Page 90 of 610
SPEC
2 - 17
MAINTENANCE SPECIFICATIONS
NOTE:
1. First, tighten the ring nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the ring nut
wrench and turn the steering right and left a few times; then loosen the ring nut one turn.
2. Retighten the ring nut 20 Nm (2.0 m • kg, 14 ft • lb). Part to be tightened Thread size Q’tyTightening torque
Nm m•kg ft•lb
Upper bracket and inner tube M8 × 1.25 2 25 2.5 18
Lower bracket and inner tube M10 × 1.25 2 60 6.0 43
Upper bracket and steering stem M22 × 1.0 1 110 11.0 80
Handlebar upper holder and upper bracket M8 × 1.25 4 23 2.3 17
Steering stem and ring nut M25 × 1.0 1 Refer to NOTE.
Front fork and cap bolt M25 × 1.0 2 23 2.3 17
Front fork and damper rod M10 × 1.0 2 23 2.3 17
Front fork and brake cable holder M6 × 1.0 1 7 0.7 5.1
Number plate M6 × 1.0 1 7 0.7 5.1
Starter knob M11 × 1.25 1 1 0.1 0.7
Starter knob stay M6 × 1.0 2 10 1.0 7.2
Grip cap upper and lower M5 × 0.8 2 4 0.4 2.9
Throttle cable cap M4 × 0.7 2 2 0.2 1.4
Brake lever mounting (bolt) M6 × 1.0 1 3 0.3 2.2
Brake lever mounting (nut) M6 × 1.0 1 4 0.4 2.9
Brake lever holder M5 × 0.8 2 4 0.4 2.9
Clutch lever mounting (bolt) M6 × 1.0 1 7 0.7 5.1
Clutch lever mounting (nut) M6 × 1.0 1 7 0.7 5.1
Clutch lever holder M5 × 0.8 2 4 0.4 2.9
Front wheel axle and axle nut M12 × 1.25 1 45 4.5 32
Front brake camshaft lever and camshaft M6 × 1.0 1 10 1.0 7.2
Rear wheel axle and axle nut M12 × 1.25 1 60 6.0 43
Rear brake camshaft lever and camshaft M6 × 1.0 1 10 1.0 7.2
Brake pedal mounting M10 × 1.25 1 30 3.0 22
Brake pedal position locknut M6 × 1.0 1 7 0.7 5.1
Front wheel nipple (spoke)—36 2 0.2 1.4
Rear wheel nipple (spoke)—36 3 0.3 2.2
Driven sprocket (nut) M10 × 1.25 4 43 4.3 31
Driven sprocket (stud) M10 × 1.25 4 30 3.0 22
Sidestand mounting (nut) M10 × 1.25 1 44 4.4 32
Engine mounting:
Engine bracket (front) and frame M8 × 1.25 2 40 4.0 29
Engine bracket (front) and engine M8 × 1.25 2 40 4.0 29
Engine bracket (upper) and frame M8 × 1.25 2 40 4.0 29
Engine bracket (upper) and cylinder head M8 × 1.25 1 40 4.0 29
Engine and frame (rear) M8 × 1.25 2 40 4.0 29
Pivot shaft and nut M12 × 1.25 1 53 5.3 38
Relay arm and swingarm M12 × 1.25 1 70 7.0 50
Page 95 of 610
SPEC
2 - 22
MAINTENANCE SPECIFICATIONS
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each ride.Part to be tightened Thread size Q’tyTightening torque
Nm m•kg ft•lb
Bead stopper M8 × 1.25 1 3 0.3 2.2
Driven sprocket (nut) M10 × 1.25 4 43 4.3 31
Driven sprocket (stud) M10 × 1.25 4 30 3.0 22
Sidestand mounting (nut) M10 × 1.25 1 44 4.4 32
Engine mounting:
Engine bracket (front) and frame M8 × 1.25 2 40 4.0 29
Engine bracket (front) and engine M8 × 1.25 2 40 4.0 29
Engine bracket (upper) and frame M8 × 1.25 2 40 4.0 29
Engine bracket (upper) and cylinder head M8 × 1.25 1 40 4.0 29
Engine and frame (rear) M8 × 1.25 2 40 4.0 29
Pivot shaft and nut M12 × 1.25 1 53 5.3 38
Relay arm and swingarm (TT-R125LW) M12 × 1.25 1 70 7.0 50
(TT-R125LWE) M12 × 1.25 1 53 5.3 38
Relay arm and connecting arm M10 × 1.25 1 35 3.5 25
Connecting arm and frame M10 × 1.25 1 35 3.5 25
Rear shock absorber assembly and frame M12 × 1.25 1 53 5.3 38
Rear shock absorber assembly and relay arm M10 × 1.25 1 35 3.5 25
Rear shock absorber and locknut (preload) M46 × 1.5 1 42 4.2 30
Drive chain tensioner (upper) M8 × 1.25 1 23 2.3 17
Drive chain tensioner (lower) M6 × 1.0 1 7 0.7 5.1
Drive chain support and swingarm M6 × 1.0 2 7 0.7 5.1
Drive chain guide and swingarm M6 × 1.0 2 7 0.7 5.1
Drive chain guard mounting M6 × 1.0 2 7 0.7 5.1
Fuel tank mounting M6 × 1.0 2 10 1.0 7.2
Fuel tank and fuel cock M6 × 1.0 2 7 0.7 5.1
Fuel tank and fuel tank bracket M6 × 1.0 4 7 0.7 5.1
Front fender mounting M6 × 1.0 4 7 0.7 5.1
Rear fender mounting M6 × 1.0 4 7 0.7 5.1
Flap guard mounting M6 × 1.0 2 4 0.4 2.9
Left side cover mounting M6 × 1.0 2 7 0.7 5.1
Seat mounting M6 × 1.0 2 7 0.7 5.1
Battery cover and battery box (TT-R125LWE) M6 × 1.0 1 5 0.5 3.6
Battery box and frame (TT-R125LWE) M6 × 1.0 2 7 0.7 5.1
Page 99 of 610
SPEC
2 - 26
EC220001
GENERAL TORQUE SPECIFICATIONS
This chart specifies torque for standard fasten-
ers with standard I.S.O. pitch threads. Torque
specifications for special components or
assemblies are included in the applicable sec-
tions of this book. To avoid warpage, tighten
multi-fastener assemblies in a crisscross fash-
ion, in progressive stages, until full torque is
reached. Unless otherwise specified, torque
specifications call for clean, dry threads. Com-
ponents should be at room temperature.
A: Distance between flats
B: Outside thread diameter
EC230000
DEFINITION OF UNITS
A
(Nut)B
(Bolt)TORQUE
SPECIFICATION
Nm m•kg ft•lb
10 mm
12 mm
14 mm
17 mm
19 mm
22 mm6 mm
8 mm
10 mm
12 mm
14 mm
16 mm6
15
30
55
85
1300.6
1.5
3.0
5.5
8.5
134.3
11
22
40
61
94
Unit Read Definition Measure
mm
cmmillimeter
centimeter10
-3 meter
10-2 meterLength
Length
kg kilogram 10
3 gram Weight
N Newton 1 kg
× m/sec2Force
Nm
m • kgNewton meter
Meter kilogramN
× m
m
× kgTorque
Torque
Pa Pascal N/m
2Pressure
N/mm Newton per millimeter N/mm Spring rate
L
cm
3Liter
Cubic centimeter—
—Volume or capacity
Volume or capacity
r/min Revolution per minute—Engine speed
GENERAL TORQUE SPECIFICATIONS/
DEFINITION OF UNITS
Page 152 of 610
2 - 27
SPEC
EC240000
CABLE ROUTING DIAGRAM
TT-R125/TT-R125LW
1Fuel tank breather hose
2CDI unit
3CDI unit band
4Clamp
5CDI magneto lead
6Air vent hose
7Wire harness
8Engine stop switch lead
9Cable guide
0Brake cable
(Brake hose for the TT-R125LW)
ABrake cable holder
(Brake hose holder for the
TT-R125LW)ÅFit the CDI unit band over the CDI unit bracket till it stops.
ıClamp the ignition coil lead.
ÇClamp the wire harness coupler.
ÎClamp the CDI magneto lead, throttle cable and starter cable.
‰Clamp the CDI magneto lead so that it does not contact the push
lever.
ÏPass the air vent hoses between the engine and swingarm.
ÌClamp the wire harness and engine stop switch lead.
ÓPass the brake cable (brake hose for the TT-R125LW) into the cable
guide.
ÈClamp the brake cable.
ÔClamp the brake hose between the paint marks.
CABLE ROUTING DIAGRAM
Page 154 of 610
2 - 28
SPEC
1Air vent hose
2Spark plug lead
3Starter cable
4Throttle cable
5Clutch cable
6Clamp
7Cable guide
8Engine oil breather hose
9Overflow hoseÅAfter clamping the starter cable, push it against the starter plunger.
ıPut the tip of the air vent hose into the main pipe.
ÇInstall the primary coil terminal (orange) to the ignition coil.
ÎFasten the ground lead together with the ignition coil.
‰Pass the starter cable so that it is not twisted.
ÏTighten the starter choke nut while taking care not to twist the starter cable.
ÌPass the clutch cable on the inside of the throttle and starter cable.
