rod Front fork and brake cable holder Number plate Starter knob Starter knob stay Grip cap upper and lower Throttle cable cap Brake lever mounting (bolt) Brake lever mounting (nut) Brake lever holder Clutch lever mou
MAINTENANCE SPECIFICATIONS SPEC Part to be tightened Î Î Î Î Î Î Thread size Relay arm and connecting arm Connecting arm and frame Rear shock absorber assembly and frame Rear shock absorber assembly and relay arm Rear shock absorber and locknut (preload) Drive chain tensioner (upper) Drive chain tensioner (lower) Drive chain support and swingarm Drive chain guide and swingarm Drive chain guard mounting Fuel tank mounting Fuel tank and fuel cock Fuel tank and fuel tank bracket Front fender mounting Rear
MAINTENANCE SPECIFICATIONS SPEC TT-R125LE Item Steering system: Steering bearing type Standard (upper) (lower) Limit Angular bearing Taper roller bearing ------- 180 mm (7.09 in) 469.4 mm (18. 46 in) K = 3.20 N/mm (0.330 kg/mm, 18.5 lb/in) No 164 cm3 (5.77 Imp oz, 5.54 US oz) 134 mm (5.27 in) Fork oil 10W or equivalent 31 mm (1.22 in) Zero mm (Zero in) --463.9 mm (18.
MAINTENANCE SPECIFICATIONS SPEC Item Drive chain: Type/manufacturer Number of links Chain slack Chain length (15 links) Front disc brake: Disc outside dia. × Thickness Deflection limit Pad thickness Master cylinder inside dia. Caliper cylinder inside dia.
MAINTENANCE SPECIFICATIONS SPEC Part to be tightened Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Upper bracket and inner tube Lower bracket and inner tube Upper bracket and steering stem Handlebar upper holder and upper bracket Steering stem and ring nut Front fork and cap bolt Front fork and damper rod Front fork and brake cable hose holder Number plate Starter knob Starter knob stay Grip cap upper and lower Throttle cable cap Front brake master cylinder Front brake master cylinder cap Brake lever mounting (bolt
MAINTENANCE SPECIFICATIONS SPEC Part to be tightened Î Î Î Î Î Î Î Î Î Î Î Î Î Î Thread size Bead stopper Driven sprocket (nut) Driven sprocket (stud) Sidestand mounting (nut) Engine mounting: Engine bracket (front) and frame Engine bracket (front) and engine Engine bracket (upper) and frame Engine bracket (upper) and cylinder head Engine and frame (rear) Pivot shaft and nut Relay arm and swingarm Relay arm and connecting arm Connecting arm and frame Rear shock absorber assembly and frame Rear shock abs
MAINTENANCE SPECIFICATIONS SPEC EC212300 ELECTRICAL Item CDI: Magneto-model (stator)/manufacturer Source coil resistance (color) Pickup coil resistance (color) CDI unit-model/manufacturer Standard Limit F1B2/MORIC 688 ~ 1,032 Ω at 20 °C (68 °F) (Brown – Green) 248 ~ 372 Ω at 20 °C (68 °F) (Red – White) 5HP-00/MORIC ----- 2JN/MORIC 6 mm (0.24 in) 0.18 ~ 0.28 Ω at 20 °C (68 °F) 6.3 ~ 9.5 kΩ at 20 °C (68 °F) --------- Resin 10 kΩ at 20 °C (68 °F) ----- CDI magneto 0.64 ~ 0.
MAINTENANCE SPECIFICATIONS SPEC Item Starter relay: Model/manufacturer Amperage rating Coil winding resistance Standard Limit MS5F-751/JIDECO 180 A 4.2 ~ 4.6 Ω at 20 °C (68 °F) ------- ACM33221 M06/Nais 75.69 ~ 92.51 Ω at 20 °C (68 °F) ----- 10 A × 1 10 A × 1 ----- Starting circuit cut-off relay: Model/manufacturer Coil winding resistance Fuse (amperage × quantity): Main fuse Reserve fuse Part to be tightened Pickup coil Neutral switch Stator Rotor Ignition coil Starter motor Thread size M6 × 1.
GENERAL TORQUE SPECIFICATIONS/ DEFINITION OF UNITS SPEC EC220001 GENERAL TORQUE SPECIFICATIONS This char t 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.
CABLE ROUTING DIAGRAM SPEC EC240000 CABLE ROUTING DIAGRAM 1 2 3 4 5 6 7 8 9 0 Ground lead Primary coil lead Clamp Wire harness Starter relay lead Rectifier/regulator lead CDI magneto lead Air vent hose Neutral switch lead Rear shock absorber assembly sub-tank hose (TT-R125LE only) A Starting circuit cut-off relay lead B CDI unit lead C Corrugated tube D Brake hose holder (Brake cable holder for the TT-R125E) E Brake hose (Brake cable for the TT-R125E) F Cable guide G Main switch lead H Engine stop switch
CABLE ROUTING DIAGRAM SPEC E Fasten the CDI magneto lead and starter relay lead. F Fasten the wire harness. G Pass the rectifier/regulator lead between the frame and air filter case. H Do not allow the CDI magneto lead to slacken except between the two plastic locking ties. I Fasten the CDI magneto lead over the engine bracket (rear). J Fasten the CDI magneto lead. K Pass the air vent hoses between the engine and swingam. L Fit the neutral switch lead into the groove in the crankcase cover.
CABLE ROUTING DIAGRAM SPEC U After connecting the main switch coupler, engine stop switch coupler, clutch switch coupler and start switch coupler, put a connector cover on the couplers and push them in at the rubber cover end. V Pass the wire harness on the oustide of the main switch coupler. W Do not allow the primary coil lead to slacken where it is bare of the protecting tube.
CABLE ROUTING DIAGRAM SPEC 1 2 3 4 5 6 7 8 9 0 A B C D E F G Throttle cable Clutch cable Starter cable Fuel tank breather hose Hose guide Clamp Cable guide Starting circuit cut-off relay Spark plug lead Starter motor lead Negative battery lead A Tighten the starter choke nut while taking care not to twist the starter cable.
CABLE ROUTING DIAGRAM SPEC E Fasten the clutch cable with the paint in the cable guide bottom recess. F Pass the throttle cable and starter cable through the cable guide. G Fasten the starter motor lead. H Pass the air vent hose between the swingarm and the frame, and the overflow hose between the engine and the swingarm. I Pass the negative battery lead on the inside of the frame as shown. J Fasten the overflow hose and air vent hoses to 2 clicks.
CABLE ROUTING DIAGRAM SPEC 1 2 3 4 5 6 7 8 Clamp Clutch switch lead Engine stop switch lead Brake hose (Brake cable for the TT-R125E) Clutch cable Throttle cable Main switch lead Start switch lead A Fasten the clutch switch lead and engine stop switch lead to 3 clicks. B Pass the brake hose (brake cable for the TT-R125E) in front of the number plate and through the cable guide. C Pass the clutch cable in back of the number plate.
INSP ADJ MAINTENANCE INTERVALS REGULAR INSPECTION AND ADJUSTMENTS PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM TIP 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 Yamaha dealer as they require special tools, data and technical skills. For TT-Rs not equipped with an odometer or an hour meter, follow the month maintenance intervals.
INSP ADJ MAINTENANCE INTERVALS GENERAL MAINTENANCE AND LUBRICATION CHART TIP 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 Yamaha dealer as they require special tools, data and technical skills. For TT-Rs not equipped with an odometer or an hour meter, follow the month maintenance intervals.
INSP ADJ MAINTENANCE INTERVALS INITIAL Nº ITEM CHECKS AND MAINTENANCE JOBS Whichever month comer first mi (km) hours 11 * Steering bearings Check bearing assemblies for looseness. Lubricate with litium soap based grease every 2,400 mi (4,000 km) or 120 hours or 12 months (whichever comes first). 1 ODOMETER READINGS 6 600 1,800 (1,000) (3,000) 30 90 3 12 3,000 (5,000) 150 3 12 Brake and clutch Apply lithium soap based grease lightly.
PRE-OPERATION INSPECTION AND MAINTENANCE INSP ADJ PRE-OPERATION INSPECTION AND MAINTENANCE 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.
ENGINE/CLUTCH ADJUSTMENT/ THROTTLE CABLE ADJUSTMENT INSP ADJ 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 lever free play Clutch lever free play adjustment steps: • Loosen the locknut 1. • Turn the adjuster 2 until free play a is within the specified limits. • Tighten the locknut. TIP • Make minute adjustment on the lever side.
THROTTLE LUBRICATION/AIR FILTER CLEANING INSP ADJ TIP 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: • Grip cap (lower) 1 2. Apply: • Lithium soap base grease On the throttle cable end a and tube guide cable winding portion b. 3. Install: • Grip cap (lower) 4 Nm (0.4 m · kg, 2.
AIR FILTER CLEANING INSP ADJ 1. Remove: • Right side cover 1 a TIP 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 • Washer 3 • Air filter element 4 • Air filter guide 5 4. Clean: • Air filter element Clean it with solvent. TIP After cleaning, remove the remaining solvent by squeezing the element. NOTICE Do not twist the element when squeezing the element. 5.
ENGINE OIL LEVEL INSPECTION INSP ADJ 6. Apply: • Yamaha foam air filter oil or other quality foam air filter oil. TIP Squeeze out the excess oil. Element should be wet but not dripping. 7. Install: • Air filter element 1 On air filter guide 2 8. Apply: • Lithium soap base grease On the matching surface a on air filter element. 9. Install: • Air filter element 1 • Washer 2 • Wing nut 3 ENGINE OIL LEVEL INSPECTION 1. Start the engine, warm it up for several minutes and wait for five minutes. 2.
ENGINE OIL LEVEL INSPECTION INSP ADJ 4. Check: • Oil level Oil level should be between maximum a and minimum b marks. Oil level is low → Add oil to proper level. TIP When inspecting the oil level, do not screw the dipstick into the oil tank. Insert the gauge lightly. Recommended oil: At -10 °C (10 °F) or higher A: Yamalube 4 (10W-30) or SAE 10W-30 type SE motor oil At 5 °C (40 °F) or higher B: Yamalube 4 (20W-40) or SAE 20W-40 type SE motor oil NOTICE • Do not add any chemical additives.
ENGINE OIL REPLACEMENT INSP ADJ 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. TIP 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.
OIL PRESSURE INSPECTION / ENGINE IDLING SPEED ADJUSTMENT INSP ADJ 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.
VALVE CLEARANCE INSPECTION AND ADJUSTMENT INSP ADJ Adjustment steps: • Adjust the pilot air screw. Refer to "PILOT AIR SCREW ADJUSTMENT" 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.
