tyre 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
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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

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 :

KEEP RECOMMENDED TYRE PRESSURE IN BOTH THE TYRES
2. Locknut
3. Adjusting nut
1. Loosen the locknut.
2. Turn the adjusting nut in direction
a to increase free play and in
direction b to decrease free
play.
3. Tighten the locknut.Valve clearance adjustmentThe correct valve clearance
changes with use, resulting in
improper fuel/air supply or engine
noise. To prevent this, the valve
clearance must be adjusted
regularly. This adjustment however,
should be left to a YAMAHA dealer.
1. Tread depth
2. Side wallTyresTo ensure maximum performance,
long service and safe operation,
note the following:
1. Tyre air pressure
Always check and correct the
tyre pressure before operating
the Motorcycle.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
1. Free play

WARNING
WARNING
Minimum tyre
tread depth :
(front and rear)
1.0 mm
Tyre inflation pressure should be
checked and adjusted when the
temperature of the tyre equals the
ambient air temperature. Tyre
inflation pressure must be adjust-
ed according to total weight of
cargo, rider, passenger, and
accessories (fairing, saddlebags,
etc. approved for this model), and
vehicle speed.Proper loading of your Motorcycle
is important for several character-
istics of your Motorcycle, such as
handling, braking, performance
and safety. Do not carry loosely
packed items that can shift.
Securely pack your heaviest items
close to the center of the Motorcy-
cle, and distribute the weight
evenly from side to side. Properly
adjust the suspension for your
load, and check the condition and
pressure of your tyres. NEVER
OVERLOAD YOUR
MOTORCYCLE. Make sure the
total weight of the cargo, rider,
passenger, and accessories
(fairing, saddlebags, etc.
approved for this model) does not
exceed the maximum load of the
Motorcycle. Operation of an over-
loaded Motorcycle could cause
tyre damage, an accident, or even
injury.2. Tyre inspection
Always check the tyres before
operating the Motorcycle. If a tyre
tread shows crosswise lines
(minimum tread depth), if the tyre
has a nail or glass fragments in it,
or if the side wall is cracked,
contact a dealer
immediately and have the tyre
replaced.YAMAHAPERIODIC MAINTENANCE AND MINOR REPAIR
6-14
Front Rear Cold tyre pressure:
Single Rider25 psi
25 psi (1.75kg/cm )
2
(1.75kg/cm )
2(2.25kg/cm )
2
(2.50kg/cm )
2
33 psi
36 psi
With Pillion Rider
Front tyre size:
2.75-18” 4PR
Rear tyre size:
3.00-18” 6PR

WARNING1. It is dangerous to ride with a
worn-out tyre. When a tyre
tread begins to show lines,
have a YAMAHA dealer replace
the tyre immediately.
WheelsTo ensure maximum performance,
long service, and safe operation,
note the following:
1. Always inspect the wheels before
a ride. Check for cracks, bends or
warpage of the wheel. Be sure the
spokes are tight and undamaged.
If any abnormal condition exists in
a wheel, consult a YAMAHA
dealer. Do not attempt even small
repairs to the wheel. If a wheel is
deformed or cracked, it must be
replaced.
2. Tyres and wheels should be
balanced whenever either one is
changed or replaced. Failure to
have a wheel balanced can result
in poor performance, adverse
handling characteristics, and
shortened tyre life.3. Ride at moderate speeds after
changing a tyre since the tyre
surface must first be broken in for
it to develop its optimal
characteristics.PERIODIC MAINTENANCE AND MINOR REPAIR
6-15

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

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

PRE-DELIVERY INSPECTION REPORT
f. Wheels
Tyre :Tyre pressure Solo Double
(PSI)
Front 25 25
Rear 33 36
R i m : Runout - Radial - 1.5 mm (Max)
- Lateral - 1.5 mm (Max)
Spokes : No loosenes
g. Locks Operation : • Ignition
• Steering• Fuel Tank Cap• Side Cover (L.H.)
h. FastenersSpecified Torque
(Ft-Lb)
1. Front Wheel Axle Nuts 25-40
2. Front Fork (Crown Handle & Inner Tube)13-202. Front Fork under Bracket Stem Nut18-223. Handle Bar Mounting Bolts 13-204. Rear Shock Absorber Mounting Bolts22-355. Rear Swing Arm Pivot Shaft Nut32-526. Rear Wheel Axle/Sprocket. Shaft Nuts60-70
B. ENGINE
a. Engine Oil : • Oil Level (For checking - Refer Pg. 6-9)
• Check for any Leakages
10-2
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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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