2005 YAMAHA TTR125 ignition

CHAPTER 5
CHASSIS
FRONT WHEEL AND FRONT BRAKE
(TT-R125/TT-R125E) .................................5-1
FRONT WHEEL
(TT-R125LW/TT-R125LWE) ......................5-8
FRONT BRAKE
(TT-R125LW/TT-R125LWE) ....................5-12
REAR WHEEL AND REAR BRAKE .......5-24
FRONT FORK ..........................................5-32
HANDLEBAR ...........................................5-42
STEERING ...............................................5-52
SWINGARM .............................................5-58
REAR SHOCK ABSORBER
ASSEMBLY .............................................5-65
CHAPTER 6
ELECTRICAL
ELECTRICAL COMPONENTS
AND WIRING DIAGRAM ...........................6-1
IGNITION SYSTEM ....................................6-3
ELECTRIC STARTING SYSTEM
(TT-R125E/TT-R125LWE) .........................6-8
CHARGING SYSTEM
(TT-R125E/TT-R125LWE) .......................6-18

1 - 8
GEN
INFO
SPECIAL TOOLS
YM-4097, 90890-04097
YM-4098, 90890-04098
YM-04099, 90890-04099Valve guide remover
Valve guide installer
Valve guide reamer
These tools are needed to rebore the new valve
guide.YM-4097
YM-4098
YM-0409990890-04097
90890-04098
90890-04099
YM-34487
90890-06754Dynamic spark tester
Ignition checker
This instrument is necessary for checking the ignition
system components.YM-34487 90890-06754
ACC-QUICK-GS-KT
90890-85505Quick gasket
®
YAMAHA Bond No.1215
This sealant (Bond) is used for crankcase mating
surface, etc.ACC-QUICK-GS-KT 90890-85505
Part number Tool name/How to use Illustration

1 - 13
GEN
INFO
STARTING AND BREAK-IN
EC190000
STARTING AND BREAK-IN
CAUTION:
Before starting the machine, perform the
checks in the pre-operation check list.
WARNING
Never start or run the engine in a closed
area. The exhaust fumes are poisonous;
they can cause loss of consciousness and
death in a very short time. Always operate
the machine in a well-ventilated area.
STARTING A COLD ENGINE
TT-R125/TT-R125LW
1. Shift the transmission into neutral.
2. Turn the fuel cock to “ON” and full open
the starter knob (CHOKE).
3. With the throttle completely closed start
the engine by kicking the kickstarter
crank forcefully with firm stroke.
4. Run the engine at idle or slightly higher
until it warms up: this usually takes about
one or two minutes.
5. The engine is warmed up when it
responds normally to the throttle with the
starter knob (CHOKE) turned off.
CAUTION:
Do not warm up the engine for extended
periods.
TT-R125E/TT-R125LWE
NOTE:
This model is equipped with an ignition circuit
cut-off system. The engine can be started
under the following conditions.
When the transmission is in neutral.
When the clutch is disengaged with the
transmission in any position. However, it is
recommended to shift into neutral before
starting the engine.
1. Shift the transmission into neutral.
2. Turn the fuel cock to “ON” and full open
the starter knob (CHOKE).
3. Turn the main switch to “ON”.
4. With the throttle completely closed start
the engine by pushing the start switch or
by kicking the kickstarter crank forcefully
with firm stroke.

SPEC
2 - 3
GENERAL SPECIFICATIONS
Transmission:
Primary reduction system Gear
Primary reduction ratio 68/19 (3.579)
Secondary reduction system Chain drive
Secondary reduction ratio 49/13 (3.769)
Transmission type Constant mesh, 5-speed
Operation Left foot operation
Gear ratio: 1st 37/14 (2.643)
2nd 32/18 (1.778)
3rd 25/19 (1.316)
4th 23/22 (1.045)
5th 21/24 (0.875)
Chassis:
Frame type Diamond
Caster angle 28.7˚
Trail 93 mm (3.66 in)
Tire:
Type With tube
Size (front) 70/100-17 40M
Size (rear) 90/100-14 49M
Manufacturer (front and rear) CHENG SHIN
Tire pressure (front and rear) 100 kPa (1.00 kgf/cm
2, 15 psi)
Brake:
Front brake type Drum brake
Operation Right hand operation
Rear brake type Drum brake
Operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (link type monocross suspension)
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas, oil damper
Wheel travel:
Front wheel travel 180 mm (7.09 in)
Rear wheel travel 160 mm (6.30 in)
Electrical:
Ignition system CDI
Generator system (TT-R125E) CDI magneto
Battery type (TT-R125E) GT4L-BS
Battery voltage/capacity (TT-R125E) 12 V/3.2 AH
Specific gravity (TT-R125E) 1.320

SPEC
2 - 6
GENERAL SPECIFICATIONS
Transmission:Primary reduction system Gear
Primary reduction ratio 68/19 (3.579)
Secondary reduction system Chain drive
Secondary reduction ratio 54/13 (4.154)
Transmission type Constant mesh, 5-speed
Operation Left foot operation
Gear ratio: 1st 37/14 (2.643) 2nd 32/18 (1.778)
3rd 25/19 (1.316)
4th 23/22 (1.045)
5th 21/24 (0.875)
Chassis: Frame type Diamond
Caster angle 28.5 ˚
Trail 107 mm (4.21 in)
Tire: Type With tube
Size (front) 70/100-19 42M
Size (rear) 90/100-16 52M
Manufacturer (front and rear) IRC
Tire pressure (front and rear) 100 kPa (1.00 kgf/cm
2, 15 psi)
Brake: Front brake type Single disc brake
Operation Right hand operation
Rear brake type Drum brake
Operation Right foot operation
Suspension: Front suspension Telescopic fork
Rear suspension Swingarm (link type monocross suspension)
Shock absorber: Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas, oil damper
Wheel travel: Front wheel travel 180 mm (7.09 in)
Rear wheel travel 168 mm (6.61 in)
Electrical: Ignition system CDI
Generator system (TT-R125LWE) CDI magneto
Battery type (TT-R125LWE) GT4L-BS
Battery voltage/capacity (TT-R125LWE) 12 V/3.2 AH
Speci fic gravity (TT-R125LWE) 1.320

