Yamaha CYGNUS 125 Owner'S Manual Download Page 52 | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

EAU22170

Adjusting the rear brake lever
free play

1

ZAUM0108

1. Brake lever free play

The brake lever free play should mea-
sure 10~20 mm (0.4~0.8 in) as shown.
Periodically check the brake lever free
play and, if necessary, adjust it as fol-
lows.
To increase the brake lever free play,
turn the adjusting nut at the brake shoe
plate in direction (a). To decrease the
brake lever free play, turn the adjusting
nut in direction (b).

1

(a)

(b)

ZAUM0320

1. Adjusting nut

EWA10650

w

If proper adjustment cannot be ob-
tained as described, have a Yamaha
dealer make this adjustment.

EAU22380

Checking the front brake pads
and rear brake shoes

The front brake pads and the rear brake
shoes must be checked for wear at the
intervals specified in the periodic main-
tenance and lubrication chart.

EAU22420

Front brake pads

ZAUM00**

1

1. Brake pad wear indicator groove

Each front brake pad is provided with a
wear indicator groove, which allows you
to check the brake pad wear without
having to disassemble the brake. To
check the brake pad wear, check the
wear indicator groove. If a brake pad has
worn to the point that the wear indicator

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Summary of Contents for CYGNUS 125

Page 1: ...5ML F8199 E0 OWNER S MANUAL NXC125 ...

Page 2: ...2003 12 12 16 02 ...

Page 3: ...amaha a reputation for dependability hly so as to enjoy all advantages of your CYGNUS X The owner s manual pect and maintain your scooter but also in how to safeguard yourself and ill help keep your scooter in the best possible condition If you have any Yamaha dealer asant rides So remember to put safety first 2003 12 12 16 02 ...

Page 4: ...cautions that must be taken to avoid damage to the scooter mation to make procedures easier or clearer nent part of this scooter and should remain with it even if the scooter is product design and quality Therefore while this manual contains the most me of printing there may be minor discrepancies between your scooter and rning this manual please consult your Yamaha dealer EWA12410 D COMPLETELY BE...

Page 5: ...ON EAUT1390 CYGNUS X OWNER S MANUAL yYamaha MotorTaiwan Co Ltd st edition January 2004 All rights reserved printing or unauthorized use out the written permission of aha MotorTaiwan Co Ltd s expressly prohibited Printed in Taiwan 2003 12 12 16 02 ...

Page 6: ...er 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 Adjusting the 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 brake fluid lev...

Page 7: ...1 2 3 4 5 6 7 8 9 TABLE OF CONTENTS IFICATIONS 8 1 UMER INFORMATION 9 1 ification numbers 9 1 2003 12 12 16 02 ...

Page 8: ...r motorist s blind spot 8 Many 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 9 Make sure that you are quali fied and that you only lend your scooter to other qualified operators 9 Know your skills and limits Staying within your limits may help you to avoid an accident 9 We recommend that you pract...

Page 9: ...r operation ey become very hot and can use burns Always wear protec e clothing that covers your legs kles and feet ssengers should also observe e above precautions Modifications Modifications made to this scooter not approved byYamaha or the removal of original equipment may render the scooter unsafe for use and may cause severe personal injury Modifications may also make your scooter illegal to u...

Page 10: ...fork area an create instability due to mproper weight distribution or erodynamic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum 9 Bulky or large accessories may seriously affect the stability of the scooter due to aerodynamic effects Wind may attempt to lift the scooter or the scooter may become unstable ...

Page 11: ...er near a lammable source e g a kerosene heater or near an open flame otherwise it could catch fire ou should swallow any gasoline hale a lot of gasoline vapor or ow gasoline to get into your eyes e your doctor immediately If any soline spills on your skin or cloth immediately wash the affected ea with soap and water and ange your clothes EAU10371 Further safe riding points 8 Be sure to signal cle...

Page 12: ...1 5 2003 12 12 16 02 ...

Page 13: ...1 6 1 2 3 4 5 6 7 8 9 Q Q Q Q Q SAFETY INFORMATION 2003 12 12 16 02 ...

Page 14: ...2 1 EAU10410 EAU10400 2 3 4 5 6 7 8 2003 12 12 16 02 ...

Page 15: ...2 2 1 2 3 4 5 6 7 8 9 DESCRIPTION EAU10420 1 2 3 5 2003 12 12 16 02 ...

Page 16: ...2 3 EAU10430 2 3 4 5 6 7 8 2003 12 12 16 02 ...

Page 17: ...he key in from the OFF po on and then turn it to LOCK ile still pushing it move the key To unlock the steering 1 2 ZAUM00 1 Turn 2 Release Push the key in and then turn it to OFF while still pushing it EWA10060 w Never turn the key to OFF or LOCK while the vehicle is moving otherwise the electrical systems will be switched off which may result in loss of control or an accident Make sure that the v...

