2001 YAMAHA TTR125 light

4 - 71
ENG

CRANKCASE, CRANKSHAFT AND BALANCER
2. Install:
l
Balancer
NOTE:

Align the punched mark
a
on the balancer
drive gear with the punched mark
b
on the
balancer driven gear.
Crankcase
1. Apply:
l
Sealant
On the right crankcase
1
.
NOTE:

Clean the contacting surface of crankcase (left
and right) before applying the sealant.
Quick gasket
®

:
ACC-QUICK-GS-KT
YAMAHA Bond No.1215:
90890-85505
2. Install:
l
Dowel pin
1

l
Right crankcase
On left crankcase.
NOTE:

l
Fit the right crankcase onto the left crank-
case. Tap lightly on the case with soft ham-
mer.
l
When installing the crankcase, the connect-
ing rod should be positioned at TDC (top
dead center).

4 - 74
ENG

TRANSMISSION, SHIFT CAM AND SHIFT FORK
REMOVAL POINTS
Transmission
1. Remove:
l
Main axle
1

l
Drive axle
2

NOTE:

l
Tap lightly on the transmission drive axle
with a soft hammer to remove.
l
Remove assembly carefully. Note the posi-
tion of each part. Pay particular attention to
the location and direction of shift forks.
EC4H4000
INSPECTION
EC4H4200
Gears
1. Inspect:
l
Matching dog
a

l
Gear teeth
b

l
Shift fork groove
c

Wear/damage
®
Replace.
2. Check:
l
Gears movement
Unsmooth movement
®
Repair or
replace.
Push rod
1. Inspect:
l
Push rod 2
1

Wear/damage/bend
®
Replace.

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).

5 - 20
CHAS

Brake master cylinder
1. Install:
l
Brake master cylinder
1

l
Brake master cylinder bracket
2

l
Bolt (brake master cylinder bracket)
3

NOTE:

l
Install the brake master cylinder bracket so
that the arrow mark
a
face upward.
l
First tighten the bolts on the upper side of the
brake master cylinder bracket, and then
tighten the bolts on the lower side.
2. Install:
l
Brake lever
1

l
Spring
2

l
Bolt (brake lever)
3

l
Nut (brake lever)
4

NOTE:

l
Apply the lithium soap base grease on the
bolt and brake lever sliding surface.
l
Apply the molybdenum disulfide grease on
the tip of the adjuster bolt.
T R..9 Nm (0.9 m · kg, 6.5 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)

Brake hose
1. Install:
l
Copper washer
1

l
Brake hose
2

l
Union bolt
3

WARNING

Always use new copper washers.
CAUTION:

Install the brake hose so that its pipe por-
tion
a
directs as show and lightly touches
the projection
b
on the brake caliper.
New
T R..26 Nm (2.6 m · kg, 19 ft · lb)

FRONT BRAKE (TT-R125LW)

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)