YAMAHA YBR125 2004 Repair Manual

6-21 Drive chain lubrication
The chain consists of many parts which work with each
other. If the chain is not maintained properly, it will wear out
quickly. Therefore, the chain must be serviced regularly.
This service is especially necessary when riding in dusty
areas.
1. Use Yamaha Chain and Cable Lube or any
brands of spray-type chain lubricant. First,
remove all dirt and mud from the chain with a
brush or cloth, then spray lubricant between both
rows of side plates and on all center rollers. The
chain should be lubricated every 500 km (300 mi).
2. To clean the chain, remove it from the machine,
dip it in solvent, and clean out as much dirt as
possible. Take the chain out of the solvent and
dry it. Immediately lubricate the chain to prevent
it from rusting.Cable inspection and lubrication
Damage to the outer housing of cables may allow
internal rusting and cause interfere with cable
movement. Replace damaged cables as soon as
possible to prevent unsafe conditions.
Lubricate the inner cable and the cable end. If it does not
operate smoothly, ask a Yamaha dealer to replace them.
RECOMMENDED LUBRICANT:
Engine oil SAE 20W50
WARNING:
6-21 Drive chain lubrication
The chain consists of many parts which work with each
other. If the chain is not maintained properly, it will wear out
quickly. Therefore, the chain must be serviced regularly.
This service is especially necessary when riding in dusty
areas.
1. Use Yamaha Chain and Cable Lube or any
brands of spray-type chain lubricant. First,
remove all dirt and mud from the chain with a
brush or cloth, then spray lubricant between both
rows of side plates and on all center rollers. The
chain should be lubricated every 500 km (300 mi).
2. To clean the chain, remove it from the machine,
dip it in solvent, and clean out as much dirt as
possible. Take the chain out of the solvent and
dry it. Immediately lubricate the chain to prevent
it from rusting.Cable inspection and lubrication
Damage to the outer housing of cables may allow
internal rusting and cause interfere with cable
movement. Replace damaged cables as soon as
possible to prevent unsafe conditions.
Lubricate the inner cable and the cable end. If it does not
operate smoothly, ask a Yamaha dealer to replace them.
RECOMMENDED LUBRICANT:
Engine oil SAE 20W50
WARNING:

6-22
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:
6-22
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:

6-23
1. Visual check
Check for scratches or damage on the inner tube and
excessive oil leakage from the front fork.
2. Operation check
Place the motorcycle on a level place.
a. Hold the motorcycle in an upright position and apply
the front brake.
b. Push down hard several times and check if the fork
rebounds smoothly.
If any damage or unsmooth movement is found with
the front fork, consult a Yamaha dealer. Front fork inspection
Securely support the motorcycle so there is no danger
of it falling over.
CAUTION:
WARNING:
6-23
1. Visual check
Check for scratches or damage on the inner tube and
excessive oil leakage from the front fork.
2. Operation check
Place the motorcycle on a level place.
a. Hold the motorcycle in an upright position and apply
the front brake.
b. Push down hard several times and check if the fork
rebounds smoothly.
If any damage or unsmooth movement is found with
the front fork, consult a Yamaha dealer. Front fork inspection
Securely support the motorcycle so there is no danger
of it falling over.
CAUTION:
WARNING:

6-24
Periodically inspect the condition of the steering. Worn out
or loose steering bearings may be dangerous. Place a stand
under the engine to raise the front wheel off the ground.
Hold the lower end of the front forks and try to move them
forward and backward. If any free play can be felt, ask a
Yamaha dealer to inspect and adjust the steering. Inspection
is easier if the front wheel is removed.
Securely support the motorcycle so there is no danger
of it falling over.Wheel bearings
If there is play in the front or rear wheel hub or if the wheel
does not turn smoothly, have a Yamaha dealer inspect the
wheel bearings. The wheel bearings should be inspected
according to the Maintenance Schedule.
Steering inspection
WARNING:
6-24
Periodically inspect the condition of the steering. Worn out
or loose steering bearings may be dangerous. Place a stand
under the engine to raise the front wheel off the ground.
Hold the lower end of the front forks and try to move them
forward and backward. If any free play can be felt, ask a
Yamaha dealer to inspect and adjust the steering. Inspection
is easier if the front wheel is removed.
Securely support the motorcycle so there is no danger
of it falling over. Wheel bearings
If there is play in the front or rear wheel hub or if the wheel
does not turn smoothly, have a Yamaha dealer inspect the
wheel bearings. The wheel bearings should be inspected
according to the Maintenance Schedule.
Steering inspection
WARNING:

