2005 YAMAHA TTR125 oil

5 - 38
CHAS
4. Montieren:
Kupferscheibe
Schraube (Dämpferrohr)
HINWEIS:
Den Dämpferrohr-Halter 1 und den T-Griff 2
zum Befestigen der Dämpferrohr-Schraube
verwenden.
Dämpferrohr-Halter:
YM-1300/90890-01294
T-Griff:
YM-01326/90890-01326
New
T R..23 Nm (2,3 m · kg, 17 ft · lb)LT
5. Montieren:
Dichtring 1
HINWEIS:
Gabelöl auf das Standrohr auftragen.
Bei der Montage des Dichtrings mit Gabelöl
bestrichene Vinyl-Montagehilfe a verwenden,
um Dichtlippe des Dichtrings zu schützen.
Dichtringe so einbauen, daß die Hersteller-
beschriftung oder Teilenummer sichtbar
bleibt.
Dichtring mit Gabeldichtring-Treibhülse
(ø30) 2 und Gabeldichtring-Treiber 3 im
Tauchrohr montieren.
Gabeldichtring-Treiber:
YM-33963/90890-01367
Gabeldichtring-Führungshülse:
YM-33281/90890-01400
New
6. Montieren:
Sicherungsring 1
HINWEIS:
Sicherungsring richtig in die Nut im Tauchrohr
einpassen.
FOURCHE AVANT
TELESKOPGABEL
4. Monter:
Rondelle en cuivre
Boulon (tige d’amortisseur)
N.B.:
Utiliser l’support de tige d’amortisseur 1 et le poignée
en T 2 afin de bloquer la tige d’amortisseur.
Support de tige d’amortisseur:
YM-1300/90890-01294
Poignée en T:
YM-01326/90890-01326
New
T R..23 Nm (2,3 m · kg, 17 ft · lb)LT
5. Monter:
Bague d’étanchéité 1
N.B.:
Enduire le tube plongeur d’huile de fourche.
Pour installer la bague d’étanchéité sans abîmer
les lèvres de la bague d’étanchéité, se servir d’une
toile en plastique a enduite d’huile de fourche.
Monter la bague d’étanchéité en veillant à ce que
son côté porteur de la marque ou du repère du
fabricant soit dirigé vers le haut.
Forcer la bague d’étanchéité dans le fourreau à
l’aide de l’accessoire de l’outil de montage de
joint de fourche (ø30) 2 et du poids de montage
de joint de fourche 3.
Poids de montage de joint de fourche:
YM-33963/90890-01367
Accessoire de l’outil de montage de
joint de fourche:
YM-33281/90890-01400
New
6. Monter:
Clip de maintien 1
N.B.:
Loger correctement le clip de maintien dans la rai-
nure du fourreau.

5 - 39
CHASFRONT FORK
7. Install:
Dust seal 1
NOTE:
Apply the lithium soap base grease on the
inner tube.
8. Check:
Inner tube smooth movement
Tightness/binding/rough spots →
Repeat the steps 2 to 7.
9. Compress the front fork fully.
10. Fill:
Front fork oil 1
CAUTION:
Be sure to use recommended fork oil. If
other oils are used, they may have an
excessively adverse effect on the front
fork performance.
Never allow foreign materials to enter the
front fork.
11. After filling, pump the inner tube slowly
up and down more than 10 times to dis-
tribute the fork oil.
Recommended oil:
Fork oil 10W or equivalent
Quantity (each front fork leg):
TT-R125/TT-R125E:
159 cm
3
(5.60 Imp oz, 5.38 US oz)
TT-R125LW:
156 cm
3
(5.49 Imp oz, 5.27 US oz)
TT-R125LWE:
158 cm
3
(5.56 Imp oz, 5.34 US oz)

5 - 40
CHASFRONT FORK
12. Measure:
Oil level a
Out of specification → Adjust.
13. Install:
Fork spring
Washer
Spacer
(TT-R125/TT-R125E/TT-R125LW)
Cap bolt 1
Dust boot
NOTE:
Temporarily tighten the cap bolt.
ÅTT-R125/TT-R125E/TT-R125LW
ıTT-R125LWE
Standard oil level:
TT-R125/TT-R125E:
122 mm (4.80 in)
TT-R125LW:
130 mm (5.12 in)
TT-R125LWE:
125 mm (4.92 in)
From the top of the inner tube,
with the inner tube fully com-
pressed, and without the fork
spring.
1
Åı
Installation
1. Install:
Front fork
NOTE:
Temporarily tighten the pinch bolt (lower
bracket).
Do not tighten the pinch bolt (upper bracket)
yet.
2. Tighten:
Cap bolt 1
3. 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 1
ÅıT R..23 Nm (2.3 m · kg, 17 ft · lb)

5 - 48
CHAS
ASSEMBLY AND INSTALLATION
Throttle grip assembly
1. Install:
Collar 1
Handlebar grip (right) 2
Apply the adhesive on the tube guide
3.
NOTE:
Before applying the adhesive, wipe off grease
or oil on the tube guide surface a with a lac-
quer thinner.
Handlebar
1. Install:
Handlebar 1
Handlebar holder 2
Main switch
(TT-R125E/TT-R125LWE) 3
Main switch holder
(TT-R125E/TT-R125LWE) 4
Bolt (handlebar holder) 5
NOTE:
Align the punched mark a on the handlebar
with the upper surface of the handlebar
holder on the upper bracket.
The handlebar holder should be installed
with the punched mark b forward.
First tighten the bolts on the front side of the
handlebar holder, and then tighten the bolts
on the rear side.
1
23
45
T R..23 Nm (2.3 m · kg, 17 ft · lb)
HANDLEBAR

5 - 49
CHAS
2. Install:
Handlebar grip (left) 1
Apply the adhesive to the handlebar 2.
NOTE:
Before applying the adhesive, wipe off grease
or oil on the handlebar surface a with a lac-
quer thinner.
3. Install:
TT-R125/TT-R125E/TT-R125LW
Collar 1
4. Install:
Throttle grip assembly 1
Grip cap (upper) 2
Throttle cable 3
On tube guide 4.
NOTE:
Apply the lithium soap base grease on the
throttle cable end and tube guide cable wind-
ing portion.
5. Install:
Throttle cable cap 1
Screw (throttle cable cap) 2
Grip cap (lower) 3
Screw (grip cap) 4
Cover (grip cap) 5
WARNING
After tightening the screws, check that the
throttle grip 6 moves smoothly. If it does
not, retighten the bolts for adjustment.
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
HANDLEBAR

5 - 59
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

5 - 60
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.

5 - 62
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