2000 YAMAHA TTR125 maintenance

SPEC
2 - 15
MAINTENANCE SPECIFICATIONS
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each ride.Part to be tightened Thread size Q’tyTightening torque
Nm m•kg ft•lb
Relay arm and connecting arm M10 ´ 1.25 1 35 3.5 25
Connecting arm and frame M10 ´ 1.25 1 35 3.5 25
Rear shock absorber assembly and frameM12 ´ 1.25 1 53 5.3 38
Rear shock absorber assembly and relay arm M10 ´ 1.25 1 35 3.5 25
Rear shock absorber and locknut (preload) M46 ´ 1.5 1 42 4.2 30
Drive chain tensioner (upper) M8 ´ 1.25 1 23 2.3 17
Drive chain tensioner (lower) M6 ´ 1.0 1 7 0.7 5.1
Drive chain support and swingarm M6 ´ 1.0 2 7 0.7 5.1
Drive chain guide and swingarm M6 ´ 1.0 2 7 0.7 5.1
Drive chain guard mounting M6 ´ 1.0 2 7 0.7 5.1
Fuel tank mounting M6 ´ 1.0 2 10 1.0 7.2
Fuel tank and fuel cock M6 ´ 1.0 2 7 0.7 5.1
Fuel tank and fuel tank bracket M6 ´ 1.0 4 7 0.7 5.1
Front fender mounting M6 ´ 1.0 4 7 0.7 5.1
Rear fender mounting M6 ´ 1.0 4 7 0.7 5.1
Flap guard mounting M6 ´ 1.0 2 7 0.7 5.1
Left side cover mounting M6 ´ 1.0 2 7 0.7 5.1
Seat mounting M6 ´ 1.0 2 7 0.7 5.1

SPEC
2 - 16
MAINTENANCE SPECIFICATIONS
EC212300
ELECTRICAL
Item Standard Limit
CDI:
Magneto-model/manufacturer 5HP-00/YAMAHA ----
Charging coil resistance (color) 688 ~ 1,032 W at 20 ˚C (68 ˚F)
(Green-Brown)----
Pickup coil resistance (color) 248 ~ 372 W at 20 ˚C (68 ˚F)
(White/Red)----
CDI unit-model/manufacturer 5HP-00/YAMAHA ----
Ignition coil:
Model/manufacturer 4KJ-10/YAMAHA ----
Minimum spark gap 6 mm (0.24 in) ----
Primary coil resistance 0.18 ~ 0.28 W at 20 ˚C (68 ˚F) ----
Secondary coil resistance 6.3 ~ 9.5 kW at 20 ˚C (68 ˚F) ----
Part to be tightened Thread size Q’tyTightening torque
Nm m•kg ft•lb
Pickup coil M6 ´ 1.0 2 10 1.0 7.2
Blind plug (neutral switch) M10 ´ 1.25 1 20 2.0 14
Stator M6 ´ 1.0 3 10 1.0 7.2
RotorM12 ´ 1.25 1 80 8.0 58
Ignition coil M6 ´ 1.0 2 7 0.7 5.1

3 - 1
INSP
ADJ

MAINTENANCE INTERVALS
EC300000
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind
that such factors as weather, terrain, geographical location, and individual usage will alter the
required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in
maintaining and lubricating your machine, consult your Yamaha dealer.
Dealer
NoteItem Checks and maintenance jobsInitial Every
10 hours
(1 month)60 hours
(6 months)120 hours
(12 months)
*
Fuel lineCheck fuel hoses for cracks or damage.
Replace if necessary.
Spark plugCheck condition.
Clean, regap or replace if necessary.
*
ValvesCheck valve clearance.
Adjust if necessary.
Air filter Clean or replace element if necessary.
*
CarburetorCheck engine idling speed and starter operation.
Adjust if necessary.
Exhaust systemsCheck for leakage.
Retighten if necessary.
Replace gasket if necessary.
Engine oilCheck oil level and vehicle for oil leakage.
Correct if necessary.
Change. (Warm engine before draining.)
ClutchCheck operation.
Adjust or replace cable.
*
Front brakeCheck operation.
Adjust brake lever free play and replace brake
shoes if necessary.Every ride
*
Rear brakeCheck operation.
Adjust brake pedal free play and replace brake
shoes if necessary.Every ride
*
WheelsCheck balance, runout, spoke tightness and for
damage.
Tighten spokes and rebalance, replace if
necessary.
*
TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
*
Wheel bearingsCheck bearing for looseness or damage.
Replace if necessary.
*
SwingarmCheck swingarm pivoting point for play.
Correct if necessary.
Lubricate with lithium soap base grease.
Drive chainCheck chain slack.
Adjust if necessary. Make sure that the rear wheel
is properly aligned.
Clean and lubricate.Every ride
*
Steering bearingsCheck bearing play and steering for roughness.
Correct accordingly.
Lubricate with lithium soap base grease every 120
hours.
SidestandCheck operation.
Lubricate and repair if necessary.
3
3

3 - 2
INSP
ADJ

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

: For USA
*
Spark arrester
*1

Clean.
*
Front forkCheck operation and for oil leakage.
Correct accordingly.
*
Rear shock
absorber assemblyCheck operation and shock absorber for oil
leakage.
Replace shock absorber assembly if necessary.
*
Chassis fastenersMake sure that all nuts, bolts and screws are
properly tightened.
Tighten if necessary.
Dealer
NoteItem Checks and maintenance jobsInitial Every
10 hours
(1 month)60 hours
(6 months)120 hours
(12 months)
3

3 - 3
INSP
ADJ

PRE-OPERATION INSPECTION AND MAINTENANCE
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation or practice, make sure the machine is in good operating condi-
tion.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
FuelCheck that a fresh gasoline is filled in the fuel tank. Check the
fuel line for leakage.P.1-12
Engine oilCheck that the oil level is correct. Check the crankcase for leak-
age.P.3-7 ~ 10
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-4
Throttle grip/housingCheck that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.P.3-4 ~ 5
BrakesCheck the play of front and rear brake and effect of front and
rear brake.P.3-15 ~ 16
Drive chainCheck chain slack and alignment. Check that the chain is lubri-
cated properly.P.3-17 ~ 18
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-20 ~ 21
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-21 ~ 23
Front forks and rear shock
absorber assemblyCheck that they operate smoothly and there is no oil leakage. P.3-19 ~ 20
Cables (wires)Check that the clutch and throttle cables move smoothly. Check
that they are not caught when the handlebars are turned or
when the front forks travel up and down.—
Muffler Check that the muffler is tightly mounted and has no cracks. P.4-2
Sprocket Check that the driven sprocket tightening nut is not loose. P.3-16
Lubrication Check for smooth operation. Lubricate if necessary. P.3-24
Bolts and nuts Check the chassis and engine for loose bolts and nuts. —
Lead connectorsCheck that the CDI magneto, CDI unit, and ignition coil are con-
nected tightly.P.1-5

3 - 5
INSP
ADJ

THROTTLE LUBRICATION/AIR FILTER CLEANING
THROTTLE LUBRICATION
1. Remove:
l
Throttle cable cap
1

NOTE:
Before adjusting the throttle cable free play,
the engine idle speed should be adjusted.
WARNING
After adjusting, turn the handlebar to
right and left and make sure that the
engine idling does not run faster.

2. Apply:
l
Lithium soap base grease
On the throttle cable end
a
and tube
guide cable winding portion
b
.
3. Install:
l
Throttle cable cap
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)

AIR FILTER CLEANING
NOTE:

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

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