Question about 2002 Yamaha TT-R 125 L

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Yamaha ttr 125 clicking sound in second gear

I believe my second gear on my bike has a broken tooth. I have a clicking sound that only happens in second gear. I've read that in order to fix the problem, I have to change second gear and the gear it meshes up with.

What gear meshes up with second gear? Does that mean I have to change first and third as well?

Also, and most importantly for me... what's involved in doing the work yourself? Is it a difficult task for someone with average, to above average mechanical abilities. I've never worked on dirtbike engines, so I was wondering if I'm biting off more than I can chew by doing the work myself. Thanks!

John

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Yes, change second gear and the gear it meshes up with. This is the voice of experience talking. Whatever caused the tooth to break applied the same pressure on the mating gear. That made the meshing gear weak such that as soon as pressure is on it again, it will break a tooth or two right away. See diagram below showing pinion gears, wheel gears and slider gears.

Yamaha ttr 125 clicking sound in second gear - 09cd321.png 4282256.png
Yamaha ttr 125 clicking sound in second gear - 3783529.png 3783529.png This is the transmission and clutch. The ENTIRE engine tears down, top end, clutch, shifter, kick starter, flywheel and electrics, forks and drum, crankshaft etc. Needed tools are a flywheel puller, case splitter, torque wrench, impact driver and circlip pliers. This is not a beginners project. You can get a factory service manual and give it a try but I don't recommend it. The service manual may or may not have a power transmission diagram. I don't have a diagram for this engine.

Posted on Jul 26, 2009

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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.

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Jun 26, 2009 | 2002 Yamaha TT-R 125

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