2006 YAMAHA TTR125 lock

3 - 4
INSP
ADJENGINE/CLUTCH ADJUSTMENT/
THROTTLE CABLE ADJUSTMENT
EC350000
ENGINE
CLUTCH ADJUSTMENT
1. Check:
Clutch lever free play a
Out of specification → Adjust.
Clutch lever free play a:
10 ~ 15 mm (0.39 ~ 0.59 in)
2. Adjust:
Clutch lever free play
NOTE:
Make minute adjustment on the lever side.
After adjustment, check proper operation of
clutch lever. Clutch lever free play adjustment steps:
Loosen the locknut 1.
Turn the adjuster 2 until free play a is
within the specified limits.
Tighten the locknut.
EC35A001
THROTTLE CABLE ADJUSTMENT
1. Check:
Throttle grip free play a
Out of specification → Adjust.
Throttle grip free play a:
3 ~ 5 mm (0.12 ~ 0.20 in)
2. Adjust:
Throttle grip free play
Throttle grip free play adjustment steps:
Loosen the locknut 1.
Turn the adjuster 2 until the specified free
play is obtained.
Tighten the locknut.

3 - 12
INSP
ADJ
VALVE CLEARANCE INSPECTION AND ADJUSTMENT
4. Check:
Valve clearance
Out of specification → Adjust.
Valve clearance (cold):
Intake valve:
0.08 ~ 0.12 mm
(0.0031 ~ 0.0047 in)
Exhaust valve:
0.10 ~ 0.14 mm
(0.0039 ~ 0.0055 in)
Checking steps:
Turn the crankshaft counterclockwise with
a wrench.
Align the T.D.C. mark a on the rotor with
the align mark b on the crankcase cover
when piston is at T.D.C. on compression
stroke.
Measure the valve clearance using a
feeler gauge 1.
Out of specification → Adjust clearance.
5. Adjust:
Valve clearance
Adjustment steps:
Loosen the locknut 1.
Turn the adjuster 3 in or out with the
valve adjusting tool 2 until specified clear-
ance is obtained.
Turning in →
Valve clearance is decreased.
Turning out →
Valve clearance is increased.
Tappet adjusting tool:
YM-8035/90890-01311
Hold the adjuster to prevent it from moving
and tighten the locknut.
T R..
Locknut:
8 Nm (0.8 m • kg, 5.8 ft • lb)

