clutch YAMAHA YBR125 2003 User Guide

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

6-8
e. Fill engine with oil. Install the oil filter cap and tighten.
NOTE:
Recommended engine oil classification; API Service “SH”
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 “SH”
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:

Brake fluid replacement
1. Complete fluid replacement should be done only bytrained service personnel.
2. Have a Yamaha dealer replace the following components during periodic maintenance or when they
are damaged or leaking.
a. Replace all rubber seals every two years.
b. Replace all hoses every four years.
!%Clutch adjustment
The clutch lever free play should be adjusted to 10 ~ 15
mm (0.4 ~ 0.6 in) at the clutch lever end. If the free play is
incorrect, adjust as follows.
1. Loosen the locknut at the handlebar.
2. Turn the adjuster in or out until proper lever free play is
obtained.
3. Tighten the locknut.
4. If the free play is still incorrect, make an adjustment at the crankcase side.
NOTE:
If proper adjustment cannot be obtained or the clutch does
not work correctly, ask a Yamaha dealer to inspect the
internal clutch mechanism.
1. Locknut 2. Adjuster a. 10 ~ 15 mm (0.4 ~ 0.6 in)
Brake fluid replacement
1. Complete fluid replacement should be done only by trained service personnel.
2. Have a Yamaha dealer replace the following components during periodic maintenance or when they
are damaged or leaking.
a. Replace all rubber seals every two years.
b. Replace all hoses every four years.
!%Clutch adjustment
The clutch lever free play should be adjusted to 10 ~ 15
mm (0.4 ~ 0.6 in) at the clutch lever end. If the free play is
incorrect, adjust as follows.
1. Loosen the locknut at the handlebar.
2. Turn the adjuster in or out until proper lever free play is
obtained.
3. Tighten the locknut.
4. If the free play is still incorrect, make an adjustment at the crankcase side.
NOTE:
If proper adjustment cannot be obtained or the clutch does
not work correctly, ask a Yamaha dealer to inspect the
internal clutch mechanism.
1. Locknut 2. Adjuster a. 10 ~ 15 mm (0.4 ~ 0.6 in)

6-24
Throttle cable and grip lubrication
The throttle twist grip assembly should be greased at the
time the cable is lubricated, since the grip must be removed
to get at the end of the throttle cable.
After removing the screws, hold the end of the cable up in
the air and put in several drops of lubricant. With the throttle
grip disassembled, coat the metal surface of the grip
assembly with a suitable all-purpose grease.Brake and shift pedals
Lubricate the pivoting parts.
RECOMMENDED LUBRICANT: Engine oil SAE 20W50
Brake and clutch levers
Lubricate the pivoting parts. RECOMMENDED LUBRICANT: Engine oil SAE 20W50
Sidestand
Lubricate the pivoting parts. Check to see that the sidestand
moves up and down smoothly. RECOMMENDED LUBRICANT: Engine oil SAE 20W50
WARNING:
If the sidestand does not move smoothly, consult a
Yamaha dealer.
CAUTION:
6-24
Throttle cable and grip lubrication
The throttle twist grip assembly should be greased at the
time the cable is lubricated, since the grip must be removed
to get at the end of the throttle cable.
After removing the screws, hold the end of the cable up in
the air and put in several drops of lubricant. With the throttle
grip disassembled, coat the metal surface of the grip
assembly with a suitable all-purpose grease. Brake and shift pedals
Lubricate the pivoting parts.
RECOMMENDED LUBRICANT: Engine oil SAE 20W50
Brake and clutch levers
Lubricate the pivoting parts. RECOMMENDED LUBRICANT: Engine oil SAE 20W50
Sidestand
Lubricate the pivoting parts. Check to see that the sidestand
moves up and down smoothly. RECOMMENDED LUBRICANT: Engine oil SAE 20W50
WARNING:
If the sidestand does not move smoothly, consult a
Yamaha dealer.
CAUTION:

MODEL YBR 125ED
Engine oil: Type Yamalube 4 or SAE 20W50 type SH
Capacity: Periodic oil change 1.0 L ( 0.220 Imp galt, 0.264 US gal)
Total amount 1.2 L ( 0.264 Imp gal, 0.317 US gal)
Air filter: Wet type element
Fuel: Type Regular unleaded gasoline
Tank capacity 13 L ( 2.860 Imp gal, 3.434 US gal)
Reserve amount 1.7 L ( 0.374 Imp gal, 0.450 US gal)
Carburetor: Type/manufacturer VM 20 / MIKUNI
Spark plug: Type/manufacturer CR7HSA / NGK or U22FSR-U / DENSO
Gap 0.7 mm (0.028 in)
Clutch type: Wet, multi-disc
8-2
MODEL YBR 125ED
Engine oil: Type Yamalube 4 or SAE 20W50 type SH
Capacity: Periodic oil change 1.0 L ( 0.220 Imp galt, 0.264 US gal)
Total amount 1.2 L ( 0.264 Imp gal, 0.317 US gal)
Air filter: Wet type element
Fuel: Type Regular unleaded gasoline
Tank capacity 13 L ( 2.860 Imp gal, 3.434 US gal)
Reserve amount 1.7 L ( 0.374 Imp gal, 0.450 US gal)
Carburetor: Type/manufacturer VM 20 / MIKUNI
Spark plug: Type/manufacturer CR7HSA / NGK or U22FSR-U / DENSO
Gap 0.7 mm (0.028 in)
Clutch type: Wet, multi-disc
8-2