2005 YAMAHA CYGNUS 125 maintenance

1
2
3
4
5
6
7
8
9
EAU10210
TABLE OF CONTENTSSAFETY INFORMATION....... 1-1
Further safe-riding points ..... 1-4
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 lights ...................... 3-2
Speedometer unit................. 3-3
Fuel gauge ............................ 3-3
Handlebar switches .............. 3-3
Front brake lever .................. 3-4
Rear brake lever ................... 3-4
Fuel tank cap ........................ 3-5
Fuel...................................... 3-6
Catalytic converter ............... 3-6
Kickstarter............................ 3-7
Seat ......................................3-7
Helmet holder ....................... 3-8
Storage compartment ........... 3-8
Luggage hook ....................... 3-9
Sidestand ...........................3-10Sidestand switch operation
check...............................3-10
PRE-OPERATION CHECKS . 4-1
Pre-operation check list ........ 4-2
OPERATION AND IMPORTANT
RIDING POINTS.................... 5-1
Starting a cold engine ........... 5-1
Starting off ............................ 5-2
Acceleration and
deceleration....................... 5-2
Braking ................................. 5-2
Tips for reducing fuel consump-
tion..................................... 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 ................. 6-3
Removing and installing
panels ................................ 6-6
Checking the spark plug ....... 6-7Engine oil and oil strainer ...... 6-8
Final transmission oil..........6-10
Air filter and V-belt case air filter
elements..........................6-11
Adjusting the carburetor..... 6-13
Adjusting the throttle cable free
play ..................................6-14
Valve clearance ..................6-14
Tires...................................6-15
Cast wheels.......................6-17
Checking the front brake lever
free play...........................6-17
Adjusting the rear brake lever
free play...........................6-18
Checking the front brake pads
and rear brake shoes ......6-18
Checking the front brake fluid
level .................................6-19
Changing the brake fluid .....6-20
Checking and lubricating the
cables..............................6-20
Checking and lubricating the
throttle grip and cable ......6-21
Lubricating the front and rear
5ML-F8199-E1ch0.pmd2004/10/04, 20:06 5

1-1
1
2
3
4
5
6
7
8
9
Q QQ Q
Q SAFETY INFORMATION
EAU10260
SCOOTERS ARE SINGLE TRACK VE-
HICLES. THEIR SAFE USE AND OP-
ERATION ARE DEPENDENT UPON
THE USE OF PROPER RIDING TECH-
NIQUES AS WELL AS THE EXPER-
TISE OF THE OPERATOR. EVERY OP-
ERATOR SHOULD KNOW THE FOL-
LOWING REQUIREMENTS BEFORE
RIDING THIS SCOOTER.
HE OR SHE SHOULD:
8OBTAIN THOROUGH INSTRUC-
TIONS FROM A COMPETENT
SOURCE ON ALL ASPECTS OF
SCOOTER OPERATION.
8OBSERVE THE WARNINGS AND
MAINTENANCE REQUIRE-
MENTS IN THE OWNER’S
MANUAL.
8OBTAIN QUALIFIED TRAINING IN
SAFE AND PROPER RIDING
TECHNIQUES.
8OBTAIN PROFESSIONAL TECH-
NICAL SERVICE AS INDICATED
BY THE OWNER’S MANUAL AND/
OR WHEN MADE NECESSARY
BY MECHANICAL CONDITIONS.Safe riding
8Always make pre-operation checks.
Careful checks may help prevent
an accident.
8This scooter is designed to carry
the operator and passenger.
8The failure of motorists to detect
and recognize scooters in traffic is
the predominating cause of auto-
mobile/scooter accidents. Many
accidents have been caused by an
automobile driver who did not see
the scooter. Making yourself con-
spicuous appears to be very effec-
tive in reducing the chance of this
type of accident.
Therefore:
9Wear a brightly colored jacket.
9Use extra caution when
approaching and passing
through intersections, since
intersections are the most
likely places for scooter
accidents to occur.
9Ride where other motorists can
see you. Avoid riding in another
motorist’s blind spot.8Many accidents involve inexperi-
enced operators. In fact, many op-
erators who have been involved in
accidents do not even have a cur-
rent driver’s license.
9Make sure that you are quali-
fied and that you only lend your
scooter to other qualified
operators.
9Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
9We recommend that you
practice riding your scooter
where there is no traffic until
you have become thoroughly
familiar with the scooter and all
of its controls.
Many accidents have been caused
by error of the scooter operator. A
typical error made by the operator
is veering wide on a turn due to
EXCESSIVE SPEED or
undercornering (insufficient lean
angle for the speed).
9Always obey the speed limit
and never travel faster than
warranted by road and traffic
conditions.
EAU10220
Q QQ Q
Q SAFETY INFORMATION
5ML-F8199-E1ch1.pmd2004/10/04, 20:07 1

3-6
1
2
3
4
5
6
7
8
9
INSTRUMENT AND CONTROL FUNCTIONS
EAU13210
FuelZAUM00**
1
1. Fuel levelMake sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.
EWA10880
w8 88 8
8Do not overfill the fuel tank, oth-
erwise it may overflow when the
fuel warms up and expands.
8 88 8
8Avoid spilling fuel on the hot
engine.
ECA10070
cCImmediately wipe off spilled fuel with
a clean, dry, soft cloth, since fuel maydeteriorate painted surfaces or plas-
tic parts.
EAU33520
Recommended fuel:
REGULAR UNLEADED GASO-
LINE ONLY
Fuel tank capacity:
7.1 L (1.86 US gal) (1.55 Imp.gal)
ECA11400
cCUse only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts, such
as the valves and piston rings, as well
as to the exhaust system.Your Yamaha engine has been designed
to use regular unleaded gasoline with a
research octane number of 91 or higher.
If knocking (or pinging) occurs, use a
gasoline of a different brand or premium
unleaded fuel. Use of unleaded fuel will
extend spark plug life and reduce main-
tenance costs.
EAU13431
Catalytic converterThis model is equipped with a catalytic
converter in the exhaust system.
EWA10860
wThe exhaust system is hot after op-
eration. Make sure that the exhaust
system has cooled down before do-
ing any maintenance work.
ECA10700
cCThe following precautions must be
observed to prevent a fire hazard or
other damages.
8 88 8
8Use only unleaded gasoline. The
use of leaded gasoline will cause
unrepairable damage to the cata-
lytic converter.
8 88 8
8Never park the vehicle near pos-
sible fire hazards such as grass
or other materials that easily
burn.
8 88 8
8Do not allow the engine to idle
too long.
5ML-F8199-E1ch3.pmd2004/10/04, 20:07 6

6-1
1
2
3
4
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17224
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17280
Safety is an obligation of the owner.
Periodic inspection, adjustment and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, and lubrication are
explained on the following pages.
The intervals given in the periodic main-
tenance and lubrication chart should be
simply considered as a general guide
under normal riding conditions. However,
DEPENDING ON THE WEATHER, TER-
RAIN, GEOGRAPHICAL LOCATION,
AND INDIVIDUAL USE, THE MAINTE-
NANCE INTERVALS MAY NEED TO BE
SHORTENED.
EWA10320
wIf you are not familiar with mainte-
nance work, have a Yamaha dealer do
it for you.
EWA10330
wThis scooter is designed for use on
paved roads only. If this scooter is
operated in abnormally dusty, muddy
or wet conditions, the air filter ele-
ment should be cleaned or replaced
more frequently, otherwise rapid en-
gine wear may result. Consult a
Yamaha dealer for proper mainte-
nance intervals.
EAU17520
Owner’s tool kitZAUM00**
1
1. Owner’s tool kitThe owner’s tool kit is located inside the
storage compartment under the seat.
(See page 3-7.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
5ML-F8199-E1ch6.pmd2004/10/04, 20:08 1

6-2
1
2
3
4
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIRNOTE:
If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
EWA10350
wModifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle unsafe
for use. Consult a Yamaha dealer be-
fore attempting any changes.
5ML-F8199-E1ch6.pmd2004/10/04, 20:08 2

6-3
1
2
3
4
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17710
Periodic maintenance and lubrication chartNOTE:
8 88 8
8The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.
8From 30000 km, repeat the maintenance intervals starting from 6000 km.
8Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical
skills.NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (u1,000 km)
ANNUAL
CHECK
1 6 12 18 24
1
*Fuel line Check fuel hoses and vacuum hose for cracks or damage.———— —
2 Spark plug Check condition.
 Clean and regap.——
 Replace.——
3*Valves Check valve clearance.
 Adjust.————
4 Air filter element Clean.——
 Replace.——
5V-belt case air filter
element Clean.————
6*Front brake Check operation, fluid level and vehicle for fluid leakage.————— —
 Replace brake pads. Whenever worn to the limit
7*Rear brake Check operation and adjust brake lever free play.————— —
 Replace brake shoes. Whenever worn to the limit
8*Brake hose Check for cracks or damage.———— —
 Replace. Every 4 years
5ML-F8199-E1ch6.pmd2004/10/04, 20:08 3

6-4
1
2
3
4
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR9
*Wheels Check runout and for damage.————
10*Tires Check tread depth and for damage.
 Replace if necessary.
 Check air pressure.
 Correct if necessary.———— —
11*Wheel bearings Check bearing for looseness or damage.————
12*Steering bearings Check bearing play and steering for roughness.—————
 Lubricate with lithium-soap-based grease. Every 24000 km
13*Chassis fasteners Make sure that all nuts, bolts and screws are properly tightened.———— —
14 Sidestand, centerstand Check operation.
 Lubricate.———— —
15*Sidestand switch Check operation.————— —
16*Front fork Check operation and for oil leakage.————
17*Shock absorber
assembly Check operation and shock absorber for oil leakage.————
18*Carburetor Adjust engine idling speed.————— —
19*Engine oil Change. (see page 3-2)—Every 3000 km
 Check oil level and vehicle for oil leakage. Every 3000 km—
20*Engine oil strainer Clean.—
21 Final transmission oil Check vehicle for oil leakage.—— —
 Change.———
22*V-belt Replace. Every 18000 km
23*Front and rear brake
switches Check operation.————— — NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (u1,000 km)
ANNUAL
CHECK
1 6 12 18 24
5ML-F8199-E1ch6.pmd2004/10/04, 20:08 4

6-5
1
2
3
4
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU18660
NOTE:
8The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8Hydraulic brake service
9Regularly check and, if necessary, correct the brake fluid level.
9Every two years replace the internal components of the brake master cylinder and caliper, and change the brake
fluid.
9Replace the brake hoses every four years and if cracked or damaged.24 Moving parts and cables Lubricate.———— —
25
*Throttle grip housing
and cable Check operation and free play.
 Adjust the throttle cable free play if necessary.
 Lubricate the throttle grip housing and cable.———— —
26*Air induction system Check the air cut-off valve, reed valve, and hose for
damage.
 Replace the entire air induction system if necessary.———— —
27*Lights, signals and
switches Check operation.
 Adjust headlight beam.————— — NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (u1,000 km)
ANNUAL
CHECK
1 6 12 18 24
5ML-F8199-E1ch6.pmd2004/10/04, 20:08 5