2003 YAMAHA YBR125 check oil

CONTENTS
DESCRIPTION............................................................. 1-1
MACHINE IDENTIFICATION ....................................... 2-1
Vehicle identification number ................................. 2-1
Engine serial number ............................................ 2-1
CONTROL FUNCTIONS .............................................. 3-1
Main switch ............................................................ 3-1
Indicator lights ........................................................ 3-2
Speedometer .......................................................... 3-3
Fuel gauge ............................................................. 3-3
Handlebar switches over left .................................. 3-4
Handlebar switches over right .............................. 3-5
Clutch lever .......................... .................................. 3-6
Shift pedal ............................................................. 3-6
Front brake lever ................................................... 3-7
Rear brake pedal ................................................... 3-7
Fuel tank cap ......................................................... 3-8
Fuel cock ............................................................... 3-9
Starter lever ......................................................... 3-10
Steering lock ....................... ................................ 3-11
Seat ...................................................................... 3-12
Side covers ......................................................... 3-13
Rear shock absorber adjustment........................ 3-14
Clutch switch operation check ............................ 3-15
XIPRE-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 IMPORT ANT 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 identification number ................................. 2-1
Engine serial number ............................................ 2-1
CONTROL FUNCTIONS .............................................. 3-1
Main switch ............................................................ 3-1
Indicator lights ........................................................ 3-2
Speedometer .......................................................... 3-3
Fuel gauge ............................................................. 3-3
Handlebar switches over left .................................. 3-4
Handlebar switches over right .............................. 3-5
Clutch lever .......................... .................................. 3-6
Shift pedal ............................................................. 3-6
Front brake lever ................................................... 3-7
Rear brake pedal ................................................... 3-7
Fuel tank cap ......................................................... 3-8
Fuel cock ............................................................... 3-9
Starter lever ......................................................... 3-10
Steering lock ....................... ................................ 3-11
Seat ...................................................................... 3-12
Side covers ......................................................... 3-13
Rear shock absorber adjustment........................ 3-14
Clutch switch operation check ............................ 3-15
XIPRE-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 IMPORT ANT 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

PERIODIC MAINTENANCE AND MINOR REPAIRS..... 6-1
Tool kit..................................................................... 6-2
PERIODIC MAINTENANCE/LUBRICATION......... 6-3
Torque specifications............................................. 6-5
Engine oil................................................................ 6-6
Oil pressure ............................................................ 6-9
Air filter .................................................................6-10
Carburetor adjustment ......................................... 6-12
Valve clearance adjustment.................................6-12
Idle speed adjustment..........................................6-13
Throttle cable adjustment....................................6-14
Spark plug inspection...........................................6-15
Rear brake adjustment ......................................... 6-16
Brake light switch adjustment ..............................6-17
Checking the front brake pads and rear brake
shoes.................................................................... 6-17
Front brake...........................................................6-18
Rear brake ............................................................ 6-18
Inspecting the brake fluid level ............................6-19
Brake fluid replacement.......................................6-20
Clutch adjustment................................................6-20
Drive chain slack check .......................................6-21
Drive chain slack adjustment...............................6-22
Drive chain lubrication..........................................6-23
Cable inspection and lubrication..........................6-23
Throttle cable and grip lubrication.......................6-24Brake and shift pedals ......................................... 6-24
Brake and clutch levers ....................................... 6-24
Sidestand ............................................................. 6-24
Front fork inspection ............................................ 6-25
Steering inspection.............................................. 6-26
Wheel bearings.................................................... 6-26
Battery.................................................................. 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
PERIODIC MAINTENANCE AND MINOR REPAIRS..... 6-1
Tool kit..................................................................... 6-2
PERIODIC MAINTENANCE/LUBRICATION......... 6-3
Torque specifications............................................. 6-5
Engine oil................................................................ 6-6
Oil pressure ............................................................ 6-9
Air filter .................................................................6-10
Carburetor adjustment ......................................... 6-12
Valve clearance adjustment.................................6-12
Idle speed adjustment..........................................6-13
Throttle cable adjustment....................................6-14
Spark plug inspection...........................................6-15
Rear brake adjustment ......................................... 6-16
Brake light switch adjustment ..............................6-17
Checking the front brake pads and rear brake
shoes.................................................................... 6-17
Front brake...........................................................6-18
Rear brake ............................................................ 6-18
Inspecting the brake fluid level ............................6-19
Brake fluid replacement.......................................6-20
Clutch adjustment................................................6-20
Drive chain slack check .......................................6-21
Drive chain slack adjustment...............................6-22
Drive chain lubrication..........................................6-23
Cable inspection and lubrication..........................6-23
Throttle cable and grip lubrication.......................6-24Brake and shift pedals ......................................... 6-24
Brake and clutch levers ....................................... 6-24
Sidestand ............................................................. 6-24
Front fork inspection ............................................ 6-25
Steering inspection.............................................. 6-26
Wheel bearings.................................................... 6-26
Battery.................................................................. 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

PRE-OPERATION CHECKS
Before using this motorcycle, check the following points:
ITEM ROUTINE
PAGE
Front brake
Check operation, condition and free play.
Adjust if necessary
Clutch
Throttle grip / cableCheck for smooth operation.
Lubricate / Adjust if necessary
Check oil level / add oil as necessary
Engine oil
Drive chainCheck chain slack and condition. Lubricate if necessary
Adjust if necessary.
Air filter
Control and meter cableCheck tire pressure, wear, damage and spoke tightness
Check for smooth operation.
Lubricate if necessary4-3 ~ 4-4
6-16 ~ 6-20
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 brakeCheck operation, free play, fluid level and fluid leakage.
Top-up with DOT #4 (or DOT #3) brake fluid if necessary.

PRE-OPERATION CHECKS
Before using this motorcycle, check the following points:
ITEM ROUTINE
PAGE
Front brake
Check operation, condition and free play.
Adjust if necessary
Clutch
Throttle grip / cableCheck for smooth operation.
Lubricate / Adjust if necessary
Check oil level / add oil as necessary
Engine oil
Drive chainCheck chain slack and condition. Lubricate if necessary
Adjust if necessary.
Air filter
Control and meter cableCheck tire pressure, wear, damage and spoke tightness
Check for smooth operation.
Lubricate if necessary4-3 ~ 4-4
6-16 ~ 6-20
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 brakeCheck operation, free play, fluid level and fluid leakage.
Top-up with DOT #4 (or DOT #3) brake fluid if necessary.


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 qualified mechanic for immediate repairs. Such
leakage could indicate a hazardous condition.
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)
Engine oil
(See page 6-6 for details)
Make sure the engine oil is at the specified level. Add oil as
necessary.
Check the oil level in a daily manner and top it up if
necessary.
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 qualified mechanic for immediate repairs. Such
leakage could indicate a hazardous condition.
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)
Engine oil
(See page 6-6 for details)
Make sure the engine oil is at the specified level. Add oil as
necessary.
Check the oil level in a daily manner and top it up if
necessary.
WARNING:
CAUTION:
CAUTION:

4-5
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
temperature.
Tire inflation pressure must be adjusted according to
total weight of cargo, rider, passenger and accessories
(fairing, saddlebags, etc. if approved for this model),
and vehicle speed.
WARNING:
Basic weight:
With oil and without fuel
Maximum load*:
Cold tire pressure:
up to 90 Kg (198 lb)
load*: 90 Kg (198 lb) ~
maximum load*: 119 Kg ( 262 lb)
160 Kg ( 353 lb)
Front Rear
* Load is the total weght of cargo, rider, passenger and accessories.
1.75 kg/cm2
25 PSI / 175 kpa 2.0 kg/cm
2
28 PSI / 200Kpa
1.75 kg/cm2
25 PSI / 175 Kpa 2.25 kg/cm
2
32 PSI / 225 Kpa
4-5
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
temperature.
Tire inflation pressure must be adjusted according to
total weight of cargo, rider, passenger and accessories
(fairing, saddlebags, etc. if approved for this model),
and vehicle speed.
WARNING:
Basic weight:
With oil and without fuel
Maximum load*:
Cold tire pressure:
up to 90 Kg (198 lb)
load*: 90 Kg (198 lb) ~
maximum load*: 119 Kg ( 262 lb)
160 Kg ( 353 lb)
Front Rear
* Load is the total weght of cargo, rider, passenger and accessories.
1.75 kg/cm2
25 PSI / 175 kpa 2.0 kg/cm
2
28 PSI / 200Kpa
1.75 kg/cm2
25 PSI / 175 Kpa 2.25 kg/cm
2
32 PSI / 225 Kpa

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

6-4
*
**
***
: It is recommended that these items be serviced by a Yamaha dealer.
: Molybdenum disulfide grease.
: Lithium soap based grease.
NOTE:
Brake fluid replacement:
1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the brake fluid level and add fluid as required.
2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.
ITEM
Front forks*
Centerstand and
sidestand
Control cables: throttle /
clutch / front brake Rear shock absorber*
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. REMARKS1,000KM
Lights and flashers
Nuts and bolts
Motorcycle Aspect
Check operation.
Check tighten.
General Check
EVERY
3,000KM
OR EVERY3,000KM
Check operation / oil leakage.
Every 500 Km
6-4
*
**
***
: It is recommended that these items be serviced by a Yamaha dealer.
: Molybdenum disulfide grease.
: Lithium soap based grease.
NOTE:
Brake fluid replacement:
1. When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the brake fluid level and add fluid as required.
2. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
3. Replace the brake hoses every four years, or if cracked or damaged.
ITEM
Front forks*
Centerstand and
sidestand
Control cables: throttle /
clutch / front brake Rear shock absorber*
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. REMARKS1,000KM
Lights and flashers
Nuts and bolts
Motorcycle Aspect
Check operation.
Check tighten.
General Check
EVERY
3,000KM
OR EVERY3,000KM
Check operation / oil leakage.
Every 500 Km

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.
!
Torque
Nm
kgf.m Item
Spark plug
Engine oil drain plug
Oil check bolt
Front wheel axle nut
Rear wheel axle nut
12,5
20
7
59
911,25
2,0
0,7
5,9
9,1
A
(Nut)
10 mm
12 mm
14 mm
17 mm
19 mm
22 mmB
(Bolt)
6 mm
8 mm
10 mm
12 mm
14 mm
16 mmGeneral torque especifications
Nm
6
15
30
55
85
130kgf.m
0,6
1,5
3,0
5,5
8,5
13,0lbf. 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 loosened for any reason.
!
Torque
Nm
kgf.m Item
Spark plug
Engine oil drain plug
Oil check bolt
Front wheel axle nut
Rear wheel axle nut
12,5
20
7
59
911,25
2,0
0,7
5,9
9,1
A
(Nut)
10 mm
12 mm
14 mm
17 mm
19 mm
22 mmB
(Bolt)
6 mm
8 mm
10 mm
12 mm
14 mm
16 mmGeneral torque especifications
Nm
6
15
30
55
85
130kgf.m
0,6
1,5
3,0
5,5
8,5
13,0lbf. ft
4,3
11
22
40
61
94
lbf.ft
9.0
14.5
5.0
43
66