2006 YAMAHA TTR125 cylinder

CHAPTER 3
REGULAR INSPECTION
AND ADJUSTMENTS
MAINTENANCE INTERVALS ...................3-1
PRE-OPERATION INSPECTION
AND MAINTENANCE ................................3-3
ENGINE ......................................................3-4
CHASSIS .................................................3-15
ELECTRICAL ...........................................3-34
CHAPTER 4
ENGINE
SEAT, FUEL TANK
AND SIDE COVERS ..................................4-1
MUFFLER ..................................................4-2
CARBURETOR ..........................................4-3
CYLINDER HEAD ....................................4-12
CAMSHAFT AND ROCKER ARMS ........4-20
VALVES AND VALVE SPRINGS ............4-24
CYLINDER AND PISTON ........................4-32
CLUTCH AND PRIMARY DRIVEN
GEAR .......................................................4-40
OIL PUMP ................................................4-49
KICK AXLE AND SHIFT SHAFT .............4-53
CDI MAGNETO
(TT-R125/TT-R125LW) ............................4-58
CDI MAGNETO AND STARTER
CLUTCH (TT-R125E/TT-R125LWE) .......4-61
ENGINE REMOVAL .................................4-66
CRANKCASE, CRANKSHAFT
AND BALANCER ....................................4-70
TRANSMISSION, SHIFT CAM
AND SHIFT FORK ...................................4-78

1 - 3
GEN
INFO
IMPORTANT INFORMATION
EC130000
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Remove all dirt, mud, dust, and foreign
material before removal and disassembly.
When washing the machine with high
pressured water, cover the part as follow.
Silencer exhaust port
2. Use proper tools and cleaning equip-
ment. Refer to “SPECIAL TOOLS” sec-
tion.
3. When disassembling the machine, keep
mated parts together. They include
gears, cylinders, pistons, and other
mated parts that have been “mated”
through normal wear. Mated parts must
be reused as an assembly or replaced.
4. During the machine disassembly, clean
all parts and place them in trays in the
order of disassembly. This will speed up
assembly time and help assure that all
parts are correctly reinstalled.
5. Keep away from fire.

1 - 15
GEN
INFO
STARTING AND BREAK-IN
BREAKING IN AFTER REPLACEMENT
After a part is replaced with a new one, it is
necessary to break it in as in a new machine.
This is required especially when the following
engine-related parts are replaced.
Cylinder
Piston
Piston ring
Valve
Camshaft
Crankshaft
Clutch
Transmission gear
Shift fork
* For warming up and inspection during
break-in, refer to “GENERAL INSPECTION
AND MAINTENANCE” section in the
CHAPTER 3 and if there is any problem,
stop the engine immediately and check.

1 - 16
GEN
INFO
TORQUE-CHECK POINTS
TORQUE-CHECK POINTS
TT-R125/TT-R125E
Engine mounting
Muffler
Steering Steering stem to
handlebar
Suspension Front Steering stem to
front fork
Rear For link type
Rear Installation of shock
absorber
Rear Installation of swing-
arm
Wheel Installation of wheel Front
Rear
Brake Front
Rear
Fuel systemFrame to engine
Frame to engine bracket
Engine bracket to engine
Muffler to cylinder head
Muffler to rear fender bracket
Muffler to seat pillar tube
Steering stem to upper bracket
Upper bracket to handlebar
Front fork to upper bracket
Front fork to lower bracket
Assembly of links
Link to frame
Link to shock absorber
Link to swingarm
Shock absorber to frame
Tightening of pivot shaft
Tightening of wheel axle
Tightening of wheel axle
Wheel to sprocket
Camshaft lever to camshaft
Camshaft lever to camshaft
Fuel tank to fuel cock
NOTE:
Concerning the tightening torque, refer to
“MAINTENANCE SPECIFICATIONS” section
in the CHAPTER 2.

1 - 17
GEN
INFO
TORQUE-CHECK POINTS
TT-R125LW/TT-R125LWE
Engine mounting
Muffler
Steering Steering stem to
handlebar
Suspension Front Steering stem to
front fork
Rear For link type
Rear Installation of shock
absorber
Rear Installation of swing-
arm
Wheel Installation of wheel Front
Rear
Brake Front
Rear
Fuel systemFrame to engine
Frame to engine bracket
Engine bracket to engine
Muffler to cylinder head
Muffler to rear fender bracket
Muffler to seat pillar tube
Steering stem to upper bracket
Upper bracket to handlebar
Front fork to upper bracket
Front fork to lower bracket
Assembly of links
Link to frame
Link to shock absorber
Link to swingarm
Shock absorber to frame
Tightening of pivot shaft
Tightening of wheel axle
Tightening of wheel axle
Wheel to sprocket
Brake caliper to front fork
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to joint
Brake hose to joint
Brake master cylinder to handlebar
Tightening of bleed screw
Brake camshaft lever to brake camshaft
Fuel tank to fuel cock
NOTE:
Concerning the tightening torque, refer to
“MAINTENANCE SPECIFICATIONS” section
in the CHAPTER 2.

1 - 19
GEN
INFO
CLEANING AND STORAGE
EC182001
STORAGE
If your machine is to be stored for 60 days or
more, some preventive measures must be
taken to avoid deterioration. After cleaning the
machine thoroughly, prepare it for storage as
follows:
1. Drain the fuel tank, fuel lines, and the car-
buretor float bowl.
2. Remove the spark plug, pour a table-
spoon of SAE 10W-30 motor oil in the
spark plug hole, and reinstall the plug.
With the engine stop switch pushed in,
kick the engine over several times to coat
the cylinder walls with oil.
3. Remove the drive chain, clean it thor-
oughly with solvent, and lubricate it. Rein-
stall the chain or store it in a plastic bag
tied to the frame.
4. Lubricate all control cables.
5. Block the frame up to raise the wheels off
the ground.
6. Tie a plastic bag over the exhaust pipe
outlet to prevent moisture from entering.
7. If the machine is to be stored in a humid
or salt-air environment, coat all exposed
metal surfaces with a film of light oil. Do
not apply oil to rubber parts or the seat
cover.
NOTE:
Make any necessary repairs before the
machine is stored.

SPEC
2 - 1
GENERAL SPECIFICATIONS
EC200000
SPECIFICATIONS
EC211000
GENERAL SPECIFICATIONS
TT-R125/TT-R125EModel name: TT-R125(V) (CDN, AUS, NZ)
TT-R125 (EUROPE, ZA)
TT-R125E(V) (USA, CDN, AUS, NZ)
TT-R125E (EUROPE, ZA)
Model code number: TT-R125: 1B29 (AUS, NZ, EUROPE, ZA)
1B2A (CDN)
TT-R125E: 1B2D (USA, AUS, NZ, EUROPE, ZA)
1B2E (CDN)
Dimensions: USA, AUS, NZ, ZA, EUROPECDN
Overall length 1,830 mm (72.0 in) 1,865 mm (73.4 in)
Overall width 785 mm (30.9 in) ←
Overall height 1,055 mm (41.5 in) ←
Seat height 775 mm (30.5 in) ←
Wheelbase 1,250 mm (49.2 in) ←
Minimum ground clearance 265 mm (10.4 in) ←
Basic weight: With oil and full fuel tank (TT-R125) 83 kg (183 lb) (TT-R125E) 90 kg (198.4 lb)
Engine: Engine type Air cooled 4-stroke, SOHC
Cylinder arrangement Single cylinder, forward inclined
Displacement 124 cm
3 (7.57 cu.in)
Bore × stroke 54.0 × 54.0 mm (2.126 × 2.126 in)
Compression ratio 10.0:1
Starting system (TT-R125) Kickstarter (TT-R125E) Kick and electric starter
Lubrication system: Wet sump

SPEC
2 - 4
GENERAL SPECIFICATIONS
TT-R125LW/TT-R125LWEModel name: TT-R125L(V) (USA, CDN) TT-R125LW(V) (AUS,NZ) TT-R125LW (EUROPE, ZA)
TT-R125LE(V) (USA, CDN) TT-R125LWE(V) (AUS, NZ)
TT-R125LWE (EUROPE, ZA)
Model code number: TT-R125LW: 1B2B (USA, AUS, NZ, EUROPE, ZA)
1B2C (CDN)
TT-R125LWE: 1B2F (USA, AUS, NZ, EUROPE, ZA)
1B2G (CDN)
Dimensions: USA, AUS, NZ, ZA, EUROPECDN
Overall length 1,885 mm (74.2 in) 1,890 mm (74.4 in)
Overall width 795 mm (31.3 in) ←
Overall height 1,085 mm (42.7 in) ←
Seat height 805 mm (31.7 in) ←
Wheelbase 1,270 mm (50.0 in) ←
Minimum ground clearance 295 mm (11.6 in) ←
Basic weight: With oil and full fuel tank (TT-R125LW) 84 kg (185 lb) (TT-R125LWE) 90 kg (198.4 lb)
Engine: Engine type Air cooled 4-stroke, SOHC
Cylinder arrangement Single cylinder, forward inclined
Displacement 124 cm
3 (7.57 cu.in)
Bore × stroke 54.0 × 54.0 mm (2.126 × 2.126 in)
Compression ratio 10.0:1
Starting system (TT-R125LW) Kickstarter (TT-R125LWE) Kick and electric starter
Lubrication system: Wet sump