2001 YAMAHA TTR125 engine

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GEN
INFO
CONTROL FUNCTIONS
FUEL TANK CAP
Remove the fuel tank cap 1 by turning coun-
terclockwise.
WARNING
Do not overfill the fuel tank. Avoid spilling
fuel on the hot engine.
SIDESTAND
This sidestand 1 is used to support only the
machine when standing or transporting it.
WARNING
lNever apply additional force to the side-
stand.
lHold up the sidestand before starting out.

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GEN
INFO
FUEL
Use regular gasoline. Always use fresh, name
brand gasoline.
WARNING
Do not overfill the fuel tank. Avoid spilling
fuel on the hot engine. Do not fill the fuel
tank above the bottom of the filler tube 1
as shown in the illustration or it may over-
flow when the fuel heats up later and
expands.
aFuel level
Recommended fuel:
For USA:
Unleaded fuel
For CDN and EUROPE:
Regular unleaded gasoline
For AUS:
Unleaded fuel only
For NZ:
Regular gasoline
Fuel tank capacity:
Total:
6.6 L (1.45 lmp gal, 1.74 US gal)
Reserve:
1.9 L (0.42 lmp gal, 0.5 US gal)
FUEL

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GEN
INFO
STARTING AND BREAK-IN
EC190000
STARTING AND BREAK-IN
CAUTION:
Before starting the machine, perform the
checks in the pre-operation check list.
WARNING
Never start or run the engine in a closed
area. The exhaust fumes are poisonous;
they can cause loss of consciousness and
death in a very short time. Always operate
the machine in a well-ventilated area.
STARTING A COLD ENGINE
1. Shift the transmission into neutral.
2. Turn the fuel cock to “ON” and full open
the starter knob (CHOKE).
3. With the throttle completely closed start
the engine by kicking the kickstarter
crank forcefully with firm stroke.
4. Run the engine at idle or slightly higher
until it warms up: this usually takes about
one or two minutes.
5. The engine is warmed up when it
responds normally to the throttle with the
starter knob (CHOKE) turned off.
CAUTION:
Do not warm up the engine for extended
periods.
EC193001
STARTING A WARM ENGINE
Do not operate the starter knob (CHOKE).
Open the throttle slightly and start the engine
by kicking the kickstater forcefully with firm
stroke.
CAUTION:
Observe the following break-in procedures
during initial operation to ensure optimum
performance and avoid engine damage.

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GEN
INFO
STARTING AND BREAK-IN
BREAK-IN
Break-in is important to better fit the moving
and sliding parts as well as the installed parts.
It is also important to accustom the rider to the
machine better.
Avoid full-throttle run on a new machine for the
first 5 hours.
After the trial run, check for loose parts, oil
leakage and other problems.
Make full inspection and adjustment especially
of slack cables and drive chain and loose
spokes.
CAUTION:
After the break-in or before each ride, you
must check the entire machine for loose fit-
tings and fasteners as per “TORQUE-
CHECK POINTS”.
Tighten all such fasteners as required.
BREAKING IN AFTER REPLACEMENT
After a part is replaced with a new one, it is
necessary to break it in as in a new machine.
This is required especially when the following
engine-related parts are replaced.
lCylinder
lPiston
lPiston ring
lValve
lCamshaft
lCrankshaft
lClutch
lTransmission gear
lShift fork
* For warming up and inspection during
break-in, refer to “GENERAL INSPECTION
AND MAINTENANCE” and if there is any
problem, stop the engine immediately and
check.

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GEN
INFO
TORQUE-CHECK POINTS
TORQUE-CHECK POINTS
TT-R125
Engine mounting
Muffler
Steering Steering stem to
handlebar
Suspension Front Steering stem to
front fork
Rear For link type
Rear Installation of shock
absorber
Rear Installation of swing-
arm
Wheel Installation of wheel Front
Rear
Brake Front
Rear
Fuel systemFrame to engine
Frame to engine bracket
Muffler to cylinder head
Muffler to rear fender bracket
Muffler to seat pillar tube
Steering stem to frame
Steering stem to upper bracket
Upper bracket to handlebar
Front fork to upper bracket
Front fork to lower bracket
Assembly of links
Link to frame
Link to shock absorber
Link to swingarm
Shock absorber to frame
Tightening of pivot shaft
Tightening of wheel axle
Tightening of wheel axle
Wheel to sprocket
Camshaft lever to camshaft
Camshaft lever to camshaft
Fuel tank to fuel cock
NOTE:
Concerning the tightening torque, refer to
“MAINTENANCE SPECIFICATIONS” section
in the CHAPTER 2.

GEN
INFO
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TORQUE-CHECK POINTS
TT-R125LW
Engine mounting
Muffler
Steering Steering stem to
handlebar
Suspension Front Steering stem to
front fork
Rear For link type
Rear Installation of shock
absorber
Rear Installation of swing-
arm
Wheel Installation of wheel Front
Rear
Brake Front
Rear
Fuel systemFrame to engine
Frame to engine bracket
Muffler to cylinder head
Muffler to rear fender bracket
Muffler to seat pillar tube
Steering stem to frame
Steering stem to upper bracket
Upper bracket to handlebar
Front fork to upper bracket
Front fork to lower bracket
Assembly of links
Link to frame
Link to shock absorber
Link to swingarm
Shock absorber to frame
Tightening of pivot shaft
Tightening of wheel axle
Tightening of wheel axle
Wheel to sprocket
Brake caliper to front fork
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to joint
Brake hose to joint
Brake master cylinder to handlebar
Tightening of bleed screw
Brake camshaft lever to brake camshaft
Fuel tank to fuel cock
NOTE:
Concerning the tightening torque, refer to
“MAINTENANCE SPECIFICATIONS” section
in the CHAPTER 2.

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GEN
INFO
CLEANING AND STORAGE
EC1B0000
CLEANING AND STORAGE
EC1B1000
CLEANING
Frequent cleaning of your machine will
enhance its appearance, maintain good over-
all performance, and extend the life of many
components.
1. Before washing the machine, block off
the end of the exhaust pipe to prevent
water from entering. A plastic bag
secured with a rubber band may be used
for this purpose.
2. If the engine is excessively greasy, apply
some degreaser to it with a paint brush.
Do not apply degreaser to the chain,
sprockets, or wheel axles.
3. Rinse the dirt and degreaser off with a
garden hose; use only enough pressure
to do the job.
CAUTION:
Excessive hose pressure may cause water
seepage and contamination of wheel bear-
ings, front forks, brakes and transmission
seals. Many expensive repair bills have
resulted from improper high pressure
detergent applications such as those avail-
able in coin-operated car washers.
4. After the majority of the dirt has been
hosed off, wash all surfaces with warm
water and a mild detergent. Use an old
toothbrush to clean hard-to-reach places.
5. Rinse the machine off immediately with
clean water, and dry all surfaces with a
soft towel or cloth.
6. Immediately after washing, remove
excess water from the chain with a paper
towel and lubricate the chain to prevent
rust.
7. Clean the seat with a vinyl upholstery
cleaner to keep the cover pliable and
glossy.
8. Automotive wax may be applied to all
painted or chromed surfaces. Avoid com-
bination cleaner-waxes, as they may con-
tain abrasives.
9. After completing the above, start the
engine and allow it to idle for several min-
utes.

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GEN
INFO
CLEANING AND STORAGE
EC182001
STORAGE
If your machine is to be stored for 60 days or
more, some preventive measures must be
taken to avoid deterioration. After cleaning the
machine thoroughly, prepare it for storage as
follows:
1. Drain the fuel tank, fuel lines, and the
carburetor float bowl.
2. Remove the spark plug, pour a table-
spoon of SAE 10W-30 motor oil in the
spark plug hole, and reinstall the plug.
With the engine stop switch pushed in,
kick the engine over several times to coat
the cylinder walls with oil.
3. Remove the drive chain, clean it thor-
oughly with solvent, and lubricate it.
Reinstall the chain or store it in a plastic
bag tied to the frame.
4. Lubricate all control cables.
5. Block the frame up to raise the wheels off
the ground.
6. Tie a plastic bag over the exhaust pipe
outlet to prevent moisture from entering.
7. If the machine is to be stored in a humid
or salt-air environment, coat all exposed
metal surfaces with a film of light oil. Do
not apply oil to rubber parts or the seat
cover.
NOTE:
Make any necessary repairs before the
machine is stored.