2007 YAMAHA TTR125 relay

SPEC
2 - 17
MAINTENANCE SPECIFICATIONS
NOTE:
1. First, tighten the ring nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the ring nut
wrench and turn the steering right and left a few times; then loosen the ring nut one turn.
2. Retighten the ring nut 20 Nm (2.0 m • kg, 14 ft • lb). Part to be tightened Thread size Q’tyTightening torque
Nm m•kg ft•lb
Upper bracket and inner tube M8 × 1.25 2 25 2.5 18
Lower bracket and inner tube M10 × 1.25 2 60 6.0 43
Upper bracket and steering stem M22 × 1.0 1 110 11.0 80
Handlebar upper holder and upper bracket M8 × 1.25 4 23 2.3 17
Steering stem and ring nut M25 × 1.0 1 Refer to NOTE.
Front fork and cap bolt M25 × 1.0 2 23 2.3 17
Front fork and damper rod M10 × 1.0 2 23 2.3 17
Front fork and brake cable holder M6 × 1.0 1 7 0.7 5.1
Number plate M6 × 1.0 1 7 0.7 5.1
Starter knob M11 × 1.25 1 1 0.1 0.7
Starter knob stay M6 × 1.0 2 10 1.0 7.2
Grip cap upper and lower M5 × 0.8 2 4 0.4 2.9
Throttle cable cap M4 × 0.7 2 2 0.2 1.4
Brake lever mounting (bolt) M6 × 1.0 1 3 0.3 2.2
Brake lever mounting (nut) M6 × 1.0 1 4 0.4 2.9
Brake lever holder M5 × 0.8 2 4 0.4 2.9
Clutch lever mounting (bolt) M6 × 1.0 1 7 0.7 5.1
Clutch lever mounting (nut) M6 × 1.0 1 7 0.7 5.1
Clutch lever holder M5 × 0.8 2 4 0.4 2.9
Front wheel axle and axle nut M12 × 1.25 1 45 4.5 32
Front brake camshaft lever and camshaft M6 × 1.0 1 10 1.0 7.2
Rear wheel axle and axle nut M12 × 1.25 1 60 6.0 43
Rear brake camshaft lever and camshaft M6 × 1.0 1 10 1.0 7.2
Brake pedal mounting M10 × 1.25 1 30 3.0 22
Brake pedal position locknut M6 × 1.0 1 7 0.7 5.1
Front wheel nipple (spoke)—36 2 0.2 1.4
Rear wheel nipple (spoke)—36 3 0.3 2.2
Driven sprocket (nut) M10 × 1.25 4 43 4.3 31
Driven sprocket (stud) M10 × 1.25 4 30 3.0 22
Sidestand mounting (nut) M10 × 1.25 1 44 4.4 32
Engine mounting:
Engine bracket (front) and frame M8 × 1.25 2 40 4.0 29
Engine bracket (front) and engine M8 × 1.25 2 40 4.0 29
Engine bracket (upper) and frame M8 × 1.25 2 40 4.0 29
Engine bracket (upper) and cylinder head M8 × 1.25 1 40 4.0 29
Engine and frame (rear) M8 × 1.25 2 40 4.0 29
Pivot shaft and nut M12 × 1.25 1 53 5.3 38
Relay arm and swingarm M12 × 1.25 1 70 7.0 50

SPEC
2 - 18
MAINTENANCE SPECIFICATIONS
NOTE:
- marked portion shall be checked for torque tightening after break-in o\
r before each ride.Part to be tightened Thread size Q
’ty Tightening torque
Nm m •kg ft •lb
Relay arm and connecting arm M10 × 1.25 1 35 3.5 25
Connecting arm and frame M10 × 1.25 1 35 3.5 25
Rear shock absorber assembly and frame M12 × 1.25 1 53 5.3 38
Rear shock absorber assembly and relay arm M10 × 1.25 1 35 3.5 25
Rear shock absorber and locknut (preload) M46 × 1.5 1 42 4.2 30
Drive chain tensioner (upper) M8 × 1.25 1 23 2.3 17
Drive chain tensioner (lower) M6 × 1.0 1 7 0.7 5.1
Drive chain support and swingarm M6 × 1.0 2 7 0.7 5.1
Drive chain guide and swingarm M6 × 1.0 2 7 0.7 5.1
Drive chain guard mounting M6 × 1.0 2 7 0.7 5.1
Fuel tank mounting M6 × 1.0 2 10 1.0 7.2
Fuel tank and fuel cock M6 × 1.0 2 7 0.7 5.1
Fuel tank and fuel tank bracket M6 × 1.0 4 7 0.7 5.1
Front fender mounting M6 × 1.0 4 7 0.7 5.1
Rear fender mounting M6 × 1.0 4 7 0.7 5.1
Flap guard mounting M6 × 1.0 2 4 0.4 2.9
Left side cover mounting M6 × 1.0 2 7 0.7 5.1
Seat mounting M6 × 1.0 2 7 0.7 5.1
Battery cover and battery box (TT-R125E) M6 × 1.0 1 5 0.5 3.6
Battery box and frame (TT-R125E) M6 × 1.0 1 7 0.7 5.1

SPEC
2 - 22
MAINTENANCE SPECIFICATIONS
NOTE:
- marked portion shall be checked for torque tightening after break-in o\
r before each ride.Part to be tightened Thread size Q
’ty Tightening torque
Nm m •kg ft •lb
Bead stopper M8 × 1.25 1 3 0.3 2.2
Driven sprocket (nut) M10 × 1.25 4 43 4.3 31
Driven sprocket (stud) M10 × 1.25 4 30 3.0 22
Sidestand mounting (nut) M10 × 1.25 1 44 4.4 32
Engine mounting: Engine bracket (front) and frame M8 × 1.25 2 40 4.0 29
Engine bracket (front) and engine M8 × 1.25 2 40 4.0 29
Engine bracket (upper) and frame M8 × 1.25 2 40 4.0 29
Engine bracket (upper) and cylinder head M8 × 1.25 1 40 4.0 29
Engine and frame (rear) M8 × 1.25 2 40 4.0 29
Pivot shaft and nut M12 × 1.25 1 53 5.3 38
Relay arm and swingarm (TT-R125LW) M12 × 1.25 1 70 7.0 50
(TT-R125LWE) M12 × 1.25 1 53 5.3 38
Relay arm and connecting arm M10 × 1.25 1 35 3.5 25
Connecting arm and frame M10 × 1.25 1 35 3.5 25
Rear shock absorber assembly and frame M12 × 1.25 1 53 5.3 38
Rear shock absorber assembly and relay arm M10 × 1.25 1 35 3.5 25
Rear shock absorber and locknut (preload) M46 × 1.5 1 42 4.2 30
Drive chain tensioner (upper) M8 × 1.25 1 23 2.3 17
Drive chain tensioner (lower) M6 × 1.0 1 7 0.7 5.1
Drive chain support and swingarm M6 × 1.0 2 7 0.7 5.1
Drive chain guide and swingarm M6 × 1.0 2 7 0.7 5.1
Drive chain guard mounting M6 × 1.0 2 7 0.7 5.1
Fuel tank mounting M6 × 1.0 2 10 1.0 7.2
Fuel tank and fuel cock M6 × 1.0 2 7 0.7 5.1
Fuel tank and fuel tank bracket M6 × 1.0 4 7 0.7 5.1
Front fender mounting M6 × 1.0 4 7 0.7 5.1
Rear fender mounting M6 × 1.0 4 7 0.7 5.1
Flap guard mounting M6 × 1.0 2 4 0.4 2.9
Left side cover mounting M6 × 1.0 2 7 0.7 5.1
Seat mounting M6 × 1.0 2 7 0.7 5.1
Battery cover and battery box (TT-R125LWE) M6 × 1.0 1 5 0.5 3.6
Battery box and frame (TT-R125LWE) M6 × 1.0 1 7 0.7 5.1

SPEC
2 - 25
MAINTENANCE SPECIFICATIONS
Starter relay:
Model/manufacturer MS5F-751/JIDECO ----
Amperage rating 180 A ----
Coil winding resistance 4.2 ~ 4.6 Ω at 20 ˚C (68 ˚F) ----
Starting circuit cut-off relay:
Model/manufacturer ACM33221/MATSUSHITA ----
Coil winding resistance 75.69 ~ 92.51 Ω at 20 ˚C (68 ˚F) ----
Fuse (amperage × quantity):
Main fuse 10 A × 1 ----
Reserve fuse 10 A × 1 ----
Part to be tightened Thread size Q’tyTightening torque
Nm m•kg ft•lb
Pickup coil M6 × 1.0 2 10 1.0 7.2
Neutral switch M10 × 1.25 1 18 1.8 13
Stator M6 × 1.0 3 10 1.0 7.2
Rotor M12 × 1.25 1 80 8.0 58
Ignition coil M6 × 1.0 2 7 0.7 5.1
Starter motor M6 × 1.0 2 10 1.0 7.2 Item Standard Limit

6 - B - V
2 - 30
SPECCABLE ROUTING DIAGRAM
TT-R125E/TT-R125LWE
1Ground lead
2 Primary coil lead
3 Clamp
4 Wire harness
5 Starter relay lead
6 Rectifier/regulator lead
7 CDI magneto lead
8 Air vent hose
9 Neutral switch lead
0 Rear shock absorber assembly
sub-tank hose (TT-R125LWE
only)
A Starting circuit cut-off relay lead
B CDI unit lead
C Corrugated tube D
Brake hose holder (Brake cable
holder for the TT-R125E)
E Brake hose (Brake cable for the
TT-R125E)
F Cable guide
G Main switch lead
H Engine stop switch lead
I Clutch switch lead
J Start switch lead
K CDI unit band
L CDI unit
M Connector cover
N Rubber cover
O Starter cable
P Throttle cable Q
Rectifier/regulator
Å Fasten the primary coil lead and
ground lead.
ı Fasten the wire harness at its
tape.
Ç Fasten the wire harness and
CDI magneto lead in front of the
rear shock absorber assembly
bracket at the protecting tube
for the CDI magneto lead.
%
$ $
!
#
"
"
$
$
%
44
2%
/
0




 -
. 1

&
%
$ Ü
Ý
Þ
ß
!"
!!
Á À!#
.
Û Ù
F
E G
H
I
J K
L
D
A
B
3
C
0
123
33 3
3
3
3
4
5
666666
7
8
9
A
B C
S
R
Q P
O
N
M
LK J
I
H
GGGGGG
F
E
D
B
A
C
30~
354
m m
( 1 .
1 8~ 1
.3
8
in )

8 - B - V
2 - 31
SPECCABLE ROUTING DIAGRAM
ÎAfter fastening the starter relay
lead, pass it on the left of the
chassis.
‰ Fasten the CDI magneto lead
and starter relay lead.
Ï Fasten the wire harness.
Ì Pass the rectifier/regulator lead
between the frame and air filter
case.
Ó Do not allow the CDI magneto
lead to slacken except between
the two plastic locking ties.
È Fasten the CDI magneto lead
over the engine bracket (rear).
Ô Fasten the CDI magneto lead. 
Pass the air vent hoses between
the engine and swingarm.
Ò Fit the neutral switch lead into
the groove in the crankcase
cover.
˜ Pass the starting circuit cut-off
relay lead under the frame and
at the right of the chassis.
ˆ Fasten the rear shock absorber
assembly sub-tank.
(TT-R125LWE only)
Ø Pass the CDI unit lead on the
outside of the main switch lead,
engine stop switch lead, clutch
switch lead and start switch
lead. ∏
After fastening the start switch
lead, clutch switch lead, engine
stop switch lead and main
switch lead, push their corru-
gated tube against the CDI unit
coupler.
ΠFasten the brake hose between
the paint marks.
 Pass the brake hose (brake
cable for the TT-R125E)
through the cable guide.
Í Fit the CDI unit band over the
CDI unit bracket till it stops.
Ê Fasten the brake cable.
E
D D
A
C
D-D
AB
AA
Û
Á
"
"
%
44
2%
/0




 -
. 1

&
%
$ Ü
Ý
Þ
ß
!#
.
Û Ù
F
E G
H
I
J K
L
D
A
B
3
C
0
123
33 3
3
3
3
4
5
666666
7
8
9
A
B C
S
R
Q P
O
N
M
LK J
I
H
GGGGGG
F
E
D
B
A
C
30~ 3
54 m
m
( 1
.
1 8~
1.
3
8
in )

2 - 32
SPECCABLE ROUTING DIAGRAM
ËAfter connecting the main
switch coupler, engine stop
switch coupler, clutch switch
coupler and start switch cou-
pler, put a connector cover on
the couplers and push them in
at the rubber cover end.
◊Pass the wire harness on the
outside of the main switch cou-
pler.
„Do not allow the primary coil
lead to slacken where it is bare
of the protecting tube.ÙFasten the CDI unit lead and
starting circuit cut-off relay lead
with a plastic locking tie at the
tape holding the main switch
lead, engine stop switch lead,
clutch switch lead, and start
switch lead together.
ÁPosition the starter cable, throt-
tle cable, CDI magneto lead,
wire harness and rear shock
absorber assembly sub-tank
hose (TT-R125LWE only) as
shown.ÛFasten the wire harness, throttle
cable, starter cable, CDI mag-
neto lead and rear shock
absorber assembly sub-tank
hose (TT-R125LWE only) at the
protecting tube for the CDI mag-
neto lead.
Fasten the rectifier/regulator
lead as shown.
Do not allow the CDI magneto
lead to slacken.
Position the plastic locking tie
ends as shown.
AA
AB
AC
E
DD
A
C
AB
"
"
$
$
%
44
2%
/0



 -
.
1
 &
%
$Ü
Ý
Þ
ß!!
Á
s!#
. ÛÙ
F
EGHIJKL
D
A B
3 C
0
1
2
3
3
33
3
3
3 45
6 6
6
6
6
6
7
8
9
A
BC
S
R
QP
O
N
M
LKJI H G G
G
G
G
G
F E D
B A
C
30~354m
m
(1.
18~
1.38
i
n)
À
Y

12 - B - V
2 - 33
SPEC
1Throttle cable
2 Clutch cable
3 Starter cable
4 Fuel tank breather hose
5 Hose guide
6 Clamp
7 Cable guide
8 Starting circuit cut-off relay
9 Spark plug lead
0 Starter motor lead
A Negative battery lead B
Engine oil breather hose
C Positive battery lead
D Overflow hose
E Air vent hose
F Primary coil lead
G Ground lead Å
Tighten the starter choke nut
while taking care not to twist the
starter cable.
ı Pass the clutch cable on the
inside of the throttle cable and
starter cable.
Ç Pass the starter cable so that it
is not twisted.
Î Pass the fuel tank breather
hose through the hose guide.
#!",%2/54).'$)!'2!-