2007 YAMAHA YBR125 brake

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
PREVENTIVE MAINTENANCE SCHEDULE
VA LV E S
SPARK PLUG
CARBURETOR
AIR FILTER
FUEL LINE
FUEL FILTER
ENGINE OIL
ENGINE OIL
FILTER SCREEN
BRAKE-FRONT &
REAR
Check valve clearances, adjust if necessary.
Check condition, gap;
Clean and reset if necessary.
Check idle speed, Choke lever operation.
Clean, inspect & lubricate. (replace if necessary)
Check fuel hose, for cracks or damage.
Replace if necessary.
Check for free flow of petrol, cleanliness of filter bowl,
replace if necessary.
Replace with recommended oil - Yamalube SG Grade
(Warm engine before draining)
Wash with petrol
Check operation./ Adjust if necessary.
Grease the brake cam.
ITEM OPERATION SNO
1
2
3
5 4
6
7
8
9
*
WHEELS 13FRONT & REAR
REAR ARM PIVOT CLUTCH
12 11BRAKE SHOES-
10
Check runout, spoke tightness, damage;
Correct it, if necessary. Check for wear, replace if necessary.
Check alignment marks on Push Lever and
Tighten with specified Torque if necessary Check Rear Arm assembly for looseness. Crankcase L.H. Adjust if necessary.
30 Days OR
500-700 KmAFTER EVERY DAYS OR KMS
REPLACE EVERY 10,000 km90 Days OR
2500-2700 Km180 Days OR
4500-5000 KmAFTER
EVERY
2000 KMS

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
PREVENTIVE MAINTENANCE SCHEDULE
EVERY 10,000 KM EVERY 10,000 KM
17
Check operation/oil leakage.
REAR SHOCK
ABSORBER
Replace if necessary.
STEERING BEARING
FRONT FORKS 16 15
Check operation/oil leakage. Repair if necessary. Check Bearing assembly for looseness;
Correct if necessary.
Relace oil Repack grease
S.NO ITEMOPERATION
DRIVE CHAIN
NUTS, BOLTS AND
FASTENERS
CENTERSTAND AND
SIDE STAND
Check Chain slack, alignment. Adjust if necessary.
Clean periodically & lubricate.
Check all Chassis fittings and fasteners for looseness.
Tighten as per specification.
Check operation and lubricate if necessary.
Check electrolyte level and top it up if necessary.
Check specific gravity and charge if required.
Check breather pipe for blockage and routing.
CONTROL CABLES
-THROTTLE
-CLUTCH
-FRONT BRAKE 18
19
20
21
BATTERY
22
Readjust or replace as required. Check operation, free play, cable damage
EVERY MONTH
IT IS RECOMMENDED THAT THE ABOVE BE SERVICED BY AUTHORIZED DEALER.
SERVICE MORE FREQUENTLY WHEN THE VEHICLE IS DRIVEN IN DUSTY AREAS.YAMAHA*
EVERY 10,000 KMS
WHEEL BEARING 14
Check Bearing assembly for looseness, damage;
Replace if necessary.
Repack grease
30 Days OR
500-700 KmAFTER EVERY DAYS OR KMS
90 Days OR
2500-2700 Km180 Days OR
4500-5000 KmAFTER
EVERY
2000 KMS

1. Locknut
2. Adjusting nut
3. Free playClutch lever free play
adjustmentThe clutch lever free play should be
adjusted to 10 ~ 15 mm. If the free
play is incorrect, adjust as follows.
1 . Loosen the locknut.
2. Turn the adjusting nut in direction
to increase free play or in
direction to decrease free
play.
3. Tighten the locknut.è
çIf proper adjustment cannot be
obtained or the clutch does not work
correctly, ask a dealer to
inspect the internal clutch
mechanism.YAMAHA
1. Adjusting nut
2. Free playFront brake adjustmentThe front brake lever free play should
be adjusted to 10 ~ 15 mm.
1. Turn the adjusting nut in direction
to increase free play and
direction to decrease free play. ç
è
When it is impossible to make the
proper adjustment, ask a YAMAHA
dealer.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
NOTE :
WARNING

1. Adjusting NutRear brake adjustmentThe rear brake pedal free play
should be adjusted to 20 ~ 30 mm at
the brake pedal end. Turn the
adjusting nut in direction to
increase free play and in direction
to decrease free play.ç
è
a. Freeplay When it is impossible to make
the proper adjustment, ask a
YAMAHA dealer.
Check the operation of the
brake light after adjusting the
rear brake.
1. Brake light switch
2. Adjusting nutBrake light switch adjustmentThe rear brake light switch is acti-
vated by the brake pedal and is
properly adjusted when the brake
light comes on just before braking
takes effect. To adjust the rear
brake light switch, hold the switch
body so it does not rotate while
turning the adjusting nut.
Turn the adjusting nut in direction ç
to make the brake light come on
earlier.
Turn the adjusting nut in direction è
to make the brake light come on
later.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
WARNING
1
2
çè

1. Wear limit line
2. Wear indicatorChecking the brake shoesA wear indicator is provided on each
brake. This indicator allows
inspection of shoe wear without
disassembling the brake. Apply the
brake and inspect the position of the
indicator. If the indicator reaches to
the wear limit line, ask a YAMAHA
dealer to replace the shoes.
1. Wear limit line
2. Wear indicator1. Free play
Drive chain slack checkSpin the wheel several times and
find the tightest position of the
chain. Check and/or adjust the
chain slack while it's in this tightest
position.
Inspect the drive chain when the
Motorcycle is on the centerstand.
Check the slack at the position
shown in the illustration. Normal
slack is approximately 20 ~ 30 mm.
If the slack exceeds 30 mm, adjust.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
NOTE :

1. Chain jointIf the chain is disassembled, be sure
the chain lock is placed in the
correct direction when installing.
1. Adjusting nut
2. Cotter pin
3. Axle nutDrive chain slack adjust-
ment1. Loosen the rear brake pedal
free play adjusting nut.
2. Remove the cotter pin from
the axle nut.
3. Loosen the axle nut.
1. Locknut
2. Adjusting hex screw4. Loosen the chain adjusting
locknuts on each chain puller. To
tighten the chain, turn the chain
adjusting hex screw in direction b
to loosen the chain, turn the chain
adjusting hex screw in direction a
and push the wheel forward. Turn
each chain adjusting hex screw
exactly the same amount to
maintain correct axle alignment.
There are marks on each chain
puller. Use these marks to align
the rear wheel.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-19

CAUTION :
5. After adjusting, be sure to tighten
each chain adjusting locknut.
Then tighten the axle nut to the
specified torque.Maintain chain slackness
within specified limits as per
specifications.
To maintain correct axle
alignment, Ensure the notch
on the adjuster is on the same
Mark on Left and Right Side.
Tightening torque:
Axle nut:
65 ft-lb (9.05 m-kg)
1. Cotter pin6. Insert a new cotter pin into the
axle nut and bend the end of the
cotter pin as shown. If the notch in
the axle nut and the cotter pin
hole do not match, tighten the nut
slightly to align them.
Always use a new cotter pin on
the axle nut.7 Adjust the free play in the
brake pedal.
Check the operation of the brake
light after adjusting the rear
brake.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
WARNING
WARNING

Brake and shift pedal
lubricationLubricate the pivoting parts.
Recommended lubricant:
20W40 Type SG
Brake and Clutch Lever
GreasingGrease the pivoting parts.
MULTIPURPOSE Recommended Grease :
Center and sidestand
lubricationLubricate the pivoting and mating
joints.
Check to see that the center and
sidestand move up and down
smoothly.
Recommended lubricant:
If the center and/or sidestand does
not move smoothly, consult
aYAMAHA dealer.20W40 Type SG
PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
WARNING