6-25
BATTERY BREATHER HOSE ROUTING
YAMAHA Battery
Check the level of the battery electrolyte and make sure
that the terminals are tight. Add distilled water if the
electrolyte level is low.
1. When inspecting the battery, make sure that the
battery breather pipe routing is correct. If the
breather pipe touches painted parts, or if its end is
in such a position that may cause gas or electrolyte
leakage, it may cause structural or esthetic
damages to the motorcycle.
2. Take care not to spill battery fluid on the chain.
Battery fluid may weaken the chain causing shorter
chain life and possibly result in an accident.
WARNING:
BATTERY
AXLE
Hole in the battery box
(breather hose goes
through the hole)
Battery breather
hose
(passes in front
of the frame and
indicated axle)
Hose junction
(holds the breather hose)
6-25
BATTERY BREATHER HOSE ROUTING
YAMAHA Battery
Check the level of the battery electrolyte and make sure
that the terminals are tight. Add distilled water if the
electrolyte level is low.
1. When inspecting the battery, make sure that the
battery breather pipe routing is correct. If the
breather pipe touches painted parts, or if its end is
in such a position that may cause gas or electrolyte
leakage, it may cause structural or esthetic
damages to the motorcycle.
2. Take care not to spill battery fluid on the chain.
Battery fluid may weaken the chain causing shorter
chain life and possibly result in an accident.
WARNING:
BATTERY
AXLE
Hole in the battery box
(breather hose goes
through the hole)
Battery breather
hose
(passes in front
of the frame and
indicated axle)
Hose junction
(holds the breather hose)

6-26
Battery electrolyte is poisonous and dangerous,
causing severe burns, etc. It contains sulfuric acid.
Avoid contact with skin, eyes or clothing.
Antidote:
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities of water or milk.
Follow with milk of magnesia, beaten egg, or vegetable
oil. Call a physician immediately.
EYES: Flush with water for 15 minutes and get prompt
medical attention.
Batteries produce explosive gases. Keep sparks, flame,
cigarrettes, etc., away. Ventilate when charging or using
it in an enclosed space. Always shield your eyes when
working near batteries.
KEEP OUT OF REACH OF CHILDREN.
A poorly maintained battery will corrode and discharge
quickly. The battery fluid should be checked at least once
a month.
The level should be between the minimum and maximum
marks. Use only ìdistilled waterî if refilling is necessary.
Normal tap water contains minerals which are harmful
to a battery; therefore, refill only with “distilled water”. Replenishing the battery fluid
1. Maximum marks
2. Minimum marks
CAUTION:
WARNING:
6-26
Battery electrolyte is poisonous and dangerous,
causing severe burns, etc. It contains sulfuric acid.
Avoid contact with skin, eyes or clothing.
Antidote:
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities of water or milk.
Follow with milk of magnesia, beaten egg, or vegetable
oil. Call a physician immediately.
EYES: Flush with water for 15 minutes and get prompt
medical attention.
Batteries produce explosive gases. Keep sparks, flame,
cigarrettes, etc., away. Ventilate when charging or using
it in an enclosed space. Always shield your eyes when
working near batteries.
KEEP OUT OF REACH OF CHILDREN.
A poorly maintained battery will corrode and discharge
quickly. The battery fluid should be checked at least once
a month.
The level should be between the minimum and maximum
marks. Use only ìdistilled waterî if refilling is necessary.
Normal tap water contains minerals which are harmful
to a battery; therefore, refill only with “distilled water”. Replenishing the battery fluid
1. Maximum marks
2. Minimum marks
CAUTION:
WARNING:

Storage the battery
1. When the motorcycle is not used for a month or longer,
remove the battery and store it in a cool, dark place.
Completely recharge the battery before reinstallation.
2. If the baterry needs to be stored for a longer period
than the period mentioned above, check the specific
gravity at least once a month, and recharge it when the
specific gravity is below normal.
3. Always make sure the connections are correct when
reinstalling the battery. The red (positive) lead is for the
+ terminal and the black (negative) lead is for the -
terminal. Always connect the red (positive) lead first,
then connect the black (negative) lead. Make sure that
the battery breather pipe is correctly routed, free of
obstructions, and in good condition.
6-27
If a fuse is blown, turn off the ignition switch and the switch
of the circuit in question. Install a new fuse of proper
amperage. Turn on the switches and see if the electrical
device operates. If the fuse immediately blows again,
consult a Yamaha dealer.
WARNING:
Do not use fuses of higher amperage rating than those
recommended. Substitution of a fuse of improper rating
can cause extensive electrical system damage and
possibly a fire.
FUSE CAPACITY:10 A Fuse replacement
1. Fuse 2. Reserve
CAUTION:
Storage the battery
1. When the motorcycle is not used for a month or longer,
remove the battery and store it in a cool, dark place.
Completely recharge the battery before reinstallation.
2. If the baterry needs to be stored for a longer period
than the period mentioned above, check the specific
gravity at least once a month, and recharge it when the
specific gravity is below normal.
3. Always make sure the connections are correct when
reinstalling the battery. The red (positive) lead is for the
+ terminal and the black (negative) lead is for the -
terminal. Always connect the red (positive) lead first,
then connect the black (negative) lead. Make sure that
the battery breather pipe is correctly routed, free of
obstructions, and in good condition.
6-27
If a fuse is blown, turn off the ignition switch and the switch
of the circuit in question. Install a new fuse of proper
amperage. Turn on the switches and see if the electrical
device operates. If the fuse immediately blows again,
consult a Yamaha dealer.
WARNING:
Do not use fuses of higher amperage rating than those
recommended. Substitution of a fuse of improper rating
can cause extensive electrical system damage and
possibly a fire.
FUSE CAPACITY:10 A Fuse replacement
1. Fuse 2. Reserve
CAUTION:

6-28
1. Screw
Headlight bulb replacement
If the headlight bulb burns out, replace the bulb as follows:
1. Remove the screws.2. Loosen the bulb connectors and remove the rubber cover.
3. Turn the bulb socket counterclockwise and remove the
bulb.
Keep flammable products and your hands away from the
bulb while it is on, as it is hot. Do not touch the bulb until it
cools down
1. Rubber cover
CAUTION:
6-28
1. Screw
Headlight bulb replacement
If the headlight bulb burns out, replace the bulb as follows:
1. Remove the screws.2. Loosen the bulb connectors and remove the rubber cover.
3. Turn the bulb socket counterclockwise and remove the
bulb.
Keep flammable products and your hands away from the
bulb while it is on, as it is hot. Do not touch the bulb until it
cools down
1. Rubber cover
CAUTION:

6-29
1. Bulb
4. Put a new bulb, install the socket and the bulb rubber
cover.
5. Reconnect the connectors.
6. Reinstall the headlight assy. If it is necessary to adjust
the headlight beam, please consult a Yamaha dealer.
Avoid touching the glass part of the headlight bulb to
keep it free from oil, otherwise the transparency of
the glass, the life of the bulb and the luminous flux
will be adversely affected. If the headlight bulb gets
soiled, thoroughly clean it with a cloth moistened with
alcohol or lacquer thinner.
WARNING:
6-29
1. Bulb
4. Put a new bulb, install the socket and the bulb rubber
cover.
5. Reconnect the connectors.
6. Reinstall the headlight assy. If it is necessary to adjust
the headlight beam, please consult a Yamaha dealer.
Avoid touching the glass part of the headlight bulb to
keep it free from oil, otherwise the transparency of
the glass, the life of the bulb and the luminous flux
will be adversely affected. If the headlight bulb gets
soiled, thoroughly clean it with a cloth moistened with
alcohol or lacquer thinner.
WARNING:

6-30 Turn signal bulb replacement
1. Remove the screws and the lens.
2. Push the bulb inward and turn it counterclockwise.
3. Place a new bulb in the socket.
4. Install the lens and the screws.
Do not over-tighten the screws as the lens may break.Taillight bulb replacement
1. Remove the lens.
2. Push the bulb inward and turn it counterclockwise.
3. Place a new bulb in the socket.
4. Install the lens.
CAUTION:
6-30 Turn signal bulb replacement
1. Remove the screws and the lens.
2. Push the bulb inward and turn it counterclockwise.
3. Place a new bulb in the socket.
4. Install the lens and the screws.
Do not over-tighten the screws as the lens may break.Taillight bulb replacement
1. Remove the lens.
2. Push the bulb inward and turn it counterclockwise.
3. Place a new bulb in the socket.
4. Install the lens.
CAUTION: