2007 YAMAHA TTR125 brake

5 - 4
CHASFRONT WHEEL AND FRONT BRAKE (TT-R125/TT-R125E)
Drum brake
1. Inspect:
Brake shoe lining surface
Glazed areas → Polish.
Use coarse sand paper.
NOTE:
After polishing, wipe the polished particles with
a cloth.
2. Measure:
Brake shoe lining thickness a
Out of specification → Replace.
NOTE:
Replace the brake shoes and springs as a set
if either is worn to the limit.
Brake shoe lining thickness:
Standard
40 mm
(0.16 in)2.0 mm
(0.08 in)
3. Measure:
Brake drum inside diameter a
Out of specification → Replace.
Brake drum inside diameter:
Standard
110 mm
(4.33 in)111 mm
(4.37 in)
4. Inspect:
Brake drum inner surface
Oil/scratches → Remove.
OilUse a rag soaked in lac-
quer thinner or a solvent.
ScratchesUse a emery cloth (lightly
and evenly polishing).

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 - 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 - 12
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)