This document is an Owner's Service Manual for Yamaha TT-R125(S), TT-R125E(S), TT-R125LW(S), and TT-R125LWE(S) models, published in March 2003. It provides comprehensive information on operation, inspection, basic maintenance, and tuning.
Function Description:
The Yamaha TT-R125 series are off-road motorcycles designed for young operators under adult instruction and supervision. They are not suitable for on-road use and are designed to carry only the operator, with a rider weight limit of 68 kg (150 lb) for TT-R125/TT-R125E models. The motorcycles feature a constant-mesh 5-speed transmission with ideally spaced gear ratios for various riding conditions, including starting, hill climbing, and acceleration. The TT-R125E and TT-R125LWE models are equipped with an electric starting system in addition to a kickstarter.
Important Technical Specifications:
General Specifications (TT-R125/TT-R125E):
- Engine Type: Air-cooled 4-stroke, SOHC
- Cylinder Arrangement: Single cylinder, forward inclined
- Displacement: 124 cm³ (7.57 cu.in)
- Bore × Stroke: 54.0 × 54.0 mm (2.126 × 2.126 in)
- Compression Ratio: 10.0:1
- Starting System: Kickstarter (TT-R125), Kick and electric starter (TT-R125E)
- Lubrication System: Wet sump
- Fuel Tank Capacity: Total: 6.6 L (1.45 Imp gal, 1.74 US gal), Reserve: 1.9 L (0.42 Imp gal, 0.5 US gal)
- Recommended Fuel: Unleaded gasoline (USA, AUS, NZ, CDN, EUROPE), Regular gasoline (ZA)
- Carburetor Type/Manufacturer: VM20SS / MIKUNI
- Spark Plug Type/Manufacturer: CR7HSA/U22FSR-U / NGK/DENSO
- Spark Plug Gap: 0.6 ~ 0.7 mm (0.02 ~ 0.03 in)
- Clutch Type: Wet, multiple-disc
- Transmission Type: Constant mesh, 5-speed, Left foot operation
- Frame Type: Diamond
- Caster Angle: 28.7°
- Trail: 93 mm (3.66 in)
- Tire Type: With tube
- Tire Size (Front): 70/100-17 40M
- Tire Size (Rear): 90/100-14 49M
- Tire Pressure (Front and Rear): 100 kPa (1.00 kgf/cm², 15 psi)
- Front Brake Type: Drum brake
- Rear Brake Type: Drum brake
- Front Suspension: Telescopic fork
- Rear Suspension: Swingarm (link type monocross suspension)
- Front Wheel Travel: 180 mm (7.09 in)
- Rear Wheel Travel: 160 mm (6.30 in)
- Ignition System: CDI
- Battery (TT-R125E): GT4L-BS, 12 V/3.2 AH, Specific gravity: 1.320
General Specifications (TT-R125LW/TT-R125LWE):
- Overall Length: 1,885 mm (74.2 in) (USA, AUS, NZ, ZA, EUROPE), 1,890 mm (74.4 in) (CDN)
- Overall Width: 795 mm (31.3 in)
- Overall Height: 1,085 mm (42.7 in)
- Seat Height: 805 mm (31.7 in)
- Wheelbase: 1,270 mm (50.0 in)
- Minimum Ground Clearance: 295 mm (11.6 in)
- Basic Weight (with oil and full fuel tank): 84 kg (185 lb) (TT-R125LW), 90 kg (198.4 lb) (TT-R125LWE)
- Front Rim Size/Material: 19 × 1.40/Steel
- Rear Rim Size/Material: 16 × 1.60/Steel
- Front Disc Brake: Disc outside dia. × Thickness: 220 × 3.0 mm (8.66 × 0.12 in)
- Brake Fluid Type: DOT #4
Usage Features:
- Starting: For cold engines, activate the starter knob (choke) fully. For TT-R125E/TT-R125LWE models, the engine can be started in neutral or with the clutch disengaged in any gear. It is recommended to shift into neutral before starting.
- Fuel Cock: Features "ON", "OFF", and "RES" (reserve) positions. Always set to "OFF" when the engine is not running and "ON" for normal riding. Use "RES" if fuel runs out and refuel promptly.
- Sidestand: Designed for supporting the machine when standing or transporting. Never apply additional force to it.
- Break-in: Crucial for new machines or after part replacement. Avoid full-throttle operation for the first 5 hours. After the initial run, check for loose parts, oil leakage, and other issues. Perform a full inspection and adjustment, especially for slack cables, drive chain, and loose spokes.
- Safety: Always wear a helmet and suitable protective clothing. Do not touch moving or heated parts. Perform pre-operation checks before each ride. This machine is for off-road use only and not for public roads.
Maintenance Features:
- Regular Inspection: The manual provides a detailed maintenance schedule, including initial checks (10 hours/1 month) and periodic checks (60 hours/6 months, 120 hours/12 months). Items requiring special tools or skills are marked for dealer service.
- Fuel Line: Check for cracks or damage, replace if necessary.
- Spark Plug: Inspect condition, clean, regap, or replace.
- Valves: Check and adjust valve clearance.
- Air Filter: Clean or replace the element. Never run the engine without it to prevent damage.
- Carburetor: Check and adjust engine idling speed and starter operation.
- Exhaust Systems: Check for leakage, retighten, and replace gaskets if necessary.
- Engine Oil: Check level and for leakage. Change oil periodically (warm engine before draining). Use recommended oil types (Yamalube 4 or SAE 10W-30/20W-40 SE motor oil, API "SE" or higher grade). Do not use chemical additives or oils labeled "ENERGY CONSERVING II" or higher.
- Clutch: Check operation, adjust or replace cable.
- Brakes: Check operation, adjust lever/pedal free play, and fluid level (for disc brakes). Bleed the system if disassembled or if fluid is low. Replace brake shoes if worn.
- Wheels: Check balance, runout, spoke tightness, and for damage. Tighten spokes and rebalance if necessary.
- Tires: Check tread depth, damage, and air pressure. Correct pressure if necessary.
- Wheel Bearings: Check for looseness or damage, replace if necessary.
- Swingarm: Check pivoting point for play, lubricate with molybdenum disulfide grease.
- Drive Chain: Check slack and alignment, clean, and lubricate. Replace sprockets and chain as a set if excessive wear is found.
- Steering Bearings: Check for play and roughness, lubricate with lithium soap base grease every 120 hours.
- Front Fork: Inspect for smooth action and oil leakage. Adjust spring preload (TT-R125LWE).
- Rear Shock Absorber: Inspect for smooth action, oil/gas leakage, and spring damage. Adjust spring preload and rebound damping force (TT-R125LWE).
- Battery (TT-R125E/TT-R125LWE): Check terminals for looseness and corrosion. Inspect charge state by measuring voltage. Do not quick charge or overcharge.
- Fuses (TT-R125E/TT-R125LWE): Check continuity and replace if blown. Use only specified amperage.
- Lubrication: Lubricate all control cables, brake/clutch lever pivots, shift pedal pivot, footrest pivot, throttle-to-handlebar contact, and drive chain.
- Storage: For long-term storage (60+ days), drain fuel, lubricate the cylinder, remove and clean the drive chain, lubricate control cables, block up the frame, cover the exhaust pipe, and coat exposed metal surfaces with light oil.
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