2004 YAMAHA YBR125 clutch

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
Kick starter .......................................................... 3-10
Steering lock....................................................... 3-11
Seat......................................................................3-12
Side covers......................................................... 3-13
Rear shock absorber adjustment ....................... 3-14
XIPRE-OPERATION CHECKS........................................ 4-1
Engine oil................................................................ 4-3
Tires........................................................................4-3
Fitting/Fasteners....................................................4-6
Switches................................................................ 4-6
Wheels ......................................................... 4-6
Fuel ........................................................... 4-7
OPERATION AND IMPORTANT RIDING POINTS....... 5-1
Starting a cold engine........................................... 5-2
Starting a warm engine .......................................... 5-2
Warming up the engine .......................................... 5-2
Shifting ................................................................... 5-3
Tips for reduccing fuel consumption...................... 5-4
Engine Break-in...................................................... 5-4
Parking ................................................................... 5-5
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
Kick starter .......................................................... 3-10
Steering lock....................................................... 3-11
Seat......................................................................3-12
Side covers......................................................... 3-13
Rear shock absorber adjustment ....................... 3-14
XIPRE-OPERATION CHECKS........................................ 4-1
Engine oil................................................................ 4-3
Tires........................................................................4-3
Fitting/Fasteners....................................................4-6
Switches................................................................ 4-6
Wheels ......................................................... 4-6
Fuel ........................................................... 4-7
OPERATION AND IMPORTANT RIDING POINTS....... 5-1
Starting a cold engine........................................... 5-2
Starting a warm engine .......................................... 5-2
Warming up the engine .......................................... 5-2
Shifting ................................................................... 5-3
Tips for reduccing fuel consumption...................... 5-4
Engine Break-in...................................................... 5-4
Parking ................................................................... 5-5

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
Front brake adjustment........................................6-16
Checking the brake shoes ...................................6-16
Rear brake adjustment.........................................6-17
Brake light switch adjustment ..............................6-18
Clutch adjustment................................................ 6-18
Drive chain slack check.......................................6-19
Drive chain slack adjustment...............................6-20
Drive chain lubrication..........................................6-21
Cable inspection and lubrication.......................... 6-21
Throttle cable and grip lubrication .......................6-22
Brake and shift pedals .........................................6-22
Brake and clutch levers .......................................6-22
Sidestand.............................................................6-22
Front fork inspection............................................6-23Steering 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................................. 6-28
Turn signal bulb replacement.............................. 6-30
Taillight bulb replacement.................................... 6-30
Front wheel removal............................................. 6-31
Front wheel installation........................................ 6-32
Rear wheel removal............................................. 6-32
Rear wheel installation......................................... 6-33
Troubleshooting.................................................... 6-34
Troubleshooting chart.......................................... 6-35
CLEANING AND STORAGE....................................... 7-1
CLEANING............................................................. 7-1
STORAGE.............................................................. 7-2
SPECIFICATIONS ........................................................ 8-1
XII
CONTENTS
DESCRIPTION............................................................. 1-1
MACHINE IDENTIFICATION....................................... 2-1
Vehicle identikfication 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
Kick starter .......................................................... 3-10
Steering lock....................................................... 3-11
Seat......................................................................3-12
Side covers......................................................... 3-13
Rear shock absorber adjustment ....................... 3-14
XIPRE-OPERATION CHECKS........................................ 4-1
Engine oil................................................................ 4-3
Tires........................................................................4-3
Fitting/Fasteners....................................................4-6
Switches................................................................ 4-6
Wheels ......................................................... 4-6
Fuel ........................................................... 4-7
OPERATION AND IMPORTANT RIDING POINTS....... 5-1
Starting a cold engine........................................... 5-2
Starting a warm engine .......................................... 5-2
Warming up the engine .......................................... 5-2
Shifting ................................................................... 5-3
Tips for reduccing fuel consumption...................... 5-4
Engine Break-in...................................................... 5-4
Parking ................................................................... 5-5

1-1 DESCRIPTION
01. Fuel cock
02. Starter lever
03. Battery
04. Fusible
05. Tool kit
06. Shift pedal
07. Shock absorber
08. Air filter
09. Kick stater
10. Dispstick11. 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
1-1 DESCRIPTION
01. Fuel cock
02. Starter lever
03. Battery
04. Fusible
05. Tool kit
06. Shift pedal
07. Shock absorber
08. Air filter
09. Kick stater
10. Dispstick11. 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

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.
3-6This motorcycle is equipped with a constant-mesh 5-speed
transmission.
The shift pedal is located on the left side of the engine and
is used in combination with the clutch when shifting.
Clutch lever
Shift pedal
1. Clutch lever1. 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.
3-6This motorcycle is equipped with a constant-mesh 5-speed
transmission.
The shift pedal is located on the left side of the engine and
is used in combination with the clutch when shifting.
Clutch lever
Shift pedal
1. Clutch lever1. Shift pedal

PRE-OPERATION CHECKS
Before using this motorcycle, check the following points:
ITEM ROUTINE
PAGE
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 necessary6-16 ~ 6-18
6-14 , 6-22
4-3 , 6-6 , 6-9
6-19 ~ 6-21
6-10 ~ 6-11
4-3 ~ 4-6 , 6-31~ 6-33
6-21 Check operation, condition and free play.
Adjust if necessary
Wheels / Tires
Clean and oil it frequently.6-18 Brakes
4-1
PRE-OPERATION CHECKS
Before using this motorcycle, check the following points:
ITEM ROUTINE
PAGE
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 necessary6-16 ~ 6-18
6-14 , 6-22
4-3 , 6-6 , 6-9
6-19 ~ 6-21
6-10 ~ 6-11
4-3 ~ 4-6 , 6-31~ 6-33
6-21 Check operation, condition and free play.
Adjust if necessary
Wheels / Tires
Clean and oil it frequently.6-18 Brakes
4-1

4-2 NOTE:
Pre-operation checks should be made each time the motorcycle is used. Such 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 which 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 them during inspection or repair.
2. If any item is not working properly, have it inspected and repaired before operating the motorcycle.
ITEMROUTINE
PAGE
Sidestand
Fittings / FastenersCheck all chassi fittings and fasteners.
Tighten / Adjust, if necessary
Check fuel level / top up as required.
Fuel tank
Lights, signals and switches
BatteryCheck electrolyte level.
Replenish with ìdistilled waterî if necessary.6-22
4-6 , 6-5
4-6 , 6-28 ~ 6-30
6-25 ~ 6-276-22
4-7
Check for proper operation
Front brake and clutch
lever pivotsCheck for smooth operation.
Lubricate if necessary
Check for smooth operation.
Lubricate if necessary
6-22 Check for smooth operation.
Lubricate if necessary Rear brake and shift pedal
shafts
WARNING:
4-2 NOTE:
Pre-operation checks should be made each time the motorcycle is used. Such 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 which 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 them during inspection or repair.
2. If any item is not working properly, have it inspected and repaired before operating the motorcycle.
ITEMROUTINE
PAGE
Sidestand
Fittings / FastenersCheck all chassi fittings and fasteners.
Tighten / Adjust, if necessary
Check fuel level / top up as required.
Fuel tank
Lights, signals and switches
BatteryCheck electrolyte level.
Replenish with ìdistilled waterî if necessary.6-22
4-6 , 6-5
4-6 , 6-28 ~ 6-30
6-25 ~ 6-276-22
4-7
Check for proper operation
Front brake and clutch
lever pivotsCheck for smooth operation.
Lubricate if necessary
Check for smooth operation.
Lubricate if necessary
6-22 Check for smooth operation.
Lubricate if necessary Rear brake and shift pedal
shafts
WARNING:

1. Do not coast for long periods with the engine off,
and do not tow the motorcycle a long distance. Even
with gears in neutral, the transmission is only
properly lubricated when the engine is running.
Inadequate lubrication may damage the
transmission.
2. Always use the clutch when changing gears. The
engine, transmission, and driveline are not
designed to withstand the shock of forced shifting
and can be damaged by shifting without using the
clutch.
5-3 Shifting
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 sho
wn in the
illustration (page 3-6).
To shift into NEUTRAL, depress the shift pedal repeatedly
until it reaches the end of its travel (you will feel a stop
when you are in first gear), then raise the pedal slightly.
CAUTION:
1. Do not coast for long periods with the engine off,
and do not tow the motorcycle a long distance. Even
with gears in neutral, the transmission is only
properly lubricated when the engine is running.
Inadequate lubrication may damage the
transmission.
2. Always use the clutch when changing gears. The
engine, transmission, and driveline are not
designed to withstand the shock of forced shifting
and can be damaged by shifting without using the
clutch.
5-3 Shifting
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 sho
wn in the
illustration (page 3-6).
To shift into NEUTRAL, depress the shift pedal repeatedly
until it reaches the end of its travel (you will feel a stop
when you are in first gear), then raise the pedal slightly.
CAUTION:

5-4 Tips for reducing fuel consumption
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. Turn off the engine instead of letting it idle for an extended
lenght of time, i.e. in traffic jams, at traffic lights or railroad
crossings.Engine Break-in
There is never a more important period in the life of your
motorcycle than the period 1.000Km. For this reason we
ask that you carefully read the following material. Because
the engine is brand new, you must not put an excessive
load on it for the first several hours of running.
During this period, prolonged full throttle operation, or any
condition which might result in excessive heating of the
engine must be avoided.
1. 0 ~ 150 Km:
Avoid operation above 1/3 throttle. Stop the engine and
let it cool for 5 to 10 minutes after every hour of
operation. Vary the speed of the motorcycle from time
to time. Do not operate it at one set throttle position.
5-4 Tips for reducing fuel consumption
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. Turn off the engine instead of letting it idle for an extended
lenght of time, i.e. in traffic jams, at traffic lights or railroad
crossings.Engine Break-in
There is never a more important period in the life of your
motorcycle than the period 1.000Km. For this reason we
ask that you carefully read the following material. Because
the engine is brand new, you must not put an excessive
load on it for the first several hours of running.
During this period, prolonged full throttle operation, or any
condition which might result in excessive heating of the
engine must be avoided.
1. 0 ~ 150 Km:
Avoid operation above 1/3 throttle. Stop the engine and
let it cool for 5 to 10 minutes after every hour of
operation. Vary the speed of the motorcycle from time
to time. Do not operate it at one set throttle position.