2003 YAMAHA TTR125 engine

5 - 32
CHAS

FRONT FORK
EC550000
FRONT FORK
Å
TT-R125E
ı
TT-R125LWE
Extent of removal:
1
Front fork removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removal
FRONT FORK REMOVAL
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.
Front wheel Refer to “FRONT WHEEL AND FRONT
BRAKE” section.
(Refer to “FRONT WHEEL” section for
the TT-R125LWE.)
Handlebar Refer to “HANDLEBAR” section.
AB
1 Cap 1–
2 Pinch bolt (upper bracket) 1 1 Only loosening.
3 Cap bolt 1 1Loosen when disassembling the front fork.
4 Pinch bolt (lower bracket) 1 1 Only loosening.
5Front fork
11
1

5 - 41
CHASHANDLEBAR
EC5B0000
HANDLEBAR
TT-R125E
Extent of removal:1 Handlebar removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalHANDLEBAR REMOVAL
Number plate
1 Clutch cable 1
2 Clutch lever 1
3 Engine stop switch 1
4 Front brake cable 1
5 Start switch 1
6 Front brake lever 1
7 Grip cap (lower) 1
8 Grip cap (upper) 1
9 Throttle cable 1
10 Throttle grip assembly 1
11 Collar 1
12 Handlebar grip (left) 1 Refer to “REMOVAL POINTS”.
13 Main switch 1
14 Handlebar holder 2
15 Handlebar 1
1

5 - 42
CHASHANDLEBAR
TT-R125LWE
Extent of removal:1 Handlebar removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalHANDLEBAR REMOVAL
Number plate
1 Clutch cable 1
2 Clutch lever 1
3 Engine stop switch 1
4 Brake master cylinder 1 Refer to “REMOVAL POINTS”.
5 Start switch 1
6 Grip cap (lower) 1
7 Grip cap (upper) 1
8 Throttle cable 1
9 Throttle grip assembly 1
10 Handlebar grip (left) 1 Refer to “REMOVAL POINTS”.
11 Main switch 1
12 Upper handlebar holder 2
13 Handlebar 1
1

5 - 47
CHAS
6. Install:
TT-R125E
Start switch 1
Bolts (start switch) 2
Front brake cable 3
Clamp
NOTE:
Apply the lithium soap base grease on the
front brake cable end.
TT-R125LWE
Start switch 1
Brake master cylinder 2
Brake master cylinder bracket 3
Bolt (brake master cylinder bracket) 4
NOTE:
Install the bracket so that the arrow mark a
face upward.
First tighten the bolts on the upper side of the
brake master cylinder bracket, and then
tighten the bolts on the lower side.
7. Install:
Engine stop switch 1
Clutch lever holder 2
Screws (clutch lever holder) 3
NOTE:
The engine stop switch and clutch lever
holder should be installed according to the
dimensions shown.
Pass the engine stop switch lead in the mid-
dle of the clutch lever holder.
8. Install:
Clutch cable 1
Clamp
NOTE:
Apply the lithium soap base grease on the
clutch cable end.
9. Adjust:
Brake lever free play
Refer to “FRONT BRAKE ADJUST-
MENT” section in the CHAPTER 3.
Clutch lever free play
Refer to “CLUTCH ADJUSTMENT”
section in the CHAPTER 3.
3
1
2
LS
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
U P3 2
4 4
a1
T R..9 Nm (0.9 m · kg, 6.5 ft · lb)
12 3
3T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
HANDLEBAR

5 - 48
CHASSTEERING
EC560000
STEERING
Extent of removal:1 Lower bracket removal2 Bearing removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalSTEERING 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 forks Refer to “FRONT FORK” section.
Handlebar Refer to “HANDLEBAR” section.
Front fender
1 Steering stem nut 1
2 Upper bracket 1
3 Special washer 1
4 Upper ring nut 1
Use special tool.
Refer to “REMOVAL POINTS”. 5 Rubber washer 1
6 Lower ring nut 1
7 Lower bracket 1
8Bearing cover
1
21

5 - 54
CHASSWINGARM
EC570000
SWINGARM
Extent of removal:1 Swingarm removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalSWINGARM 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.
Rear wheel Refer to “REAR WHEEL AND REAR
BRAKE” section.
1 Drive chain tensioner (upper) 1
2 Drive chain tensioner (lower) 1
3 Bolt (connecting arm-frame) 1
4 Bolt (rear shock absorber-relay arm) 1Hold the swingarm.
5 Pivot shaft 1
6 Swingarm 1
1

5 - 61
CHASREAR SHOCK ABSORBER ASSEMBLY
EC580000
REAR SHOCK ABSORBER ASSEMBLY
Extent of removal:1 Rear shock absorber assembly removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalREAR SHOCK ABSORBER
ASSEMBLY 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.
Seat and side covers Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section in the CHAPTER 4.
1 Bolt (rear shock absorber assem-
bly-relay arm)1 Hold the swingarm.
2 Bolt (rear shock absorber assem-
bly-frame)1
3 Bushing 1 Refer to “REMOVAL POINTS”.
4 Rear shock absorber assembly 1
1

6 - 1
–+ELEC

* The illustration shows the TT-R125LWE
12345 7 6890A
EDCB

ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC600000
ELECTRICAL
EC610000
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC611000
ELECTRICAL COMPONENTS
1
CDI unit
2
Main switch
3
Start switch
4
Clutch switch
5
Engine stop switch
6
Starting circuit cut-off
relay
7
Ignition coil
8
Battery
9
Starter relay
0
Fuse
A
Rectifier/regulator
B
Neutral switch
C
CDI magneto
D
Starter motor
E
Spark plug
COLOR CODE
B ...................... Black
Br ..................... Brown
G...................... Green
O...................... Orange
R ...................... Red
Sb .................... Sky blueW ..................... White
Y ...................... Yellow
B/W.................. Black/White
L/Y ................... Blue/Yellow
R/W ................. Red/White
EC612000
WIRING DIAGRAM
B
R/W
WB
RYW
BR Y
10A
R
BR/W
ON
OFFR
BrRB/WBB/WBr B
ON OFF
R/WBr BB
R/WSbR/W
BB BL/Y
OFF RUN
BBBB/W
W
YWSbBSbY B
G
WBrRG
WBrRB
B/WR
W Br
GO
R
SbR/WR/WR/WR/W
R/W
B
R
B/WBrBr
B
L/Y
BSb
YW
RWBrG
RWBrG
B/W
B/W
BOO
B
B
1
2
3
45 67
8
90 A
BC
DE