2004 YAMAHA YBR125 fuel pressure

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

4-4
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*:116 Kg ( 256 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 kpa2.0 kg/cm
2
28 PSI / 200Kpa
1.75 kg/cm2
25 PSI / 175 Kpa2.25 kg/cm
2
32 PSI / 225 Kpa
Proper loading of your motorcycle is important for the
handling, braking, and other performance and safety
characteristics of your motorcyle. Do not carry loosely
packed items that can shift. Securely pack your
heaviest items close to the center of the motorcycle,
and distribute the weight evenly from side to side.
Properly adjust the suspension for your load, and
check the condition and pressure of your tires. NEVER
OVERLOAD YOUR MOTORCYCLE. Make sure the total
weight of the cargo, rider, passenger, and accessories
(fairing, saddlebags, etc. if approved for this model)
does not exceed the maximum load of the motorcycle.
Operation of an overloaded motorcycle could cause
tire damage, an accident, or even injury.
WARNING:
4-4
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*:116 Kg ( 256 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 kpa2.0 kg/cm
2
28 PSI / 200Kpa
1.75 kg/cm2
25 PSI / 175 Kpa2.25 kg/cm
2
32 PSI / 225 Kpa
Proper loading of your motorcycle is important for the
handling, braking, and other performance and safety
characteristics of your motorcyle. Do not carry loosely
packed items that can shift. Securely pack your
heaviest items close to the center of the motorcycle,
and distribute the weight evenly from side to side.
Properly adjust the suspension for your load, and
check the condition and pressure of your tires. NEVER
OVERLOAD YOUR MOTORCYCLE. Make sure the total
weight of the cargo, rider, passenger, and accessories
(fairing, saddlebags, etc. if approved for this model)
does not exceed the maximum load of the motorcycle.
Operation of an overloaded motorcycle could cause
tire damage, an accident, or even injury.
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