light YAMAHA YBR125 2003 Owners Manual

IX
ACCESSORIES AND LOADING
Adding accessories or cargo to your machine can adversely affect stability and handling if the weight distribution of the machine
is changed. To avoid the possibility of an accident, extreme caution should be used if adding cargo or accessories to your
machine.
Use extra care if riding a machine which has added cargo or acessories. Genuine Yamaha accessories have been specifically
designed for use on this machine. Since Yamaha cannot test all other accessories which may be available, you must personally
be responsible for the proper selection, installation and use of non-Yamaha accessories.
You should use extreme caution when selecting and installing any accessories. Keep in mind these guidelines for mounting
accessories in addition to those provided under “LOADING”.
1. Never install accessories or carry cargo that would impair the performance of your machine. Carefully inspect the accessory
before using it to make sure it does not in any way reduce ground clearance or cornering clearance, limit suspension travel,
steering travel or control operation, or obscure lights or reflectors.
a. Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic
changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept
to a minimum.
b. Bulky or large accessories may seriously affect the stability of the machine due to aerodynamic effects. Wind may
attempt to lift the machine, or the machine may become unstable in cross winds. These accessories may also cause instability
when being passed by or passing large vehicles.
c. Certain accessories can displace the operator from his or her normal riding position. This improper position limits the
freedom of movement of the operator and may limit control ability. Therefore such accessories are not recommended.
2. Caution must be used if adding electrical accessories. If these accessories exceed the capacity of the machine’s electrical
system, an electric failure could result, which could cause a dangerous loss of lights or engine power.
IX
ACCESSORIES AND LOADING
Adding accessories or cargo to your machine can adversely affect stability and handling if the weight distribution of the machine
is changed. To avoid the possibility of an accident, extreme caution should be used if adding cargo or accessories to your
machine.
Use extra care if riding a machine which has added cargo or acessories. Genuine Yamaha accessories have been specifically
designed for use on this machine. Since Yamaha cannot test all other accessories which may be available, you must personally
be responsible for the proper selection, installation and use of non-Yamaha accessories.
You should use extreme caution when selecting and installing any accessories. Keep in mind these guidelines for mounting
accessories in addition to those provided under “LOADING”.
1. Never install accessories or carry cargo that would impair the performance of your machine. Carefully inspect the accessory
before using it to make sure it does not in any way reduce ground clearance or cornering clearance, limit suspension travel,
steering travel or control operation, or obscure lights or reflectors.
a. Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic
changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept
to a minimum.
b. Bulky or large accessories may seriously affect the stability of the machine due to aerodynamic effects. Wind may
attempt to lift the machine, or the machine may become unstable in cross winds. These accessories may also cause instability
when being passed by or passing large vehicles.
c. Certain accessories can displace the operator from his or her normal riding position. This improper position limits the
freedom of movement of the operator and may limit control ability. Therefore such accessories are not recommended.
2. Caution must be used if adding electrical accessories. If these accessories exceed the capacity of the machine’s electrical
system, an electric failure could result, which could cause a dangerous loss of lights or engine power.

