2006 YAMAHA TTR125 clutch

8 - B - V
2 - 31
SPECCABLE ROUTING DIAGRAM
ÎAfter fastening the starter relay
lead, pass it on the left of the
chassis.
‰ Fasten the CDI magneto lead
and starter relay lead.
Ï Fasten the wire harness.
Ì Pass the rectifier/regulator lead
between the frame and air filter
case.
Ó Do not allow the CDI magneto
lead to slacken except between
the two plastic locking ties.
È Fasten the CDI magneto lead
over the engine bracket (rear).
Ô Fasten the CDI magneto lead. 
Pass the air vent hoses between
the engine and swingarm.
Ò Fit the neutral switch lead into
the groove in the crankcase
cover.
˜ Pass the starting circuit cut-off
relay lead under the frame and
at the right of the chassis.
ˆ Fasten the rear shock absorber
assembly sub-tank.
(TT-R125LWE only)
Ø Pass the CDI unit lead on the
outside of the main switch lead,
engine stop switch lead, clutch
switch lead and start switch
lead. ∏
After fastening the start switch
lead, clutch switch lead, engine
stop switch lead and main
switch lead, push their corru-
gated tube against the CDI unit
coupler.
ΠFasten the brake hose between
the paint marks.
 Pass the brake hose (brake
cable for the TT-R125E)
through the cable guide.
Í Fit the CDI unit band over the
CDI unit bracket till it stops.
Ê Fasten the brake cable.
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2 - 32
SPECCABLE ROUTING DIAGRAM
ËAfter connecting the main
switch coupler, engine stop
switch coupler, clutch switch
coupler and start switch cou-
pler, put a connector cover on
the couplers and push them in
at the rubber cover end.
◊Pass the wire harness on the
outside of the main switch cou-
pler.
„Do not allow the primary coil
lead to slacken where it is bare
of the protecting tube.ÙFasten the CDI unit lead and
starting circuit cut-off relay lead
with a plastic locking tie at the
tape holding the main switch
lead, engine stop switch lead,
clutch switch lead, and start
switch lead together.
ÁPosition the starter cable, throt-
tle cable, CDI magneto lead,
wire harness and rear shock
absorber assembly sub-tank
hose (TT-R125LWE only) as
shown.ÛFasten the wire harness, throttle
cable, starter cable, CDI mag-
neto lead and rear shock
absorber assembly sub-tank
hose (TT-R125LWE only) at the
protecting tube for the CDI mag-
neto lead.
Fasten the rectifier/regulator
lead as shown.
Do not allow the CDI magneto
lead to slacken.
Position the plastic locking tie
ends as shown.
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12 - B - V
2 - 33
SPEC
1Throttle cable
2 Clutch cable
3 Starter cable
4 Fuel tank breather hose
5 Hose guide
6 Clamp
7 Cable guide
8 Starting circuit cut-off relay
9 Spark plug lead
0 Starter motor lead
A Negative battery lead B
Engine oil breather hose
C Positive battery lead
D Overflow hose
E Air vent hose
F Primary coil lead
G Ground lead Å
Tighten the starter choke nut
while taking care not to twist the
starter cable.
ı Pass the clutch cable on the
inside of the throttle cable and
starter cable.
Ç Pass the starter cable so that it
is not twisted.
Î Pass the fuel tank breather
hose through the hose guide.
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14 - B - V
2 - 34
SPEC
‰Fasten the clutch cable with the
paint in the cable guide bottom
recess.
Ï Pass the throttle cable and
starter cable through the cable
guide.
Ì Fasten the starter motor lead.
Ó Pass the engine oil breather
hose and overflow hose
between the right half of the
swingarm and frame. È
Pass the negative battery lead
on the inside of the frame as
shown.
Ô Fasten the engine oil breather
hose, overflow hose and air
vent hoses to 2 clicks.
 After fastening the starter cable,
push it against the starter
plunger.
Ò Put the tip of the air vent hose
into the frame. ˜
Install the primary coil terminal
(orange) to the ignition coil.
ˆ Fasten the ground lead together
with the ignition coil.
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Pass the overflow hose
between the right half of the
swingarm and frame.
Fasten the overflow hose and
air vent hoses to 2 clicks.
KAfter fastening the starter
cable, push it against the
starter plunger.
LPut the tip of the air vent hose
into the frame.

