2007 YAMAHA YBR125 wheel

TABLE OF CONTENTSAir filter ...........................................................6-10
Carburetor adjustment ................................. 6-11
Idle speed adjustment .................................6-12
Throttle cable free play adjustment .............6-12
Valve clearance adjustment .........................6-13
Tyres ..............................................................6-13
Wheels ..........................................................6-15
Clutch lever free play adjustment ................6-16
Front brake adjustment ................................6-16
Rear brake adjustment ................................6-17
Brake light switch adjustment .....................6-17
Checking the brake shoes ...........................6-18
Drive chain slack check ................................6-18
Drive chain slack adjustment ......................6-19
Drive chain lubrication ..................................6-21
Cable inspection and lubrication .................6-21
Throttle cable and grip lubrication ...............6-21
Brake and shift pedal lubrication .................6-22
Brake and clutch lever lubrication ................6-22
Center and sidestand lubrication ................6-22
Front fork inspection .....................................6-23
Steering inspection ......................................6-23
Wheel bearings ............................................6-24
Battery ...........................................................6-24Fuse replacement ........................................6-26
Headlight bulb replacement ........................6-27
Turn signal and taillight bulb
replacement..................................................6-28
Front wheel removal .....................................6-28
Front wheel installation ................................6-30
Rear wheel removal .....................................6-30
Rear wheel installation ................................6-32
Troubleshooting...........................................6-32
Troubleshooting chart ..................................6-33
CLEANING & STORAGE
A. Cleaning .................................................... 7-1
B. Storage ...................................................... 7-2
SPECIFICATIONS ........................................... 8-1
CUSTOMER INFORMATION........................... 9-1
Key identification number ............................. 9-1
Frame serial number ................................... 9-1
Engine serial number .................................. 9-1
DETATCHMENTS
Pre-Delivery Inspection ................................10-1
Installation....................................................10-5
GREEN BOOK
78910
Libero5TS8.pmd11/3/2006, 8:50 PM 2

PRE-OPERATION CHECKS
4-1
Owners are personally responsible for their vehicle's condition. Your Motorcycle's vital functions can start to
deteriorate quickly and unexpectedly- even if it remains unused (for instance, if it is exposed to the elements). Any
damage. fluid leak or loss of tyre pressure could have serious consequence Therefore' it is very important that, in
addition to a thorough visual inspection, you check the following points before each ride.
PRE - OPERATION CHECK LIST
Brake and shift pedal shafts Engine oil
Control and meter cable Wheels and tyres Drive chain Clutch
Throttle grip and housing Rear brake Front brake
Lubricate if necessary.Check tyre pressure, wear, damage and spoke tightness.
Lubricate if necessary. Check for smooth operation. Lubricate if necessary.
Check for smooth operation. Tighten spokes if necessary. Adjust if necessary.
6-21
6-22 6-13 ~ 6-15 6-18 ~ 6-21
Check oil level.
Fill with oil if necessary.
Check chain slack and condition. Check operation, condition and free play.
Adjust if necessary.
Lubricate if necessary. Check for smooth operation. Adjust if necessary.
Check operation, condition and free play.Adjust if necessary. Check operation, condition and free play.
ITEM
CHECKS
6-8 ~ 6-9 6-12, 6-213-3, 6-16
3-4, 6-17
3-4, 6-16PAGE

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

WARNING1. It is dangerous to ride with a
worn-out tyre. When a tyre
tread begins to show lines,
have a YAMAHA dealer replace
the tyre immediately.
WheelsTo ensure maximum performance,
long service, and safe operation,
note the following:
1. Always inspect the wheels before
a ride. Check for cracks, bends or
warpage of the wheel. Be sure the
spokes are tight and undamaged.
If any abnormal condition exists in
a wheel, consult a YAMAHA
dealer. Do not attempt even small
repairs to the wheel. If a wheel is
deformed or cracked, it must be
replaced.
2. Tyres and wheels should be
balanced whenever either one is
changed or replaced. Failure to
have a wheel balanced can result
in poor performance, adverse
handling characteristics, and
shortened tyre life.3. Ride at moderate speeds after
changing a tyre since the tyre
surface must first be broken in for
it to develop its optimal
characteristics.PERIODIC MAINTENANCE AND MINOR REPAIR
6-15

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 :
Front fork inspectionSecurely support the Motorcycle
so there is no danger of it falling
over.
1. Visual check
Check for scratches or damage
on the inner tube and traces of oil
leakage from the front fork.2. Operation check
Place the Motorcycle on a level
place.
a. Hold the Motorcycle in an
upright position and apply the
front brake.
b. Push down hard on the
handlebars several times and
check if the fork rebounds
smoothly.
If any damage or unsmooth
movement is found with the front
fork, consult a YAMAHA dealer.
Steering inspectionPeriodically inspect the condition of
the steering. Worn out or loose
steering bearings may be danger-
ous. Place a stand under the engine
to raise the front wheel off the
ground. Hold the lower end of the
front forks and try to move them
forward and backward. If any free
play can be felt, ask a YAMAHA
dealer to inspect and adjust the
steering. Inspection is easier if the
front wheel is removed.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
WARNING