2003 YAMAHA TTR125 fuel tank removal

CHAPTER 4
ENGINE
SEAT, FUEL TANK
AND SIDE COVERS
..................................4-1
MUFFLER
..................................................4-2
CARBURETOR
..........................................4-3
CYLINDER HEAD
....................................4-12
CAMSHAFT AND ROCKER ARMS
........4-20
VALVES AND VALVE SPRINGS
............4-24
CYLINDER AND PISTON
........................4-32
CLUTCH AND PRIMARY
DRIVEN GEAR
........................................4-40
OIL PUMP
................................................4-49
KICK AXLE AND SHIFT SHAFT
.............4-53
CDI MAGNETO
AND STARTER CLUTCH
.........................4-58
ENGINE REMOVAL
.................................4-63
CRANKCASE, CRANKSHAFT
AND BALANCER
....................................4-67
TRANSMISSION, SHIFT CAM
AND SHIFT FORK
...................................4-75
CHAPTER 5
CHASSIS
FRONT WHEEL AND FRONT BRAKE
(TT-R125E)
................................................5-1
FRONT WHEEL (TT-R125LWE)
...............5-8
FRONT BRAKE (TT-R125LWE)
..............5-12
REAR WHEEL AND REAR BRAKE
.......5-24
FRONT FORK
..........................................5-32
HANDLEBAR
...........................................5-41
STEERING
...............................................5-48
SWINGARM
.............................................5-54
REAR SHOCK ABSORBER
ASSEMBLY
.............................................5-61
CHAPTER 6
ELECTRICAL
ELECTRICAL COMPONENTS
AND WIRING DIAGRAM
...........................6-1
IGNITION SYSTEM
....................................6-2
ELECTRIC STARTING SYSTEM
...............6-6
CHARGING SYSTEM
...............................6-16

4 - 1
ENG

EC400000
ENGINE
EC4R0000
SEAT, FUEL TANK AND SIDE COVERS
Extent of removal:
1
Seat removal
2
Fuel tank removal
3
Side covers removal
4
Number plate removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removal
SEAT, FUEL TANK AND SIDE
COVERS REMOVAL
Turn the fuel cock to “OFF”.
1 Seat 1
2 Air scoop (left and right) 2
3 Fuel hose 1 Remove on fuel tank side.
4 Fitting band 1
5 Bolt (fuel tank) 2
6 Fuel tank 1
7 Left side cover 1
8 Right side cover 1
9Number plate
1
13
4
2
3

SEAT, FUEL TANK AND SIDE COVERS

4 - 2
ENG

MUFFLER
MUFFLER
Extent of removal:
1
Muffler removal
Extent of removal Order Part name Q’ty Remarks
MUFFLER REMOVAL
Preparation for removal Right side cover Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
1 Bolt (spark arrester) 3
2 Spark arrester 1
3 Nut (muffler) 2
4 Bolt (muffler) 1
5Muffler
1
1

4 - 3
ENG

CARBURETOR
CARBURETOR
Extent of removal:
1
Carburetor removal
Extent of removal Order Part name Q’ty Remarks
CARBURETOR REMOVAL
Preparation for removal Fuel tank
Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Number plate
1 Fuel hose 1
2 Over flow hose 1
3 Air vent hose 2
4 Starter plunger/starter knob 1
5 Carburetor top cover 1
6 Clamp (air cleaner joint) 1 Loosen the screw (air cleaner joint).
7 Clamp (carburetor joint) 1 Loosen the screws (carburetor joint).
8Carburetor
1
1

4 - 12
ENGCYLINDER HEAD
CYLINDER HEAD
CYLINDER HEAD SIDE COVER AND TAPPET COVER
Extent of removal:1 Cylinder head side cover and tappet cover removal
Extent of removal Order Part name Q’ty Remarks
CYLINDER HEAD SIDE COVER
AND TAPPET COVER
REMOVAL
Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Muffler Refer to “MUFFLER” section.
Carburetor Refer to “CARBURETOR” section.
CDI unit Remove from the frame.
1 Engine bracket 1
2 Spark plug 1
3 Cylinder head side cover 1
4 Tappet cover 2
5 Crankshaft end accessing screw 1
6Timing mark accessing screw
1
1

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 - 63
ENG

ENGINE REMOVAL
ENGINE REMOVAL
Extent of removal:
1
Engine removal
Extent of removal Order Part name Q’ty Remarks
ENGINE REMOVAL
Preparation for removal Hold the machine by placing the
suitable stand under the frame.
Seat, fuel tank and side covers Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Carburetor Refer to “CARBURETOR” section.
Muffler Refer to “MUFFLER” section.
Clutch cable Disconnect at engine side.
Spark plug cap
Disconnect the CDI magneto
lead.
Disconnect the neutral switch
lead.
Starter motor Refer to “ELECTRIC STARTING SYS-
TEM” section in the CHAPTER 6.
Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT”
section in the CHAPTER 3.

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