Yamaha YBR125ED Owner'S Manual Download Page 48

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6-3

PERIODIC MAINTENANCE / LUBRICATION

Wheel bearings*

Battery*

Check looseness and damage.

Check electrolyte level, routing breather pipe.

ITEM

How it sounds

/ Adjust if necessary.

REMARKS

1,000KM

Fuel line

Air filter

Carburetor*

Valves*

Muffler

Brakes*

Engine oil

Steering bearings*

Rear arm pivot*

Check fuel hose, for cracks or damage.

Clean or replace if necessary.

Adjust

Check damage, Retighten.

Check operation, adjust.
Grease the brake cam.

Replace / Check level

Check loosenes.
Repack every 12,000 km or 12 month.**

Check rear arm assembly for looseness.
Moderately repack.***

EVERY

3,000KM

OR ERERY
6 MONTHS

Wheels* and tires

Check tire pressure, runout and spoke tightness.

Spark plug

Check condition and clean if necessary.
Replace if necessary every 12,000 Km.

3,000KM

6-3

PERIODIC MAINTENANCE / LUBRICATION

Wheel bearings*

Battery*

Check looseness and damage.

Check electrolyte level, routing breather pipe.

ITEM

How it sounds

/ Adjust if necessary.

REMARKS

1,000KM

Fuel line

Air filter

Carburetor*

Valves*

Muffler

Brakes*

Engine oil

Steering bearings*

Rear arm pivot*

Check fuel hose, for cracks or damage.

Clean or replace if necessary.

Adjust

Check damage, Retighten.

Check operation, adjust.
Grease the brake cam.

Replace / Check level

Check loosenes.
Repack every 12,000 km or 12 month.**

Check rear arm assembly for looseness.
Moderately repack.***

EVERY

3,000KM

OR ERERY
6 MONTHS

Wheels* and tires

Check tire pressure, runout and spoke tightness.

Spark plug

Check condition and clean if necessary.
Replace if necessary every 12,000 Km.

3,000KM

Summary of Contents for YBR125ED

Page 1: ......

Page 2: ...g spare parts from a Yamaha dealer or reference in case the vehicle is stolen 1 FRAME SERIAL NUMBER II 2 ENGINE SERIAL NUMBER IDENTIFICATION NUMBERS RECORD Record the frame serial number and engine serial number in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or reference in case the vehicle is stolen 1 FRAME SERIAL NUMBER ...

Page 3: ...ion September 2003 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor da Amazônia Ltda is expressly prohibited Printed in Brazil III YBR 125ED OWNER S MANUAL 2003 Yamaha Motor da Amazônia Ltda 2st edition September 2003 ...

Page 4: ... of this motorcycle If you have any questions about the operation or maintenance of your motorcycle please consult a Yamaha dealer YAMAHA MOTOR DA AMAZÕNIA LTDA IV CONHEÇA A AMAZÔNIA INTRODUCTION Congratulations on your purchase of the YAMAHA YBR 125ED This model is the result of Yamaha s vast experience in the production of fine sporting touring and pacesetting racing machines It represents the h...

Page 5: ...ith it even if the machine is subsequently sold Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product information available at the time of printing There may be minor discrepancies between your machine and this manual If there is any question concerning this manual please consult your Yamaha dealer Particularly important i...

Page 6: ...ILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPECTIONS...

Page 7: ...y the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering insufficient lean angle for the speed Never travel faster than warranted by conditions 4 Ride cautiously in unfamiliar areas You may encounter hidden obstacles which could cause an accident 5 The operator s posture is important for proper control The operator should keep both hands on the handlebars and both feet on ...

Page 8: ...r visualization easier 7 Items above must also be followed by pillion rider MODIFICATION Modifications made to the machine not approved by Yamaha or the removal of original equipment may render your machine unsafe for use and may cause severe personal injury Modifications may also make your machine illegal to use PROTECTIVE APPAREL The majority of fatalities from machine accidents are the result o...

Page 9: ...he machine or the machine may become unstable in cross winds These accessories may also cause instability when being passed by or passing large vehicles c Certain accessories can displace the operator from his or her normal riding position This improper position limits the freedom of movement of the operator and may limit control ability Therefore such accessories are not recommended 2 Caution mus...

Page 10: ...type OFF for manual type If it should lean over gasoline may leak out of the carburetor or fuel tank 5 If you should swallow any gasoline inhale a lot of gasoline vapor or allow gasoline to get in your eyes see your doctor immediately If any gasoline spills on your skin or clothing immediately wash it off with soap and water and change your clothes GASOLINE AND EXHAUST GAS 1 GASOLINE IS HIGHLY FLA...

Page 11: ...RE OPERATION CHECKS 4 1 Brakes 4 3 Brake fluid leakage 4 4 Engine oil 4 4 Tires 4 5 Clutch 4 8 Throttle grip 4 8 Fitting Fasteners 4 8 Switches 4 8 Wheels 4 8 Fuel 4 9 OPERATION AND IMPORTANT RIDING POINTS 5 1 Starting a cold engine 5 2 Starting a warm engine 5 4 Warming up the engine 5 4 Shifting 5 5 Engine Break in 5 6 Parking 5 7 CONTENTS DESCRIPTION 1 1 MACHINE IDENTIFICATION 2 1 Vehicle ident...

Page 12: ...ttery 6 27 Replenishing the battery fluid 6 28 Fuse replacement 6 29 Headlight bulb replacement 6 30 Turn signal bulb replacement 6 32 Taillight bulb replacement 6 32 Front wheel removal 6 33 Front wheel installation 6 34 Rear wheel removal 6 35 Rear wheel installation 6 36 Troubleshooting 6 36 Troubleshooting chart 6 37 CLEANING AND STORAGE 7 1 CLEANING 7 1 STORAGE 7 2 SPECIFICATIONS 8 1 XII PERI...

Page 13: ...ool kit 06 Shift Pedal 07 Shock absorber 08 Air filter 09 Dispstick 10 Rear brake pedal 11 Clutch lever 12 Handlebar switches over right 13 Speedometer 14 Main switch 15 Fuel gauge 16 Front brake lever 17 Throttle 18 Handlebar switches over left 19 Fuel tank cap DESCRIPTION ...

Page 14: ... serial number NOTE Model code is indicated by 4th to 8th digits and serial number is indicated by 12th to 17th digits Record these numbers for reference in case of ordering parts from a Yamaha dealer MACHINE IDENTIFICATION 2 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space provided Engine serial number The engin...

Page 15: ...fer to page 3 11 Steering lock for instructions NOTE Always turn the main switch to OFF or LOCK and remove the key when the motorcycle is unattended LOCK CONTROL FUNCTIONS Main switch The main switch controls the ignition and the electrical system It s operation is described below ON Electrical circuits are switched on Engine can be started The key cannot be removed OFF All electrical circuits are...

Page 16: ...en the transmission is in neutral Indicator lights 1 Turn indicator lights 2 High beam indicator light 3 Neutral indicator light N 0 3 2 1 F E 3 0 0 0 0 Km h 140 130 120 110 100 90 80 70 60 50 40 30 20 10 0 Turn indicator lights The corresponding indicator fhashes when the turn switch is moved to the or High beam indicator light This indicator comes on when the headlight high beam is used Neutral ...

Page 17: ... main switch is in OFF position The speedometer shows riding speed This speedometer is equipped with an odometer 0 1 F E 3 0 0 0 0 Km h 140 130 120 110 100 90 80 70 60 50 40 30 20 10 0 1 Adjustind knob 2 Odometer 1 Fuel gauge 0 2 1 F E 3 0 0 0 0 140 130 120 110 100 90 80 70 60 50 40 30 20 10 0 Km h Fuel gauge Speedometer 0 1 F E 3 0 0 0 0 Km h 140 130 120 110 100 90 80 70 60 50 40 30 20 10 0 1 Adj...

Page 18: ...eft hand turn push the switch to Once the switch is released it will return to the center position To cancel the signal push the switch in after it has returned to the center position HORN SWITCH Press the switch to sound the horn Handlebar switches over left 1 Light switch 2 Pass switch 3 Dimmer switch 4 Turn signal switch LIGHTS SWITCH Turning the light switch to turns on the meter lights headli...

Page 19: ... the engine when pushing the starter switch See starting instructions prior to starting the engine CAUTION Handlebar switches over rigt 1 ENGINE STOP switch shuts the engine off 2 Starter switch ENGINE STOP switch The engine stop switch is a safety device for use in an emergency such as when the motorcycle overturns or if trouble occurs in the throttle system Turn the switch to to start the engine...

Page 20: ...ngage the clutch The lever should be pulled rapidly and released slowly for smooth clutch operation 3 6 This motorcycle is equipped with a constant mesh 5 speed transmission The shift pedal is located on the left side of the engine and is used in combination with the clutch when shifting Clutch lever Shift pedal 1 Clutch lever 1 Shift pedal 1 5 4 3 2 N 1 Clutch lever Shift pedal 1 Clutch lever 1 S...

Page 21: ... apply the front brake 3 7 The rear brake pedal is on the right side of the motorcycle Press down the brake pedal to apply the rear brake Front brake lever Rear brake pedal 1 Front brake lever 1 Rear brake pedal 1 Front brake lever Rear brake pedal 1 Front brake lever 1 Rear brake pedal 1 ...

Page 22: ...osition Be sure the cap is properly installed and locked in place before riding the motorcycle WARNING Fuel tank cap TO OPEN Insert the key and turn it 1 4 turn clockwise The lock will be released and the cap can be opened TO CLOSE Push the tank cap into position with the key inserted To remove the key turn it counterclockwise to the original position Be sure the cap is properly installed and lock...

Page 23: ...t of fuel while riding set the fuel cock to this position Fill the tank at the first opportunity be sure to set fuel cock back to ON after refueling Fuel cock ON OFF RES F UE L The fuel cock supplies fuel from the tank to the carburetor while filtering it also The fuel cock has three positions OFF With the fuel cock in this position fuel will not flow Always set the fuel cock to this position when...

Page 24: ...n the engine has warmed up push the knob down to close the circuit 3 10 Starter lever 1 Starter lever 1 Starting a cold engine requires a richer air fuel mixture A separate starter circuit supplies the mixture Pull the starter knob up to open the circuit for starting When the engine has warmed up push the knob down to close the circuit Starter lever 1 Starter lever 1 ...

Page 25: ...y To release the lock turn the key to OFF Never turn the key to LOCK position when the motorcycle is moving WARNING LOCK OFF PUSH Steering lock The steering is locked when the main switch is turned to LOCK To lock the steering turn the handlebars all the way to the left With the key at OFF position push it into the main switch and release it turn it counterclockwise to LOCK and remove the key To r...

Page 26: ...obe into the receptacle on the frame then tighten the bolts Reinstall the side covers Seat 1 Tornillo 1 To remove the seat remove the side covers see page 3 13 then remove the bolts and release the lobe from the rear portion of the frame To reinstall the seat insert the lobe into the receptacle on the frame then tighten the bolts Reinstall the side covers Seat 1 Tornillo 1 ...

Page 27: ...orward To reinstall reverse the removal procedures 3 13 Remove the key nad then pull the cover towards yourself to release the fitting pin and then pull it forward To reinstall reverse the removal procedures Side covers 1 Pull 2 Pull forward 1 Pull 2 Pull forward Side covers 1 Pull 2 Pull forward 1 Pull 2 Pull forward ...

Page 28: ...tting Uneven adjustment can cause poor handling and loss of stability 1 2 3 4 5 6 7 Adjusting position Soft Standard Hard CAUTION Rear shock absorber adjustment 1 Spring preload adjusting ring 2 Position indicator Each shock absorber is equipped with a spring preload adjusting ring Adjust spring preload as follows Turn the adjusting ring in direction to increase spring preload and in direction to ...

Page 29: ...OP SWITCH TO TRANSMISSION IS IN GEAR PULL IN CLUTCH LEVER AND WARNING 3 15 If improper operation is noted consult a Yamaha dealer or other qualified mechanic immediately Clutch switch operation check Check the operation of the clutch switch against the information below TURN MAIN SWITCH TO ON AND ENGINE STOP SWITCH TO TRANSMISSION IS IN GEAR PULL IN CLUTCH LEVER AND PUSH STARTER SWITCH ENGINE WILL...

Page 30: ...20 4 8 6 14 6 24 4 4 6 6 6 9 6 21 6 23 6 10 6 11 4 5 4 8 6 26 6 23 Check operation condition and free play Adjust if necessary Wheels Tires Clean and oil it frequently 4 8 6 20 Rear brake Check operation free play fluid level and fluid leakage Top up with DOT 4 or DOT 3 brake fluid if necessary 4 1 PRE OPERATION CHECKS Before using this motorcycle check the following points ITEM ROUTINE PAGE Front...

Page 31: ...Adjust if necessary Check fuel level top up as required Fuel tank Lights signals and switches Battery Check electrolyte level Replenish with distilled water if necessary 6 24 4 8 6 5 4 8 6 30 6 32 6 27 6 29 6 24 4 9 4 10 Check for proper operation Front brake and clutch lever pivots Check for smooth operation Lubricate if necessary Check for smooth operation Lubricate if necessary 6 24 Check for s...

Page 32: ...the disc pads Refer to page 6 18 4 Check the brake shoes Refer to page 6 18 NOTE When a brake service is necessary consult a Yamaha dealer or other qualified mechanic WARNING Brakes See page 6 16 for details 1 Brake lever and brake pedal Check for correct free play in the front brake lever and rear brake pedal and adjust if necessary Make sure the brakes are working properly by checking at low spe...

Page 33: ...he oil level in a daily manner and top it up if CAUTION WARNING CAUTION 4 4 Brake fluid leakage Apply the brake for several seconds Check to see if any brake fluid leaks out from the pipe joints or the master cylinder Brake fluid may deteriorate painted surfaces or plastic parts Never spill any fluid If spilled clean it up immediately If brake fluid leakage is found ask a Yamaha dealer or other qu...

Page 34: ...5 kg cm2 25 PSI 175 kpa 2 0 kg cm2 28 PSI 200Kpa 1 75 kg cm2 25 PSI 175 Kpa 2 25 kg cm2 32 PSI 225 Kpa Tires To ensure maximum performance long service and safe operation note the following 1 Tire air pressure Always check and adjust the tire pressure before operating the machine Tire inflation pressure should be checked and adjusted when the temperature of the tire equals the ambient air temperat...

Page 35: ...s in it or if the side wall is cracked contact a Yamaha dealer or other qualified mechanic and have the tire replaced 1 Tread depth 2 Side wall 3 wear indicator WARNING Proper loading of your motorcycle is important for the handling braking and other performance and safety characteristics of your motorcyle Do not carry loosely packed items that can shift Securely pack your heaviest items close to ...

Page 36: ...ded If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality replacement WARNING WARNING After extensive tests the tires listed below have been approved by Yanaha for this model The front and rear tires should always be by the same manufacturer and of the same design No guarantee concerning handling characteristics can be given if a tire co...

Page 37: ...qualified mechanic to make any necessary adjustments Fitting Fasteners Alway check the tightness of chassis fittings and fasteners before a ride Use the chart on page 6 5 to find the correct torque Switches Check the operation of the starter switch main switch Engine Stop switch Wheels To ensure maximum performance long service and safe operation note the following 1 Always inspect the wheels befo...

Page 38: ...ber of 91 or higher If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenance cost If unleaded gasoline is not available then leaded regular gasoline can be used Gasohol There are two types of gasohol gasohol containing ethanol and that containing methanol Gasohol containing ethanol can be use...

Page 39: ...lways be sure the sidestand is up Failure to retract the sidestand completely can result in a serious accident when you try to turn a corner CAUTION CAUTION 1 Be very careful if you are carrying object while riding the motorcycle 2 Be vareful not to put any object near battery terminals Electrical failure or acid corrosion may occur OPERATION AND IMPORTANT RIDING POINTS Before riding this motorcyc...

Page 40: ...ter 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 starter CHOKE completely NOTE The engine is warm when it responds normally to the throttle with the starter turned off Starting a cold engine 1 Turn the fuel cock to ON 2 Turn the main switch to ON and the engine st...

Page 41: ...D PUSH STARTER SWITCH ENGINE WILL START MOTORCYCLE CAN BE RIDDEN IF TRANSMISSION IS IN NEUTRAL PUSH STARTER SWITCH ENGINE WILL START PUT TRANSMISSION IN GEAR MOTORCYCLE CAN BE RIDDEN WARNING TURN THE MAIN SWITCH TO ON AND ENGINE STOP SWITCH TO Before going through the following steps check the function of the clutch switch See page 3 15 ADVERTENCIA IF TRANSMISSION IS IN GEAR IF TRANSMISSION IS IN ...

Page 42: ...normally See the Break in section prior to operating the motorcycle for the first time CAUTION CAUTION Starting a warm engine The starter lever is not required when the engine is warm If the engine fail to start with the procedures above try to start it again with the throttle grip opened 1 4 to 1 2 Warming up the engine For an extended engine life always warm the engine up never accelerate hard w...

Page 43: ...nd of its travel you will feel a stop when you are in first gear then raise the pedal slightly CAUTION 1 Do not coast for long periods with the engine off and do not tow the motorcycle a long distance Even with gears in neutral the transmission is only properly lubricated when the engine is running Inadequate lubrication may damage the transmission 2 Always use the clutch when changing gears The e...

Page 44: ...tion Vary the speed of the motorcycle from time to time Do not operate it at one set throttle position Tips for reducing fuel consumption Your 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 Turn off the starter lever as soon as possible 3 Shift up swiftly and avoid high engine spe...

Page 45: ...r children are not likely to touch the motorcycle Do not park the motorcycle on a slope or soft ground the motorcycle may fall over CAUTION CAUTION WARNING 2 150 500 Km Avoid prolonged operation above 1 2 throttle Allow the machine to rev freely through the gears but do not use full throttle at any time 3 500 1 000 Km Avoid cruising speeds in excess of 3 4 throttle After 1 000Km of operation be su...

Page 46: ...ustment and lubrication are explained in the following pages If you are not familiar with motorcycle service this work should be done by a Yamaha dealer CAUTION PERIODIC MAINTENANCE AND MINOR REPAIRS Perodic inspection adjustment and lubrication will keep your motorcycle in the safest and most efficient condition possible Safety is an OBLIGATION of the motorcycle owner The maintenance and lubricat...

Page 47: ...the owner s tool kit are to assist you in the performance of periodic maintenance However some other tools such as a torque wrench are also necessary to perform the maintenance correctly 1 Tool kit 1 WARNING NOTE If you do not have necessary tools required during a service operation take your motorcycle to a Yamaha dealer for service Modifications to this motorcycle not approved by Yamaha may caus...

Page 48: ...ry 12 000 km or 12 month Check rear arm assembly for looseness Moderately repack EVERY 3 000KM OR ERERY 6 MONTHS Wheels and tires Check tire pressure runout and spoke tightness Spark plug Check condition and clean if necessary Replace if necessary every 12 000 Km 3 000KM PERIODIC MAINTENANCE LUBRICATION Battery Check electrolyte level routing breather pipe ITEM How it sounds Adjust if necessary RE...

Page 49: ...er Drive chain Fittings fasteners Check operation oil leakage Check operation looseness Adujst Check operation Lubricate every 12 000 Km Check chain slack lubricate adjust if necessary Check looseness REMARKS 1 000KM Lights and flashers Nuts and bolts Motorcycle Aspect Check operation Check tighten General Check EVERY 3 000KM OR EVERY 3 000KM Check operation oil leakage Every 500 Km ITEM Front for...

Page 50: ... mm 22 mm B Bolt 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm General torque especifications Nm 6 15 30 55 85 130 kgf m 0 6 1 5 3 0 5 5 8 5 13 0 lbf ft 4 3 11 22 40 61 94 lbf ft 9 0 14 5 5 0 43 66 Torque specifications Use a torque wrench to tighten these items It is recommended that these items be checked occasionally specially before a long trip Always check the tightness of these items whenever they are l...

Page 51: ...vel 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 1 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...

Page 52: ... the specified torque Tightening torque Drain plug 20 N m 2 0 kgf m 14 5 lbf t 1 Dipstick 1 Engine oil drain plug 1 2 Engine oil and filter replacement a Warm up the engine for a few minutes b Stop the engine Place an oil pan under the engine and remove the dipstick c Remove the drain plug and drain the oil d Reinstall the drain plug check if the gasket is damaged and lighten it to the specified t...

Page 53: ...oil pressure Oil quantity Total amount 1 2 L 0 264 Imp gal 0 317 US gal Periodic oil change 1 0 L 0 220 Imp gal 0 264 US gal Recommended oil Yamalube 4 CAUTION CAUTION CAUTION e Fill engine with oil Install the oil filter cap and tighten NOTE Do not put in any chemical additives Engine oil also lubricates the clutch and additives could cause clutch slippage Be sure no foreign material enters the c...

Page 54: ...ten the check bolt to the specified torque Check bolt torque 7 N m 0 7 Kgf m 5 0 lbf ft 1 Check bolt 1 Oil pressure 1 Remove the check bolt in the cylinder head 2 Start the engine and keep it idling until oil flows out of the bleed hole If no oil comes out after one minute turn off the engine immediately so it will not seize In such a case go to the nearest Yamaha dealer or other qualified mechani...

Page 55: ...he air filter case cover by removing the bolts 3 Remove the clamp 4 Remove the air filter from the case Air filter The air filter should be cleaned at the specified intervals It should be cleaned more frequently if you are riding in unusually wet or dusty areas 1 Remove the right side cover pag 3 13 2 Remove the air filter case cover by removing the bolts 3 Remove the clamp 4 Remove the air filter...

Page 56: ...ke sure the element is properly seated in the air filter case The engine should never be run without the air filter element installed excessive piston and or cylinder wear may result 6 11 CAUTION CAUTION 5 Remove the air filter elements from the guide and clean them with solvent After cleaning remove the remaining solvent by squeezing the air filter 6 Apply recommended oil to the entire surface of...

Page 57: ...after many tests If the settings are changed poor engine performance and damage may result 6 12 CAUTION Valve clearance adjustment The correct valve clearance changes with use resulting in improper fuel air supply or engine noise To prevent this valve clearance must be adjusted regularly This adjustment however should be left to a professional Yamaha service technician Carburetor adjustment The ca...

Page 58: ...le speed cannot be obtained by performing the above adjustment consult a Yamaha dealer 6 13 Standard idle speed 1 300 1 400 r min 1 Throttle stop screw Idle speed adjustment 1 NOTE A diagnostic tachometer must be used for this procedure 1 Attach the tachometer Start the engine and warm it up for a few minutes normally 1 or 2 minutes at approximately 1 000 to 2 000 r min Occasionally rev the engine...

Page 59: ...es free play 3 Tighten the locknut 6 14 Free play 3 7 mm 0 12 0 28 in Throttle cable adjustment 1 Free play 2 Locknut 3 Adjuster NOTE Before checking the throttle cable free play the engine idling speed should be adjusted The throttle cable should have an specified free play in the turning direction at the grip flange If the free play is incorrect follow the instructions below 1 Loosen the locknut...

Page 60: ...Before installing the spark plug measure the electrode gap with a wire thickness gauge and adjust the gap to specification as necessary Spark plug gap 0 7 mm 0 028 in When installing the plug always clean the gasket surface and use a new gasket Wipe off any grime from the threads and torque the spark plug properly Spark plug torque 12 5 N m 1 25 Kgf m 9 lbf ft NOTE If a torque wrench is not availa...

Page 61: ...e this adjustment Check the operation of the brake light after adjusting the rear brake 1 Adjusting nut CAUTION Rear brake adjustment A a Free play 20 30 mm 0 8 1 2 in Check the free play the rear brake pedal free play should be adjusted to 20 30 mm 0 8 1 2 in at the brake pedal end Turn the adjusting nut in direction to increase free play and in direction to decrease free play Press the brake ped...

Page 62: ...t come on earlier Turn the adjusting nut in direction b to make the brake light come on later 1 Brake light switch 2 Adjusting nut Checking the front brake pads and rear brake shoes A wear indicator is provided on each brake This indicator allows checking of brake pad shoe wear without disassembling the brake Brake light switch adjustment 1 Brake light switch 2 Adjusting nut Checking the front bra...

Page 63: ...r reaches the wear limit line ask a Yamaha dealer to replace the shoes 1 Wear indicator 2 Wear limit 1 Wear limit line 2 Wear indicator FRONT BRAKE Apply the brake and inspect the wear indicator If the wear indicator is almost in contact with the disc plate ask a Yamaha dealer to replace the pads REAR BRAKE Apply the brake and inspect the wear indicator If the indicator reaches the wear limit line...

Page 64: ...ful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock 5 Brake fluid may deteriorate painted surfaces or plastic parts Always clean up spilled fluid immediately 6 Have a Yamaha dealer check the cause if the brake fluid level goes down Inspecting the brake fluid level Insufficient brake fluid may le...

Page 65: ...he adjuster in or out until proper lever free play is obtained 3 Tighten the locknut 4 If the free play is still incorrect make an adjustment at the crankcase side NOTE If proper adjustment cannot be obtained or the clutch does not work correctly ask a Yamaha dealer to inspect the internal clutch mechanism 1 Locknut 2 Adjuster a 10 15 mm 0 4 0 6 in Brake fluid replacement 1 Complete fluid replacem...

Page 66: ...ack is approximately 20 30 mm 0 8 1 2 in If the slack exceeds 30 mm 1 2 in adjust a 20 30 mm 0 8 1 2 in Drive chain slack check NOTE Spin the wheel several times and find the tightest position of the chain Check and or adjust the chain slack while it is in this tightest position To check the chain slack the motorcycle must be held straight up with both wheels on the ground and without rider Check ...

Page 67: ...tch 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 Drive cha...

Page 68: ...ricate the inner cable and the cable end If it does not operate smoothly ask a Yamaha dealer to replace them RECOMMENDED LUBRICANT Engine oil SAE 20W50 WARNING Drive chain lubrication The 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 ri...

Page 69: ...nd Lubricate the pivoting parts Check to see that the sidestand moves up and down smoothly RECOMMENDED LUBRICANT Engine oil SAE 20W50 WARNING If the sidestand does not move smoothly consult a Yamaha dealer CAUTION Throttle cable and grip lubrication The throttle twist grip assembly should be greased at the time the cable is lubricated since the grip must be removed to get at the end of the throttl...

Page 70: ...ont fork consult a Yamaha dealer Front fork inspection Securely support the motorcycle so there is no danger of it falling over CAUTION WARNING 1 Visual check Check for scratches or damage on the inner tube and excessive 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 sev...

Page 71: ...e motorcycle so there is no danger of it falling over Wheel bearings If 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 The wheel bearings should be inspected according to the Maintenance Schedule Steering inspection WARNING Periodically inspect the condition of the steering Worn out Wheel bearings If there is play...

Page 72: ...ATTERY AXLE Hole in the battery box breather hose goes through the hole Battery breather hose passes in front of the frame and indicated axle BATTERY BREATHER HOSE ROUTING Battery Check the level of the battery electrolyte and make sure that the terminals are tight Add distilled water if the electrolyte level is low 1 When inspecting the battery make sure that the battery breather pipe routing is ...

Page 73: ...th The level should be between the minimum and maximum marks Use only distilled water if refilling is necessary Normal tap water contains minerals which are harmful to a battery therefore refill only with distilled water Replenishing the battery fluid 1 Maximum marks 2 Minimum marks CAUTION WARNING 2 1 Battery electrolyte is poisonous and dangerous causing severe burns etc It contains sulfuric aci...

Page 74: ...the electrical device operates If the fuse immediately blows again consult a Yamaha dealer WARNING Do not use fuses of higher amperage rating than those recommended Substitution of a fuse of improper rating can cause extensive electrical system damage and possibly a fire FUSE CAPACITY 10 A Fuse replacement 1 Fuse 2 Reserve CAUTION Storage the battery 1 When the motorcycle is not used for a month o...

Page 75: ...rs and remove the rubber cover 3 Turn the bulb socket counterclockwise and remove the bulb 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 1 Rubber cover CAUTION 1 1 1 Screw Headlight bulb replacement 2 Loosen the bulb connectors and remove the rubber cover 1 Rubber cover ...

Page 76: ...ulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner WARNING 1 Bulb 4 Put a new bulb install the socket and the bulb rubber cover 5 Reconnect the connectors 6 Reinstall the headlight assy If it is necessar...

Page 77: ...he bulb inward and turn it counterclockwise 3 Place a new bulb in the socket 4 Install the lens CAUTION Turn signal bulb replacement 1 Remove the screws and the lens 2 Push the bulb inward and turn it counterclockwise 3 Place a new bulb in the socket 4 Install the lens and the screws Do not over tighten the screws as the lens may break Taillight bulb replacement 1 Remove the lens 2 Push the bulb i...

Page 78: ...move the axle nut and axle NOTE Do not depress the brake lever when the disc is off the caliper as the brake pads will be forced shut 1 Axle nut 2 Speedometer cable CAUTION Front wheel removal 1 Place the motorcycle on the centerstand 2 Remove the speedometer cable 3 Remove the axle nut and axle NOTE Do not depress the brake lever when the disc is off the caliper as the brake pads will be forced s...

Page 79: ...eir projection fitted on their respective slits Axle nut torque 59 N m 5 9 Kgf m 43 lb ft 2 Make sure the slot inthe brake shoe plate fits over the stopper on the front fork outer tube 3 Make sure the axle nut is properly torqued Front wheel installation When installing the front wheel reverse the removal 2 Make sure the slot inthe brake shoe plate fits over the stopper on the front fork outer tub...

Page 80: ...stand 2 Remove the cotter pin and nut Then remove the tension bar from the brake shoe plate 3 Remove the brake adjusting nut and brake rod from the brake cam lever 4 Remove the axle nut and axle 5 Remove the wheel assembly 1 Nut 2 Cotter pin 3 Tension bar CAUTION 1 Adjusting Nut 2 Brake Rod 3 Axle Nut 3 2 1 Rear wheel removal 1 Nut 2 Cotter pin 3 Tension bar 1 Adjusting Nut 2 Brake Rod 3 Axle Nut ...

Page 81: ...like Yamaha parts but they are often inferior Consequently they have a shorter service life and can lead to expensive repair bills CAUTION Rear wheel installation When installing the rear wheel reverse the removal procedures Pay attention to the following points 1 Adjust the drive chain 2 Tighten the axle nut and the tension bar nut to the specified tightening torque Axle nut torque 91 N m 9 1 Kgf...

Page 82: ...ce spark plugs Ask Yamaha dealer to inspect Battery good Check fluid recharge and check connections Troubleshooting chart Go to compression check Engine doesn t start go to compression check Open the throttle hal way and start the engine Engine doesn t start ask Yamaha dealer to inspect Engine doesn t start go to battery check WARNING Never check the fuel system while smoking or in the vicinity of...

Page 83: ...7 Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy 8 Automotive type wax may be applied to all painted and chrome plated surfaces Avoid combination cleaner waxes Many contain abrasives which may mar the paint or protective finish When finished start the engine and let it idle for several minutes CAUTION CAUTION CLEANING AND STORAGE A CLEANING Frequent thorough cl...

Page 84: ...nd charge it Store it in a dry place and recharge it once a month Do not store the battery in an excessively warm or cold place less than 0ºC 30ºF or more than 30ºC 90ºF NOTE Make any necessary repairs before storing the machine B STORAGE Long term storage 30 days or more of your machine will require some preventive procedures to guard against deterioration After thoroughly cleaning the machine pr...

Page 85: ...us 1 750 mm 70 in Engine Type Air cooled 4 stroke gasoline SOHC Cylinder arrangement Single cylinder Forward inclined Displacement 123 7 cm3 Bore x Stroke 54 x 54 mm 2 13 x 2 13 in Compression rate 10 0 1 Starting system Electric starter Lubrication system Wet sump SPECIFICATIONS MODEL YBR 125 ED Dimension Overall length 1 980 mm 78 in Overall width 745 mm 29 in Overall height 1 050 mm 41 in Seat ...

Page 86: ...k capacity 13 L 2 860 Imp gal 3 434 US gal Reserve amount 1 7 L 0 374 Imp gal 0 450 US gal Carburetor Type manufacturer VM 20 MIKUNI Spark plug Type manufacturer CR7HSA NGK or U22FSR U DENSO Gap 0 7 mm 0 028 in Clutch type Wet multi disc 8 2 MODEL YBR 125ED Engine oil Type Yamalube 4 or SAE 20W50 type SH Capacity Periodic oil change 1 0 L 0 220 Imp galt 0 264 US gal Total amount 1 2 L 0 264 Imp ga...

Page 87: ...18 3rd 25 19 4th 23 22 5th 21 24 Chassis Frame type Diamond Caster angle 26º 20 Trail 103 mm 4 0 in Tire Type With tube Size Front 2 75 18 42P MT 39 Rear 90 90 18 57P MT 15 MODEL YBR 125ED Transmission Primary reduction system Spur gear Primary reduction rate 68 20 Secondary reduction system Chain drive Secondary reduction rate 45 14 Transmission type Constant mesh 5 speed Operation Left foot oper...

Page 88: ...nt Coil spring Oil damper Rear Gas Coil spring Oil damper Front 120 mm 5 0 in Rear 105 mm 4 0 in Electrical Ignition system CDI Generator system AC Magneto generator Battery type capacity 12N 5 5 3B 12V 5 5 Ah MODEL YBR 125ED Brakes Front brake type Single Disc brake Operation Right hand operation Rear brake type Drum brake Operation Right foot operation Suspension Front Telescopic fork Rear Swing...

Page 89: ... wattage x quantity Panel 12V x 3 4W 2pc Neutral lamp 14V x 3W 1pc Headlight 14V x 3W 1pc Flasher light 14V x 3W 2pc MODEL YBR 125ED Headlight type Halogen bulb Bulb wattage x quantity Headlight 12V 35w 35w 1pc tail Brake light 12V 5w 21w 1pc Flasher light 12V 10w 4pc Indicator light wattage x quantity Panel 12V x 3 4W 2pc Neutral lamp 14V x 3W 1pc Headlight 14V x 3W 1pc ...

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Yamaha YBR125ED, Owner'S Manual

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