2001 YAMAHA TTR125 clutch

4 - 65
ENGCRANKCASE, CRANKSHAFT AND BALANCER
CRANKCASE, CRANKSHAFT AND BALANCER
Extent of removal:1 Crankcase separation2 Balancer removal
3 Crankshaft removal
Extent of removal Order Part name Q’ty Remarks
CRANKCASE, CRANKSHAFT
AND BALANCER REMOVAL
Preparation for removal Engine Refer to “ENGINE REMOVAL” section.
Piston Refer to “CYLINDER AND PISTON” sec-
tion.
Primary drive gear Refer to “CLUTCH AND PRIMARY
DRIVEN GEAR” section.
Kick axle assembly
Refer to “KICK AXLE AND SHIFT
SHAFT” section.
Segment
Rotor and stator Refer to “CDI MAGNETO” section.

4 - 66
ENGCRANKCASE, CRANKSHAFT AND BALANCER
Extent of removal Order Part name Q’ty Remarks
1 Intake timing chain guide 1
2 Timing chain 1
3 Bolt [45 mm (1.8 in)] 7
4 Bolt [55 mm (2.2 in)] 1
5 Bolt [30 mm (1.2 in)] 2
6 Lead guide 1
7 Clutch cable holder 1
8 Right crankcase 1
Use special tool.
Refer to “REMOVAL POINTS”.
9 Left crankcase 1
10 Balancer 1
11 Crankshaft 1 Use special tool.
Refer to “REMOVAL POINTS”.
12 Bearing 3 Refer to “REMOVAL POINTS”.
3
21

4 - 67
ENGCRANKCASE, CRANKSHAFT AND BALANCER
REMOVAL POINTS
Crankcase
1. Remove:
lBolt (crankcase)
lLead guide 1
lClutch cable holder 2
NOTE:
Loosen each bolt 1/4 of a turn at a time and
after all the bolts are loosened, remove them.
2. Remove:
lRight crankcase 1
Use the crankcase separating tool 2.
NOTE:
lFully tighten the tool holding bolts, but make
sure the tool body is parallel with the case. If
necessary, one screw may be backed out
slightly to level tool body.
lAs pressure is applied, alternately tap on the
front engine mounting boss and transmission
shafts.
CAUTION:
Use soft hammer to tap on the case half.
Tap only on reinforced portions of case. Do
not tap on gasket mating surface. Work
slowly and carefully. Make sure the case
halves separate evenly. If one end “hangs
up”, take pressure off the push screw, re-
align, and start over. If the cases do not
separate, check for a remaining case screw
or fitting. Do not force.
Crankcase separating tool:
YU-1135-A/90890-01135

4 - 72
ENG

CRANKCASE, CRANKSHAFT AND BALANCER
3. Tighten:
l
Lead guide
1

l
Clutch cable holder
2

l
Bolt (crankcase) [45 mm (1.8 in)]
3

l
Bolt (crankcase) [55 mm (2.2 in)]
4

l
Bolt (crankcase) [30 mm (1.2 in)]
5

NOTE:

l
Apply Quick gasket
®

(YAMAHA Bond
No.1215) on end of the crankcase bolts [45
mm (1.8 in)]
3
, as shown.
l
Tighten the crankcase bolts in stage, using a
crisscross pattern.
Quick gasket
®

:
ACC-QUICK-GS-KT
YAMAHA Bond No.1215:
90890-85505
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

4. Check:
l
Crankshaft and transmission operation
Unsmooth operation
®
Repair.
5. Install:
l
Timing chain
1

l
Intake timing chain guide
2

l
Bolt (intake timing chain guide)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)LT

5 - 41
CHAS

HANDLEBAR
EC5B0000
HANDLEBAR
TT-R125
Extent of removal:
1
Handlebar removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removal
HANDLEBAR REMOVAL
Number plate
1 Clutch cable 1
2 Clutch lever 1
3 Engine stop switch 1
4 Front brake cable 1
5 Front brake lever 1
6 Grip cap (lower) 1
7 Grip cap (upper) 1
8 Throttle cable 1
9 Throttle grip assembly 1
10 Collar 1
11 Handlebar grip (left) 1 Refer to “REMOVAL POINTS”.
12 Handlebar holder 2
13 Handlebar 1
1

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CHAS

HANDLEBAR
TT-R125LW
Extent of removal:
1
Handlebar removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removal
HANDLEBAR REMOVAL
Number plate
1 Clutch cable 1
2 Clutch lever 1
3 Engine stop switch 1
4 Brake master cylinder 1 Refer to “REMOVAL POINTS”.
5 Grip cap (lower) 1
6 Grip cap (upper) 1
7 Throttle cable 1
8 Throttle grip assembly 1
1

5 - 48
CHAS
6. Install:
TT-R125
lFront brake lever holder 1
lBolts (front brake lever holder) 2
lFront brake cable 3
lClamp
NOTE:
Apply the lithium soap base grease on the
front brake cable end.
TT-R125LW
lBrake master cylinder 1
lBrake master cylinder bracket 2
lBolt (brake master cylinder bracket) 3
NOTE:
lInstall the bracket so that the arrow mark a
face upward.
lFirst tighten the bolts on the upper side of the
brake master cylinder bracket, and then
tighten the bolts on the lower side.
7. Install:
lEngine stop switch 1
lClutch lever holder 2
lBolts (clutch lever holder) 3
NOTE:
lThe engine stop switch and clutch lever
holder should be installed according to the
dimensions shown.
lPass the engine stop switch lead in the mid-
dle of the clutch lever holder.
8. Install:
lClutch cable 1
lClamp
NOTE:
Apply the lithium soap base grease on the
clutch cable end.
9. Adjust:
lBrake lever free play
Refer to “FRONT BRAKE ADJUST-
MENT” section in the CHAPTER 3.
lClutch lever free play
Refer to “CLUTCH ADJUSTMENT”
section in the CHAPTER 3.
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
T R..9 Nm (0.9 m · kg, 6.5 ft · lb)
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
HANDLEBAR