2005 YAMAHA TTR125 light

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 - 10
INSP
ADJOIL PRESSURE INSPECTION/PILOT AIR SCREW
ADJUSTMENT/ENGINE IDLING SPEED ADJUSTMENT
OIL PRESSURE INSPECTION
1. Check:
Oil pressure
Checking steps:
Slightly loosen the oil pressure check bolt
1.
Start the engine and keep it idling until oil
starts to seep from the oil pressure check
bolt. If no oil comes out after one minute,
turn the engine off so it will not seize.
Check oil passages and oil pump for dam-
age or leakage.
Start the engine after solving the prob-
lem(s) and recheck the oil pressure.
Tighten the oil pressure check bolt.
T R..
Oil pressure check bolt:
7 Nm (0.7 m • kg, 5.1 ft • lb)
PILOT AIR SCREW ADJUSTMENT
1. Adjust:
Pilot air screw 1
Adjustment steps:
NOTE:
To optimize the fuel flow at a smaller throttle
opening, each machine’s pilot air screw has
been individually set at the factory. Before
adjusting the pilot air screw, turn it in fully
and count the number of turns. Record this
number as the factory-set number of turns
out.
Screw in the pilot air screw until it is lightly
seated.
Back out by the specified number of turns.
Pilot air screw:
2-1/2 ~ 3-1/2 turns out (example)
ENGINE IDLING SPEED ADJUSTMENT
1. Start the engine and thoroughly warm it
up.
2. Attach:
Inductive tachometer
To spark plug lead.
3. Adjust:
Engine idling speed

3 - 14
INSP
ADJ
SPARK ARRESTER CLEANING (For USA)
SPARK ARRESTER CLEANING (For USA)
WARNING
Be sure the exhaust pipe and muffler are
cool before cleaning the spark arrester.
Do not start the engine when cleaning the
exhaust system.
1. Remove:
Bolt (spark arrester) 1
2. Remove:
Spark arrester 1
Pull the spark arrester out of the muf-
fler.
3. Clean:
Spark arrester
Tap the spark arrester lightly, then use
a wire brush to remove any carbon
deposits.
4. Install:
Spark arrester
Insert the spark arrester into the muffler
and align the bolt holes.
Bolt (spark arrester)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

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

3 - 34
INSP
ADJ
ELECTRICAL/SPARK PLUG INSPECTION
EC370000
ELECTRICAL
EC371001
SPARK PLUG INSPECTION
1. Remove:
Spark plug
2. Inspect:
Electrode 1
Wear/damage → Replace.
Insulator color 2
Normal condition is a medium to light
tan color.
Distinctly different color → Check the
engine condition.
NOTE:
When the engine runs for many hours at low
speeds, the spark plug insulator will become
sooty, even if the engine and carburetor are in
good operating condition.
3. Measure:
Plug gap a
Use a wire gauge or thickness gauge.
Out of specification → Regap.
4. Clean the plug with a spark plug cleaner
if necessary.
Spark plug gap:
0.6 ~ 0.7 mm (0.02 ~ 0.03 in)
Standard spark plug:
CR7HSA (NGK)
U22FSR-U (DENSO)
5. Tighten:
Spark plug
NOTE:
Before installing a spark plug, clean the gas-
ket surface and plug surface.
Finger-tighten a the spark plug before torqu-
ing to specification b.
T R..13 Nm (1.3 m · kg, 9.4 ft · lb)

3 - 35
INSP
ADJ
BATTERY INSPECTION AND CHARGING
(TT-R125E/TT-R125LWE)
WARNING
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of
poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
Wear protective eye gear when handling
or working near batteries.
Charge batteries in a well-ventilated area.
Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
Skin — Wash with water.
Eyes — Flush with water for 15 minutes
and get immediate medical attention.
INTERNAL
Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.
CAUTION:
Charging time, charging amperage and
charging voltage for an MF battery are dif-
ferent from those of conventional batteries.
The MF battery should be charged as
explained in the charging method illustra-
tions. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charging
the battery.
BATTERY INSPECTION AND CHARGING
(TT-R125E/TT-R125LWE)

4 - 8
ENGCARBURETOR
EC464600
Float
1. Inspect:
Float 1
Damage → Replace.
Coasting enricher
1. Inspect:
Diaphragm 1
Spring 2
Cover 3
Tears (diaphragm)/damage →
Replace.
ASSEMBLY AND INSTALLATION
Carburetor
1. Install:
Diaphragm 1
Spring 2
Cover 3
Screw 4
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)LT
2. Install:
Throttle stop screw 1
Pilot air screw 2
3. Install:
Pilot air jet 1 1
Pilot air jet 2 2 Note the following installation points:
Turn in the pilot air screw until it is lightly
seated.
Turn out the pilot air screw by the number
of turns recorded before removing.
Pilot air screw:
2-1/2 ~ 3-1/2
(example)

4 - 18
ENGCYLINDER HEAD
5. Install:
Timing chain tensioner
6. Turn:
Crankshaft
Counterclockwise several turns
7. Check:
Rotor “I” mark
Align with the crankcase stationary
pointer.
Camshaft match mark
Align with the cylinder head stationary
pointer.
Out of alignment → Adjust. Installation steps:
While pressing the tensioner rod lightly
with fingers, use a thin screwdriver and
wind the tensioner rod up fully clockwise.
With the rod fully wound, install the gasket
1 and the chain tensioner 2, and tighten
the bolts 3 to the specified torque.
T R..
Bolt (chain tensioner):
10 Nm (1.0 m • kg, 7.2 ft • lb)
Release the screwdriver, check the ten-
sioner rod to come out and tighten the
gasket 4 and the cap bolt 5 to the speci-
fied torque.
T R..
Cap bolt (timing chain tensioner):
8 Nm (0.8 m • kg, 5.8 ft • lb)
8. Tighten:
Bolt 1
NOTE:
Tighten the bolt while holding the rotor nut with
a wrench.
T R..20 Nm (2.0 m · kg, 14 ft · lb)