2004 YAMAHA TTR125 steering

5 - 52
CHASSTEERING
EC560000
STEERING
Extent of removal:1 Lower bracket removal2 Bearing removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalSTEERING REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNINGSupport the machine securely so there is nodanger of it falling over.
Front forks Refer to “FRONT FORK” section.
Handlebar Refer to “HANDLEBAR” section.
Front fender
1 Steering stem nut 1
2 Upper bracket 1
3 Special washer 1
4 Upper ring nut 1
Use special tool.
Refer to “REMOVAL POINTS”. 5 Rubber washer 1
6 Lower ring nut 1
7 Lower bracket 1
8Bearing cover
1
21

5 - 53
CHASSTEERING
Extent of removal Order Part name Q’ty Remarks
9 Bearing inner race (upper) 1
10 Bearing (upper) 1
11 Bearing outer race (upper) 1
Refer to “REMOVAL POINTS”. 12 Bearing outer race (lower) 1
13Bearing (lower)
1
2

5 - 54
CHAS
EC563000
REMOVAL POINTS
EC563202
Ring nut
1. Remove:
Ring nut 1
Use the steering nut wrench 2.
WARNING
Support the steering shaft so that it may
not fall down.
Steering nut wrench:
YU-33975/90890-01403
Bearing race
1. Remove:
Bearing race 1
Remove the bearing race using long
rod 2 and the hammer.
EC563300
Bearing (lower)
1. Remove:
Bearing (lower) 1
Use the floor chisel 2.
CAUTION:
Take care not to damage the steering shaft
thread.
EC564000
INSPECTION
Steering stem
1. Inspect:
Steering stem 1
Bend/damage → Replace.
STEERING

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CHAS
Bearing and bearing race
1. Wash the bearings and bearing races
with a solvent.
2. Inspect:
Bearing
Bearing race
Pitting/damage → Replace bearings
and bearing races as a set.
Install the bearing in the bearing races.
Spin the bearings by hand. If the bear-
ings hang up or are not smooth in their
operation in the bearing races, replace
bearings and bearing races as a set.
EC565000
ASSEMBLY AND INSTALLATION
Lower bracket
1. Install:
Bearing (lower) 1
NOTE:
Apply the lithium soap base grease on the dust
seal lip and bearing inner circumference.
2. Install:
Bearing outer race (lower)
Bearing outer race (upper)
3. Install:
Bearing (upper)
Bearing inner race 1
Bearing cover 2
NOTE:
Apply the lithium soap base grease on the
bearing and bearing cover lip.
STEERING

5 - 56
CHAS
4. Install:
Lower bracket 1
NOTE:
Apply the lithium soap base grease on the
bearing.
5. Install:
Lower ring nut 1
Rubber washer
Upper ring nut
Special washer
Tighten the ring nut using the steering
nut wrench 2.
NOTE:
Install the lower ring nut with its larger cham-
fered portion a facing downward.
Refer to “STEERING HEAD INSPEC-
TION AND ADJUSTMENT” section in
the CHAPTER 3.
6. Check the steering shaft by turning it lock
to lock. If there is any binding, remove the
steering shaft assembly and inspect the
steering bearings.
T R..20 Nm (2.0 m · kg, 14 ft · lb)
7. Install:
Upper bracket 1
Steering stem nut 2
Starter knob bracket 3
NOTE:
Do not tighten the steering stem nut yet.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
8. Install:
Front forks 1
NOTE:
Temporarily tighten the pinch bolts (lower
bracket) 2.
Do not tighten the pinch bolts (upper bracket)
yet.
STEERING

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CHAS
9. Tighten:
Steering stem nut 1
10. Install:
Cap 2
11. After tightening the nut, check the steer-
ing for smooth movement. If not, adjust
the steering by loosening the ring nut little
by little.
T R..110 Nm (11.0 m · kg, 80 ft · lb)
12. Adjust:
Front fork top end a
ÅTT-R125/TT-R125E/TT-R125LW
ıTT-R125LWE
Front fork top end (standard) a:
Zero mm (Zero in)
a
Åı
13. Tighten:
Pinch bolts (lower bracket) 1
Pinch bolts (upper bracket) 2
T R..60 Nm (6.0 m · kg, 43 ft · lb)
T R..25 Nm (2.5 m · kg, 18 ft · lb)
STEERING