INSPADJ
FAHRWERK
HYDRAULISCHE BREMSANLAGE
ENTL ÜFTEN (TT-R125LW/TT-R125LWE)
WARNUNG
Die Anlage muss entlüftet werden, wenn:
 die Anlage zerlegt wurde,
 ein Schlauch gel öst oder erneuert wurde,
 der Fl üssigkeitsstand sehr niedrig ist,
 die Anlage nicht einwandfrei funktioniert.
Eine nicht korrekt durchgef ührte Entl üftung
kann zur Verminderung der Bremsleistung
f ü hren.
1. Demontieren:
 Hauptbremszylinder-Verschlu ssdeckel
 Membran
2. Entl üften:
 Bremsfl üssigkeit
Arbeitsschritte: a. Ausgleichsbeh älter mit der empfohle-
nen Bremsfl üssigkeit bef üllen. Darauf
achten, dass keine Flüssigkeit versch üt-
tet wird und der Ausgleichsbeh älter nicht
ü berl äuft.
b. Membran einsetzen.
c. Durchsichtigen Kunststoffschlauch 2
fest auf Entl üftungsschraube 1 aufste-
cken.
d. Freies Schlauchende in Auffangbeh älter
f ü hren.
e. Den Bremshebel mehrmals langsam bet ätigen.
f. Den Bremshebel ziehen und in dieser Stellung halten.
g. Die Entl üftungsschraube lockern und
den Bremshebel bis zum Anschlag
bewegen.
h. Die Entl üftungsschraube festziehen,
danach den Handbremshebel loslassen.
T R..
Entl üftungsschraube:
6 Nm (0,6 m • kg, 4,3 ft • lb)
i. Schritte (e) bis (h) solange wiederholen, bis sich keine Luftblasen mehr im Kunst-
stoffschlauch befinden.
PARTIE CYCLE
PURGE DE L ’AIR DU SYST ÈME DE
FREINAGE (TT-R125LW/TT-R125LWE)
AVERTISSEMENT
Purger le syst ème de freinage si:
Le syst ème a été d émont é.
Un tuyan de frein a été desserr é ou depos é.
Le liquide de frein est tr ès bas.
Le frein fonctionne mal.
Si le syst ème de freinage n ’est pas correctement
purg é, cela peut se traduire par une dangereuse
perte d ’efficacit é de freinage.
1. D époser:
Couvercle du ma ître cylindre de frein
Diaphragme
2. Purger:
Liquide de frein
Etapes de purge de l ’air:
a. Ajouter du liquide de frein correct dans le ré servoir.
b. Mettre en place le diaphragme. Prendre garde à ne pas renverser ou faire d éborder le
r é servoir.
c. Connecter herm étiquement le tuyau transpa-
rent en mati ère plastique 2, à la vis de purge
1 de l ’étrier.
d. Mettre l ’autre extr émit é du tuyau dans un
r é cipient.
e. Actionner lentement le levier de frein à plu-
sieurs reprises.
f. Serrer le levier et le maintenir à cette posi-
tion.
g. Desserrer la vis de purge d ’air et laisser aller
le levier jusqu ’à sa limite.
h. Resserrer la vis de purge d ’air quand le
levier a atteint la limite de sa course, puis
rel âcher le levier.
T R..
Vis de purge:
6 Nm (0,6 m • kg, 4,3 ft • lb)
i. Refaire le op érations (e) à (h) jusqu ’à l’é li-
mination totale des bulles d ’air du syst ème.
3 - 15
PARTIE CYCLE/PURGE DE L ’AIR DU SYST ÈME DE FREINAGE
(TT-R125LW/TT-R125LWE)
FAHRWERK/HYDRAULISCHE BREMSANLAGE ENTL ÜFTEN (TT-R125LW/TT-R125LWE)

3 - 16
INSP
ADJ
3. Install:
Diaphragm
Brake master cylinder cap
NOTE:
If bleeding is difficult, it may be necessary to
let the brake fluid system stabilize for a few
hours. Repeat the bleeding procedure when
the tiny bubbles in the system have disap-
peared.
j. Add brake fluid to the level line on the
reservoir.
WARNING
Check the operation of the brake after
bleeding the brake system.
FRONT BRAKE ADJUSTMENT
TT-R125/TT-R125E
1. Check:
Brake lever free play a
Out of specification → Adjust.
2. Adjust:
Brake lever free play
NOTE:
For minute adjustment, loosen the locknut 2
on the lever side and adjust with the adjuster
3.
CAUTION:
Make sure that there is no brake drag after
adjusting the brake lever free play.
Brake lever free play a:
10 ~ 15 mm (0.39 ~ 0.59 in)
Brake lever free play adjustment steps:
Loosen the locknuts 1.
Turn the locknuts until free play a is
within the specified limits by changing their
tightening position.
Tighten the locknuts.
FRONT BRAKE ADJUSTMENT

3 - 17
INSP
ADJ
TT-R125LW/TT-R125LWE
1. Check:
Brake lever free play a
Out of specification → Adjust.
2. Adjust:
Brake lever free play
CAUTION:
Make sure that there is no brake drag after
adjusting the brake lever free play.
Brake lever free play a:
2 ~ 5 mm (0.08 ~ 0.20 in)
Brake lever free play adjustment steps:
Loosen the locknut 1.
Turn the adjuster 2 until the free play a
is within the specified limits.
Tighten the locknut.
REAR BRAKE ADJUSTMENT
1. Check:
Brake pedal free play a
Out of specification → Adjust.
2. Adjust:
Brake pedal free play
CAUTION:
Make sure that there is no brake drag after
adjusting the brake pedal play.
Brake pedal free play a:
20 ~ 30 mm (0.79 ~ 1.18 in)
Brake pedal free play adjustment step:
Turn the adjuster 1 until the free play a is
within the specified limits.
REAR BRAKE ADJUSTMENT