VALVE CLEARANCE INSPECTION AND ADJUSTMENT INSP ADJ 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) Checking steps: • Turn the crankshaft counterclockwise with a wrench. • Align the T.D.C. mark a on the rotor with the align mark b on the crankcase cover when piston is at T.D.C. on compression stroke. • Measure the valve clearance using a feeler gauge 1.
VALVE CLEARANCE INSPECTION AND ADJUSTMENT INSP ADJ • 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) TIP 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.
SPARK ARRESTER CLEANING INSP ADJ SPARK ARRESTER CLEANING 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: • Bolt (spark arrester) 1 2. Remove: • Cap 1 • Spark arrester 2 Pull the spark arrester out of the muffler. 3. Clean: • Spark arrester Tap the spark arrester lightly, then use a wire brush to remove any carbon deposits 4.
CHASSIS / BRAKE SYSTEM AIR BLEEDING (TT-R125LE) INSP ADJ EC360000 CHASSIS EC361012 BRAKE SYSTEM AIR BLEEDING (TT-R125LE) 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. • The brake operation is faulty. A dangerous loss of braking performance may occur if the brake system is not properly bled. 1. Remove: • Brake master cylinder cap • Diaphragm 2. Bleed: • Brake fluid Air bleeding steps: a.
FRONT BRAKE ADJUSTMENT INSP ADJ TIP 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. 3. Install: • Diaphragm • Brake master cylinder cap FRONT BRAKE ADJUSTMENT TT-R125E 1. Check: • Brake lever free play a Out of specification → Adjust.
REAR BRAKE ADJUSTMENT INSP ADJ TT-R125LE 1. Check: • Brake lever free play a Out of specification → Adjust. Brake lever free play a: 2 ~ 5 mm (0.08 ~ 0.20 in) 2. Adjust: • Brake lever free play Brake lever free play adjustment steps: • Loosen the locknut 1. • Turn the adjuster 2 until the free play a is within the specified limits. • Tighten the locknut. NOTICE Make sure that there is no brake drag after adjusting the brake lever free play. REAR BRAKE ADJUSTMENT 1.
BRAKE PEDAL HEIGHT ADJUSTMENT/FRONT BRAKE PAD INSPECTION AND REPLACEMENT (TT-R125LE) INSP ADJ BRAKE PEDAL HEIGHT ADJUSTMENT 1. Check: • Brake pedal height a Out of specification → Adjust. Brake pedal height a: 1 mm (0.04 in) 2. Adjust: • Brake pedal height Pedal height adjustment steps: • Loosen the locknut 1. • Turn the adjusting bolt 2 until the pedal height a is within specified height. • Tighten the locknut. FRONT BRAKE PAD INSPECTION AND REPLACEMENT (TT-R125LE) 1. Remove: • Plug 2.
FRONT BRAKE SHOE INSPECTION (TT-R125E) INSP ADJ • 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. NOTICE 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. TIP Apply the lithium soap base grease on the caliper support bolt Brake caliper support bolt: 22 Nm (2.
REAR BRAKE SHOE INSPECTION / BRAKE FLUID LEVEL INSPECTION (TT-R125LE) / SPROCKETS INSPECTION INSP ADJ REAR BRAKE SHOE INSPECTION 1. Inspect: • 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 a. Outside the limit → Replace the brake shoe. Refer to "REAR WHEEL AND REAR BRAKE" section in the CHAPTER 5. BRAKE FLUID LEVEL INSPECTION (TT-R125LE) 1.
DRIVE CHAIN INSPECTION INSP ADJ 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 (15 links) a Out of specification → Replace. Drive chain length (15 links): : 194.3 mm (7.65 in) 4. Check: • Drive chain stiffness a Clean and oil the chain and hold as illustrated.
DRIVE CHAIN SLACK ADJUSTMENT INSP ADJ 6. 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 a In the center between the drive axle and rear wheel axle. Out of specification → Adjust. Drive chain slack: 35 ~ 50 mm (1.4 ~ 2.
FRONT FORK INSPECTION/FRONT FORK SPRING PRELOAD ADJUSTMENT (TT-R125LE) INSP ADJ 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. FRONT FORK SPRING PRELOAD ADJUSTMENT (TT-R125LE) 1 a b 1 2 3 4 1. Adjust: • Spring preload By turning the adjuster 1. Stiffer a → Increase the spring preload. (Turn the adjuster 1 in.) Softer b → Decrease the spring preload. (Turn the adjuster 1 out.
REAR SHOCK ABSORBER ASSEMBLY INSPECTION / REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 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 PRELOAD ADJUSTMENT 1. Elevate the rear wheel by placing the suitable stand under the engine. 2. Remove: • Left side cover 3. Loosen: • Locknut 1 4.
REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT (TT-R125LE) INSP ADJ 5. Tighten: • Locknut 42 Nm (4.2 m · kg, 30 ft · lb) 6. Install: • Left side cover 7 Nm (0.7 m · kg, 5.1 ft · lb) EC36N014 REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT (TT-R125LE) a b 1 1. Adjust: • Rebound damping force By turning the adjuster 1. Stiffer a → Increase the rebound damping force. (Turn the adjuster 1 in.) Softer b → Decrease the rebound damping force. (Turn the adjuster 1 out.
REAR SHOCK ABSORBER COMPRESSION DAMPING FORCE ADJUSTMENT (TT-R125LE) INSP ADJ EC36c000 REAR SHOCK ABSORBER COMPRESSION DAMPING FORCE ADJUSTMENT (TT-R125LE) b a 1 1. Adjust: • Compression damping force By turning the adjuster 1. Stiffer a → Increase the compression damping force. (Turn the adjuster 1 in.) Softer b → Decrease the compression damping force. (Turn the adjuster 1 out.
TIRE PRESSURE CHECK/SPOKES INSPECTION AND TIGHTENING/WHEEL INSPECTION INSP ADJ EC36Q000 TIRE PRESSURE CHECK 1. Measure: • Tire pressure Out of specification → Adjust. Standard tire pressure: 100 kPa (1.00 kgf/cm2, 15 psi) TIP • 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.
STEERING HEAD INSPECTION AND ADJUSTMENT INSP ADJ 2. Inspect: • Bearing free play Exist play → Replace. 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. 3. Check: • Steering smooth action Turn the handlebar lock to lock. Unsmooth action → Adjust steering ring nut. 4.
STEERING HEAD INSPECTION AND ADJUSTMENT INSP ADJ • Tighten the lower ring nut 6 using steering nut wrench 7 and turn the steering right and left a few times. TIP 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.
STEERING HEAD INSPECTION AND ADJUSTMENT INSP ADJ NOTICE 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.
LUBRICATION INSP ADJ LUBRICATION To ensure smooth operation of all components, lubricate your machine during setup, after breakin, and after every ride. 1 2 3 4 5 6 7 8 9 All control cable Brake and clutch lever pivots Shift pedal pivot Footrest pivot Throttle-to-handlebar contact Drive chain Tube guide cable winding portion Throttle cable end Brake and clutch cable ends (Clutch cable end only for the TT-R125LE) A Use Yamaha cable lube or equivalent on these areas.
ELECTRICAL/SPARK PLUG INSPECTION INSP ADJ EC370000 ELECTRICAL EC371001 SPARK PLUG INSPECTION 1. Remove: • Spark plug 2. 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. TIP 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. 3.
BATTERY INSPECTION AND CHARGING INSP ADJ BATTERY INSPECTION AND CHARGING WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries. • Charge batteries in a well-ventilated area. • Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes).
BATTERY INSPECTION AND CHARGING INSP ADJ TIP Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Remove: • Battery cover 2. Disconnect: • Battery leads (from the battery terminals) NOTICE First, disconnect the negative battery lead 1, and then the positive battery lead 2. 3. Remove: • Battery 4.
BATTERY INSPECTION AND CHARGING INSP ADJ • Check the charge of the battery, as shown in the charts and the following example. Example Open-circuit voltage = 12.0 V Charging time = 6.5 hours Charge of the battery = 20 ~ 30% A Relationship between the open-circuit voltage and the charging time at 20 °C (68 °F) (These values vary with the temperature, the condition of the battery plates, and the electrolyte level.
BATTERY INSPECTION AND CHARGING INSP ADJ • Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger. • Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks.
INSP ADJ BATTERY INSPECTION AND CHARGING Charging method using a variable voltage charger Measure the opencircuit voltage prior to charging. Charger Ammeter Connect a charger and ammeter to the battery and start charging. YES Is the amperage higher than the standard charging amperage written on the battery? TIP Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. TIP Set the charging voltage to 16-17 V.
BATTERY INSPECTION AND CHARGING INSP ADJ Charging method using a constant voltage charger Measure the opencircuit voltage prior to charging. TIP Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. Connect a charger and ammeter to the battery and start charging. YES Is the amperage higher than the standard charging amperage written on the battery? NO This type of battery charger cannot charge an MF battery. A variable voltage - charger is recommended.
FUSE INSPECTION INSP ADJ 6. Install: • Battery 7. Check: • Battery terminals Dirt → Clean with a wire brush. Loose connection → Connect properly. 8. Lubricate: • Battery terminal Recommended lubricant: Lithium soap base grease 9. Connect: • Battery leads (to the battery terminals) NOTICE First, connect the positive lead 1, then the negative lead 2. 10. Install: • Battery cover FUSE INSPECTION NOTICE To avoid a short circuit, always set the main switch to OFF when checking or replacing a fuse. 1.
FUSE INSPECTION INSP ADJ 3. Replace: • Blown fuse Replacement steps: • Set the main switch to "OFF". • Install a new fuse of the correct amperage. • Set on the switches to verify if the electrical circuit is operational. • If the fuse immediately blows again, check the electrical circuit. Items Amperage rating Qty Main fuse 10 A 1 WARNING Never use a fuse with an amperage rating other than that specified.
SEAT, FUEL TANK AND SIDE COVERS ENG EC400000 ENGINE EC4R0000 SEAT, FUEL TANK AND SIDE COVERS 8 7 Nm (0.7 m • kg, 5.1 ft • lb) 1 2 7 4 7 Nm (0.7 m • kg, 5.1 ft • lb) 6 5 3 7 Nm (0.7 m • kg, 5.1 ft • lb) 5 9 2 10 Nm (1.0 m • kg, 7.2 ft • lb) 7 Nm (0.7 m • kg, 5.1 ft • lb) 1 Seat removal 3 Side covers removal Extent of removal: Extent of removal Order 7 Nm (0.7 m • kg, 5.
