2003 YAMAHA TTR125 crankcase

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
Battery negative lead 1
Lead holder 2
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)

4 - 52
ENGOIL PUMP
Oil strainer
1. Inspect:
Oil strainer
Cracks/damage → Replace.
Contamination → Clean the flushing oil.
ASSEMBLY AND INSTALLATION
Oil pump
1. Install:
Oil pump housing 1
Outer rotor 2
Inner rotor 3
Pin 4
Oil pump shaft 5
Pin 6
Oil pump cover 7
Washer 8
Circlip 9
Conical spring washer 0
Oil pump driven gear A
Circlip B
Screws C
NOTE:
Apply engine oil onto the outer rotor, inner
rotor and oil pump shaft.
Install the conical spring washer in the direc-
tion as shown.
2. Install:
Oil strainer
Gasket
Oil pump assembly
Screws (oil pump assembly)
NOTE:
Apply engine oil onto the crankcase oil pas-
sage and oil pump assembly.
New
New
T R..5 Nm (0.5 m · kg, 3.6 ft · lb)
New
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
3. Install:
Oil pump drive gear 1
Rotary filter 2
NOTE:
Install the oil pump drive gear with its groove
a facing the engine.
Install the rotary filter with the dog b facing
out.
Align the rotary filter dog b with groove c of
the crankshaft.

4 - 54
ENGKICK AXLE AND SHIFT SHAFT
REMOVAL POINTS
Kick axle
1. Remove:
Kick axle assembly 1
NOTE:
Unhook the torsion spring 2 from the hole in
the crankcase.
Segment
1. Remove:
Screw (segment)
Segment 1
NOTE:
Loosen the screw using the T30 bit.
INSPECTION
Kick axle and kickstarter segment gear
1. Check:
Kickstarter segment gear smooth
movement
Unsmooth movement → Replace.
2. Inspect:
Kick axle 1
Wear/damage → Replace.
Kickstarter segment gear and kick idle gear
1. Inspect:
Kickstarter segment gear 1
Kick idle gear 2
Gear teeth a
Wear/damage → Replace.
Kick axle clip
1. Measure:
Kick axle clip friction force (torsion
spring)
Out of specification → Replace.
Use a spring gauge 1.
Kick axle clip friction force:
0.65 ~ 1.35 kg (1.4 ~ 3.0 lb)

4 - 56
ENGKICK AXLE AND SHIFT SHAFT
Shift shaft
1. Install:
Shift shaft 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip of the left crankcase side.
Hook the spring ends onto the stopper 2.
Kick axle assembly
1. Install:
Kickstarter segment gear 1
Plain washer 2
Torsion spring 3
On kick axle 4.
NOTE:
Make sure the stopper a of the torsion spring
fits into the hole b on the kick axle.
2. Install:
Spring guide 1
NOTE:
Slide the spring guide into the kick axle, make
sure the groove a in the spring guide fits on
the stopper of the torsion spring.
3. Install:
Kick axle assembly 1
NOTE:
Apply the engine oil on the kick axle.
Slide the kick axle assembly into the crank-
case, make sure the clip 2 and kick axle
stopper b fit into their home positions a, c.
4. Hook:
Torsion spring 1
NOTE:
Turn the torsion spring clockwise and hook
into the proper hole a in the crankcase.

4 - 58
ENGCDI MAGNETO AND STARTER CLUTCH
CDI MAGNETO AND STARTER CLUTCH
Extent of removal:1 Pickup coil/stator removal2 Starter clutch/wheel gear removal
Extent of removal Order Part name Q’ty Remarks
CDI MAGNETO AND STATOR
REMOVAL
Preparation for removal Fuel tank
1 CDI magneto lead 1
2 Neutral switch lead 1
3 Left crankcase cover 1
4 Nut (rotor) 1
Use special tool.
Refer to “REMOVAL POINTS”.
5 Rotor 1
6 Starter clutch 1
7 Woodruff key 1
8 Starter wheel gear 1
9 Plain washer 1
10 Plate (starter idle gear) 1
11 Starter idle gear 1
12 Lead guide 1
13Pickup coil/stator assembly
1
1
2
1
1

4 - 62
ENG

7. Install:

Crankcase cover (left)
8. Connect:

Neutral switch lead
1

NOTE:

Pass the neutral switch lead into the crank-
case cover groove as shown.
9. Connect:

CDI magneto lead
Refer to “CABLE ROUTING DIAGRAM”
section in the CHAPTER 2.
CDI MAGNETO AND STARTER CLUTCH

4 - 64
ENG

ENGINE REMOVAL
Extent of removal Order Part name Q’ty Remarks
1 Drive sprocket cover 1
2 Bolt (drive sprocket) 2
Refer to “REMOVAL POINTS”. 3 Drive sprocket holder 1
4 Drive sprocket 1
5 Shift pedal link 1
6 Crankcase breather hose 1
7 Engine bracket (upper) 1
8 Engine skidplate 1
9 Engine bracket (front) 1
10 Engine mounting bolt (rear) 2
11Engine
1Refer to “REMOVAL POINTS”.
1

4 - 67
ENGCRANKCASE, CRANKSHAFT AND BALANCER
CRANKCASE, CRANKSHAFT AND BALANCER
Extent of removal:1 Crankcase separation2 Balancer removal
3 Crankshaft removal
Extent of removal Order Part name Q’ty Remarks
CRANKCASE, CRANKSHAFT
AND BALANCER REMOVAL
Preparation for removal Engine Refer to “ENGINE REMOVAL” section.
Piston Refer to “CYLINDER AND PISTON” sec-
tion.
Primary drive gear Refer to “CLUTCH AND PRIMARY
DRIVEN GEAR” section.
Kick axle assembly
Refer to “KICK AXLE AND SHIFT
SHAFT” section.
Segment
Rotor and stator Refer to “CDI MAGNETO AND
STARTER CLUTCH” section.