2002 YAMAHA TTR125 warning

5 - 20
CHAS
Brake master cylinder
1. Install:
lBrake master cylinder 1
lBrake master cylinder bracket 2
lBolt (brake master cylinder bracket) 3
NOTE:
lInstall the brake master cylinder 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.
2. Install:
lBrake lever 1
lSpring 2
lBolt (brake lever) 3
lNut (brake lever) 4
NOTE:
lApply the lithium soap base grease on the
bolt and brake lever sliding surface.
lApply 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:
lCopper washer 1
lBrake hose 2
lUnion 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 - 21
CHAS
2. Pass the brake hose through the cable
guide 1.
3. Install:
lCopper washer 1
lJoint 2
lBrake hose 3
WARNING
Always use a new copper washer.
NOTE:
When turning the joint over the brake hose,
hold the brake hose so that it may not be
twisted.
New
T R..26 Nm (2.6 m · kg, 19 ft · lb)
T R..14 Nm (1.4 m · kg, 10 ft · lb)
4. Install:
lBrake hose holder 1
lBolt (brake hose holder ) 2
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
FRONT BRAKE (TT-R125LW)

5 - 22
CHAS
Brake fluid
1. Fill:
lBrake fluid
Until the fluid level reaches “LOWER”
level line a.
WARNING
lUse only the designated quality brake
fluid:
otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.
lRefill with the same type of brake fluid;
mixing fluids may result in a harmful chem-
ical reaction and lead to poor performance.
lBe careful that water does not enter the
brake master cylinder when refilling.
Water will significantly lower the boiling
point of the fluid and may result in vapor
lock.
CAUTION:
Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled fluid
immediately.
Recommended brake fluid:
DOT #4
2. Air bleed:
lBrake system
Refer to “BRAKE SYSTEM AIR
BLEEDING” section in the CHAPTER
3.
3. Inspect:
lBrake fluid level
Fluid at lower level ® Fill up.
Refer to “BRAKE FLUID LEVEL
INSPECTION” section in the CHAP-
TER 3.
FRONT BRAKE (TT-R125LW)

5 - 24
CHAS
REAR WHEEL AND REAR BRAKE
Extent of removal:1 Rear wheel removal 2 Wheel bearing removal
3 Brake shoe plate assembly removal and disassembly
Extent of removal Order Part name Q’ty Remarks
Preparation for removalREAR WHEEL AND DRUM
BRAKE
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is nodanger of it falling over.
1 Brake rod 1
2 Axle nut 1
3 Drive chain puller (right) 1
4 Wheel axle 1
5 Drive chain puller (left) 1
6 Drive chain 1
7 Rear wheel 1 Refer to “REMOVAL POINTS”.
8 Collar (right) 1
9 Brake shoe plate assembly 1
10Collar (left)
1
231
REAR WHEEL AND REAR BRAKE

5 - 27
CHASREAR WHEEL AND REAR BRAKE
NOTE:
The bending value is shown by one half of the
dial gauge reading.
WARNING
Do not attempt to straighten a bent axle.
Drum brake
1. Inspect:
lBrake shoe lining surface
Glazed areas ® Polish.
Use coarse sand paper.
NOTE:
After polishing, wipe the polished particles with
a cloth.
2. Measure:
lBrake 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
4.0 mm
(0.16 in)2.0 mm
(0.08 in)
3. Measure:
lBrake drum inside diameter a
Out of specification ® Replace.
Brake drum inside diameter:
Standard
110 mm
(4.33 in)111 mm
(4.37 in)

5 - 29
CHASREAR WHEEL AND REAR BRAKE
5. Install:
lSprings 1
lBrake shoes 2
On brake shoe plate 3
NOTE:
lApply the lithium soap base grease on the
pivot pin.
lWhen installing the springs and brake shoes,
take care not to damage the springs.
lWhen replacing the brake shoes, replace the
springs as a set.
WARNING
Do not apply grease to the brake shoe lin-
ings.
New
Rear wheel
1. Install:
lWheel bearing 1
lSpacer 2
lWheel bearing 3
lOil seal 4
NOTE:
lApply the lithium soap base grease on the oil
seal lip when installing.
lInstall the bearing with seal facing outward.
lUse a socket that matches the outside diam-
eter of the race of the bearing.
lRight side of bearing shall be installed first.
lInstall the oil seal with its manufacture’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of the bearing.
Contact should be made only with the outer
race.
New

5 - 32
CHASFRONT FORK
EC550000
FRONT FORK
Extent of removal:1 Front fork removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalFRONT FORK REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is nodanger of it falling over.
Front wheel Refer to “FRONT WHEEL AND FRONT
BRAKE” section.
(Refer to “FRONT WHEEL” section for
the TT-R125LW.)
Handlebar Refer to “HANDLEBAR” section.
1 Cap 1
2 Pinch bolt (upper bracket) 1 Only loosening.
3 Cap bolt 1Loosen when disassembling the front fork.
4 Pinch bolt (lower bracket) 1 Only loosening.
5Front fork
1
1

5 - 36
CHASFRONT FORK
Inner tube
1. Inspect:
lInner tube surface a
Score marks ® Repair or replace.
Use #1,000 grit wet sandpaper.
Damaged oil lock piece ® Replace.
lInner tube bends
Out of specification ® Replace.
Use the dial gauge 1.
NOTE:
The bending value is shown by one half of the
dial gauge reading.
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken the
tube.
2. Inspect:
lPiston metal 1
Wear/damage ® Replace.
Inner tube bending limit:
0.2 mm (0.008 in)
Outer tube
1. Inspect:
lOuter tube 1
lSlide metal 2
Score marks/wear/damage ® Replace
outer tube assembly.
Cap bolt
1. Inspect:
lCap bolt 1
lO-ring 2
Wear/damage ® Replace.