2003 YAMAHA YBR125 maintenance

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 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.
If you have any questions about the operation or maintenance of your motorcycle, please consult a
Yamaha dealer.

  

 
IV

 

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 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.
If you have any questions about the operation or maintenance of your motorcycle, please consult a
Yamaha dealer.

  

 
IV

 


VI
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.
WARNING:
VI
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.
WARNING:

VII
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 OWNER’S MANUAL.
3. OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.
4. OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL AND/OR WHEN
MADE NECESSARY BY MECHANICAL CONDITIONS.
SAFE RIDING
1. Always make pre-operation checks. Careful checks may help prevent an accident.
2. Many accidents involve inexperienced operators.
a. Know your skills and limits. Staying within your limits may help you to avoid an accident.
b. Only lend your machine to experienced operators.
3. Many machine accidents have been caused by machine operator errors. A typical error made by 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 the operator footrests during operation to maintain control of the machine.
6. Never ride under the influence of alcohol or drugs.
SAFETY INFORMATION
VII
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 OWNER’S MANUAL.
3. OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.
4. OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL AND/OR WHEN
MADE NECESSARY BY MECHANICAL CONDITIONS.
SAFE RIDING
1. Always make pre-operation checks. Careful checks may help prevent an accident.
2. Many accidents involve inexperienced operators.
a. Know your skills and limits. Staying within your limits may help you to avoid an accident.
b. Only lend your machine to experienced operators.
3. Many machine accidents have been caused by machine operator errors. A typical error made by 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 the operator footrests during operation to maintain control of the machine.
6. Never ride under the influence of alcohol or drugs.
SAFETY INFORMATION

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


NOTE:
Pre-operation checks should be made each time the motorcycle is used. Su\
ch an inspection can be thoroughly accomplished
in a very short time; and the added safety it assures is more than worth\
the time involved. If any maintenance service or
adjustment is needed, consult the chart above to refer to the pages in w\
hich the service or adjustment is described.
1. The engine, exhaust pipe, and muffler will be very hot after the engine \
has been run.
Be careful not to touch them or to allow any clothing item to contact th\
em during inspection or repair.
2. If any item is not working properly, have it inspected and repaired before operating the motorcycle.
ITEM ROUTINE
PAGE
Sidestand
Fittings / Fasteners Check all chassi fittings and fasteners.
Tighten / 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 ~ 6-296-24
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 smooth operation.
Lubricate if necessary
Rear brake and shift pedal
shafts
WARNING:

NOTE:
Pre-operation checks should be made each time the motorcycle is used. Su\
ch an inspection can be thoroughly accomplished
in a very short time; and the added safety it assures is more than worth\
the time involved. If any maintenance service or
adjustment is needed, consult the chart above to refer to the pages in w\
hich the service or adjustment is described.
1. The engine, exhaust pipe, and muffler will be very hot after the engine \
has been run.
Be careful not to touch them or to allow any clothing item to contact th\
em during inspection or repair.
2. If any item is not working properly, have it inspected and repaired before operating the motorcycle.
ITEM ROUTINE
PAGE
Sidestand
Fittings / Fasteners Check all chassi fittings and fasteners.
Tighten / 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 ~ 6-296-24
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 smooth operation.
Lubricate if necessary
Rear brake and shift pedal
shafts
WARNING:

$Always wipe off spilled fuel immediately with a dry and clean
soft cloth. Fuel may deteriorate painted surfaces or plastic
parts. Fuel
1. Fuel level 2. Filler tube
Make sure there is sufficient fuel in the tank.
Do not overfill the fuel tank. Avoid spilling fuel on the
hot engine. Do not fill the fuel tank above the bottom of
the filler tube as shown in the illustration or it may
overflow when the fuel heats up later and expands.
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)
WARNING:
CAUTION:
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.
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 used if ethanol content does not exceed 10%.
Gasohol containing methanol is not recommended by
Yamaha because it can cause fuel system damage or
vehicle performance problems.
$Always wipe off spilled fuel immediately with a dry and clean
soft cloth. Fuel may deteriorate painted surfaces or plastic
parts. Fuel
1. Fuel level 2. Filler tube
Make sure there is sufficient fuel in the tank.
Do not overfill the fuel tank. Avoid spilling fuel on the
hot engine. Do not fill the fuel tank above the bottom of
the filler tube as shown in the illustration or it may
overflow when the fuel heats up later and expands.
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)
WARNING:
CAUTION:
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.
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 used if ethanol content does not exceed 10%.
Gasohol containing methanol is not recommended by
Yamaha because it can cause fuel system damage or
vehicle performance problems.

PERIODIC MAINTENANCE AND MINOR REPAIRS
6-1 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. YOU MUST TAKE INTO
CONSIDERATION THAT WEATHER, TERRAIN,
GEOGRAPHICAL LOCATIONS, AND A VARIETY OF
INDIVIDUAL USES ALL TEND TO DEMAND THAT EACH
OWNER ALTER THIS TIME SCHEDULE TO SHORTER
INTERVALS TO MATCH THE ENVIRONMENT.
The most important points of motorcycle inspection,
adjustment, 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
6-1 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. YOU MUST TAKE INTO
CONSIDERATION THAT WEATHER, TERRAIN,
GEOGRAPHICAL LOCATIONS, AND A VARIETY OF
INDIVIDUAL USES ALL TEND TO DEMAND THAT EACH
OWNER ALTER THIS TIME SCHEDULE TO SHORTER
INTERVALS TO MATCH THE ENVIRONMENT.
The most important points of motorcycle inspection,
adjustment, 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:

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 cause loss of performance, excessive
emissions, and render it unsafe for use. Consult a
Yamaha dealer before attempting any changes.
!
Tool kit
The tools provided in 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 cause loss of performance, excessive
emissions, and render it unsafe for use. Consult a
Yamaha dealer before attempting any changes.
!
Tool kit
The tools provided in 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: