brake YAMAHA YBR125 2003 Owners Manual

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

1-1
DESCRIPTION
01. Fuel cock
02. Starter lever
03. Battery
04. Fusible
05. Tool kit
06. Shift Pedal
07. Shock absorber
08. Air filter
09. Dispstick
10. Rear brake pedal
11. Clutch lever
12. Handlebar switches over right
13. Speedometer
14. Main switch
15. Fuel gauge
16. Front brake lever
17. Throttle
18. Handlebar switches over left
19. Fuel tank cap
1-1
DESCRIPTION
01. Fuel cock
02. Starter lever
03. Battery
04. Fusible
05. Tool kit
06. Shift Pedal
07. Shock absorber
08. Air filter
09. Dispstick
10. Rear brake pedal
11. Clutch lever
12. Handlebar switches over right
13. Speedometer
14. Main switch
15. Fuel gauge
16. Front brake lever
17. Throttle
18. Handlebar switches over left
19. Fuel tank cap

The front brake lever is located on the right handlebar. Pull
it toward the handlebar to apply the front brake.
"The rear brake pedal is on the right side of the motorcycle.
Press down the brake pedal to apply the rear brake.
Front brake lever Rear brake pedal
1. Front brake lever
1. Rear brake pedal
1
The front brake lever is located on the right handlebar. Pull
it toward the handlebar to apply the front brake.

"The rear brake pedal is on the right side of the motorcycle.
Press down the brake pedal to apply the rear brake.
Front brake lever Rear brake pedal
1. Front brake lever
1. Rear brake pedal
1

PRE-OPERATION CHECKS
Before using this motorcycle, check the following points:
ITEM ROUTINE
PAGE
Front brake
Check operation, condition and free play.
Adjust if necessary
Clutch
Throttle grip / cableCheck for smooth operation.
Lubricate / Adjust if necessary
Check oil level / add oil as necessary
Engine oil
Drive chainCheck chain slack and condition. Lubricate if necessary
Adjust if necessary.
Air filter
Control and meter cableCheck tire pressure, wear, damage and spoke tightness
Check for smooth operation.
Lubricate if necessary4-3 ~ 4-4
6-16 ~ 6-20
4-8 , 6-14 , 6-24
4-4 , 6-6 , 6-9
6-21 ~ 6-23
6-10 ~ 6-11
4-5 ~ 4-8 , 6-26
6-23 Check operation, condition and free play.
Adjust if necessary
Wheels / Tires
Clean and oil it frequently.4-8 , 6-20 Rear brakeCheck operation, free play, fluid level and fluid leakage.
Top-up with DOT #4 (or DOT #3) brake fluid if necessary.

PRE-OPERATION CHECKS
Before using this motorcycle, check the following points:
ITEM ROUTINE
PAGE
Front brake
Check operation, condition and free play.
Adjust if necessary
Clutch
Throttle grip / cableCheck for smooth operation.
Lubricate / Adjust if necessary
Check oil level / add oil as necessary
Engine oil
Drive chainCheck chain slack and condition. Lubricate if necessary
Adjust if necessary.
Air filter
Control and meter cableCheck tire pressure, wear, damage and spoke tightness
Check for smooth operation.
Lubricate if necessary4-3 ~ 4-4
6-16 ~ 6-20
4-8 , 6-14 , 6-24
4-4 , 6-6 , 6-9
6-21 ~ 6-23
6-10 ~ 6-11
4-5 ~ 4-8 , 6-26
6-23 Check operation, condition and free play.
Adjust if necessary
Wheels / Tires
Clean and oil it frequently.4-8 , 6-20 Rear brakeCheck operation, free play, fluid level and fluid leakage.
Top-up with DOT #4 (or DOT #3) brake fluid if necessary.



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:



Brakes
(See page 6-16 for details)
1. Brake lever and brake pedal
Check for correct free play in the front brake lever and
rear brake pedal and adjust if necessary. Make sure
the brakes are working properly by checking at low
speed shortly after starting out.
A soft, spongy feeling in the brake lever indicates a
failure in the brake system. Do not operate the
motorcycle until the failure in the brake system is
corrected. Ask a Yamaha dealer or other qualified
mechanic for immediate repairs. A soft, spongy feeling
could indicate a hazardous condition in the brake
system.2. Brake fluid
Check the brake fluid level. Add fluid if necessary.
RECOMMENDED BRAKE FLUID: DOT #4
NOTE:
If DOT #4 is not available, #3 can be used.
3. Check the disc pads.
Refer to page 6-18
4. Check the brake shoes.
Refer to page 6-18
NOTE:
When a brake service is necessary, consult a Yamaha
dealer or other qualified mechanic.
WARNING:


Brakes
(See page 6-16 for details)
1. Brake lever and brake pedal
Check for correct free play in the front brake lever and
rear brake pedal and adjust if necessary. Make sure
the brakes are working properly by checking at low
speed shortly after starting out.
A soft, spongy feeling in the brake lever indicates a
failure in the brake system. Do not operate the
motorcycle until the failure in the brake system is
corrected. Ask a Yamaha dealer or other qualified
mechanic for immediate repairs. A soft, spongy feeling
could indicate a hazardous condition in the brake
system.2. Brake fluid
Check the brake fluid level. Add fluid if necessary.
RECOMMENDED BRAKE FLUID: DOT #4
NOTE:
If DOT #4 is not available, #3 can be used.
3. Check the disc pads.
Refer to page 6-18
4. Check the brake shoes.
Refer to page 6-18
NOTE:
When a brake service is necessary, consult a Yamaha
dealer or other qualified mechanic.
WARNING:

4-4
Brake fluid leakage
Apply the brake for several seconds. Check to see if any
brake fluid leaks out from the pipe joints or the master
cylinder.
Brake fluid may deteriorate painted surfaces or plastic parts.
Never spill any fluid. If spilled, clean it up immediately.
If brake fluid leakage is found, ask a Yamaha dealer or
other qualified mechanic for immediate repairs. Such
leakage could indicate a hazardous condition.
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)
Engine oil
(See page 6-6 for details)
Make sure the engine oil is at the specified level. Add oil as
necessary.
Check the oil level in a daily manner and top it up if
necessary.
CAUTION:
WARNING:
CAUTION:
4-4
Brake fluid leakage
Apply the brake for several seconds. Check to see if any
brake fluid leaks out from the pipe joints or the master
cylinder.
Brake fluid may deteriorate painted surfaces or plastic parts.
Never spill any fluid. If spilled, clean it up immediately.
If brake fluid leakage is found, ask a Yamaha dealer or
other qualified mechanic for immediate repairs. Such
leakage could indicate a hazardous condition.
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)
Engine oil
(See page 6-6 for details)
Make sure the engine oil is at the specified level. Add oil as
necessary.
Check the oil level in a daily manner and top it up if
necessary.
WARNING:
CAUTION:
CAUTION:

4-7 After extensive tests, the tires listed below have been
approved by Yanaha for this model. The front and rear
tires should always be by the same manufacturer and
of the same design. No guarantee concerning handling
characteristics can be given if a tire combination other
than one approved by Yamaha is used on this
motorcycle.
Front
Rear
Size Manufacturer
Type
Minimum tire tread depth
(from and rear)0,8 mm (0.0315 in) 2.75-18 PIRELLI
42P MT 39
90/90-18 PIRELLI
57P MT 15
1. It is dangerous to ride with a worn-out tire. When
the tire tread begin to show signs of wear, replace
the tire immediately. Brakes, tires and related wheel
parts should be left to a Yamaha dealer.
2. Patching a punctured tube is not recommended. If
it is absolutely necessary to do so, use great care
and replace the tube as soon as possible with a
good quality replacement.
WARNING:WARNING:
4-7 After extensive tests, the tires listed below have been
approved by Yanaha for this model. The front and rear
tires should always be by the same manufacturer and
of the same design. No guarantee concerning handling
characteristics can be given if a tire combination other
than one approved by Yamaha is used on this
motorcycle.
Front
Rear
Size Manufacturer
Type
Minimum tire tread depth
(from and rear)0,8 mm (0.0315 in) 2.75-18 PIRELLI
42P MT 39
90/90-18 PIRELLI
57P MT 15
1. It is dangerous to ride with a worn-out tire. When
the tire tread begin to show signs of wear, replace
the tire immediately. Brakes, tires and related wheel
parts should be left to a Yamaha dealer.
2. Patching a punctured tube is not recommended. If
it is absolutely necessary to do so, use great care
and replace the tube as soon as possible with a
good quality replacement.
WARNING: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