YAMAHA YBR125 2004 Service Manual

PERIODIC MAINTENANCE AND MINOR REPAIRS
6-1 Perodic inspection, adjustment, and lubrication will keep
your motorcycle in the safest and most efficient condition
possible. Safety is an OBLIGATION of the motorcycle
owner.
The maintenance and lubrication schedule chart should be
considered strictly as a guide to general maintenance and
lubrication intervals. YOU MUST TAKE INTO
CONSIDERATION THAT WEATHER, TERRAIN,
GEOGRAPHICAL LOCATIONS, AND A VARIETY OF
INDIVIDUAL USES ALL TEND TO DEMAND THAT EACH
OWNER ALTER THIS TIME SCHEDULE TO SHORTER
INTERVALS TO MATCH THE ENVIRONMENT.
The most important points of motorcycle inspection,
adjustment, and lubrication are explained in the following
pages.If you are not familiar with motorcycle service, this work
should be done by a Yamaha dealer.CAUTION:
PERIODIC MAINTENANCE AND MINOR REPAIRS
6-1 Perodic inspection, adjustment, and lubrication will keep
your motorcycle in the safest and most efficient condition
possible. Safety is an OBLIGATION of the motorcycle
owner.
The maintenance and lubrication schedule chart should be
considered strictly as a guide to general maintenance and
lubrication intervals. YOU MUST TAKE INTO
CONSIDERATION THAT WEATHER, TERRAIN,
GEOGRAPHICAL LOCATIONS, AND A VARIETY OF
INDIVIDUAL USES ALL TEND TO DEMAND THAT EACH
OWNER ALTER THIS TIME SCHEDULE TO SHORTER
INTERVALS TO MATCH THE ENVIRONMENT.
The most important points of motorcycle inspection,
adjustment, and lubrication are explained in the following
pages.If you are not familiar with motorcycle service, this work
should be done by a Yamaha dealer.CAUTION:

NOTE:
If you do not have necessary tools required during a service
operation, take your motorcycle to a Yamaha dealer for
service.
Modifications to this motorcycle not approved by
Yamaha may cause loss of performance, excessive
emissions, and render it unsafe for use. Consult a
Yamaha dealer before attempting any changes.
6-2 Tool kit
The tools provided in the ownerís tool kit are to assist you
in the performance of periodic maintenance. However, some
other tools such as a torque wrench are also necessary to
perform the maintenance correctly.
1. Tool kit
WARNING:
NOTE:
If you do not have necessary tools required during a service
operation, take your motorcycle to a Yamaha dealer for
service.
Modifications to this motorcycle not approved by
Yamaha may cause loss of performance, excessive
emissions, and render it unsafe for use. Consult a
Yamaha dealer before attempting any changes.
6-2 Tool kit
The tools provided in the ownerís tool kit are to assist you
in the performance of periodic maintenance. However, some
other tools such as a torque wrench are also necessary to
perform the maintenance correctly.
1. Tool kit
WARNING:

6-3 PERIODIC MAINTENANCE / LUBRICATION
Wheel bearings* Battery*
Check looseness and damage. Check electrolyte level, routing breather pipe.
ITEM
How it sounds
/ Adjust if necessary.
REMARKS1,000KM
Fuel line Air filter
Carburetor*Valves*
Muffler
Brakes* Engine oil
Steering bearings* Rear arm pivot*Check fuel hose, for cracks or damage.Clean or replace if necessary.
Adjust
Check damage, Retighten.
Check operation, adjust.
Grease the brake cam. Replace / Check level
Check loosenes.
Repack every 12,000 km or 12 month.** Check rear arm assembly for looseness.
Moderately repack.***
EVERY
3,000KM
OR ERERY
6 MONTHS
Wheels* and tires
Check tire pressure, runout and spoke tightness.
Spark plugCheck condition and clean if necessary.
Replace if necessary every 12,000 Km.
3,000KM
6-3 PERIODIC MAINTENANCE / LUBRICATION
Wheel bearings* Battery*
Check looseness and damage. Check electrolyte level, routing breather pipe.
ITEM
How it sounds
/ Adjust if necessary.
REMARKS1,000KM
Fuel line Air filter
Carburetor*Valves*
Muffler
Brakes* Engine oil
Steering bearings* Rear arm pivot*Check fuel hose, for cracks or damage.Clean or replace if necessary.
Adjust
Check damage, Retighten.
Check operation, adjust.
Grease the brake cam. Replace / Check level
Check loosenes.
Repack every 12,000 km or 12 month.** Check rear arm assembly for looseness.
Moderately repack.***
EVERY
3,000KM
OR ERERY
6 MONTHS
Wheels* and tires
Check tire pressure, runout and spoke tightness.
Spark plugCheck condition and clean if necessary.
Replace if necessary every 12,000 Km.
3,000KM

6-4 *
**
***: It is recommended that these items be serviced by a Yamaha dealer.
: Molybdenum disulfide grease.
: Lithium soap based grease.
ITEM
Front forks*
Centerstand and
sidestand*
Control cables: throttle /
clutch / front brakeRear shock absorber*
Drive chain
Fittings / fastenersCheck operation / oil leakage.
Check operation, looseness.
Adujst / Check operation
Lubricate every 12,000 Km. Check chain slack / lubricate, adjust if necessary.
Check and looseness.REMARKS1,000KM
Lights and flashers
Nuts and bolts
Motorcycle AspectCheck 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.
ITEM
Front forks*
Centerstand and
sidestand*
Control cables: throttle /
clutch / front brakeRear shock absorber*
Drive chain
Fittings / fastenersCheck operation / oil leakage.
Check operation, looseness.
Adujst / Check operation
Lubricate every 12,000 Km. Check chain slack / lubricate, adjust if necessary.
Check and looseness.REMARKS1,000KM
Lights and flashers
Nuts and bolts
Motorcycle AspectCheck operation.
Check tighten.
General Check
EVERY
3,000KM
OR EVERY3,000KM
Check operation / oil leakage.
Every 500 Km

Torque specifications
Use a torque wrench to tighten these items. It is
recommended that these items be checked occasionally,
specially before a long trip. Always check the tightness of
these items whenever they are loosened for any reason.
6-5
Torque
Nm
kgf.m Item
Spark plug
Engine oil drain plug
Oil check bolt
Front wheel axle nut
Rear wheel axle nut
12,5
20
7
45
911,25
2,0
0,7
4,5
9,1
A
(Nut)
10 mm
12 mm
14 mm
17 mm
19 mm
22 mmB
(Bolt)
6 mm
8 mm
10 mm
12 mm
14 mm
16 mmGeneral torque especifications
Nm
6
15
30
55
85
130kgf.m
0,6
1,5
3,0
5,5
8,5
13,0lbf. ft
4,3
11
22
40
61
94
lbf.ft
9.0
14.5
5.0
32.5
66
Torque specifications
Use a torque wrench to tighten these items. It is
recommended that these items be checked occasionally,
specially before a long trip. Always check the tightness of
these items whenever they are loosened for any reason.
6-5
Torque
Nm
kgf.m Item
Spark plug
Engine oil drain plug
Oil check bolt
Front wheel axle nut
Rear wheel axle nut
12,5
20
7
45
911,25
2,0
0,7
4,5
9,1
A
(Nut)
10 mm
12 mm
14 mm
17 mm
19 mm
22 mmB
(Bolt)
6 mm
8 mm
10 mm
12 mm
14 mm
16 mmGeneral torque especifications
Nm
6
15
30
55
85
130kgf.m
0,6
1,5
3,0
5,5
8,5
13,0lbf. ft
4,3
11
22
40
61
94
lbf.ft
9.0
14.5
5.0
32.5
66

6-6
1. Engine oil filler cap
1. Maximum mark 2.Minimum mark
Engine oil
1. Oil level measurement
a. Place the motorcycle on a level place and hold it in an
upright position. Warm up the engine for several
minutes.
NOTE:
Be sure the motorcycle is positioned straight up when
checking the oil level. A slight tilt toward the side can result
in false readings.
b. With the engine stopped, with the engine stopped,
unscrew the oil filler cap/ dispstick and rest it on the
threads of the ok.
NOTE:
Wait a few minutes until the oil level settles before checking.
c. Remove the oil filler cap/ dispstick, clean it with a dry
cloth and check the oil level.
NOTE:
To check the oil level the oil filler cap/ dispstick can not be
screwed, just lightly seated in place.
d. The oil level should be between the maximum and
minimum marks. If the level is low, add oil to raise it to the
indicated level, check for oil leakage.
6-6
1. Engine oil filler cap
1. Maximum mark 2.Minimum mark
Engine oil
1. Oil level measurement
a. Place the motorcycle on a level place and hold it in an
upright position. Warm up the engine for several
minutes.
NOTE:
Be sure the motorcycle is positioned straight up when
checking the oil level. A slight tilt toward the side can result
in false readings.
b. With the engine stopped, with the engine stopped,
unscrew the oil filler cap/ dispstick and rest it on the
threads of the ok.
NOTE:
Wait a few minutes until the oil level settles before checking.
c. Remove the oil filler cap/ dispstick, clean it with a dry
cloth and check the oil level.
NOTE:
To check the oil level the oil filler cap/ dispstick can not be
screwed, just lightly seated in place.
d. The oil level should be between the maximum and
minimum marks. If the level is low, add oil to raise it to the
indicated level, check for oil leakage.

6-7
2. Engine oil and filter replacement
a. Warm up the engine for a few minutes.
b. Stop the engine. Place an oil pan under the engine and
remove the dipstick.
c. Remove the drain plug and drain the oil.
d. Reinstall the drain plug, check if the gasket is damaged
and tighten it to the specified torque.
Tightening torque:
Drain plug:
20 N.m (2.0 kgf.m, 14.5 lbf.t)
1.Dipstick
1. Engine oil drain plug
6-7
2. Engine oil and filter replacement
a. Warm up the engine for a few minutes.
b. Stop the engine. Place an oil pan under the engine and
remove the dipstick.
c. Remove the drain plug and drain the oil.
d. Reinstall the drain plug, check if the gasket is damaged
and tighten it to the specified torque.
Tightening torque:
Drain plug:
20 N.m (2.0 kgf.m, 14.5 lbf.t)
1.Dipstick
1. Engine oil drain plug

6-8 e.Fill engine with oil. Install the oil filter cap and tighten.
NOTE:
Recommended engine oil classification; API Service ìSHî
type or equivalent
Do not put in any chemical additives. Engine oil also
lubricates the clutch and additives could cause clutch
slippage.
Be sure no foreign material enters the crankcase.
f. Start the engine and warm up for a few minutes.
While warming up, check for oil leakage. If oil
leakage is found, stop the engine immediately, and
check for the cause.
g. Stop the engine and check the oil level.
After replacing the engine oil, be sure to check the oil
pressure.
Oil quantity:
Total amount:
1.2 L ( 0.264 Imp gal, 0.317 US gal)
Periodic oil change:
1.0 L ( 0.220 Imp gal, 0.264 US gal) Recommended oil:
Yamalube 4
CAUTION:
CAUTION:
CAUTION:
6-8 e.Fill engine with oil. Install the oil filter cap and tighten.
NOTE:
Recommended engine oil classification; API Service ìSHî
type or equivalent
Do not put in any chemical additives. Engine oil also
lubricates the clutch and additives could cause clutch
slippage.
Be sure no foreign material enters the crankcase.
f. Start the engine and warm up for a few minutes.
While warming up, check for oil leakage. If oil
leakage is found, stop the engine immediately, and
check for the cause.
g. Stop the engine and check the oil level.
After replacing the engine oil, be sure to check the oil
pressure.
Oil quantity:
Total amount:
1.2 L ( 0.264 Imp gal, 0.317 US gal)
Periodic oil change:
1.0 L ( 0.220 Imp gal, 0.264 US gal) Recommended oil:
Yamalube 4
CAUTION:
CAUTION:
CAUTION:

6-9 Oil pressure
1. Remove the check bolt 1 in the cylinder head.
2. Start the engine and keep it idling until oil flows out
of the bleed hole. If no oil comes out after one
minute, turn off the engine immediately so it will
not seize. In such a case go to the nearest Yamaha
dealer or other qualified mechanic for repairs.
3. After checking, tighten the check bolt to the
specified torque.
Check bolt torque:
7 N.m (0.7 Kgf.m, 5.0 lbf.ft)
1. Check bolt
6-9 Oil pressure
1. Remove the check bolt 1 in the cylinder head.
2. Start the engine and keep it idling until oil flows out
of the bleed hole. If no oil comes out after one
minute, turn off the engine immediately so it will
not seize. In such a case go to the nearest Yamaha
dealer or other qualified mechanic for repairs.
3. After checking, tighten the check bolt to the
specified torque.
Check bolt torque:
7 N.m (0.7 Kgf.m, 5.0 lbf.ft)
1. Check bolt

6-10Air filter
The air filter should be cleaned at the specified intervals.
It should be cleaned more frequently if you are riding in
unusually wet or dusty areas.
1. Remove the right side cover.(pag. 3-13)
2. Remove the air filter case cover by removing the bolts.
3. Remove the clamp.
4. Remove the air filter from the case.
6-10Air filter
The air filter should be cleaned at the specified intervals.
It should be cleaned more frequently if you are riding in
unusually wet or dusty areas.
1. Remove the right side cover.(pag. 3-13)
2. Remove the air filter case cover by removing the bolts.
3. Remove the clamp.
4. Remove the air filter from the case.