2004 YAMAHA TTR125 relay

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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.
WARNINGSupport 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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CHASSWINGARM
EC578000
SWINGARM DISASSEMBLY
Extent of removal:1 Swingarm disassembly 2 Connecting arm removal and disassembly
3 Relay arm removal and disassembly
Extent of removal Order Part name Q’ty Remarks
SWINGARM DISASSEMBLY
1Drive chain guard 1
2Drive chain support 1
3Drive chain guide 1
4Dust cover 4
5Collar 1
6Connecting arm 1
7Oil seal 2
8Collar 2
9Dust cover 2
0Bushing 1
ARelay arm 1
BDust cover 2
CBushing 1
DSwingarm 1
3
1
2

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CHASSWINGARM
REMOVAL POINTS
Bushing
1. Remove:
Bushing 1
NOTE:
Remove the bushing by pressing.
INSPECTION
Wash the bushings, collars, and covers in a
solvent.
Swingarm
1. Inspect:
Bushing 1
Bushing 2
Damage/pitting → Replace bushings as
a set.
2. Inspect:
Dust cover
Damage → Replace.
3. Inspect:
Swingarm
Damage/bends/cracks → Replace.
Relay arm
1. Inspect:
Collar 1
Bushing 2
Damage/pitting → Replace collar and
bushing as a set.
Bushing 3
Bushing 4
Damage/pitting → Replace bushings as
a set.
Collar 5
Bushing 6
Bushing 7
Damage/pitting → Replace collars and
bushing as a set.
2. Inspect:
Oil seal 8
Dust cover 9
Damage → Replace.
3. Inspect:
Relay arm 0
Damage/bends/cracks → Replace.

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CHAS
Connecting arm
1. Inspect:
Collar 1
Bushing 2
Damage/pitting → Replace collar and
bushings as a set.
2. Inspect:
Dust cover 3
Damage → Replace.
3. Inspect:
Connecting arm 4
Damage/bends/cracks → Replace.
EC575000
ASSEMBLY AND INSTALLATION
Bushing
1. Install:
Bushing
NOTE:
Make sure to press in the bushing so that they
are flush with the surface of the connecting
arm and relay arm.
Swingarm assembly
1. Install:
Bushing 1
Dust covers 2
On swingarm.
NOTE:
Apply the molybdenum disulfide grease on the
bushing and dust cover lip.
SWINGARM

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CHAS
2. Install:
Oil seals 1
Collars 2
Bushing 3
Dust covers 4
Dust covers 5
Rubber boot 6
On relay arm.
NOTE:
Apply the molybdenum disulfide grease on the
bushing, collar, oil seal lip and dust cover lip.
3. Install:
Collar 1
Dust covers 2
On connecting arm.
NOTE:
Apply the molybdenum disulfide grease on the
collar and dust cover lip.
4. Install:
Relay arm 1
Bolt (relay arm)
Plain washer
Nut (relay arm)
TT-R125/TT-R125E/TT-R125LW
TT-R125LWE
On swingarm.
NOTE:
Apply the molybdenum disulfide grease on the
bolt (relay arm).
T R..70 Nm (7.0 m · kg, 50 ft · lb)
T R..53 Nm (5.3 m · kg, 38 ft · lb)
SWINGARM

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CHASSWINGARM
5. Install:
Connecting arm 1
Bolt (connecting arm)
Plain washer
Nut (connecting arm)
On relay arm.
NOTE:
Apply the molybdenum disulfide grease on the
bolt (connecting arm).
6. Install:
Drive chain guide 1
Collars
Bolts (drive chain guide) 2
T R..35 Nm (3.5 m · kg, 25 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
7. Install:
Drive chain support 1
Collars
Bolts (drive chain support) 2
Drive chain guard 3
Bolts (drive chain guide) 4
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)LT
Installation
1. Install:
Swingarm
Pivot shaft 1
Plain washer
Nut (pivot shaft)
NOTE:
Apply the molybdenum disulfide grease on the
pivot shaft.
2. Check:
Swingarm side play a
Free play exists → Replace bushing.
Swingarm up and down movement b
Unsmooth movement/binding/rough
spots → Grease or replace bushing.
T R..53 Nm (5.3 m · kg, 38 ft · lb)

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CHAS
3. Install:
Bolt (rear shock absorber - relay arm) 1
Plain washer
Nut (rear shock absorber-relay arm)
NOTE:
Apply the molybdenum disulfide grease on the
bolt (rear shock absorber - relay arm).
T R..35 Nm (3.5 m · kg, 25 ft · lb)
4. Install:
Bolt (connecting arm-frame) 1
Plain washer
Nut (connecting arm-frame)
NOTE:
Apply the molybdenum disulfide grease on the
bolt (connecting arm - frame).
T R..35 Nm (3.5 m · kg, 25 ft · lb)
5. Install:
Drive chain tensioner (lower) 1
Collar
Bolt [drive chain tensioner (lower)]
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
6. Install:
Bushing 1
Drive chain tensioner (upper) 2
Plain washer 3
Bolt [drive chain tensioner (upper)] 4
NOTE:
Apply the lithium soap base grease on the
bushing inner surface.
T R..23 Nm (2.3 m · kg, 17 ft · lb)
SWINGARM

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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.
WARNINGSupport 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