1989 - 2004 YAMAHA BREEZE 125 Service Repair Manual

YAMAHA YFA1 Service Manual

_YAMAHA LIT-11616-06-75 3FA-28197-10

YFA1W SERVICE MANUAL © 1988 by Yamaha Motor Corporation, U.S.A. 1st edition, November 1988 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly Prohibited. Printed in U.S.A. LIT-11616-06-75

NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic's education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha machines have a basic understanding of the mechanical concepts and procedures inherent in machine repair tech· nology. Without such knowledge, attempted repairs or service to this model may render it unfit to use and/or unsafe. Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Autho· rized Yamaha dealers and will, where applicable, appear in future editions of this manual. TECHNICAL PUBLICATIONS SERVICE DIVISION MOTORCYCLE GROUP YAMAHA MOTOR CO., LTO. HOW TO USE THIS MANUAL PARTICULARLY IMPORTANT INFORMATION This material is distinguished by the following notation. NOTE: Lh WARNING: A NOTE provides key information to make procedures easier or clearer. A CAUTION indicates special procedures that must be followed to avoid damage to the machine. A WARNING indicates special procedures that must be followed to avoid injury to a machine operator or person inspecting or repairing the machine. MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by·step format. The informa· tion has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., • Bearings Pitting/Damage ~ Replace. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures.

CD ® I ~ EF~ 101ta 1 ISPECI p~1 ® ® 1~6JlilNl ENG •• ® ® ICOOll ~I ICARBI f I (j) ® IORIVI-ra-1 ICHASI~I ® @ I ElECI iii I I~~~~I? I @ ~ @ ~ @ ~ @ ~ @ ~ @ I0l @ [11 @ , iLT) @ 1 ® i ® 1 - Gl e m @ @ ® ~ ~ ~ ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols CD to ® are designed as thumb tabs to indicate the chapter's number and content. CD General information ® Specifications ® Periodic inspection and adjustment ® Engine ® Cool i ng system ® Carburetion (j) 0 rive tra in ® Chassis ® Electrical @ Troubleshooting Illustrated symbols @ to @ are used to identify the specifications appearing in the text. @ Filling fluid @ Lubricant @ Special tool @ Tightening @ Wear lim it, clearance @ Engine speed @n,V,A Illustrated symbols @ to ® in the exploded diagram indicate grade of lubricant and location of lubrication point. @ Apply locking agent (LOCTITE@) @ Apply engine oil ® Apply gear oil ® Apply molybdenum disulfide oil @ Apply wheel bearing grease @ Apply lightweight lithium-soap base grease ® Apply molybdenum disulfide grease

INDEX GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL CARBURETION CHASSIS ELECTRICAL TROUBLESHOOTING ott. I--- GEN INFO SPEC II!JJ 1--- INSP ADJ ENG CARS CHAS ELEC ? I---~. TRBL SHTG

CONTENTS CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION ..................................... 1-1 VEHICLE IDENTIFICATION NUMBER .......................... 1-1 FRAME SERIAL NUMBER .................................... 1-1 ENGINE SERIAL NUMBER .. " ................. ____ . _ .. _ . ___ . _ 1-1 IMPORTANT INFORMATION. _ ..... _ ............................. 1-2 PREPARATION FOR REMOVAL ............. " ................ 1-2 ALL 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 CI RCLIPS ........ _ ........................................ _ 1-3 SPECIAL TOOLS .................................... _ ......... _1-4 FOR TUNE UP ........................... _ . __ ............... 1-4 FOR ENGINE SERVICE ...................................... 1-5 FOR CHASSIS SERVICE ...................................... 1-8 FOR ELECTRICAL COMPONENTS .......................... _ .. 1-8 CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS .................................... 2-1 MAINTENANCE SPECIFICATIONS ...................... , ... , ..... 2-4 ENGINE ................................................... 2-4 CHASSIS ................................................. 2-10 ELECTRICAL ............................................. 2-13 GENERAL TORQUE SPECIFICATIONS ........................... 2-15 DEFINITION OF UNITS ........................................ 2-15 LUBRICATION POINTS AND LUBRICANT TYPE ................... 2-16 ENGINE ................................................. 2-16 CHASSIS ................................................. 2-16 LUBRICATION DIAGRAM ...................................... 2-17 CABLE ROUTING ............................................. 2-18

CHAPTER 3. PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION .............................................. 3-1 PERIODIC MAINTENANCE/LUBRICATION INTERVALS .............. 3-1 FENDERS .................................................... 3-2 REMOVAL ................................................ 3-2 INSTALLATION ............................................ 3-4 ENGINE ...................................................... 3-5 VALVE CLEARANCE ADJUSTMENT ........................... 3-5 TIMING CHAIN ADJUSTMENT ................................ 3-7 IDLING SPEED ADJUSTMENT ................................ 3-8 THROTTLE CABLE FREE PLAY ADJUSTMENT .................. 3-9 SPARK PLUG INSPECTION ................................... 3-9 IGNITION TIMING CHECK .................................. 3-10 COMPRESSION PRESSURE MEASUREMENT ................... 3-12 ENGINE 01 L LEVEL INSPECTION ............................ 3-13 ENGINE OIL REPLACEMENT ................................ 3-14 TRANSMISSION OIL LEVEL INSPECTION ..................... 3-15 TRANSMISSION OIL REPLACEMENT ......................... 3-16 AIR FILTER CLEANING .................................... 3-17 CARBURETOR JOINT INSPECTION ........................... 3-20 FUEL LINE INSPECTION .................................... 3-20 CRANKCASE BREATHER HOSE INSPECTION .................. 3-21 EXHAUST SYSTEM INSPECTION ............................. 3-21 V-BELT INSPECTION ....................................... 3-22 CHASSIS .................................................... 3-23 FRONT BRAKE ADJUSTMENT ............................... 3-23 ott. ~G~E-N- INFO SPEC IPjJ ~IN~S~P- ADJ ~ .• ..---~ ENG • CARB CHAS REAR BRAKE ADJUSTMENT ................................ 3-23 ~ BRAKE SHOE INSPECTION .................................. 3-25 == DRIVE CHAIN SLACK ADJUSTMENT ......................... 3-25 DRIVE CHAIN LUBRiCATION ............................... 3-27 STEERING SYSTEM INSPECTION ............................ 3-27 TOE-IN ADJUSTMENT ...................................... 3-28 TIRE INSPECTION ......................................... 3-29 WHEEL INSPECTION ....................................... 3-32 CABLE INSPECTION AND LUBRiCATION ...................... 3-32 LEVER LUBRICATION ..................................... 3-33 FRONT SUSPENSION LUBRICATION ......................... 3-33 STEERING COLUMN LUBRICATION .......................... 3-33 REAR SUSPENTION LUBRICATION .......................... 3-33 ELECTRICAL ................................................ 3-34 BATTERY INSPECTION ..................................... 3-34 FUSE INSPECTION ......................................... 3-34 HEADLIGHT BEAM ADJUSTMENT ........................... 3-37 HEADLIGHT BULB REPLACEMENT .......................... 3-38 ELEC ? • ..---- TRBL SHTG

CHAPTER 4 ENGINE OVERHAUL ENGINE REMOVAL . ........................................... 4-1 ENG I N E 0 I L ....................................... , , .. , . , . 4-1 TRANSMISSION OIL. ........................................ 4-1 FENDERS .................................................. 4-1 CARBURETOR ............................................. 4-1 MUFF LER ................................................. 4-2 STARTING MOTOR .......................................... 4-3 LEADS AN D HOSES ......................................... 4-3 ENGINE REMOVAL ......................................... 4-3 ENGINE DISASSEMBLY . ........... , ..................... , . , .... 4-5 CYLINDER HEAD, CYLINDER AND PISTON ..................... 4-5 PRIMARY SHEAVE AND SECONDARY SHEAVE .................. 4-7 ELECTRIC STARTING DRIVE ........................ , ........ 4-9 SHIFT LEVER ............................................. 4-10 CDI MAGNETO ............................................ 4-10 OIL PU M P. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 TIMING CHAIN ............................................ 4-12 CRANKCASE (RIGHT) .......................... , ......... , .4-12 SHIFTER AND TRANSMISSION ............................... 4-13 CRANKSHAFT AND BALANCER .............................. 4-14 CAMSHAFT, ROCKER ARM AND VALVE ...................... 4-14 INSPECTION AND REPAIR .. ................................... 4-17 CYLINDER HEAD .......................................... 4-17 VA LV E SEAT .............................................. 4-18 VALVE AND VALVE GUIDE ................................. 4-21 CAMSHAFT ............................................... 4-22 ROCKER ARM AND ROCKER ARM SHAFT ..................... 4-23 VALVE SPRING ............................................ 4-24 TIMING CHAIN, CHAIN GUIDE AND SPROCKET ................ 4-24 CYLINDER AND PISTON .................................... 4-25 PISTON RING ............................................. 4·27 PISTON PIN ............................................... 4·27 CRANKSHAFT AND CONNECTING ROD ....................... 4-28 ELECTRIC STARTER DRIVES ................................ 4·29 CLUTCH .................................................. 4-30 TRANSMISSION AND SHIFTER ............................... 4-31 PRIMARY SHEAVE AND SECONDARY SHEAVE ................. 4-32 V-BELT .... ',' ............................................. 4-33 OIL PUMP AND STRAINER ........................ , ......... 4-34 OIL DELIVERY PIPE ............ , ........................... 4-34 CRANKCASE .............................................. 4-35 BEAR INGS AND 01 L SEALS ................................. 4-35 CIRCLIPS AND WASHERS ................................... 4-35

ENGINE ASSEMBLY AND ADJUSTMENT .......................... 4-36 CAMSHAFT, ROCKER ARM AND VALVE ...................... 4-36 CRANKSHAFT AND BALANCER .............................. 4-37 SHIFTER AND TRANSMISSION ............................... 4-37 CRANKCASE (RIGHT) ...................................... 4-38 TIMING CHAIN ............................................ 4-43 OIL PUMP .. " ............................................. 4-43 CDI MAGNETO ............................................ 4-43 SHIFT LEVER .......... " ................................. 4-44 ELECTRIC STARTING DRIVE ................................ 4-45 PRIMARY SHEAVE AND SECONDARY SHEAVE ................. 4-45 CYLINDER HEAD, CYLINDER AND PISTON .................... 4-47 REMOUNTING ENGINE ..................................... 4-55 CHAPTER 5. CARBURETION CARBURETOR ................................................ 5-1 SECTIONAL VIEW .......................................... 5-2 REMOVAL ................................................ 5-3 DISASSEMBLY ............................................. 5-4 INSPECTION ............................................... 5-5 ASSEMBLY ................................................ 5-7 INSTALLATION ............................................ 5-7 FLOAT HEIGHT ADJUSTMENT .............................. 5-8 FUEL LEVEL ADJUSTMENT ................................. 5-9 CHAPTER 6. CHASSIS FRONT WHEEL ............................................... 6-1 REMOVAL ................................................ 6-2 INSPECTION ............................................... 6-3 INSTALLATION ............................................ 6-5 REAR WHEEL ................................................. 6-8 REMOVAL ................................................ 6-9 INSPECTION .............................................. 6-12 INSTALLATION ........................................... 6-15 FRONT SUSPENSION .......................................... 6-18 REMOVAL ............................................... 6-19 INSPECTION .............................................. 6-20 INSTALLATION ........................................... 6-21 .-. 1--___ -- GEN INFO SPEC fi INSP ADJ ~ .• 1---- .... ; ENG • CARB ~ 1----- CHAS ELEC ? t----........ ..... --. TRBL SHTG

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1989 - 2004 YAMAHA BREEZE 125 Service Repair Manual

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