2001 YAMAHA TTR125 brake

5 - 25
CHAS

Extent of removal Order Part name Q’ty Remarks
11 Lock washer 2
12 Wheel sprocket 1
13 Oil seal 1
14 Wheel bearing 2 Refer to “REMOVAL POINTS”.
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
3
2

REAR WHEEL AND REAR BRAKE

5 - 26
CHAS

REAR WHEEL AND REAR BRAKE
REMOVAL POINTS
EC523101
Rear wheel
1. Remove:
l
Wheel
1

NOTE:

Push the wheel forward and remove the drive
chain
2
.
EC513201
Wheel bearing (if necessary)
1. Remove:
l
Bearing
1

NOTE:

Remove the bearing using a general bearing
puller
2
.
INSPECTION
EC514100
Wheel
1. Measure:
l
Wheel runout
Out of limit
®
Repair/replace.
2. Inspect:
l
Bearing
Rotate inner race with a finger.
Rough spot/seizure
®
Replace.
NOTE:

Replace the bearings, oil seal and wheel collar
(wheel sprocket side) as a set.
Wheel runout limit:
Radial
1
: 2.0 mm (0.08 in)
Lateral
2
: 2.0 mm (0.08 in)
EC514200
Wheel axle
1. Measure:
lWheel axle bends
Out of specification ® Replace.
Use the dial gauge 1.
Wheel axle bending limit:
0.5 mm (0.020 in)

5 - 27
CHASREAR WHEEL AND REAR BRAKE
NOTE:
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:
lBrake shoe lining surface
Glazed areas ® Polish.
Use coarse sand paper.
NOTE:
After polishing, wipe the polished particles with
a cloth.
2. Measure:
lBrake shoe lining thickness a
Out of specification ® Replace.
NOTE:
Replace the brake shoes and springs as a set
if either is worn to the limit.
Brake shoe lining thickness:
Standard
4.0 mm
(0.16 in)2.0 mm
(0.08 in)
3. Measure:
lBrake drum inside diameter a
Out of specification ® Replace.
Brake drum inside diameter:
Standard
110 mm
(4.33 in)111 mm
(4.37 in)

5 - 28
CHASREAR WHEEL AND REAR BRAKE
4. Inspect:
lBrake drum inner surface.
Oil/scratches ® Remove.
OilUse a rag soaked in lac-
quer thinner or a solvent.
ScratchesUse a emery cloth (lightly
and evenly polishing).
ASSEMBLY AND INSTALLATION
Brake shoe plate assembly
1. Install:
lBrake camshaft 1
NOTE:
Apply the lithium soap base grease on the
brake camshaft.
2. Check:
lBrake camshaft operation
Unsmooth operation ® Repair.
3. Install:
lWear indicator plate 1
NOTE:
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.
4. Install:
lBrake camshaft lever 1
NOTE:
Install the brake camshaft lever in relation to
the punch mark a as shown.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

5 - 29
CHASREAR WHEEL AND REAR BRAKE
5. Install:
lSprings 1
lBrake shoes 2
On brake shoe plate 3
NOTE:
lApply the lithium soap base grease on the
pivot pin.
lWhen installing the springs and brake shoes,
take care not to damage the springs.
lWhen replacing the brake shoes, replace the
springs as a set.
WARNING
Do not apply grease to the brake shoe lin-
ings.
New
Rear wheel
1. Install:
lWheel bearing 1
lSpacer 2
lWheel bearing 3
lOil seal 4
NOTE:
lApply the lithium soap base grease on the oil
seal lip when installing.
lInstall the bearing with seal facing outward.
lUse a socket that matches the outside diam-
eter of the race of the bearing.
lRight side of bearing shall be installed first.
lInstall the oil seal with its manufacture’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of the bearing.
Contact should be made only with the outer
race.
New

5 - 30
CHASREAR WHEEL AND REAR BRAKE
2. Install:
lWheel sprocket 1
lLock washers 2
NOTE:
lTighten the nuts in stage, using a crisscross
pattern.
lBend the lock washer tab.
New
T R..26 Nm (2.6 m · kg, 19 ft · lb)
3. Install:
lCollar (left)
lBrake shoe plate assembly
lCollar (right)
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
4. Install:
lRear wheel
NOTE:
Make sure that the slot a on the brake shoe
plate with the stopper b on the swingarm.
5. Install:
lDrive chain 1
NOTE:
Push the wheel 2 forward and install the drive
chain.
6. Install:
lDrive chain puller (left) 1
lPlain washer 2
lWheel axle 3
NOTE:
lApply the lithium soap base grease on the
wheel axle.
lInsert the wheel axle from left side.

5 - 31
CHAS

REAR WHEEL AND REAR BRAKE
7. Install:
l
Drive chain puller (right)
1

l
Plain washer
2

l
Axle nut
3

NOTE:

Temporarily tighten the axle nut at this point.
8. Adjust:
l
Drive chain slack
a

Refer to “DRIVE CHAIN SLACK
ADJUSTMENT” section in the CHAP-
TER 3.
Drive chain slack:
35 ~ 50 mm (1.4 ~ 2.0 in)
9. Tighten:
l
Axle nut
1

T R..60 Nm (6.0 m · kg, 43 ft · lb)

10. Install:
l
Spring
1

l
Brake rod
2

l
Pin
3

l
Wing nut
4

On brake camshaft lever
5
.
11. Adjust:
l
Brake pedal free play
Refer to “REAR BRAKE ADJUST-
MENT” section in the CHAPTER 3.

5 - 32
CHASFRONT FORK
EC550000
FRONT FORK
Extent of removal:1 Front fork removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalFRONT FORK REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is nodanger of it falling over.
Front wheel Refer to “FRONT WHEEL AND FRONT
BRAKE” section.
(Refer to “FRONT WHEEL” section for
the TT-R125LW.)
Handlebar Refer to “HANDLEBAR” section.
1 Cap 1
2 Pinch bolt (upper bracket) 1 Only loosening.
3 Cap bolt 1Loosen when disassembling the front fork.
4 Pinch bolt (lower bracket) 1 Only loosening.
5Front fork
1
1