2008 YAMAHA YZF-R125 brake pads

TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS.......................................3-1
Main switch/steering lock ................3-1
Indicator and warning lights ............3-2
Tachometer ....................................3-3
Multi-function display ......................3-3
Handlebar switches ........................3-4
Clutch lever .....................................3-5
Shift pedal .......................................3-6
Brake lever .....................................3-6
Brake pedal ....................................3-6
Fuel tank cap ..................................3-7
Fuel .................................................3-7
Catalytic converters ........................3-8
Rider seat .......................................3-9
Anti-theft device housing ................3-9
Sidestand ......................................3-10
Ignition circuit cut-off system ........3-10
PRE-OPERATION CHECKS..............4-1
Pre-operation check list ..................4-2OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
Starting the engine ......................... 5-1
Shifting ........................................... 5-2
Tips for reducing fuel
consumption ............................... 5-3
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
Owner’s tool kit ............................... 6-1
Periodic maintenance and
lubrication chart .......................... 6-2
Removing and installing the
cowlings and panel ..................... 6-6
Checking the spark plug ................. 6-8
Engine oil and oil filter element ...... 6-9
Coolant ......................................... 6-12
Replacing the air filter element
and cleaning the check hose .... 6-14
Adjusting the engine idling
speed ........................................ 6-14
Adjusting the throttle cable free
play ........................................... 6-15
Valve clearance ............................ 6-16
Tires ............................................. 6-16
Cast wheels .................................. 6-18
Adjusting the clutch lever free
play ........................................... 6-19Checking the front brake lever
free play .................................... 6-20
Adjusting the brake pedal free
play ........................................... 6-20
Checking the front and rear
brake pads ................................ 6-20
Checking the brake fluid level ...... 6-21
Changing the brake fluid .............. 6-22
Drive chain slack .......................... 6-22
Cleaning and lubricating the
drive chain ................................ 6-24
Checking and lubricating the
cables ....................................... 6-24
Checking and lubricating the
throttle grip and cable ............... 6-25
Checking and lubricating the
brake and shift pedals .............. 6-25
Checking and lubricating the
brake and clutch levers ............ 6-26
Checking and lubricating the
sidestand .................................. 6-26
Lubricating the swingarm
pivots ........................................ 6-27
Checking the front fork ................. 6-27
Checking the steering .................. 6-28
Checking the wheel bearings ....... 6-28
Battery ......................................... 6-29
Replacing the fuses ..................... 6-30
Replacing a headlight bulb .......... 6-31
Tail/brake light ............................. 6-31U5D7E0E0.book Page 1 Tuesday, December 18, 2007 10:13 AM

PRE-OPERATION CHECKS
4-2
4
EAU15605
Pre-operation check list
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-7
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-9
CoolantCheck coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-12
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-20, 6-21
Rear brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-20, 6-21
ClutchCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-19
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
7*Front brakeCheck operation, fluid level and
vehicle for fluid leakage.√√√√√√
Replace brake pads. Whenever worn to the limit
8*Rear brakeCheck operation, fluid level and
vehicle for fluid leakage.√√√√√√
Replace brake pads. Whenever worn to the limit
9*Brake hosesCheck for cracks or damage.√√√√√
Replace. Every 4 years
10*WheelsCheck runout and for damage.√√√√
11*TiresCheck tread depth and for dam-
age.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√√
12*Wheel bearingsCheck bearing for looseness or
damage.√√√√
13*SwingarmCheck operation and for exces-
sive play.√√√√
Lubricate with lithium-soap-based
grease.Every 24000 km (14000 mi)
14 Drive chainCheck chain slack, alignment and
condition.
Adjust and lubricate chain with a
special O-ring chain lubricant
thoroughly.Every 1000 km (600 mi) and after washing the motorcycle or riding in the rain NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)6000 km
(3500 mi)12000 km
(7000 mi)18000 km
(10500 mi)24000 km
(14000 mi)
U5D7E0E0.book Page 3 Tuesday, December 18, 2007 10:13 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6
EAUT1220
Checking the front brake lever
free play The brake lever free play should mea-
sure 3.0–5.0 mm (0.12–0.20 in) as
shown. Periodically check the brake le-
ver free play and, if necessary, have a
Yamaha dealer check the brake sys-
tem.
WARNING
EWA10640
An incorrect brake lever free play in-
dicates a hazardous condition in the
brake system. Do not operate the
motorcycle until the brake system
has been checked or repaired by aYamaha dealer.
EAUM1353
Adjusting the brake pedal free
play The brake pedal free play should mea-
sure 3.5–4.5 mm (0.14–0.18 in) as
shown. Periodically check the brake
pedal free play and, if necessary, have
a Yamaha dealer adjust it.
WARNING
EWAM1030
An incorrect brake pedal free play
indicates a hazardous condition in
the brake system. Do not operate the
motorcycle until the brake system
has been checked or repaired by aYamaha dealer.
EAU22390
Checking the front and rear
brake pads The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU22440
Front brake pads
1. Remove the front brake caliper by
removing the bolts.
2. Check each front brake pad for
damage and measure the lining
thickness. If a brake pad is dam-
aged or if the lining thickness is
1. Brake lever free play
1. Brake pedal free play
1. Bolt
2. Brake caliper
3. Lining thickness
U5D7E0E0.book Page 20 Tuesday, December 18, 2007 10:13 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6 less than 0.8 mm (0.03 in), have a
Yamaha dealer replace the brake
pads as a set.
3. Install the front brake caliper by in-
stalling the bolts, then tightening
them to the specified torque.
EAU22500
Rear brake pads
Check each rear brake pad for damage
and measure the lining thickness. If a
brake pad is damaged or if the lining
thickness is less than 1 mm (0.04 in),
have a Yamaha dealer replace the
brake pads as a set.
EAU22580
Checking the brake fluid level Front brake
Rear brake
Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
Observe these precautions:


When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.


Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.


Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
Tightening torque:
Brake caliper bolt:
30 Nm (3.0 m·kgf, 22 ft·lbf)1. Lining thickness
1. Minimum level mark
1. Minimum level mark
Recommended brake fluid:
DOT 4
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6


Be careful that water does not en-
ter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.


Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.


As the brake pads wear, it is nor-
mal for the brake fluid level to grad-
ually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAUM1360
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrica-
tion chart. In addition, have the brake
hose replaced every four years or
whenever it is damaged or leaking.
EAU22760
Drive chain slack The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22773
To check the drive chain slack
1. Place the motorcycle on the side-
stand.NOTE:When checking and adjusting the drive
chain slack, there should be no weighton the motorcycle.
2. Shift the transmission into the neu-
tral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain, and
then measure the drive chain slack
as shown.Drive chain slack:
30.0–40.0 mm (1.18–1.57 in)
U5D7E0E0.book Page 22 Tuesday, December 18, 2007 10:13 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
66. Pull the wheel axle out, remove the
speed sensor by pulling it out, and
then remove the wheel.
CAUTION:
ECA11050
Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will beforced shut.
EAUM2430
To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Install the speed sensor at the
wheel hub.NOTE:Make sure that the projections on the
speed sensor rotor are aligned with the
notches in the wheel hub and that the
slot in the speed sensor fits over the re-tainer on the fork leg.
3. Insert the wheel axle.
4. Lower the front wheel so that it is
on the ground.
5. Push down hard on the handlebar
several times to check for proper
fork operation.
6. Install the brake caliper by install-
ing the bolts.
NOTE:Make sure that there is enough space
between the brake pads before install-
ing the brake caliper onto the brakedisc.
7. Install the brake hose holder by in-
stalling the bolt.
8. Install the speed sensor lead hold-
er by installing the bolt.
9. Tighten the wheel axle, front wheel
axle pinch bolt and brake caliper
bolts to the specified torques.
1. Brake hose holder
2. Brake caliper bolt
3. Brake caliper
4. Axle bolt
1. Speedometer gear unit
Tightening torques:
Wheel axle:
59 Nm (5.9 m·kgf, 43 ft·lbf)
Front wheel axle pinch bolt:
14 Nm (1.4 m·kgf, 10 ft·lbf)
Brake caliper bolt:
30 Nm (3.0 m·kgf, 22 ft·lbf)
U5D7E0E0.book Page 34 Tuesday, December 18, 2007 10:13 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-35
6
EAU25080
Rear wheel
EAU25311
To remove the rear wheel
WARNING
EWA10820


It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no dangerof it falling over.
1. Loosen the axle nut.
2. Lift the rear wheel off the ground
according to the procedure on
page 6-32.3. Remove the axle nut.
4. Loosen the locknut on each side of
the swingarm.
5. Turn the drive chain slack adjust-
ing bolts fully in direction (a) and
push the wheel forward.
6. Remove the drive chain from the
rear sprocket.
NOTE:

If the drive chain is difficult to re-
move, remove the wheel axle first,
and then lift the wheel upward
enough to remove the drive chain
from the rear sprocket.


The drive chain cannot be disas-sembled.7. While supporting the brake caliper
bracket, pull the wheel axle out,
and then remove the wheel.
CAUTION:
ECA11070
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise thebrake pads will be forced shut.
EAU39411
To install the rear wheel
1. Install the wheel and the brake cal-
iper bracket by inserting the wheel
axle from the left-hand side.NOTE:

Make sure that the slot in the brake
caliper bracket is fit over the retain-
er on the swingarm.


Make sure that there is enough
space between the brake pads be-fore installing the wheel.
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Brake caliper
U5D7E0E0.book Page 35 Tuesday, December 18, 2007 10:13 AM