CONTENTS
DESCRIPTION............................................................. 1-1
MACHINE IDENTIFICATION ....................................... 2-1
Vehicle identification number ................................. 2-1
Engine serial number ............................................ 2-1
CONTROL FUNCTIONS .............................................. 3-1
Main switch ............................................................ 3-1
Indicator lights ........................................................ 3-2
Speedometer .......................................................... 3-3
Fuel gauge ............................................................. 3-3
Handlebar switches over left .................................. 3-4
Handlebar switches over right .............................. 3-5
Clutch lever .......................... .................................. 3-6
Shift pedal ............................................................. 3-6
Front brake lever ................................................... 3-7
Rear brake pedal ................................................... 3-7
Fuel tank cap ......................................................... 3-8
Fuel cock ............................................................... 3-9
Starter lever ......................................................... 3-10
Steering lock ....................... ................................ 3-11
Seat ...................................................................... 3-12
Side covers ......................................................... 3-13
Rear shock absorber adjustment........................ 3-14
Clutch switch operation check ............................ 3-15
XIPRE-OPERATION
CHECKS........................................ 4-1
Brakes ................................................................... 4-3
Brake fluid leakage ................................................ 4-4
Engine oil ................................................................ 4-4
Tires ........................................................................\
4-5
Clutch ..................................................................... 4-8
Throttle grip ............................ ................................ 4-8
Fitting/Fasteners .................................................... 4-8
Switches ................................................................ 4-8
Wheels ......................................................... 4-8
Fuel ........................................................... 4-9
OPERATION AND IMPORT ANT RIDING POINTS....... 5-1
Starting a cold engine .................................................. 5-2
Starting a warm engine ................................................ 5-4
Warming up the engine ................................................ 5-4
Shifting ........................................................................\
.. 5-5
Engine Break-in ............................................................ 5-6
Parking ........................................................................\
.. 5-7
CONTENTS
DESCRIPTION ............................................................. 1-1
MACHINE IDENTIFICATION ....................................... 2-1
Vehicle identification number ................................. 2-1
Engine serial number ............................................ 2-1
CONTROL FUNCTIONS .............................................. 3-1
Main switch ............................................................ 3-1
Indicator lights ........................................................ 3-2
Speedometer .......................................................... 3-3
Fuel gauge ............................................................. 3-3
Handlebar switches over left .................................. 3-4
Handlebar switches over right .............................. 3-5
Clutch lever .......................... .................................. 3-6
Shift pedal ............................................................. 3-6
Front brake lever ................................................... 3-7
Rear brake pedal ................................................... 3-7
Fuel tank cap ......................................................... 3-8
Fuel cock ............................................................... 3-9
Starter lever ......................................................... 3-10
Steering lock ....................... ................................ 3-11
Seat ...................................................................... 3-12
Side covers ......................................................... 3-13
Rear shock absorber adjustment........................ 3-14
Clutch switch operation check ............................ 3-15
XIPRE-OPERATION
CHECKS........................................ 4-1
Brakes ................................................................... 4-3
Brake fluid leakage ................................................ 4-4
Engine oil ................................................................ 4-4
Tires ........................................................................\
4-5
Clutch ..................................................................... 4-8
Throttle grip ............................ ................................ 4-8
Fitting/Fasteners .................................................... 4-8
Switches ................................................................ 4-8
Wheels ......................................................... 4-8
Fuel ........................................................... 4-9
OPERATION AND IMPORT ANT RIDING POINTS....... 5-1
Starting a cold engine .................................................. 5-2
Starting a warm engine ................................................ 5-4
Warming up the engine ................................................ 5-4
Shifting ........................................................................\
.. 5-5
Engine Break-in ............................................................ 5-6
Parking ........................................................................\
.. 5-7