SPEC
2 - 23
MAINTENANCE SPECIFICATIONS
EC212300
ELECTRICAL
TT-R125/TT-R125LW
Item Standard Limit
CDI:
Magneto-model (stator)/manufacturer 5HP-01/YAMAHA ----
Charging coil resistance (color) 688 ~ 1,032 Ω at 20 ˚C (68 ˚F)
(Green-Brown)----
Pickup coil resistance (color) 248 ~ 372 Ω at 20 ˚C (68 ˚F)
(White-Red)----
CDI unit-model/manufacturer 5HP-00/YAMAHA ----
Ignition coil:
Model/manufacturer 4KJ-10/YAMAHA ----
Minimum spark gap 6 mm (0.24 in) ----
Primary coil resistance 0.18 ~ 0.28 Ω at 20 ˚C (68 ˚F) ----
Secondary coil resistance 6.3 ~ 9.5 kΩ at 20 ˚C (68 ˚F) ----
Part to be tightened Thread size Q’tyTightening torque
Nm m•kg ft•lb
Pickup coil M6 × 1.0 2 10 1.0 7.2
Blind plug (neutral switch) M10 × 1.25 1 20 2.0 14
Stator M6 × 1.0 3 10 1.0 7.2
Rotor M12 × 1.25 1 80 8.0 58
Ignition coil M6 × 1.0 2 7 0.7 5.1

SPEC
2 - 24
MAINTENANCE SPECIFICATIONS
TT-R125E/TT-R125LWE
Item Standard Limit
CDI:
Magneto-model/manufacturer 5HP-10/YAMAHA ----
Source coil resistance (color) 688 ~ 1,032 Ω at 20 ˚C (68 ˚F)
(Brown – Green)----
Pickup coil resistance (color) 248 ~ 372 Ω at 20 ˚C (68 ˚F)
(Red – White)----
CDI unit-model/manufacturer 5HP-00/YAMAHA ----
Ignition coil:
Model/manufacturer 4KJ-10/YAMAHA ----
Minimum spark gap 6 mm (0.24 in) ----
Primary winding resistance 0.18 ~ 0.28 Ω at 20 ˚C (68 ˚F) ----
Secondary winding resistance 6.3 ~ 9.5 kΩ at 20 ˚C (68 ˚F) ----
Spark plug cap:
Type Resin ----
Resistance 10 kΩ at 20 ˚C (68 ˚F) ----
Charging system:
System type CDI magneto ----
Model/manufacturer 5HP-10/YAMAHA ----
Normal output 14 V/100 W at 5,000 r/min ----
Charging coil resistance (color) 0.64 ~ 0.96 Ω at 20 ˚C (68 ˚F)
(White – Black)----
Lighting coil resistance (color) 0.52 ~ 0.78 Ω at 20 ˚C (68 ˚F)
(Yellow – Black)----
Rectifier/regulator:
Regulator type Semiconductor short circuit ----
Model/manufacture SH620B-12/SHINDENGEN ----
No-load regulated voltage 14.0 ~ 15.0 V ----
Rectifier capacity 8 A ----
Electric starting system:
Type Constant mesh ----
Starter motor:
Model/manufacturer 5HP00/YAMAHA ----
Operation voltage 12 V ----
Output 0.25 kW ----
Armature coil resistance 0.017 ~ 0.021 Ω at 20 ˚C (68 ˚F) ----
Brush overall length 10 mm (0.40 in) 3.5 mm
(0.14 in)
Brush quantity 2 pcs. ----
Spring force 5.52 ~ 8.28 N
(560 ~ 840 g, 19.8 ~ 29.7 oz)----
Commutator diameter 22 mm (0.9 in) 21 mm
(0.8 in)
Mica undercut (depth) 1.5 mm (0.06 in) ----

SPEC
2 - 25
MAINTENANCE SPECIFICATIONS
Starter relay:
Model/manufacturer MS5F-751/JIDECO ----
Amperage rating 180 A ----
Coil winding resistance 4.2 ~ 4.6 Ω at 20 ˚C (68 ˚F) ----
Starting circuit cut-off relay:
Model/manufacturer ACM33221/MATSUSHITA ----
Coil winding resistance 75.69 ~ 92.51 Ω at 20 ˚C (68 ˚F) ----
Fuse (amperage × quantity):
Main fuse 10 A × 1 ----
Reserve fuse 10 A × 1 ----
Part to be tightened Thread size Q’tyTightening torque
Nm m•kg ft•lb
Pickup coil M6 × 1.0 2 10 1.0 7.2
Neutral switch M10 × 1.25 1 18 1.8 13
Stator M6 × 1.0 3 10 1.0 7.2
Rotor M12 × 1.25 1 80 8.0 58
Ignition coil M6 × 1.0 2 7 0.7 5.1
Starter motor M6 × 1.0 2 10 1.0 7.2 Item Standard Limit