2007 YAMAHA TTR125 brake

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CHASFRONT BRAKE (TT-R125LW/TT-R125LWE)
BRAKE CALIPER AND BRAKE MASTER CYLINDER DISASSEMBLY
Extent of removal:1 Brake caliper disassembly2 Brake master cylinder disassembly
Extent of removal Order Part name Q’ty Remarks
Preparation for removalBRAKE CALIPER AND BRAKE
MASTER CYLINDER DISAS-
SEMBLY
Hold the machine by placing the
suitable stand under the engine.
WARNINGSupport the machine securely so there is no
danger of it falling over.
1Brake pad 2
2Brake caliper bracket 1
3Brake caliper piston 2
Refer to “REMOVAL POINTS”. 4Brake caliper dust seal 2
5Brake caliper piston seal 2
6Pin boot 1
7Sleeve boot 1
8Brake master cylinder cap 1
9Diaphragm 1
0Brake master cylinder boot 1
ACirclip 1
BWasher 1
CBrake master cylinder kit 1
2
1

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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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CHAS
Brake caliper
1. Inspect:
Brake caliper cylinder inner surface a
Wear/score marks → Replace brake
caliper assembly.
2. Inspect:
Brake caliper piston 1
Wear/score marks → Replace brake
caliper piston assembly.
WARNING
Replace the brake caliper piston seals and
brake caliper dust seals 2 whenever a
brake caliper is disassembled.
3. Inspect:
Brake caliper bracket 1
Cracks/damage → Replace the brake
caliper assembly.
Guide pin 2
Rust/damage → Replace the brake cal-
iper assembly.
Sleeve boot 3
Pin boot 4
Wear/damage → Replace.
4. Inspect:
Brake caliper support bolt 1
Scorches/rust/damage → Replace.
Brake hose
1. Inspect:
Brake hose 1
Crack/damage → Replace.
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 master cylinder
1. Install:
Brake master cylinder 1
Brake master cylinder bracket 2
Bolt (brake master cylinder bracket) 3
NOTE:
Install the brake master cylinder bracket so
that the arrow mark a face upward.
First tighten the bolts on the upper side of the
brake master cylinder bracket, and then
tighten the bolts on the lower side.
ÅTT-R125LW
ıTT-R125LWE
2. Install:
Brake lever 1
Spring 2
Bolt (brake lever) 3
Nut (brake lever) 4
NOTE:
Apply the lithium soap base grease on the
bolt and brake lever sliding surface.
Apply the molybdenum disulfide grease on
the tip of the adjuster bolt.
T R..9 Nm (0.9 m · kg, 6.5 ft · lb)
Å
U P2 1
3 3
a ı
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
Brake hose
1. Install:
Copper washer 1
Brake hose 2
Union bolt 3
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose so that its pipe por-
tion a directs as show and lightly touches
the projection b on the brake caliper.
New
T R..26 Nm (2.6 m · kg, 19 ft · lb)
FRONT BRAKE (TT-R125LW/TT-R125LWE)