2006 YAMAHA CYGNUS 125 brake

WARNING

If the brake lever fails, do not ride
the motorcycle before
troubleshooting, and ask your
YAHAMA agency to repair the brake.
Soft brake means troubles in thebrake system.front brake lever
Hold the brake lever for a few minutes
to check leakage in the brake pipe joint
or main cylinder. If leakages detected,
ask your agency to repair it
immediately. The leakage of brake
fluid means troubles in brake system.■ ■■ ■
■Engine oil level1.Uphold the motorcycle by center-stand.■ ■■ ■
■Brake fluid (disk brake)If the oil level is below the LOWER
signal, take your motorcycle to the
agency for refueling.
■ ■■ ■
■Brake lever free travel
rear brake lever
drum brake disk brake
drum brake
PRE-OPERATION CHECKS
Rear brake
Front disk brake(idle motion)
Travel
10-20mm
Front drum brake
10-20mm
10-20mm
NOTE: When checking the engine oil level,
the motorcycle must be upright. Even
a small incline will cause fault result
of inspection.
This inspection should be took when
you buying the vehicle or every1,000 km mileage.
2.Start the engine and warm the ve-
hicle for a few minutes, then shut off
the engine.
3.Wait a few minutes, so that the en-
gine oil flows back, take the oil dip rod
out of the crankcase, clean the rod,
put it back to the dipstick hole (do not
turn around), take it out again to check
the oil level.Oil replaced periodically
Oil replaced periodically(including the oil needed for
replacing filter element)Special engine oil used
for four-stroke motor-
cycle
YAHAMA Four-stroke
YAMALUBE engine oil,
SAE 20W-40 combustion
engine oil (API) , Spec. SF1.0L
1.2L
1.upper limit 2.lower limit
6-2
front (right)
rear (left)
1
2

MAINTENANCE
9 Adjust throttle grip7-7
10 Check ignition plug7-7
11 Check front/rear brake7-8
12 Check front fork7-9
13 Check steering system7-9
14 Replace fuse7-9
15 Accumulator7-10

Periodical maintenance/lubrication table
MAINTENANCE


Periodical maintenanceSee detailed description and time requirement for the general periodical maintenance of motorcycle and exhaust gas
control system in the "Consumer Manual".
The information supplied in this chapter is some kind of easy maintenance which can be finished by consumer him/
herself. If you are not familiar with the repair and maintenance procedure, ask the agency to finish it.
Items
Air drain*
Ignition plugCheck the clearance, adjust if necessary.
1,500km or 2 months
DescriptionRunning-in
500km
Check the working condition, clean or replace if necessary.
Air filterClean every 1,000km, replace if necessary.
Carburetor*Check idle speed/start operation, adjust if necessary.
Check the fuel tube (or vacuum tube) for crackles or damages, replace if necessary.
Fuel line*
Engine oil
Replace (warming engine before exhausting)
Engine oil filter*
Crankcase filter*
Clean every 1,000km, replace if necessary. Clean, replace if necessary.
Gear oil*Check leakage, replace every 3,000km.Front brake*(dish brake)
Check action/brake fluid leakage, see "Note". Replace if necessary.
Front brake(drum brake)
Check action, replace if necessary.
1,500km or 2 months
At the firstEvery
Check action, replace if necessary.
Lubricate a little. **
Check wearing and damage. Repair if necessary.
Check the fastening/damages of the bearing assembly, replace when there are damages.
Rear brake
Wheel
Wheel bearing* Front shaft
7-1

*: Recommended to be finished by a YAMAHA specified maintenance station.
**: Use lithium grease.
Replace brake fluid:
1.Replace brake fluid when disassembling the main cylinder or cartridge style cylinder. Check the liquid level
in normal condition, re-fuel if necessary.
2.It's recommended that you should replace the oil seals in the main cylinder and cartridge style cylinder
every 2 years.
3.It's recommended to change brake tube every 4 years, or replace it when found crackles.Steering bearing*
Front fork*Rear shock absorber *V belt
Check the fastening degree of bearing assembly, modify and re-lubricate if necessary.**Check action/leakage, repair if necessary.
Check action/leakage, repair if necessary.
Check the wear and damages, replace if necessary.Check the accessories and fasteners in the chassis. Modify if necessary. Accessory/Fastener*
Center/side stand* Check action, repair if necessary.
Items
1,500km or 2 months
DescriptionRunning-in
500km
1,500km or 2 months
At the firstEvery
MAINTENANCECAUTION:
7-2