Page 18: ...ngine oil is changed before the m 1800 mi interval the indica t be reset after the oil change next periodic oil change to be d at the correct time setting the oil change indicator the indicator changes from red ECA10280 cC After 1000 km 600 mi of operation the engine oil must be changed 2003 12 12 16 03 ...

Page 19: ...t of he fuel tank The needle moves s E Empty as the fuel level ses When the needle reaches the refuel as soon as possible allow the fuel tank to empty it mpletely EAU12343 Handlebar switches ZAUM00 1 2 3 1 Dimmer switch 2 Turn signal switch 4 6 3 Horn switch ZAUM00 1 1 Start switch 2003 12 12 16 03 ...

Page 20: ...ted on the ndlebar grip To apply the front ull this lever toward the handle EAU12950 Rear brake lever ZAUM00 1 1 Rear brake lever The rear brake lever is located on the left handlebar grip To apply the rear brake pull this lever toward the handle bar grip 2003 12 12 16 03 ...

Page 21: ...ck and the match marks gned 1 h marks 2 Turn the key clockwise to the origi nal position and then remove it NOTE The fuel tank cap cannot be installed unless the key is in the lock In addi tion the key cannot be removed if the cap is not properly installed and locked 3 Close the lid EWA10130 w Make sure that the fuel tank cap is properly installed before riding 2003 12 12 16 03 ...

Page 22: ...ill spark plug life and reduce main costs EAU13440 Catalytic converter This vehicle is equipped with a catalytic converter in the muffler EWA10860 w The exhaust system is hot after op eration Make sure that the exhaust system has cooled down before do ing any maintenance work ECA10700 cC The following precautions must be observed to prevent a fire hazard or other damages 8 8 8 8 8 Use only unleade...

Page 23: ...nto the main switch d then turn it counterclockwise OFF ON push inward when turning the key ld the seat up se the seat ld the seat down and then push down to lock it in place move the key from the main itch if the scooter will be left un ended NOTE Make sure that the seat is properly se cured before riding 2003 12 12 16 03 ...

Page 24: ...1 1 Storage compartment There is a storage compartment under the seat See page 3 7 EWA10960 w 8 8 8 8 8 Do not exceed the load limit of 5 kg 11 lb for the storage com partment 8 8 8 8 8 Do not exceed the maximum load of 170 kg 374 lb for the ve hicle ECA10080 cC Keep the following points in mind when using the storage compart 2003 12 12 16 03 ...

Page 25: ...e your scooter unat nded with the seat open EAUT1070 Luggage hook ZAUM00 1 1 Luggage hook EWAT1030 w 8 8 8 8 8 Do not exceed the load limit of 3 kg 7 lb for the luggage hook 8 8 8 8 8 Do not exceed the maximum load of 170 kg 374 lb for the ve hicle 2003 12 12 16 03 ...

Page 26: ...tch operation check Check the operation of the sidestand switch against the information below EWA10260 w 8 8 8 8 8 The vehicle must be placed on the centerstand during this in spection 8 8 8 8 8 If a malfunction is noted have a Yamaha dealer check the system before riding 2003 12 12 16 03 ...

Page 27: ...3 11 1 2 3 4 5 6 7 8 9 INSTRUMENT AND CONTROL FUNCTIONS 2003 12 12 16 03 ...

Page 28: ...lements Any damage fluid leakage or loss ces Therefore it is very important in addition to a thorough visual inspec e he vehicle is used Such an inspection can be accomplished in a very short n worth the time involved EWA11150 ot working properly have it inspected and repaired before operating EAU15580 2003 12 12 16 03 ...

Page 29: ...akage 6 8 akage 6 10 Yamaha dealer bleed hydraulic system wear ervoir mmended brake fluid to specified level m for leakage 6 18 6 19 ssary 6 18 6 19 on is smooth maha dealer adjust cable free play and lubricate cable and 6 14 6 21 d tread depth 6 15 6 17 on is smooth g points if necessary 6 21 2003 12 12 16 03 ...

Page 30: ...4 3 n is smooth sary 6 21 bolts and screws are properly tightened on circuit cut off system ve Yamaha dealer check vehicle 3 10 CHECKS PAGE 2003 12 12 16 03 ...

Page 31: ... the engine by pushing the art switch or by kicking the kstarter while applying the front rear brake ngine fails to start by pushing t switch release the switch wait econds and then try again Each g attempt should be as short as e to preserve the battery Do not he engine more than 5 seconds one attempt If the engine does rt with the starter motor try us kickstarter ECA11040 cC For maximum engine l...

Page 32: ...he pressure EWA10300 w 8 8 8 8 8 Avoid braking hard or suddenly especially when leaning over to one side otherwise the scooter may skid or overturn 8 8 8 8 8 Railroad crossings streetcar rails iron plates on road con struction sites and manhole cov ers become extremely slippery when wet Therefore slow down when approaching such areas and cross them with caution 8 8 8 8 8 Keep in mind that braking ...