2 - 35
SPEC
1Clamp
2Clutch switch lead
3Engine stop switch lead
4Brake hose (Brake cable for the
TT-R125E)
5Clutch cable
6Throttle cable
7Main switch lead
8Start switch leadÅFasten the clutch switch lead
and engine stop switch lead to 3
clicks.
ıPass the brake hose (brake
cable for the TT-R125E) in front
of the number plate and through
the cable guide.
ÇPass the clutch cable in back of
the number plate.
ÎStarting at the forepart, pass the
main switch lead, clutch cable
and start switch lead in that
order.
‰Pass the start switch lead in
back of the starter cable.ÏPass the main switch lead on
the right of the number plate
stay.
ÌFasten the throttle cable
adjuster cover and start switch
lead with a plastic locking tie
ends downward.
ÓFasten the start switch lead to 3
clicks.
ÈPass the start switch lead in the
middle of the brake master cyl-
inder bracket. (TT-R125LWE
only)
ÔPass the engine stop switch
lead in the middle of the clutch
holder.
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3
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2
3
4
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CABLE ROUTING DIAGRAM

3 - 1
INSP
ADJ
MAINTENANCE INTERVALS
EC300000
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind
that such factors as weather, terrain, geographical location, and individual usage will alter the
required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in
maintaining and lubricating your machine, consult your Yamaha dealer.
Dealer
NoteItem Checks and maintenance jobsInitial Every
10 hours
(1 month)60 hours
(6 months)120 hours
(12 months)
*Fuel lineCheck fuel hoses for cracks or damage.
Replace if necessary.
Spark plugCheck condition.
Clean, regap or replace if necessary.
*ValvesCheck valve clearance.
Adjust if necessary.
Air filter Clean or replace element if necessary.
*CarburetorCheck engine idling speed and starter operation.
Adjust if necessary.
Exhaust systemsCheck for leakage.
Retighten if necessary.
Replace gasket if necessary.
Engine oilCheck oil level and vehicle for oil leakage.
Correct if necessary.
Change. (Warm engine before draining.)
ClutchCheck operation.
Adjust or replace cable.
*Front brakeCheck operation.
Adjust brake lever free play.
Check fluid level and leakage.
(TT-R125LW/TT-R125LWE only)Every ride
*Rear brakeCheck operation.
Adjust brake pedal free play and replace brake
shoes if necessary.Every ride
*WheelsCheck balance, runout, spoke tightness and for
damage.
Tighten spokes and rebalance, replace if
necessary.
*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
*Wheel bearingsCheck bearing for looseness or damage.
Replace if necessary.
*SwingarmCheck swingarm pivoting point for play.
Correct if necessary.
Lubricate with molybdenum disulfide grease.
Drive chainCheck chain slack.
Adjust if necessary. Make sure that the rear wheel
is properly aligned.
Clean and lubricate.Every ride
*Steering bearingsCheck bearing play and steering for roughness.
Correct accordingly.
Lubricate with lithium soap base grease every 120
hours.

3 - 3
INSP
ADJ
PRE-OPERATION INSPECTION AND MAINTENANCE
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation or practice, make sure the machine is in good operating condi-
tion.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
FuelCheck that a fresh gasoline is filled in the fuel tank. Check the
fuel line for leakage.P.1-12
Engine oilCheck that the oil level is correct. Check the crankcase for leak-
age.P.3-7 ~ 10
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-4
Throttle grip/housingCheck that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.P.3-4 ~ 5
BrakesCheck the play of front and rear brake and effect of front and
rear brake.
Check fluid level and leakage. (TT-R125LW/TT-R125LWE only)P.3-15 ~ 20
Drive chainCheck chain slack and alignment. Check that the chain is lubri-
cated properly.P.3-21 ~ 22
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-27 ~ 28
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-28 ~ 32
Front forks and rear shock
absorber assemblyCheck that they operate smoothly and there is no oil leakage. P.3-23 ~ 26
Cables (wires)Check that the clutch and throttle cables move smoothly. Check
that they are not caught when the handlebars are turned or
when the front forks travel up and down.—
Muffler Check that the muffler is tightly mounted and has no cracks. P.4-2
Sprocket Check that the driven sprocket tightening nut is not loose. P.3-20
Lubrication Check for smooth operation. Lubricate if necessary. P.3-33
Bolts and nuts Check the chassis and engine for loose bolts and nuts.—
Lead connectorsCheck that the CDI magneto, CDI unit, and ignition coil are con-
nected tightly.P.1-5

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.