MUFFLER ENG MUFFLER 10 Nm (1.0 m • kg, 7.2 ft • lb) 1 2 10 Nm (1.0 m • kg, 7.2 ft • lb) 60 Nm (6.0 m • kg, 43 ft • lb) 4 5 3 10 Nm (1.0 m • kg, 7.2 ft • lb) 30 Nm (3.0 m • kg, 22 ft • lb) 10 Nm (1.0 m • kg, 7.2 ft • lb) 10 Nm (1.0 m • kg, 7.2 ft • lb) Extent of removal: Extent of removal 1 Muffler removal Order Q’ty MUFFLER REMOVAL Right side cover Preparation for removal 1 Part name 1 2 3 4 5 Remarks Refer to SEAT, FUEL TANK AND SIDE COVERS section.
CARBURETOR ENG CARBURETOR 4 5 6 1 4 7 3 8 2 9 3 Extent of removal: Extent of removal 1 Carburetor removal Order Q’ty CARBURETOR REMOVAL Fuel tank Preparation for removal 1 Part name 1 2 3 4 5 6 7 8 9 Fuel hose Over flow hose Air vent hose Starter plunger/starter knob Trottle main cable Trottle return cable Clamp (air cleaner joint) Clamp (carburetor joint) Carburetor 4-3 Remarks Refer to SEAT, FUEL TANK AND SIDE COVERS section.
CARBURETOR ENG EC468000 CARBURETOR DISASSEMBLY Extent of removal: Extent of removal 1 1 Carburetor disassembly Order Part name Q’ty 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 CARBURETOR DISASSEMBLY Throttle shaft Throttle valve Jet needle set Lever 1 Starter plunger Float chamber Float pivot pin Float Needle valve Main jet washer Needle valve seat holder Needle valve seat Main jet Main jet nozzle Pilot jet Pilot air jet 1 Pilot air jet 2 Pilot air screw Throttle stop screw Coasting enriche
CARBURETOR ENG 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 #100 (620-14231-20) is available to correct this. EC464000 INSPECTION Carburetor 1. Inspect: • Carburetor body Contamination → Clean. TIP • Use a petroleum based solvent for cleaning. Blow out all passages and jets with compressed air.
CARBURETOR ENG EC464301 Throttle valve 1. Check: • Free movement Stick → Repair or replace. 1 TIP Insert the throttle valve 1 into the carburetor body, and check for free movement. EC464401 1 Jet needle 1. Inspect: • Jet needle 1 Bends/wear → Replace. Fuel level 1. Measure: • Fuel level a Out of specification → Adjust. Fuel level: 6.0 ~ 7.0 mm (0.24 ~ 0.28 in) Below the float chamber mating surface Measurement and adjustment steps: • Connect the fuel level gauge 1 to the float chamber.
CARBURETOR ENG EC464600 Float 1. Inspect: • Float 1 Damage → Replace. Starter plunger 2 1. Inspect: • Cold starter plunger 1 • Hot starter plunger 2 Wear/damage → Replace. 1 Coasting enricher 1. Inspect: • Diaphragm 1 • Spring 2 • Cover 3 Tears (diaphragm)/damage → Replace. 2. Inspect: • Throttle shaft 1 • Spring 2 • Lever 1 3 • Spring 1 4 Dirt → Clean.
CARBURETOR ENG ASSEMBLY AND INSTALLATION Carburetor 1. Install: • Diaphragm 1 • Spring 2 • Cover 3 • Screw 4 4 LT 2 1 3 2 Nm (0.2 m • kg, 1.4 ft • lb) 2. Install: • Jet needle 1 • Spring 2 • Holder 3 • Throttle valve 4 4 3 1 2 3. Install: • Spring 1 1 To lever 1 2 2 1 a 2 4. Install: • Spring 1 • To throttle shaft 2 b TIP Install the bigger hook a of the spring fits on the stopper b of the throttle shaft pulley.
CARBURETOR ENG 5. Install: • Throttle shaft assembly • Plain washer (resin) 1 • Valve lever 2 1 2 TIP • Apply the fluorchemical grease on the bearings. • Make sure the stopper of the TPS spring fits into the recess in the carburetor. 6. Install: • O-ring • Valve lever housing cover • Bolt (valve lever housing cover) 7. Install: • Pilot jet 1 • Main jet nozzle 2 • Main jet 3 • Needle valve seat 4 • Needle valve seat holder 5 • Main jet washer 6 8.
CARBURETOR 2 9. Install: • Gasket • Float chamber 1 • Screw (float chamber) 2 2 1 2 ENG 2 Carburetor installation 1. Install: • Spring 1 • Starter plunger 2 • On starter cable 3 2. Install: • Throttle cable (pull) 1 4 Nm (0.4 m • kg, 2.9 ft • lb 2 • Throttle cable (return) 2 1 11 Nm (1.1 m • kg, 8.0 ft • lb) 3. Install: • Carburetor assembly TIP Install the projection between the carburetor joint slots.
CARBURETOR ENG 4. Install: • Throttle ca ble cover 1 • Screw (throttle cable cover) 2 1 4 Nm (0.4 m • kg, 2.9 ft • lb) 2 5. Tighten • Screw (carburetor joint) 1 • Screw (air carburetor joint) 2 2 1 6. Adjust: • Throttle grip free play Refer to "THROTTLE CABLE ADJUSTMENT" section in the CHAPTER 3. 7. Adjust: • Idle speed Refer to ENGINE IDLING SPEED ADJUSTMENT section in the CHAPTER 3.
CYLINDER HEAD ENG CYLINDER HEAD CYLINDER HEAD SIDE COVER AND TAPPET COVER Extent of removal: Extent of removal 1 Cylinder head side cover and tappet cover removal Order Part name Q’ty Remarks CYLINDER HEAD SIDE COVER AND TAPPET COVER REMOVAL Preparation for removal Refer to SEAT, FUEL TANK AND SIDE COVERS section. Refer to MUFFLER section. Refer to CARBURETOR section. Remove from the frame.
CYLINDER HEAD ENG CYLINDER HEAD Extent of removal: Extent of removal 1 Cylinder head removal Order Part name Q’ty Remarks CYLINDER HEAD REMOVAL 1 1 Bolt (camshaft sprocket) 1 2 Bolt (timing chain tensioner cap) 1 3 Timing chain tensioner 1 4 Gasket 1 5 Camshaft sprocket 1 6 Cylinder head 1 7 Dowel pin 2 8 Gasket 1 4-13 Refer to REMOVAL POINTS .
CYLINDER HEAD ENG REMOVAL POINTS Cylinder head 1. Align: • I mark (with stationary pointer) Checking steps: • Turn the crankshaft counterclockwise with wrench. • Align the I mark a on the rotor with the stationary pointer b on the crankcase cover. When the I mark is aligned with the stationary pointer, the piston is at the Top Dead Center (T.D.C.).
CYLINDER HEAD ENG 4. Remove: • Bolt (camshaft sprocket) 1 • Camshaft sprocket 2 TIP Attach a wire a to the timing chain to prevent it from falling into the crankcase. 5. Remove: • Bolts (cylinder head) • Cylinder head TIP • 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.
CYLINDER HEAD ENG 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. TIP 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 2. Install: • Cylinder head • Copper washer • Bolt (cylinder head) M8 22 Nm (2.
CYLINDER HEAD ENG 3. Install: • Timing chain • Camshaft sprocket Installation steps: • Turn the crankshaft counterclockwise with a wrench. • Align the I mark a on the rotor with the stationary pointer b on the crankcase cover. • Align the match mark c on the camshaft sprocket with the stationary pointer d on the cylinder head. • Fit the timing chain 1 onto camshaft sprocket 2 and install the camshaft sprocket on the camshaft.
CYLINDER HEAD ENG 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.
CYLINDER HEAD ENG 9. Check: • Valve clearance Out of specification → Adjust. Refer to VALVE CLEARANCE INSPECTION AND ADJUSTMENT section in the CHAPTER 3. 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.
CAMSHAFT AND ROCKER ARMS ENG CAMSHAFT AND ROCKER ARMS Extent of removal: Extent of removal 1 Camshaft removal Order 2 Rocker arm removal Part name Q’ty Remarks CAMSHAFT AND ROCKER ARMS REMOVAL Preparation for removal 1 2 Cylinder head 1 2 3 4 5 6 Refer to CYLINDER HEAD section. Camshaft bearing holder Intake rocker arm shaft Exhaust rocker arm shaft Camshaft Intake rocker arm Exhaust rocker arm 4-20 1 1 1 1 1 1 Refer to REMOVAL POINTS.
CAMSHAFT AND ROCKER ARMS ENG REMOVAL POINTS Rocker arm shaft 1. Remove: • Rocker arm shafts TIP Use a slide hammer bolt 1 and weight 2 to slide out the rocker arm shafts. Small slide hammer set: YU-1083-A Slide hammer bolt: 90890-01085 Weight: 90890-01084 Camshaft 1. Remove: • Camshaft 1 • Camshaft bearing 2 TIP Screw in a suitable length of 8 mm bolt 3 into the threaded end of the camshaft and pull out the camshaft. INSPECTION Camshaft 1.
CAMSHAFT AND ROCKER ARMS ENG Rocker arms and rocker arm shafts 1. Inspect: • Cam lobe contact surface a • Adjuster surface 1 Wear/pitting/scratches/blue discoloration → Replace. Measurement steps: • Measure the inside diameter a 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 b of the rocker arm shafts. Out of specification → Replace.
CAMSHAFT AND ROCKER ARMS ENG LT 5. Install: • Camshaft bearing holder 1 • Bolt 2 4-23 10 Nm (1.0 m · kg, 7.
VALVES AND VALVE SPRINGS ENG VALVES AND VALVE SPRINGS Extent of removal: Extent of removal 1 Valves and valve springs removal Order Q’ty VALVES AND VALVE SPRINGS REMOVAL Cylinder head Camshaft and rocker arms Preparation for removal 1 Part name 1 2 3 4 5 6 7 Valve cotter Valve spring retainer Valve spring Intake valve Exhaust valve Valve stem seal Valve spring seat Refer to CYLINDER HEAD section. Refer to CAMSHAFT AND ROCKER ARMS section. 4 2 2 1 2 2 2 4-24 Remarks Refer to REMOVAL POINTS .
VALVES AND VALVE SPRINGS ENG 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 TIP Attach a valve spring compressor 2 between the valve spring retainer and the cylinder head to remove the valve cotters.
VALVES AND VALVE SPRINGS ENG INSPECTION Valve 1. Measure: • Stem-to-guide clearance Stem-to-guide clearance = valve guide inside diameter a valve stem diameter b 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) 2.
