2006 YAMAHA TTR125 cylinder

SPEC
2 - 7
MAINTENANCE SPECIFICATIONS
EC212000
MAINTENANCE SPECIFICATIONS
EC212100
ENGINE
Item Standard Limit
Cylinder head:
Warp limit ---- 0.03 mm
(0.0012 in)
Cylinder:
Bore size 54.000 ~ 54.019 mm
(2.1260 ~ 2.1267 in)----
Out of round limit ---- 0.05 mm
(0.0020 in)
Camshaft:
Drive method Chain drive (left) ----
Cam dimensions
Intake“A”25.881 ~ 25.981 mm
(1.0189 ~ 1.0229 in)25.851 mm
(1.0178 in)
“B”21.195 ~ 21.295 mm
(0.8344 ~ 0.8384 in)21.165 mm
(0.8333 in)
Exhaust“A”25.841 ~ 25.941 mm
(1.0174 ~ 1.0213 in)25.811 mm
(1.0162 in)
“B”21.050 ~ 21.150 mm
(0.8287 ~ 0.8327 in)21.020 mm
(0.8276 in)
Camshaft runout limit ---- 0.03 mm
(0.0012 in)

SPEC
2 - 10
MAINTENANCE SPECIFICATIONS
Piston:
Piston to cylinder clearance 0.020 ~ 0.026 mm
(0.0008 ~ 0.0010 in)0.15 mm
(0.0059 in)
Piston size “D”53.977 ~ 53.996 mm
(2.1251 ~ 2.1258 in)----
Piston over size (2nd) 54.5 mm (2.1457 in) ----
(4th) 55.0 mm (2.1654 in) ----
Measuring point “H”5 mm (0.20 in) ----
Piston off-set 0.5 mm (0.0197 in) ----
Piston pin bore inside diameter 15.002 ~ 15.013 mm
(0.5906 ~ 0.5911 in)15.043 mm
(0.5922 in)
Piston pin outside diameter 14.991 ~ 15.000 mm
(0.5902 ~ 0.5906 in)14.971 mm
(0.5894 in)
Piston rings:
Top ring
Type Barrel ----
Dimensions (B × T) 1.0 × 2.1 mm (0.04 × 0.08 in) ----
End gap (installed) 0.15 ~ 0.30 mm
(0.006 ~ 0.012 in)0.4 mm
(0.016 in)
Side clearance (installed) 0.035 ~ 0.090 mm
(0.0014 ~ 0.0035 in)0.12 mm
(0.0047 in)
2nd ring
Type Taper ----
Dimensions (B × T) 1.0 × 2.1 mm (0.04 × 0.08 in) ----
End gap (installed) 0.30 ~ 0.45 mm
(0.012 ~ 0.018 in)0.55 mm
(0.022 in)
Side clearance 0.020 ~ 0.060 mm
(0.0008 ~ 0.0024 in)0.12 mm
(0.0047 in)
Oil ring
Dimensions (B × T) 2.0 × 2.2 mm (0.08 × 0.09 in) ----
End gap (installed) 0.20 ~ 0.70 mm (0.01 ~ 0.03 in) ----Item Standard Limit
H
D
T
B
B
T
B
T

SPEC
2 - 13
MAINTENANCE SPECIFICATIONS
Part to be tightened Thread size Q’tyTightening torque
Nm m•kg ft•lb
Spark plug M10 × 1.0 1 13 1.3 9.4
Cylinder head bolt M8 × 1.25 4 22 2.2 16
Cylinder head bolt M6 × 1.0 2 10 1.0 7.2
Oil pressure check bolt M6 × 1.0 1 7 0.7 5.1
Cylinder head side cover M6 × 1.0 2 10 1.0 7.2
Tappet cover M45 × 1.5 2 18 1.8 13
Timing chain guide M6 × 1.0 1 10 1.0 7.2
Adjusting screw (valve) and locknut M5 × 0.5 2 8 0.8 5.8
Camshaft sprocket M8 × 1.25 1 20 2.0 14
Bearing plate cover (camshaft) M6 × 1.0 1 10 1.0 7.2
Timing chain tensioner cap bolt M6 × 1.0 1 8 0.8 5.8
Timing chain tensioner M6 × 1.0 2 10 1.0 7.2
Oil pump assembly M6 × 1.0 2 7 0.7 5.1
Oil pump cover M5 × 0.8 1 5 0.5 3.6
Engine oil drain bolt M12 × 1.5 1 20 2.0 14
Carburetor joint M6 × 1.0 2 10 1.0 7.2
Carburetor joint clamp (air filter) M4 × 0.7 1 2 0.2 1.4
Coasting enricher cover M4 × 0.7 2 2 0.2 1.4
Air filter case M6 × 1.0 3 7 0.7 5.1
Muffler M6 × 1.0 2 10 1.0 7.2
Muffler M10 × 1.25 1 60 6.0 43
Muffler M8 × 1.25 1 30 3.0 22
Muffler guard M6 × 1.0 7 10 1.0 7.2
Spark arrester M6 × 1.0 3 10 1.0 7.2
Crankcase M6 × 1.0 10 10 1.0 7.2
Left crankcase cover M6 × 1.0 7 10 1.0 7.2
Drive sprocket cover M6 × 1.0 2 12 1.2 8.7
Right crankcase cover M6 × 1.0 9 10 1.0 7.2
Lead guide (CDI magneto lead) M6 × 1.0 1 7 0.7 5.1
Timing mark accessing screw M14 × 1.5 1 7 0.7 5.1
Crankshaft end accessing screw M32 × 1.5 1 7 0.7 5.1
Kickstarter crank M12 × 1.0 1 50 5.0 36
Starter clutch (TT-R125E/TT-R125LWE) M8 × 1.25 3 30 3.0 22
Plate (starter idle gear) (TT-R125E/TT-R125LWE) M6 × 1.0 2 7 0.7 5.1
Primary drive gear M12 × 1.0 1 70 7.0 50
Clutch spring M5 × 0.8 4 6 0.6 4.3
Clutch boss M12 × 1.0 1 60 6.0 43
Adjusting screw (push rod) and locknut M6 × 1.0 1 8 0.8 5.8
Bearing plate cover (main axle) M6 × 1.0 2 7 0.7 5.1
Drive sprocket M5 × 0.8 2 6 0.6 4.3
Shift arm M6 × 1.0 1 10 1.0 7.2
Shift rod and shift pedal M6 × 1.0 1 7 0.7 5.1
Shift rod and shift arm M6 × 1.0 1 7 0.7 5.1
Shift pedal M6 × 1.0 1 12 1.2 8.7

SPEC
2 - 14
MAINTENANCE SPECIFICATIONS
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each ride.
Cylinder head tightening sequenceSegment M6 × 1.0 1 12 1.2 8.7
Stopper lever M6 × 1.0 1 10 1.0 7.2 Part to be tightened Thread size Q’tyTightening torque
Nm m•kg ft•lb

SPEC
2 - 17
MAINTENANCE SPECIFICATIONS
NOTE:
1. First, tighten the ring nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the ring nut
wrench and turn the steering right and left a few times; then loosen the ring nut one turn.
2. Retighten the ring nut 20 Nm (2.0 m • kg, 14 ft • lb). Part to be tightened Thread size Q’tyTightening torque
Nm m•kg ft•lb
Upper bracket and inner tube M8 × 1.25 2 25 2.5 18
Lower bracket and inner tube M10 × 1.25 2 60 6.0 43
Upper bracket and steering stem M22 × 1.0 1 110 11.0 80
Handlebar upper holder and upper bracket M8 × 1.25 4 23 2.3 17
Steering stem and ring nut M25 × 1.0 1 Refer to NOTE.
Front fork and cap bolt M25 × 1.0 2 23 2.3 17
Front fork and damper rod M10 × 1.0 2 23 2.3 17
Front fork and brake cable holder M6 × 1.0 1 7 0.7 5.1
Number plate M6 × 1.0 1 7 0.7 5.1
Starter knob M11 × 1.25 1 1 0.1 0.7
Starter knob stay M6 × 1.0 2 10 1.0 7.2
Grip cap upper and lower M5 × 0.8 2 4 0.4 2.9
Throttle cable cap M4 × 0.7 2 2 0.2 1.4
Brake lever mounting (bolt) M6 × 1.0 1 3 0.3 2.2
Brake lever mounting (nut) M6 × 1.0 1 4 0.4 2.9
Brake lever holder M5 × 0.8 2 4 0.4 2.9
Clutch lever mounting (bolt) M6 × 1.0 1 7 0.7 5.1
Clutch lever mounting (nut) M6 × 1.0 1 7 0.7 5.1
Clutch lever holder M5 × 0.8 2 4 0.4 2.9
Front wheel axle and axle nut M12 × 1.25 1 45 4.5 32
Front brake camshaft lever and camshaft M6 × 1.0 1 10 1.0 7.2
Rear wheel axle and axle nut M12 × 1.25 1 60 6.0 43
Rear brake camshaft lever and camshaft M6 × 1.0 1 10 1.0 7.2
Brake pedal mounting M10 × 1.25 1 30 3.0 22
Brake pedal position locknut M6 × 1.0 1 7 0.7 5.1
Front wheel nipple (spoke)—36 2 0.2 1.4
Rear wheel nipple (spoke)—36 3 0.3 2.2
Driven sprocket (nut) M10 × 1.25 4 43 4.3 31
Driven sprocket (stud) M10 × 1.25 4 30 3.0 22
Sidestand mounting (nut) M10 × 1.25 1 44 4.4 32
Engine mounting:
Engine bracket (front) and frame M8 × 1.25 2 40 4.0 29
Engine bracket (front) and engine M8 × 1.25 2 40 4.0 29
Engine bracket (upper) and frame M8 × 1.25 2 40 4.0 29
Engine bracket (upper) and cylinder head M8 × 1.25 1 40 4.0 29
Engine and frame (rear) M8 × 1.25 2 40 4.0 29
Pivot shaft and nut M12 × 1.25 1 53 5.3 38
Relay arm and swingarm M12 × 1.25 1 70 7.0 50

