2004 YAMAHA YBR125 oil 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

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:

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

6-8 e.Fill engine with oil. Install the oil filter cap and tighten.
NOTE:
Recommended engine oil classification; API Service ìSHî
type or equivalent
Do not put in any chemical additives. Engine oil also
lubricates the clutch and additives could cause clutch
slippage.
Be sure no foreign material enters the crankcase.
f. Start the engine and warm up for a few minutes.
While warming up, check for oil leakage. If oil
leakage is found, stop the engine immediately, and
check for the cause.
g. Stop the engine and check the oil level.
After replacing the engine oil, be sure to check the oil
pressure.
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) Recommended oil:
Yamalube 4
CAUTION:
CAUTION:
CAUTION:
6-8 e.Fill engine with oil. Install the oil filter cap and tighten.
NOTE:
Recommended engine oil classification; API Service ìSHî
type or equivalent
Do not put in any chemical additives. Engine oil also
lubricates the clutch and additives could cause clutch
slippage.
Be sure no foreign material enters the crankcase.
f. Start the engine and warm up for a few minutes.
While warming up, check for oil leakage. If oil
leakage is found, stop the engine immediately, and
check for the cause.
g. Stop the engine and check the oil level.
After replacing the engine oil, be sure to check the oil
pressure.
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) Recommended oil:
Yamalube 4
CAUTION:
CAUTION:
CAUTION:

6-9 Oil pressure
1. Remove the check bolt 1 in the cylinder head.
2. Start the engine and keep it idling until oil flows out
of the bleed hole. If no oil comes out after one
minute, turn off the engine immediately so it will
not seize. In such a case go to the nearest Yamaha
dealer or other qualified mechanic for repairs.
3. After checking, tighten the check bolt to the
specified torque.
Check bolt torque:
7 N.m (0.7 Kgf.m, 5.0 lbf.ft)
1. Check bolt
6-9 Oil pressure
1. Remove the check bolt 1 in the cylinder head.
2. Start the engine and keep it idling until oil flows out
of the bleed hole. If no oil comes out after one
minute, turn off the engine immediately so it will
not seize. In such a case go to the nearest Yamaha
dealer or other qualified mechanic for repairs.
3. After checking, tighten the check bolt to the
specified torque.
Check bolt torque:
7 N.m (0.7 Kgf.m, 5.0 lbf.ft)
1. Check bolt