Front brake (drum brake)
1.Hold the brake lever, check whether
the wear indicator 1 reaches wear
margin 2.
2.If the indicator points to the wear
margin, ask your agency to replace the
brake block.
WARNING

1.Use the specified brake fluid,
otherwise, the rubber seal ring will
distort and cause leakage, thus ren-
der brake failure.
2.Refuel the same model of brake
fluid. Mix different brake fluid will
cause hazard chemical reaction
and render brake failure.
3.Avoid water going into the main
cylinder when refueling, it will de-
crease the boiling point of the brakeMAINTENANCE■ ■■ ■
■Check front/rear brakeFront brake (dish brake)
Hold the front brake lever, if the wear
indicator of brake block touches the
brake disc, ask your agency to replace
the brake block.
Brake fluid: YAHAMA brake fluid
DOT #3 or DOT #4. fluid and arise air bind.
4.The brake fluid will erode the
varnish surface and plastic
components, clean the fluid imme-
diately if splashed.
5.If you cannot refuel the brake fluid
to the standard level, seek assis-
tance from your agency.Rear brake
1.Hold the brake lever, check whether
the wear indicator reaches wear margin.
1. wear indicator 2. wear margin2.If the indicator points to the wear
margin, ask your agency to replace the
brake block.
7-8
wear indicator
brake disc
1
2
21

MAINTENANCE
■ ■■ ■
■Check front forkThe motorcycle shall be securely
supported when being checked, so
that it would not fall over.1.Visual examination
Check the inner tubes for scratches,
damages or oil leakage.
2.Action examination
Pull the motorcycle to a flat place.
a.Hold the handlebar and keep the
motorcycle upright, grasp the front and
rear brake lever to avoid slipping when
checking.
b.Actuate the handlebar up and right
for several times to check the action
of front fork.
CAUTION:

If you find any damage, oil leakage
or malfunction, ask your agency tocheck it.■ ■■ ■
■Check steering systemWorn or loose steering bearings may
cause danger. Place a stand under the
engine to raise the front wheel off
ground. Hold the lower ends of the
front fork and move them forward and
backward. If any free play can be felt,
ask your agency to check it.
WARNING

Make sure that the motorcycle
stands steadily when checking thesteering system to avoid hazard.Fuse specification: 15A
■ ■■ ■
■Replace fuse1.Remove the cover of accumulator.
2.Remove the negative terminal (-) and
positive terminal (+), then you can
take out the fuse.
3.Replace the blown fuse.CAUTION:

Do not use fuses of a higher amper-
age rating than recommended to
avoid extensive damages to the elec-
trical system, which may result infire.
WARNING
7-9

TROUBLE SHOOTING■ ■■ ■
■Engine cannot start1.Whether the main switch locates on
position ON?
2.Is fuel enough? Whether the needle
points within the fuel range (above E
line)?
3.While pressing start switch, do you
hold rear brake lever?
4.While pressing start switch, do you
turn throttle grip? (See references listed
in page 10)
If you have already confirmed the 1-4
procedures, and the motorcycle still
cannot start:
5.Locate the main switch on position
ON, press horn switch, the horn does
not operate means there is possible
fuse failure.
6.If the fuse is good, use kick-starter
to start the engine and seek help from
your agency.
8-1
■ ■■ ■
■Shut-down suddenly while
runningCheck the oil level.
Refuel as soon as possible if the fuel
is not enough.■ ■■ ■
■Lights failureCheck as per following:
1.Whether the main switch locates on
position ON?
2.After starting the engine, check
whether the front headlight and rear
light is on?
3.Can the switches operate well?
4.Press horn switch, does the horn
operate?
The horn operates well means bulb
failure; the horn does not operate
means that there is possible fuse
failure.
The troubles other than listed
above or if you have any
questions, please consult your
agency.

Running gear
Item Specification
Item Specification
Tyre
specification
Front
Rear
3.5-10 51J
3.5-10 51J
Model
Hand operated mechanical
drum/hydraulic dish brake
Hand operated mechanical
drum brake
ModelExpanding sleeve
Telescopic
TypeCushion strokeCoil spring/oil damper
Coil spring/oil damper
90mm
75mmFront headlight
Position lightFront turn signalRear turn signalTaillight/stoplightInstrument light12V 35W/35W x 1
12V 5W x 1
12V 10W x 2
12V 16W x 2
12V 5W/21W x 1
12V 1.7W x 3 Front
Rear
SPECIFICATION
Break system Suspension gear
Front
Rear
Front
Rear
Shock absorber
Front
Rear
Lights and illumination
9-2