SPEC
2 - 20
MAINTENANCE SPECIFICATIONS
Drive chain:
Type/manufacturer DID428HD/DAIDO ----
Number of links 122 links ----
Chain slack 35 ~ 50 mm (1.4 ~ 2.0 in) ----
Chain length (10 links) ----121.4 mm
(4.78 in)
Front disc brake:
Disc outside dia. × Thickness 220 × 3.0 mm (8.66 × 0.12 in)220 × 2.5 mm
(8.66 × 0.10 in)
Deflection limit ----0.15 mm (0.006 in)
Pad thickness 4.0 mm (0.16 in)0.8 mm (0.03 in)
Master cylinder inside dia. 11.0 mm (0.433 in) ----
Caliper cylinder inside dia. 22.22 mm (0.875 in) × 2 ----
Brake fluid type DOT #4 ----
Rear drum brake:
Drum brake type Leading, trailing ----
Drum inside diameter 110 mm (4.33 in) 111 mm (4.37 in)
Lining thickness 4.0 mm (0.16 in) 2.0 mm (0.08 in)
Shoe spring free length 50.5 mm (1.99 in) ----
Brake lever and brake pedal:
Brake lever free play (lever end) 2 ~ 5 mm (0.08 ~ 0.20 in) ----
Brake pedal position
(vertical height below footrest top)1 mm (0.04 in) ----
Brake pedal free play 20 ~ 30 mm (0.79 ~ 1.18 in) ----
Clutch lever free play (lever end) 10 ~ 15 mm (0.39 ~ 0.59 in) ----
Throttle grip free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----Item Standard Limit