VALVES AND VALVE SPRINGS ENG 3. Inspect: • Valve face Pitting/wear → Grind the face. • Valve stem end Mushroom shape or diameter larger than the body of the stem → Replace. 4. Measure: • Margin thickness a 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: • Runout (valve stem) Out of specification → Replace. Runout limit: 0.01 mm (0.0004 in) TIP • When installing a new valve always replace the guide.
VALVES AND VALVE SPRINGS ENG 8. Measure: • Valve seat width a 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) b 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.
VALVES AND VALVE SPRINGS ENG • 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. TIP 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. TIP After every lapping operation be sure to clean off all of the compound from the valve face and valve seat.
VALVES AND VALVE SPRINGS ENG 2. Measure: • Compressed spring force a Out of specification → Replace. b Installed length Compressed spring force: Intake: 19.5 ~ 22.3 kgf at 25.6 mm (42.93 ~ 49.23 lbf at 1.01 in) Exhaust: 19.5 ~ 22.3 kgf at 25.6 mm (42.93 ~ 49.23 lbf at 1.01 in) 3. Measure: • Spring tilt a Out of specification → Replace. Spring tilt limit: Intake: 2.5°/1.7 mm (0.07 in) Exhaust: 2.5°/1.7 mm (0.07 in) ASSEMBLY AND INSTALLATION Valve 1.
VALVES AND VALVE SPRINGS ENG 3. Install: • Valve cotters 1 TIP While compressing the valve spring with a valve spring compressor 2, install the valve cotters. Valve spring compressor: YM-4019/90890-04019 4. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood. NOTICE Hitting the valve tip with excessive force could damage the valve.
CYLINDER AND PISTON ENG CYLINDER AND PISTON Extent of removal: Extent of removal 1 Cylinder removal Order 2 Piston removal Part name Q’ty Remarks CYLINDER AND PISTON REMOVAL Preparation for removal 1 1 Cylinder head 1 2 3 4 5 6 7 8 Refer to CYLINDER HEAD section. Exhaust timing chain guide Cylinder/O-ring Dowel pin Gasket Piston pin clip Piston pin Piston Piston ring set 4-32 1 1/1 2 1 2 1 1 1 Refer to REMOVAL POINTS.
CYLINDER AND PISTON ENG REMOVAL POINTS Piston 1. Remove: • Piston pin clips 1 • Piston pin 2 • Piston 3 TIP • Before removing the piston pin clip, cover the crankcase opening with a clean towel or rag to prevent the clip from falling into the crankcase 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.
CYLINDER AND PISTON ENG 2. Measure: • Piston-to-cylinder clearance Piston-to-cylinder clearance measurement steps: 1st step: • Measure the cylinder bore C with the cylinder bore gauge. TIP 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.
CYLINDER AND PISTON ENG • 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. 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.
CYLINDER AND PISTON ENG Piston ring 1. Measure: • Ring side clearance Use a feeler gauge. Out of specification → Replace the piston and rings as a set. TIP 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.
CYLINDER AND PISTON ENG ASSEMBLY AND INSTALLATION Piston ring and piston 1. Install: • Piston rings (onto the piston) TIP • 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. a: Top ring end b: 2nd ring end c: Oil ring end (upper) d: Oil ring end (lower) 3.
CYLINDER AND PISTON ENG Cylinder 1. Install: • Dowel pins 1 • Gasket (cylinder) 2 New 2. Install: • O-ring New • Cylinder 1 • Exhaust timing chain guide NOTICE • 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. TIP After installing, check the smooth movement of the piston.
CLUTCH AND PRIMARY DRIVEN GEAR ENG EC490000 CLUTCH AND PRIMARY DRIVEN GEAR EC498000 CLUTCH PLATE AND FRICTION PLATE Extent of removal: Extent of removal 1 Clutch plate and friction plate removal Order Part name CLUCTH PLATE AND FRICTION PLATE REMOVAL Drain the engine oil Preparation for removal Engine skidplate Starter motor 1 Q’ty 1 2 3 4 5 6 7 8 9 10 11 12 1 Kickstarter crank Starter motor lead holder Negative battery lead Gasket Dowel pin Pressure plate Ball Friction plate Clutch plate Nut/
ENG CLUTCH AND PRIMARY DRIVEN GEAR EC498100 PRIMARY DRIVEN GEAR Extent of removal: Extent of removal 1 Primary driven gear removal Order 2 Primary drive gear removal Part name Q’ty Remarks PRIMARY DRIVEN GEAR REMOVAL 1 2 1 2 3 4 5 6 7 8 Nut (clutch boss) Lock washer Clutch boss Thrust plate Primary driven gear Nut (primary drive gear) Primary drive gear Straight key 4-40 1 1 1 1 1 1 1 1 Use special tool. Refer to REMOVAL POINTS. Refer to REMOVAL POINTS.
CLUTCH AND PRIMARY DRIVEN GEAR ENG PUSH LEVER Extent of removal: Extent of removal 1 1 Push lever removal Order 1 2 3 4 5 Part name PUSH LEVER REMOVAL Clutch cable Push lever Spring Circlip Oil seal 4-41 Q’ty 1 1 1 1 1 Remarks
CLUTCH AND PRIMARY DRIVEN GEAR ENG EC493000 REMOVAL POINTS Clutch boss 1. Remove: • Nut 1 • Lock washer • Clutch boss 2 A B TIP Straighten the lock washer tab and use the clutch holding tool 3 to hold the clutch boss. Clutch holding tool: YM-91042/90890-04086 A For USA and CDN B Except for USA and CDN Primary drive gear 1. Remove: • Nut (primary drive gear) 1 • Primary drive gear 2 TIP • Place a folded rag or aluminum plate between the teeth of the primary drive gear and primary driven gear.
CLUTCH AND PRIMARY DRIVEN GEAR ENG EC484400 Clutch spring 1. Measure: • Clutch spring free length a Out of specification → Replace springs as a set. Clutch spring free length: 33 mm (1.30 in) : 31 mm (1.22 in) 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.
CLUTCH AND PRIMARY DRIVEN GEAR ENG Push rod 1. Inspect: • 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 TIP • 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.
CLUTCH AND PRIMARY DRIVEN GEAR ENG Clutch 1. Install: • Primary driven gear 1 • Thrust plate 2 • Clutch boss 3 2. Install: • Lock washer New • Nut (clutch boss) 1 60 Nm (6.0 m • kg, 43 ft • lb) TIP Use the clutch holding tool 2 to hold the clutch boss. A Clutch holding tool: YM-91042/90890-04086 B A For USA and CDN B Except for USA and CDN 3. Bend: • Lock washer tab 4.
CLUTCH AND PRIMARY DRIVEN GEAR ENG 5. Install: • Ball TIP Apply the engine oil on the ball. 6. Install: • Push rod 1 1 • Push plate 2 • Washer 3 • Nut (push rod 1) 4 7. Install: • Pressure plate 1 • Clutch spring 2 • Bolt (clutch spring) 3 6 Nm (0.6 m • kg, 4.3 ft • lb) TIP • Align the arrow mark a on the pressure plate with the punched mark b on the clutch boss. • Tighten the bolts in stage, using a crisscross pattern. 8.
CLUTCH AND PRIMARY DRIVEN GEAR ENG 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.
OIL PUMP ENG OIL PUMP Extent of removal: Extent of removal 1 Oil pump removal Order Part name Q’ty Remarks OIL PUMP REMOVAL Preparation for removal 1 Clutch and primary drive gear 1 2 3 4 5 Rotary filter Oil pump drive gear Oil pump assembly Gasket Oil strainer Refer to CLUTCH AND PRIMARY DRIVEN GEAR section.
OIL PUMP ENG OIL PUMP DISASSEMBLY Extent of removal: Extent of removal 1 Oil pump disassembly Order Part name Q’ty OIL PUMP DISASSEMBLY 1 1 2 3 4 5 6 7 8 9 10 11 12 Circlip Oil pump driven gear Conical spring washer Circlip Washer Oil pump cover Pin Oil pump shaft Pin Inner rotor Outer rotor Oil pump housing 4-49 1 1 1 1 1 1 2 1 1 1 1 1 Remarks
OIL PUMP ENG INSPECTION Oil pump 1. Inspect: • 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.
OIL PUMP ENG 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 0 • Oil pump driven gear A • Circlip B New • Screws C 5 Nm (0.5 m • kg, 3.6 ft • lb) TIP • Apply engine oil onto the outer rotor, inner rotor and oil pump shaft.
KICK AXLE AND SHIFT SHAFT ENG KICK AXLE AND SHIFT SHAFT KICK AXLE AND SHIFT SHAFT Extent of removal: Extent of removal 1 Kick axle removal Order 2 Shift shaft removal Part name Q’ty Remarks KICK AXLE AND SHIFT SHAFT REMOVAL Preparation for removal 1 2 1 2 3 4 5 6 7 8 9 10 11 12 Shift pedal link Refer to ENGINE REMOVAL section. Clutch Refer to CLUTCH AND PRIMARY DRIVEN GEAR section.
KICK AXLE AND SHIFT SHAFT ENG REMOVAL POINTS Kick axle 1. Remove: • Kick axle assembly 1 TIP Unhook the torsion spring 2 from the hole in the crankcase. Segment 1. Remove: • Screw (segment) • Segment 1 TIP Loosen the screw using the T30 bit. INSPECTION 1 Kick axle and ratchet wheel 1. Check: • Ratchet wheel smooth movement Unsmooth movement → Replace. 2. Inspect: • Kick axle 1 Wear/damage → Replace. Kickstarter segment gear and kick idle gear 3 2 1 1.
KICK AXLE AND SHIFT SHAFT ENG EC4B4400 Shift shaft 1. Inspect: • Shift shaft 1 Bend/damage → Replace. • Spring 2 Broken → Replace. EC4B4500 Stopper lever 1 1. Inspect: • Stopper lever 1 Wear/damage → Replace. • Torsion spring 2 Broken → Replace. 2 EC4C5000 ASSEMBLY AND INSTALLATION Segment LT 1. Install: • Segment 1 • Screw (segment) 2 12 Nm (1.2 m • kg, 8.7 ft • lb) TIP • Align the notch a on the segment with the pin b on the shift cam. • Tighten the screw using the T30 bit.
KICK AXLE AND SHIFT SHAFT ENG Shift shaft 1. Install: • Shift shaft 1 TIP • Apply the lithium soap base grease on the oil seal lip of the left crankcase side. • Hook the spring ends onto the stopper 2. 1 Kick axle assembly 1. Install: • Ratchet idle gear 1 • Kickstarter segment gear 3 • Plain washer 2 • Torsion spring 4 On kick axle 5. TIP Make sure the stopper a of the torsion spring fits into the hole b on the kick axle. 5 2 3 b 2 4 a 2.
KICK AXLE AND SHIFT SHAFT ENG Kick idle gear 1. Install: • Washer 1 • Kick idle gear 2 • Washer 3 • Circlip 4 New TIP • Apply the engine oil on the kick idle gear inner circumference. • Install the kick idle gear with its depressed side toward you.
CDI MAGNETO AND STARTER CLUTCH ENG CDI MAGNETO AND STARTER CLUTCH Extent of removal: 1 Pickup coil/stator removal Extent of removal Order 2 1 Part name Q’ty Remarks CDI MAGNETO AND STATOR REMOVAL Preparation for removal 1 2 Starter clutch/wheel gear removal Fuel tank 1 2 3 4 5 6 7 8 9 10 11 12 13 CDI magneto lead Neutral switch lead Left crankcase cover Nut (rotor) Rotor Starter clutch Woodruff key Starter wheel gear Plain washer Plate (starter idle gear) Starter idle gear Lead guide Pickup co
CDI MAGNETO AND STARTER CLUTCH ENG 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 a • Stator outer surface b Damage → Inspect the crankshaft runout and crankshaft bearing. If necessary, replace CDI magneto and/ or stator. EC4L4200 Woodruff key 1.
CDI MAGNETO AND STARTER CLUTCH ENG 3. Check: • Starter clutch operation A 1 • Install the starter clutch drive gear 1 onto the starter clutch 2 and hold the starter clutch. • When turning the starter clutch drive gear counterclockwise B, the starter clutch and the starter clutch drive gear should engage. If the starter clutch drive gear and starter clutch do not engage, the starter clutch is faulty and must be replaced. • When turning the starter clutch drive gear clockwise A, it should turn freely.
CDI MAGNETO AND STARTER CLUTCH ENG 3. Install the starter clutch 1 on the rotor 2. b 2 1 a TIP • Install the starter clutch with its plate portion a facing the rotor. • Insert the plate portion of the starter clutch so that it is flush with the surface of contact b with the rotor. 4. Tighten: • Bolt (starter clutch) 30 Nm (3.0 m · kg, 22 ft · lb) TIP Caulk a the end of the starter clutch holding bolt near its outer diameter to serve as a stopper. 5.
CDI MAGNETO AND STARTER CLUTCH ENG 7. Install: • Crankcase cover (left) 8. Connect: • Neutral switch lead 1 TIP Pass the neutral switch lead into the crankcase cover groove as shown. 9. Connect: • CDI magneto lead Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2.
ENGINE REMOVAL ENG ENGINE REMOVAL Extent of removal: 1 Engine removal Extent of removal Preparation for removal Order Part name ENGINE REMOVAL Hold the machine by placing the suitable stand under the frame. Seat, fuel tank and side covers Q’ty Remarks 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 cap Disconnect the CDI magneto lead.
ENGINE REMOVAL Extent of removal 1 Order 1 2 3 4 5 6 7 8 9 10 11 Part name Drive sprocket cover Bolt (drive sprocket) Drive sprocket holder Drive sprocket Shift pedal link Crankcase breather hose Engine bracket (upper) Engine skidplate Engine bracket (front) Engine mounting bolt (rear) Engine 4-63 Q’ty 1 2 1 1 1 1 1 1 1 2 1 ENG Remarks Refer to REMOVAL POINTS Refer to REMOVAL POINTS
ENGINE REMOVAL ENG REMOVAL POINTS Drive sprocket 1. Remove: • Bolt (drive sprocket) • Drive sprocket holder 1 • Drive sprocket 2 • Drive chain 3 TIP Remove the drive sprocket together with the drive chain. Engine removal 1. Remove: • Engine 1 From left side. TIP 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 40 Nm (4.
ENGINE REMOVAL ENG TIP • 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. Shift pedal link 1. Install: • Shift pedal link 1 • Bolt (shift pedal link) 2 10 Nm (1.0 m · kg, 7.2 ft · lb) TIP Adjust the center a of the front end of the shift pedal to match the highest point of the footrest. Drive sprocket 1.
CRANKCASE, CRANKSHAFT AND BALANCER ENG CRANKCASE, CRANKSHAFT AND BALANCER Extent of removal: 1 Crankcase separation Extent of removal Order 2 Balancer removal Part name Q’ty 3 Crankshaft removal Remarks CRANKCASE, CRANKSHAFT AND BALANCER REMOVAL Preparation for removal Engine Refer to ENGINE REMOVAL section. Piston Refer to CYLINDER AND PISTON section. Primary drive gear Refer to CLUTCH AND PRIMARY DRIVEN GEAR section. Refer to KICK AXLE AND SHIFT SHAFT section.
CRANKCASE, CRANKSHAFT AND BALANCER Extent of removal 1 2 3 Order Part name Q’ty 1 2 3 4 5 6 7 8 9 10 11 Intake timing chain guide Timing chain Bolt [45 mm (1.8 in)] Bolt [55 mm (2.2 in)] Bolt [30 mm (1.2 in)] Lead guide Clutch cable holder Right crankcase Left crankcase Balancer Crankshaft 1 1 7 1 2 1 1 1 1 1 1 12 Bearing 3 4-67 ENG Remarks Use special tool. Refer to REMOVAL POINTS. Use special tool. Refer to REMOVAL POINTS. Refer to REMOVAL POINTS.
CRANKCASE, CRANKSHAFT AND BALANCER ENG REMOVAL POINTS Crankcase 1. Remove: • Bolt (crankcase) • Lead guide 1 • Clutch cable holder 2 TIP 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 TIP • Fully tighten the tool holding bolts, but make sure the tool body is parallel with the case.
CRANKCASE, CRANKSHAFT AND BALANCER ENG Crankshaft 1. Remove: • Crankshaft 1 Use the crankcase separating tool 2. Crankcase separating tool: YU-1135-A/90890-01135 NOTICE Do not use a hammer to drive out the crankshaft. Bearing 1. Remove: • Bearing 1 TIP • 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.
CRANKCASE, CRANKSHAFT AND BALANCER ENG Crankcase 1. Inspect: • Contacting surface a Scratches → Replace. • Engine mounting boss b, crankcase Cracks/damage → Replace. 2. Inspect: • Bearing Rotate inner race with a finger. Rough spot/seizure → Replace. Crankshaft 1. Measure: • Runout limit a • Connecting rod big end side clearance b • Crank width c Out of specification → Replace. Use the dial gauge and a thickness gauge. Dial gauge & stand set: YU-3097/90890-01252 Runout limit: Standard — 0.
CRANKCASE, CRANKSHAFT AND BALANCER ENG Balancer 1. Inspect: • Balancer Cracks/damage → Replace. ASSEMBLY AND INSTALLATION Bearing 1. Install: • Bearing 1 New On crankcase (left and right). TIP Install the bearing by pressing its outer race parallel. Crankshaft 1. Install: • Crankshaft 1 Use the crankshaft installing tool 2, 3, 4, 5.
CRANKCASE, CRANKSHAFT AND BALANCER ENG 2. Install: • Balancer TIP Align the punched mark a on the balancer drive gear with the punched mark b 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 TIP Clean the contacting surface of crankcase (left and right) before applying the sealant. 2. Install: • Dowel pin 1 • Right crankcase On left crankcase. TIP • Fit the right crankcase onto the left crankcase.
CRANKCASE, CRANKSHAFT AND BALANCER ENG 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) TIP • 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.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG TRANSMISSION, SHIFT CAM AND SHIFT FORK Extent of removal: 1 Shift cam and shift fork removal Extent of removal Order 2 Part name Q’ty TRANSMISSION, SHIFTCAM AND SHIFT FORK REMOVAL Engine Preparação para remoção 1 2 Main axle and drive axle removal Refer to ENGINE REMOVAL section.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG REMOVAL POINTS Transmission 1. Remove: • Main axle 1 • Drive axle 2 TIP • 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: • Matching dog a • Gear teeth b • Shift fork groove c Wear/damage → Replace. 2.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG 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. 2. Inspect: • Shift cam 1 • Shift fork guide bar 2 Bend/wear/damage → Replace. 3. Check: • Shift fork movement On its guide bar. Unsmooth operation → Replace shift fork and/or guide bar.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG Transmission 1. Install: • 4th pinion gear (22T) 1 • 3rd pinion gear (19T) 2 • 2nd pinion gear (18T) 3 • 5th pinion gear (24T) 4 On main axle 5. TIP • Apply the molybdenum disulfide oil on the gears inner circumference. • Install the 5th pinion gear so that measurement a is 83.25 ~ 83.45 mm (3.278 ~ 3.285 in). 2. 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.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG 3. Install: • Plain washer 1 • Circlip 2 New TIP • Be sure the circlip sharp-edged corner a is positioned opposite side to the plain washer and gear b. • Be sure the circlip end c is positioned at axle spline groove d. 4. Install: • Push rod 2 On main axle. TIP 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.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG Shift cam and shift fork 1. Install: • Shift fork 1 (L) 1 • Shift fork 2 (C) 2 • Shift fork 3 (R) 3 TIP • 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. 2. Install: • Shift cam 1 TIP Apply the engine oil on the shift cam. 3.
FRONT WHEEL AND FRONT BRAKE (TT-R125E) CHAS EC500000 CHASSIS FRONT WHEEL AND FRONT BRAKE (TT-R125E) Extent of removal: Extent of removal 1 Front wheel removal 2 Wheel bearing removal 3 Brake shoe plate assembly removal and disassembly Order Part name Q’ty FRONT WHEEL AND DRUM BRAKE 1 3 2 WARNING Support the machine securely so there is no danger of it falling over. Hold the machine by placing the suitable stand under the engine.
FRONT WHEEL AND FRONT BRAKE (TT-R125E) CHAS Extent of removal 1 Order Part name Q’ty 11 Brake shoe 2 12 Spring 2 13 Brake camshaft lever 1 14 Wear indicator plate 1 15 Brake camshaft 1 16 Brake shoe plate 1 5-2 Remarks
FRONT WHEEL AND FRONT BRAKE (TT-R125E) CHAS REMOVAL POINTS EC513201 Wheel bearing (if necessary) 1. Remove: • Bearing 1 TIP 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) 2. Inspect: • Bearing Rotate inner race with a finger. Rough spot/seizure → Replace. TIP Replace the bearings, oil seal and wheel collar as a set. EC514200 Wheel axle 1.
