2001 YAMAHA TTR125 oil

ENG
4 - 65
CARTER-MOTEUR, VILEBREQUIN ET BALANCIER
KURBELGEHÄUSE, KURBELWELLE UND AUSGLEICHSWELLE
KURBELGEHÄUSE, KURBELWELLE UND AUSGLEICHSWELLE
Demontage-Arbeiten:1 Kurbelgehäuse teilen2 Ausgleichswelle demontieren
3 Kurbelwelle demontieren
Demontage-ArbeitenReihen-
folgeBauteilAnz.Bemerkungen
KURBELGEHÄUSE, KURBEL-
WELLE UND AUSGLEICHS-
WELLE DEMONTIEREN
Vorbereitung für den
AusbauMotorSiehe unter “MOTOR AUSBAUEN”.
KolbenSiehe unter “ZYLINDER UND KOLBEN”.
PrimärantriebszahnradSiehe unter “KUPPLUNG UND PRI-
MÄRABTRIEBSZAHNRAD”.
Kickstarterwelle komplett
Siehe unter “KICKSTARTERWELLE
UND SCHALTWELLE”.
Kickstarter-Zahnsegment
Rotor und StatorSiehe unter “LICHTMASCHINENRO-
TOR”.
CARTER-MOTEUR, VILEBREQUIN ET BALANCIER
Déposes à effectuer:1 Séparation du carter-moteur2 Dépose du balancier
3 Dépose du vilebrequin
Déposes à effectuerOrdreNom de pièceQtéRemarques
DÉPOSE DU CARTER-
MOTEUR, DU VILEBREQUIN
ET DU BALANCIER
Préparation à la déposeMoteurSe reporter à “DÉPOSE DU MOTEUR”.
PistonSe reporter à “CYLINDRE ET PISTON”.
Pignon menant primaireSe reporter à “EMBRAYAGE ET PIGNON
MENÉ PRIMAIRE”.
Axe de kick complet
Se reporter à “AXE DE KICK ET ARBRE
DE SÉLECTEUR”.
Étoile de sélection
Rotor et statorSe reporter à “MAGNÉTO CDI”.

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.

5 - 1
CHAS

FRONT WHEEL AND FRONT BRAKE (TT-R125)
EC500000
CHASSIS
FRONT WHEEL AND FRONT BRAKE (TT-R125)
Extent of removal:
1
Front wheel removal
2
Wheel bearing removal
3
Brake shoe plate assembly removal and disassembly
Extent of removal Order Part name Q’ty Remarks
Preparation for removal
FRONT WHEEL AND DRUM
BRAKE
Hold the machine by placing the
suitable stand under the engine.
WARNING

Support the machine securely so there is no
danger of it falling over.
1 Brake cable holder 1
2 Brake cable 1 Disconnect at the lever side, first.
3 Axle nut 1
4 Wheel axle 1
5 Front wheel 1
6 Collar set 1
7 Brake shoe plate assembly 1
8 Oil seal 1
9 Wheel bearing 2 Refer to “REMOVAL POINTS”.
10Spacer
1
2
3
1

5

5 - 3
CHAS

FRONT WHEEL AND FRONT BRAKE (TT-R125)
REMOVAL POINTS
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.
Wheel runout limit:
Radial
1
: 2.0 mm (0.08 in)
Lateral
2
: 2.0 mm (0.08 in)
2. Inspect:
l
Bearing
Rotate inner race with a finger.
Rough spot/seizure
®
Replace.
NOTE:

Replace the bearings, oil seal and wheel collar
as a set.
EC514200
Wheel axle
1. Measure:
l
Wheel axle bends
Out of specification
®
Replace.
Use the dial gauge
1
.
NOTE:

The bending value is shown by one half of the
dial gauge reading.
WARNING

Do not attempt to straighten a bent axle.
Wheel axle bending limit:
0.5 mm (0.020 in)

5 - 3
CHAS

DEMONTAGEPUNKTE
Radlager (falls erforderlich)
1. Demontieren:
l
Lager
1

HINWEIS:

Lager mit einem herkömmlichen Lageraustrei-
ber
2
demontieren.
PRÜFEN
Rad
1. Messen:
l
Max. Schlag
Unvorschriftsmäßig
®
Reparieren/
erneuern.
2. Prüfen:
l
Lager
Inneren Lagerlaufring mit einem Finger
drehen.
Rauheit/Lager fest
®
Erneuern.
HINWEIS:

Lager, Dichtring und Paßhülse satzweise
erneuern.
Maximal zulässiger Schlag:
Max. Höhenschlag
1
: 2,0 mm
Max. Seitenschlag
2
: 2,0 mm
Radachse
1. Messen:

l
Radachsenbiegung
Unvorschriftsmäßig
®
Erneuern.
Meßuhr
1
verwenden.
HINWEIS:

Der Verzug ergibt sich aus der Hälfte des von
der Meßuhr angezeigten Wertes.
WARNUNG

Niemals versuchen, eine verbogene Achse
zu richten.
Maximal zulässige Achsbiegung:
0,5 mm
ROUE AVANT ET FREIN AVANT (TT-R125)
VORDERRAD UND VORDERRADBREMSE (TT-R125)
PIÈCES À DÉPOSER
Roulement de roue (si nécessaire)
1. Déposer:
l
Roulement
1
N.B.:

Déposer le roulement à l’aide de l’extracteur de
roulements universel
2
.
INSPECTION
Roue
1. Mesurer:
l
Déformation de la roue
Hors spécifications
®
Réparer ou rempla-
cer.
2. Examiner:
l
Roulement
Faire tourner la cage interne à l’aide d’un
doigt.
Dureté/grippage
®
Remplacer.
N.B.:

Remplacer à la fois les roulements, la bague d’étan-
chéité et l’entretoise épaulée.
Limite de voile de roue:
Radial
1
: 2,0 mm (0,08 in)
Latéral
2
: 2,0 mm (0,08 in)
Axe de roue
1. Mesurer:

l
Déformations de l’axe de roue
Hors spécifications
®
Remplacer.
Utiliser un comparateur à cadran
1
.
N.B.:

Pour obtenir la déformation, il faut diviser en deux
la valeur affichée sur le comparateur à cadran.
AVERTISSEMENT

Ne pas tenter de redresser un axe déformé.
Limite de déformation d’axe de roue:
0,5 mm (0,020 in)

5 - 4
CHAS

FRONT WHEEL AND FRONT BRAKE (TT-R125)
Drum brake
1. Inspect:
l
Brake shoe lining surface
Glazed areas
®
Polish.
Use coarse sand paper.
NOTE:

After polishing, wipe the polished particles with
a cloth.
2. Measure:
l
Brake 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
40 mm
(0.16 in)2.0 mm
(0.08 in)
3. Measure:
l
Brake drum inside diameter
a

Out of specification
®
Replace.
Brake drum inside diameter:
Standard
110 mm
(4.33 in)111 mm
(4.37 in)
4. Inspect:
l
Brake 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).