2003 YAMAHA TTR125 length

4 - 44
ENGCLUTCH AND PRIMARY DRIVEN GEAR
EC484400
Clutch spring
1. Measure:
Clutch spring free length a
Out of specification → Replace springs
as a set.
Clutch spring free length:
33 mm (1.30 in)
: 31 mm (1.22 in)
EC484500
Friction plate
1. Measure:
Friction plate thickness
Out of specification → Replace friction
plate as a set.
Measure at all four points.
EC484600
Clutch plate
1. Measure:
Clutch plate warpage
Out of specification → Replace clutch
plate as a set.
Use a surface plate 1 and thickness
gauge 2.
Push lever
1. Inspect:
Push lever 1
Wear/damage → Replace.
Friction plate thickness:
2.92 ~ 3.08 mm
(0.115 ~ 0.121 in)
: 2.8 mm (0.110 in)
Warp limit:
0.2 mm (0.008 in)

5 - 35
CHASFRONT FORK
Damper rod holder:
YM-1300/90890-01294
T-handle:
YM-1326/90890-01326
3. Remove:
Oil seal 1
Using slotted-hand screwdriver.
CAUTION:
Take care not to scratch the outer tube.
EC554000
INSPECTION
Damper rod
1. Inspect:
Damper rod
Bend/damage → Replace damper rod.
CAUTION:
The front fork with a built-in piston rod has
a very sophisticated internal construction
and is particularly sensitive to foreign
material.
Use enough care not to allow any foreign
material to come in when the oil is replaced
or when the front fork is disassembled and
reassembled.
EC554400
Fork spring
1. Measure:
Fork spring free length a
Out of specification → Replace.
Fork spring free length:
Standard
TT-R125E:
327 mm (12.9 in)
TT-R125LWE:
453.6 mm
(17.86 in)TT-R125E:
322 mm (12.7 in)
TT-R125LWE:
448.6 mm
(17.66 in)

6 - 14
–+ELEC
5. Measure:
Brush length a
Out of specification → Replace.
Brush length wear limit:
3.5 mm (0.14 in)
6. Measure:
Brush spring force
Fatigue/out of specification → Replace
as a set.
Brush spring force:
5.52 ~ 8.28 N
(560 ~ 840 g, 19.8 ~ 29.7 oz)
ASSEMBLY
1. Install:
Brush spring 1
Brush 2
212
2. Install:
Armature assembly 1
Install while holding down the brush
using a thin screw driver.
CAUTION:
Be careful not to damage the brush during
installation.
ELECTRIC STARTING SYSTEM