Yamaha TT-R125EY Service Manual

TT-R125EYTT-R125LEY1B2-F8197-14SERVICE MANUALLIT-11626-22-26

MEMO

4-7ENGCARBURETOR12Coasting enricher1. Inspect:• Diaphragm 1• Spring 2• Cover 3Tears (diaphragm)/damage → Replace.EC464600Float1. Inspect:• Float 1Dama

4-8ENG213421321421abCARBURETOR2. Install:• Jet needle 1• Spring 2• Holder 3• Throttle valve 4ASSEMBLY AND INSTALLATIONCarburetor1. Install:• Diaphragm

4-9ENGCARBURETOR125. Install:• Throttle shaft assembly• Plain washer (resin) 1• Valve lever 2• Apply the fluorchemical grease on thebearings.• Make su

4-10ENG2122221CARBURETORCarburetor installation1. Install:• Spring 1• Starter plunger 2• On starter cable 39. Install:• Gasket• Float chamber 1• Screw

4-11ENG1212CARBURETOR4. Install:• Throttle ca ble cover 1• Screw (throttle cable cover) 25. Tighten• Screw (carburetor joint) 1• Screw (air carburetor

4-12ENGCYLINDER HEADCYLINDER HEADCYLINDER HEAD SIDE COVER AND TAPPET COVERExtent of removal: 1 Cylinder head side cover and tappet cover removalCYLIND

4-13ENGCYLINDER HEADExtent of removal: 1 Cylinder head removalCYLINDER HEAD REMOVAL1 Bolt (camshaft sprocket) 12 Bolt (timing chain tensioner cap) 13

4-14ENGCYLINDER HEADREMOVAL POINTSCylinder head1. Align:• I mark(with stationary pointer)Checking steps:• Turn the crankshaft counterclockwise withwre

4-15ENGCYLINDER HEAD4. Remove:• Bolt (camshaft sprocket) 1• Camshaft sprocket 2Attach a wire a to the timing chain to prevent itfrom falling into the

4-16ENGCYLINDER HEAD• If the warpage is out of specification,resurface the cylinder head.• Place #400 ~ 600 grit wet sandpaper on thesurface plate, an

INDEXGENINFOSPECINSPADJCHASGENERAL INFORMATIONSPECIFICATIONSREGULAR INSPECTION ANDADJUSTMENTSENGINECHASSISELECELECTRICAL–+ENG123456

4-17ENGCYLINDER HEAD3. Install:• Timing chain• Camshaft sprocketInstallation steps:• Turn the crankshaft counterclockwise witha wrench.• Align the I m

4-18ENGCYLINDER HEAD5. Install:• Timing chain tensionerInstallation steps:• While pressing the tensioner rod lightly withfingers, use a thin screwdriv

4-19ENGCYLINDER HEAD9. Check:• Valve clearanceOut of specification → Adjust.Refer to VALVE CLEARANCE INSPEC-TION AND ADJUSTMENT section in theCHAPTER

4-20ENGCAMSHAFT AND ROCKER ARMSCAMSHAFT AND ROCKER ARMSExtent of removal: 1 Camshaft removal 2 Rocker arm removalCAMSHAFT AND ROCKER ARMSREMOVALCylind

4-21ENGCAMSHAFT AND ROCKER ARMSINSPECTIONCamshaft1. Inspect:• Cam lobesPitting/scratches/blue discoloration →Replace.2. Measure:• Cam lobes length a a

4-22ENGCAMSHAFT AND ROCKER ARMSASSEMBLY AND INSTALLATION1. Apply:• Molybdenum disulfide oil(onto the camshaft cam lobe and rockerarm hole)• Engine oil

4-23ENG5. Install:• Camshaft bearing holder 1• Bolt 2CAMSHAFT AND ROCKER ARMS10 Nm (1.0 m · kg, 7.2 ft · lb)LT

4-24ENGVALVES AND VALVE SPRINGSVALVES AND VALVE SPRINGSExtent of removal: 1 Valves and valve springs removalVALVES AND VALVE SPRINGSREMOVALCylinder he

4-25ENGVALVES AND VALVE SPRINGSREMOVAL POINTSValve1. Check:• Valve sealingLeakage at the valve seat → Inspect thevalve face, valve seat and valve seat

4-26ENGVALVES AND VALVE SPRINGS2. Replace:• Valve guideReplacement steps:To ease guide removal, installation and tomaintain correct fit heat the cylin

EC0A0000CONTENTSCHAPTER 1GENERAL INFORMATION MACHINE IDENTIFICATION ... 1-1IMPORTANT INFORMATION ... 1-2CHECKING OF C

4-27ENGVALVES AND VALVE SPRINGS5. Measure:• Runout (valve stem)Out of specification → Replace.3. Inspect:• Valve facePitting/wear → Grind the face.• V

4-28ENG9. Lap:• Valve face• Valve seatAfter refacing the valve seat or replacing thevalve and valve guide, the valve seat and valveface should be lapp

4-29ENGFree length (valve spring):Intake:38.78 mm (1.52 in)<Limit>: 36.84 mm (1.45 in)Exhaust:38.78 mm (1.52 in)<Limit>: 36.84 mm (1.45 in

4-30ENGVALVES AND VALVE SPRINGS3. Measure:• Spring tilt aOut of specification → Replace.2. Measure:• Compressed spring force aOut of specification →

4-31ENGVALVES AND VALVE SPRINGS3. Install:• Valve cotters 1While compressing the valve spring with a valvespring compressor 2, install the valve cotte

4-32ENGCYLINDER AND PISTONCYLINDER AND PISTON1 Exhaust timing chain guide 12 Cylinder/O-ring 1/13 Dowel pin 24 Gasket 15 Piston pin clip 26 Piston pin

4-33ENGCYLINDER AND PISTONDo not use a hammer to drive the piston pinout.Piston ring1. Remove:• Piston ringsSpread the end gaps apart while at the sam

4-34ENGCYLINDER AND PISTON2. Measure:• Piston-to-cylinder clearancePiston-to-cylinder clearancemeasurement steps:1st step:• Measure the cylinder bore

4-35ENGCYLINDER AND PISTONPiston pin1. Inspect:• Piston pinBlue discoloration/grooves → Replace,then inspect the lubrication system.• If out of specif

4-36ENGCYLINDER AND PISTON2. Position:• Piston ring(in cylinder)Insert a ring into the cylinder and push itapproximately 40 mm (1.57 in) into the cyli

CHAPTER 3REGULAR INSPECTIONAND ADJUSTMENTSMAINTENANCE INTERVALS ... 3-1PRE-OPERATION INSPECTIONAND MAINTENANCE ...

