2001 YAMAHA TTR125 oil

5 - 47
CHAS

2. Install:
l
Handlebar grip (left)
1

Apply the adhesive to the handlebar
2
.
NOTE:

Before applying the adhesive, wipe off grease
or oil on the handlebar surface
a
with a lac-
quer thinner.
3. Install:
l
Collar
1

4. Install:
lThrottle grip assembly 1
lGrip cap (upper) 2
lThrottle cables 3
On tube guide 4.
NOTE:
Apply the lithium soap base grease on the
throttle cable end and tube guide cable wind-
ing portion.
5. Install:
lThrottle cable cap 1
lScrew (throttle cable cap) 2
lGrip cap (lower) 3
lScrew (grip cap) 4
lCover (grip cap) 5
WARNING
After tightening the screws, check that the
throttle grip 6 moves smoothly. If it does
not, retighten the bolts for adjustment.
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
HANDLEBAR

5 - 56
CHASSWINGARM
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 Remarks
SWINGARM DISASSEMBLY
1Drive chain guard 1
2Drive chain support 1
3Drive chain guide 1
4Dust cover 4
5Collar 1
6Connecting arm 1
7Oil seal 2
8Collar 2
9Dust cover 2
0Bushing 1
ARelay arm 1
BDust cover 2
CBushing 1
DSwingarm 1
3
1
2

5 - 57
CHASSWINGARM
REMOVAL POINTS
Bushing
1. Remove:
lBushing 1
NOTE:
Remove the bushing by pressing.
INSPECTION
Wash the bushings, collars, and covers in a
solvent.
Swingarm
1. Inspect:
lBushing 1
lBushing 2
Damage/pitting ® Replace bushings as
a set.
2. Inspect:
lDust cover
Damage ® Replace.
3. Inspect:
lSwingarm
Damage/bends/cracks ® Replace.
Relay arm
1. Inspect:
lCollar 1
lBushing 2
Damage/pitting ® Replace collar and
bushing as a set.
lBushing 3
lBushing 4
Damage/pitting ® Replace bushings as
a set.
lCollar 5
lBushing 6
lBushing 7
Damage/pitting ® Replace collars and
bushing as a set.
2. Inspect:
lOil seal 8
lDust cover 9
Damage ® Replace.
3. Inspect:
lRelay arm 0
Damage/bends/cracks ® Replace.

5 - 59
CHAS
2. Install:
lOil seals 1
lCollars 2
lBushing 3
lDust covers 4
lDust covers 5
lRubber boot 6
On relay arm.
NOTE:
Apply the molybdenum disulfide grease on the
bushing, collar, oil seal lip and dust cover lip.
3. Install:
lCollar 1
lDust covers 2
On connecting arm.
NOTE:
Apply the molybdenum disulfide grease on the
collar and dust cover lip.
4. Install:
lRelay arm 1
lBolt (relay arm)
lPlain washer
lNut (relay arm)
On swingarm.
NOTE:
Apply the molybdenum disulfide grease on the
bolt (relay arm).
5. Install:
lConnecting arm 1
lBolt (connecting arm)
lPlain washer
lNut (connecting arm)
On relay arm.
NOTE:
Apply the molybdenum disulfide grease on the
bolt (connecting arm).
T R..53 Nm (5.3 m · kg, 38 ft · lb)
T R..35 Nm (3.5 m · kg, 25 ft · lb)
SWINGARM

5 - 63
CHASREAR SHOCK ABSORBER ASSEMBLY
HANDLING NOTE
WARNING
This rear shock absorber contains high-
pressure nitrogen gas. To prevent the dan-
ger of explosion, read and understand the
following information before handling the
shock absorber.
The manufacturer can not be held responsi-
ble for property damage or personal injury
that may result from improper handling.
1. Never tamper or attempt to open the
rear shock absorber.
2. Never throw the rear shock absorber
into an open flame or other high heat.
The rear shock absorber may explode
as a result of nitrogen gas expansion
and/or damage to the hose.
3. Be careful not to damage any part of
the rear shock absorber. A damaged
rear shock absorber will impair the
damping performance or cause a mal-
function.
4. Take care not to scratch the contact
surface of the piston rod with the cyl-
inder; or oil could leak out.
5. When scrapping the rear shock
absorber, follow the instruction on
disposal.
NOTES ON DISPOSAL (YAMAHA DEALERS
ONLY)
Gas pressure must be released before dispos-
ing of a rear shock absorber and gas cylinder.
To release the gas pressure, drill a 2 ~ 3-mm
(0.08 ~ 0.12-in) hole through the gas cylinder
at a point 12 mm (0.5 in) a from its end as
shown.
WARNING
Wear eye protection to prevent eye damage
from released gas or metal chips.

5 - 64
CHAS
EC583000
REMOVAL POINTS
Bushing
1. Remove:
lBushing 1
NOTE:
Remove the bushing by pressing.
EC584000
INSPECTION
Rear shock absorber assembly
1. Inspect:
lDamper rod 1
Bends/damage ® Replace rear shock
absorber assembly
lShock absorber 2
Oil leaks ® Replace rear shock
absorber assembly
Gas leaks ® Replace rear shock
absorber assembly
lSpring 3
Damage ® Replace rear shock
absorber assembly
Fatigue ® Replace rear shock
absorber assembly
Move spring up and down.
EC585000
ASSEMBLY AND INSTALLATION
Bushing
1. Install:
lBushing 1
NOTE:
Install the bushing by pressing.
REAR SHOCK ABSORBER ASSEMBLY

6 - 1
–+ELEC

* The illustration shows the TT-R125LW
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC600000
ELECTRICAL
EC610000
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC611000
ELECTRICAL COMPONENTS
1
CDI unit
2
Engine stop switch
3
Ignition coil
4
CDI magneto
5
Spark plug
COLOR CODE
B.......................Black
Br .....................Brown
G ......................Green
O ......................Orange
R ......................Red
W......................WhiteB/R .................. Black/Red
B/W ................. Black/White
G/L .................. Green/Blue
G/W ................. Green/White
W/L .................. White/Blue
W/R ................. White/Red
EC612000
WIRING DIAGRAM
6

6 - 2
–+ELEC

IGNITION SYSTEM
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.
*marked: Only when the ignition checker is used.
NOTE:

l
Remove the following parts before inspection.
1) Seat
2) Fuel tank
l
Use the following special tools in this inspection.
Spark gap test*Clean or replace
spark plug.
Check entire ignition
system for connection.Repair or replace.
Check engine stop switch. Replace.
Check ignition coil. Primary coil Replace.
Secondary coilReplace.
Check CDI magneto. Pickup coil Replace.
Charging coil Replace.
Replace CDI unit.
Dynamic spark tester:
YM-34487
Ignition checker:
90890-06754
Pocket tester:
YU-3112-C/90890-03112
No Spark
OK
OK
OK
OK
Spark
No good
No good
No good
No good
No good
No good