2003 YAMAHA YBR125 Owners Manual

Brake fluid replacement
1. Complete fluid replacement should be done only bytrained service personnel.
2. Have a Yamaha dealer replace the following components during periodic maintenance or when they
are damaged or leaking.
a. Replace all rubber seals every two years.
b. Replace all hoses every four years.
!%Clutch adjustment
The clutch lever free play should be adjusted to 10 ~ 15
mm (0.4 ~ 0.6 in) at the clutch lever end. If the free play is
incorrect, adjust as follows.
1. Loosen the locknut at the handlebar.
2. Turn the 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 replacement should be done only by trained service personnel.
2. Have a Yamaha dealer replace the following components during periodic maintenance or when they
are damaged or leaking.
a. Replace all rubber seals every two years.
b. Replace all hoses every four years.
!%Clutch adjustment
The clutch lever free play should be adjusted to 10 ~ 15
mm (0.4 ~ 0.6 in) at the clutch lever end. If the free play is
incorrect, adjust as follows.
1. Loosen the locknut at the handlebar.
2. Turn the 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)

!


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 ~ 1.2 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 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 ~ 1.2 in)

!
Drive chain slack adjustment
1. Locknut 2. Adjusting bolt
1. Loosen the rear brake pedal free play adjusting nut.
2. Loosen the axle nut.
3. Loosen the chain adjusting locknuts on each chainpuller. To tighten the chain, turn the chain adjusting nuts
in direction  .To loosen the chain turn the chain
adjusting nuts in direction  and push the wheel
forward. Turn each chain adjusting nut exactly the same
amount to maintain correct axle alignment. There are
marks on each chain puller. Use these marks to align
the rear wheel. 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
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 chain slack adjustment
1. Locknut 2. Adjusting bolt
1. Loosen the rear brake pedal free play adjusting nut.
2. Loosen the axle nut.
3. Loosen the chain adjusting locknuts on each chain puller. To tighten the chain, turn the chain adjusting nuts
in direction  .To loosen the chain turn the chain
adjusting nuts in direction  and push the wheel
forward. Turn each chain adjusting nut exactly the same
amount to maintain correct axle alignment. There are
marks on each chain puller. Use these marks to align
the rear wheel. 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
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:

6-23 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.
1. Use Yamaha Chain and Cable Lube or any
brands of spray-type chain lubricant. First,
remove all dirt and mud from the chain with a
brush or cloth, then spray lubricant between both
rows of side plates and on all center rollers. The
chain should be lubricated every 500 km (300 mi).
2. To clean the chain, remove it from the machine,
dip it in solvent, and clean out as much dirt as
possible. Take the chain out of the solvent and
dry it. Immediately lubricate the chain to prevent
it from rusting.Cable inspection and lubrication
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.
Lubricate 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:
6-23 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.
1. Use Yamaha Chain and Cable Lube or any
brands of spray-type chain lubricant. First,
remove all dirt and mud from the chain with a
brush or cloth, then spray lubricant between both
rows of side plates and on all center rollers. The
chain should be lubricated every 500 km (300 mi).
2. To clean the chain, remove it from the machine,
dip it in solvent, and clean out as much dirt as
possible. Take the chain out of the solvent and
dry it. Immediately lubricate the chain to prevent
it from rusting.Cable inspection and lubrication
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.
Lubricate 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:

6-24
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.Brake and shift pedals
Lubricate the pivoting parts.
RECOMMENDED LUBRICANT: Engine oil SAE 20W50
Brake and clutch levers
Lubricate the pivoting parts. RECOMMENDED LUBRICANT: Engine oil SAE 20W50
Sidestand
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:
6-24
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. Brake and shift pedals
Lubricate the pivoting parts.
RECOMMENDED LUBRICANT: Engine oil SAE 20W50
Brake and clutch levers
Lubricate the pivoting parts. RECOMMENDED LUBRICANT: Engine oil SAE 20W50
Sidestand
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:

6-25
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.
If any damage or unsmooth movement is found with
the front fork, consult a Yamaha dealer. Front fork inspection
Securely support the motorcycle so there is no danger
of it falling over.
CAUTION:
WARNING:
6-25
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.
If any damage or unsmooth movement is found with
the front fork, consult a Yamaha dealer. Front fork inspection
Securely support the motorcycle so there is no danger
of it falling over.
CAUTION:
WARNING:

6-26
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. 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.
Securely support the 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:
6-26
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. 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.
Securely support the 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:

!"
BATTERY BREATHER HOSE ROUTING
YAMAHA 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 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.
2. Take care not to spill battery fluid on the chain.
Battery fluid may weaken the chain causing shorter
chain life and possibly result in an accident.
WARNING:
Hose junction
(holds the breather hose)
BATTERY
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
YAMAHA 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 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.
2. Take care not to spill battery fluid on the chain.
Battery fluid may weaken the chain causing shorter
chain life and possibly result in an accident.
WARNING:
Hose junction
(holds the breather hose)
BATTERY
AXLE
Hole in the battery box
(breather hose goes
through the hole)
Battery breather
hose
(passes in front
of the frame and
indicated axle)