4-37ENGCYLINDER AND PISTONASSEMBLY AND INSTALLATIONPiston ring and piston1. Install:• Piston rings(onto the piston)• Be sure to install the 2nd piston

4-38ENGCYLINDER AND PISTON2. Install:• O-ring• Cylinder 1• Exhaust timing chain guide• Install the cylinder with one hand whilecompressing the piston

4-39ENGCLUTCH AND PRIMARY DRIVEN GEAREC490000CLUTCH AND PRIMARY DRIVEN GEAREC498000CLUTCH PLATE AND FRICTION PLATE1 Kickstarter crank 12 Starter motor

4-40ENGEC498100PRIMARY DRIVEN GEARCLUTCH AND PRIMARY DRIVEN GEAR1 Nut (clutch boss) 12 Lock washer 13 Clutch boss 14 Thrust plate 15 Primary driven ge

4-41ENGPUSH LEVERExtent of removal: 1 Push lever removal1 Clutch cable 12 Push lever 13 Spring 14 Circlip 15 Oil seal 1PUSH LEVER REMOVAL1Extent of re

4-42ENGA BCLUTCH AND PRIMARY DRIVEN GEARPrimary drive gear1. Remove:• Nut (primary drive gear) 1• Primary drive gear 2• Place a folded rag or aluminum

4-43ENGCLUTCH AND PRIMARY DRIVEN GEAREC484500Friction plate1. Measure:• Friction plate thicknessOut of specification → Replace frictionplate as a set

4-44ENGCLUTCH AND PRIMARY DRIVEN GEAREC495000ASSEMBLY AND INSTALLATIONPush lever1. Install:• Push lever 1• Apply the lithium soap base grease on the o

4-45ENGA BCLUTCH AND PRIMARY DRIVEN GEAR2. Install:• Lock washer• Nut (clutch boss) 1Use the clutch holding tool 2 to hold the clutchboss.Clutch1. Ins

4-46ENGCLUTCH AND PRIMARY DRIVEN GEAR7. Install:• Pressure plate 1• Clutch spring 2• Bolt (clutch spring) 3• Align the arrow mark a on the pressure pl

CHAPTER 5CHASSISFRONT WHEEL AND FRONT BRAKE(TT-R125E) ... 5-1FRONT WHEEL(TT-R125LE) ...

4-47ENGCLUTCH AND PRIMARY DRIVEN GEAR9. Adjust:• Push lever positionAdjustment steps:• Loosen the locknut 1.• Turn the push rod 1 2 clockwise orcount

4-48ENGOIL PUMPOIL PUMP1 Rotary filter 12 Oil pump drive gear 13 Oil pump assembly 14 Gasket 15 Oil strainer 1Extent of removal: 1 Oil pump removalOIL

4-49ENGOIL PUMP DISASSEMBLYOIL PUMP1 Circlip 12 Oil pump driven gear 13 Conical spring washer 14 Circlip 15 Washer 16 Oil pump cover 17 Pin 28 Oil pum

4-50ENGOIL PUMP2. Measure:• Tip clearance A(between the inner rotor 1 and the outerrotor 2)• Side clearance B(between the outer rotor 2 and the oilpu

4-51ENGOIL PUMPASSEMBLY AND INSTALLATIONOil pump1. Install:• Oil pump housing 1• Outer rotor 2• Inner rotor 3• Pin 4• Oil pump shaft 5• Pin 6• Oil pum

4-52ENGKICK AXLE AND SHIFT SHAFTKICK AXLE AND SHIFT SHAFTKICK AXLE AND SHIFT SHAFTExtent of removal: 1 Kick axle removal 2 Shift shaft removal1 Kick a

4-53ENG11a32KICK AXLE AND SHIFT SHAFTSegment1. Remove:• Screw (segment)• Segment 1Loosen the screw using the T30 bit.REMOVAL POINTSKick axle1. Remove:

4-54ENG21KICK AXLE AND SHIFT SHAFTEC4C5000ASSEMBLY AND INSTALLATIONSegment1. Install:• Segment 1• Screw (segment) 2• Align the notch a on the segment

4-55ENG31224ab512EbacKICK AXLE AND SHIFT SHAFT3. Install:• Kick axle assembly 1• Apply the engine oil on the kick axle.• Slide the kick axle assembly

4-56ENGKICK AXLE AND SHIFT SHAFTKick idle gear1. Install:• Washer 1• Kick idle gear 2• Washer 3• Circlip 4• Apply the engine oil on the kick idle gear

1-1GENINFOMACHINE IDENTIFICATIONEC124000MODEL LABELThe model label 1 is affixed to the frame underthe rider's seat. This information will be need

4-57ENGCDI MAGNETO AND STARTER CLUTCHCDI MAGNETO AND STARTER CLUTCH1 CDI magneto lead 12 Neutral switch lead 13 Left crankcase cover 14 Nut (rotor) 15

4-58ENGCDI MAGNETO AND STARTER CLUTCHEC4L4200Woodruff key1. Inspect:• Woodruff key 1Damage → Replace.REMOVAL POINTSRotor1. Remove:• Nut (rotor) 1• Pla

4-59ENG12AB4123ECDI MAGNETO AND STARTER CLUTCH3. Check:• Starter clutch operation• Install the starter clutch drive gear 1 ontothe starter clutch 2 an

4-60ENG213E12baCDI MAGNETO AND STARTER CLUTCH5. Install:• Starter wheel gear 1• Woodruff key 2• Rotor 3• Clean the tapered portion of the crankshaftan

4-61ENGCDI MAGNETO AND STARTER CLUTCH7. Install:• Crankcase cover (left)8. Connect:• Neutral switch lead 1Pass the neutral switch lead into the crankc

4-62ENGENGINE REMOVALENGINE REMOVALENGINE REMOVALHold the machine by placing thesuitable stand under the frame.Seat, fuel tank and side coversCarburet

4-63ENGENGINE REMOVALRefer to REMOVAL POINTS1 Drive sprocket cover 12 Bolt (drive sprocket) 23 Drive sprocket holder 14 Drive sprocket 15 Shift pedal

4-64ENGENGINE REMOVALREMOVAL POINTSDrive sprocket1. Remove:• Bolt (drive sprocket)• Drive sprocket holder 1• Drive sprocket 2• Drive chain 3Remove the

