2003 YAMAHA TTR125 engine

4 - 45
ENGCLUTCH AND PRIMARY DRIVEN GEAR
Push rod
1. Inspect:
Push rod 1 1
Ball 2
Wear/damage/bend → Replace.
Primary drive gear
1. Inspect:
Primary drive gear
Wear/damage → Replace.
EC495000
ASSEMBLY AND INSTALLATION
Push lever
1. Install:
Push lever 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
Apply the engine oil on the push lever.
Primary drive gear
1. Install:
Straight key
Primary drive gear 1
Washer 2
Nut (primary drive gear) 3
Primary driven gear 4
NOTE:
Install the primary drive gear with the stamp
a facing out.
Place a folded rag or aluminum plate 5
between the teeth of the primary drive gear
and primary driven gear.
T R..70 Nm (7.0 m · kg, 50 ft · lb)

4 - 46
ENGCLUTCH AND PRIMARY DRIVEN GEAR
Clutch
1. Install:
Conical spring washer 1
Thrust plate 2
Primary driven gear 3
Thrust plate 4
Clutch boss 5
2. Install:
Lock washer
Nut (clutch boss) 1
NOTE:
Use the clutch holding tool 2 to hold the clutch
boss.
ÅFor USA and CDN
ıExcept for USA and CDN
3. Bend:
Lock washer tab
Clutch holding tool:
YM-91042/90890-04086
New
T R..60 Nm (6.0 m · kg, 43 ft · lb)
Å
ı
4. Install:
Friction plate 1
Clutch plate 2
NOTE:
Install the clutch plates and friction plates
alternately on the clutch boss, starting with a
friction plate and ending with a friction plate.
Apply the engine oil on the friction plates and
clutch plates.
Be sure to install a clutch plate with projec-
tion a offset approximately 90˚ from previ-
ous plates projection. Continue this
procedure in a clockwise direction until all
clutch plates are installed.

4 - 47
ENGCLUTCH AND PRIMARY DRIVEN GEAR
5. Install:
Ball
NOTE:
Apply the engine oil on the ball.
6. Install:
Push rod 1 1
Push plate 2
Washer 3
Nut (push rod 1) 4
7. Install:
Pressure plate 1
Clutch spring 2
Bolt (clutch spring) 3
NOTE:
Align the arrow mark a on the pressure
plate with the punched mark b on the clutch
boss.
Tighten the bolts in stage, using a crisscross
pattern.
T R..6 Nm (0.6 m · kg, 4.3 ft · lb)
8. Check:
Push lever position
Push the push lever assembly in the
arrow direction and make sure that the
mach mark are aligned → adjust.
aMatch mark on the push lever assembly
bMatch mark on the crankcase

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 - 53
ENGKICK AXLE AND SHIFT SHAFT
KICK AXLE AND SHIFT SHAFT
KICK AXLE AND SHIFT SHAFT
Extent of removal:1 Kick axle removal2 Shift shaft removal
Extent of removal Order Part name Q’ty Remarks
KICK AXLE AND SHIFT SHAFT
REMOVAL
Preparation for removal Shift pedal link Refer to “ENGINE REMOVAL” section.
Clutch Refer to “CLUTCH AND PRIMARY
DRIVEN GEAR” section.
1 Kick axle assembly 1 Refer to “REMOVAL POINTS”.
2 Circlip 1
3 Washer 1
4 Kick idle gear 1
5 Washer 1
6 Circlip 1
7 Shift shaft 1
8 Circlip 1
9 Torsion spring 1
10 Bolt (stopper lever) 1
11 Stopper lever 1
12 Spring 1
13 Segment 1 Refer to “REMOVAL POINTS”.
1
2

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 - 57
ENGKICK AXLE AND SHIFT SHAFT
Kick idle gear
1. Install:
Circlip 1
Washer 2
Kick idle gear 3
Washer 4
Circlip 5
NOTE:
Apply the engine oil on the kick idle gear
inner circumference.
Install the kick idle gear with its depressed
side toward you.
New
New

4 - 60
ENGCDI MAGNETO AND STARTER CLUTCH
3. Check:
Starter clutch operation
Install the starter clutch drive gear 1 onto
the starter clutch 2 and hold the starter
clutch.
When turning the starter clutch drive gear
counterclockwise ı, the starter clutch and
the starter clutch drive gear should
engage. If the starter clutch drive gear and
starter clutch do not engage, the starter
clutch is faulty and must be replaced.
When turning the starter clutch drive gear
clockwise Å, it should turn freely.
If the starter clutch drive gear does not
turn freely, the starter clutch is faulty and
must be replaced.
Å
ı
1
2
EC4L5000
ASSEMBLY AND INSTALLATION
CDI magneto
1. Install:
Stator 1
Bolt (stator)
Lead guide
Screw (lead guide) 2
Pickup coil 3
Bolt (pickup coil)
2. Install:
Stater idle gear 1
Plate 2
Bolt 3
Washer 4
NOTE:
Apply the engine oil on the starter idle gear
inner circumference.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)LT
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)LT
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)LT
4
1
2
3
ET R..7 Nm (0.7 m · kg, 5.1 ft · lb)