2007 YAMAHA TTR125 brake

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CHAS
2. Pass the brake hose through the cable
guide 1.
3. Install:
Copper washer 1
Joint 2
Brake hose 3
WARNING
Always use a new copper washer.
NOTE:
When turning the joint over the brake hose,
hold the brake hose so that it may not be
twisted.
New
T R..26 Nm (2.6 m · kg, 19 ft · lb)
T R..14 Nm (1.4 m · kg, 10 ft · lb)
4. Install:
Brake hose holder 1
Bolt (brake hose holder) 2
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
FRONT BRAKE (TT-R125LW/TT-R125LWE)

5 - 22
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)

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CHAS
4. Install:
Diaphragm
Brake master cylinder cap 1
Screw (brake master cylinder cap) 2
CAUTION:
After installation, while pulling in the lever,
check whether there is any brake fluid leak-
ing where the union bolts are installed
respectively at the brake master cylinder
and brake caliper.
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
FRONT BRAKE (TT-R125LW/TT-R125LWE)

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

5 - 25
CHAS
Extent of removal Order Part name Q’ty Remarks
11 Nut (wheel sprocket) 4
12 Wheel sprocket 1
13 Oil seal 1
14 Wheel bearing 2 Refer to “REMOVAL POINTS”.
15 Spacer 1
16 Brake shoe 2
17 Spring 2
18 Brake camshaft lever 1
19 Wear indicator plate 1
20 Brake camshaft 1
21 Brake shoe plate 1
3
2
REAR WHEEL AND REAR BRAKE

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CHASREAR WHEEL AND REAR BRAKE
REMOVAL POINTS
EC523101
Rear wheel
1. Remove:
Wheel 1
NOTE:
Push the wheel forward and remove the drive
chain 2.
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
(wheel sprocket side) 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.
Wheel axle bending limit:
0.5 mm (0.020 in)

5 - 27
CHASREAR WHEEL AND REAR BRAKE
NOTE:
The bending value is shown by one half of the
dial gauge reading.
WARNING
Do not attempt to straighten a bent axle.
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
4.0 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)

5 - 28
CHASREAR WHEEL AND REAR BRAKE
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).
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.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)