Yamaha TT-R125(M) 2000–2001 Service Manual Set (P/N 5HP-28199-80)

The editions share six workshop sections: general information, specifications, regular inspection and adjustment, engine, chassis, and electrical. Their coverage overlaps, while brake layouts and electrical circuits vary; matching the model and regional code helps you select the appropriate procedures and test data.

PDF Search, Bookmarks and Wiring Detail

Search and navigation: Text search is available across the manuals, although some specification-table words in the EX/LX/LEX PDF do not search reliably. The V, W, EX/LX/LEX and English T editions have detailed bookmarks; the other files mainly link to contents pages. Small wire codes in the denser electric-start schematics require zooming.

The ZIP contains 11 printable PDFs totaling 5,425 pages: nine trilingual English/French/German editions and two English editions. This total includes original covers and introductory material, 15 blank pages, and the warranty page in the EX/LX/LEX edition.

Engine Overhaul, Chassis Service and Starting-System Diagnosis

These selected workshop topics outline the repair coverage rather than reproduce the full contents. Additional subjects include starting and break-in guidance, cleaning, and storage preparation.

• Engine and carburetor: Step-by-step cylinder-head, camshaft, rocker-arm, valve, piston and ring procedures, plus carburetor disassembly, inspection and adjustment.
• Bottom-end repair: Engine removal, clutch and primary-drive service, oil-pump overhaul, kick and shift mechanisms, crankcase separation, crankshaft, balancer and transmission inspection.
• Brakes and chassis: Wheel and bearing service, drum and hydraulic front-brake procedures, fork rebuilding, steering-head work, swingarm linkage service and rear-shock replacement.
• Routine inspection: Maintenance schedules, pre-operation checks, oil-pressure inspection, valve and idle adjustment, drive-chain setup, spoke checks, steering adjustment and lubrication points.
• Electrical diagnosis: Ignition fault isolation, with battery, starter-motor, starting-interlock and charging-system tests in the applicable electric-start publications.
• Workshop references: Cable-routing drawings, wiring schematics, diagnostic flowcharts, exploded job views, torque tables, wear limits, clearances and electrical test specifications.

The material is suited to experienced owners performing routine service and mechanics taking on component-level repair; Yamaha identifies selected work as requiring special tools, service data and technical skill.

Carburetor, Valve Train and Internal Engine Work

The Mikuni carburetor sections reach the float, needle valve, jets, pilot-air screw, throttle valve, starter plunger and coasting enricher. Fuel-level checks and component inspection criteria support assessment of mixture and fuel-delivery problems.

Top-end coverage extends beyond adjustment work to valve-guide replacement and reaming, valve-seat contact inspection and lapping, spring inspection, cylinder-bore measurement and piston-ring checks. The timing-system material includes sprocket alignment and chain-tensioner installation.

Illustrated job charts identify removal scope, part sequence, required replacement seals or circlips, lubricants, locking agents and assembly torque references. These details help mechanics plan component work and identify the tools and replacement items involved before disassembly.

Electric-start editions also document the starter clutch and its associated gears, alongside the rotor, stator and pickup-coil assembly.

Wheel, Brake and Suspension Differences

The standard-wheel configuration uses a 70/100-17 front tire and 90/100-14 rear tire. The collection also includes the separately identified large-wheel publications, with hydraulic front-disc-brake procedures covering the caliper, master cylinder and bleeding.

Fork chapters cover oil seals, damper rods, internal inspection, filling and reassembly. Steering and swingarm sections add bearing, race, bushing, connecting-arm and relay-arm service. Yamaha recommends dealer maintenance for the front fork because of its sensitive internal construction.

Rear-shock coverage includes removal, bushing service, external inspection, spring-preload adjustment and installation. The nitrogen-charged shock is not covered as an owner-openable assembly; Yamaha warns against opening it and assigns gas-pressure release for disposal to dealers.

Ignition, Starter Interlocks and Charging Tests

Kick-start schematics identify the CDI unit, engine-stop switch, ignition coil, magneto and spark plug. No-spark charts distinguish connection faults from stop-switch, ignition-coil, pickup-coil and charging-coil faults before the CDI unit is considered.

Electric-start publications add battery and starter-relay checks, clutch and neutral-switch tests, starting-circuit cut-off operation, and starter-motor inspection and repair. Charging-system charts cover the wiring, charging output, magneto and rectifier/regulator.

Visual references include the M edition's three cable-routing drawings, component-location views, kick-start and electric-start wiring diagrams with wire-color codes, and exploded views of the carburetor, crankcase/crankshaft/balancer and front fork.

Special Tools and Assembly Cautions

The M edition's tool list pairs North American and other-market numbers. Examples include crankcase separator YU-01135-A / 90890-01135 and valve spring compressor YM-04019 / 90890-04019.

It also lists fork-seal driver weight YM-33963 / 90890-01367, attachment YM-33281 / 90890-01400, and ignition checker YM-34487 / 90890-06754.

Yamaha warns that crankshaft movement during camshaft installation can cause damage or incorrect valve timing. The fork assembly instructions also identify a damage risk if the damper rod drops into a vertically held inner tube.

Fork and gas-charged shock work involves stored-energy hazards; follow Yamaha's handling warnings and use qualified service support where the publication calls for dealer-level tools or skills.

Examples of Cold Valve Clearances and Ignition Test Data

The TT-R125(M) valve-adjustment section lists cold clearances of 0.08–0.12 mm for the intake valve and 0.10–0.14 mm for the exhaust valve.

Its electrical test data specify pickup-coil resistance of 248–372 Ω and secondary ignition-coil resistance of 6.3–9.5 kΩ, both at 20°C (68°F). The secondary-coil test specification applies with the spark plug cap removed.