2005 YAMAHA TTR125 engine assembly

4 - 52
ENGOIL PUMP
Oil strainer1. Inspect:
●Oil strainer
Cracks/damage → Replace.
Contamination → Clean the flushing oil.
ASSEMBLY AND INSTALLATION
Oil pump
1. Install:
●Oil pump housing 1
●Outer rotor 2
●Inner rotor 3
●Pin 4
●Oil pump shaft 5
●Pin 6
●Oil pump cover 7
●Washer 8
●Circlip 9
●Conical spring washer 0
●Oil pump driven gear A
●Circlip B
●Screws C
NOTE:
●Apply engine oil onto the outer rotor, inner
rotor and oil pump shaft.
●Install the conical spring washer in the direc-
tion as shown.
2. Install:
●Oil strainer
●Gasket
●Oil pump assembly
●Screws (oil pump assembly)
NOTE:
Apply engine oil onto the crankcase oil pas-
sage and oil pump assembly.
New
New
T R..5 Nm (0.5 m · kg, 3.6 ft · lb)
New
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
NOTE:
● Install the oil pump drive gear with its groove
a facing the engine.
●Install the rotary filter with the dog b facing
out.
●Align the rotary filter dog b with groove c of
the crankshaft.
3. Install:
● Washer 1
● Oil pump drive gear 2
● Rotary filter 3
● Install the washer with stamped "H" for the
side of the engine.

4 - 53
ENGKICK AXLE AND SHIFT SHAFT
KICK AXLE AND SHIFT SHAFT
KICK AXLE AND SHIFT SHAFT
Extent of removal:1 Kick axle removal2 Shift shaft removal
Extent of removal Order Part name Q’ty Remarks
KICK AXLE AND SHIFT SHAFT
REMOVAL
Preparation for removal Shift pedal link Refer to “ENGINE REMOVAL” section.
Clutch Refer to “CLUTCH AND PRIMARY
DRIVEN GEAR” section.
1 Kick axle assembly 1 Refer to “REMOVAL POINTS”.
2 Circlip 1
3 Washer 1
4 Kick idle gear 1
5 Washer 1
6 Circlip 1
7 Shift shaft 1
8 Circlip 1
9 Torsion spring 1
10 Bolt (stopper lever) 1
11 Stopper lever 1
12 Spring 1
13 Segment 1 Refer to “REMOVAL POINTS”.
1
2

4 - 56
ENGKICK AXLE AND SHIFT SHAFT
Shift shaft
1. Install:
Shift shaft 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip of the left crankcase side.
Hook the spring ends onto the stopper 2.
Kick axle assembly
1. Install:
Kickstarter segment gear 1
Plain washer 2
Torsion spring 3
On kick axle 4.
NOTE:
Make sure the stopper a of the torsion spring
fits into the hole b on the kick axle.
2. Install:
Spring guide 1
NOTE:
Slide the spring guide into the kick axle, make
sure the groove a in the spring guide fits on
the stopper of the torsion spring.
3. Install:
Kick axle assembly 1
NOTE:
Apply the engine oil on the kick axle.
Slide the kick axle assembly into the crank-
case, make sure the clip 2 and kick axle
stopper b fit into their home positions a, c.
4. Hook:
Torsion spring 1
NOTE:
Turn the torsion spring clockwise and hook
into the proper hole a in the crankcase.

4 - 63
ENG
CDI MAGNETO AND STARTER CLUTCH
(TT-R125E/TT-R125LWE)
3. Check:
Starter clutch operation
Install the starter clutch drive gear 1 onto
the starter clutch 2 and hold the starter
clutch.
When turning the starter clutch drive gear
counterclockwise ı, the starter clutch and
the starter clutch drive gear should
engage. If the starter clutch drive gear and
starter clutch do not engage, the starter
clutch is faulty and must be replaced.
When turning the starter clutch drive gear
clockwise Å, it should turn freely.
If the starter clutch drive gear does not
turn freely, the starter clutch is faulty and
must be replaced.
Å
ı
1
2
EC4L5000
ASSEMBLY AND INSTALLATION
CDI magneto
1. Install:
Stator 1
Bolt (stator)
Lead guide
Screw (lead guide) 2
Pickup coil 3
Bolt (pickup coil)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)LT
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)LT
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)LT
2. Install:
Stater idle gear 1
Plate 2
Bolt 3
Washer 4
NOTE:
Apply the engine oil on the starter idle gear
inner circumference.
4
1
2
3
ET R..7 Nm (0.7 m · kg, 5.1 ft · lb)

4 - 68
ENGENGINE REMOVAL
REMOVAL POINTS
Drive sprocket
1. Remove:
Bolt (drive sprocket)
Drive sprocket holder 1
Drive sprocket 2
Drive chain 3
NOTE:
Remove the drive sprocket together with the
drive chain.
Engine removal
1. Remove:
Engine 1
From left side.
NOTE:
Make sure that the couplers, hoses and cables
are disconnected.
ASSEMBLY AND INSTALLATION
Engine installation
1. Install:
Engine 1
Install the engine from left side.
Engine mounting bolt (rear) 2
Engine bracket (front) 3
Bolt (engine bracket) 4
Engine mounting bolt (lower) 5
Engine mounting bolt (front) 6
Engine bracket (upper) 7
Engine mounting bolt (upper) 8
Bolt (engine bracket) 9
T R..40 Nm (4.0 m · kg, 29 ft · lb)
T R..40 Nm (4.0 m · kg, 29 ft · lb)
T R..40 Nm (4.0 m · kg, 29 ft · lb)
T R..40 Nm (4.0 m · kg, 29 ft · lb)
T R..40 Nm (4.0 m · kg, 29 ft · lb)
T R..40 Nm (4.0 m · kg, 29 ft · lb)

4 - 70
ENGCRANKCASE, CRANKSHAFT AND BALANCER
CRANKCASE, CRANKSHAFT AND BALANCER
Extent of removal:1 Crankcase separation2 Balancer removal
3 Crankshaft removal
Extent of removal Order Part name Q’ty Remarks
CRANKCASE, CRANKSHAFT
AND BALANCER REMOVAL
Preparation for removal Engine Refer to “ENGINE REMOVAL” section.
Piston Refer to “CYLINDER AND PISTON” sec-
tion.
Primary drive gear Refer to “CLUTCH AND PRIMARY
DRIVEN GEAR” section.
Kick axle assembly
Refer to “KICK AXLE AND SHIFT
SHAFT” section.
Segment
Rotor for the TT-R125/
TT-R125LWRefer to “CDI MAGNETO” section for the
TT-R125/TT-R125LW.
(Rotor and starter clutch for the
TT-R125E/TT-R125LWE)(Refer to “CDI MAGNETO AND
STARTER CLUTCH” section for the
TT-R125E/TT-R125LWE.)

5 - 1
CHASFRONT WHEEL AND FRONT BRAKE (TT-R125/TT-R125E)
EC500000
CHASSIS
FRONT WHEEL AND FRONT BRAKE (TT-R125/TT-R125E)
Extent of removal:1 Front wheel removal2 Wheel bearing removal
3 Brake shoe plate assembly removal and disassembly
Extent of removal Order Part name Q’ty Remarks
Preparation for removalFRONT WHEEL AND DRUM
BRAKE
Hold the machine by placing the
suitable stand under the engine.
WARNINGSupport the machine securely so there is no
danger of it falling over.
1 Brake cable holder 1
2 Brake cable 1 Disconnect at the lever side, first.
3 Axle nut 1
4 Wheel axle 1
5 Front wheel 1
6 Collar set 1
7 Brake shoe plate assembly 1
8 Oil seal 1
9 Wheel bearing 2 Refer to “REMOVAL POINTS”.
10Spacer
1
2
3
1

5 - 13
CHASFRONT BRAKE (TT-R125LW/TT-R125LWE)
BRAKE CALIPER AND BRAKE MASTER CYLINDER DISASSEMBLY
Extent of removal:1 Brake caliper disassembly2 Brake master cylinder disassembly
Extent of removal Order Part name Q’ty Remarks
Preparation for removalBRAKE CALIPER AND BRAKE
MASTER CYLINDER DISAS-
SEMBLY
Hold the machine by placing the
suitable stand under the engine.
WARNINGSupport the machine securely so there is no
danger of it falling over.
1Brake pad 2
2Brake caliper bracket 1
3Brake caliper piston 2
Refer to “REMOVAL POINTS”. 4Brake caliper dust seal 2
5Brake caliper piston seal 2
6Pin boot 1
7Sleeve boot 1
8Brake master cylinder cap 1
9Diaphragm 1
0Brake master cylinder boot 1
ACirclip 1
BWasher 1
CBrake master cylinder kit 1
2
1