check engine light YAMAHA YBR125 2004 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
Kick starter .......................................................... 3-10
Steering lock....................................................... 3-11
Seat......................................................................3-12
Side covers......................................................... 3-13
Rear shock absorber adjustment ....................... 3-14
XIPRE-OPERATION CHECKS........................................ 4-1
Engine oil................................................................ 4-3
Tires........................................................................4-3
Fitting/Fasteners....................................................4-6
Switches................................................................ 4-6
Wheels ......................................................... 4-6
Fuel ........................................................... 4-7
OPERATION AND IMPORTANT RIDING POINTS....... 5-1
Starting a cold engine........................................... 5-2
Starting a warm engine .......................................... 5-2
Warming up the engine .......................................... 5-2
Shifting ................................................................... 5-3
Tips for reduccing fuel consumption...................... 5-4
Engine Break-in...................................................... 5-4
Parking ................................................................... 5-5
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
Kick starter .......................................................... 3-10
Steering lock....................................................... 3-11
Seat......................................................................3-12
Side covers......................................................... 3-13
Rear shock absorber adjustment ....................... 3-14
XIPRE-OPERATION CHECKS........................................ 4-1
Engine oil................................................................ 4-3
Tires........................................................................4-3
Fitting/Fasteners....................................................4-6
Switches................................................................ 4-6
Wheels ......................................................... 4-6
Fuel ........................................................... 4-7
OPERATION AND IMPORTANT RIDING POINTS....... 5-1
Starting a cold engine........................................... 5-2
Starting a warm engine .......................................... 5-2
Warming up the engine .......................................... 5-2
Shifting ................................................................... 5-3
Tips for reduccing fuel consumption...................... 5-4
Engine Break-in...................................................... 5-4
Parking ................................................................... 5-5

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
Front brake adjustment........................................6-16
Checking the brake shoes ...................................6-16
Rear brake adjustment.........................................6-17
Brake light switch adjustment ..............................6-18
Clutch adjustment................................................ 6-18
Drive chain slack check.......................................6-19
Drive chain slack adjustment...............................6-20
Drive chain lubrication..........................................6-21
Cable inspection and lubrication.......................... 6-21
Throttle cable and grip lubrication .......................6-22
Brake and shift pedals .........................................6-22
Brake and clutch levers .......................................6-22
Sidestand.............................................................6-22
Front fork inspection............................................6-23Steering inspection.............................................. 6-24
Wheel bearings.................................................... 6-24
Battery.................................................................. 6-25
Replenishing the battery fluid .............................. 6-26
Storage the battery.............................................. 6-27
Fuse replacement................................................ 6-27
Headlight bulb replacement................................. 6-28
Turn signal bulb replacement.............................. 6-30
Taillight bulb replacement.................................... 6-30
Front wheel removal............................................. 6-31
Front wheel installation........................................ 6-32
Rear wheel removal............................................. 6-32
Rear wheel installation......................................... 6-33
Troubleshooting.................................................... 6-34
Troubleshooting chart.......................................... 6-35
CLEANING AND STORAGE....................................... 7-1
CLEANING............................................................. 7-1
STORAGE.............................................................. 7-2
SPECIFICATIONS ........................................................ 8-1
XII
CONTENTS
DESCRIPTION............................................................. 1-1
MACHINE IDENTIFICATION....................................... 2-1
Vehicle identikfication 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
Kick starter .......................................................... 3-10
Steering lock....................................................... 3-11
Seat......................................................................3-12
Side covers......................................................... 3-13
Rear shock absorber adjustment ....................... 3-14
XIPRE-OPERATION CHECKS........................................ 4-1
Engine oil................................................................ 4-3
Tires........................................................................4-3
Fitting/Fasteners....................................................4-6
Switches................................................................ 4-6
Wheels ......................................................... 4-6
Fuel ........................................................... 4-7
OPERATION AND IMPORTANT RIDING POINTS....... 5-1
Starting a cold engine........................................... 5-2
Starting a warm engine .......................................... 5-2
Warming up the engine .......................................... 5-2
Shifting ................................................................... 5-3
Tips for reduccing fuel consumption...................... 5-4
Engine Break-in...................................................... 5-4
Parking ................................................................... 5-5

