2005 YAMAHA TTR125 jet

SPEC
2 - 11
MAINTENANCE SPECIFICATIONS
Crankshaft:
Crank width “A”46.95 ~ 47.00 mm
(1.848 ~ 1.850 in)----
Runout limit “C”---- 0.03 mm
(0.0012 in)
Big end side clearance “D”0.15 ~ 0.45 mm
(0.0059 ~ 0.0177 in)0.5 mm
(0.02 in)
Clutch:
Friction plate thickness 2.92 ~ 3.08 mm
(0.115 ~ 0.121 in)2.8 mm
(0.110 in)
Quantity 5 ----
Clutch plate thickness 1.05 ~ 1.35 mm
(0.041 ~ 0.053 in)----
Quantity 4 ----
Warp limit ---- 0.2 mm
(0.008 in)
Clutch spring free length 33 mm (1.30 in) 31 mm
(1.22 in)
Quantity 4 ----
Clutch release method Inner push, cam push ----
Push rod bending limit ---- 0.5 mm
(0.020 in)
Shifter:
Shifter type Cam drum and guide bar ----
Kick starter:
Type Kick and mesh type ----
Kick clip friction force 6.4 ~ 13.2 N
(0.65 ~ 1.35 kg, 1.4 ~ 3.0 lb)----
Carburetor:
I.D. mark 5HP1 10 ----
Main jet (M.J) #105 ----
Main jet nozzle (N.J) N-6M ----
Main air jet (M.A.J)ø1.2 ----
Jet needle-clip position (J.N) 5HGM56-2 ----
Cutaway (C.A) 2.5 ----
Pilot air jet 1 (P.A.J.1) #80 ----
Pilot air jet 2 (P.A.J.2) #145 ----
Pilot outlet (P.O)ø1.05 ----
Pilot jet (P.J) #15 ----
Pilot air screw (example) (A.S) (2-1/2 ~ 3-1/2 turns out) ----
Bypass (B.P)ø1.0 ----
Needle valve seat size (V.S) 1.8 ----
Starter jet 1 (G.S.1) #22.5 ----
Starter jet 2 (G.S.2) #1.2 ----
Fuel level (F.L) 6.0 ~ 7.0 mm (0.24 ~ 0.28 in) ----
Engine idle speed 1,300 ~ 1,500 r/min ----Item Standard Limit

4 - 4
ENG

CARBURETOR
EC468000
CARBURETOR DISASSEMBLY
Extent of removal:
1
Carburetor disassembly
Extent of removal Order Part name Q’ty Remarks
CARBURETOR DISASSEMBLY
1
Throttle cable 1
2
Throttle valve 1 Refer to “REMOVAL POINTS”.
3
Jet needle set 1
4
Carburetor top cover 1
5
Starter plunger 1
6
Float chamber 1
7
Float pivot pin 1
8
Float 1
9
Needle valve 1
0
Main jet washer 1
A
Needle valve seat holder 1
B
Needle valve seat 1
C
Main jet 1
D
Main jet nozzle 1
E
Pilot jet 1
F
Pilot air jet 1 1
G
Pilot air jet 2 1
H
Pilot air screw 1 Refer to “REMOVAL POINTS”.
I
Throttle stop screw 1
J
Coasting enricher 1
1

4 - 5
ENG

CARBURETOR
HANDLING NOTE
At high altitudes, the atmospheric pressure is
lower. This can make the fuel mixture too rich,
leading to such problems as fouled.
Spark plugs and slow response at high engine
speeds. A special part, High Altitude Main Jet
1
#102.5 (620-1423A-71-A0) is available to
correct this.
EC463000
REMOVAL POINTS
Throttle valve
1. Remove:

Throttle valve
1


Spring (throttle valve)
2


Carburetor top cover
3


Throttle cable
4

NOTE:

While compressing the spring (throttle valve),
disconnect the throttle cable.
Pilot air screw
1. Remove:

Pilot air screw
1

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
removing 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.