FRONT WHEEL AND FRONT BRAKE (TT-R125E) CHAS Drum brake 1. Inspect: • Brake shoe lining surface Glazed areas → Polish. Use coarse sand paper. TIP After polishing, wipe the polished particles with a cloth. 2. Measure: • Brake shoe lining thickness a Out of specification → Replace. Brake shoe lining thickness: Standard 4.0 mm (0.16 in) 2.0 mm 0.08 in) TIP Replace the brake shoes and springs as a set if either is worn to the limit. 3.
FRONT WHEEL AND FRONT BRAKE (TT-R125E) CHAS ASSEMBLY AND INSTALLATION Brake shoe plate assembly 1. Install: • Brake camshaft 1 TIP Apply the lithium soap base grease on the brake camshaft. 2. Check: • Brake camshaft operation Unsmooth operation → Repair. 3. Install: • Wear indicator plate 1 TIP When installing the wear indicator plate to the brake camshaft align the projection a on the wear indicator plate with the slots b on the brake camshaft. 1 4. Install: • Brake camshaft lever 1 a 10 Nm (1.
FRONT WHEEL AND FRONT BRAKE (TT-R125E) CHAS Front wheel 1. Install: • Wheel bearing 1 • Spacer 2 • Wheel bearing 3 • Oil seal 4 New TIP • 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.
FRONT WHEEL AND FRONT BRAKE (TT-R125E) CHAS 5. Install: • Axle nut 1 45 Nm (4.5 m · kg, 32 ft · lb) 6. Install: • Brake cable TIP 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.
FRONT WHEEL (TT-R125LE) CHAS FRONT WHEEL (TT-R125LE) Extent of removal: Extent of removal 1 Front wheel removal 3 Brake disc removal Order 2 Wheel bearing removal Part name Q’ty FRONT WHEEL REMOVAL Preparation for removal 1 WARNING Hold the machine by placing the suitable stand under the engine. 3 2 3 1 2 3 4 5 6 7 8 9 Axle nut Washer Wheel axle Front wheel Collar Oil seal Wheel bearing Spacer Brake disk Support the machine securely so there is no danger of it falling over.
FRONT WHEEL (TT-R125LE) CHAS REMOVAL POINTS EC513201 Wheel bearing (if necessary) 1. Remove: • Bearing 1 TIP 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) 2. Inspect: • Bearing Rotate inner race with a finger. Rough spot/seizure → Replace. TIP Replace the bearings, oil seal and wheel collar as a set. EC514200 Wheel axle 1.
FRONT WHEEL (TT-R125LE) CHAS Brake disc 1. Measure: • 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 a 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.
FRONT WHEEL (TT-R125LE) CHAS LT 2. Install: • Brake disc 1 • Bolt (brake disc) 2 12 Nm (1.2 m · kg, 8.7 ft · lb) TIP Tighten the bolts in stage, using a crisscross pattern. 3. Install: • Collar 1 TIP • 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 TIP Install the brake disc 1 between the brake pads 2 correctly. 5. Install: • Wheel axle 1 6. Install: • Washer 1 • Axle nut 2 45 Nm (4.
FRONT BRAKE (TT-R125LE) CHAS FRONT BRAKE (TT-R125LE) 1 Brake hose removal 3 Brake master cylinder removal Extent of removal: Extent of removal Order 2 Brake caliper removal Part name Q’ty Remarks FRONT BRAKE REMOVAL Preparation for removal WARNING Hold the machine by placing the suitable stand under the engine. Drain the brake fluid. Support the machine securely so there is no danger of it falling over. Refer to "REMOVAL POINTS".
FRONT BRAKE (TT-R125LE) CHAS BRAKE CALIPER AND BRAKE MASTER CYLINDER DISASSEMBLY Extent of removal: Extent of removal 1 Brake caliper disassembly Order 2 Brake master cylinder disassembly Part name Q’ty BRAKE CALIPER AND BRAKE MASTER CYLINDER DISASSEMBLY Preparation for removal 1 2 WARNING Support the machine securely so there is no danger of it falling over. Hold the machine by placing the suitable stand under the engine.
FRONT BRAKE (TT-R125LE) CHAS REMOVAL POINTS Brake fluid 1. Remove: • Brake master cylinder cap 1 TIP Do not remove the diaphragm. 2. Connect the transparent hose 2 to the bleed screw 1 and place a suitable container under its end. 3. Loosen the bleed screw and drain the brake fluid while pulling in the lever. NOTICE • 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.
FRONT BRAKE (TT-R125LE) CHAS Brake caliper piston seal kit 1. Remove: • Brake caliper dust seal 1 • Brake caliper piston seal 2 TIP Remove the brake caliper piston seals and brake caliper dust seals by pushing them with a finger. NOTICE 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. INSPECTION Brake master cylinder 1.
FRONT BRAKE (TT-R125LE) CHAS Brake caliper 1. Inspect: • Brake caliper cylinder inner surface a 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.
FRONT BRAKE (TT-R125LE) CHAS 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. 2.
FRONT BRAKE (TT-R125LE) CHAS 2. Install: • Pin boot 1 On brake caliper 2. TIP 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 TIP • 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.
FRONT BRAKE (TT-R125LE) CHAS 2. Install: • Brake master cylinder cup (primary) 1 • Brake master cylinder cup (secondary) 2 On brake master cylinder piston 3. TIP 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. TIP Install the spring at the smaller diameter side. 4.
FRONT BRAKE (TT-R125LE) CHAS 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) TIP • Install the brake master cylinder bracket so that the arrow mark a 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.
FRONT BRAKE (TT-R125LE) CHAS 2. Pass the brake hose through the cable guide 1. 3. 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. TIP When turning the joint over the brake hose, hold the brake hose so that it may not be twisted. 4. Install: • Brake hose holder 1 • Bolt (brake hose holder) 2 7 Nm (0.7 m · kg, 5.
FRONT BRAKE (TT-R125LE) CHAS Brake fluid .................................. .................................. ............................................................. . .. .. .. .. .. .. .. .. a 1. Fill: • Brake fluid Until the fluid level reaches "LOWER" level line a. 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.
FRONT BRAKE (TT-R125LE) CHAS 4. Install: • Diaphragm • Brake master cylinder cap 1 • Screw (brake master cylinder cap) 2 2 Nm (0.2 m · kg, 1.4 ft · lb) NOTICE 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.
REAR WHEEL AND REAR BRAKE CHAS REAR WHEEL AND REAR BRAKE Extent of removal: Extent of removal 1 Rear wheel removal 2 Wheel bearing removal 3 Brake shoe plate assembly removal and disassembly Order Part name Q’ty REAR WHEEL AND DRUM BRAKE 1 2 3 WARNING Support the machine securely so there is no danger of it falling over. Hold the machine by placing the suitable stand under the engine.
REAR WHEEL AND REAR BRAKE CHAS Extent of removal 2 3 Order Part name Q’ty 11 Nut (wheel sprocket) 4 12 Wheel sprocket 1 13 Oil seal 1 14 Wheel bearing 2 15 Spacer 1 16 Brake shoe 2 17 Spring 2 18 Brake camshaft lever 1 19 Wear indicator plate 1 20 Brake camshaft 1 21 Brake shoe plate 1 5-25 Remarks Refer to "REMOVAL POINTS".
REAR WHEEL AND REAR BRAKE CHAS REMOVAL POINTS EC523101 Rear wheel 1. Remove: • Wheel 1 TIP Push the wheel forward and remove the drive chain 2. EC513201 Wheel bearing (if necessary) 1. Remove: • Bearing 1 TIP Remove the bearing using a general bearing puller2. 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) 2. Inspect: • Bearing Rotate inner race with a finger. Rough spot/seizure → Replace.
REAR WHEEL AND REAR BRAKE CHAS TIP The bending value is shown by one half of the dial gauge reading. WARNING Do not attempt to straighten a bent axle. Drum brake 1 Inspect: • Brake shoe lining surface Glazed areas → Polish. Use coarse sand paper. TIP After polishing, wipe the polished particles with a cloth. 2. Measure: • Brake shoe lining thickness a Out of specification → Replace. Brake shoe lining thickness: Standard 4.0 mm (0.16 in) 2.0 mm (0.
REAR WHEEL AND REAR BRAKE CHAS 4. Inspect: • Brake drum inner surface. Oil/scratches → Remove. Oil Scratches Use a rag soaked in lacquer thinner or a solvent. Use a emery cloth (lightly and evenly polishing). ASSEMBLY AND INSTALLATION Brake shoe plate assembly 1. Install: • Brake camshaft 1 TIP Apply the lithium soap base grease on the brake camshaft. 2. Check: • Brake camshaft operation Unsmooth operation → Repair. 3.
REAR WHEEL AND REAR BRAKE CHAS 5. Install: • Springs 1 New • Brake shoes 2 On brake shoe plate 3 TIP • 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.
REAR WHEEL AND REAR BRAKE CHAS 2. Install: • Wheel sprocket 1 • Lock washers 2 New • Nut (wheel sprocket) 3 43 Nm (4.3 m · kg, 31 ft · lb) TIP • Tighten the nuts in stage, using a crisscross pattern. • Bend the lock washer tab. 3. Install: • Collar (left) • Brake shoe plate assembly • Collar (right) TIP Apply the lithium soap base grease on the oil seal lip. 4. Install: • Rear wheel TIP Make sure that the slot a on the brake shoe plate with the stopper b on the swingarm. 5.
REAR WHEEL AND REAR BRAKE CHAS 7. Install: • Drive chain puller (right) 1 • Plain washer 2 • Axle nut 3 TIP Temporarily tighten the axle nut at this point. 8. Adjust: • Drive chain slack a 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.
FRONT FORK CHAS EC550000 FRONT FORK 23 Nm (2.3 m • kg, 17 ft • lb) 60 Nm (6.0 m • kg, 43 ft • lb) 25 Nm (2.5 m • kg, 18 ft • lb) TT-R125E TT-R125LE Part name Q’ty A TT-R125E B TT-R125LE Extent of removal: Extent of removal 1 Front fork removal Order FRONT FORK REMOVAL Preparation for removal WARNING Hold the machine by placing the suitable stand under the engine Support the machine securely so there is no danger of it falling over.
FRONT FORK CHAS EC558000 FRONT FORK DISASSEMBLY A TT-R125E B TT-R125LE Extent of removal: Extent of removal 2 1 1 Oil seal removal Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 2 Damper rod removal Part name FRONT FORK DISASSEMBLY Dust boot Cap bolt Spacer Washer Fork spring Dust seal Stopper ring Bolt (damper rod) Damper rod Inner tube Oil flow stopper Piston metal Oil seal Outer tube 5-33 Q’ty A 1 1 1 1 1 1 1 1 1 1 1 1 1 1 B 1 1 1 1 1 1 1 1 1 1 1 1 1 Remarks Refer to "REMOVAL POINTS".
