2002 YAMAHA TTR125 Owners Manual

SPEC
2 - 20
MAINTENANCE SPECIFICATIONS
Rear drum brake:
Drum brake type Leading, trailing ----
Drum inside diameter 110 mm (4.33 in) 111 mm (4.37 in)
Lining thickness 4.0 mm (0.16 in) 2.0 mm (0.08 in)
Shoe spring free length 50.5 mm (1.99 in) ----
Brake lever and brake pedal:
Brake lever free play (lever end) 2 ~ 5 mm (0.08 ~ 0.20 in) ----
Brake pedal position
(vertical height below footrest top)1 mm (0.04 in) ----
Brake pedal free play 20 ~ 30 mm (0.79 ~ 1.18 in) ----
Clutch lever free play (lever end) 10 ~ 15 mm (0.39 ~ 0.59 in) ----
Throttle grip free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----Item Standard Limit

SPEC
2 - 21
MAINTENANCE SPECIFICATIONS
NOTE:
1. First, tighten the ring nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the ring nut
wrench and turn the steering right and left a few times; then loosen the ring nut one turn.
2. Retighten the ring nut 20 Nm (2.0 m • kg, 14 ft • lb).Part to be tightened Thread size Q’tyTightening torque
Nm m•kg ft•lb
Upper bracket and inner tube M8 ´ 1.25 2 25 2.5 18
Lower bracket and inner tube M10 ´ 1.25 2 60 6.0 43
Upper bracket and steering stem M22 ´ 1.0 1 110 11.0 80
Handlebar upper holder and upper bracket M8 ´ 1.25 4 23 2.3 17
Steering stem and ring nut M25 ´ 1.0 1 Refer to NOTE.
Front fork and cap bolt M25 ´ 1.0 2 23 2.3 17
Front fork and damper rod M10 ´ 1.0 2 23 2.3 17
Front fork and brake hose holder M6 ´ 1.0 2 7 0.7 5.1
Number plate M6 ´ 1.0 1 7 0.7 5.1
Starter knob M11 ´ 1.25 1 1 0.1 0.7
Starter knob stay M6 ´ 1.0 2 10 1.0 7.2
Grip cap upper and lower M5 ´ 0.8 2 4 0.4 2.9
Throttle cable cap M4 ´ 0.7 2 2 0.2 1.4
Front brake master cylinder M6 ´ 1.0 2 9 0.9 6.5
Front brake master cylinder cap M4 ´ 0.7 2 2 0.2 1.4
Brake lever mounting (bolt) M6 ´ 1.0 1 7 0.7 5.1
Brake lever mounting (nut) M6 ´ 1.0 1 7 0.7 5.1
Brake lever adjuster and locknut M6 ´ 0.75 1 4 0.4 2.9
Clutch lever mounting (bolt) M6 ´ 1.0 1 7 0.7 5.1
Clutch lever mounting (nut) M6 ´ 1.0 1 7 0.7 5.1
Clutch lever holder M5 ´ 0.8 2 4 0.4 2.9
Front brake master cylinder and joint M10 ´ 1.25 1 26 2.6 19
Front brake hose and joint M10 ´ 1.25 1 14 1.4 10
Front brake hose union bolt M10 ´ 1.25 1 26 2.6 19
Front brake caliper and front fork M8 ´ 1.25 2 30 3.0 22
Brake caliper support bolt M8 ´ 1.25 1 22 2.2 16
Front brake caliper and bleed screw M7 ´ 1.0 1 6 0.6 4.3
Front wheel axle and axle nut M12 ´ 1.25 1 45 4.5 32
Front brake disc and wheel hub M6 ´ 1.0 4 12 1.2 8.7
Rear wheel axle and axle nut M12 ´ 1.25 1 60 6.0 43
Rear brake camshaft lever and camshaft M6 ´ 1.0 1 10 1.0 7.2
Brake pedal mounting M10 ´ 1.25 1 30 3.0 22
Brake pedal position locknut M6 ´ 1.0 1 7 0.7 5.1
Front wheel nipple (spoke) — 36 2 0.2 1.4
Rear wheel nipple (spoke) — 36 3 0.3 2.2

SPEC
2 - 22
MAINTENANCE SPECIFICATIONS
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each ride.Part to be tightened Thread size Q’tyTightening torque
Nm m•kg ft•lb
Bead stopper M8 ´ 1.25 1 3 0.3 2.2
Driven sprocket (nut) M10 ´ 1.25 4 43 4.3 31
Driven sprocket (stud) M10 ´ 1.25 4 30 3.0 22
Sidestand mounting (nut) M10 ´ 1.25 1 44 4.4 32
Engine mounting:
Engine bracket (front) and frame M8 ´ 1.25 2 40 4.0 29
Engine bracket (front) and engine M8 ´ 1.25 2 40 4.0 29
Engine bracket (upper) and frame M8 ´ 1.25 2 40 4.0 29
Engine bracket (upper) and cylinder head M8 ´ 1.25 1 40 4.0 29
Engine and frame (rear) M8 ´ 1.25 2 40 4.0 29
Pivot shaft and nut M12 ´ 1.25 1 53 5.3 38
Relay arm and swingarm M12 ´ 1.25 1 53 5.3 38
Relay arm and connecting arm M10 ´ 1.25 1 35 3.5 25
Connecting arm and frame M10 ´ 1.25 1 35 3.5 25
Rear shock absorber assembly and frame M12 ´ 1.25 1 53 5.3 38
Rear shock absorber assembly and relay arm M10 ´ 1.25 1 35 3.5 25
Rear shock absorber and locknut (preload) M46 ´ 1.5 1 42 4.2 30
Drive chain tensioner (upper) M8 ´ 1.25 1 23 2.3 17
Drive chain tensioner (lower) M6 ´ 1.0 1 7 0.7 5.1
Drive chain support and swingarm M6 ´ 1.0 2 7 0.7 5.1
Drive chain guide and swingarm M6 ´ 1.0 2 7 0.7 5.1
Drive chain guard mounting M6 ´ 1.0 2 7 0.7 5.1
Fuel tank mounting M6 ´ 1.0 2 10 1.0 7.2
Fuel tank and fuel cock M6 ´ 1.0 2 7 0.7 5.1
Fuel tank and fuel tank bracket M6 ´ 1.0 4 7 0.7 5.1
Front fender mounting M6 ´ 1.0 4 7 0.7 5.1
Rear fender mounting M6 ´ 1.0 4 7 0.7 5.1
Flap guard mounting M6 ´ 1.0 2 4 0.4 2.9
Left side cover mounting M6 ´ 1.0 2 7 0.7 5.1
Seat mounting M6 ´ 1.0 2 7 0.7 5.1

SPEC
2 - 23
MAINTENANCE SPECIFICATIONS
EC212300
ELECTRICAL
Item Standard Limit
CDI:
Magneto-model (stator)/manufacturer 5HP-01/YAMAHA ----
Charging coil resistance (color) 688 ~ 1,032 W at 20 ˚C (68 ˚F)
(Green-Brown)----
Pickup coil resistance (color) 248 ~ 372 W at 20 ˚C (68 ˚F)
(White-Red)----
CDI unit-model/manufacturer 5HP-00/YAMAHA ----
Ignition coil:
Model/manufacturer 4KJ-10/YAMAHA ----
Minimum spark gap 6 mm (0.24 in) ----
Primary coil resistance 0.18 ~ 0.28 W at 20 ˚C (68 ˚F) ----
Secondary coil resistance 6.3 ~ 9.5 kW at 20 ˚C (68 ˚F) ----
Part to be tightened Thread size Q’tyTightening torque
Nm m•kg ft•lb
Pickup coil M6 ´ 1.0 2 10 1.0 7.2
Blind plug (neutral switch) M10 ´ 1.25 1 20 2.0 14
Stator M6 ´ 1.0 3 10 1.0 7.2
Rotor M12 ´ 1.25 1 80 8.0 58
Ignition coil M6 ´ 1.0 2 7 0.7 5.1

2 - 24
SPEC

GENERAL TORQUE SPECIFICATIONS/
DEFINITION OF UNITS
EC220001
GENERAL TORQUE SPECIFICATIONS
This chart specifies torque for standard fasten-
ers with standard I.S.O. pitch threads. Torque
specifications for special components or
assemblies are included in the applicable sec-
tions of this book. To avoid warpage, tighten
multi-fastener assemblies in a crisscross fash-
ion, in progressive stages, until full torque is
reached. Unless otherwise specified, torque
specifications call for clean, dry threads. Com-
ponents should be at room temperature.
A
(Nut)B
(Bolt)TORQUE
SPECIFICATION
Nm m•kg ft•lb
10 mm
12 mm
14 mm
17 mm
19 mm
22 mm6 mm
8 mm
10 mm
12 mm
14 mm
16 mm6
15
30
55
85
1300.6
1.5
3.0
5.5
8.5
134.3
11
22
40
61
94
A: Distance between flats
B: Outside thread diameter
EC230000
DEFINITION OF UNITS
Unit Read Definition Measure
mm
cmmillimeter
centimeter10
-3

meter
10
-2

meterLength
Length
kg kilogram 10
3

gram Weight
N Newton 1 kg
´
m/sec
2

Force
Nm
m • kgNewton meter
Meter kilogramN
´
m
m
´
kgTorque
Torque
Pa Pascal N/m
2

Pressure
N/mm Newton per millimeter N/mm Spring rate
L
cm
3

Liter
Cubic centimeter—
—Volume or capacity
Volume or capacity
r/min Revolution per minute — Engine speed

SPEC

2 - 1
CARACTÉRISTIQUES
CARACTÉRISTIQUES GÉNÉRALES
TT-R125
Nom du modèle: TT-R125P
(USA, sauf Californie, CDN, AUS, NZ)
TT-R125PC (Californie)
TT-R125 (EUROPE)
Numéro de code de modèle: 5HPB (USA, AUS, NZ, EUROPE)
5HPC (CDN)
Dimensions: USA, AUS, NZ,
EUROPECDN
Longueur hors tout 1.830 mm (72,0 in)
1.865 mm (73,4 in)
Largeur hors tout 785 mm (30,9 in)
¬
Hauteur hors tout 1.055 mm (41,5 in)
¬
Hauteur de la selle 775 mm (30,5 in)
¬
Empattement 1.250 mm (49,2 in)
¬
Garde au sol minimale 265 mm (10,4 in)
¬
Poids net:
Avec huile et réservoir de carburant rempli 83 kg (183 lb)
Moteur:
Type de moteur 4 temps, refroidissement par air, un arbre à cames en
tête (SOHC)
Disposition du cylindre Monocylindre, incliné vers l’avant
Cylindrée 124 cm
3

(7,57 cu.in)
Alésage
´
course 54,0
´
54,0 mm (2,126
´
2,126 in)
Taux de compression 10,0:1
Système de démarrage Kick
Système de graissage: Carter humide
Type ou grade d’huile:
Huile de moteur (USA et CDN)
À –10 ˚C (10 ˚F) ou plus

Yamalube 4 (10W-30) ou huile moteur SAE 10W-30
de grade SE
À 5 ˚C (40 ˚F) ou plus
õ
Yamalube 4 (20W-40) ou huile moteur SAE 20W-40
de grade SE
(Sauf USA et CDN)
API “SE” ou grade supérieur
CARACTÉRISTIQUES GÉNÉRALES

SPEC

2 - 2
Quantité d’huile:
Huile de moteur
Vidange périodique 1,0 L (0,88 Imp qt, 1,06 US qt)
Quantité totale 1,2 L (1,06 Imp qt, 1,27 US qt)
Filtre à air: Élément de type humide
Carburant:
Type Carburant sans plomb (USA)
Essence normale sans plomb (CDN et EUROPE)
Essence sans plomb uniquement (AUS)
Essence ordinaire (NZ)
Capacité du réservoir 6,6 L (1,45 Imp gal, 1,74 US gal)
Quantité de la réserve 1,9 L (0,42 Imp gal, 0,5 US gal)
Carburateur:
Type VM20SS
Fabricant MIKUNI
Bougie:
Type CR7HSA/U22FSR-U
Fabricant NGK/DENSO
Écartement 0,6 à 0,7 mm (0,02 à 0,03 in)
Type d’embrayage: Humide, multidisque
Boîte de vitesses:
Système de réduction primaire Pignon
Taux de réduction primaire 68/19 (3,579)
Système de réduction secondaire Entraînement par chaîne
Taux de réduction secondaire 49/13 (3,769)
Type de boîte de vitesses Prise constante, 5 rapports
Commande Pied gauche
Démultiplication: 1re 37/14 (2,643)
2e 32/18 (1,778)
3e 25/19 (1,316)
4e 23/22 (1,045)
5e 21/24 (0,875)
Partie cycle:
Type de cadre Losange
Angle de chasse 28,7˚
Chasse 93 mm (3,66 in)
Pneus:
Type Avec chambre à air
Taille (avant) 70/100-17 40M
Taille (arrière) 90/100-14 49M
Fabricant (avant et arrière) CHENG SHIN
Pression de gonflage du pneu (avant et arrière) 100 kPa (1,00 kgf/cm
2

, 15 psi)
CARACTÉRISTIQUES GÉNÉRALES

SPEC

2 - 3
Freins:
Type de frein avant Frein à tambour
Commande Main droite
Type de frein arrière Frein à tambour
Commande Pied droit
Suspension:
Suspension avant Fourche télescopique
Suspension arrière Bras oscillant (suspension monocross à liaison)
Amortisseur:
Amortisseur avant Ressort hélicoïdal/amortisseur hydraulique
Amortisseur arrière Ressort hélicoïdal/pneumatique, amortisseur
hydraulique
Débattement de roue:
Débattement de roue avant 180 mm (7,09 in)
Débattement de roue arrière 160 mm (6,30 in)
Partie électrique:
Système d’allumage Magnéto CDI
CARACTÉRISTIQUES GÉNÉRALES