PERIODIC MAINTENANCE AND MINOR REPAIRS..... 6-1
Tool kit..................................................................... 6-2
PERIODIC MAINTENANCE/LUBRICATION......... 6-3
Torque specifications............................................. 6-5
Engine oil................................................................ 6-6
Oil pressure ............................................................ 6-9
Air filter .................................................................6-10
Carburetor adjustment ......................................... 6-12
Valve clearance adjustment.................................6-12
Idle speed adjustment..........................................6-13
Throttle cable adjustment....................................6-14
Spark plug inspection...........................................6-15
Rear brake adjustment ......................................... 6-16
Brake light switch adjustment ..............................6-17
Checking the front brake pads and rear brake
shoes.................................................................... 6-17
Front brake...........................................................6-18
Rear brake ............................................................ 6-18
Inspecting the brake fluid level ............................6-19
Brake fluid replacement.......................................6-20
Clutch adjustment................................................6-20
Drive chain slack check .......................................6-21
Drive chain slack adjustment...............................6-22
Drive chain lubrication..........................................6-23
Cable inspection and lubrication..........................6-23
Throttle cable and grip lubrication.......................6-24Brake and shift pedals ......................................... 6-24
Brake and clutch levers ....................................... 6-24
Sidestand ............................................................. 6-24
Front fork inspection ............................................ 6-25
Steering inspection.............................................. 6-26
Wheel bearings.................................................... 6-26
Battery.................................................................. 6-27
Replenishing the battery fluid .............................. 6-28
Fuse replacement................................................ 6-29
Headlight bulb replacement................................. 6-30
Turn signal bulb replacement.............................. 6-32
Taillight bulb replacement.................................... 6-32
Front wheel removal............................................. 6-33
Front wheel installation........................................ 6-34
Rear wheel removal............................................. 6-35
Rear wheel installation ......................................... 6-36
Troubleshooting.................................................... 6-36
Troubleshooting chart.......................................... 6-37
CLEANING AND STORAGE....................................... 7-1
CLEANING............................................................. 7-1
STORAGE.............................................................. 7-2
SPECIFICATIONS ........................................................ 8-1
XII
PERIODIC MAINTENANCE AND MINOR REPAIRS..... 6-1
Tool kit..................................................................... 6-2
PERIODIC MAINTENANCE/LUBRICATION......... 6-3
Torque specifications............................................. 6-5
Engine oil................................................................ 6-6
Oil pressure ............................................................ 6-9
Air filter .................................................................6-10
Carburetor adjustment ......................................... 6-12
Valve clearance adjustment.................................6-12
Idle speed adjustment..........................................6-13
Throttle cable adjustment....................................6-14
Spark plug inspection...........................................6-15
Rear brake adjustment ......................................... 6-16
Brake light switch adjustment ..............................6-17
Checking the front brake pads and rear brake
shoes.................................................................... 6-17
Front brake...........................................................6-18
Rear brake ............................................................ 6-18
Inspecting the brake fluid level ............................6-19
Brake fluid replacement.......................................6-20
Clutch adjustment................................................6-20
Drive chain slack check .......................................6-21
Drive chain slack adjustment...............................6-22
Drive chain lubrication..........................................6-23
Cable inspection and lubrication..........................6-23
Throttle cable and grip lubrication.......................6-24Brake and shift pedals ......................................... 6-24
Brake and clutch levers ....................................... 6-24
Sidestand ............................................................. 6-24
Front fork inspection ............................................ 6-25
Steering inspection.............................................. 6-26
Wheel bearings.................................................... 6-26
Battery.................................................................. 6-27
Replenishing the battery fluid .............................. 6-28
Fuse replacement................................................ 6-29
Headlight bulb replacement................................. 6-30
Turn signal bulb replacement.............................. 6-32
Taillight bulb replacement.................................... 6-32
Front wheel removal............................................. 6-33
Front wheel installation........................................ 6-34
Rear wheel removal............................................. 6-35
Rear wheel installation ......................................... 6-36
Troubleshooting.................................................... 6-36
Troubleshooting chart.......................................... 6-37
CLEANING AND STORAGE....................................... 7-1
CLEANING............................................................. 7-1
STORAGE.............................................................. 7-2
SPECIFICATIONS ........................................................ 8-1
XII


0
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F
E30000
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14013012011 01009080706050403020100
Turn indicator lights " "
The corresponding indicator fhashes when the turn
switch is moved to the “ “ or “ “.
High beam indicator light "


"
This indicator comes on when the headlight high beam
is used.
Neutral indicator light " N "
This indicator comes on when the transmission is in
neutral. Indicator lights



 


 



 

 


0
3
2
1
F
E30000
Km h
14013012011 01009080706050403020100
Turn indicator lights " "
The corresponding indicator fhashes when the turn
switch is moved to the “ “ or “ “.
High beam indicator light "


"
This indicator comes on when the headlight high beam
is used.
Neutral indicator light " N "
This indicator comes on when the transmission is in
neutral. Indicator lights



 


 



 

 

Handlebar switches over left
1. Light switch 2. Pass switch
3. Dimmer switch 4. Turn signal switch
5. Horn switch
3-4LIGHTS SWITCH
Turning the light switch to “ “, turns on the meter light\
s,
headlight and tail-lights.
PASS SWITCH " "
Press the switch to operate the passing light.
Dimmer switch
Turn the switch to " " for the high beam and to " "
for the low beam.
TURN SIGNAL SWITCH " "
To signal a right-hand turn, push the switch to “ “ ; to
signal a left-hand turn, push the switch to “ “ .
Once the switch is released it will return to the center
position. To cancel the signal, push the switch in after it
has returned to the center position.
HORN SWITCH " "
Press the switch to sound the horn.
Handlebar switches over left
1. Light switch 2. Pass switch
3. Dimmer switch 4. Turn signal switch
5. Horn switch
3-4LIGHTS SWITCH
Turning the light switch to “ “, turns on the meter light\
s,
headlight and tail-lights.
PASS SWITCH " "
Press the switch to operate the passing light.
Dimmer switch
Turn the switch to " " for the high beam and to " "
for the low beam.
TURN SIGNAL SWITCH " "
To signal a right-hand turn, push the switch to “ “ ; to
signal a left-hand turn, push the switch to “ “ .
Once the switch is released it will return to the center
position. To cancel the signal, push the switch in after it
has returned to the center position.
HORN SWITCH " "
Press the switch to sound the horn.


NOTE:
Pre-operation checks should be made each time the motorcycle is used. Su\
ch an inspection can be thoroughly accomplished
in a very short time; and the added safety it assures is more than worth\
the time involved. If any maintenance service or
adjustment is needed, consult the chart above to refer to the pages in w\
hich the service or adjustment is described.
1. The engine, exhaust pipe, and muffler will be very hot after the engine \
has been run.
Be careful not to touch them or to allow any clothing item to contact th\
em during inspection or repair.
2. If any item is not working properly, have it inspected and repaired before operating the motorcycle.
ITEM ROUTINE
PAGE
Sidestand
Fittings / Fasteners Check all chassi fittings and fasteners.
Tighten / Adjust, if necessary
Check fuel level / top up as required.
Fuel tank
Lights, signals and switches
Battery Check electrolyte level.
Replenish with “distilled water” if necessary. 6-24
4-8 , 6-5
4-8 , 6-30 ~ 6-32 6-27 ~ 6-296-24
4-9 ~ 4-10
Check for proper operation
Front brake and clutch lever pivots Check for smooth operation.
Lubricate if necessary
Check for smooth operation.
Lubricate if necessary
6-24
Check for smooth operation.
Lubricate if necessary
Rear brake and shift pedal
shafts
WARNING:

NOTE:
Pre-operation checks should be made each time the motorcycle is used. Su\
ch an inspection can be thoroughly accomplished
in a very short time; and the added safety it assures is more than worth\
the time involved. If any maintenance service or
adjustment is needed, consult the chart above to refer to the pages in w\
hich the service or adjustment is described.
1. The engine, exhaust pipe, and muffler will be very hot after the engine \
has been run.
Be careful not to touch them or to allow any clothing item to contact th\
em during inspection or repair.
2. If any item is not working properly, have it inspected and repaired before operating the motorcycle.
ITEM ROUTINE
PAGE
Sidestand
Fittings / Fasteners Check all chassi fittings and fasteners.
Tighten / Adjust, if necessary
Check fuel level / top up as required.
Fuel tank
Lights, signals and switches
Battery Check electrolyte level.
Replenish with “distilled water” if necessary. 6-24
4-8 , 6-5
4-8 , 6-30 ~ 6-32 6-27 ~ 6-296-24
4-9 ~ 4-10
Check for proper operation
Front brake and clutch lever pivots Check for smooth operation.
Lubricate if necessary
Check for smooth operation.
Lubricate if necessary
6-24
Check for smooth operation.
Lubricate if necessary
Rear brake and shift pedal
shafts
WARNING:

