2004 YAMAHA TTR125 clutch

3 - 4
INSP
ADJENGINE/CLUTCH ADJUSTMENT/
THROTTLE CABLE ADJUSTMENT
EC350000
ENGINE
CLUTCH ADJUSTMENT
1. Check:
Clutch lever free play a
Out of specification → Adjust.
Clutch lever free play a:
10 ~ 15 mm (0.39 ~ 0.59 in)
2. Adjust:
Clutch lever free play
NOTE:
Make minute adjustment on the lever side.
After adjustment, check proper operation of
clutch lever. Clutch lever free play adjustment steps:
Loosen the locknut 1.
Turn the adjuster 2 until free play a is
within the specified limits.
Tighten the locknut.
EC35A001
THROTTLE CABLE ADJUSTMENT
1. Check:
Throttle grip free play a
Out of specification → Adjust.
Throttle grip free play a:
3 ~ 5 mm (0.12 ~ 0.20 in)
2. Adjust:
Throttle grip free play
Throttle grip free play adjustment steps:
Loosen the locknut 1.
Turn the adjuster 2 until the specified free
play is obtained.
Tighten the locknut.

3 - 8
INSP
ADJ
ENGINE OIL LEVEL INSPECTION
4. Check:
Oil level
Oil level should be between maximum
a and minimum b marks.
Oil level is low → Add oil to proper
level.
NOTE:
When inspecting the oil level, do not screw the
dipstick into the oil tank. Insert the gauge
lightly.
(For USA and CDN)
CAUTION:
Do not add any chemical additives.
Engine oil also lubricates the clutch and
additives could cause clutch slippage.
Do not allow foreign material to enter the
crankcase.
Recommended oil:
At –10 ˚C (10 ˚F) or higher Å:
Yamalube 4 (10W-30) or SAE
10W-30 type SE motor oil
At 5 ˚C (40 ˚F) or higher ı:
Yamalube 4 (20W-40) or SAE
20W-40 type SE motor oil
(Except for USA and CDN)
CAUTION:
Do not add any chemical additives or use
oils with a grade of CD a or higher.
Do not use oils labeled “ENERGY CON-
SERVING II” b or higher. Engine oil also
lubricates the clutch and additives could
cause clutch slippage.
Do not allow foreign materials to enter the
crankcase.
Recommended oil:
Refer to the following chart for
selection of oils which are suited
to the atmospheric temperatures.
Recommended engine oil classi-
fication:
API STANDARD:
API “SE” or higher grade
(Designed primarily for motor-
cycles)

3 - 33
INSP
ADJ
LUBRICATION
LUBRICATION
To ensure smooth operation of all compo-
nents, lubricate your machine during setup,
after break-in, and after every ride.
1All control cable
2Brake and clutch lever pivots
3Shift pedal pivot
4Footrest pivot
5Throttle-to-handlebar contact
6Drive chain
7Tube guide cable winding portion
8Throttle cable end
9Brake and clutch cable ends
(Clutch cable end only for the TT-R125LW/
TT-R125LWE)ÅUse Yamaha cable lube or equivalent on these
areas.
ıUse SAE 10W-30 motor oil or suitable chain
lubricants.
ÇLubricate the following areas with high quality,
lightweight lithium-soap base grease.
AAA
AAB
CC

4 - 40
ENGCLUTCH AND PRIMARY DRIVEN GEAR
EC490000
CLUTCH AND PRIMARY DRIVEN GEAR
EC498000
CLUTCH PLATE AND FRICTION PLATE
Extent of removal:1 Clutch plate and friction plate removal
Extent of removal Order Part name Q’ty Remarks
CLUCTH PLATE AND FRIC-
TION PLATE REMOVAL
Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT”
section in the CHAPTER 3.
Engine skidplate Refer to “ENGINE REMOVAL” section.
Starter motor for the TT-R125E/
TT-R125LWE1 Refer to “ELECTRIC STARTING SYS-
TEM” section in the CHAPTER 6 for the
TT-R125E/TT-R125LWE.
1 Kickstarter crank 1
2 Starter motor lead holder 2 TT-R125E/TT-R125LWE
3 Negative battery lead 1 TT-R125E/TT-R125LWE
4 Gasket 1
5 Dowel pin 2
6 Pressure plate 1
7 Ball 1
8 Friction plate 5
9 Clutch plate 4
10 Nut/washer 1/1
11 Push rod 1 1
12Push plate
1
1

4 - 41
ENGCLUTCH AND PRIMARY DRIVEN GEAR
EC498100
PRIMARY DRIVEN GEAR
Extent of removal:1 Primary driven gear removal2 Primary drive gear removal
Extent of removal Order Part name Q’ty Remarks
PRIMARY DRIVEN GEAR
REMOVAL
1 Nut (clutch boss) 1
Use special tool.
Refer to “REMOVAL POINTS”. 2 Lock washer 1
3 Clutch boss 1
4 Thrust plate 1
5 Primary driven gear 1
6 Thrust plate 1
7 Conical spring washer 1
8 Nut (primary drive gear) 1
Refer to “REMOVAL POINTS”.
9 Primary drive gear 1
10Straight key
1
2
1

4 - 42
ENGCLUTCH AND PRIMARY DRIVEN GEAR
PUSH LEVER
Extent of removal:1 Push lever removal
Extent of removal Order Part name Q’ty Remarks
PUSH LEVER REMOVAL
1 Clutch cable 1
2 Push lever 1
3 Spring 1
4 Circlip 1
5Oil seal
1
1

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ENGCLUTCH AND PRIMARY DRIVEN GEAR
EC493000
REMOVAL POINTS
Clutch boss
1. Remove:
Nut 1
Lock washer
Clutch boss 2
NOTE:
Straighten the lock washer tab and use the
clutch holding tool 3 to hold the clutch boss.
ÅFor USA and CDN
ıExcept for USA and CDN
Clutch holding tool:
YM-91042/90890-04086Å
ı
Primary drive gear
1. Remove:
Nut (primary drive gear) 1
Primary drive gear 2
NOTE:
Place a folded rag or aluminum plate
between the teeth of the primary drive gear
and primary driven gear.
Take care not to damage the gear teeth.
EC494000
INSPECTION
EC484100
Clutch housing and boss
1. Inspect:
Clutch housing 1
Cracks/wear/damage → Replace.
Clutch boss 2
Scoring/wear/damage → Replace.
EC484201
Primary driven gear
1. Check:
Circumferential play
Free play exists → Replace.
Gear teeth a
Wear/damage → Replace.

4 - 44
ENGCLUTCH AND PRIMARY DRIVEN GEAR
EC484400
Clutch spring
1. Measure:
Clutch spring free length a
Out of specification → Replace springs
as a set.
Clutch spring free length:
33 mm (1.30 in)
: 31 mm (1.22 in)
EC484500
Friction plate
1. Measure:
Friction plate thickness
Out of specification → Replace friction
plate as a set.
Measure at all four points.
EC484600
Clutch plate
1. Measure:
Clutch plate warpage
Out of specification → Replace clutch
plate as a set.
Use a surface plate 1 and thickness
gauge 2.
Push lever
1. Inspect:
Push lever 1
Wear/damage → Replace.
Friction plate thickness:
2.92 ~ 3.08 mm
(0.115 ~ 0.121 in)
: 2.8 mm (0.110 in)
Warp limit:
0.2 mm (0.008 in)