Question about 2002 Yamaha TT-R 125

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Poping noise in the 1rst gear. all other gears seem fine

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If you hear a loud clicking noise when riding at 5mph and slowly accelerating to 25mph, you have a broken tooth on first gear. The pressure that broke the gear tooth was present on the gear that it meshes with. Both gears must be replaced. If only the known broken gear is replaced you will need to do the repair all over again 10 minutes after completing the first repair because the meshing gear will loose it's weakened tooth. In this case I believe the meshing gear is actually the main shaft. I don't have a gear shift pattern diagram for your bike but when the gearbox is opened up the meshing gear will be obvious.

The entire engine gets completely torn down. Not recommended for the novice mechanic. Flywheel puller, torque wrench, impact driver and case splitter required. I would install new crank bearings and seals (at least do the seals) and a new drive axle bearing and seal at the sprocket end. Now is the time to do it while the engine is already apart.

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Posted on Jun 26, 2009

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