2000 YAMAHA TTR125 transmission

4 - 72
ENGCRANKCASE, CRANKSHAFT AND BALANCER
3. Tighten:
lLead guide 1
lClutch cable holder 2
lBolt (crankcase)
NOTE:
lApply Quick gasket® (Yamaha bond No.
1215) on end of the crankcase bolts [15 mm
(0.6 in)] 3, as shown.
lTighten the crankcase bolts in stage, using a
crisscross pattern.
Quick gasket®:
ACC-QUICK-GS-KT
Yamaha bond No. 1215:
90890-85505
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
4. Check:
lCrankshaft and transmission operation
Unsmooth operation ® Repair.
5. Install:
lTiming chain 1
lIntake timing chain guide 2
lBolt (intake timing chain guide)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)LT

4 - 73
ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
TRANSMISSION, SHIFT CAM AND SHIFT FORK
Extent of removal:1 Shift cam and shift fork removal2 Main axle and drive axle removal
Extent of removal Order Part name Q’ty Remarks
TRANSMISSION, SHIFTCAM
AND SHIFT FORK REMOVAL
Preparation for removal Engine Refer to “ENGINE REMOVAL” section.
Separate the crankcase. Refer to “CRANKCASE, CRANKSHAFT
AND BALANCER” section.
1 Shift fork guide bar 1 (short) 1
2 Shift fork guide bar 2 (long) 1
3 Shift cam 1
4 Shift fork 2 (C) 1
5 Shift fork 3 (R) 1
6 Shift fork 1 (L) 1
7 Main axle 1
Refer to “REMOVAL POINTS”.
8 Drive axle 1
9 Push rod 2 1
10 Washer 1
1
2

4 - 74
ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
REMOVAL POINTS
Transmission
1. Remove:
lMain axle 1
lDrive axle 2
NOTE:
lTap lightly on the transmission drive axle
with a soft hammer to remove.
lRemove assembly carefully. Note the posi-
tion of each part. Pay particular attention to
the location and direction of shift forks.
EC4H4000
INSPECTION
EC4H4200
Gears
1. Inspect:
lMatching dog a
lGear teeth b
lShift fork groove c
Wear/damage ® Replace.
2. Check:
lGears movement
Unsmooth movement ® Repair or
replace.
Push rod
1. Inspect:
lPush rod 2 1
Wear/damage/bend ® Replace.

4 - 75
ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
EC4H4600
Bearing
1. Inspect:
lBearing 1
Rotate inner race with a finger.
Rough spot/seizure ® Replace.
Shift fork and shift cam
1. Inspect:
lShift fork 1
Wear/damage/scratches ® Replace.
2. Inspect:
lShift cam 1
lShift fork guide bar 2
Bend/wear/damage ® Replace.
3. Check:
lShift fork movement
On its guide bar.
Unsmooth operation ® Replace shift
fork and/or guide bar.
NOTE:
For a malfunctioning shift fork, replace not only
the shift fork itself but the two gears each adja-
cent to the shift fork.

4 - 76
ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
Transmission
1. Install:
l4th pinion gear (22T) 1
l3rd pinion gear (19T) 2
l2nd pinion gear (18T) 3
l5th pinion gear (24T) 4
On main axle 5.
NOTE:
lApply the molybdenum disulfide oil on the
gears’ inner circumference.
lInstall the 5th pinion gear so that measure-
ment a is 83.25 ~ 83.45 mm (3.278 ~
3.285 in).
2. Install:
l2nd wheel gear (32T) 1
l5th wheel gear (21T) 2
l3rd wheel gear (25T) 3
l4th wheel gear (23T) 4
l1st wheel gear (37T) 5
On drive axle 6.
NOTE:
Apply the molybdenum disulfide oil on the
gears’ inner circumference.

4 - 77
ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
3. Install:
lPlain washer 1
lCirclip 2
NOTE:
lBe sure the circlip sharp-edged corner a is
positioned opposite side to the plain washer
and gear b.
lBe sure the circlip end c is positioned at
axle spline groove d.
New
4. Install:
lPush rod 2
On main axle.
NOTE:
Apply the engine oil on the push rod 2.
5. Install:
lWasher 1
On drive axle.
6. Install:
lMain axle
lDrive axle
Install these in the left crankcase at the
same time.
NOTE:
lApply the lithium soap base grease on the oil
seal lip.
lWhen installing the drive axle into the crank-
case, pay careful attention to the crankcase
oil seal lip.

4 - 78
ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
Shift cam and shift fork
1. Install:
lShift fork 1 (L) 1
lShift fork 2 (C) 2
lShift fork 3 (R) 3
NOTE:
lMesh the shift fork #1 (L) with the 2nd wheel
gear and #3 (R) with the 4th wheel gear on
the drive axle.
lMesh the shift fork #2 (C) with the 3rd pinion
gear on the main axle.
2. Install:
lShift cam 1
NOTE:
Apply the engine oil on the shift cam.
3. Install:
lShift fork guide bar 1 (short) 1
lShift fork guide bar 2 (long) 2
NOTE:
lApply the engine oil on the guide bars.
lBe sure the long bar is inserted into the shift
forks #1 and #3 and the short one into #2.
4. Check:
lShifter operation
lTransmission operation
Unsmooth operation ® Repair.

CHAS
5 - 8
HINTERRAD UND HINTERRADBREMSE
Demontage-Arbeiten:1 Hinterrad demontieren2 Radlager demontieren
3 Bremsankerplatte demontieren und zerlegen
Demontage-ArbeitenReihen-
folgeBauteil Anz. Bemerkungen
Vorbereitung für den
AusbauHINTERRAD UND TROMMEL-
BREMSE
Maschine durch Anbringung
eines geeigneten Ständers unter
dem Motor sicher abstellen.
1 Bremsgestänge 1
2 Achsmutter 1
3 Antriebskettenspanner (rechts) 1
4 Radachse 1
5 Antriebskettenspanner (links) 1
6 Antriebskette 1
7 Hinterrad 1 Siehe unter “DEMONTAGEPUNKTE”.
8 Distanzhülse (rechts) 1
9 Bremsankerplatte 1
10 Distanzhülse (links) 1
WARNUNG
Die Maschine muß sicher stehen, damitsie nicht umfallen kann.
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ROUE ARRIÈRE ET FREIN ARRIÈRE
HINTERRAD UND HINTERRADBREMSE
ROUE ARRIÈRE ET FREIN ARRIÈRE
Déposes à effectuer:1 Dépose de la roue arrière2 Dépose des roulements de roue
3 Dépose et démontage de flasque de frein complet
Déposes à effectuer Ordre Nom de pièce Qté Remarques
Préparation à la déposeDÉPOSE DE LA ROUE
ARRIÈRE ET DU FREIN À
TAMBOUR
Caler le véhicule en plaçant un sup-
port adéquat sous le moteur.
1 Tringle de frein 1
2 Écrou d’axe 1
3Tendeur de chaîne de transmission
(droit)1
4 Axe de roue 1
5Tendeur de chaîne de transmission
(gauche)1
6 Chaîne de transmission 1
7 Roue arrière 1 Se reporter à “ÉLÉMENTS À DÉPOSER”.
8 Collier (droit) 1
9 Flasque de frein complet 1
10 Collier (gauche) 1
AVERTISSEMENT
Caler le véhicule de sorte à ce qu’il ne risque
pas de basculer.
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