2003 YAMAHA TTR125 suspension

1 - 16
GEN
INFO
TORQUE-CHECK POINTS
TORQUE-CHECK POINTS
TT-R125E
Engine mounting
Muffler
Steering Steering stem to
handlebar
Suspension Front Steering stem to
front fork
Rear For link type
Rear Installation of shock
absorber
Rear Installation of swing-
arm
Wheel Installation of wheel Front
Rear
Brake Front
Rear
Fuel systemFrame to engine
Frame to engine bracket
Engine bracket to engine
Muffler to cylinder head
Muffler to rear fender bracket
Muffler to seat pillar tube
Steering stem to frame
Steering stem to upper bracket
Upper bracket to handlebar
Front fork to upper bracket
Front fork to lower bracket
Assembly of links
Link to frame
Link to shock absorber
Link to swingarm
Shock absorber to frame
Tightening of pivot shaft
Tightening of wheel axle
Tightening of wheel axle
Wheel to sprocket
Camshaft lever to camshaft
Camshaft lever to camshaft
Fuel tank to fuel cock
NOTE:
Concerning the tightening torque, refer to
“MAINTENANCE SPECIFICATIONS” section
in the CHAPTER 2.

1 - 17
GEN
INFO
TORQUE-CHECK POINTS
TT-R125LWE
Engine mounting
Muffler
Steering Steering stem to
handlebar
Suspension Front Steering stem to
front fork
Rear For link type
Rear Installation of shock
absorber
Rear Installation of swing-
arm
Wheel Installation of wheel Front
Rear
Brake Front
Rear
Fuel systemFrame to engine
Frame to engine bracket
Engine bracket to engine
Muffler to cylinder head
Muffler to rear fender bracket
Muffler to seat pillar tube
Steering stem to frame
Steering stem to upper bracket
Upper bracket to handlebar
Front fork to upper bracket
Front fork to lower bracket
Assembly of links
Link to frame
Link to shock absorber
Link to swingarm
Shock absorber to frame
Tightening of pivot shaft
Tightening of wheel axle
Tightening of wheel axle
Wheel to sprocket
Brake caliper to front fork
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to joint
Brake hose to joint
Brake master cylinder to handlebar
Tightening of bleed screw
Brake camshaft lever to brake camshaft
Fuel tank to fuel cock
NOTE:
Concerning the tightening torque, refer to
“MAINTENANCE SPECIFICATIONS” section
in the CHAPTER 2.

GEN
INFO
CONTRÔLE DU SERRAGE AU COUPLE
CONTRÔLE DU SERRAGE AU COUPLE
TT-R125E
Ancrage du moteur
Pot d’échappement
Direction Colonne de direction
au guidon
Suspension Avant Arbre de direction à la
fourche avant
Arrière Pour type à liaison
Arrière Installation de l’amortis-
seur arrière
Arrière Installation du bras
oscillant
Roue Installation de la roue Avant
Arrière
Frein Avant
Arrière
Circuit de carburantCadre au moteur
Cadre au support de moteur
Support de moteur à moteur
Pot d’échappement à culasse
Pot d’échappement à support de garde-bove
arrière
Pot d’échappement sur tuyau de montant de
selle
Colonne de direction au cadre
Colonne de direction au té supérieur
Té supérieur au guidon
Fourche avant au té supérieur
Fourche avant au té inférieur
Toutes les liaisons
Liaison au cadre
Liaison à l’amortisseur
Liaison au bras oscillant
Amortisseur au cadre
Serrage de l’axe
Serrage de l’axe de roue
Serrage de l’axe de roue
Roue à couronne
Biellette à came de frein
Biellette à came de frein
Réservoir de carburant à robinet de carbu-
rant
N.B.:
Prière de se référer à la section “CARACTÉRISTI-
QUES D’ENTRETIEN” au CHAPITRE 2 afin de
connaître les couples de serrage.
1 - 16

GEN
INFO
CONTRÔLE DU SERRAGE AU COUPLE
TT-R125LWE
Ancrage du moteur
Pot d’échappement
Direction Colonne de direction
au guidon
Suspension Avant Arbre de direction à la
fourche avant
Arrière Pour type à liaison
Arrière Installation de l’amortis-
seur arrière
Arrière Installation du bras
oscillant
Roue Installation de la roue Avant
Arrière
Frein Avant
Arrière
Circuit de carburantCadre au moteur
Cadre au support de moteur
Support de moteur à moteur
Pot d’échappement à culasse
Pot d’échappement à support de garde-bove
arrière
Pot d’échappement sur tuyau de montant de
selle
Colonne de direction au cadre
Colonne de direction au té supérieur
Té supérieur au guidon
Fourche avant au té supérieur
Fourche avant au té inférieur
Toutes les liaisons
Liaison au cadre
Liaison à l’amortisseur
Liaison au bras oscillant
Amortisseur au cadre
Serrage de l’axe
Serrage de l’axe de roue
Serrage de l’axe de roue
Roue à couronne
Étrier de frein à fourche avant
Disque de frein à roue
Serrage du boulon de raccord
Maître cylindre de frein à raccord
Flexible de frein à raccord
Maître cylindre de frein à guidon
Serrage de la vis de purge
Biellette de frein à came de frein
Réservoir de carburant à robinet de carbu-
rant
N.B.:
Prière de se référer à la section “CARACTÉRISTI-
QUES D’ENTRETIEN” au CHAPITRE 2 afin de
connaître les couples de serrage.
1 - 17

SPEC

2 - 3
GENERAL SPECIFICATIONS
Brake:
Front brake type Drum brake
Operation Right hand operation
Rear brake type Drum brake
Operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (link type monocross suspension)
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas, oil damper
Wheel travel:
Front wheel travel 180 mm (7.09 in)
Rear wheel travel 160 mm (6.30 in)
Electrical:
Ignition system CDI
Generator system CDI magneto
Battery type GT4L-BS
Battery voltage/capacity 12 V/3.2 AH
Specific gravity 1.320

SPEC

2 - 6
GENERAL SPECIFICATIONS
Brake:
Front brake type Single disc brake
Operation Right hand operation
Rear brake type Drum brake
Operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (link type monocross suspension)
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas, oil damper
Wheel travel:
Front wheel travel 180 mm (7.09 in)
Rear wheel travel 168 mm (6.61 in)
Electrical:
Ignition system CDI
Generator system CDI magneto
Battery type GT4L-BS
Battery voltage/capacity 12 V/3.2 AH
Specific gravity 1.320

SPEC
2 - 15
MAINTENANCE SPECIFICATIONS
EC212201
CHASSIS
TT-R125E
Item Standard Limit
Steering system:
Steering bearing type (upper) Angular bearing ----
(lower) Taper roller bearing ----
Front suspension:
Front fork travel 180 mm (7.09 in) ----
Fork spring free length 327 mm (12.87 in) 322 mm (12.68 in)
Spring rate, STD K = 3.00 N/mm
(0.310 kg/mm, 17.4 lb/in)----
Optional spring/spacer No ----
Oil capacity 159 cm
3
(5.60 Imp oz, 5.38 US oz)----
Oil level 122 mm (4.80 in) ----
Oil grade Fork oil 10W or equivalent ----
Inner tube outer diameter 30 mm (1.18 in) ----
Front fork top end Zero mm (Zero in) ----
Rear suspension:
Shock absorber travel 65 mm (2.56 in) ----
Spring free length 178 mm (7.01 in) ----
Fitting length 165 mm (6.50 in) ----
Spring rate, STD K = 50.5 N/mm
(5.1 kg/mm, 286 lb/in)----
Optional spring No ----
Enclosed gas pressure 1,500 kPa
(15 kg/cm
2, 213 psi)----
Wheel:
Front wheel type Spoke wheel ----
Rear wheel type Spoke wheel ----
Front rim size/material 17 × 1.40/Steel ----
Rear rim size/material 14 × 1.60/Steel ----
Rim runout limit:
Radial ---- 2.0 mm (0.08 in)
Lateral ---- 2.0 mm (0.08 in)
Drive chain:
Type/manufacturer DID428HD/DAIDO ----
Number of links 116 links ----
Chain slack 35 ~ 50 mm (1.4 ~ 2.0 in) ----
Chain length (10 links) ----121.4 mm
(4.78 in)

SPEC
2 - 19
MAINTENANCE SPECIFICATIONS
TT-R125LWE
Item Standard Limit
Steering system:
Steering bearing type (upper) Angular bearing ----
(lower) Taper roller bearing ----
Front suspension:
Front fork travel 180 mm (7.09 in) ----
Fork spring free length 453.6 mm (17.86 in) 448.6 mm
(17.66 in)
Spring rate, STD K = 3.20 N/mm
(0.330 kg/mm, 18.5 lb/in)----
Optional spring/spacer No ----
Oil capacity 158 cm
3
(5.56 Imp oz, 5.34 US oz)----
Oil level 125 mm (4.92 in) ----
Oil grade Fork oil 10W or equivalent ----
Inner tube outer diameter 30 mm (1.18 in) ----
Front fork top end Zero mm (Zero in) ----
Rear suspension:
Shock absorber travel 65 mm (2.56 in) ----
Spring free length 170.5 mm (6.71 in) ----
Fitting length 160.5 mm (6.32 in) ----
Spring rate, STD K = 61.8 N/mm
(6.3 kg/mm, 352 lb/in)----
Optional spring No ----
Enclosed gas pressure 1,200 kPa
(12 kg/cm
2, 171 psi)----
Wheel:
Front wheel type Spoke wheel ----
Rear wheel type Spoke wheel ----
Front rim size/material 19 × 1.40/Steel ----
Rear rim size/material 16 × 1.60/Steel ----
Rim runout limit:
Radial ---- 2.0 mm (0.08 in)
Lateral ---- 2.0 mm (0.08 in)
Drive chain:
Type/manufacturer DID428HD/DAIDO ----
Number of links 122 links ----
Chain slack 35 ~ 50 mm (1.4 ~ 2.0 in) ----
Chain length (10 links) ----121.4 mm
(4.78 in)
Front disc brake:
Disc outside dia. × Thickness 220 × 3.0 mm (8.66 × 0.12 in)220 × 2.5 mm
(8.66 × 0.10 in)
Deflection limit ----0.15 mm (0.006 in)
Pad thickness 4.0 mm (0.16 in)0.8 mm (0.03 in)
Master cylinder inside dia. 11.0 mm (0.433 in) ----
Caliper cylinder inside dia. 22.22 mm (0.875 in) × 2 ----
Brake fluid type DOT #4 ----