Yamaha YBR125 Custom Manuale utente

YBR125(JYM125/125-2)

Chongqing Jianshe·YAMAHA Motor Co.,Ltd

First edition Jan.2003

in whole or part,or use without written

authorization of company,prohibited.

Notice

This service manual compiled by ChongqingYAMAHA Motor co.,Ltd, is specially used for dealer and maintenance

station of Chongqing JiansheYAMAHA Motor co.,Ltd. It is not possible to include all the knowledge of a mechanic in one

manual,it is only used for repairing and maintaining JiansheYAMAHA motorcycle and understand the principle of vehicle,

procedure of maintenance as well as technology of maintenance.If without the knowledge on this field,the improper ass-

embly and dangerous condition occuredafter assembly would be happened when repairing the motorcycle.

Chongqing JiansheYAMAHA Motor co.,Ltd is continually striving to improve all its models.Modifications and si-

gnificant changes in specifications of procedures will be forwarded to all authorized dealers and will appear in future

editions of this manual where applicable.

Note:

Design and specification are subject to changes without notice.

Important Information

Warning



Particularly important information is distinguished in this manual by the following notations:

The safety Alert Symbol means ATTENTION!BECOME ALERT!YOUR SAFETY IS INVOLED!

Failure to follow WARNING instructions could result in severe injury of death to the vehicle operator,

a bystander or a person inspecting or repairing the vehicle.



CAOTION A CAUTION indicates special precautions that must be taken to avoid damage to the machine.

NOTE: A NOTE Provides key information to make procedures easier or clearer.

How to use this manual

Manual Organization

Exploded Diagram

This manual includes many chapters which explain the main contents of each title individually.

First title:An abbreviation and symbol in the upper right corner of each page indecates the current chapt

Second title:This title is shown in the left of section symbol of upper right corner of each page.

Third title:It is a title of the smallest unit,which is compiled step by step and matched with relevent pictur

In order to understand the parts and treatment procedure,the exploded diagram is provided at the begin

of each exploded chapter:

.A clear exploded diagramis used for disassembly and reassembly of the motorcycle.

.In the exploded diagram,the numbers as symbolsis used for explaining the removing procedure.If there

around the numbers,it is the explanation of disassembly procedure.

Symbolin the exploded diagram is the explanation of work and key points.For the meaning of each symb

page.

.There is work indication tableunder each exploded diagram,which provides such informations as work proc

name of parts key pionts of work etc.

.For other informationsconcerning work,there is detailed explanation on progressive stepsbesides explod

and work indication table.

Index

§1 General information

§2 Specification

§3 Periodic inspection

and adjustment

§5 Carburetor

§6 Chassis

§7 Electrical system

§4 Engine

§8 Troubleshooting

GEN

INFO

ADJ

Chapter 1 General information

Chapter 2 Specification

Chapter 3 Periodic inspection and adjustment

Motorcycle identification

Motorcycle identifcation code

Points for attention in maintenance

Special tool

Main specification

Inspection specification

Engine

Chassis

Electrical system

Main tighten torque specification

Position to be applied lubricating-oil and kinds of lubricating-oil

Engine

Chassis

Engine lubrication diagram

Layout of cable pipeline

Brief introduction/Contents of periodic inspection

Removal and installation of cushion,fuel tank and cover alike

Inspection and adjustment of air valve clearance

Adjustment of idle speed

Drainage/Check and adjustment of free play of throttle cable

Check of spark plug

Check of compression pressure

Check of lubricating -oil quantity of engine

Replacement of engine lubricating-oil/Check of lubricating-oil pressure

Check and adjustment of clutch

Check and clear of air filter

Adjustment of front brake (drum rype)

Check of front brake pad

Check of front brake(disk type)