5-2
Starting a cold engine
1. Turn the fuel cock to “ON”.
2. Turn the main switch to “ON” and the engine stop switch
to “ “.
3. Shift transmission into neutral.
NOTE:
When the transmission is in neutral, the neutral indicator
light should be on. If the light does not come on, ask a
Yamaha dealer to inspect it.
4. Fully open the starter (CHOKE) and completely close the throttle grip.
5. Start the engine by pushing the starter switch.
NOTE:
This motorcycle is equipped with a starting and an ignition
circuit cut-off switch.
1. The engine can be started only under the following conditions:
a. The transmission is in neutral.
b. The transmission is in gear and the clutch is disengaged.
2. The motorcycle must not be ridden when the sidestand is down. NOTE:
If the engine fails to start, release the starter switch, wait a
few seconds, then try again. Each attempt should be as
short as possible to preseve the battery. Do not crank the
engine more than 10 seconds on any one attempt.
6. After starting the engine, turn back the starter to an
intermediate position.
NOTE:
To obtain maximum engine life and service, do not ever
thoroughly accelerate it while the engine is cold.
7. After warming up the engine, turn back the starter (CHOKE) completely.
NOTE:
The engine is warm when it responds normally to the throttle
with the starter turned off.
5-2
Starting a cold engine
1. Turn the fuel cock to “ON”.
2. Turn the main switch to “ON” and the engine stop switch
to “ “.
3. Shift transmission into neutral.
NOTE:
When the transmission is in neutral, the neutral indicator
light should be on. If the light does not come on, ask a
Yamaha dealer to inspect it.
4. Fully open the starter (CHOKE) and completely close the throttle grip.
5. Start the engine by pushing the starter switch.
NOTE:
This motorcycle is equipped with a starting and an ignition
circuit cut-off switch.
1. The engine can be started only under the following conditions:
a. The transmission is in neutral.
b. The transmission is in gear and the clutch is disengaged.
2. The motorcycle must not be ridden when the sidestand is down. NOTE:
If the engine fails to start, release the starter switch, wait a
few seconds, then try again. Each attempt should be as
short as possible to preseve the battery. Do not crank the
engine more than 10 seconds on any one attempt.
6. After starting the engine, turn back the starter to an
intermediate position.
NOTE:
To obtain maximum engine life and service, do not ever
thoroughly accelerate it while the engine is cold.
7. After warming up the engine, turn back the starter (CHOKE) completely.
NOTE:
The engine is warm when it responds normally to the throttle
with the starter turned off.

1. Do not coast for long periods with the engine off,and do not tow the motorcycle a long distance. Even
with gears in neutral, the transmission is only
properly lubricated when the engine is running.
Inadequate lubrication may damage the
transmission.
2. Always use the clutch when changing gears. The engine, transmission, and driveline are not
designed to withstand the shock of forced shifting
and can be damaged by shifting without using the
clutch.

Shifting
The transmission lets you control the amount of power you
have available at a given speed for starting, accelerating,
climbing hills, etc. The use of shift pedal is sho
wn in the
illustration (page 3-6).
To shift into NEUTRAL, depress the shift pedal repeatedly
until it reaches the end of its travel (you will feel a stop
when you are in first gear), then raise the pedal slightly.
CAUTION:
1. Do not coast for long periods with the engine off,
and do not tow the motorcycle a long distance. Even
with gears in neutral, the transmission is only
properly lubricated when the engine is running.
Inadequate lubrication may damage the
transmission.
2. Always use the clutch when changing gears. The engine, transmission, and driveline are not
designed to withstand the shock of forced shifting
and can be damaged by shifting without using the
clutch.

