2005 YAMAHA TTR125 oil

5 - 29
CHASREAR WHEEL AND REAR BRAKE
5. Install:
Springs 1
Brake shoes 2
On brake shoe plate 3
NOTE:
Apply the lithium soap base grease on the
pivot pin.
When installing the springs and brake shoes,
take care not to damage the springs.
When replacing the brake shoes, replace the
springs as a set.
WARNING
Do not apply grease to the brake shoe lin-
ings.
New
Rear wheel
1. Install:
Wheel bearing 1
Spacer 2
Wheel bearing 3
Oil seal 4
NOTE:
Apply the lithium soap base grease on the oil
seal lip when installing.
Install the bearing with seal facing outward.
Use a socket that matches the outside diam-
eter of the race of the bearing.
Right side of bearing shall be installed first.
Install the oil seal with its manufacture’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of the bearing.
Contact should be made only with the outer
race.
New

5 - 30
CHASREAR WHEEL AND REAR BRAKE
2. Install:
Wheel sprocket 1
Lock washers 2
Nut (wheel sprocket) 3
NOTE:
Tighten the nuts in stage, using a crisscross
pattern.
Bend the lock washer tab.
New
T R..43 Nm (4.3 m · kg, 31 ft · lb)
3. Install:
Collar (left)
Brake shoe plate assembly
Collar (right)
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
4. Install:
Rear wheel
NOTE:
Make sure that the slot a on the brake shoe
plate with the stopper b on the swingarm.
5. Install:
Drive chain 1
NOTE:
Push the wheel 2 forward and install the drive
chain.
6. Install:
Drive chain puller (left) 1
Plain washer 2
Wheel axle 3
NOTE:
Apply the lithium soap base grease on the
wheel axle.
Insert the wheel axle from left side.

5 - 33
CHASFRONT FORK
EC558000
FRONT FORK DISASSEMBLY
ÅTT-R125/TT-R125E/TT-R125LW
ıTT-R125LWE
Extent of removal:1 Oil seal removal2 Damper rod removal
Extent of removal Order Part name Q’ty Remarks
FRONT FORK DISASSEMBLYAB
1Dust boot 1 1
2Cap bolt 1 1 Refer to “REMOVAL POINTS”.
3Spacer 1–
4Washer 1 1
5Fork spring 1 1 Drain the fork oil.
6Dust seal 1 1
Use special tool.
Refer to “REMOVAL POINTS”. 7Stopper ring 1 1
8Bolt (damper rod) 1 1
9Damper rod 1 1
0Inner tube 1 1
AOil flow stopper 1 1
BPiston metal 1 1
COil seal 1 1
DOuter tube
11
2
1

5 - 34
CHASFRONT FORK
HANDLING NOTE
NOTE:
The front fork requires careful attention. So it is
recommended that the front fork be main-
tained at the dealers.
CAUTION:
To prevent an accidental explosion of air,
the following instructions should be
observed:
The front fork with a built-in piston rod has
a very sophisticated internal construction
and is particularly sensitive to foreign
material.
Use enough care not to allow any foreign
material to come in when the oil is replaced
or when the front fork is disassembled and
reassembled.
EC553000
REMOVAL POINTS
Cap bolt
1. Remove:
Cap bolt 1
From the inner tube.
NOTE:
Before removing the front fork from the
machine, loosen the cap bolt.
ÅTT-R125/TT-R125E/TT-R125LW
ıTT-R125LWE
Inner tube
1. Remove:
Dust seal 1
Stopper ring 2
Using slotted-head screwdriver.
CAUTION:
Take care not to scratch the inner tube.
1
Åı
2. Remove:
Bolt (damper rod)
Damper rod
Inner tube
Oil flow stopper
Piston metal
NOTE:
Use the damper rod holder 1 and the T-han-
dle 2 to lock the damper rod.

5 - 35
CHASFRONT FORK
Damper rod holder:
YM-1300/90890-01294
T-handle:
YM-1326/90890-01326
3. Remove:
Oil seal 1
Using slotted-hand screwdriver.
CAUTION:
Take care not to scratch the outer tube.
EC554000
INSPECTION
Damper rod
1. Inspect:
Damper rod
Bend/damage → Replace damper rod.
CAUTION:
The front fork with a built-in piston rod has
a very sophisticated internal construction
and is particularly sensitive to foreign
material.
Use enough care not to allow any foreign
material to come in when the oil is replaced
or when the front fork is disassembled and
reassembled.

5 - 36
CHASFRONT FORK
EC554400
Fork spring
1. Measure:
Fork spring free length a
Out of specification → Replace.
Fork spring free length:
Standard
TT-R125/TT-R125E:
327 mm (12.9 in)
TT-R125LW:
339 mm (13.3 in)
TT-R125LWE:
453.6 mm
(17.86 in)TT-R125/TT-R125E:
322 mm (12.7 in)
TT-R125LW:
334 mm (13.1 in)
TT-R125LWE:
448.6 mm
(17.66 in)
Inner tube
1. Inspect:
Inner tube surface a
Score marks → Repair or replace.
Use #1,000 grit wet sandpaper.
Damaged oil lock piece → Replace.
Inner tube bends
Out of specification → Replace.
Use the dial gauge 1.
NOTE:
The bending value is shown by one half of the
dial gauge reading.
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken the
tube.
2. Inspect:
Piston metal 1
Wear/damage → Replace.
Inner tube bending limit:
0.2 mm (0.008 in)

5 - 37
CHAS
Outer tube
1. Inspect:
Outer tube 1
Slide metal 2
Score marks/wear/damage → Replace
outer tube assembly.
Cap bolt
1. Inspect:
Cap bolt 1
O-ring 2
Wear/damage → Replace.
EC555000
ASSEMBLY AND INSTALLATION
Front fork assembly
1. Wash the all parts in a clean solvent.
2. Install:
Piston metal 1
Damper rod 2
Oil flow stopper 3
On inner tube 4.
CAUTION:
To install the damper rod into the inner
tube, hold the inner tube aslant. If the inner
tube is held vertically, the damper rod may
fall into it and be damaged.
3. Install:
Inner tube
On outer tube.
FRONT FORK

5 - 38
CHASFRONT FORK
4. Install:
Copper washer
Bolt (damper rod)
NOTE:
Use the damper rod holder 1 and the T-han-
dle 2 to lock the damper rod.
Damper rod holder:
YM-1300/90890-01294
T-handle:
YM-01326/90890-01326
New
T R..23 Nm (2.3 m · kg, 17 ft · lb)LT
5. Install:
Oil seal 1
NOTE:
Apply the fork oil on the inner tube.
When installing the oil seal, use vinyl seat a
with fork oil applied to protect the oil seal lip.
Install the oil seal with its manufacturer's
marks or number facing upside.
Press the oil seal into the outer tube with fork
seal driver attachment (ø30) 2 and fork seal
driver weight 3.
Fork seal driver weight:
YM-33963/90890-01367
Fork seal driver attachment:
YM-33281/90890-01400
New
6. Install:
Stopper ring 1
NOTE:
Fit the stopper ring correctly in the groove in
the outer tube.