2003 YAMAHA TTR125 boot

4. When transporting the machine in
another vehicle, be sure is kept
upright and that the fuel cock is
turned to the “OFF”. If it should lean
over, gasoline may leak out of the car-
buretor or fuel tank.
5. Never start your engine or let it run for
any length of time in a closed area.
The exhaust fumes are poisonous and
may cause loss of consciousness and
death within a short time. Always
operate your machine in an area with
adequate ventilation.
6. Always wear a helmet, gloves, boots,
trousers, and jacket for motocross
riding.

SAFETY INFORMATION

1. Do not ride it on the street.
2. Do not run the engine inside a building.
3. This is a one-seater motorbike. Do not give
any person a ride.
4. Let’s learn how to ride properly. Ask your
parents for any question.
5. When riding the machine, be sure to wear
the protective apparel as illustrated.
1
Helmet
2
Goggles
3
Mouth guard
4
Gloves
5
Boots
6
Motocross pants
7
Long sleeved trainer
8
Protector

5 - 13
CHASFRONT BRAKE (TT-R125LW)
BRAKE CALIPER AND BRAKE MASTER CYLINDER DISASSEMBLY
Extent of removal:1 Brake caliper disassembly2 Brake master cylinder disassembly
Extent of removal Order Part name Q’ty Remarks
Preparation for removalBRAKE CALIPER AND BRAKE
MASTER CYLINDER DISAS-
SEMBLY
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is no
danger of it falling over.
1Brake pad 2
2Brake caliper bracket 1
3Brake caliper piston 2 Refer to “REMOVAL POINTS”.
4Brake caliper dust seal 2
Refer to “REMOVAL POINTS”.
5Brake caliper piston seal 2
6Pin boot 1
7Sleeve boot 1
8Brake master cylinder cap 1
9Diaphragm 1
0Brake master cylinder boot 1
ACirclip 1
BWasher 1
CBrake master cylinder kit 1
2
1

5 - 16
CHAS
Brake caliper
1. Inspect:
Brake caliper cylinder inner surface a
Wear/score marks → Replace brake
caliper assembly.
2. Inspect:
Brake caliper piston 1
Wear/score marks → Replace brake
caliper piston assembly.
WARNING
Replace the brake caliper piston seals and
brake caliper dust seals 2 whenever a
brake caliper is disassembled.
3. Inspect:
Brake caliper bracket 1
Cracks/damage → Replace the brake
caliper assembly.
Guide pin 2
Rust/damage → Replace the brake cal-
iper assembly.
Sleeve boot 3
Pin boot 4
Wear/damage → Replace.
4. Inspect:
Brake caliper support bolt 1
Scorches/rust/damage → Replace.
Brake hose
1. Inspect:
Brake hose 1
Crack/damage → Replace.
FRONT BRAKE (TT-R125LW)

5 - 17
CHASFRONT BRAKE (TT-R125LW)
ASSEMBLY AND INSTALLATION
WARNING
All internal parts should be cleaned in
new brake fluid only.
Internal parts should be lubricated with
brake fluid when installed.
Replace the brake caliper piston seals
and brake caliper dust seals whenever a
brake caliper is disassembled.
Brake caliper piston
1. Clean:
Brake caliper
Brake caliper piston seal
Brake caliper dust seal
Brake caliper piston
Clean them with brake fluid.
2. Install:
Brake caliper piston seal 1
Brake caliper dust seal 2
WARNING
Always use new brake caliper piston seals
and brake caliper dust seals.
NOTE:
Fit the brake caliper piston seals and brake
caliper dust seals onto the slot on brake cali-
per correctly.
New
New
3. Install:
Brake caliper piston 1
NOTE:
Apply the brake fluid on the brake caliper pis-
ton wall.
CAUTION:
Install the brake caliper piston with its
shallow depressed side a facing the
brake caliper.
Never force to insert.
Brake caliper
1. Install:
Sleeve boot 1.
On brake caliper bracket 2.

5 - 18
CHASFRONT BRAKE (TT-R125LW)
2. Install:
Pin boot 1
On brake caliper 2.
NOTE:
Apply the lithium soap base grease on the pin
boot inner surface.
3. Install:
Brake caliper bracket 1
Bolt (brake caliper bracket) 2
Brake pad 3
T R..30 Nm (3.0 m · kg, 22 ft · lb)
4. Install:
Brake caliper 1
NOTE:
Apply the lithium soap base grease on the
guide pin 2.
Install the brake caliper into the guide pin
and turn it clockwise.
5. Install:
Brake caliper support bolt 1
NOTE:
Apply the lithium soap base grease on the
brake caliper support bolt.
T R..22 Nm (2.2 m · kg, 16 ft · lb)
Brake master cylinder kit
1. Clean:
Brake master cylinder
Brake master cylinder kit
Clean them with brake fluid.

5 - 19
CHASFRONT BRAKE (TT-R125LW)
2. Install:
Brake master cylinder cup (primary) 1
Brake master cylinder cup (secondary) 2
On brake master cylinder piston 3.
NOTE:
Apply the brake fluid on the brake master cyl-
inder cup.
WARNING
After installing, cylinder cup should be
installed as shown direction. Wrong instal-
lation cause improper brake performance.
3. Install:
Spring 1
On brake master cylinder piston 2.
NOTE:
Install the spring at the smaller diameter side.
4. Install:
Brake master cylinder kit 1
Washer 2
Circlip 3
Brake master cylinder boot 4
On brake master cylinder 5
NOTE:
Apply the brake fluid on the brake master
cylinder kit.
When installing the circlip, use a long nose
circlip pliers.

5 - 33
CHASFRONT FORK
EC558000
FRONT FORK DISASSEMBLY
Extent of removal:1 Oil seal removal2 Damper rod removal
Extent of removal Order Part name Q’ty Remarks
FRONT FORK DISASSEMBLY
1Dust boot 1
2Cap bolt 1 Refer to “REMOVAL POINTS”.
3Spacer 1
4Washer 1
5Fork spring 1 Drain the fork oil.
6Dust seal 1
Use special tool.
Refer to “REMOVAL POINTS”. 7Stopper ring 1
8Bolt (damper rod) 1
9Damper rod 1
0Inner tube 1
AOil flow stopper 1
BPiston metal 1
COil seal 1
DOuter tube
1
2
1