3 - 18
INSP
ADJ
BRAKE PEDAL HEIGHT ADJUSTMENT
1. Check:
Brake pedal height a
Out of specification → Adjust.
2. Adjust:
Brake pedal height
FRONT BRAKE PAD INSPECTION AND
REPLACEMENT (TT-R125LW/TT-R125LWE)
1. Remove:
Plug
2. Inspect:
Brake pad thickness a
Out of specification → Replace as a set.
Brake pedal height a:
1 mm (0.04 in)
Pedal height adjustment steps:
Loosen the locknut 1.
Turn the adjusting bolt 2 until the pedal
height a is within specified height.
Tighten the locknut.
Brake pad thickness a:
Standard
4.0 mm
(0.16 in)0.8 mm
(0.03 in)
3. Replace:
Brake pad
Brake pad replacement steps:
Remove the brake caliper support bolt 1.
Turn the brake caliper 2 counterclock-
wise a.
Replace the brake pads 3.
BRAKE PEDAL HEIGHT ADJUSTMENT/FRONT BRAKE PAD
INSPECTION AND REPLACEMENT (TT-R125LW/TT-R125LWE)

3 - 24
INSP
ADJ
REAR SHOCK ABSORBER ASSEMBLY
INSPECTION
1. Inspect:
Swingarm smooth action
Abnormal noise/unsmooth action →
Grease the pivoting points or repair the
pivoting points.
Damage/oil leakage → Replace.
REAR SHOCK ABSORBER SPRING
PRELOAD ADJUSTMENT
1. Elevate the rear wheel by placing the
suitable stand under the engine.
2. Remove:
Left side cover
3. Loosen:
Locknut 1
4. Adjust:
Spring preload
By turning the adjuster 2.
NOTE:
Be sure to remove all dirt and mud from
around the locknut and adjuster before
adjustment.
The length of the spring (installed) changes
1.5 mm (0.06 in) per turn of the adjuster.
CAUTION:
Never attempt to turn the adjuster beyond
the maximum or minimum setting.Stiffer →Increase the spring preload.
(Turn the adjuster 2 in.)
Softer →Decrease the spring preload.
(Turn the adjuster 2 out.)
Spring length (installed) a:
Standard length Extent of adjustment
TT-R125/TT-R125E/
TT-R125LW:
165 mm
(6.50 in)
TT-R125LWE:
160.5 mm
(6.32 in)TT-R125/TT-R125E/
TT-R125LW:
155 ~ 175 mm
(6.10 ~ 6.89 in)
TT-R125LWE:
147.5 ~ 167.5 mm
(5.81 ~ 6.59 in)
REAR SHOCK ABSORBER ASSEMBLY INSPECTION/
REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT

3 - 25
INSP
ADJ
5. Tighten:
Locknut
6. Install:
Left side cover
T R..42 Nm (4.2 m · kg, 30 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
EC36N014
REAR SHOCK ABSORBER REBOUND
DAMPING FORCE ADJUSTMENT
(TT-R125LWE)
1. Adjust:
Rebound damping force
By turning the adjuster 1.
STANDARD POSITION:
This is the position which is back by the spe-
cific number of clicks from the fully turned-in
position.
CAUTION:
Never go beyond the maximum or mini-
mum adjustment positions.Stiffer a → Increase the rebound damp-
ing force. (Turn the adjuster
1 in.)
Softer b → Decrease the rebound
damping force. (Turn the
adjuster 1 out.)
Extent of adjustment:
Maximum Minimum
Fully turned in
position20 clicks out
(from maximum
position)
Standard position:
About 12 clicks out
b
a
1
REAR SHOCK ABSORBER REBOUND DAMPING FORCE
ADJUSTMENT (TT-R125LWE)