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Yamaha TTR125 TT-R125 Motorcycle Complete Workshop Service Repair Manual 2003

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🏷️ Basic Information Identification Make: Yamaha Model: TTR125 / TT-R125 Year: 2003 Codes Engine Code: 4XM Generation Model Generation: First Generation (pre-2008 redesign) 👋 Introduction Market Position Market Segment: Entry-level...
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Yamaha TTR125 TT-R125 Motorcycle Complete Workshop Service Repair Manual 2003
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
TTR125 / TT-R125
Year:
2003
Codes
Engine Code:
4XM
Generation
Model Generation:
First Generation (pre-2008 redesign)
👋 Introduction
Market Position
Market Segment:
Entry-level off-road/trail motorcycle, popular for youth riders and recreational trail riding.
Competitive Analysis
Key Competitors 2003:
Honda XR100R/CRF100F, Kawasaki KLX125, Suzuki DR-Z125.
Key Features
Model Highlights:
User-friendly, reliable, simple to maintain, suitable for learning and trail riding, electric start option available on some variants.
📋 Manual Details
Coverage Areas
Manual Coverage:
Complete Workshop Service and Repair
Page Count
Estimated Page Count:
Approx. 300-400 pages (typical for this era and scope)
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable Digital File (PDF)
📖 Manual Coverage
Systems Covered
Engine Systems:
Top end (cylinder, piston, valves), bottom end (crankshaft, connecting rod, bearings), cooling system (air-cooled), lubrication system (oil pump, filter), fuel system (carburetor, fuel lines), ignition system (CDI, spark plug), exhaust system
Transmission Drivetrain Systems:
Clutch (automatic centrifugal), gearbox (5-speed constant mesh), final drive (chain, sprockets), shift mechanism
Chassis Suspension Steering Systems:
Frame, front forks (telescopic), rear suspension (monoshock), steering assembly (handlebars, triple clamps, steering stem bearings), swingarm
Brake Systems:
Front brake (drum), rear brake (drum), brake levers, cables
Electrical Systems:
Wiring diagrams, lighting system (headlight, taillight, brake light), ignition system components, battery, fuses, switches
Bodywork Fittings:
Body panels (fenders, shrouds, seat), footpegs, handlebars, levers, controls, plastics
Procedures Included
Maintenance Procedures:
Oil changes, air filter cleaning/replacement, spark plug inspection/replacement, chain lubrication/adjustment, brake adjustment, valve clearance checks
Troubleshooting Procedures:
Diagnosis of common problems (starting issues, poor performance, electrical faults), symptom-based troubleshooting guides
Repair Procedures:
Engine disassembly and reassembly, carburetor overhaul, clutch inspection and replacement, suspension component service, brake system overhaul, electrical component testing and replacement
Disassembly Reassembly Procedures:
Step-by-step instructions for major component removal and installation
Technical Depth
Technical Depth:
Comprehensive: Covers routine maintenance to complete engine and transmission rebuilds, including detailed diagrams and specifications.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
Print Quality
Print Quality Recommendation:
High resolution for clear text and diagrams, suitable for printing.
Binding Type
Binding Type For Print:
Spiral-bound or comb-bound recommended for lay-flat usability in a workshop environment.
Paper Type
Paper Type Recommendation:
Durable, grease-resistant paper for workshop use if printed.
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, SOHC, 2-valve, air-cooled single-cylinder
Displacement:
124 cc (7.58 cubic inches)
Bore X Stroke:
54.0 mm x 54.5 mm
Compression Ratio:
9.5:1 (typical for this model)
Performance
Estimated Horsepower:
Approx. 10-12 HP (at crankshaft, varies slightly)
Estimated Torque:
Approx. 7-8 lb-ft (at crankshaft, varies slightly)
Fuel System
Carburetor Model:
Mikuni VM20SS (typical specification)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Lubrication System
Oil Capacity:
Approx. 0.9 Liters (0.95 US qt)
Oil Type:
Yamalube 4 (or equivalent API SG, SAE 10W-40)
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh
Clutch Type:
Automatic centrifugal clutch
Features
Gear Ratios:
Specific gear ratios available in the manual, typically: 1st: 2.500, 2nd: 1.750, 3rd: 1.333, 4th: 1.090, 5th: 0.913 (check manual for exact values)
Final Drive Ratio:
Typically 4.533 (49/11 teeth, check manual for variations)
Transmission Oil Type:
Yamalube 4 (or equivalent API SG, SAE 10W-40)
Transmission Oil Capacity:
Approx. 0.55 Liters (0.58 US qt)
📐 Dimensions
Exterior
Overall Length:
Approx. 1830 mm (72.0 in)
Overall Width:
Approx. 795 mm (31.3 in)
Overall Height:
Approx. 1080 mm (42.5 in)
Wheelbase:
Approx. 1270 mm (50.0 in)
Ground Clearance:
Approx. 250 mm (9.8 in)
Seat Height:
Approx. 805 mm (31.7 in)
Weights
Dry Weight:
Approx. 79 kg (174 lbs)
Wet Weight:
Approx. 83 kg (183 lbs) (with all fluids)
Fuel Tank Capacity:
Approx. 5.7 Liters (1.5 US gal)
🛡️ Safety Features
Ratings
Safety Certification:
Not applicable in the same manner as automobiles. Designed for off-road use.
Active Features
Braking System:
Drum brakes front and rear for reliable stopping power suitable for off-road conditions.
Suspension:
Provides stable handling and absorbs terrain irregularities.
Passive Features
Frame Construction:
Robust steel frame designed for durability in off-road environments.
Tire Type:
Knobby tires for off-road traction and grip.
💡 Technology Features
Infotainment
Infotainment System:
Not applicable. Designed as a basic off-road machine with no electronic entertainment features.
Driver Assistance
Electronic Aids:
None. Focus is on mechanical simplicity and rider control.
Connectivity
Connectivity Features:
Not applicable.
🔧 Maintenance
Service Intervals
Engine Oil Change Interval:
Every 1,000 km (600 miles) or 6 months (check manual for exact mileage/time for specific conditions)
Air Filter Cleaning Interval:
Every 500 km (300 miles) or as needed based on riding conditions (dusty environments require more frequent checks)
Spark Plug Inspection Interval:
Every 1,000 km (600 miles)
Valve Clearance Check Interval:
Every 5,000 km (3,000 miles) or annually
Fluid Specifications
Engine Oil Grade:
SAE 10W-40
Engine Oil Standard:
API SG or higher, JASO MA certified
Brake Fluid Type:
DOT 3 or DOT 4 (for applicable systems, though this model uses drum brakes which typically don't require fluid)
Known Issues
Common Wear Items:
Tires, brake pads (if applicable), chain and sprockets, air filter, spark plug, clutch plates (due to automatic engagement).
Carburetor Maintenance:
Carburetors can become gummed up if the bike sits for extended periods without fuel stabilizer; regular cleaning and adjustment may be needed.
Suspension Wear:
Fork seals and rear shock absorbers can wear over time, leading to leaks or reduced damping performance.
📚 Vehicle History
Brand Heritage
Yamaha Motorcycle History:
Yamaha Motor Company, established in 1955, has a long and successful history in motorcycle manufacturing, known for innovation, performance, and reliability across various disciplines including off-road.
Model Evolution
Ttr Series Introduction:
The TTR line was introduced to provide accessible and capable off-road motorcycles. The TTR125 specifically replaced smaller displacement models and offered a step up in performance and features for young riders and casual trail users.
Production
Production Period:
The TTR125 has been in continuous production since its introduction, with significant updates occurring in later model years (e.g., 2008 redesign with larger wheels and disc brakes).
Manufacturing Location:
Primarily manufactured in Japan by Yamaha Motor Corporation.
🏆 Awards & Recognition
Recognitions
Industry Accolades:
While specific awards for the 2003 model are not widely documented, the TTR125 has consistently been recognized by the off-road community for its value, reliability, and suitability for its intended purpose as a beginner/intermediate trail bike.
Ratings
Rider Reviews:
Generally rated highly by owners for its ease of use, low maintenance costs, and fun factor in trail riding scenarios.
Certifications
Emissions Standards:
Designed to meet emissions standards relevant to its production year and market. Specific certifications would be detailed in official Yamaha documentation.
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