4-65ENGENGINE REMOVAL2. Install:• Drive sprocket holder 1• Bolt (drive sprocket)• Apply the lithium soap base grease on thethread of the engine mounti

4-66ENGCRANKCASE, CRANKSHAFT AND BALANCERCRANKCASE, CRANKSHAFT AND BALANCERCRANKCASE, CRANKSHAFT ANDBALANCER REMOVALEnginePistonPrimary drive gearKick

1-2GENINFOIMPORTANT INFORMATION4. During the machine disassembly, clean allparts and place them in trays in the order ofdisassembly. This will speed u

4-67ENGCRANKCASE, CRANKSHAFT AND BALANCER1 Intake timing chain guide 12 Timing chain 13 Bolt [45 mm (1.8 in)] 74 Bolt [55 mm (2.2 in)] 15 Bolt [30 mm

4-68ENGCRANKCASE, CRANKSHAFT AND BALANCER2. Remove:• Right crankcase 1Use the crankcase separating tool 2.REMOVAL POINTSCrankcase1. Remove:• Bolt (cra

4-69ENGCRANKCASE, CRANKSHAFT AND BALANCERBearing1. Remove:• Bearing 1• Remove the bearing from the crankcase bypressing its inner race as shown in.• D

4-70ENGCRANKCASE, CRANKSHAFT AND BALANCERCrankcase1. Inspect:• Contacting surface aScratches → Replace.• Engine mounting boss b, crankcaseCracks/damag

4-71ENGCRANKCASE, CRANKSHAFT AND BALANCERA BA For USA and CDNB Except for USA and CDN• Hold the connecting rod at top dead centerwith one hand while t

4-72ENGCRANKCASE, CRANKSHAFT AND BALANCER2. Install:• Dowel pin 1• Right crankcaseOn left crankcase.• Fit the right crankcase onto the left crankcase.

4-73ENGCRANKCASE, CRANKSHAFT AND BALANCER4. Check:• Crankshaft and transmission operationUnsmooth operation → Repair.3. Tighten:• Lead guide 1• Clutch

4-74ENGTRANSMISSION, SHIFT CAM AND SHIFT FORKTRANSMISSION, SHIFT CAM AND SHIFT FORK1 Shift fork guide bar 1 (short) 12 Shift fork guide bar 2 (long) 1

4-75ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK2. Check:• Gears movementUnsmooth movement → Repair or replace.REMOVAL POINTSTransmission1. Remove:• Mai

4-76ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK2. Inspect:• Shift cam 1• Shift fork guide bar 2Bend/wear/damage → Replace.EC4H4600Bearing1. Inspect:• Be

1-3GENINFOIMPORTANT INFORMATIONEC132000ALL REPLACEMENT PARTS1. We recommend to use Yamaha genuine partsfor all replacements. Use oil and/or greasereco

4-77ENGTRANSMISSION, SHIFT CAM AND SHIFT FORKTransmission1. Install:• 4th pinion gear (22T) 1• 3rd pinion gear (19T) 2• 2nd pinion gear (18T) 3• 5th p

4-78ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK4. Install:• Push rod 2On main axle.Apply the engine oil on the push rod 2.6. Install:• Main axle• Drive

4-79ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK3. Install:• Shift fork guide bar 1 (short) 1• Shift fork guide bar 2 (long) 2• Apply the engine oil on t

5-1CHASFRONT WHEEL AND FRONT BRAKE (TT-R125E)EC500000CHASSISFRONT WHEEL AND FRONT BRAKE (TT-R125E)Extent of removal: 1 Front wheel removal 2 Wheel bea

5-2CHAS11 Brake shoe 212 Spring 213 Brake camshaft lever 114 Wear indicator plate 115 Brake camshaft 116 Brake shoe plate 1FRONT WHEEL AND FRONT BRAKE

5-3CHASFRONT WHEEL AND FRONT BRAKE (TT-R125E)EC514200Wheel axle1. Measure:• Wheel axle bendsOut of specification → Replace.Use the dial gauge 1.REMOVA

5-4CHASBrake shoe lining thickness:Standard <Limit>4.0 mm 2.0 mm(0.16 in) 0.08 in)Oil Use a rag soaked in lacquerthinner or a solventScratches U

5-5CHAS11aFRONT WHEEL AND FRONT BRAKE (TT-R125E)3. Install:• Wear indicator plate 1When installing the wear indicator plate to thebrake camshaft align

5-6CHASFRONT WHEEL AND FRONT BRAKE (TT-R125E)Front wheel1. Install:• Wheel bearing 1• Spacer 2• Wheel bearing 3• Oil seal 4• Apply the lithium soap ba

5-7CHASFRONT WHEEL AND FRONT BRAKE (TT-R125E)7. Install:• Brake cable holder 15. Install:• Axle nut 16. Install:• Brake cableBrake camshaft lever si

1-4GENINFOCHECKING OF CONNECTION6. Connect:• ConnectorThe two connectors "click" together. 7. Check for continuity with a tester.• If there

5-8CHASFRONT WHEEL (TT-R125LE)FRONT WHEEL (TT-R125LE)Extent of removal: 1 Front wheel removal 2 Wheel bearing removal3 Brake disc removal1 Axle nut 12

5-9CHASFRONT WHEEL (TT-R125LE)EC514200Wheel axle1. Measure:• Wheel axle bendsOut of specification → Replace.Use the dial gauge 1.REMOVAL POINTSEC51320

5-10CHASFRONT WHEEL (TT-R125LE)Disc wear limit:Standard <Limit>3.0 mm 2.5 mm(0.12 in) (0.10 in)2. Measure:• Brake disc thickness aOut of limit

5-11CHASFRONT WHEEL (TT-R125LE)4 Install:• Front wheelInstall the brake disc 1 between the brake pads2 correctly.2. Install:• Brake disc 1• Bolt (b

5-12CHASFRONT BRAKE (TT-R125LE)FRONT BRAKE (TT-R125LE)1 Brake hose holder 22 Union bolt 13 Brake hose 14 Joint 15 Brake caliper support bolt 16 Brake

5-13CHASBRAKE CALIPER AND BRAKE MASTER CYLINDER DISASSEMBLY1 Brake pad 22 Brake caliper bracket 13 Brake caliper piston 24 Brake caliper dust seal 25

5-14CHASFRONT BRAKE (TT-R125LE)Brake caliper piston1. Remove:• Brake caliper pistonUse compressed air and proceed carefully.• Cover piston with rag an

5-15CHASFRONT BRAKE (TT-R125LE)Brake caliper piston seal kit1. Remove:• Brake caliper dust seal 1• Brake caliper piston seal 2Remove the brake caliper

5-16CHASFRONT BRAKE (TT-R125LE)2. Inspect:• Brake caliper piston 1Wear/score marks → Replace brakecaliper piston assembly.Replace the brake caliper pi

5-17CHASFRONT BRAKE (TT-R125LE)• All internal parts should be cleaned in newbrake fluid only.• Internal parts should be lubricated withbrake fluid whe

1-5GENINFOSPECIAL TOOLSSPECIAL TOOLSThe proper special tools are necessary for complete and accurate tune-up and assembly. Using thecorrect special to

5-18CHASFRONT BRAKE (TT-R125LE)5. Install:• Brake caliper support bolt 1Apply the lithium soap base grease on the brakecaliper support bolt.2. Install

5-19CHASFRONT BRAKE (TT-R125LE)3. Install:• Spring 1On brake master cylinder piston 2.Install the spring at the smaller diameter side.2. Install:• Bra

5-20CHASFRONT BRAKE (TT-R125LE)Brake master cylinder1. Install:• Brake master cylinder 1• Brake master cylinder bracket 2• Bolt (brake master cylinder

5-21CHASFRONT BRAKE (TT-R125LE)2. Pass the brake hose through the cableguide 1.Always use a new copper washer.When turning the joint over the brake ho

5-22CHAS...

5-23CHASFRONT BRAKE (TT-R125LE)4. Install:• Diaphragm• Brake master cylinder cap 1• Screw (brake master cylinder cap) 2After installation, while pulli

5-24CHASREAR WHEEL AND REAR BRAKEREAR WHEEL AND REAR BRAKE1 Brake rod 12 Axle nut 13 Drive chain puller (right) 14 Wheel axle 15 Drive chain puller (l

5-25CHAS11 Nut (wheel sprocket) 412 Wheel sprocket 113 Oil seal 114 Wheel bearing 215 Spacer 116 Brake shoe 217 Spring 218 Brake camshaft lever 119 We

5-26CHASREAR WHEEL AND REAR BRAKEINSPECTIONEC514100Wheel1. Measure:• Wheel runoutOut of limit → Repair/replace.REMOVAL POINTSEC523101Rear wheel1. Remo

5-27CHASREAR WHEEL AND REAR BRAKE3. Measure:• Brake drum inside diameter aOut of specification → Replace.The bending value is shown by one half of th

TT-R125EY/TT-R125LEYSERVICE MANUAL©2008 by Yamaha Motor da Amazônia Ltda.1st Edition, June 2008All rights reserved. Any reprinting orunauthorized use

1-6GENINFOSPECIAL TOOLSPart number Tool name/How to use IllustrationYM-8035YM-1312-AYU-33270-BYM-33963YM-33281YU-33975YS-1880-AYU-3112-CYU-8036-BYM-40

5-28CHASREAR WHEEL AND REAR BRAKE2. Check:• Brake camshaft operationUnsmooth operation → Repair.4. Inspect:• Brake drum inner surface.Oil/scratches →

5-29CHASREAR WHEEL AND REAR BRAKERear wheel1. Install:• Wheel bearing 1• Spacer 2• Wheel bearing 3• Oil seal 4• Apply the lithium soap base grease on

5-30CHASREAR WHEEL AND REAR BRAKE4. Install:• Rear wheelMake sure that the slot a on the brake shoeplate with the stopper b on the swingarm.2. Install

5-31CHASREAR WHEEL AND REAR BRAKE8. Adjust:• Drive chain slack a7. Install:• Drive chain puller (right) 1• Plain washer 2• Axle nut 3Temporarily tight

5-32CHASEC550000FRONT FORKFRONT FORKAB1 Cap 1 -2 Pinch bolt (upper bracket) 1 1 Only loosening.3 Cap bolt 1 1 Loosen when disassembling thefront fork.

5-33CHASEC558000FRONT FORK DISASSEMBLYFRONT FORKExtent of removal: 1 Oil seal removal 2 Damper rod removalA TT-R125EB TT-R125LEAB1 Dust boot 1 12 Cap

5-34CHAS11A BFRONT FORKEC553000REMOVAL POINTSCap bolt1. Remove:• Cap bolt 1From the inner tube.Before removing the front fork from the machine,loosen

5-35CHASDamper rod holder:YM-1300/90890-01294T-handle:YM-1326/90890-01326FRONT FORK3. Remove:• Oil seal 1Using slotted-hand screwdriver.Take care not

5-36CHASFRONT FORKInner tube1. Inspect:• Inner tube surface aScore marks → Repair or replace.Use #1,000 grit wet sandpaper.Damaged oil lock piece → Re

5-37CHASFRONT FORKEC555000ASSEMBLY AND INSTALLATIONFront fork assembly1. Wash the all parts in a clean solvent.2. Install:• Piston metal 1• Damper rod

1-7GENINFOSPECIAL TOOLSYM-91042YM-4097YM-4098YM-04099YM-34487ACC-QUICK-GS-KT90890-0408690890-0409790890-0409890890-0409990890-0675490890-85505YM-91042

5-38CHASFRONT FORK5. Install:• Oil seal 1• Apply the fork oil on the inner tube.• When installing the oil seal, use vinyl seat awith fork oil applied

5-39CHASFRONT FORK7. Install:• Dust seal 1Apply the lithium soap base grease on the innertube.8. Check:• Inner tube smooth movementTightness/binding/r

5-40CHAS11A BFRONT FORKa1ABInstallation1. Install:• Front fork• Temporarily tighten the pinch bolt (lowerbracket).• Do not tighten the pinch bolt (upp

5-41CHASFRONT FORK4. Tighten:• Pinch bolt (lower bracket) 1• Pinch bolt (upper bracket) 2• Screw (dust boot) 3• Make sure that the dust boot holes a a

5-42CHASHANDLEBARExtent of removal: 1 Handlebar removalExtent of removal Order Part name Q’ty Remarks1 Clutch cable 12 Clutch lever 13 Engine stop swi

5-43CHASTT-R125LEHANDLEBARExtent of removal: 1 Handlebar removalExtent of removal Order Part name Q’ty Remarks1 Clutch cable 12 Clutch lever 13 Engine

5-44CHASTHROTTLE GRIP ASSEMBLY DISASSEMBLY1 Handlebar grip (right) 12 Collar 13 Tube guide 1Extent of removal: 1 Throttle grip assembly disassemblyTH

5-45CHASHANDLEBARREMOVAL POINTSBrake master cylinder1. Remove:• Brake master cylinder bracket 1• Brake master cylinder 2• Do not let the brake master

5-46CHASHANDLEBARHandlebar1. Install:• Handlebar 1• Handlebar holder 2• Main switch 3• Main switch holder 4• Bolt (handlebar holder) 5• Align the punc

5-47CHAS121HANDLEBAR4. Install:• Throttle grip assembly 1• Throttle cable 2On tube guide .Apply the lithium soap base grease on thethrottle cable end

2-1SPECGENERAL SPECIFICATIONSEC200000SPECIFICATIONSEC211000GENERAL SPECIFICATIONSTT-R125EModel name: TT-R125EYModel code number: 39C1Dimensions:Overal

5-48CHASHANDLEBAR214433126. Install:TT-R125E• Start switch 1• Bolts (start switch) 2• Front brake cable 3• ClampApply the lithium soap base grease on

5-49CHASHANDLEBAR12338. Install:• Clutch cable 1• ClampApply the lithium soap base grease on the clutchcable end.9. Adjust:• Brake lever free playRefe

5-50CHASSTEERINGEC560000STEERINGExtent of removal: 1 Lower bracket removal 2 Bearing removal1 Steering stem nut 12 Upper bracket 13 Special washer 14

5-51CHAS9 Bearing inner race (upper) 110 Bearing (upper) 111 Bearing outer race (upper) 112 Bearing outer race (lower) 113 Bearing (lower) 1Refer to “

5-52CHASSteering nut wrench:YU-33975/90890-01403STEERINGBearing race1. Remove:• Bearing race 1Remove the bearing race using long rod2 and the hammer.E

5-53CHASSTEERINGBearing and bearing race1. Wash the bearings and bearing races with asolvent.2. Inspect:• Bearing• Bearing racePitting/damage → Repla

5-54CHASSTEERING5. Install:• Lower ring nut 1• Rubber washer• Upper ring nut• Special washerTighten the ring nut using the steering nutwrench 2.Instal

5-55CHASaABSTEERINGA TT-R125EB TT-R125LE9. Tighten:• Steering stem nut 1110 Nm (11.0 m · kg, 80 ft · lb)10. Install:• Cap 211. After tightening the nu

5-56CHASSWINGARMEC570000SWINGARMExtent of removal: 1 Swingarm removal1 Drive chain tensioner (upper) 12 Drive chain tensioner (lower) 13 Bolt (connect

5-57CHASExtent of removal: 1 Swingarm disassembly 2 Connecting arm removal and disassembly3 Relay arm removal and disassembly1 Drive chain guard 12 Dr

2-2SPECGENERAL SPECIFICATIONSOil capacity:Engine oilPeriodic oil change 1.0 L (0.88 Imp qt, 1.06 US qt)Total amount 1.2 L (1.06 Imp qt, 1.27 US qt)Air

5-58CHASSWINGARMINSPECTIONWash the bushings, collars, and covers in asolvent.Swingarm1. Inspect:• Bushing 1• Bushing 2Damage/pitting → Replace bushing

5-59CHASSWINGARMEC575000ASSEMBLY AND INSTALLATIONBushing1. Install:• BushingMake sure to press in the bushing so that theyare flush with the surface o

5-60CHASSWINGARM3. Install:• Collar 1• Dust covers 2On connecting arm.Apply the molybdenum disulfide grease on thecollar and dust cover lip.2. Install

5-61CHASSWINGARMInstallation1. Install:• Swingarm• Pivot shaft 1• Plain washer• Nut (pivot shaft)Apply the molybdenum disulfide grease on thepivot sha

5-62CHASSWINGARM5. Install:• Drive chain tensioner (lower) 1• Collar• Bolt [drive chain tensioner (lower)]3. Install:• Bolt (rear shock absorber - rel

5-63CHASREAR SHOCK ABSORBER ASSEMBLYEC580000REAR SHOCK ABSORBER ASSEMBLYExtent of removal: 1 Rear shock absorber assembly removal1 Bolt (rear shock ab

5-64CHASREAR SHOCK ABSORBER ASSEMBLYHANDLING NOTEThis rear shock absorber contains high-pressure nitrogen gas. To prevent the dangerof explosion, read

5-65CHASAAAAABBBBBREAR SHOCK ABSORBER ASSEMBLYEC584000INSPECTIONRear shock absorber assembly1. Inspect:• Damper rod 1Bends/damage → Replace rear shoc

5-66CHASREAR SHOCK ABSORBER ASSEMBLYInstallation1. Install:• Rear shock absorber assemblyOn frame.Install the rear shock absorber assembly withits war

5-67CHAS13ab= 0~2 mm2REAR SHOCK ABSORBER ASSEMBLY4. Install:TT-R125LE• Rear shock absorber assembly sub-tank 1• Screw clamp 2• Locking tie 3• Install

2-3SPECGENERAL SPECIFICATIONSTransmission:Primary reduction system GearPrimary reduction ratio 68/19 (3.579)Secondary reduction system Chain driveSeco

6-1ELEC–+ELECTRICAL COMPONENTS ANDWIRING DIAGRAMEC600000ELECTRICALEC610000ELECTRICAL COMPONENTS AND WIRING DIAGRAMEC611000ELECTRICAL COMPONENTS1 CDI u

6-2ELEC–+IGNITION SYSTEMEC620000IGNITION SYSTEMINSPECTION STEPSUse the following steps for checking the possibility of the malfunctioning engine being

6-3ELEC–+Minimum spark gap:6.0 mm (0.24 in)RB/WBrB1324IGNITION SYSTEMEC624000COUPLERS AND LEADSCONNECTIONINSPECTION1. Check:• Couplers and leads conne

6-4ELEC–+BB12IGNITION SYSTEMENGINE STOP SWITCH INSPECTION1. Inspect:• Engine stop switch conductTester (+) lead → Black lead 1Tester (_) lead → Black

6-5ELEC–+Br GRW12IGNITION SYSTEM2. Inspect:• Secondary coil resistanceOut of specification → Replace.When inspecting the secondary coil resistance,rem

6-6ELEC–+2. Inspect:• Source coil resistanceOut of specification → Replace.IGNITION SYSTEMBr GRW12Tester (+) lead → Brown lead 1Tester (_) lead →

6-7ELEC–+ELECTRIC STARTING SYSTEMSTARTING CIRCUIT CUT-OFF SYSTEMOPERATIONIf the main switch is set to "ON", the starter motorcan only operat

6-8ELEC–+INSPECTION STEPSIf the starter motor will not operate, use the following inspection steps.• Remove the following parts before inspection.1) S

6-9ELEC–+2431ELECTRIC STARTING SYSTEMSTARTER MOTOR OPERATION1. Connect the positive battery terminal 1 andstarter motor lead 2 with a jumper lead 3.No

6-10ELEC–+STARTER RELAY INSPECTION1. Remove:• Starter relay2. Inspect:• Starter relay conductUse 12 V battery.Battery (+) lead → Starter relay termina

2-4SPECGENERAL SPECIFICATIONSTT-R125LEModel name: TT-R125LEYModel code number: 19CADimensions:Overall length 1,885 mm (74.2 in)Overall width 795 mm (

6-11ELEC–+CLUTCH SWITCH INSPECTION1. Inspect:• Clutch switch continuitySTART SWITCH INSPECTION1. Inspect:• Start switch continuityBB12BB12ELECTRIC STA

6-12ELEC–+STARTER MOTORELECTRIC STARTING SYSTEMExtent of removal: 1 Starter motor disassembly1 Starter motor front cover 12 Plain washer 13 O-ring 34

6-13ELEC–+ELECTRIC STARTING SYSTEMOut of specification → Replace the startermotor.3. Measure:• Mica undercut aINSPECTION AND REPAIR1. Inspect:• Commu

6-14ELEC–+2. Instal:• Armature assembly 1Install while holding down the brush usinga thin screw driver.Be careful not to damage the brush duringinstal

6-15ELEC–+12abNew1abNew2321NewLS3. Install:• O-ring 1• Starter motor yoke 2Align the match mark a on the starter motoryoke with the match mark b on t

6-16ELEC–+EC680000CHARGING SYSTEMEC681001INSPECTION STEPSIf the battery is not charged, use the following inspection steps.*1 marked: Refer to “FUSE I

6-17ELEC–+WBRY21WSbYB12CHARGING SYSTEMEC624000COUPLERS AND LEADSCONNECTIONINSPECTION1. Check:• Couplers and leads connectionRust/dust/looseness/short-

YAMAHA MOTOR DA AMAZÔNIA LTDA.

2-5SPECGENERAL SPECIFICATIONSOil capacity:Engine oilPeriodic oil change 1.0 L (0.88 Imp qt, 1.06 US qt)Total amount 1.2 L (1.06 Imp qt, 1.27 US qt)Air

2-6SPECGENERAL SPECIFICATIONSTransmission:Primary reduction system GearPrimary reduction ratio 68/19 (3.579)Secondary reduction system Chain driveSeco

2-7SPECMAINTENANCE SPECIFICATIONSEC212000MAINTENANCE SPECIFICATIONSEC212100ENGINEABItem Standard LimitCylinder head:Warp limit ---- 0.03 mm(0.0012 in)

2-8SPECMAINTENANCE SPECIFICATIONS"A" head diameter IN 25.9 ~ 26.1 mm ----(1.0197 ~ 1.0276 in)EX 21.9 ~ 22.1 mm ----(0.8622 ~ 0.8701 in)"

INTRODUCTIONCongratulations on your purchase of a YamahaTT-R125E/TT-R125LE. This model is theculmination of Yamaha's vast experience in theproduc

2-9SPECMAINTENANCE SPECIFICATIONSValve spring:Free length IN 38.78 mm (1.52 in) 36.84 mm(1.45 in)EX 38.78 mm (1.52 in) 36.84 mm(1.45 in)Set length (va

2-10SPECMAINTENANCE SPECIFICATIONSType Taper ----Dimensions (B × T) 1.0 × 2.1 mm (0.04 × 0.08 in) ----End gap (installed) 0.15 ~ 0.30 mm 0.40 mm(0.006

2-11SPECMAINTENANCE SPECIFICATIONSCarburetor:I.D. mark 1B2S00Main jet (M.J) #100 ----Main jet nozzle (N.J) N-9M ----Main air jet (M.A.J) ø0.9 ----Jet

2-12SPECMAINTENANCE SPECIFICATIONSLubrication system:Oil filter type Wire mesh type ----Oil pump type Trochoid type ----Tip clearance 0.15 mm 0.2 mm(0

2-13SPECMAINTENANCE SPECIFICATIONSTightening torquePart to be tightened Thread size Q'ty Nm m•kg ft•lbSpark plug M10 x 1.0 1 13 1.3 9.4Cylinder h

2-14SPECMAINTENANCE SPECIFICATIONSCylinder head tightening sequenceTightening torquePart to be tightened Thread size Q'ty Nm m•kg ft•lbSegment M6

2-15SPECMAINTENANCE SPECIFICATIONSItem Standard LimitSteering system:Steering bearing type (upper) Angular bearing ----(lower) Taper roller bearing --

2-16SPECMAINTENANCE SPECIFICATIONSDrum brake:Front drum brake type Leading, trailing ----Rear drum brake type Leading, trailing ----Front drum inside

2-17SPECMAINTENANCE SPECIFICATIONSTightening torquePart to be tightened Thread size Q'ty Nm m•kg ft•lbUpper bracket and inner tube M8 × 1.25 2 25

2-18SPECMAINTENANCE SPECIFICATIONSRelay arm and connecting arm M10 × 1.25 1 35 3.5 25Connecting arm and frame M10 × 1.25 1 35 3.5 25Rear shock absorbe

YAMAHA MOTOR CORPORATION, U.S.A.OFF-ROAD MOTORCYCLE LIMITED WARRANTYYAMAHA MOTOR CORPORATION, U.S.A. OFF-ROAD MOTORCYCLE LIMITED WARRANTYSPECIFIC EXCL

2-19SPECMAINTENANCE SPECIFICATIONSWheel:Front wheel type Spoke wheel ---Rear wheel type Spoke wheel ---Front rim size/material 19 × 1.40/Steel ---Rear

2-20SPECMAINTENANCE SPECIFICATIONSRear drum brake:Drum brake type Leading, trailing ----Drum inside diameter 110 mm (4.33 in) 111 mm (4.37 in)Lining t

2-21SPECMAINTENANCE SPECIFICATIONSTightening torquePart to be tightened Thread size Q'ty Nm m•kg ft•lbUpper bracket and inner tube M8 × 1.25 2 25

2-22SPECMAINTENANCE SPECIFICATIONSTIPÎ - marked portion shall be checked for torque tightening after break-in or before each ride.Bead stopper M8 × 1.

2-23SPECMAINTENANCE SPECIFICATIONSEC212300ELECTRICALItem Standard LimitCDI:Magneto-model (stator)/manufacturer F1B2/MORIC ---Source coil resistance (c

2-24SPECMAINTENANCE SPECIFICATIONSItem Standard LimitStarter relay:Model/manufacturer MS5F-751/JIDECO ---Amperage rating 180 A ---Coil winding resista

2-25SPECGENERAL TORQUE SPECIFICATIONS/DEFINITION OF UNITSThis chart specifies torque for standardfasteners with standard I.S.O. pitch threads.Torque s

2-26SPECCABLE ROUTING DIAGRAMD Brake hose holder(Brake cableholder for the TT-R125E)E Brake hose (Brake cable forthe TT-R125E)F Cable guideG Main swit

2-27SPECCABLE ROUTING DIAGRAME Fasten the CDI magneto leadand starter relay lead.F Fasten the wire harness.G Pass the rectifier/regulator leadbetween

2-28SPECCABLE ROUTING DIAGRAMU After connecting the main switchcoupler, engine stop switchcoupler, clutch switch couplerand start switch coupler, put

THIS MACHINE IS DESIGNED FOR OFF-ROAD USE ONLY. It is illegal for this machineto be operated on any public street, road, or high-way. Off-road use on

2-29SPEC15K65M13121476ADFEHL442915B115126101415115151417N1613C8106G13J611KHLLCABLE ROUTING DIAGRAM1 Throttle cable2 Clutch cable3 Starter cable4 Fuel

2-30SPEC15K65M13121476ADFEHL442915B115126101415115151417N1613C8106G13J611KHLLCABLE ROUTING DIAGRAME Fasten the clutch cable withthe paint in the cable

2-31SPEC8754CD6EFB7I83J1A1H1G32CABLE ROUTING DIAGRAM1 Clamp2 Clutch switch lead3 Engine stop switch lead4 Brake hose (Brake cablefor the TT-R125E)5 Cl

3-1INSPADJMAINTENANCE INTERVALSREGULAR INSPECTION AND ADJUSTMENTSPERIODIC MAINTENANCE CHART FOR THE EMISSIONCONTROL SYSTEMFrom 18 months or 4,200 mi (

3-2INSPADJMAINTENANCE INTERVALSGENERAL MAINTENANCE AND LUBRICATION CHARTFrom 18 months or 4,200 mi (7,000 km) or 210 hours, repeat the maintenance int

3-3INSPADJMAINTENANCE INTERVALSThe air filter needs more frequent service if you are riding in unusually wet or dusty areas.Hydraulic brake service (T

3-4INSPADJPRE-OPERATION INSPECTION ANDMAINTENANCEPRE-OPERATION INSPECTION AND MAINTENANCEBefore riding for break-in operation or practice, make sure t

3-5INSPADJENGINE/CLUTCH ADJUSTMENT/THROTTLE CABLE ADJUSTMENTEC350000ENGINECLUTCH ADJUSTMENT1. Check:• Clutch lever free play aOut of specification →

3-6INSPADJTHROTTLE LUBRICATION/AIR FILTER CLEANINGAfter adjusting, turn the handlebar to rightand left and make sure that the engineidling does not ru

3-7INSPADJaAIR FILTER CLEANING1. Remove:• Right side cover 1Loosen the quick screw 2 and remove the rightside cover from the holding boss a.2. Remove:

6. ONLY OPERATE THE MACHINE IN ANAREA WITH ADEQUATE VENTILA-TION.Never start the engine or let it run forany length of time in an enclosed area.Exhaus

3-8INSPADJENGINE OIL LEVEL INSPECTIONENGINE OIL LEVEL INSPECTION1. Start the engine, warm it up for severalminutes and wait for five minutes.2. Place

3-9INSPADJENGINE OIL LEVEL INSPECTION4. Check:• Oil levelOil level should be between maximum aand minimum b marks.Oil level is low → Add oil to prope

3-10INSPADJENGINE OIL REPLACEMENT5. Install:• Dipstick6. Start the engine and let it warm up for severalminutes.7. Turn off the engine and inspect the

3-11INSPADJOIL PRESSURE INSPECTION /ENGINE IDLING SPEED ADJUSTMENTOIL PRESSURE INSPECTION1. Check:• Oil pressureChecking steps:• Slightly loosen the o

3-12INSPADJVALVE CLEARANCE INSPECTION ANDADJUSTMENTVALVE CLEARANCE INSPECTIONAND ADJUSTMENT• The valve clearance should be adjusted whenthe engine is

3-13INSPADJ4. Check:• Valve clearanceOut of specification → Adjust.VALVE CLEARANCE INSPECTION ANDADJUSTMENTValve clearance (cold):Intake valve:0.08 ~

3-14INSPADJVALVE CLEARANCE INSPECTION ANDADJUSTMENT• Measure the valve clearance.• If the clearance is incorrect, repeat abovesteps until specified cl

3-15INSPADJSPARK ARRESTER CLEANINGSPARK ARRESTER CLEANING• Be sure the exhaust pipe and muffler arecool before cleaning the spark arrester.• Do not st

3-16INSPADJCHASSIS / BRAKE SYSTEM AIR BLEEDING(TT-R125LE)EC360000CHASSISEC361012BRAKE SYSTEM AIR BLEEDING(TT-R125LE)Bleed the brake system if:• The sy

3-17INSPADJFRONT BRAKE ADJUSTMENTIf bleeding is difficult, it may be necessary tolet the brake fluid system stabilize for a fewhours. Repeat the bleed

EC080000HOW TO USE THIS MANUALFINDING THE REQUIRED PAGE1. This manual consists of six chapters; "Gen-eral Information", "Specifications

3-18INSPADJREAR BRAKE ADJUSTMENTTT-R125LE1. Check:• Brake lever free play aOut of specification → Adjust.Brake lever free play a:2 ~ 5 mm (0.08 ~ 0.20

3-19INSPADJBRAKE PEDAL HEIGHT ADJUSTMENT/FRONT BRAKE PADINSPECTION AND REPLACEMENT (TT-R125LE)BRAKE PEDAL HEIGHT ADJUSTMENT1. Check:• Brake pedal heig

3-20INSPADJFRONT BRAKE SHOE INSPECTION (TT-R125E)• Connect the transparent hose 4 to the bleedscrew 5 and place the suitable containerunder its end.•

3-21INSPADJREAR BRAKE SHOE INSPECTION / BRAKE FLUID LEVELINSPECTION (TT-R125LE) / SPROCKETS INSPECTIONSPROCKETS INSPECTION1. Inspect:• Sprocket teet

3-22INSPADJDRIVE CHAIN INSPECTIONEC369002DRIVE CHAIN INSPECTION1. Remove:• Master link clip• Joint 1• Drive chain 22. Clean:• Drive chainPlace it in k

3-23INSPADJDRIVE CHAIN SLACK ADJUSTMENTDRIVE CHAIN SLACK ADJUSTMENT1. Elevate the rear wheel by placing the suitablestand under the engine.2. Check:•

3-24INSPADJ1ab1234FRONT FORK INSPECTION/FRONT FORKSPRING PRELOAD ADJUSTMENT (TT-R125LE)EC36C000FRONT FORK INSPECTION1. Inspect:• Front fork smooth act

3-25INSPADJREAR SHOCK ABSORBER ASSEMBLY INSPECTION / REARSHOCK ABSORBER SPRING PRELOAD ADJUSTMENTREAR SHOCK ABSORBER ASSEMBLYINSPECTION1. Inspect:• Sw

3-26INSPADJba1REAR SHOCK ABSORBER REBOUND DAMPINGFORCE ADJUSTMENT (TT-R125LE)EC36N014REAR SHOCK ABSORBER REBOUNDDAMPING FORCE ADJUSTMENT(TT-R125LE)1.

3-27INSPADJba1REAR SHOCK ABSORBER COMPRESSIONDAMPING FORCE ADJUSTMENT (TT-R125LE)EC36c000REAR SHOCK ABSORBERCOMPRESSION DAMPING FORCEADJUSTMENT (TT-R1

EC083000MANUAL FORMATAll of the procedures in this manual are organized in a sequential, step-by-step format. The informa-tion has been complied to pr

3-28INSPADJTIRE PRESSURE CHECK/SPOKES INSPECTIONAND TIGHTENING/WHEEL INSPECTIONSPOKES INSPECTION ANDTIGHTENING1. Inspect:• Spokes 1Bend/damage → Rep

3-29INSPADJSTEERING HEAD INSPECTION ANDADJUSTMENT2. Inspect:• Bearing free playExist play → Replace.STEERING HEAD INSPECTION ANDADJUSTMENT1. Elevate t

3-30INSPADJG• Tighten the lower ring nut 6 using steeringnut wrench 7 and turn the steering rightand left a few times.Set the torque wrench to the ste

3-31INSPADJSTEERING HEAD INSPECTION ANDADJUSTMENTFirst tighten the bolts on the front side ofthe handlebar holder, and then tighten thebolts on the re

3-32INSPADJLUBRICATIONTo ensure smooth operation of all components,lubricate your machine during setup, after break-in, and after every ride.1 All con

3-33INSPADJELECTRICAL/SPARK PLUG INSPECTIONEC370000ELECTRICALEC371001SPARK PLUG INSPECTION1. Remove:• Spark plug2. Inspect:• Electrode 1Wear/damage →

3-34INSPADJBATTERY INSPECTION AND CHARGINGBATTERY INSPECTION ANDCHARGINGBatteries generate explosive hydrogen gasand contain electrolyte which is made

3-35INSPADJBATTERY INSPECTION AND CHARGINGSince MF batteries are sealed, it is not possibleto check the charge state of the battery bymeasuring the sp

3-36INSPADJBATTERY INSPECTION AND CHARGING5. Charge:• Battery(refer to the appropriate charging methodillustration)Do not quick charge a battery.• Nev

3-37INSPADJBATTERY INSPECTION AND CHARGING• Before removing the battery charger leadclips from the battery terminals, be sureto turn off the battery c

1234GENINFOSPECENG65CHASELEC–+E78FKGILHEDCBA90JTR..MBFLSMSLTNewINSPADJILLUSTRATED SYMBOLS(Refer to the illustration)Illustrated symbols 1 to 6 are d

3-38INSPADJBATTERY INSPECTION AND CHARGINGCharging method using a variable voltage chargerMeasure the open-circuit voltage prior tocharging.Connect a

3-39INSPADJBATTERY INSPECTION AND CHARGINGCharging method using a constant voltage chargerMeasure the open-circuit voltage prior tocharging.Leave the

3-40INSPADJFUSE INSPECTIONFUSE INSPECTIONTo avoid a short circuit, always set the mainswitch to OFF when checking or replacing afuse.1. Remove:• Batte

3-41INSPADJ3. Replace:• Blown fuse4. Install:• Battery coverNever use a fuse with an amperage ratingother than that specified. Improvising orusing a f

4-1ENG10 Nm (1.0 m kg, 7.2 ft lb)••7 Nm (0.7 m kg, 5.1 ft lb)••7 Nm (0.7 m kg, 5.1 ft lb)••718422397 Nm (0.7 m kg, 5.1 ft lb)••7 Nm (0.7 m kg, 5.1 ft

4-2ENGMUFFLERMUFFLERExtent of removal: 1 Muffler removal1245310 Nm (1.0 m kg, 7.2 ft lb)••10 Nm (1.0 m kg, 7.2 ft lb)••10 Nm (1.0 m kg, 7.2 ft lb)••30

4-3ENGCARBURETORCARBURETOR44172398356Extent of removal: 1 Carburetor removalCARBURETOR REMOVALFuel tankPreparation forremoval1 Fuel hose 12 Over flow

4-4ENGCARBURETOREC468000CARBURETOR DISASSEMBLYExtent of removal: 1 Carburetor disassembly1 Throttle shaft 12 Throttle valve 13 Jet needle set 14 Lever

4-5ENGCARBURETORHANDLING NOTEAt high altitudes, the atmospheric pressure islower. This can make the fuel mixture too rich,leading to such problems as

4-6ENG11CARBURETOREC464301Throttle valve1. Check:• Free movementStick → Repair or replace.Insert the throttle valve 1 into the carburetorbody, and ch