2001 YAMAHA TTR125 oil

4 - 42
ENG

CLUTCH AND PRIMARY DRIVEN GEAR
PUSH LEVER
Extent of removal:
1
Push lever removal
Extent of removal Order Part name Q’ty Remarks
PUSH LEVER REMOVAL
1 Clutch cable 1
2 Push lever 1
3 Spring 1
4 Circlip 1
5Oil seal
1
1

4 - 45
ENG

CLUTCH AND PRIMARY DRIVEN GEAR
Push rod
1. Inspect:
l
Push rod 1
1

l
Ball
2

Wear/damage/bend
®
Replace.
Primary drive gear
1. Inspect:
l
Primary drive gear
Wear/damage
®
Replace.
EC495000
ASSEMBLY AND INSTALLATION
Push lever
1. Install:
l
Push lever
1
NOTE:
lApply the lithium soap base grease on the oil
seal lip.
lApply the engine oil on the push lever.
Primary drive gear
1. Install:
lStraight key
lPrimary drive gear 1
lWasher 2
lNut (primary drive gear) 3
lPrimary driven gear 4
NOTE:
lInstall the primary drive gear with the stamp
a facing out.
lPlace a folded rag or aluminum plate 5
between the teeth of the primary drive gear
and primary driven gear.
T R..70 Nm (7.0 m · kg, 50 ft · lb)

4 - 46
ENGCLUTCH AND PRIMARY DRIVEN GEAR
Clutch
1. Install:
lConical spring washer 1
lThrust plate 2
lPrimary driven gear 3
lThrust plate 4
lClutch boss 5
2. Install:
lLock washer
lNut (clutch boss) 1
NOTE:
Use the clutch holding tool 2 to hold the clutch
boss.
For USA and CDN
õExcept for USA and CDN
3. Bend:
lLock washer tab
Clutch holding tool:
YM-91042/90890-04086
New
T R..60 Nm (6.0 m · kg, 43 ft · lb)

õ
4. Install:
lFriction plate 1
lClutch plate 2
NOTE:
lInstall the clutch plates and friction plates
alternately on the clutch boss, starting with a
friction plate and ending with a friction plate.
lApply the engine oil on the friction plates and
clutch plates.
lBe sure to install a clutch plate with projec-
tion a offset approximately 90˚ from previ-
ous plates projection. Continue this
procedure in a clockwise direction until all
clutch plates are installed.

4 - 47
ENGCLUTCH AND PRIMARY DRIVEN GEAR
5. Install:
lBall
NOTE:
Apply the engine oil on the ball.
6. Install:
lPush rod 1 1
lPush plate 2
lWasher 3
lNut (push rod 1) 4
7. Install:
lPressure plate 1
lClutch spring 2
lBolt (clutch spring) 3
NOTE:
lAlign the arrow mark a on the pressure
plate with the punched mark b on the clutch
boss.
lTighten the bolts in stage, using a crisscross
pattern.
T R..6 Nm (0.6 m · kg, 4.3 ft · lb)
8. Check:
lPush lever position
Push the push lever assembly in the
arrow direction and make sure that the
mach mark are aligned ® adjust.
aMatch mark on the push lever assembly
bMatch mark on the crankcase

4 - 49
ENGOIL PUMP
OIL PUMP
Extent of removal:1 Oil pump removal
Extent of removal Order Part name Q’ty Remarks
OIL PUMP REMOVAL
Preparation for removal Clutch and primary drive gear Refer to “CLUTCH AND PRIMARY
DRIVEN GEAR” section.
1 Rotary filter 1
2 Oil pump drive gear 1
3 Oil pump assembly 1
4 Gasket 1
5Oil strainer
1
1

4 - 50
ENGOIL PUMP
OIL PUMP DISASSEMBLY
Extent of removal:1 Oil pump disassembly
Extent of removal Order Part name Q’ty Remarks
OIL PUMP DISASSEMBLY
1Circlip 1
2Oil pump driven gear 1
3Conical spring washer 1
4Circlip 1
5Washer 1
6Oil pump cover 1
7Pin 2
8Oil pump shaft 1
9Pin 1
0Inner rotor 1
AOuter rotor 1
BOil pump housing 1
1

4 - 51
ENG

OIL PUMP
INSPECTION
Oil pump
1. Inspect:
l
Oil pump drive gear
l
Oil pump driven gear
l
Oil pump housing
l
Oil pump cover
Cracks/wear/damage
®
Replace.
2. Measure:
l
Tip clearance


(between the inner rotor
1
and the
outer rotor
2
)
l
Side clearance
õ

(between the outer rotor
2
and the oil
pump housing
3
)
Out of specification
®
Replace the oil
pump assembly.
l
Housing and rotor clearance
‚

(between the pump housing
3
and the
rotors
1

2
)
Out of specification
®
Replace the oil
pump assembly.
Tip clearance

:
0.15 mm (0.0059 in)
: 0.20 mm (0.0079 in)
Side clearance
õ
:
0.06 ~ 0.10 mm
(0.0024 ~ 0.0039 in)
: 0.15 mm (0.0059 in)
Housing and rotor clearance
‚
:
0.06 ~ 0.10 mm
(0.0024 ~ 0.0039 in)
: 0.15 mm (0.0059 in)
Rotary filter
1. Inspect:
l
Rotary filter
Cracks/damage
®
Replace.

4 - 52
ENG

OIL PUMP
Oil strainer
1. Inspect:
l
Oil strainer
Cracks/damage
®
Replace.
Contamination
®
Clean the flushing oil.
ASSEMBLY AND INSTALLATION
Oil pump
1. Install:
l
Oil pump housing
1

l
Outer rotor
2

l
Inner rotor
3

l
Pin
4

l
Oil pump shaft
5

l
Pin
6

l
Oil pump cover
7

l
Washer
8

l
Circlip
9

l
Conical spring washer
0

l
Oil pump driven gear
A

l
Circlip
B

l
Screws
C

NOTE:

l
Apply engine oil onto the outer rotor, inner
rotor and oil pump shaft.
l
Install the conical spring washer in the direc-
tion as shown.
2. Install:
l
Oil strainer
l
Gasket
l
Oil pump assembly
l
Screws (oil pump assembly)
NOTE:

Apply engine oil onto the crankcase oil pas-
sage and oil pump assembly.
New
New
T R..5 Nm (0.5 m · kg, 3.6 ft · lb)
New
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)

3. Install:
l
Oil pump drive gear
1
lRotary filter 2
NOTE:
lInstall the oil pump drive gear with its groove
a facing the engine.
lInstall the rotary filter with the dog b facing
out.
lAlign the rotary filter dog b with groove c of
the crankshaft.