2002 Yamaha TT-R125 / TT-R125LW Service Manual
Complete service and maintenance guide for TT-R125(R) and TT-R125LW(R) trail bikes. Covers engine, chassis, and electrical systems with detailed repair procedures. PN 5HP-28199-84
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Sample pages from the 2002 Yamaha TT-R125 / TT-R125LW Service Manual manual
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Models Covered & Key Technical Specifications
Yamaha TT-R125(R) & TT-R125LW(R) — 2002 Manufacturer Tactical Primer | TT-R125 Series Compendium.
- Prescribed Displacement Data: 124 cm³ (7.57 cu.in) is specified as the engine cylinder volume Architecture.
- Documented Precision Specs: The valve clearance (cold) intake reaches 0.08–0.12 mm (0.0031–0.0047 in) governs optimal combustion chamber tolerance Protocol.
- Maximum Bolt Torques: Cylinder head fasteners require 22 Nm (2.2 m•kg, 16 ft•lb) for M8 specifications Norms.
- System Displacement Data: Engine displacement establishes 124 cm³ (7.57 cu.in) single-cylinder architecture for power delivery Bounds.
- Technical Circuit Specs: The spark plug gap is designed for 0.6–0.7 mm (0.02–0.03 in) electrode spacing Topology.
- Advanced Size Parameters: Fuel tank capacity sets 6.6 L (1.45 Imp gal, 1.74 US gal) total volume Architecture.
Professional Workshop Service Manual & Technical Specifications
Full-Coverage Safety Manual: Motorcycle Yamaha TT-R125(R) & TT-R125LW(R) Manual 2002 - Trail-Ready Maintenance & Repair Guide Information-Suite
Technical-Domain: TT-R125(R) and TT-R125LW(R) (2002 models) // Assembly-Group: Engine, Transmission, Chassis Systems Logic // Conceptual-Layout: 510-page comprehensive service documentation with multilingual support (English, French, German).
| Integrated-Framework | Parameters | Context |
|---|---|---|
| Engine Documentation | 4-stroke SOHC, 124cc displacement, CDI magneto system | Chapters 1–4 detail operation, maintenance intervals, clutch adjustment, spark plug inspection, and carburetor service procedures |
| Chassis Network | Front fork, swingarm, drum/disc brakes, steering bearings | Chapters 3 and 5 cover suspension geometry, brake system air bleeding (TT-R125LW), wheel inspection, and handlebar adjustment |
| Electrical System | CDI magneto, ignition coil, spark plug specifications | Complete electrical component data with wiring diagram routing documented |
Major sections focus on General Information and Machine Identification, advancing through Specifications and Regular Inspection and Adjustments, establishing Engine procedures and then transitioning to Chassis systems, concluding with Electrical component data and cable routing specifications.
Precise Protocol
The document encompasses detailed coverage of fundamental network components across all vehicle systems. The manual provides specifications for engine oil replacement at 1.0 L periodic change capacity, fuel system requirements (6.6 L total tank capacity with 1.9 L reserve), and maintenance intervals spanning 10-hour initial checks through 120-hour periodic service. Valve clearance reference data is included for cold-engine measurement at 0.08–0.12 mm (intake) and 0.10–0.14 mm (exhaust). Drive chain slack documentation specifies 35–50 mm adjustment range with proper lubrication using SAE 10W-30 motor oil or equivalent chain lubricants.
Advanced Sequences
Reassembly procedures are specified for the carburetor assembly, including jet needle positioning, float chamber fuel level measurement (6.0–7.0 mm below mating surface), and pilot air screw adjustment recorded at factory settings. The manual documents complete carburetor disassembly sequences with identification of main jet specifications (#105), pilot jet (#15), and starter jets (#22.5, #1.2). Cylinder head service includes timing chain alignment procedures with "I" mark rotor positioning, camshaft sprocket match marks, and sequential bolt-tightening patterns for proper gasket seating.
Strategic Parameters
Service intervals are documented for brake system maintenance covering front drum brake inspection (TT-R125) and hydraulic disc brake system air bleeding (TT-R125LW). The manual includes front brake pad thickness limits (standard 4.0 mm, minimum 0.8 mm for TT-R125LW) and rear brake shoe wear indicator positioning. Steering head bearing adjustment procedures reference ring nut torque specifications: initial tightening at 38 Nm, final tightening at 20 Nm after one-turn loosening sequence.
Integrated Protocol
Component locations are identified for the fuel cock (three-position: OFF, ON, RES reserve), engine stop switch functionality, and complete cable routing diagrams showing CDI magneto lead clamp points, brake cable guidance, and throttle/clutch cable routing through protective guides. The document includes lubrication point mapping for all control cables, brake and clutch lever pivots, shift pedal pivot, footrest pivot, and throttle-to-handlebar contact surfaces.
Precise Methodology
Calibration requirements are specified for the spark plug gap at 0.6–0.7 mm using wire gauge measurement, engine idle speed at 1,300–1,500 r/min with inductive tachometer observation, and fuel level measurement using the dedicated gauge (YM-1312-A) positioned vertically beside the float chamber. Pre-operation inspection procedures establish the complete maintenance checklist covering fuel system integrity, engine oil level verification, transmission smooth operation, brake effectiveness front and rear, drive chain slack and alignment, wheel spoke tightness, and steering smooth action through full handlebar lock-to-lock travel. The manual documents torque specifications for all critical fasteners including spark plug (13 Nm), cylinder head bolts (22 Nm M8 / 10 Nm M6), and wheel rim spokes (2 Nm front, 3 Nm rear) to ensure proper pressure slip prevention through verified assembly torque.
Models Covered: TT-R125(R), TT-R125LW(R) (2002) — USA, Canada, Australia, New Zealand, Europe, South Africa editions Languages: English, French, German Total Pages: 510 with specifications, wiring diagrams, exploded diagrams, and maintenance interval charts
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