clutch YAMAHA YBR125 2007 User Guide

OPERATION AND IMPORTANT RIDING POINTS
Tips for reducing fuel
consumptionYour 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. Move the strater Lever to “Off” 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 on the engine.
5. Turn off the engine instead of
letting it idle for an extended
length of time, i.e. in traffic jams, at
traffic lights or rail- road crossings.
6. Do not drive with excessive load
on the Motorcycle.
7. Plan your route in advance.
Running-inThere is never a more important
period in the life of your Motorcycle
than the period between zero and
1,000 kms. 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 1,000 kms. The
various parts in the engine wear and
polish themselves to the correct
operating clearances. During this
period, prolonged full throttle
operation, or any condition which
might result in excessive heating of
the engine, must be avoided.Be sure to replace the engine
oil as per recommended
schedule.
1,000 kms and below :
Avoid prolonged full-throttle
operation. Vary speed
occasionally.
5-3
CAUTION :
8. Avoid frequent braking.
9. Always maintain your tyre
pressure as per recommendation
10. Get your motorcycle serviced
periodically after every 2000 kms.
If any engine trouble should occur
during the "Running-in" period,
consult a YAMAHA dealer
immediately.
CAUTION :

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
PREVENTIVE MAINTENANCE SCHEDULE
VA LV E S
SPARK PLUG
CARBURETOR
AIR FILTER
FUEL LINE
FUEL FILTER
ENGINE OIL
ENGINE OIL
FILTER SCREEN
BRAKE-FRONT &
REAR
Check valve clearances, adjust if necessary.
Check condition, gap;
Clean and reset if necessary.
Check idle speed, Choke lever operation.
Clean, inspect & lubricate. (replace if necessary)
Check fuel hose, for cracks or damage.
Replace if necessary.
Check for free flow of petrol, cleanliness of filter bowl,
replace if necessary.
Replace with recommended oil - Yamalube SG Grade
(Warm engine before draining)
Wash with petrol
Check operation./ Adjust if necessary.
Grease the brake cam.
ITEM OPERATION SNO
1
2
3
5 4
6
7
8
9
*
WHEELS 13FRONT & REAR
REAR ARM PIVOT CLUTCH
12 11BRAKE SHOES-
10
Check runout, spoke tightness, damage;
Correct it, if necessary. Check for wear, replace if necessary.
Check alignment marks on Push Lever and
Tighten with specified Torque if necessary Check Rear Arm assembly for looseness. Crankcase L.H. Adjust if necessary.
30 Days OR
500-700 KmAFTER EVERY DAYS OR KMS
REPLACE EVERY 10,000 km90 Days OR
2500-2700 Km180 Days OR
4500-5000 KmAFTER
EVERY
2000 KMS

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
PREVENTIVE MAINTENANCE SCHEDULE
EVERY 10,000 KM EVERY 10,000 KM
17
Check operation/oil leakage.
REAR SHOCK
ABSORBER
Replace if necessary.
STEERING BEARING
FRONT FORKS 16 15
Check operation/oil leakage. Repair if necessary. Check Bearing assembly for looseness;
Correct if necessary.
Relace oil Repack grease
S.NO ITEMOPERATION
DRIVE CHAIN
NUTS, BOLTS AND
FASTENERS
CENTERSTAND AND
SIDE STAND
Check Chain slack, alignment. Adjust if necessary.
Clean periodically & lubricate.
Check all Chassis fittings and fasteners for looseness.
Tighten as per specification.
Check operation and lubricate if necessary.
Check electrolyte level and top it up if necessary.
Check specific gravity and charge if required.
Check breather pipe for blockage and routing.
CONTROL CABLES
-THROTTLE
-CLUTCH
-FRONT BRAKE 18
19
20
21
BATTERY
22
Readjust or replace as required. Check operation, free play, cable damage
EVERY MONTH
IT IS RECOMMENDED THAT THE ABOVE BE SERVICED BY AUTHORIZED DEALER.
SERVICE MORE FREQUENTLY WHEN THE VEHICLE IS DRIVEN IN DUSTY AREAS.YAMAHA*
EVERY 10,000 KMS
WHEEL BEARING 14
Check Bearing assembly for looseness, damage;
Replace if necessary.
Repack grease
30 Days OR
500-700 KmAFTER EVERY DAYS OR KMS
90 Days OR
2500-2700 Km180 Days OR
4500-5000 KmAFTER
EVERY
2000 KMS

1. Locknut
2. Adjusting nut
3. Free playClutch lever free play
adjustmentThe clutch lever free play should be
adjusted to 10 ~ 15 mm. If the free
play is incorrect, adjust as follows.
1 . Loosen the locknut.
2. Turn the adjusting nut in direction
to increase free play or in
direction to decrease free
play.
3. Tighten the locknut.è
çIf proper adjustment cannot be
obtained or the clutch does not work
correctly, ask a dealer to
inspect the internal clutch
mechanism.YAMAHA
1. Adjusting nut
2. Free playFront brake adjustmentThe front brake lever free play should
be adjusted to 10 ~ 15 mm.
1. Turn the adjusting nut in direction
to increase free play and
direction to decrease free play. ç
è
When it is impossible to make the
proper adjustment, ask a YAMAHA
dealer.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
NOTE :
WARNING

Brake and shift pedal
lubricationLubricate the pivoting parts.
Recommended lubricant:
20W40 Type SG
Brake and Clutch Lever
GreasingGrease the pivoting parts.
MULTIPURPOSE Recommended Grease :
Center and sidestand
lubricationLubricate the pivoting and mating
joints.
Check to see that the center and
sidestand move up and down
smoothly.
Recommended lubricant:
If the center and/or sidestand does
not move smoothly, consult
aYAMAHA dealer.20W40 Type SG
PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
WARNING

SPECIFICATIONS
8-1
SpecificationsModel LIBERO (5TS8)
Dimensions
Kerb weight :(With Engine Oil &
90% Fuel in Tank)- 119Kg.
Engine ::
Overall length 2,000 mm
Overall width 730 mm
Overall height 1,050 mm
Seat height (Upto Rider) 800 mm
(Upto Pillion Rider) 850 mm
Wheelbase 1,290 mm
Ground clearance 173 mm
Minimum turning radius 2,000 mm
Engine type
Cylinder arrangement
Displacement
Bore x Stroke 49X56
Compression ratio 9 : 1
Starting system
Lubrication system
Maximum power 7.6
Maximum torque 0.80Air cooled 4-stroke,SOHC
Forward inclined single
cylinder
106 cm
mm
Kick starter
Wet sump
PS(5.59 KW) @ 7500
Kgm. @ 6000
3
RPM
RPM
EngineOil:
Capacity
Air filter:
Fuel :
Carburettor:Type:
:
Periodic oil change 1.0
Total amount
Type G
Fuel tank capacity
Reserve amount
Type Variable Venturi Type
Manufacturer M/S Keihin Fie PrivateBe sure to use motor oils that do not contain
antifriction modifiers. Passenger car motor oils (often
labelled Energy conserving) contain anti-friction
additives which will cause clutch and/or starter clutch
slippage, resulting in reduced component life and
poor engine performance.
YAMALUBE 4-Stroke motor
oil (20W40 type SG)
L
1.2 L (First fill/Overhaul)
Wet type element
asoline (Petrol)
13.0 Litres
1.7Litres
Limited India.
CAUTION :

8-2
Spark plug :
Clutch type :
Transmission :
Chassis: Type/Manufacturer P-RA7HC--(CHAMPION)
Spark plug gap 0.8 ± 0.1 mm
Primary reduction system Spur gear
Primary reduction ratio 3.722 (67/18)
Secondary reduction system Chain drive
Secondary reduction ratio 3.214 (45/14)
Transmission type Constant mesh 4 speed
Operation
Gear ratio 1st 3
2nd 1.688 (27/16)
3rd 1.200 (24/20)
4th 0.875 (21/24)
Frame type Double Cradle
Caster angle
Trail 91mmWet, multiple-disc
Left foot operation
.000 (33/11)
26.4
o
Tyre with Tube
Size
Front
Rear 3.00
Air pressure (cold tyre ):
Single Rider
Front
Rear 33
With Pillion and rider
Front
Rear2.75 x18” 4PR
X18” 6PR
25 psi (1.75 Kgf/cm )
psi (2.25Kgf/cm )
25 psi (1.75Kgf/cm )
36 psi (2.5 Kgf/cm )
2
2
2
2
SPECIFICATIONS

10-1
1. Check for any missing item(s), scratches in painted/plated part(s), saddle or other external
visual damages and take corrective action.
Check each of the following items individually and mention the corrective action (as per the
recommended specifications) in the boxes provided.2. Check for missing part(s), if any.A. FRAME
a. Brakes
Front : Free Play at Lever End (10 ~ 15 mm)
Rear :Free Play at Rear Brake (20 ~ 30 mm)
b. Clutch :Free Play at Lever End (10 ~ 15 mm)c. Throttle :Free Play at Throttle Grip (3 ~7 mm)d. Steering :Check for Free Movemente. Suspension
Front Fork : Check for any sticky movement
Rear Shock Abs : For Free Stroking & Setting on both
(To be filled in by the Dealer on receipt of the Motorcycle from YMIS)
Odo-Meter
ReadingDate of
Inspection
Frame
No.Engine
No.Date of
SaleFound OK
Set RightReplaced
Cleaned
Lubricated
RCL
S
PRE-DELIVERY INSPECTION REPORT
No.
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PRE-DELIVERY INSPECTION REPORT10-4
C. ELECTRICAL
a. Ignition Switch Operation
b. Left Hand Switch Operation & Pass Beam
• Horn
• Indicator• Head Light
c. All Bulbs - Functioningd. Battery
• Electrolyte Level
• Specific Gravity• Routing of Breather Pipe• Fuse• Routing of Positive Wire (Red) Below Breather Pipe
D. ROAD TEST
a. Starting
b. Gear Shifting Operationc. Clutch Operationd. Application of Brakes (Front and Rear)e. Speedo/ Odo Meter Operationf. Fuel gauge OperationEXPLAINED BYSIGNATURE: _____________ NAME:
CUSTOMER’S SIGN
MAIN SELLING DLR’S STAMP, SIGNATURE
service2.pmd11/3/2006, 8:50 PM 4

10-5
1. Operation of all the locks (Ignition, Steering, Fuel Tank Cap, Side Cover L.H.).
2. Fuel Cock Lever Operation and its reserve position; Fuel Tank Capacity including reserve & Fuel
Gauge.
3. Operation and function of Starter Lever.
4. Operation of Kick Lever.
5. Operation of Throttle.
6. Operation of Handle Bar Switches, their Functions and Pass Beam.
7. Disadvantages of riding on half Clutch (Never ride with clutch pressed).
8. Gear shifting pattern.
9. Tyre inflation pressure :Front - 25 Psi Rear - 33 Psi (Solo), 36 Psi (Double)
10. Never give sudden acceleration; always accelerate gradually
11. Simultaneous use of Front and Rear Brakes.
12. Never ride with your foot on Rear brake Pedal.
13. Whenever parking the Motorcycle on the Side Stand, ensure that the Fuel Cock Lever is in closed
position.
14. Always adjust both the right and left Shock Absorbers to the same position.INSTALLATIONProcedures to be explained to the customer on delivery of the Motorcycle by the Dealer's
Representative.
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