2007 YAMAHA TTR125 brake fluid

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INSP
ADJ
REAR BRAKE SHOE INSPECTION
1. Inspect:
Brake shoe lining wear limit
BRAKE FLUID LEVEL INSPECTION
(TT-R125LW/TT-R125LWE)
1. Place the brake master cylinder so that
its top is in a horizontal position.
2. Inspect:
Brake fluid level
Fluid at lower level → Fill up.
aLower level
WARNING
Use only designated quality brake fluid to
avoid poor brake performance.
Refill with same type and brand of brake
fluid; mixing fluids could result in poor
brake performance.
Be sure that water or other contaminants
do not enter brake master cylinder when
refilling.
Clean up spilled fluid immediately to
avoid erosion of painted surfaces or plas-
tic parts. Brake shoe lining wear limit checking
steps:
Fully push down the brake pedal and hold
it in position.
Then check the brake shoe wear indicator
1 is within the wear limit a.
Outside the limit → Replace the brake
shoe.
Refer to “REAR WHEEL AND REAR BRAKE”
section in the CHAPTER 5.
Recommended brake fluid:
DOT #4
SPROCKETS INSPECTION
1. Inspect:
Sprocket teeth a
Excessive wear → Replace.
NOTE:
Replace the drive, driven sprockets and drive
chain as a set.
REAR BRAKE SHOE INSPECTION/BRAKE FLUID LEVEL INSPECTION
(TT-R125LW/TT-R125LWE)/SPROCKETS INSPECTION

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CHAS
FRONT BRAKE (TT-R125LW/TT-R125LWE)
Extent of removal:1 Brake hose removal 2 Brake caliper removal
3 Brake master cylinder removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalFRONT BRAKE REMOVAL
Hold the machine by placing the
suitable stand under the engine.
Drain the brake fluid.
WARNINGSupport the machine securely so there is nodanger of it falling over.
Refer to “REMOVAL POINTS”.
1 Brake hose holder 2
2 Union bolt 1
3 Brake hose 1
4 Joint 1
5 Brake caliper support bolt 1
6 Brake caliper 1 Refer to “REMOVAL POINTS”.
7 Brake lever 1
8 Brake master cylinder bracket 1
9Brake master cylinder
1
3
12
2
3
FRONT BRAKE (TT-R125LW/TT-R125LWE)

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CHASFRONT BRAKE (TT-R125LW/TT-R125LWE)
REMOVAL POINTS
Brake fluid
1. Remove:
Brake master cylinder cap 1
NOTE:
Do not remove the diaphragm.
2. Connect the transparent hose 2 to the
bleed screw 1 and place a suitable con-
tainer under its end.
3. Loosen the bleed screw and drain the
brake fluid while pulling in the lever.
CAUTION:
Do not reuse the drained brake fluid.
Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled
fluid immediately.
Brake caliper
1. Remove:
Brake caliper 1
NOTE:
Turn the brake caliper counterclockwise and
pull out it from the guide pin 2 on the brake
caliper bracket.
Brake caliper piston
1. Remove:
Brake caliper piston
Use compressed air and proceed care-
fully.
WARNING
Cover piston with rag and use extreme
caution when expelling piston from cylin-
der.
Never attempt to pry out piston.
Brake caliper piston removal steps:
Insert a piece of rag into the brake caliper
to lock one brake caliper.
Carefully force the piston out of the brake
caliper cylinder with compressed air.

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CHAS
Brake caliper piston seal kit
1. Remove:
Brake caliper dust seal 1
Brake caliper piston seal 2
NOTE:
Remove the brake caliper piston seals and
brake caliper dust seals by pushing them with
a finger.
CAUTION:
Never attempt to pry out brake caliper pis-
ton seals and brake caliper dust seals.
WARNING
Replace the brake caliper piston seals and
brake caliper dust seals whenever a brake
caliper is disassembled.
INSPECTION
Brake master cylinder
1. Inspect:
Brake master cylinder inner surface a
Wear/scratches → Replace brake mas-
ter cylinder assembly.
Stains → Clean.
WARNING
Use only new brake fluid.
2. Inspect:
Diaphragm 1
Crack/damage → Replace.
3. Inspect:
Brake master cylinder piston 1
Brake master cylinder cup 2
Wear/damage/score marks → Replace
brake master cylinder kit.
FRONT BRAKE (TT-R125LW/TT-R125LWE)

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CHASFRONT BRAKE (TT-R125LW/TT-R125LWE)
ASSEMBLY AND INSTALLATION
WARNING
All internal parts should be cleaned in
new brake fluid only.
Internal parts should be lubricated with
brake fluid when installed.
Replace the brake caliper piston seals
and brake caliper dust seals whenever a
brake caliper is disassembled.
Brake caliper piston
1. Clean:
Brake caliper
Brake caliper piston seal
Brake caliper dust seal
Brake caliper piston
Clean them with brake fluid.
2. Install:
Brake caliper piston seal 1
Brake caliper dust seal 2
WARNING
Always use new brake caliper piston seals
and brake caliper dust seals.
NOTE:
Fit the brake caliper piston seals and brake
caliper dust seals onto the slot on brake cali-
per correctly.
New
New
3. Install:
Brake caliper piston 1
NOTE:
Apply the brake fluid on the brake caliper pis-
ton wall.
CAUTION:
Install the brake caliper piston with its
shallow depressed side a facing the
brake caliper.
Never force to insert.
Brake caliper
1. Install:
Sleeve boot 1.
On brake caliper bracket 2.

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CHASFRONT BRAKE (TT-R125LW/TT-R125LWE)
2. Install:
Pin boot 1
On brake caliper 2.
NOTE:
Apply the lithium soap base grease on the pin
boot inner surface.
3. Install:
Brake caliper bracket 1
Bolt (brake caliper bracket) 2
Brake pad 3
T R..30 Nm (3.0 m · kg, 22 ft · lb)
4. Install:
Brake caliper 1
NOTE:
Apply the lithium soap base grease on the
guide pin 2.
Install the brake caliper into the guide pin
and turn it clockwise.
5. Install:
Brake caliper support bolt 1
NOTE:
Apply the lithium soap base grease on the
brake caliper support bolt.
T R..22 Nm (2.2 m · kg, 16 ft · lb)
Brake master cylinder kit
1. Clean:
Brake master cylinder
Brake master cylinder kit
Clean them with brake fluid.

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CHASFRONT BRAKE (TT-R125LW/TT-R125LWE)
2. Install:
Brake master cylinder cup (primary) 1
Brake master cylinder cup (secondary) 2
On brake master cylinder piston 3.
NOTE:
Apply the brake fluid on the brake master cyl-
inder cup.
WARNING
After installing, cylinder cup should be
installed as shown direction. Wrong instal-
lation cause improper brake performance.
3. Install:
Spring 1
On brake master cylinder piston 2.
NOTE:
Install the spring at the smaller diameter side.
4. Install:
Brake master cylinder kit 1
Washer 2
Circlip 3
Brake master cylinder boot 4
On brake master cylinder 5
NOTE:
Apply the brake fluid on the brake master
cylinder kit.
When installing the circlip, use a long nose
circlip pliers.

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CHAS
Brake fluid
1. Fill:
Brake fluid
Until the fluid level reaches “LOWER”
level line a.
WARNING
Use only the designated quality brake
fluid:
otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.
Refill with the same type of brake fluid;
mixing fluids may result in a harmful chem-
ical reaction and lead to poor performance.
Be careful that water does not enter the
brake master cylinder when refilling.
Water will significantly lower the boiling
point of the fluid and may result in vapor
lock.
CAUTION:
Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled fluid
immediately.
Recommended brake fluid:
DOT #4
2. Air bleed:
Brake system
Refer to “BRAKE SYSTEM AIR
BLEEDING” section in the CHAPTER
3.
3. Inspect:
Brake fluid level
Fluid at lower level → Fill up.
Refer to “BRAKE FLUID LEVEL
INSPECTION” section in the CHAP-
TER 3.
FRONT BRAKE (TT-R125LW/TT-R125LWE)