OWNER’S MANUAL YBR 125K 5YJ-F8199-E0 OWNER’S MANUAL YBR 125K 5YJ-F8199-E0
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: 2. ENGINE SERIAL NUMBER: II 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.
YBR 125K OWNER’S MANUAL © 2003 Yamaha Motor da Amazônia Ltda. 1st edition, January 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 125K OWNER’S MANUAL © 2003 Yamaha Motor da Amazônia Ltda. 1st edition, January 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.
INTRODUCTION Congratulations on your purchase of the YAMAHA YBR 125K. This model is the result of Yamahaís vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftmanship and reliability that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle.
Particularly important information is distinguished in this manual by the following notations: NOTE: A NOTE provides key information to make procedures easier or clearer. CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the machine. WARNING: Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the machine.
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 AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE.
SAFETY INFORMATION TWO-WHEELED MACHINES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING. HE OR SHE SHOULD. 1. OBTAIN THOROUGH INSTRUCTIONS FORM A COMPETENT SOURCE ON ALL ASPECTS OF MACHINE OPERATION. 2. OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNERíS MANUAL. 3.
PROTECTIVE APPAREL The majority of fatalities from machine accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries. 1. Always wear an approved helmet. 2. Wear a face shield or goggles. Wind on your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard. 3. The use of heavy boots, jacket, trousers, gloves, etc.
ACCESSORIES AND LOADING Adding accessories or cargo to your machine can adversely affect stability and handling if the weight distribution of the machine is changed. To avoid the possibility of an accident, extreme caution should be used if adding cargo or accessories to your machine. Use extra care if riding a machine which has added cargo or acessories. Genuine Yamaha accessories have been specifically designed for use on this machine.
GASOLINE AND EXHAUST GAS 1. 2. GASOLINE IS HIGHLY FLAMMABLE: a. Always turn off the engine when refueling. b. Take care not to spill any gasoline on the engine or exhaust system when refueling. c. Never refuel while smoking or in the vicinity of an open flame. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your motorcycle in an area that has adequate ventilation.
CONTENTS DESCRIPTION ............................................................. 1-1 PRE-OPERATION CHECKS ........................................ 4-1 Engine oil ................................................................ 4-3 MACHINE IDENTIFICATION ....................................... 2-1 Vehicle identification number ................................. 2-1 Engine serial number ............................................ 2-1 Tires .................................................................
Steering inspection .............................................. 6-24 Wheel bearings .................................................... 6-24 Battery .................................................................. 6-25 Replenishing the battery fluid .............................. 6-26 Storage the battery .............................................. 6-27 Fuse replacement ................................................ 6-27 Headlight bulb replacement .................................
DESCRIPTION 01. 02. 03. 04. 05. 06. 07. 08. 09. 10. Fuel cock Starter lever Battery Fusible Tool kit Shift pedal Shock absorber Air filter Kick stater Dispstick 11. Rear brake pedal 12. Clutch lever 13. Handlebar switches over right 14. Speedometer 15. Main switch 16. Fuel gauge 17. Front brake lever 18. Throttle 10. Handlebar switches over left 20. Fuel tank cap Fuel cock Starter lever Battery Fusible Tool kit Shift pedal Shock absorber Air filter Kick stater Dispstick 11. Rear brake pedal 12.
MACHINE IDENTIFICATION 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 engine serial number is stamped on right-hand engine crankcase. 1. Frame number 1. Engine serial number 2. Production year NOTE: A B Model code is indicated by 4th to 8th A digits and serial number is indicated by 12th to 17th digits B.
CONTROL FUNCTIONS ON: Electrical circuits are switched on. Engine can be started. The key cannot be removed. Main switch The main switch controls the ignition and the electrical system. Itís operation is described below. OFF: All electrical circuits are switched off. The key can be removed. LOCK: The steering is locked and all electrical circuits are switched off. The key can be removed. Refer to page (3-11) ìSteering lockî for instructions.
Indicator lights Turn indicator lights " " The corresponding indicator fhashes when the turn switch is moved to the ì ì or ì ì. " High beam indicator light " This indicator comes on when the headlight high beam is used. Neutral indicator light " N " This indicator comes on when the transmission is in neutral. 1. Turn indicator lights " 2. High beam indicator light " 3.
Fuel gauge Speedometer 1. Adjustind knob 2. Odometer 1. Fuel gauge The fuel gauge indicates the quantity of the remaining gasoline in the tank. The gauge needle moves from ìFî (Full) to ìEî (Empty) as the fuel level decreases. When the needle reaches the ìRED ZONEî, refill the tank at the earliest opportunity. The speedometer shows riding speed. This speedometer is equipped with an odometer. NOTE: The fuel meter needle does not move when the main switch is in ìOFFî position.
LIGHTS SWITCH Turning the light switch to ì headlight and tail-lights. Handlebar switches over left PASS SWITCH " ì, turns on the meter lights, " Press the switch to operate the passing light. Dimmer switch Turn the switch to " for the low beam. 1. Light switch 3. Dimmer switch 5. Horn switch " for the high beam and to " " TURN SIGNAL SWITCH " " To signal a right-hand turn, push the switch to ì ì ; to signal a left-hand turn, push the switch to ì ì.
“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 ì î to start the engine, and turn the switch to ì î to stop the engine. Handlebar switches over rigt 1.
Clutch lever Shift pedal 1. Clutch lever 1. Shift pedal The clutch lever is located on the left handlebar. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth clutch operation. 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.
Front brake lever Rear brake pedal 1. Front brake lever 1. Rear brake pedal The rear brake pedal is on the right side of the motorcycle. Press down on the brake pedal to apply the rear brake. The front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake. 3-7 Front brake lever Rear brake pedal 1. Front brake lever 1. Rear brake pedal The rear brake pedal is on the right side of the motorcycle. Press down on the brake pedal to apply the rear brake.
TO OPEN: Insert the key and turn it 1/4 turn clockwise. The lock will be released and the cap can be opened. Fuel tank cap TO CLOSE: Push the tank cap into position with the key inserted. To remove the key, turn it counterclockwise to the original position. WARNING: Be sure the cap is properly installed and locked in place before riding the motorcycle. 3-8 TO OPEN: Insert the key and turn it 1/4 turn clockwise. The lock will be released and the cap can be opened.
The fuel cock supplies fuel from the tank to the carburetor while filtering it also. The fuel cock has three positions: Fuel cock OFF: With the fuel cock in this position, fuel will not flow. Always set the fuel cock to this position when the engine is not running. ON: With the fuel cock in this position, fuel flows to the carburetor. Set the fuel cock to this position when starting the engine and while riding. RES: This indicates reserve.
Starter lever Kick starter 1. Starter lever 1. Kick starter Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies the mixture. Rotate the kick starter away from the engine. Push the starter down lightly with your foot until the gears engage, then kick smoothly and forcefully to start the engine. Shift to neutral before starting. 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.
Steering lock The steering is locked when the main switch is turned to ìLOCKî. To lock the steering, turn the handlebars all the way to the left. With the key at ìOFFî position, push it into the main switch and release it, turn it counterclockwise to ìLOCKî, and remove the key. To release the lock, turn the key to ìOFFî. OFF (PUSH) WARNING: Never turn the key to “LOCK” position when the motorcycle is moving. LOCK 1. Push 2. Release 3.
To remove the seat, remove the side covers (see page 313), then remove the bolts and release the lobe from the rear portion of the frame. Seat To reinstall the seat, insert the lobe into the receptacle on the frame, then tighten the bolts. Reinstall the side covers. 3-12 To remove the seat, remove the side covers (see page 313), then remove the bolts and release the lobe from the rear portion of the frame.
Side covers 1. Pull 1. Pull 2. Pull forward 2. Pull forward Remove the key nad then pull the cover towards yourself 1 to release the fitting pin, and then, pull it forward 2. To reinstall, reverse the removal procedures. Insert the key and turn it 1/4 clockwise. Pull the cover towards yourself 1 to release the fitting pin, and then, pull it forward 2. To reinstall, reverse the removal procedures. 3-13 Side covers 1. Pull 1. Pull 2. Pull forward Insert the key and turn it 1/4 clockwise.
Each shock absorber is equipped with a spring preload adjusting ring. Adjust spring preload as follows. Turn the adjusting ring in direction a to increase spring preload and in direction b to decrease spring preload. Make sure that the appropriate notch in the adjusting ring is aligned with the position indicator on the rear shock absorber. Rear shock absorber adjustment CAUTION: Always adjust each shock absorber to the same setting. Uneven adjustment can cause poor handling and loss of stability. 1.
PRE-OPERATION CHECKS Before using this motorcycle, check the following points: ITEM ROUTINE PAGE Brakes Check operation, condition and free play. Adjust if necessary 6-16 ~ 6-18 Clutch Check operation, condition and free play. Adjust if necessary 6-18 Throttle grip / cable Engine oil Drive chain Air filter Wheels / Tires Control and meter cable Check for smooth operation.
ROUTINE ITEM Rear brake and shift pedal Check for smooth operation. shafts Lubricate if necessary PAGE 6-22 Front brake and clutch lever pivots Check for smooth operation. Lubricate if necessary 6-22 Sidestand Check for smooth operation. Lubricate if necessary 6-22 Fittings / Fasteners Fuel tank Check all chassi fittings and fasteners. Tighten / Adjust, if necessary Check fuel level / top up as required.
Engine oil (See page 6-6 for details) Make sure the engine oil is at the specified level. Add oil as necessary. 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. 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.
WARNING: Basic weight: With oil and without fuel 116 Kg ( 256 lb) Maximum load*: 160 Kg ( 353 lb) Cold tire pressure: up to 90 Kg (198 lb) load*: 90 Kg (198 lb) ~ maximum load*: Front 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 the center of the motorcycle, and distribute the weight evenly from side to side.
2. Tire inspection Always check the tires before operating the motorcycle. If a tire tread shows crosswise lines (minimum tread depth), if the tire has a nail or glass fragments in it, or if the side wall is cracked, contact a Yamaha dealer or other qualified mechanic and have the tire replaced. WARNING: After extensive tests, the tires listed below have been approved by Yamaha for this model. The front and rear tires should always be by the same manufacturer and of the same design.
Wheels To 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 or other qualified mechanic. Do not attempt even small repairs to the wheel. If a wheel is deformed or cracked, it must be replaced. 2.
Fuel CAUTION: Always wipe off spilled fuel immediately with a dry and clean soft cloth. Fuel may deteriorate painted surfaces or plastic parts. Recommended fuel: UNLEADED FUEL Fuel tank capacity: Total: 13.0 L ( 2.860 Imp gal, 3.434 US gal) Reserve: 1.7 L ( 0.374 Imp gal, 0.450 Us gal) 1. Fuel level Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number ([R+m]/2) of 86 or higher, or research octane number of 91 or higher.
OPERATION AND IMPORTANT RIDING POINTS CAUTION: 1. Be very careful if you are carrying object while riding the motorcycle CAUTION: Before riding this motorcycle, become thoroughly familiar with all operating controls and their functions. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. 2. Be vareful not to put any object near battery terminals. Electrical failure or acid corrosion may occur.
Starting a cold engine Starting a warm engine The starter lever is not required when the engine is warm. 1. Turn the fuel cock to ìONî. 2. Turn the main switch to ìONî and the engine stop switch to ì ì. 3. Shift transmission into neutral. CAUTION: If the engine fails to start with the procedures above, try to start again with the throttle grip opened 1/4 to 1/2. NOTE: When the transmission is in neutral, the neutral indicator light should be on.
Shifting 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. The transmission lets you control the amount of power you have available at a given speed for starting, accelerating, climbing hills, etc. The use of shift pedal is shown in the illustration (page 3-6).
Tips for reducing fuel consumption Engine Break-in Your motorcycleís 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 speeds during acceleration. 4. Do not double-clutch or rev the engine while shifting down and avoid high engine speeds with no load engine. 5.
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. Parking When parking the motorcycle, stop the engine and remove the ignition key. Turn the fuel cock to ìOFFî whenever stopping the engine. 3. 500 ~ 1,000 Km: Avoid cruising speeds in excess of 3/4 throttle. WARNING: The muffler and exhaust pipe are hot.
PERIODIC MAINTENANCE AND MINOR REPAIRS CAUTION: 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 lubrication schedule chart should be considered strictly as a guide to general maintenance and lubrication intervals.
NOTE: If you do not have necessary tools required during a service operation, take your motorcycle to a Yamaha dealer for service. Tool kit WARNING: Modifications to this motorcycle not approved by Yamaha may cause loss of performance, excessive emissions, and render it unsafe for use. Consult a Yamaha dealer before attempting any changes. 1. Tool kit The tools provided in the ownerís tool kit are to assist you in the performance of periodic maintenance.
PERIODIC MAINTENANCE / LUBRICATION 1,000KM REMARKS ITEM Valves* How it sounds / Adjust if necessary. Spark plug Check condition and clean if necessary. Replace if necessary every 12,000 Km. Air filter Clean or replace if necessary. Fuel line Check fuel hose, for cracks or damage. Carburetor* Adjust Battery* Check electrolyte level, routing breather pipe. Engine oil Replace / Check level Muffler Check damage, Retighten. Brakes* Check operation, adjust. Grease the brake cam.
ITEM 1,000KM REMARKS Front forks* Check operation / oil leakage. Rear shock absorber* Check operation / oil leakage. Drive chain Check chain slack / lubricate, adjust if necessary. Fittings / fasteners Check and looseness. Centerstand and sidestand* Check operation, looseness. Control cables: throttle / clutch / front brake Adujst / Check operation Lubricate every 12,000 Km. Lights and flashers Check operation. Nuts and bolts Check tighten.
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 loosened for any reason. A (Nut) B (Bolt) 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 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 Item Spark plug Torque Nm kgf.m lbf.ft 12,5 1,25 9.
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 minutes. NOTE: Be sure the motorcycle is positioned straight up when checking the oil level. A slight tilt toward the side can result in false readings. b. With the engine stopped, with the engine stopped, unscrew the oil filler cap/ dispstick and rest it on the threads of the ok. 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 tighten it to 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 6-7 2. Engine oil and filter replacement a. Warm up the engine for a few minutes. b. Stop the engine.
e.Fill engine with oil. Install the oil filter cap and tighten. CAUTION: Do not put in any chemical additives. Engine oil also lubricates the clutch and additives could cause clutch slippage. Recommended oil: Yamalube 4 CAUTION: Be sure no foreign material enters the crankcase. 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) f. Start the engine and warm up for a few minutes. While warming up, check for oil leakage.
1. Remove the check bolt 1 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 mechanic for repairs. 3. After checking, tighten the check bolt to the specified torque. Oil pressure Check bolt torque: 7 N.m (0.7 Kgf.m, 5.0 lbf.ft) 1. Check bolt 6-9 1. Remove the check bolt 1 in the cylinder head. 2.
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 from the case. 6-10 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.
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 the filter and squeeze out the excess oil. The air filter should be wet but not dripping. Recommended oil: Engine oil 20W50 7. Reinstall the air filter and lock it with the clamp. 8. Install the air filter case cover and the right side cover.
Carburetor adjustment Valve clearance adjustment The carburetor is a vital part of the engine. Adjusting should be left to a Yamaha dealer who has the professional knowledge, specialized data, and equipment to do so properly. However, the following may be serviced by the owner as part of routine maintenance. 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.
Idle speed adjustment 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 to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle. 2. Set the idle to the specified engine speed by adjusting the throttle stop screw; turn the screw in to increase engine speed and out to decrease engine speed. 1.
NOTE: Before checking the throttle cable free play, the engine idling speed should be adjusted. Throttle cable adjustment 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. 2. Turning the adjuster to: Direction A : increase free play Direction B: reduces free play 3. Tighten the locknut. 1. Free play 2. Locknut 3. Adjuster Free play: 3 ~ 7 mm (0.12 ~ 0.
Spark plug inspection Standard spark plug: CR7HSA (NGK) and U22FSR-U (DENSO) 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. 1. Spark plug gap The spark plug is an important engine component and is easy to inspect.
Front brake adjustment Cheking the brakes shoes 1. Adjuster 2. Locknut 1. Wear limit line 3. Free play The front brake lever free play should be adjusted to 10 ~15 mm (0,4 ~0.6 in). 2. Wear indicator Apply the brake and inspect the wear indicator. If the indicator reaches the wear limit line, ask a Yamaha delaer to replace the shoes. 1. Loosen the locknut 2. Turn the adjusting nut in direction clockwise to increase free play and direction counterclockwise to decrease free play. 3.
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 a to increase free play and in direction b to decrease free play. Press the brake pedal several times and check if the wheel turns free when the pedal is released. Rear brake adjustment CAUTION: For brake pedal adjustment, be sure to proceed as follows (it is advisable to have a Yamaha dealer make this adjustment.
Brake light switch adjustment 1. Brake light switch Clutch adjustment 2. Adjusting nut 1. Lock nut The rear brake light switch is activated by the brake pedal and is properly adjusted when the brake light comes on just before braking takes effect. To adjust the rear brake light switch, hold the switchbody so it does not rotate while turning the adjusting nut. Turn the adjusting nut in direction a to make the brake light come on earlier.
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 the slack at the position shown in the illustration. Normal slack 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.
Drive chain slack adjustment CAUTION: Too little chain slack will overload the engine and other vital parts. Keep the slack within the specified limits. To maintain correct axle alignment, Ensure the notch 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 1. Locknut 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) 2. Adjusting bolt 1.
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 riding in dusty areas. Cable inspection and lubrication WARNING: Damage to the outer housing of cables may allow internal rusting and cause interfere with cable movement. Replace damaged cables as soon as possible to prevent unsafe conditions. 1.
Brake and shift pedals Lubricate the pivoting parts. 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 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.
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 several times and check if the fork rebounds smoothly. Front fork inspection WARNING: If any damage or unsmooth movement is found with the front fork, consult a Yamaha dealer.
Steering inspection 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. Periodically inspect the condition of the steering. Worn out or loose steering bearings may be dangerous. 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.
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. BATTERY BREATHER HOSE ROUTING WARNING: 1. 2. When inspecting the battery, make sure that the battery breather pipe routing is correct. If the breather pipe touches painted parts, or if its end is in such a position that may cause gas or electrolyte leakage, it may cause structural or esthetic damages to the motorcycle.
Replenishing the battery fluid CAUTION: 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, cigarrettes, etc.
Storage the battery 1. When the motorcycle is not used for a month or longer, remove the battery and store it in a cool, dark place. Completely recharge the battery before reinstallation. 2. If the baterry needs to be stored for a longer period than the period mentioned above, check the specific gravity at least once a month, and recharge it when the specific gravity is below normal. 3. Always make sure the connections are correct when reinstalling the battery.
Headlight bulb replacement 1. Rubber cover 1. Screw 2. Loosen the bulb connectors and remove the rubber cover. 3. Turn the bulb socket counterclockwise and remove the bulb. If the headlight bulb burns out, replace the bulb as follows: 1. Remove the screws. CAUTION: 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 6-28 Headlight bulb replacement 1. Rubber cover 1. Screw 2.
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 necessary to adjust the headlight beam, please consult a Yamaha dealer. 1. Bulb WARNING: Avoid touching the glass part of the headlight bulb 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.
Taillight bulb replacement 1. Remove the lens. 2. Push the bulb inward and turn it counterclockwise. 3. Place a new bulb in the socket. 4. Install the lens. 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. CAUTION: Do not over-tighten the screws as the lens may break. 6-30 Taillight bulb replacement 1. Remove the lens. 2.
1. Place the motorcycle on the centerstand. 2. Loosen the front brake cable by loosening the adjusting bolt. 3. Remove the speedometer cable by loosening the cable clip. 4. With the help of ar appropriete tool completely loose the axle nut and remove it. Front wheel removal 1. Lock nut 2. Clip 3. Axle nut CAUTION: It is advisable to have a Yamaha dealer service the wheel. Securely support the motorcycle so there is no danger of it falling over. 6-31 1. Place the motorcycle on the centerstand. 2.
Front wheel installation Rear wheel removal 1. Nut When installing the front wheel, reverse the removal procedures. Pay attention to the following points: 2. Cotter pin 3. Tension bar CAUTION: It is advisable to have a Yamaha dealer service the wheel. Securely support the motorcycle so there is no danger of it falling over. 2. Make sure the slot in the brake shoe plate fits over the stopper on the front fork outer tube. 3. Make sure the axle nut is properly torqued. 1.
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.m, 66 lbf.ft) Tension bar nut: 19 N.m (1.9 Kgf.m, 14 lbf.ft) 3. Adjust the rear brake. 1. Adjusting Nut 2. Brake Rod 3. Axle Nut 3. Remove the brake adjusting nut and brake rod from the brake cam lever. 4. Remove the axle nut and axle.
Troubleshooting Although Yamaha motorcycles receive a rigid inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems can cause poor starting and loss of power. The troubleshooting chart describes a quick, easy, procedure for making checks. If your motorcycle requires any repair, bring it to a Yamaha dealer.
Troubleshooting chart 1. Fuel Check if there is fuel in the fuel tank WARNING: Never check the fuel system while smoking or in the vicinity of an open flame. Enough fuel Go to compression check No fuel Supply fuel Engine doesnít start, go to compression check 2. Compression Use electric starter 3.
CLEANING AND STORAGE CAUTION: Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin-operated car washers. A. CLEANING Frequent, 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.
7. If storing in a humid or salt-air atmosphere, coat all exposed metal surfaces with a light film of oil. Do not apply oil to any rubber parts or the seat cover. 8. Remove the battery and 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 0∫C (30∫F) or more than 30∫C (90∫F). B. STORAGE Long term storage (30 days or more) of your machine will require some preventive procedures to guard against deterioration.
SPECIFICATIONS MODEL YBR 125K Dimension: Overall length Overall width Overall height Seat height Wheel base Minimum ground clearance 1,980 745 1,050 780 1,290 175 mm ( 78 in) mm ( 29 in) mm ( 41 in) mm ( 31 in) mm ( 51 in) mm ( 7 in) Basic weight: With oil and without fuel: 105 Kg ( 231.5 lb) 116 Kg ( 255.
MODEL YBR 125K 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 gal, 0.317 US gal) Air filter: Wet type element Fuel: Type Tank capacity Reserve amount Regular unleaded gasoline 13 L ( 2.860 Imp gal, 3.434 US gal) 1.7 L ( 0.374 Imp gal, 0.450 US gal) Carburetor: Type/manufacturer VM 20 / MIKUNI Spark plug: Type/manufacturer Gap CR7HSA / NGK or U22FSR-U / DENSO 0.7 mm (0.
MODEL YBR 125K Transmission: Primary reduction system Primary reduction rate Secondary reduction system Secondary reduction rate Transmission type Operation Gear ratio 1st 2nd 3rd 4th 5th Spur gear 68 / 20 Chain drive 45 / 14 Constant mesh 5-speed Left foot operation 37 / 14 32 / 18 25 / 19 23 / 22 21 / 24 Chassis: Frame type Caster angle Trail Diamond 26∫ 20î 103 mm ( 4,0 in) Tire: Type Size: With tube Front Rear 2.
MODEL YBR 125K Brakes: Front brake type Operation Rear brake type Operation Drum brake Right hand operation Drum brake Right foot operation Suspension: Front Rear Telescopic fork Swingarm (New monocross suspension) Shock absorber: Front Rear Coil spring, Oil damper Gas, Coil spring, Oil damper Front Rear 120 mm ( 5.0 in) 105 mm ( 4.
MODEL YBR 125K Headlight type: Halogen bulb Bulb wattage x quantity: Headlight tail / Brake light Flasher light 12V 35w /35w (1pc) 12V 5w / 21w (1pc) 12V 10w (4pc) Indicator light wattage x quantity: Panel Neutral lamp Headlight Flasher light 12V x 3,4W (2pc) 14V x 3W (1pc) 14V x 3W (1pc) 14V x 3W (2pc) 8-5 MODEL YBR 125K Headlight type: Halogen bulb Bulb wattage x quantity: Headlight tail / Brake light Flasher light 12V 35w /35w (1pc) 12V 5w / 21w (1pc) 12V 10w (4pc) Indicator light wattage