4-2 NOTE:
Pre-operation checks should be made each time the motorcycle is used. Such 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 which 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 them during inspection or repair.
2. If any item is not working properly, have it inspected and repaired before operating the motorcycle.
ITEMROUTINE
PAGE
Sidestand
Fittings / FastenersCheck all chassi fittings and fasteners.
Tighten / Adjust, if necessary
Check fuel level / top up as required.
Fuel tank
Lights, signals and switches
BatteryCheck electrolyte level.
Replenish with ìdistilled waterî if necessary.6-22
4-6 , 6-5
4-6 , 6-28 ~ 6-30
6-25 ~ 6-276-22
4-7
Check for proper operation
Front brake and clutch
lever pivotsCheck for smooth operation.
Lubricate if necessary
Check for smooth operation.
Lubricate if necessary
6-22 Check for smooth operation.
Lubricate if necessary Rear brake and shift pedal
shafts
WARNING:
4-2 NOTE:
Pre-operation checks should be made each time the motorcycle is used. Such 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 which 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 them during inspection or repair.
2. If any item is not working properly, have it inspected and repaired before operating the motorcycle.
ITEMROUTINE
PAGE
Sidestand
Fittings / FastenersCheck all chassi fittings and fasteners.
Tighten / Adjust, if necessary
Check fuel level / top up as required.
Fuel tank
Lights, signals and switches
BatteryCheck electrolyte level.
Replenish with ìdistilled waterî if necessary.6-22
4-6 , 6-5
4-6 , 6-28 ~ 6-30
6-25 ~ 6-276-22
4-7
Check for proper operation
Front brake and clutch
lever pivotsCheck for smooth operation.
Lubricate if necessary
Check for smooth operation.
Lubricate if necessary
6-22 Check for smooth operation.
Lubricate if necessary Rear brake and shift pedal
shafts
WARNING:

5-2 Starting a cold engine
1. Turn the fuel cock to ìONî.
2. Turn the main switch to ìONî and the engine stop switch
to ì ì.
3. Shift transmission into neutral.
NOTE:
When the transmission is in neutral, the neutral indicator
light should be on. If the light does not come on, ask a
Yamaha dealer to inspect it.
4. Fully open the starter (CHOKE) and completely close
the throttle grip.
5. Kick the starter to start the engine.
6. After starting the engine, turn back the starter to an
intermediate position.
NOTE:
To obtain maximum engine life and service, do not ever
thoroughly accelerate it while the engine is cold.
7. After warming up the engine, turn back the stater
(CHOKE) completely.
NOTE:
The engine is warm when it responds normally to the throttle
with the starter turned off.
Starting a warm engine
The starter lever is not required when the engine is warm.
CAUTION:
If the engine fails to start with the procedures above, try to
start again with the throttle grip opened 1/4 to 1/2.
Warming up the engine
For 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.
CAUTION:
See the ìBreak-in sectionî prior to operating the motorcycle
for the first time.
5-2 Starting a cold engine
1. Turn the fuel cock to ìONî.
2. Turn the main switch to ìONî and the engine stop switch
to ì ì.
3. Shift transmission into neutral.
NOTE:
When the transmission is in neutral, the neutral indicator
light should be on. If the light does not come on, ask a
Yamaha dealer to inspect it.
4. Fully open the starter (CHOKE) and completely close
the throttle grip.
5. Kick the starter to start the engine.
6. After starting the engine, turn back the starter to an
intermediate position.
NOTE:
To obtain maximum engine life and service, do not ever
thoroughly accelerate it while the engine is cold.
7. After warming up the engine, turn back the stater
(CHOKE) completely.
NOTE:
The engine is warm when it responds normally to the throttle
with the starter turned off.
Starting a warm engine
The starter lever is not required when the engine is warm.
CAUTION:
If the engine fails to start with the procedures above, try to
start again with the throttle grip opened 1/4 to 1/2.
Warming up the engine
For 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.
CAUTION:
See the ìBreak-in sectionî prior to operating the motorcycle
for the first time.

6-6
1. Engine oil filler cap
1. Maximum mark 2.Minimum mark
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.
6-6
1. Engine oil filler cap
1. Maximum mark 2.Minimum mark
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.

6-20
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 a .To loosen the chain turn the chain
adjusting nuts in direction b 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:
6-20
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 a .To loosen the chain turn the chain
adjusting nuts in direction b 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: