2002 YAMAHA TTR125 transmission

4 - 64
ENG
DÉPOSE DU MOTEUR
MOTOR AUSBAUEN
HINWEIS:
lLithiumfett auf die Gewinde der Motorbefesti-
gungsschrauben (hinten) 2 auftragen.
lDie Motorhalterschraube (oben) festziehen
8, und dann die Schrauben (Motorbügel) 9
festziehen.
Schalthebel-Gelenk
1. Montieren:
lSchalthebel-Gelenk 1
lSchraube (Schalthebel-Gelenk) 2
HINWEIS:
Die Mitte a des vordersten Punktes des
Schalthebels auf den höchsten Punkt der Fuß-
raste ausrichten.
T R..10 Nm (1,0 m · kg)
Antriebsritzel
1. Montieren:
lAntriebsritzel 1
lAntriebskette 2
HINWEIS:
Antriebsritzel und Antriebskette montieren.
2. Montieren:
lAntriebsritzel-Halter 1
lSchraube (Antriebsritzel)
T R..6 Nm (0,6 m · kg)
3. Montieren:
lAntriebsritzel-Deckel 1
lSchraube (Antriebsritzel-Deckel) 2
T R..12 Nm (1,2 m · kg)
N.B.:
lEnduire le filet des boulons de montage du
moteur 2 de graisse à base de savon au lithium.
lSerrer le boulon de montage du moteur (supé-
rieur) 8, puis serrer les boulons (support de
moteur) 9.
Tige de pédale de sélecteur
1. Installer:
lTige de pédale de sélecteur 1
lBoulon (tige de pédale de sélecteur) 2
N.B.:
Placer la pédale de sélection de sorte que le milieu a
de son extrémité avant soit à la même hauteur que le
point le plus élevé du repose-pied.
T R..10 Nm (1,0 m · kg, 7,2 ft · lb)
Pignon menant
1. Installer:
lPignon menant 1
lChaîne de transmission 2
N.B.:
Monter en même temps le pignon menant et la
chaîne de transmission.
2. Installer:
lCache de pignon menant 1
lBoulon (cache de pignon menant)
T R..6 Nm (0,6 m · kg, 4,3 ft · lb)
3. Installer:
lCache de chaîne 1
lVis (cache de chaîne) 2
T R..12 Nm (1,2 m · kg, 8,7 ft · lb)

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
ENGCRANKCASE, CRANKSHAFT AND BALANCER
3. Tighten:
lLead guide 1
lClutch cable holder 2
lBolt (crankcase) [45 mm (1.8 in)] 3
lBolt (crankcase) [55 mm (2.2 in)] 4
lBolt (crankcase) [30 mm (1.2 in)] 5
NOTE:
lApply Quick gasket® (YAMAHA Bond
No.1215) on end of the crankcase bolts [45
mm (1.8 in)] 3, as shown.
lTighten 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:
lCrankshaft and transmission operation
Unsmooth operation ® Repair.
5. Install:
lTiming chain 1
lIntake timing chain guide 2
lBolt (intake timing chain guide)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)LT

4 - 73
ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
TRANSMISSION, SHIFT CAM AND SHIFT FORK
Extent of removal:1 Shift cam and shift fork removal2 Main axle and drive axle removal
Extent of removal Order Part name Q’ty Remarks
TRANSMISSION, SHIFTCAM
AND SHIFT FORK REMOVAL
Preparation for removal Engine Refer to “ENGINE REMOVAL” section.
Separate the crankcase. Refer to “CRANKCASE, CRANKSHAFT
AND BALANCER” section.
1 Shift fork guide bar 1 (short) 1
2 Shift fork guide bar 2 (long) 1
3 Shift cam 1
4 Shift fork 2 (C) 1
5 Shift fork 3 (R) 1
6 Shift fork 1 (L) 1
7 Main axle 1
Refer to “REMOVAL POINTS”.
8 Drive axle 1
9 Push rod 2 1
10 Washer 1
1
2

4 - 74
ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
REMOVAL POINTS
Transmission
1. Remove:
lMain axle 1
lDrive axle 2
NOTE:
lTap lightly on the transmission drive axle
with a soft hammer to remove.
lRemove 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:
lMatching dog a
lGear teeth b
lShift fork groove c
Wear/damage ® Replace.
2. Check:
lGears movement
Unsmooth movement ® Repair or
replace.
Push rod
1. Inspect:
lPush rod 2 1
Wear/damage/bend ® Replace.

4 - 75
ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
EC4H4600
Bearing
1. Inspect:
lBearing 1
Rotate inner race with a finger.
Rough spot/seizure ® Replace.
Shift fork and shift cam
1. Inspect:
lShift fork 1
Wear/damage/scratches ® Replace.
2. Inspect:
lShift cam 1
lShift fork guide bar 2
Bend/wear/damage ® Replace.
3. Check:
lShift fork movement
On its guide bar.
Unsmooth operation ® Replace shift
fork and/or guide bar.
NOTE:
For a malfunctioning shift fork, replace not only
the shift fork itself but the two gears each adja-
cent to the shift fork.

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.