ÓClamp the clutch cable with the paint in the cable guide bottom recess.
ÈPass the throttle cable and starter cable into the cable guide.
ÔPass the engine oil breather hose and overflow hose between the right
half of the swingarm and pillar tube.
Clamp the engine oil breather hose, overflow hose and air vent hose to 2 clicks.
CABLE ROUTING DIAGRAM
Page 156 of 610
2 - 29
SPEC
1Engine stop switch lead
2Engine stop switch
3Fuel tank breather hose
4Clamp
5Brake cable
(Brake hose for the TT-R125LW)
6Clutch cable
7Throttle cableÅPass the engine stop switch lead in the middle of the clutch holder.
ıClamp the engine stop switch lead to the handlebar to 3 clicks.
ÇPass the brake cable (brake hose for the TT-R125LW) in front of the
number plate and through the cable guide.
ÎPass the clutch cable in back of the number plate.
‰Insert the fuel tank breather hose into the hole in the starter knob stay
more the 30 mm (1.18 in).
ÏClamp the throttle cable adjuster cover to the handlebar with the clamp
ends downward.
CABLE ROUTING DIAGRAM
Page 158 of 610
2 - 30
SPECCABLE ROUTING DIAGRAM
TT-R125E/TT-R125LWE
1Ground lead
2Primary coil lead
3Clamp
4Wire harness
5Starter relay lead
6Rectifier/regulator lead
7CDI magneto lead
8Air vent hose
9Neutral switch lead
0Rear shock absorber assembly
sub-tank hose (TT-R125LWE
only)
AStarting circuit cut-off relay lead
BCDI unit lead
CCorrugated tubeDBrake hose holder (Brake cable
holder for the TT-R125E)
EBrake hose (Brake cable for the
TT-R125E)
FCable guide
GMain switch lead
HEngine stop switch lead
IClutch switch lead
JStart switch lead
KCDI unit band
LCDI unit
MConnector cover
NRubber cover
OStarter cable
PThrottle cableQRectifier/regulator
ÅFasten the primary coil lead and
ground lead.
ıFasten the wire harness at its
tape.
ÇFasten the wire harness and
CDI magneto lead in front of the
rear shock absorber assembly
bracket at the protecting tube
for the CDI magneto lead.
30~35 mm
(1.18~1.38 in)
E
DD
A
C
B-B
D-D
E
B
BC
TT-R125EA
L
1
3
4 2
3
35
3
36
7
3
3
8
9 0 A 3 B C
DEFGHIJKOP
7
4
0
3 3M
N
3Q
3 F
E
DË
◊
„
Ù
AB
AA
Û
ÁAC
N
Ì
Ï ‰ Î
Ç ı Å
Ó
È
Ô
Ò ˜ ˆ Ø ∏
ŒÂÍ ÊÂ
Page 160 of 610
2 - 31
SPECCABLE ROUTING DIAGRAM
ÎAfter fastening the starter relay
lead, pass it on the left of the
chassis.
‰Fasten the CDI magneto lead
and starter relay lead.
ÏFasten the wire harness.
ÌPass the rectifier/regulator lead
between the frame and air filter
case.
ÓDo not allow the CDI magneto
lead to slacken except between
the two plastic locking ties.
ÈFasten the CDI magneto lead
over the engine bracket (rear).
ÔFasten the CDI magneto lead.Pass the air vent hoses between
the engine and swingarm.
ÒFit the neutral switch lead into
the groove in the crankcase
cover.
˜Pass the starting circuit cut-off
relay lead under the frame and
at the right of the chassis.
ˆFasten the rear shock absorber
assembly sub-tank.
(TT-R125LWE only)
ØPass the CDI unit lead on the
outside of the main switch lead,
engine stop switch lead, clutch
switch lead and start switch
lead.∏After fastening the start switch
lead, clutch switch lead, engine
stop switch lead and main
switch lead, push their corru-
gated tube against the CDI unit
coupler.
ŒFasten the brake hose between
the paint marks.
ÂPass the brake hose (brake
cable for the TT-R125E)
through the cable guide.
ÍFit the CDI unit band over the
CDI unit bracket till it stops.
ÊFasten the brake cable.
30~35 mm
(1.18~1.38 in)
E
DD
A
C
B-B
D-D
E
B
BC
TT-R125EA
L
1
3
4 2
3
35
3
36
7
3
3
8
9 0 A 3 B C
DEFGHIJKOP
7
4
0
3 3M
N
3Q
3 F
E
DË
◊
„
Ù
AB
AA
Û
ÁAC
N
Ì
Ï ‰ Î
Ç ı Å
Ó
È
Ô
Ò ˜ ˆ Ø ∏
ŒÂÍ ÊÂ