4 - 6
ENGCARBURETOR
EC464000
INSPECTION
Carburetor
1. Inspect:
Carburetor body
Contamination → Clean.
NOTE:
Use a petroleum based solvent for cleaning.
Blow out all passages and jets with com-
pressed air.
Never use a wire.
2. Inspect:
Main jet 1
Main jet nozzle 2
Pilot jet 3
NOTE:
Use a petroleum based solvent for cleaning.
Blow out all passages and jets with com-
pressed air.
Never use a wire.
Needle valve
1. Inspect:
Needle valve 1
Needle valve seat 2
Grooved wear a → Replace.
Dust b → Clean.
NOTE:
Always replace the needle valve and needle
valve seat as a set.

4 - 7
ENGCARBURETOR
EC464301
Throttle valve
1. Check:
Free movement
Stick → Repair or replace.
NOTE:
Insert the throttle valve 1 into the carburetor
body, and check for free movement.
EC464401
Jet needle
1. Inspect:
Jet needle 1
Bends/wear → Replace.
Clip groove
Free play exists/wear → Replace.
Clip position
Fuel level
1. Measure:
Fuel level a
Out of specification → Adjust.
Standard clip position:
No. 2 Groove
Fuel level:
6.0 ~ 7.0 mm (0.24 ~ 0.28 in)
Below the float chamber mat-
ing surface
Measurement and adjustment steps:
Connect the fuel level gauge 1 to the float
chamber.
Fuel level gauge:
YM-1312-A/90890-01312
Hold the fuel level gauge vertically next to
the float chamber mating surface.
Loosen the drain screw.
Measure the fuel level with the fuel level
gauge.
NOTE:
Keep the carburetor and fuel level gauge
vertically when measuring the fuel level.
If the fuel level is not within specification,
inspect the needle valve seat and needle
valve.
If either is worn, replace them both.
If both are fine, adjust the fuel level by
bending the float tab b on the float.
Recheck the fuel level.

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 - 9
ENG
4. Install:
Pilot jet 1
Main jet nozzle 2
Main jet 3
Needle valve seat 4
Needle valve seat holder 5
Main jet washer 6
5. Install:
Needle valve 1
Float 2
Float pivot pin 3
NOTE:
After installing the needle valve to the float,
install them to the carburetor.
Check the float for smooth movement.
6. Install:
Gasket
Float chamber 1
Screw (float chamber) 2
7. Install:
Spring 1
Starter plunger 2
On starter cable 3.
8. Install:
Jet needle set 1
Needle holder 2
On throttle valve 3.
NOTE:
Align the projections a on the throttle valve
with the grooves b in the needle holder.
CARBURETOR

5 - 39
CHAS
7. Montieren:
Dichtring 1
HINWEIS:
Lithiumfett auf Standrohr auftragen.
8. Kontrollieren:
Leichtgängigkeit des Standrohrs
Schwergängigkeit/Klemmen/Rauhig-
keit → Schritte 2 bis 7 wiederholen.
9. Teleskopgabel vollständig eintauchen.
10. Befüllen:
Gabelöl 1
ACHTUNG:
Nur die empfohlene Ölsorte verwenden.
Falls anderes Öl verwendet wird, kann die
Funktionsweise der Telekopgabel erheb-
lich beeinträchtigt werden.
Es dürfen keine Fremdkörper in die Tele-
skopgabel gelangen.
11. Nach dem Befüllen muß die Gabel mehr-
mals (miadestens 10 Mol) langsam ein-
und ausgefedert werden, damit sich das
Gabelöl verteilt.
Empfohlene Ölsorte:
Gabelöl 10W oder gleichwertig
Füllmenge (pro Gabelbein):
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)
FOURCHE AVANT
TELESKOPGABEL
7. Monter:
Joint antipoussière 1
N.B.:
Enduire le tube plongeur de graisse à base de savon
au lithium.
8. Contrôler:
Coulissement régulier du tube plongeur
Étroitesse/points durs/surface inégale →
Recommencer les étapes 2 à 7.
9. Comprimer à fond la fourche avant.
10. Remplir:
Huile de fourche avant 1
ATTENTION:
Utiliser sans faute le type d’huile de fourche
recommandé. Des huiles de type différent
pourraient modifier le comportement de la
fourche avant.
Ne laisser en aucun cas pénétrer de la crasse
ou tout objet dans la fourche avant.
11. Après avoir rempli le tube plongeur, le pom-
per lentement plus de 10 fois pour répartir
l’huile de fourche.
Huile recommandée:
Huile de fourche 10W ou équiva-
lente
Quantité (chaque bras de fourche):
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)