2006 YAMAHA TTR125 engine

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 - 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

SPEC
2 - 26
EC220001
GENERAL TORQUE SPECIFICATIONS
This chart specifies torque for standard fasten-
ers with standard I.S.O. pitch threads. Torque
specifications for special components or
assemblies are included in the applicable sec-
tions of this book. To avoid warpage, tighten
multi-fastener assemblies in a crisscross fash-
ion, in progressive stages, until full torque is
reached. Unless otherwise specified, torque
specifications call for clean, dry threads. Com-
ponents should be at room temperature.
A: Distance between flats
B: Outside thread diameter
EC230000
DEFINITION OF UNITS
A
(Nut)B
(Bolt)TORQUE
SPECIFICATION
Nm m•kg ft•lb
10 mm
12 mm
14 mm
17 mm
19 mm
22 mm6 mm
8 mm
10 mm
12 mm
14 mm
16 mm6
15
30
55
85
1300.6
1.5
3.0
5.5
8.5
134.3
11
22
40
61
94
Unit Read Definition Measure
mm
cmmillimeter
centimeter10
-3 meter
10-2 meterLength
Length
kg kilogram 10
3 gram Weight
N Newton 1 kg
× m/sec2Force
Nm
m • kgNewton meter
Meter kilogramN
× m
m
× kgTorque
Torque
Pa Pascal N/m
2Pressure
N/mm Newton per millimeter N/mm Spring rate
L
cm
3Liter
Cubic centimeter—
—Volume or capacity
Volume or capacity
r/min Revolution per minute—Engine speed
GENERAL TORQUE SPECIFICATIONS/
DEFINITION OF UNITS

152 - A - V
2 - 27
SPEC
EC240000
CABLE ROUTING DIAGRAM
TT-R125/TT-R125LW
1 CDI unit
2 CDI unit band
3 Clamp
4 CDI magneto lead
5 Air vent hose
6 Wire harness
7 Engine stop switch lead
8 Cable guide
9 Brake cable
(Brake hose for the TT-R125LW)
0 Brake cable holder
(Brake hose holder for the
TT-R125LW) Å
Fit the CDI unit band over the CDI unit bracket till it stops.
ı Clamp the ignition coil lead.
Ç Clamp the wire harness coupler.
Î Clamp the CDI magneto lead, throttle cable and starter cable.
‰ Clamp the CDI magneto lead so that it does not contact the push
lever.
Ï Pass the air vent hoses between the engine and swingarm.
Ì Clamp the wire harness and engine stop switch lead.
Ó Pass the brake cable (brake hose for the TT-R125LW) into the cable
guide.
È Clamp the brake cable.
Ô Clamp the brake hose between the paint marks.
CABLE ROUTING DIAGRAM
1
2
3
3
3
7
6
8
9
0 3
3
4
5
Î È
É
Ê
Ë
Ì
Í
Ï
Ð

2 - 29
SPEC
1Engine stop switch lead
2 Engine stop switch
3 Clamp
4 Brake cable
5 (Brake hose for the TT-R125LW)
Clutch cable
6 Throttle cable Å
Pass the engine stop switch lead in the middle of the clutch holder.
ı Clamp the engine stop switch lead to the handlebar to 3 clicks.
Ç Pass the brake cable (brake hose for the TT-R125LW) in front of the
number plate and through the cable guide.
Î Pass the clutch cable in back of the number plate.
‰ Clamp the throttle cable adjuster cover to the handlebar with the clamp
ends downward.
CABLE ROUTING DIAGRAM

6 - B - V
2 - 30
SPECCABLE ROUTING DIAGRAM
TT-R125E/TT-R125LWE
1Ground lead
2 Primary coil lead
3 Clamp
4 Wire harness
5 Starter relay lead
6 Rectifier/regulator lead
7 CDI magneto lead
8 Air vent hose
9 Neutral switch lead
0 Rear shock absorber assembly
sub-tank hose (TT-R125LWE
only)
A Starting circuit cut-off relay lead
B CDI unit lead
C Corrugated tube D
Brake hose holder (Brake cable
holder for the TT-R125E)
E Brake hose (Brake cable for the
TT-R125E)
F Cable guide
G Main switch lead
H Engine stop switch lead
I Clutch switch lead
J Start switch lead
K CDI unit band
L CDI unit
M Connector cover
N Rubber cover
O Starter cable
P Throttle cable Q
Rectifier/regulator
Å Fasten the primary coil lead and
ground lead.
ı Fasten the wire harness at its
tape.
Ç Fasten the wire harness and
CDI magneto lead in front of the
rear shock absorber assembly
bracket at the protecting tube
for the CDI magneto lead.
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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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D D
A
C
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30~ 3
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( 1
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in )

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.
AA
AB
AC
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