front wheel YAMAHA YBR125 2007 Owners Manual

TABLE OF CONTENTSAir filter ...........................................................6-10
Carburetor adjustment ................................. 6-11
Idle speed adjustment .................................6-12
Throttle cable free play adjustment .............6-12
Valve clearance adjustment .........................6-13
Tyres ..............................................................6-13
Wheels ..........................................................6-15
Clutch lever free play adjustment ................6-16
Front brake adjustment ................................6-16
Rear brake adjustment ................................6-17
Brake light switch adjustment .....................6-17
Checking the brake shoes ...........................6-18
Drive chain slack check ................................6-18
Drive chain slack adjustment ......................6-19
Drive chain lubrication ..................................6-21
Cable inspection and lubrication .................6-21
Throttle cable and grip lubrication ...............6-21
Brake and shift pedal lubrication .................6-22
Brake and clutch lever lubrication ................6-22
Center and sidestand lubrication ................6-22
Front fork inspection .....................................6-23
Steering inspection ......................................6-23
Wheel bearings ............................................6-24
Battery ...........................................................6-24Fuse replacement ........................................6-26
Headlight bulb replacement ........................6-27
Turn signal and taillight bulb
replacement..................................................6-28
Front wheel removal .....................................6-28
Front wheel installation ................................6-30
Rear wheel removal .....................................6-30
Rear wheel installation ................................6-32
Troubleshooting...........................................6-32
Troubleshooting chart ..................................6-33
CLEANING & STORAGE
A. Cleaning .................................................... 7-1
B. Storage ...................................................... 7-2
SPECIFICATIONS ........................................... 8-1
CUSTOMER INFORMATION........................... 9-1
Key identification number ............................. 9-1
Frame serial number ................................... 9-1
Engine serial number .................................. 9-1
DETATCHMENTS
Pre-Delivery Inspection ................................10-1
Installation....................................................10-5
GREEN BOOK
78910
Libero5TS8.pmd11/3/2006, 8:50 PM 2

PRE-OPERATION CHECKS
4-1
Owners are personally responsible for their vehicle's condition. Your Motorcycle's vital functions can start to
deteriorate quickly and unexpectedly- even if it remains unused (for instance, if it is exposed to the elements). Any
damage. fluid leak or loss of tyre pressure could have serious consequence Therefore' it is very important that, in
addition to a thorough visual inspection, you check the following points before each ride.
PRE - OPERATION CHECK LIST
Brake and shift pedal shafts Engine oil
Control and meter cable Wheels and tyres Drive chain Clutch
Throttle grip and housing Rear brake Front brake
Lubricate if necessary.Check tyre pressure, wear, damage and spoke tightness.
Lubricate if necessary. Check for smooth operation. Lubricate if necessary.
Check for smooth operation. Tighten spokes if necessary. Adjust if necessary.
6-21
6-22 6-13 ~ 6-15 6-18 ~ 6-21
Check oil level.
Fill with oil if necessary.
Check chain slack and condition. Check operation, condition and free play.
Adjust if necessary.
Lubricate if necessary. Check for smooth operation. Adjust if necessary.
Check operation, condition and free play.Adjust if necessary. Check operation, condition and free play.
ITEM
CHECKS
6-8 ~ 6-9 6-12, 6-213-3, 6-16
3-4, 6-17
3-4, 6-16PAGE

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

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.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
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.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
WARNING

1. Indicator Screws (1 No.)Turn signal and taillight
bulb replacement1. Remove the screws and the
lense.
2. Push the bulb inward and turn it
counterclockwise.
3. Place a new bulb in the socket.
Push the bulb inward and turn it
clockwise until it engages into the
socket.
4. Install the lense and the
screws.1. Tail lamp Screws (2 Nos.)
Do not over-tighten the screws as
the lense may break.
Front wheel removalIt is advisable to have a
YAMAHA dealer service the
wheel.
Securely support the
Motorcycle so there is no
danger of it falling over.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
WARNING
CAUTION :

1. Brake cable adjusting nut1. Place the Motorcycle on the
centerstand.
2. Fully loosen the brake cable
adjusting bolt at the handlebar
lever holder.
3 Fully loosen the brake cable
adjusting nut at the wheel hub and
remove the cable from the brake
cam lever.
1. Clip
2. Speedometer cable4. Remove the speedometer cable
from the front wheel side. First
remove the clip and then pull the
cable out.
1. Cotter pin
2. Axle nut5. Remove the cotter pin and axle
nut.
6. Remove the wheel axle. Make
sure the Motorcycle is properly
supported.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-29

1. StopperFront wheel installationWhen installing the front wheel,
reverse the removal procedure.
Pay attention to the following points:
1. Make sure the slot in the brake
shoe plate fits over the stopper on
the front fork outer tube.
2. Make sure the axle nut is properly
torqued and a new cotter pin is
installed.Always use a new cotter pin.
Axle nut torque:
33 ft-lb (4.55 m-kg)
3. Adjust the free play in the brake
lever.PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
WARNING
Rear wheel removalIt is advisable to service the
wheel by a YAMAHA dealer.
Securely support the
Motorcycle so there is no
danger of it falling over.
WARNING

A. CLEANINGFrequent, thorough cleaning of your
Motorcycle will not only enhance its
appearance but will improve its
general performance and extend
the useful life of many components.1. Before cleaning the Motorcycle:
a. Block off the end of the exhaust
pipe to prevent water entry; a
plastic bag and strong rubber
band may be used.
b. Make sure the spark plug and all
filler caps are properly installed.
2. If the engine case is excessively
greasy, apply degreaser with a
paint brush. Do not apply
degreaser to the chain, sprockets,
or wheel axles.
3. Rinse the dirt and degreaser off
with a garden hose. Use only
enough pressure to do the job.Direct excessive Hose Pressure
may cause water Entry Into Wheel
Bearing, Front Fork Brakes,
Transmission Seals & Electrical
Parts, there-by leading to its
Detorioration.
7-1
Improper cleaning can damage
the cowlings, panels and other
plastic parts. Use only a soft,
clean cloth or sponge with mild
detergent and water to clean
plastic.
Do not use any harsh chemical
products on plastic parts.
Alaways use clean cloth or
sponge for cleaning the
Motorcycle.
CAUTION :4. After riding on dirty roads, wash
the Motorcycle with cold water
immediately. Do not use warm
water to clean the tyre.
5. Once the majority of the dirt has
been hosed off, wash all surfaces
with warm water and mild,
detergent-type soap. An old
toothbrush or bottle brush is
handy for hard-to-get-at places.
6. Rinse the Motorcycle off
immediately with clean water and
dry all surfaces with a chamois,
clean towel, or soft absorbent
cloth.
7. Dry the chain and lubricate it to
prevent rust.
CAUTION :CLEANING AND STORAGE