Shifting
The transmission lets you control the amount of power you
have available at a given speed for starting, accelerating,
climbing hills, etc. The use of shift pedal is sho
wn in the
illustration (page 3-6).
To shift into NEUTRAL, depress the shift pedal repeatedly
until it reaches the end of its travel (you will feel a stop
when you are in first gear), then raise the pedal slightly.
CAUTION:

5-6
Tips for reducing fuel consumption
Your motorcycle’s fuel consumption depends to a large
extent on your riding style. The following tips can help reduce
fuel consumption.
1. Warm up the engine before riding.
2. Turn off the starter lever as soon as possible.
3. Shift up swiftly and avoid high engine speeds during
acceleration.
4. Do not double-clutch or rev the engine while shifting down and avoid high engine speeds with no load engine.
5. Turn off the engine instead of letting it idle for an extended lenght of time, i.e. in traffic jams, at traffic lights or railroad
crossings. Engine Break-in
There is never a more important period in the life of your
motorcycle than the period 1.000Km. For this reason we
ask that you carefully read the following material. Because
the engine is brand new, you must not put an excessive
load on it for the first several hours of running.
During this period, prolonged full throttle operation, or any
condition which might result in excessive heating of the
engine must be avoided.
1. 0 ~ 150 Km:
Avoid operation above 1/3 throttle. Stop the engine and
let it cool for 5 to 10 minutes after every hour of
operation. Vary the speed of the motorcycle from time
to time. Do not operate it at one set throttle position.
5-6
Tips for reducing fuel consumption
Your motorcycle’s fuel consumption depends to a large
extent on your riding style. The following tips can help reduce
fuel consumption.
1. Warm up the engine before riding.
2. Turn off the starter lever as soon as possible.
3. Shift up swiftly and avoid high engine speeds during
acceleration.
4. Do not double-clutch or rev the engine while shifting down and avoid high engine speeds with no load engine.
5. Turn off the engine instead of letting it idle for an extended lenght of time, i.e. in traffic jams, at traffic lights or railroad
crossings. Engine Break-in
There is never a more important period in the life of your
motorcycle than the period 1.000Km. For this reason we
ask that you carefully read the following material. Because
the engine is brand new, you must not put an excessive
load on it for the first several hours of running.
During this period, prolonged full throttle operation, or any
condition which might result in excessive heating of the
engine must be avoided.
1. 0 ~ 150 Km:
Avoid operation above 1/3 throttle. Stop the engine and
let it cool for 5 to 10 minutes after every hour of
operation. Vary the speed of the motorcycle from time
to time. Do not operate it at one set throttle position.

6-4
*
**
***
: It is recommended that these items be serviced by a Yamaha dealer.
: Molybdenum disulfide grease.
: Lithium soap based grease.
NOTE:
Brake fluid replacement:
1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the brake fluid level and add fluid as required.
2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.
ITEM
Front forks*
Centerstand and
sidestand
Control cables: throttle /
clutch / front brake Rear shock absorber*
Drive chain
Fittings / fasteners
Check operation / oil leakage.
Check operation, looseness.
Adujst / Check operation
Lubricate every 12,000 Km.
Check chain slack / lubricate, adjust if necessary.
Check looseness. REMARKS1,000KM
Lights and flashers
Nuts and bolts
Motorcycle Aspect
Check operation.
Check tighten.
General Check
EVERY
3,000KM
OR EVERY3,000KM
Check operation / oil leakage.
Every 500 Km
6-4
*
**
***
: It is recommended that these items be serviced by a Yamaha dealer.
: Molybdenum disulfide grease.
: Lithium soap based grease.
NOTE:
Brake fluid replacement:
1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the brake fluid level and add fluid as required.
2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.
ITEM
Front forks*
Centerstand and
sidestand
Control cables: throttle /
clutch / front brake Rear shock absorber*
Drive chain
Fittings / fasteners
Check operation / oil leakage.
Check operation, looseness.
Adujst / Check operation
Lubricate every 12,000 Km.
Check chain slack / lubricate, adjust if necessary.
Check looseness. REMARKS1,000KM
Lights and flashers
Nuts and bolts
Motorcycle Aspect
Check operation.
Check tighten.
General Check
EVERY
3,000KM
OR EVERY3,000KM
Check operation / oil leakage.
Every 500 Km