SPEC
2 - 21
MAINTENANCE SPECIFICATIONS
NOTE:
1. First, tighten the ring nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the ring nut
wrench and turn the steering right and left a few times; then loosen the ring nut one turn.
2. Retighten the ring nut 20 Nm (2.0 m • kg, 14 ft • lb). Part to be tightened Thread size Q’tyTightening torque
Nm m•kg ft•lb
Upper bracket and inner tube M8 × 1.25 2 25 2.5 18
Lower bracket and inner tube M10 × 1.25 2 60 6.0 43
Upper bracket and steering stem M22 × 1.0 1 110 11.0 80
Handlebar upper holder and upper bracket M8 × 1.25 4 23 2.3 17
Steering stem and ring nut M25 × 1.0 1 Refer to NOTE.
Front fork and cap bolt M25 × 1.0 2 23 2.3 17
Front fork and damper rod M10 × 1.0 2 23 2.3 17
Front fork and brake hose holder M6 × 1.0 2 7 0.7 5.1
Number plate M6 × 1.0 1 7 0.7 5.1
Starter knob M11 × 1.25 1 1 0.1 0.7
Starter knob stay M6 × 1.0 2 10 1.0 7.2
Grip cap upper and lower M5 × 0.8 2 4 0.4 2.9
Throttle cable cap M4 × 0.7 2 2 0.2 1.4
Front brake master cylinder M6 × 1.0 2 9 0.9 6.5
Front brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
Brake lever mounting (bolt) M6 × 1.0 1 7 0.7 5.1
Brake lever mounting (nut) M6 × 1.0 1 7 0.7 5.1
Brake lever adjuster and locknut M6 × 0.75 1 4 0.4 2.9
Clutch lever mounting (bolt) M6 × 1.0 1 7 0.7 5.1
Clutch lever mounting (nut) M6 × 1.0 1 7 0.7 5.1
Clutch lever holder M5 × 0.8 2 4 0.4 2.9
Front brake master cylinder and joint M10 × 1.25 1 26 2.6 19
Front brake hose and joint M10 × 1.25 1 14 1.4 10
Front brake hose union bolt M10 × 1.25 1 26 2.6 19
Front brake caliper and front fork M8 × 1.25 2 30 3.0 22
Brake caliper support bolt M8 × 1.25 1 22 2.2 16
Front brake caliper and bleed screw M7 × 1.0 1 6 0.6 4.3
Front wheel axle and axle nut M12 × 1.25 1 45 4.5 32
Front brake disc and wheel hub M6 × 1.0 4 12 1.2 8.7
Rear wheel axle and axle nut M12 × 1.25 1 60 6.0 43
Rear brake camshaft lever and camshaft M6 × 1.0 1 10 1.0 7.2
Brake pedal mounting M10 × 1.25 1 30 3.0 22
Brake pedal position locknut M6 × 1.0 1 7 0.7 5.1
Front wheel nipple (spoke)—36 2 0.2 1.4
Rear wheel nipple (spoke)—36 3 0.3 2.2

SPEC
2 - 22
MAINTENANCE SPECIFICATIONS
NOTE:
- marked portion shall be checked for torque tightening after break-in o\
r before each ride.Part to be tightened Thread size Q
’ty Tightening torque
Nm m •kg ft •lb
Bead stopper M8 × 1.25 1 3 0.3 2.2
Driven sprocket (nut) M10 × 1.25 4 43 4.3 31
Driven sprocket (stud) M10 × 1.25 4 30 3.0 22
Sidestand mounting (nut) M10 × 1.25 1 44 4.4 32
Engine mounting: Engine bracket (front) and frame M8 × 1.25 2 40 4.0 29
Engine bracket (front) and engine M8 × 1.25 2 40 4.0 29
Engine bracket (upper) and frame M8 × 1.25 2 40 4.0 29
Engine bracket (upper) and cylinder head M8 × 1.25 1 40 4.0 29
Engine and frame (rear) M8 × 1.25 2 40 4.0 29
Pivot shaft and nut M12 × 1.25 1 53 5.3 38
Relay arm and swingarm (TT-R125LW) M12 × 1.25 1 70 7.0 50
(TT-R125LWE) M12 × 1.25 1 53 5.3 38
Relay arm and connecting arm M10 × 1.25 1 35 3.5 25
Connecting arm and frame M10 × 1.25 1 35 3.5 25
Rear shock absorber assembly and frame M12 × 1.25 1 53 5.3 38
Rear shock absorber assembly and relay arm M10 × 1.25 1 35 3.5 25
Rear shock absorber and locknut (preload) M46 × 1.5 1 42 4.2 30
Drive chain tensioner (upper) M8 × 1.25 1 23 2.3 17
Drive chain tensioner (lower) M6 × 1.0 1 7 0.7 5.1
Drive chain support and swingarm M6 × 1.0 2 7 0.7 5.1
Drive chain guide and swingarm M6 × 1.0 2 7 0.7 5.1
Drive chain guard mounting M6 × 1.0 2 7 0.7 5.1
Fuel tank mounting M6 × 1.0 2 10 1.0 7.2
Fuel tank and fuel cock M6 × 1.0 2 7 0.7 5.1
Fuel tank and fuel tank bracket M6 × 1.0 4 7 0.7 5.1
Front fender mounting M6 × 1.0 4 7 0.7 5.1
Rear fender mounting M6 × 1.0 4 7 0.7 5.1
Flap guard mounting M6 × 1.0 2 4 0.4 2.9
Left side cover mounting M6 × 1.0 2 7 0.7 5.1
Seat mounting M6 × 1.0 2 7 0.7 5.1
Battery cover and battery box (TT-R125LWE) M6 × 1.0 1 5 0.5 3.6
Battery box and frame (TT-R125LWE) M6 × 1.0 1 7 0.7 5.1