maintenance YAMAHA YBR125 2007 Owner's Manual

1. Wear limit line
2. Wear indicatorChecking the brake shoesA wear indicator is provided on each
brake. This indicator allows
inspection of shoe wear without
disassembling the brake. Apply the
brake and inspect the position of the
indicator. If the indicator reaches to
the wear limit line, ask a YAMAHA
dealer to replace the shoes.
1. Wear limit line
2. Wear indicator1. Free play
Drive chain slack checkSpin the wheel several times and
find the tightest position of the
chain. Check and/or adjust the
chain slack while it's in this tightest
position.
Inspect the drive chain when the
Motorcycle is on the centerstand.
Check the slack at the position
shown in the illustration. Normal
slack is approximately 20 ~ 30 mm.
If the slack exceeds 30 mm, adjust.
PERIODIC MAINTENANCE AND MINOR REPAIR
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NOTE :

1. Chain jointIf the chain is disassembled, be sure
the chain lock is placed in the
correct direction when installing.
1. Adjusting nut
2. Cotter pin
3. Axle nutDrive chain slack adjust-
ment1. Loosen the rear brake pedal
free play adjusting nut.
2. Remove the cotter pin from
the axle nut.
3. Loosen the axle nut.
1. Locknut
2. Adjusting hex screw4. Loosen the chain adjusting
locknuts on each chain puller. To
tighten the chain, turn the chain
adjusting hex screw in direction b
to loosen the chain, turn the chain
adjusting hex screw in direction a
and push the wheel forward. Turn
each chain adjusting hex screw
exactly the same amount to
maintain correct axle alignment.
There are marks on each chain
puller. Use these marks to align
the rear wheel.
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CAUTION :
5. After adjusting, be sure to tighten
each chain adjusting locknut.
Then tighten the axle nut to the
specified torque.Maintain chain slackness
within specified limits as per
specifications.
To maintain correct axle
alignment, Ensure the notch
on the adjuster is on the same
Mark on Left and Right Side.
Tightening torque:
Axle nut:
65 ft-lb (9.05 m-kg)
1. Cotter pin6. Insert a new cotter pin into the
axle nut and bend the end of the
cotter pin as shown. If the notch in
the axle nut and the cotter pin
hole do not match, tighten the nut
slightly to align them.
Always use a new cotter pin on
the axle nut.7 Adjust the free play in the
brake pedal.
Check the operation of the brake
light after adjusting the rear
brake.
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WARNING
WARNING

Drive chain lubricationThe 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. The drive chain should be
lubricated every 5,000 km.
2. To clean the chain thoroughly,
remove it from the Motorcycle,
dip it in solvent, and clean out as
much dirt as possible. Then, take
the chain out of the solvent to dry
it, and then dip the chain in oil of
20W40. Remove the chain and
hang it on a peg for a while till the
excess oil drips down completely.
Then using a clean cloth wipe the
chain.
Cable inspection and
lubricationDamage to the outer housing of
cables may lead to internal rusting
and interfere with the cable
movement. Replace damaged
cables as soon as possible to
prevent unsafe conditions.
Lubricate the cables with anti-
corrosive oil and cable ends. If a
cable does not operate smoothly,
ask a YAMAHA dealer to replace it.
Recommended lubricant:
20W40 Type SG
Throttle cable and grip
lubricationThe throttle twist grip assembly
should be greased at the time that
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.
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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
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WARNING

CAUTION :
Front fork inspectionSecurely support the Motorcycle
so there is no danger of it falling
over.
1. Visual check
Check for scratches or damage
on the inner tube and traces of 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 on the
handlebars 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.
Steering inspectionPeriodically inspect the condition of
the steering. Worn out or loose
steering bearings may be danger-
ous. 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.
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WARNING

Securely support the Motorcycle
so there is no danger of it falling
over.
Wheel bearingsIf 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.
1. Maximum level mark
2. Minimum level markBattery1. Battery is located inside the
L.H. side panel (for removal &
installation of L.H. side panel
please refer page 6-5)
2. Open the lid.
3. Check the level of the battery
electrolyte and make sure that
the terminals are tight.
Top up with distilled water if the
electrolyte level is low.
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WARNING

When inspecting the battery, be
sure the breather hose is routed
correctly. If the breather hose is
positioned in such a way as to
cause battery electrolyte or gas to
exit onto the frame, structural and
cosmetic damage to the
Motorcycle can occur.
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,
cigarettes etc., away. Ventilate
when charging or using in an
enclosed space. Always shield
your eyes when working near
batteries. KEEP OUT OF REACH
OF CHILDREN.Replenishing the battery fluid
Normal tap water contains
minerals which are harmful to a
battery; therefore, refill only with
distilled water.
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 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 level and
maximum level marks. Use only
distilled water if refilling is necessary.
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ENSURE THAT BATTERY ELECTROLYTE LEVEL IS MAINTAINED BETWEEN
MAX . AND MIN. MARKS. IF REQUIRED, ADD DISTILLED WATER ONLY
CAUTION :
CAUTION :WARNING

Battery storage
1. When the Motorcycle will not be
used for a month or longer,
remove the battery, fully charge it
and store it in a cool, dry place.
Completely recharge the battery
before reinstallation.
2. If the battery will be stored for
longer than two months, check
the specific gravity of the fluid at
least once a month and fully
recharge the battery when it is too
low.
3. Always make sure the
connections are correct when
putting the battery back in the
motorcycle. Make sure the
breather hose is properly
connected and is not damaged or
obstructed.
1. Main fuseFuse replacementThe fuse is located behind panel A.
(See page 6-6 for panel removal and
installation procedures.)
If the fuse is blown, turn off the main
switch. 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.Do not use fuse of higher
amperage rating than those
recommended. Substitution of a
fuse of improper rating can cause
extensive electrical system
damage and possibly a fire.
Specified fuse: 10A
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CAUTION :
1

1. Screw (2 Nos.)
2. Bolt (1Headlight bulb replacementIf the headlight bulb burns out,
replace the bulb as follows:
1. Remove the two screws from the
Head Light.
2. Loosen bolt.
3. Remove head light bezel assy.
Forward.
No.)1. Bulb holder
3. Remove headlight bulb holder
from bezel
1. Bulb (Halogen)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.
4. Remove the defective bulb.
5. Put a new bulb into position and
secure it in place with the bulb
holder.
6. Install the Head Light Assy.
7. If the headlight beam adjustment
is necessary, ask a YAMAHA
dealer to make adjustment.
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WARNING
1