2003 YAMAHA TTR125 warning

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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

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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

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CHASREAR SHOCK ABSORBER ASSEMBLY
HANDLING NOTE
WARNING
This rear shock absorber contains high-
pressure nitrogen gas. To prevent the dan-
ger of explosion, read and understand the
following information before handling the
shock absorber.
The manufacturer can not be held responsi-
ble for property damage or personal injury
that may result from improper handling.
1. Never tamper or attempt to open the
rear shock absorber.
2. Never throw the rear shock absorber
into an open flame or other high heat.
The rear shock absorber may explode
as a result of nitrogen gas expansion
and/or damage to the hose.
3. Be careful not to damage any part of
the rear shock absorber. A damaged
rear shock absorber will impair the
damping performance or cause a mal-
function.
4. Take care not to scratch the contact
surface of the piston rod with the cyl-
inder; or oil could leak out.
5. When scrapping the rear shock
absorber, follow the instruction on
disposal.

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CHAS
NOTES ON DISPOSAL (YAMAHA DEALERS
ONLY)
Gas pressure must be released before dispos-
ing of a rear shock absorber and gas cylinder.
TT-R125E
To release the gas pressure, drill a 2 ~ 3-mm
(0.08 ~ 0.12-in) hole through the gas cylinder
at a point a from its end as shown.
WARNING
Wear eye protection to prevent eye damage
from released gas or metal chips.
TT-R125LWE
To release the gas pressure, press on the gas
valve needle with a suitable tool as shown,
until all of the gas is released (the hissing has
stopped).
ÅTT-R125E
ıTT-R125LWE
Å
ı
EC583000
REMOVAL POINTS
Bushing
1. Remove:
Bushing 1
NOTE:
Remove the bushing by pressing.
EC584000
INSPECTION
Rear shock absorber assembly
1. Inspect:
Damper rod 1
Bends/damage → Replace rear shock
absorber assembly.
Shock absorber 2
Oil leaks → Replace rear shock
absorber assembly.
Gas leaks → Replace rear shock
absorber assembly.
Spring 3
Damage → Replace rear shock
absorber assembly.
Fatigue → Replace rear shock
absorber assembly.
Move spring up and down.
REAR SHOCK ABSORBER ASSEMBLY

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CHAS
EC585000
ASSEMBLY AND INSTALLATION
Bushing
1. Install:
Bushing 1
NOTE:
Install the bushing by pressing.
Installation
1. Install:
Rear shock absorber assembly
On frame.
NOTE:
Install the rear shock absorber assembly with
its warning label a facing left side of the
machine (for TT-R125E).
2. Install:
Bolt (rear shock absorber assembly -
frame)
Plain washer 1
Nut (rear shock absorber assembly -
frame) 2
NOTE:
Apply the molybdenum disulfide grease on the
bolt (rear shock absorber assembly - frame).
T R..53 Nm (5.3 m · kg, 38 ft · lb)
3. Install:
Bolt (rear shock absorber assembly -
relay arm)
Plain washer 1
Nut (rear shock absorber assembly -
relay arm) 2
NOTE:
Apply the molybdenum disulfide grease on the
bolt (rear shock absorber assembly - relay
arm).
T R..35 Nm (3.5 m · kg, 25 ft · lb)
REAR SHOCK ABSORBER ASSEMBLY

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–+ELEC
EC624000
COUPLERS AND LEADS CONNECTION
INSPECTION
1. Check:
Couplers and leads connection
Rust/dust/looseness/short-circuit →
Repair or replace.
STARTER MOTOR OPERATION
1. Connect the positive battery terminal 1
and starter motor lead 2 with a jumper
lead 3.
Not operate → Repair or replace the
starter motor.
WARNING
A wire that is used as a jumper lead must
have at least the same capacity or more
as that of the a battery lead, otherwise the
jumper lead may burn.
This check is likely to produce sparks,
therefore make sure nothing flammable is
in the vicinity.
STARTING CIRCUIT CUT-OFF RELAY
INSPECTION
1. Remove:
Starting circuit cut-off relay
2. Inspect:
Starting circuit cut-off relay conduct
Use 12 V battery.
Battery (+) lead → Sky blue lead 1
Battery (–) lead → Red/White lead 2
Tester (+) lead → Red/White lead 3
Tester (–) lead → Red/White lead 4
R/W
3R/W
4Tester selec-
tor position
Connected
to battery
Ω × 1Not
connected
to battery
2 4
3
1
ELECTRIC STARTING SYSTEM