2003 YAMAHA TTR125 lock

4 - 7
ENG
CARBURATEUR
VERGASER
Drosselventil
1. Kontrollieren:
Freigängigkeit
Stick → Reparieren oder erneuern.
HINWEIS:
Drosselventil 1 in den Vergaser hineinschie-
ben und auf Freigängigkeit prüfen.
Düsennadel
1. Kontrollieren:
Düsennadel 1
Verbiegung/Verschleiß → Erneuern.
Clip-Nut
Spiel/Verschleiß → Erneuern.
Clip-Position
Kraftstoffstand
1. Messen:
Kraftstoffstand a
Nicht vorschriftsmäßig → Einstellen.
Standard-Clip-Position
Nut Nr.2
Kraftstoffstand
6,0–7,0 mm
Unterhalb der Schwimmerkam-
mer-Dichtfläche
Arbeitsschritte
Kraftstoffstandmesser 1 an die Schwim-
merkammer anschließen.
Kraftstoffstandmesser
YM-1312-A/90890-01312
Kraftstoffstandmesser senkrecht neben die
Schwimmerkammer-Dichtfläche halten.
Die Ablaßschraube lockern.
Kraftstoffstand mit dem Kraftstoffstand-
messer messen.
HINWEIS:
Vergaser und Kraftstoffstandmesser müs-
sen sich beim Messen des Kraftstoffstands
in senkrechter Stellung befinden.
Falls der Kraftstoffstand nicht korrekt ist,
Nadelventilsitz und Nadelventil prüfen.
Falls ein Bauteil verschlissen ist, beide
Teile erneuern.
Falls beide Bauteile in Ordnung sind, kann
der Schwimmerstand durch leichtes Bie-
gen des Schwimmerhabels b eingestellt
werden.
Kraftstoffstand erneut messen.
Boisseau
1. Contrôler:
Souplesse du mouvement
Calage → Réparer ou remplacer.
N.B.:
Introduire le boisseau 1 dans le carburateur et con-
trôler le mouvement correct.
Aiguille
1. Examiner:
Aiguille 1
Déformations/usure → Remplacer.
Gorge de l’agrafe
Jeu/usure → Remplacer.
Position d’agrafe
Niveau de carburant
1. Mesurer:
Niveau de carburant a
Hors spécifications → Régler.
Position standard de l’agrafe:
Gorge n˚2
Niveau de carburant:
6,0 à 7,0 mm (0,24 à 0,28 in)
en dessous du plan de joint de la
cuve à niveau constant
Étapes de la mesure et du réglage:
Fixer la jauge du niveau de carburant 1 à la
cuve à niveau constant.
Jauge de niveau de carburant:
YM-1312-A/90890-01312
Maintenir la jauge à côté du plan de joint de la
cuve à niveau constant en veillant à ce qu’elle
soit à la verticale.
Desserrer la vis de vidange.
Contrôler le niveau de carburant à l’aide de la
jauge.
N.B.:
Mesurer le niveau du carburant en maintenant à
la fois le carburateur et la jauge de niveau à la
verticale.
Si le niveau de carburant est incorrect, contrô-
ler le pointeau et son siège.
Si l’un de ces composants est usé, les rempla-
cer tous les deux.
Si ces deux pièces sont en bon état, régler le
niveau du flotteur en courbant légèrement sa
languette b.
Vérifier à nouveau le niveau de carburant.

4 - 14
ENGCYLINDER HEAD
REMOVAL POINTS
Cylinder head
1. Align:
“I” mark
(with stationary pointer)
Checking steps:
Turn the crankshaft counterclockwise with
a wrench.
Align the “I” mark a on the rotor with the
stationary pointer b on the crankcase
cover. When the “I” mark is aligned with
the stationary pointer, the piston is at the
Top Dead Center (T.D.C.).
NOTE:
In order to be sure that the piston is at Top
Dead Center, the match mark c on the
camshaft sprocket must align with the sta-
tionary pointer d on the cylinder head as
shown in the illustration.
2. Loosen:
Camshaft sprocket bolt 1
NOTE:
Remove the bolt while holding the rotor nut
with a wrench.
3. Remove:
Bolt (timing chain tensioner cap) 1
Bolt (timing chain tensioner) 2
Timing chain tensioner 3

4 - 17
ENGCYLINDER HEAD
3. Install:
Timing chain
Camshaft sprocket
4. Install:
Washer
Bolt (camshaft sprocket)
NOTE:
Temporarily tighten the bolt (camshaft sprocket)
at this point. Installation steps:
Turn the crankshaft counterclockwise with
a wrench.
Align the “I” mark a on the rotor with the
stationary pointer b on the crankcase
cover.
Align the match mark c on the camshaft
sprocket with the stationary pointer d on
the cylinder head.
Fit the timing chain 1 onto camshaft
sprocket 2 and install the camshaft
sprocket on the camshaft.
NOTE:
When installing the camshaft sprocket, keep
the timing chain as tense as possible on the
exhaust side.
CAUTION:
Do not turn the crankshaft during instal-
lation of the camshaft. Damage or
improper valve timing will result.
Remove the safety wire from the timing
chain.

4 - 18
ENGCYLINDER HEAD
5. Install:
Timing chain tensioner
6. Turn:
Crankshaft
Counterclockwise several turns
7. Check:
Rotor “I” mark
Align with the crankcase stationary
pointer.
Camshaft match mark
Align with the cylinder head stationary
pointer.
Out of alignment → Adjust. Installation steps:
While pressing the tensioner rod lightly
with fingers, use a thin screwdriver and
wind the tensioner rod up fully clockwise.
With the rod fully wound, install the gasket
1 and the chain tensioner 2, and tighten
the bolts 3 to the specified torque.
T R..
Bolt (chain tensioner):
10 Nm (1.0 m • kg, 7.2 ft • lb)
Release the screwdriver, check the ten-
sioner rod to come out and tighten the
gasket 4 and the cap bolt 5 to the speci-
fied torque.
T R..
Cap bolt (timing chain tensioner):
8 Nm (0.8 m • kg, 5.8 ft • lb)
8. Tighten:
Bolt 1
NOTE:
Tighten the bolt while holding the rotor nut with
a wrench.
T R..20 Nm (2.0 m · kg, 14 ft · lb)

4 - 41
ENGCLUTCH AND PRIMARY DRIVEN GEAR
EC498100
PRIMARY DRIVEN GEAR
Extent of removal:1 Primary driven gear removal2 Primary drive gear removal
Extent of removal Order Part name Q’ty Remarks
PRIMARY DRIVEN GEAR
REMOVAL
1 Nut (clutch boss) 1
Use special tool.
Refer to “REMOVAL POINTS”. 2 Lock washer 1
3 Clutch boss 1
4 Thrust plate 1
5 Primary driven gear 1
6 Thrust plate 1
7 Conical spring washer 1
8 Nut (primary drive gear) 1
Refer to “REMOVAL POINTS”.
9 Primary drive gear 1
10Straight key
1
2
1

4 - 43
ENGCLUTCH AND PRIMARY DRIVEN GEAR
EC493000
REMOVAL POINTS
Clutch boss
1. Remove:
Nut 1
Lock washer
Clutch boss 2
NOTE:
Straighten the lock washer tab and use the
clutch holding tool 3 to hold the clutch boss.
ÅFor USA and CDN
ıExcept for USA and CDN
Clutch holding tool:
YM-91042/90890-04086Å
ı
Primary drive gear
1. Remove:
Nut (primary drive gear) 1
Primary drive gear 2
NOTE:
Place a folded rag or aluminum plate
between the teeth of the primary drive gear
and primary driven gear.
Take care not to damage the gear teeth.
EC494000
INSPECTION
EC484100
Clutch housing and boss
1. Inspect:
Clutch housing 1
Cracks/wear/damage → Replace.
Clutch boss 2
Scoring/wear/damage → Replace.
EC484201
Primary driven gear
1. Check:
Circumferential play
Free play exists → Replace.
Gear teeth a
Wear/damage → Replace.

4 - 46
ENGCLUTCH AND PRIMARY DRIVEN GEAR
Clutch
1. Install:
Conical spring washer 1
Thrust plate 2
Primary driven gear 3
Thrust plate 4
Clutch boss 5
2. Install:
Lock washer
Nut (clutch boss) 1
NOTE:
Use the clutch holding tool 2 to hold the clutch
boss.
ÅFor USA and CDN
ıExcept for USA and CDN
3. Bend:
Lock washer tab
Clutch holding tool:
YM-91042/90890-04086
New
T R..60 Nm (6.0 m · kg, 43 ft · lb)
Å
ı
4. Install:
Friction plate 1
Clutch plate 2
NOTE:
Install the clutch plates and friction plates
alternately on the clutch boss, starting with a
friction plate and ending with a friction plate.
Apply the engine oil on the friction plates and
clutch plates.
Be sure to install a clutch plate with projec-
tion a offset approximately 90˚ from previ-
ous plates projection. Continue this
procedure in a clockwise direction until all
clutch plates are installed.

4 - 48
ENGCLUTCH AND PRIMARY DRIVEN GEAR
9. Adjust:
Push lever position
Adjustment steps:
Loosen the locknut 1.
Turn the push rod 1 2 clockwise or coun-
terclockwise to match alignment marks.
Hold the push rod 1 to prevent it from
moving and tighten the locknut to specifi-
cation.
Tighten the locknut 1.
T R..
Locknut:
8 Nm (0.8 m • kg, 5.8 ft • lb)
10. Install:
Dowel pins
Gasket (right crankcase cover)
Right crankcase cover
Bolts (right crankcase cover)
NOTE:
Apply Quick gasket® (YAMAHA Bond
No.1215) to end of the right crankcase cover
bolts, as shown.
Tighten the bolts in stages, using a criss-
cross pattern.
Quick gasket®:
ACC-QUICK-GS-KT
YAMAHA Bond No.1215:
90890-85505
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
11. Install:
Kickstarter crank 1
Nut (kickstarter crank) 2
NOTE:
Install the kickstarter crank so that there is 5 ~
10 mm (0.2 ~ 0.4 in) a between the kickstarter
crank and the right crankcase cover.
T R..50 Nm (5.0 m · kg, 36 ft · lb)