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2002 Yamaha TT-R125(P) TT-R125LW(P) Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Yamaha Model: TT-R125 Model Variant: TT-R125(P), TT-R125LW(P) Year: 2002 Codes Chassis Code: 4SP (TT-R125), 5FP (TT-R125LW) Engine Code: 4EX1 👋 Introduction Market Position Market Position:...
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Type: Motorcycle
Vendor:
Sku: 336215
2002 Yamaha TT-R125(P) TT-R125LW(P) Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
TT-R125
Model Variant:
TT-R125(P), TT-R125LW(P)
Year:
2002
Codes
Chassis Code:
4SP (TT-R125), 5FP (TT-R125LW)
Engine Code:
4EX1
👋 Introduction
Market Position
Market Position:
The Yamaha TT-R125 series is positioned as a versatile entry-level to intermediate off-road motorcycle, popular for trail riding, recreational use, and as a platform for learning advanced riding techniques. It competes with other small-displacement dirt bikes from manufacturers like Honda, Kawasaki, and Suzuki.
Competitive Analysis
Competitive Analysis:
The TT-R125 offers a good balance of performance, reliability, and ease of use. The LW (Long Wheelbase) version provides increased stability and rider comfort for taller individuals or more challenging terrain. Its air-cooled engine simplifies maintenance, making it a favored choice for those new to motorcycle mechanics.
Key Features
Key Features:
Reliable 124cc air-cooled SOHC engine, five-speed transmission, electric start (on some models/years, though not explicitly stated for all 2002 variants, the manual will cover both kick and electric start if applicable), durable steel frame, capable suspension, and Yamaha's reputation for quality and longevity.
📋 Manual Details
Coverage Areas
Coverage Areas:
Full Service, Repair, Maintenance, Troubleshooting, Electrical, Mechanical, Chassis, Engine, Drivetrain
Page Count
Page Count:
Estimated 300+ pages (typical for factory service manuals)
Manual Type
Manual Type:
Factory Service Repair Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF - implied by typical product offerings for this type of manual)
📖 Manual Coverage
Systems Covered
Systems Covered:
Engine: Top End (Cylinder Head, Piston, Rings), Bottom End (Crankshaft, Connecting Rod, Bearings), Valve Train (Timing, Adjustment), Lubrication System (Oil Pump, Filter), Cooling System (Air Cooled), Fuel System (Carburetor, Jetting, Fuel Tank, Lines), Ignition System (CDI, Spark Plug), Exhaust System. Drivetrain: Transmission (Gears, Shifting), Clutch (Operation, Adjustment), Final Drive (Chain, Sprockets). Chassis: Frame, Swingarm, Suspension (Front Forks, Rear Shock Absorber, Linkages), Steering System (Handlebars, Headset), Brakes (Front and Rear Drum/Disc Brakes, Master Cylinder, Caliper, Lines), Wheels and Tires, Electrical System (Wiring Harness, Lighting, Battery, Ignition Switch, Kill Switch).
Electrical System Details:
Comprehensive wiring diagrams, troubleshooting charts for starting system, ignition system, lighting, and all electrical components. Location of electrical parts.
Braking System Details:
Front disc brake: Hydraulic caliper, master cylinder, brake pads, rotor specifications. Rear drum brake: Brake shoes, brake drum inspection and adjustment. Brake fluid type and bleeding procedures.
Procedures Included
Procedures Included:
Routine Maintenance (Oil Changes, Filter Replacement, Chain Adjustment, Spark Plug Replacement, Air Filter Cleaning), Engine Disassembly and Reassembly, Carburetor Cleaning and Adjustment, Valve Clearance Adjustment, Suspension Fork Seal Replacement, Brake System Bleeding and Service, Clutch Adjustment, Wheel Bearing Replacement, Electrical System Troubleshooting and Repair, Torque Specifications for all fasteners, Diagnostic Procedures for common issues.
Troubleshooting Procedures:
Detailed symptom-based troubleshooting guides for engine performance issues, starting problems, electrical faults, braking issues, and chassis handling concerns.
Technical Depth
Technical Depth:
Comprehensive: Covers everything from basic owner maintenance to full engine rebuilds, including detailed diagnostic trees and specifications for all components. Suitable for both DIY enthusiasts and professional technicians.
📊 Manual Specifications
File Format
File Format:
PDF (Searchable text and high-resolution illustrations)
Searchability:
Fully searchable text content for quick access to specific information.
Print Quality
Print Quality:
High-resolution, clear diagrams and text, suitable for printing individual pages or the entire manual.
Binding Type
Binding Type:
N/A (Digital)
Paper Type
Paper Type:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, SOHC, 2-valve, Air-cooled
Bore X Stroke:
54 mm x 54.5 mm
Displacement:
124 cc
Compression Ratio:
9.5:1
Carburetor:
Mikuni VM20SS (typical for this model)
Valve Actuation:
SOHC (Single Overhead Camshaft)
Performance
Horsepower:
Approx. 10-12 HP (at the crankshaft, estimated)
Torque:
Approx. 7-8 lb-ft (at the crankshaft, estimated)
Carburetor Size:
20 mm
Fuel System
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
1.6 US gal (6.0 L)
Fuel Delivery:
Carburetor
🔧 Transmission
Standard
Transmission Type:
Constant mesh, 5-speed
Clutch Type:
Wet, multi-disc
Final Drive:
Chain
Features
Gear Ratios:
Specific ratios available in manual
📐 Dimensions
Exterior
Overall Length:
TT-R125: 1845 mm (72.6 in), TT-R125LW: 1955 mm (77.0 in)
Overall Width:
805 mm (31.7 in)
Overall Height:
1135 mm (44.7 in)
Seat Height:
TT-R125: 805 mm (31.7 in), TT-R125LW: 880 mm (34.6 in)
Wheelbase:
TT-R125: 1275 mm (50.2 in), TT-R125LW: 1345 mm (53.0 in)
Weights
Wet Weight:
Approx. 90 kg (198 lbs) for TT-R125, Approx. 94 kg (207 lbs) for TT-R125LW
Ground Clearance:
Approx. 305 mm (12.0 in) for TT-R125LW
Dry Weight:
Approx. 82 kg (181 lbs) for TT-R125
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Off-road motorcycle, not typically subject to DOT/NHTSA ratings)
Active Features
Active Features:
Responsive braking system, dependable engine management.
Passive Features
Passive Features:
Robust frame construction, durable suspension components.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Off-road motorcycle, no infotainment system)
Driver Assistance
Driver Assistance Features:
N/A (Off-road motorcycle, no electronic driver assistance features beyond basic ignition and kill switch functionality).
Connectivity
Connectivity Options:
N/A (Off-road motorcycle)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 1000 km (600 miles) or 6 months, whichever comes first (refer to manual for exact specifications).
Air Filter Cleaning:
Every 500 km (300 miles) or as needed in dusty conditions.
Valve Clearance Check:
Every 6000 km (3700 miles).
Spark Plug Replacement:
Every 6000 km (3700 miles).
Chain Lubrication And Adjustment:
Lubricate and adjust chain tension every 500 km (300 miles) or more frequently under severe conditions.
Fluid Specifications
Engine Oil Type:
Yamalube 4 (or equivalent SAE 10W-40 API SG or higher) API SG/JASO MA
Engine Oil Capacity:
0.90 L (0.95 US qt) without oil filter change, 0.95 L (1.00 US qt) with oil filter change.
Brake Fluid Type:
DOT 3 or DOT 4
Coolant Type:
N/A (Air-cooled)
Known Issues
Known Issues:
Carburetor jetting can sometimes be lean from the factory, leading to performance issues; clutch wear can occur with aggressive use; suspension may require tuning for different rider weights or terrain.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Yamaha has a long and distinguished history in motorcycle manufacturing, particularly in off-road and motocross disciplines, known for innovation and performance.
Model Evolution
Model Evolution:
The TT-R125 series was introduced as a successor to earlier trail bikes, offering a modern package with an emphasis on reliability and usability for younger or less experienced riders. The LW variant was added to cater to a broader range of rider sizes and skill levels. The 2002 model represents an early iteration of this successful platform.
Production
Production Years:
The TT-R125 platform has been in continuous production with various updates since its introduction in the early 2000s.
🏆 Awards & Recognition
Recognitions
Recognitions:
While specific awards for the 2002 model are not widely documented, the TT-R125 series has consistently been praised in enthusiast reviews for its reliability, ease of use, and value as a beginner-friendly off-road bike.
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