2006 YAMAHA TTR125 wheel

5 - 5
CHASFRONT WHEEL AND FRONT BRAKE (TT-R125/TT-R125E)
ASSEMBLY AND INSTALLATION
Brake shoe plate assembly
1. Install:
Brake camshaft 1
NOTE:
Apply the lithium soap base grease on the
brake camshaft.
2. Check:
Brake camshaft operation
Unsmooth operation → Repair.
3. Install:
Wear indicator plate 1
NOTE:
When installing the wear indicator plate to the
brake camshaft align the projection a on the
wear indicator plate with the slots b on the
brake camshaft.
4. Install:
Brake camshaft lever 1
NOTE:
Install the brake camshaft lever in relation to
the punch mark a as shown.
1
1a
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
5. Install:
Springs 1
Brake shoes 2
NOTE:
Apply the lithium soap base grease on the
pivot pin.
WARNING
Do not apply grease to the brake shoe lin-
ings.
New

5 - 6
CHASFRONT WHEEL AND FRONT BRAKE (TT-R125/TT-R125E)
Front wheel
1. Install:
Wheel bearing 1
Spacer 2
Wheel bearing 3
Oil seal 4
NOTE:
Apply the lithium soap base grease on the
wheel bearing and oil seal lip when installing.
Install the wheel bearing so that the enclosed
side is facing outward.
Use a socket that matches the outside diam-
eter of the race of the bearing.
Left side of wheel bearing shall be installed first.
Install the oil seal with its manufacture's
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of the bearing.
Contact should be made only with the outer
race.
2. Install:
Brake shoe plate assembly
Collar set 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
New
3. Install:
Front wheel
NOTE:
Make sure that the slot a on the brake shoe
plate with the stopper b on the front fork outer
tube.
4. Install:
Wheel axle 1

5 - 7
CHASFRONT WHEEL AND FRONT BRAKE (TT-R125/TT-R125E)
5. Install:
Axle nut 1
T R..45 Nm (4.5 m · kg, 32 ft · lb)
6. Install:
Brake cable
NOTE:
Brake camshaft lever side of brake cable shall
be installed first.
7. Install:
Brake cable holder 1
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
8. Adjust:
Brake lever free play
Refer to “FRONT BRAKE ADJUST-
MENT” section in the CHAPTER 3.

5 - 8
CHAS
FRONT WHEEL (TT-R125LW/TT-R125LWE)
Extent of removal:1 Front wheel removal2 Wheel bearing removal
3 Brake disc removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalFRONT WHEEL REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNINGSupport the machine securely so there is nodanger of it falling over.
1 Axle nut 1
2 Washer 1
3 Wheel axle 1
4 Front wheel 1
5 Collar 2
6 Oil seal 2
7 Wheel bearing 2 Refer to “REMOVAL POINTS”.
8 Spacer 1
9Brake disk
1
2
31
3
FRONT WHEEL (TT-R125LW/TT-R125LWE)

5 - 9
CHASFRONT WHEEL (TT-R125LW/TT-R125LWE)
REMOVAL POINTS
EC513201
Wheel bearing (if necessary)
1. Remove:
Bearing 1
NOTE:
Remove the bearing using a general bearing
puller 2.
INSPECTION
EC514100
Wheel
1. Measure:
Wheel runout
Out of limit → Repair/replace.
2. Inspect:
Bearing
Rotate inner race with a finger.
Rough spot/seizure → Replace.
NOTE:
Replace the bearings, oil seal and wheel collar
as a set.
Wheel runout limit:
Radial 1: 2.0 mm (0.08 in)
Lateral 2: 2.0 mm (0.08 in)
EC514200
Wheel axle
1. Measure:
Wheel axle bends
Out of specification → Replace.
Use the dial gauge 1.
NOTE:
The bending value is shown by one half of the
dial gauge reading.
WARNING
Do not attempt to straighten a bent axle.
Wheel axle bending limit:
0.5 mm (0.020 in)

5 - 10
CHASFRONT WHEEL (TT-R125LW/TT-R125LWE)
Brake disc
1. Measure:
Brake disc deflection
Use the dial gauge 1.
Out of specification → Inspect wheel runout.
If wheel runout is in good condition,
replace the brake disc.
2. Measure:
Brake disc thickness a
Out of limit → Replace.
Disc deflection limit:
0.15 mm (0.006 in)
Disc wear limit:
Standard
3.0 mm
(0.12 in)2.5 mm
(0.10 in)
ASSEMBLY AND INSTALLATION
Front wheel
1. Install:
Wheel bearing 1
Spacer 2
Wheel bearing 3
Oil seal 4
NOTE:
Apply the lithium soap base grease on the
wheel bearing and oil seal lip when installing.
Install the wheel bearing so that the enclosed
side is facing outward.
Use a socket that matches the outside diam-
eter of the race of the bearing.
Left side of wheel bearing shall be installed first.
Install the oil seal with its manufacture’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of the bearing.
Contact should be made only with the outer
race.
New

5 - 11
CHASFRONT WHEEL (TT-R125LW/TT-R125LWE)
2. Install:
Brake disc 1
Bolt (brake disc) 2
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)LT
3. Install:
Collar 1
NOTE:
Apply the lithium soap base grease on the oil
seal lips.
Install the longer collar on the brake disc 2
side.
4. Install:
Front wheel
NOTE:
Install the brake disc 1 between the brake
pads 2 correctly.
5. Install:
Wheel axle 1
6. Install:
Washer 1
Axle nut 2
T R..45 Nm (4.5 m · kg, 32 ft · lb)

5 - 24
CHAS
REAR WHEEL AND REAR BRAKE
Extent of removal:1 Rear wheel removal 2 Wheel bearing removal
3 Brake shoe plate assembly removal and disassembly
Extent of removal Order Part name Q’ty Remarks
Preparation for removalREAR WHEEL AND DRUM
BRAKE
Hold the machine by placing the
suitable stand under the engine.
WARNINGSupport the machine securely so there is nodanger of it falling over.
1 Brake rod 1
2 Axle nut 1
3 Drive chain puller (right) 1
4 Wheel axle 1
5 Drive chain puller (left) 1
6 Drive chain 1
7 Rear wheel 1 Refer to “REMOVAL POINTS”.
8 Collar (right) 1
9 Brake shoe plate assembly 1
10Collar (left)
1
231
REAR WHEEL AND REAR BRAKE