Yamaha YBR125ED 2005 User manual

2005

YBR125ED

3D9-F8197-E0

SERVICE MANUAL

EAS00000

YBR125ED 2005

SERVICE MANUAL

First edition, January 2005

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

EAS00002

NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-

ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in

one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha

vehicles should have a basic understanding of mechanics and the techniques to repair these types

of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to

render the vehicle unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and

significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-

ers and will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to

the vehicle operator, a bystander or a person checking or repairing the vehicle.

A CAUTION indicates special precautions that must be taken to avoid damage

to the vehicle.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

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HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are

laid out with the individual steps in sequential order.

1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of

each page indicate the current chapter.

Refer to “SYMBOLS”.

2Each chapter is divided into sections. The current section title is shown at the top of each page,

except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section

title(s) appears.

3Sub-section titles appear in smaller print than the section title.

4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of

each removal and disassembly section.

5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a

disassembly step.

6Symbols indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

8Jobs requiring more information (such as special tools and technical data) are described sequen-

tially.

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SYMBOLS

The following symbols are not relevant to

every vehicle. Symbols 1to 8indicate the

subject of each chapter.

1General information

2Specifications

3Periodic checks and adjustments

4Chassis

5Engine

6Carburetor

7Electrical system

8Troubleshooting

Symbols 9to Findicate the following.

9Serviceable with engine mounted

0Filling fluid

ALubricant

BSpecial tool

CTightening torque

DWear limit, clearance

EEngine speed

FElectrical data

Symbols Gto Lin the exploded diagrams

indicate the types of lubricants and lubrication

points.

GEngine oil

HGear oil

IMolybdenum-disulfide oil

JWheel-bearing grease

KLithium-soap-based grease

LMolybdenum-disulfide grease

Symbols Mto Nin the exploded diagrams

indicate the following.

MApply locking agent (LOCTITE®)

NReplace the part

GHI

JKL

GEN

INFO

SPEC

CHK

ADJ

CHAS

ENG

CARB

–+

ELEC TRBL

SHTG

EGM

BLS M

New

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TABLE OF CONTENTS

GENERAL INFORMATION GEN

INFO 1

SPECIFICATIONS SPEC 2

PERIODIC CHECKS AND

ADJUSTMENTS CHK

ADJ 3

CHASSIS CHAS 4

ENGINE ENG 5

CARBURETOR CARB 6

ELECTRICAL SYSTEM ELEC 7

TROUBLESHOOTING TRBL

SHTG 8

–+

GEN

INFO

CHAPTER 1

GENERAL INFORMATION

VEHICLE IDENTIFICATION............................................................................1-1

VEHICLE IDENTIFICATION NUMBER .....................................................1-1

MODEL LABEL..........................................................................................1-1

IMPORTANT INFORMATION .........................................................................1-2

PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-2

REPLACEMENT PARTS...........................................................................1-2

GASKETS, OIL SEALS AND O-RINGS ....................................................1-2

LOCK WASHERS/PLATES AND COTTER PINS .....................................1-3

BEARINGS AND OIL SEALS ....................................................................1-3

CIRCLIPS ..................................................................................................1-3

CHECKING THE CONNECTIONS ..................................................................1-4

SPECIAL TOOLS ............................................................................................1-5

1 - 1

GEN

INFO

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GENERAL INFORMATION

VEHICLE IDENTIFICATION

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VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1is

stamped into the right side of the steering head

pipe.

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MODEL LABEL

The model label 1is affixed to the frame. This

information will be needed to order spare

parts.

VEHICLE IDENTIFICATION

1 - 2

GEN

INFO

IMPORTANT INFORMATION

EAS00020

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND

DISASSEMBLY

1. Before removal and disassembly, remove all

dirt, mud, dust and foreign material.

2. Use only the proper tools and cleaning

equipment.

Refer to the “SPECIAL TOOLS”.

3. When disassembling, always keep mated

parts together. This includes gears, cylin-

ders, pistons and other parts that have been

“mated”through normal wear. Mated parts

must always be reused or replaced as an

assembly.

4. During disassembly, clean all of the parts

and place them in trays in the order of dis-

assembly. This will speed up assembly and

allow for the correct installation of all parts.

5. Keep all parts away from any source of fire.

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REPLACEMENT PARTS

Use only genuine Yamaha parts for all

replacements. Use oil and grease recom-

mended by Yamaha for all lubrication jobs.

Other brands may be similar in function and

appearance, but inferior in quality.

EAS00022

GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all

gaskets, seals and O-rings. All gasket sur-

faces, oil seal lips and O-rings must be

cleaned.

2. During reassembly, properly oil all mating

parts and bearings and lubricate the oil seal

lips with grease.

1 - 3

GEN

INFO

IMPORTANT INFORMATION

EAS00023

LOCK WASHERS/PLATES AND COTTER

PINS

After removal, replace all lock washers/plates

1and cotter pins. After the bolt or nut has

been tightened to specification, bend the lock

tabs along a flat of the bolt or nut.

EAS00024

BEARINGS AND OIL SEALS

Install bearings and oil seals so that the manu-

facturer’s marks or numbers are visible. When

installing oil seals, lubricate the oil seal lips

with a light coat of lithium-soap-based grease.

Oil bearings liberally when installing, if appro-

priate.

1Oil seal

CAUTION:

Do not spin the bearing with compressed

air because this will damage the bearing

surfaces.

1Bearing

EAS00025

CIRCLIPS

Before reassembly, check all circlips carefully

and replace damaged or distorted circlips.

Always replace piston pin clips after one use.

When installing a circlip 1, make sure the

sharp-edged corner 2is positioned opposite

the thrust 3that the circlip receives.

4Shaft

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