Check the brake liquid quantity/Exhausting air

Replacing brake fluid

Check and adjust rear brake

Check and adjust brake light switch

Check and adjust driving chain

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1-1

1-2

1-5

2-1

2-4

2-6

2-8

2-9

2-12

2-13

2-14

2-16

3-1

3-3

3-5

3-7

3-8

3-9

3-10

3-11

3-12

3-13

3-14

3-16

3-17

3-18

3-19

3-20

3-21

Check of front fork

Adjustment of rear shock absorber

Check of tire

Check of steering device

Check of battery

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Electrical system

Chapter 4 Disassembly of engine

Dissassembly of engine

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Disassembly of exhaust pipe and lead wire

Disassembly of carburetor,clutch cable,speedometer cable and driving chain

Disassembly of engine

Disconnection of engine

Disasembly of cylinder head,cylinder and piston

Disassembly of starting motor,clutch and oil pump

Disassembly of starting axle and idle gear

Disassembly of shift axle

Disassembly of rotator

Disconnection of crankcase

Disassembly of balance device,transmission and shift rod

Disassembly of crank,balance block

Disassembly of rocker arm,camshaft

Disassembly of air valve

Cylinder head

Air valve seat

Air valve and guide pipe of air valve

Air valve spring

Camshaft

Rocker arm and rocker arm shaft

Timing chain,sprocket,guide plate of chain,chain tensioner

Cylinder and piston

Piston pin

Piston ring

Crank

Balance device

Clutch

Transmission,shift rod

Check and repair

…

4-1

4-2

4-3

4-4

4-7

4-10

4-11

4-12

4-13

4-14

4-15

4-16

4-18

4-19

4-21

4-22

4-23

4-24

4-25

4-26

4-27

4-28

4-29

4-31

4-33

3-22

3-23

3-24

3-25

3-26

Kick starter

Engine oil pump,filter

Crankcase

Bearing,oil seal

Elastic circlip,washer

Assembly and adjustment of engine

Air valve

Rocker arm,cam shaft

Crank,balance device

Transmission

Shift cam,shifting fork

Crankcase

Shift axle,starting axle,idle gear

Clutch,engine il pump

Timing ,pneumatic system

Rotator,starting mechanism,chain guide plate,idle pulley

Piston and piston ring

Cylinder and piston

Cylinder head

Cam axle and locating key

General drawing of carburetor

Removal of carburetor

Adjustment of fuel level

Inspection of front and rear wheels

Front wheel

Inspection of front wheel

Speedometer gear assy

Front brake

Installation of front wheel

Rear wheel

Rear brake hub

Drive chain,sprocket

Drive chain

Inspection of drive chain

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Assembly and adjustment of engine

Chapter 5 Disassembling of carburetor

Chapte 6 Motorcycle body

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4-36

4-37

4-38

4-39

4-40

4-41

4-43

4-45

4-46

4-49

4-51

4-54

4-59

4-60

4-62

4-63

4-64

4-65

5-1

5-2

5-5

6-1

6-4

6-5

6-6

6-9

6-10

6-13

6-15

6-17

Inspection of clutch hub

Installation of drive chain

Removal of front fork

Inspection of front fork

Front fork assembling

Steering shaft and handle

Removal of handle

Inspection of handle

Inspection of front steering shaft

Installation of steering shaft

Installation of handle bar

Rear shock absorber and rear arm

Removal

Inspection

General drawing of circuit

Electric components

Inspection of socket connector

Inspection of switch

Ignition system

Starting system

Starting motor

Charge system

Lighting system

Signal system

Electric appliance system

Compression system

Intake and exhaust system

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Front fork

Chapter 7 Circuit

Chapter 8 Troubleshooting

Troubleshooting of engine

6-17

6-18

6-19

6-22

6-23

6-27

6-28

6-29

6-30

6-31

6-32

6-33

7-1

7-3

7-5

7-6

7-8

7-12

7-17

7-22

7-26

7-31

8-1

8-2

8-3

Chapter 1 General information

Motorcycle identification

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Motorcycle identification code

Points for attention in maintenance

Special tool

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