YAMAHA YBR125 2003 Service Manual

TURN THE MAIN SWITCH TO “ON” AND ENGINE STOP SWITCH TO “ ”
5-3
Before going through the following steps, check the
function of the clutch switch (See page 3-15)
ADVERTENCIA:
IF TRANSMISSION IS IN GEARPULL IN CLUTCH LEVER
AND PUSH STARTER SWITCH; ENGINE WILL START
MOTORCYCLE CAN BE RIDDEN
IF TRANSMISSION IS IN NEUTRAL
PUSH STARTER SWITCH; ENGINE WILL START
PUT TRANSMISSION IN GEAR
MOTORCYCLE CAN BE RIDDEN
WARNING:
TURN THE MAIN SWITCH TO “ON” AND ENGINE STOP SWITCH TO “ ”
5-3
Before going through the following steps, check the
function of the clutch switch (See page 3-15)
ADVERTENCIA:
IF TRANSMISSION IS IN GEARPULL IN CLUTCH LEVER
AND PUSH STARTER SWITCH; ENGINE WILL START
MOTORCYCLE CAN BE RIDDEN
IF TRANSMISSION IS IN NEUTRAL
PUSH STARTER SWITCH; ENGINE WILL START PUT TRANSMISSION IN GEAR
MOTORCYCLE CAN BE RIDDEN
WARNING:

 Starting a warm engine
The starter lever is not required when the engine is warm.
If the engine fail to start with the procedures above, try to
start it again with the throttle grip opened 1/4 to 1/2.Warming up the engine
For an extended engine life always warm the engine up
never accelerate hard while the engine is cold.
To check if engine temperature is normal, rev the engine
with the choke closed and check to see if it responds
normally.
See the “Break-in section” prior to operating the
motorcycle for the first time.
CAUTION:
CAUTION:
 Starting a warm engine
The starter lever is not required when the engine is warm.
If the engine fail to start with the procedures above, try to
start it again with the throttle grip opened 1/4 to 1/2.Warming up the engine
For an extended engine life always warm the engine up
never accelerate hard while the engine is cold.
To check if engine temperature is normal, rev the engine
with the choke closed and check to see if it responds
normally.
See the “Break-in section” prior to operating the
motorcycle for the first time.
CAUTION:
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:
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.

5-7
2. 150 ~ 500 Km:
Avoid prolonged operation above 1/2 throttle. Allow the
machine to rev freely through the gears, but do not use
full throttle at any time.
3. 500 ~ 1,000 Km: Avoid cruising speeds in excess of 3/4 throttle.
After 1,000Km of operation, be sure to replace the engine
oil.
4. After 1,000 Km: Avoid prolonged full throttle operation. Vary speeds
occasionally.
If any engine trouble should occur during the break-in
period, consult a Yamaha dealer immediately. Parking
When parking the motorcycle, stop the engine and remove
the ignition key. Turn the fuel cock to “OFF” whenever
stopping the engine.
The muffler and exhaust pipe are hot. Park the
motorcycle in a place where pedestrians or children
are not likely to touch the motorcycle. Do not park the
motorcycle on a slope or soft ground; the motorcycle
may fall over.
CAUTION:
CAUTION:
WARNING:
5-7
2. 150 ~ 500 Km:
Avoid prolonged operation above 1/2 throttle. Allow the
machine to rev freely through the gears, but do not use
full throttle at any time.
3. 500 ~ 1,000 Km: Avoid cruising speeds in excess of 3/4 throttle.
After 1,000Km of operation, be sure to replace the engine
oil.
4. After 1,000 Km: Avoid prolonged full throttle operation. Vary speeds
occasionally.
If any engine trouble should occur during the break-in
period, consult a Yamaha dealer immediately. Parking
When parking the motorcycle, stop the engine and remove
the ignition key. Turn the fuel cock to “OFF” whenever
stopping the engine.
The muffler and exhaust pipe are hot. Park the
motorcycle in a place where pedestrians or children
are not likely to touch the motorcycle. Do not park the
motorcycle on a slope or soft ground; the motorcycle
may fall over.
CAUTION:
CAUTION:
WARNING:

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.
!
Tool kit
The tools provided in the owner’s 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
1
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.
!
Tool kit
The tools provided in the owner’s 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
1
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.
REMARKS 1,000KM
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 plug Check 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.
REMARKS 1,000KM
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 plug Check 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.
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

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.
!
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
59
911,25
2,0
0,7
5,9
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
43
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.
!
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
59
911,25
2,0
0,7
5,9
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
43
66