check engine light YAMAHA YBR125 2003 Owners Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2003, Model line: YBR125, Model: YAMAHA YBR125 2003Pages: 90, PDF Size: 3.85 MB
Page 11 of 90
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
Page 12 of 90
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
Page 31 of 90
![YAMAHA YBR125 2003 Owners Manual
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 w](/img/51/53660/w960_53660-30.png "YAMAHA YBR125 2003 Owners Manual
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 w")
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:
Page 51 of 90
!!
1. Engine oil filler cap
1. Maximum mark 2.Minimum mark
1
Engine oil
1. Oil level measurement
a. Place the motorcycle on a level place and hold it in anupright 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.
!!
1. Engine oil filler cap
1. Maximum mark 2.Minimum mark
1
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.
Page 52 of 90
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 andremove the dipstick.
c. Remove the drain plug and drain the oil.
d. Reinstall the drain plug, check if the gasket is damaged and lighten 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
1
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 andremove the dipstick.
c. Remove the drain plug and drain the oil.
d. Reinstall the drain plug, check if the gasket is damaged and lighten 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
1
Page 67 of 90
!
Drive chain slack adjustment
1. Locknut 2. Adjusting bolt
1. Loosen the rear brake pedal free play adjusting nut.
2. Loosen the axle nut.
3. Loosen the chain adjusting locknuts on each chainpuller. To tighten the chain, turn the chain adjusting nuts
in direction .To loosen the chain turn the chain
adjusting nuts in direction and push the wheel
forward. Turn each chain adjusting nut exactly the same
amount to maintain correct axle alignment. There are
marks on each chain puller. Use these marks to align
the rear wheel. Too little chain slack will overload the engine and other vital
parts. Keep the slack within the specified limits.
To maintain correct axle alignment, Ensure the notch on
the adjuster is on the same mark on left and right side
4. After adjusting, be sure to tighten each chain adjusting
locknut. The tighten the axle nut to the specified torque
Axle nut torque: 91 N.m (9.1 Kgf.m, 66 lbf.ft)
Locknut torque: 15 N.m (1.5 Kgf.m, 11 lbf.ft)
5. Adjust the free play in the brake pedal.
Check the operation of the brake light after adjusting
the rear brake.
CAUTION:
CAUTION:
!
Drive chain slack adjustment
1. Locknut 2. Adjusting bolt
1. Loosen the rear brake pedal free play adjusting nut.
2. Loosen the axle nut.
3. Loosen the chain adjusting locknuts on each chain puller. To tighten the chain, turn the chain adjusting nuts
in direction .To loosen the chain turn the chain
adjusting nuts in direction and push the wheel
forward. Turn each chain adjusting nut exactly the same
amount to maintain correct axle alignment. There are
marks on each chain puller. Use these marks to align
the rear wheel. Too little chain slack will overload the engine and other vital
parts. Keep the slack within the specified limits.
To maintain correct axle alignment, Ensure the notch on
the adjuster is on the same mark on left and right side
4. After adjusting, be sure to tighten each chain adjusting
locknut. The tighten the axle nut to the specified torque
Axle nut torque: 91 N.m (9.1 Kgf.m, 66 lbf.ft)
Locknut torque: 15 N.m (1.5 Kgf.m, 11 lbf.ft)
5. Adjust the free play in the brake pedal.
Check the operation of the brake light after adjusting
the rear brake.
CAUTION:
CAUTION: