2004 YAMAHA YBR125 engine 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
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

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

4-3
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: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:
4-3
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: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:

5-5 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.
3. 500 ~ 1,000 Km:
Avoid cruising speeds in excess of 3/4 throttle.
After 1,000Km of operation, be sure to replace the engine
oil.
4. After 1,000 Km:
Avoid prolonged full throttle operation. Vary speeds
occasionally.
If any engine trouble should occur during the break-in
period, consult a Yamaha dealer immediately.Parking
When parking the motorcycle, stop the engine and remove
the ignition key. Turn the fuel cock to ìOFFî whenever
stopping the engine.
The muffler and exhaust pipe are hot. Park the
motorcycle in a place where pedestrians or children
are not likely to touch the motorcycle. Do not park the
motorcycle on a slope or soft ground; the motorcycle
may fall over.
CAUTION:
CAUTION:
WARNING:
5-5 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.
3. 500 ~ 1,000 Km:
Avoid cruising speeds in excess of 3/4 throttle.
After 1,000Km of operation, be sure to replace the engine
oil.
4. After 1,000 Km:
Avoid prolonged full throttle operation. Vary speeds
occasionally.
If any engine trouble should occur during the break-in
period, consult a Yamaha dealer immediately.Parking
When parking the motorcycle, stop the engine and remove
the ignition key. Turn the fuel cock to ìOFFî whenever
stopping the engine.
The muffler and exhaust pipe are hot. Park the
motorcycle in a place where pedestrians or children
are not likely to touch the motorcycle. Do not park the
motorcycle on a slope or soft ground; the motorcycle
may fall over.
CAUTION:
CAUTION:
WARNING:

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.
REMARKS1,000KM
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 plugCheck 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.
REMARKS1,000KM
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 plugCheck condition and clean if necessary.
Replace if necessary every 12,000 Km.
3,000KM

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.
6-5
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
45
911,25
2,0
0,7
4,5
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
32.5
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.
6-5
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
45
911,25
2,0
0,7
4,5
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
32.5
66

6-6
1. Engine oil filler cap
1. Maximum mark 2.Minimum mark
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.
NOTE:
Wait a few minutes until the oil level settles before checking.
c. Remove the oil filler cap/ dispstick, clean it with a dry
cloth and check the oil level.
NOTE:
To check the oil level the oil filler cap/ dispstick can not be
screwed, just lightly seated in place.
d. The oil level should be between the maximum and
minimum marks. If the level is low, add oil to raise it to the
indicated level, check for oil leakage.
6-6
1. Engine oil filler cap
1. Maximum mark 2.Minimum mark
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.
NOTE:
Wait a few minutes until the oil level settles before checking.
c. Remove the oil filler cap/ dispstick, clean it with a dry
cloth and check the oil level.
NOTE:
To check the oil level the oil filler cap/ dispstick can not be
screwed, just lightly seated in place.
d. The oil level should be between the maximum and
minimum marks. If the level is low, add oil to raise it to the
indicated level, check for oil leakage.