FRONT FORK CHAS HANDLING NOTE TIP The front fork requires careful attention. So it is recommended that the front fork be maintained at the dealers. NOTICE 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.
FRONT FORK CHAS Damper rod holder: YM-1300/90890-01294 T-handle: YM-1326/90890-01326 3. Remove: • Oil seal 1 Using slotted-hand screwdriver. NOTICE Take care not to scratch the outer tube. EC554000 INSPECTION Damper rod 1. Inspect: • Damper rod Bend/damage → Replace damper rod. NOTICE The front fork with a built-in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material.
FRONT FORK CHAS EC554400 Fork spring 1. Measure: • Fork spring free length a Out of specification → Replace. Fork spring free length: Standard TT-R125E: TT-R125E: 478.7 mm (18.82 in) 472.2 mm (18.59 in) TT-R125LE: TT-R125LE: 469.4 mm (18.46 in) 463.9 mm (18.23 in) Inner tube 1. Inspect: • Inner tube surface a 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.
FRONT FORK CHAS 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. EC555000 ASSEMBLY AND INSTALLATION Front fork assembly 1. Wash the all parts in a clean solvent. 2. Install: • Piston metal 1 • Damper rod 2 • Oil flow stopper 3 On inner tube 4. NOTICE To install the damper rod into the inner tube, hold the inner tube aslant.
FRONT FORK CHAS LT 4. Install: • Copper washer New • Bolt (damper rod) 23 Nm (2.3 m · kg, 17 ft · lb) TIP 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. 5. Install: • Oil seal 1 New TIP • Apply the fork oil on the inner tube. • When installing the oil seal, use vinyl seat a with fork oil applied to protect the oil seal lip. • Install the oil seal with its manufacturer's marks or number facing upside.
FRONT FORK CHAS 7. Install: • Dust seal 1 TIP 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. 9. Compress the front fork fully. 10. Fill: • Front fork oil 1 Recommended oil: Fork oil 10W or equivalent Quantity (each front fork leg): TT-R125E: 171 cm3 (6.02 Imp oz, 5.78 US oz) TT-R125LE: 164 cm3 (5.77 Imp oz, 5.54 US oz) NOTICE • Be sure to use recommended fork oil.
FRONT FORK CHAS 12. Measure: • Oil level a Out of specification → Adjust. Standard oil level: TT-R125E: 120 mm (4.72 in) TT-R125LE: 134 mm (5.27 in) From the top of the inner tube, with the inner tube fully compressed, and without the fork spring. A 1 13. Install: • Fork spring • Washer • Spacer (TT-R125E) • Cap bolt 1 • Dust boot B 1 TIP Temporarily tighten the cap bolt. A TT-R125E B TT-R125LE Installation 1. Install: • Front fork TIP • Temporarily tighten the pinch bolt (lower bracket).
FRONT FORK CHAS 4. 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 TIP • Make sure that the dust boot holes a are positioned outward. • Tighten the screw (dust boot) until the top of the dust boot is touching the lower bracket.
HANDLEBAR CHAS EC5B0000 HANDLEBAR TT-R125E Extent of removal: Extent of removal 1 Handlebar removal Order Q’ty Remarks HANDLEBAR REMOVAL Number plate Preparation for removal 1 Part name 1 Clutch cable 1 2 Clutch lever 1 3 Engine stop switch 1 4 Front brake cable 1 5 Start switch 1 6 Front brake lever 1 7 Grip cap (lower) 1 8 Grip cap (upper) 1 9 Throttle cable 2 10 Throttle grip assembly 1 11 Collar 1 12 Handlebar grip (left) 1 13 Main switch 1 14 Handlebar
HANDLEBAR CHAS TT-R125LE Extent of removal: Extent of removal 1 Handlebar removal Order Q’ty Remarks HANDLEBAR REMOVAL Number plate Preparation for removal 1 Part name 1 Clutch cable 1 2 Clutch lever 1 3 Engine stop switch 1 4 Brake master cylinder 1 5 Start switch 1 6 Grip cap (lower) 1 7 Grip cap (upper) 1 8 Throttle cable 2 9 Throttle grip assembly 1 10 Handlebar grip (left) 1 11 Main switch 1 12 Upper handlebar holder 2 13 Handlebar 1 5-43 Refer to "REMOV
HANDLEBAR CHAS THROTTLE GRIP ASSEMBLY DISASSEMBLY Extent of removal: Extent of removal 1 Throttle grip assembly disassembly Order Part name Q’ty Remarks THROTTLE GRIP ASSEMBLY DISASSEMBLY 1 1 Handlebar grip (right) 1 2 Collar 1 3 Tube guide 1 5-44 Refer to "REMOVAL POINTS".
HANDLEBAR CHAS REMOVAL POINTS Brake master cylinder 1. Remove: • Brake master cylinder bracket 1 • Brake master cylinder 2 NOTICE • 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. Handlebar grip 1. Remove: • Handlebar grip 1 TIP 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.
HANDLEBAR CHAS ASSEMBLY AND INSTALLATION Throttle grip assembly 1. Install: • Collar 1 • Handlebar grip (right) 2 Apply the adhesive on the tube guide 3. TIP Before applying the adhesive, wipe off grease or oil on the tube guide surface a with a lacquer thinner. Handlebar 1. Install: • Handlebar 1 • Handlebar holder 2 • Main switch 3 • Main switch holder 4 • Bolt (handlebar holder) 5 23 Nm (2.
HANDLEBAR CHAS 2. Install: • Handlebar grip (left) 1 Apply the adhesive to the handlebar 2. TIP Before applying the adhesive, wipe off grease or oil on the handlebar surface a with a lacquer thinner. 3. Install: TT-R125E • Collar 1 2 1 4. Install: • Throttle grip assembly 1 • Throttle cable 2 On tube guide . TIP Apply the lithium soap base grease on the throttle cable end and tube guide cable winding portion. 5. Install: • Grip cap (lower) 1 • Grip cap (upper) • Screw (grip cap) 4 Nm (0.4 m · kg, 2.
HANDLEBAR CHAS 6. Install: TT-R125E • Start switch 1 • Bolts (start switch) 2 3 4 Nm (0.4 m · kg, 2.9 ft · lb) 2 1 2 • Front brake cable 3 • Clamp TIP Apply the lithium soap base grease on the front brake cable end. TT-R125LE • Start switch 1 • Brake master cylinder 2 • Brake master cylinder bracket 3 • Bolt (brake master cylinder bracket) 4 4 3 4 9 Nm (0.9 m · kg, 6.5 ft · lb) 1 TIP • Install the bracket so that the arrow mark a face upward.
HANDLEBAR CHAS 3 2 7. Install: • Engine stop switch 1 • Clutch lever holder 2 • Screws 3 4 Nm (0.4 m · kg, 2.9 ft · lb) 1 3 TIP • 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 TIP 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.
STEERING CHAS EC560000 STEERING 110 Nm (11.0 m • kg, 80 ft • lb) 10 Nm (1.0 m • kg, 7.2 ft • lb) 25 Nm (2.5 m • kg, 18 ft • lb) • Tighten ring nut. 38 Nm (3.8 m • kg, 27 ft • lb) • Loosen it one turn. • Retighten it. 20 Nm (2.0 m • kg, 14 ft • lb) 60 Nm (6.
STEERING CHAS 110 Nm (11.0 m • kg, 80 ft • lb) 10 Nm (1.0 m • kg, 7.2 ft • lb) 25 Nm (2.5 m • kg, 18 ft • lb) • Tighten ring nut. 38 Nm (3.8 m • kg, 27 ft • lb) • Loosen it one turn. • Retighten it. 20 Nm (2.0 m • kg, 14 ft • lb) 60 Nm (6.0 m • kg, 43 ft • lb) Extent of removal 2 Order 9 10 11 12 13 Part name Bearing Bearing Bearing Bearing Bearing inner race (upper) (upper) outer race (upper) outer race (lower) (lower) 5-51 Q’ty 1 1 1 1 1 Remarks Refer to “REMOVAL POINTS”..
STEERING CHAS 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. NOTICE Take care not to damage the steering shaft thread. EC564000 INSPECTION Steering stem 1.
STEERING CHAS 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.
STEERING CHAS 4. Install: • Lower bracket 1 TIP Apply the lithium soap base grease on the bearing. 5. Install: • Lower ring nut 1 20 Nm (2.0 m · kg, 14 ft · lb) • Rubber washer • Upper ring nut • Special washer Tighten the ring nut using the steering nut wrench 2. TIP Install the lower ring nut with its larger chamfered portion a facing downward. Refer to "STEERING HEAD INSPECTION AND ADJUSTMENT" section in the CHAPTER 3. 6. Check the steering shaft by turning it lock to lock.
STEERING CHAS 9. Tighten: • Steering stem nut 1 110 Nm (11.0 m · kg, 80 ft · lb) 10. Install: • Cap 2 11. After tightening the nut, check the steering for smooth movement. If not, adjust the steering by loosening the ring nut little by little. A B 12. Adjust: • Front fork top end a Front fork top end (standard) a: Zero mm (Zero in) A TT-R125E B TT-R125LE a 13. Tighten: • Pinch bolts (lower bracket) 1 60 Nm (6.0 m · kg, 43 ft · lb) • Pinch bolts (upper bracket) 2 25 Nm (2.
SWINGARM CHAS EC570000 SWINGARM Extent of removal: Extent of removal 1 Swingarm removal Order Part name Q’ty SWINGARM REMOVAL Preparation for removal 1 1 2 3 4 5 6 Remarks WARNING Hold the machine by placing the suitable stand under the engine. Support the machine securely so there is no danger of it falling over. Rear wheel Refer to "REAR WHEEL AND REAR BRAKE" section.
SWINGARM CHAS EC578000 SWINGARM DISASSEMBLY Extent of removal: 1 Swingarm disassembly 2 Connecting arm removal and disassembly 3 Relay arm removal and disassembly Extent of removal Order Part name Q’ty SWINGARM DISASSEMBLY 2 1 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Drive chain Drive chain Drive chain Dust cover Collar Connecting Oil seal Collar Dust cover Bushing Relay arm Dust cover Bushing Swingarm guard support guide 1 1 1 4 1 1 2 2 2 1 1 2 1 1 arm 5-57 Remarks
SWINGARM CHAS REMOVAL POINTS Bushing 1. Remove: • Bushing 1 TIP 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. 2. Inspect: • Dust cover Damage → Replace. 3. Inspect: • Swingarm Damage/bends/cracks → Replace. Relay arm 1. Inspect: • Collar 1 • Bushing 2 Damage/pitting → Replace collar and bushing as a set.
SWINGARM CHAS Connecting arm 1. Inspect: • Collar 1 • Bushing 2 Damage/pitting → Replace collar and bushings as a set. 2. Inspect: • Dust cover 3 Damage → Replace. 3. Inspect: • Connecting arm 4 Damage/bends/cracks → Replace. EC575000 ASSEMBLY AND INSTALLATION Bushing 1. Install: • Bushing TIP 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.
SWINGARM CHAS 2. Install: • Oil seals 1 • Collars 2 • Bushing 3 • Dust covers 4 • Dust covers 5 • Rubber boot 6 On relay arm. TIP 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. TIP 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) TT-R125E 70 Nm (7.0 m · kg, 50 ft · lb) TT-R125LE 53 Nm (5.
SWINGARM CHAS 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. TIP Apply the molybdenum disulfide grease on the bolt (connecting arm). 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.
SWINGARM CHAS 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) TIP Apply the molybdenum disulfide grease on the bolt (rear shock absorber - relay arm). 4. Install: • Bolt (connecting arm-frame) 1 • Plain washer • Nut (connecting arm-frame) 35 Nm (3.5 m · kg, 25 ft · lb) TIP Apply the molybdenum disulfide grease on the bolt (connecting arm - frame). 5.
REAR SHOCK ABSORBER ASSEMBLY CHAS EC580000 REAR SHOCK ABSORBER ASSEMBLY Extent of removal: Extent of removal 1 Rear shock absorber assembly removal Order Part name Q’ty REAR SHOCK ABSORBER ASSEMBLY REMOVAL WARNING Support the machine securely so there is no danger of it falling over. Hold the machine by placing the suitable stand under the engine. Preparation for removal Seat and side covers 1 1 2 3 4 Remarks Refer to "SEAT, FUEL TANK AND SIDE COVERS" section in the CHAPTER 4.
REAR SHOCK ABSORBER ASSEMBLY CHAS HANDLING NOTE WARNING This rear shock absorber contains highpressure 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.
REAR SHOCK ABSORBER ASSEMBLY CHAS A NOTES ON DISPOSAL (YAMAHA DEALERS ONLY) Gas pressure must be released before disposing of a rear shock absorber and gas cylinder. TT-R125E To release the gas pressure, drill a 2 ~ 3 mm (0.08 ~ 0.12 in) hole through the gas cylinder at a point a from its end as shown. B WARNING Wear eye protection to prevent eye damage from released gas or metal chips.
REAR SHOCK ABSORBER ASSEMBLY CHAS EC585000 ASSEMBLY AND INSTALLATION Bushing 1. Install: • Bushing 1 TIP Install the bushing by pressing. Installation 1. Install: • Rear shock absorber assembly On frame. TIP Install the rear shock absorber assembly with its warning label a facing left side of the machine (for TT-R125E). 2. Install: • Bolt (rear shock absorber assembly frame) • Plain washer 1 • Nut (rear shock absorber assembly frame) 2 53 Nm (5.
REAR SHOCK ABSORBER ASSEMBLY CHAS 4. Install: TT-R125LE • Rear shock absorber assembly sub-tank 1 • Screw clamp 2 1 4 Nm (0.4 m · kg, 2.9 ft · lb) 3 • Locking tie 3 a b = 0~2 mm TIP • Install the rear shock absorber assembly sub-tank so that its bottom portion directs as shown and lightly touches the projection a on the frame. • Install the rear shock absorber assembly sub-tank with a clearance b between the sub-tank and frame. • Fasten the sub-tank hose with the locking tie.
ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELEC – + EC600000 ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 8 9 0 A B C D E COLOR CODE CDI unit Main switch Start switch Clutch switch Engine stop switch Starting circuit cut-off relay Ignition coil Battery Starter relay Fuse Rectifier/regulator Neutral switch CDI magneto Starter motor Spark plug W ............. White Y .............. Yellow B/W ......... Black/White L/Y ...........
IGNITION SYSTEM ELEC – + EC620000 IGNITION SYSTEM INSPECTION STEPS 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. Spark gap test Spark *Clean or replace spark plug. No Spark Check entire ignition system for connection. No good Repair or replace. OK Check main switch. No good Replace. OK Check engine stop switch. No good Replace. OK Check ignition coil.
IGNITION SYSTEM – ELEC + EC622001 SPARK GAP TEST 1. Disconnect the spark plug cap from spark plug. 2. Connect the dynamic spark tester 1 (ignition checker 2) as shown. • Spark plug cap 3 • Spark plug 4 3. Kick the kick starter. 4. Check the ignition spark gap. 5. Start engine, and increase spark gap until misfire occurs. 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.
IGNITION SYSTEM – ELEC + ENGINE STOP SWITCH INSPECTION 1 B 2 1. Inspect: • Engine stop switch conduct B Tester (+) lead → Black lead 1 Tester (_) lead → Black lead 2 B 1 B 2 PUSH IN Tester selector position Ωx1 FREE No continuous while being pushed → Replace. Continuous while being freed → Replace. EC626002 IGNITION COIL INSPECTION 1. Inspect: • Primary coil resistance Out of specification → Replace.
IGNITION SYSTEM ELEC – + 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 x 1 TIP When inspecting the secondary coil resistance, remove the spark plug cap. CDI MAGNETO INSPECTION 1. Inspect: • Pickup coil resistance Out of specification → Replace.
IGNITION SYSTEM 1 ELEC – 2. Inspect: • Source coil resistance Out of specification → Replace.
ELECTRIC STARTING SYSTEM ELEC – + ELECTRIC STARTING SYSTEM STARTING CIRCUIT CUT-OFF SYSTEM OPERATION 2 If the main switch is set to "ON", the starter motor can only operate if at least one of the following conditions is met: 3 1 • The transmission is in neutral (the neutral switch is closed). • The clutch lever is pulled to the handlebar (the clutch switch is closed). 4 8 The starting circuit cut-off relay prevents the starter motor from operating when neither of these conditions has been met.
ELECTRIC STARTING SYSTEM ELEC – + INSPECTION STEPS If the starter motor will not operate, use the following inspection steps. *1 Check fuse No good Replace fuse and check wire harness. OK *2 Check battery No good Recharge or replace. OK Check each coupler and wire connection. OK *3 Check main switch. OK Check starter motor operation. OK Check starting circuit cut-off relay. OK Check starter relay. No good No good No good Repair or replace. Replace. Repair or replace. No good Replace.
ELECTRIC STARTING SYSTEM – ELEC + EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: • Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. STARTER MOTOR OPERATION 1. Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3. Not operate → Repair or replace the starter motor. WARNING • A wire that is used as a jumper lead must have at least the same capacity or more as that of the a battery lead, otherwise the jumper lead may burn.
ELECTRIC STARTING SYSTEM – ELEC + STARTER RELAY INSPECTION 1. Remove: • Starter relay 2. Inspect: • Starter relay conduct Use 12 V battery. Battery (+) lead Battery (–) lead → Starter relay terminal 1 → Starter relay terminal 2 Tester (+) lead Tester (–) lead → Starter relay terminal 3 → Starter relay terminal 4 Ter- Terminal minal 3 4 Tester selector position Connected to battery Ωx1 Not connected to battery Continuous while not connected to the battery → Replace.
ELECTRIC STARTING SYSTEM – ELEC + CLUTCH SWITCH INSPECTION 1 2 1. Inspect: • Clutch switch continuity B B Tester (+) lead → Black lead 1 Tester (_) lead → Black lead 2 B 1 B 2 PULL Tester selector position Ωx1 FREE No continuous while being pulled → Replace. Continuous while being freed → Replace. START SWITCH INSPECTION 1 B 2 1.
ELECTRIC STARTING SYSTEM ELEC – STARTER MOTOR 1 8 6 7 8 3 New 4 7 5 2 1 3 Extent of removal: Extent of removal New 3 New 1 Starter motor disassembly Order Part name Q’ty Remarks STARTER MOTOR REMOVAL Preparation for removal 1 Drain the engine oil. 1 Starter motor.
ELECTRIC STARTING SYSTEM ELEC – + INSPECTION AND REPAIR 1. Inspect: • Commutator Dirt → Clean it with #600 grit sandpaper. 2. Measure: • Commutator diameter a Commutator wear limit: 21.0 mm (0.83 in) Out of specification → Replace the starter motor. 3. Measure: • Mica undercut a Mica undercut: 1.5 mm (0.06 in) Out of specification → Scrape the mica to the proper value (a hacksaw blade can be ground to fit).
ELECTRIC STARTING SYSTEM ELEC – + 5. Measure: • Brush length a Out of specification → Replace. Brush length wear limit: 3.5 mm (0.14 in) 6. Measure: • Brush spring force Fatigue/out of specification → Replace as a set. Brush spring force: 5.52 ~ 8.28 N (560 ~ 840 g, 19.8 ~ 29.7 oz) 2 ASSEMBLY 1. Install: • Brush spring 1 • Brush 2 2 1 2. Instal: • Armature assembly 1 Install while holding down the brush using a thin screw driver. NOTICE Be careful not to damage the brush during installation.
ELECTRIC STARTING SYSTEM + TIP Align the match mark a on the starter motor yoke with the match mark b on the starter motor rear cover. a a – 3. Install: • O-ring 1 New • Starter motor yoke 2 1 New 2 b ELEC 4. Install: • O-ring 1 New • Plain washer 2 • Starter motor front cover 3 1 New b 2 3 TIP • For installation, align the projections on the washer with the slots in the front cover. • Align the match mark a on the starter motor yoke with the match mark b on the starter motor front cover. 5.
CHARGING SYSTEM ELEC – + EC680000 CHARGING SYSTEM EC681001 INSPECTION STEPS If the battery is not charged, use the following inspection steps. *1 Check fuse. No good Replace fuse and check wire harness. No good Recharge or replace. No good Repair or replace. OK Charging system is good. OK *2 Check battery. OK Check each coupler and wire connection. OK Check charging voltage. No good Check CDI magneto. Charging coil No good Replace. OK Replace rectifier/regulator.
CHARGING SYSTEM ELEC – + EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: • Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. 2 W B R Y 1 CHARGING VOLTAGE INSPECTION 1. Start the engine. 2. Inspect: • Charging voltage Out of specification → If no failure is found in checking the source coil resistance, replace the rectifier/regulator. Tester (+) lead → Red lead 1 Tester (–) lead → Black lead 2 1 W Sb Y B Charging voltage Tester selector position 14.
YAMAHA MOTOR DA AMAZÔNIA LTDA.