Page 33: ...above 1 3 very hour of operation stop the and then let it cool for five to utes e engine speed from time to time operate the engine at one set position 150 500 km 90 300 mi Avoid prolonged operation above 1 2 throttle Rev the engine freely through the gears but do not use full throttle at any time 500 1000 km 300 600 mi Avoid prolonged operation above 3 4 throttle ECA10350 cC After 1000 km 600 mi ...

Page 34: ...5 4 RIDING POINTS 2003 12 12 16 03 ...

Page 35: ...onsult a a dealer for proper mainte intervals EAU17520 Owner s tool kit ZAUM00 1 1 Owner s tool kit The 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 tool...

Page 36: ...6 2 MINOR REPAIR 2003 12 12 16 04 ...

Page 37: ...s starting from 6000 km ormed by aYamaha dealer as they require special tools data and technical MAINTENANCE JOB ODOMETER READING u 1 000 km ANNUAL CHECK 1 6 12 18 24 acuum hose for cracks or damage vel and vehicle for fluid leakage Whenever worn to the limit ust brake lever free play Whenever worn to the limit age Every 4 years 2003 12 12 16 04 ...

Page 38: ...ess ap based grease Every 24000 km s and screws are properly tightened oil leakage ck absorber for oil leakage d Every 3000 km le for oil leakage Every 3000 km age Every 18000 km MAINTENANCE JOB ODOMETER READING u 1 000 km ANNUAL CHECK 1 6 12 18 24 2003 12 12 16 04 ...

Page 39: ...reas the brake fluid level onents of the brake master cylinder and caliper and change the brake and if cracked or damaged e play free play if necessary p housing and cable ve reed valve and hose for duction system if necessary MAINTENANCE JOB ODOMETER READING u 1 000 km ANNUAL CHECK 1 6 12 18 24 2003 12 12 16 04 ...

Page 40: ...anel in the original position and then install the screws Panel C To remove the panel Remove the screws and then take the panel off 1 A fastener ll the panel e panel in the original position n install quick fasteners B ve the panel e the screws and then take the f 2003 12 12 16 04 ...

Page 41: ... he owner s tool kit plug wrench To check the spark plug 1 Check that the porcelain insulator around the center electrode of the spark plug is a medium to light tan the ideal color when the vehicle is ridden normally NOTE If the spark plug shows a distinctly dif ferent color the engine could be defec tive Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the vehi...

Page 42: ...e engine oil must also be changed at the initial 1000 km 600 mi and when the oil change indicator changes from green to red The oil change indicator must be reset after the initial 1000 km 600 mi See page 3 2 for reset procedures To check the engine oil level 1 Place the vehicle on the centerstand NOTE Make sure that the vehicle is positioned straight up when checking the oil level A slight tilt t...

Page 43: ...p and ain bolts to drain the oil from the ankcase ECA10410 C removing the engine oil drain he O ring spring and oil r will fall out Take care not to ese parts 1 er cap ZAUM00 1 1 Engine oil drain bolt A ZAUM00 1 1 Engine oil drain bolt B 4 Clean the oil strainer with solvent and then check it for damage and replace it if necessary 5 Check the O ring for damage and replace it if necessary 6 Install...

Page 44: ...st after the oil change for the next oil change to be indicated at the time EAU20060 Final transmission oil The final transmission case must be checked for oil leakage before each ride If any leakage is found have aYamaha dealer check and repair the scooter In addition the final transmission oil must be changed as follows at the intervals specified in the periodic maintenance and lubrication chart...

Page 45: ...he e or wheel eck the final transmission case oil leakage If oil is leaking eck for the cause EAUT1341 Air filter and V belt case air fil ter elements The air filter and V belt case air filter el ements should be cleaned at the inter vals specified in the periodic mainte nance and lubrication chart Clean both filter elements more frequently if you are riding in unusually wet or dusty areas Cleanin...

Page 46: ...0 1 1 Air filter element holder 3 Pull the air filter element out and then clean it with solvent After cleaning remove the remaining solvent by squeezing the element EWA10430 w Use only a dedicated parts cleaning solvent To avoid the risk of fire or explosion do not use gasoline or solvents with a low flash point ECA10520 cC To avoid damaging the air filter ele ment handle it gently and carefully ...

Page 47: ...e carburetor is an important part of the engine and requires very sophisti cated adjustment Therefore all carbu retor adjustments should be left to a Yamaha dealer who has the necessary professional knowledge and experience tall theV belt air filter case cover installing the screws 2003 12 12 16 04 ...

Page 48: ... with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the in tervals specified in the periodic mainte nance and lubrication chart 1 2 a b ut ng nut hten the locknut 2003 12 12 16 04 ...

Page 49: ...istics r vehicle you should keep the ng precautions in mind EVER OVERLOAD THE VE CLE Operation of an over aded motorcycle may result in e damage loss of control or severe injury Make sure that the total weight of rider passenger cargo and accessories does not exceed the specified maximum load for the vehicle 8 8 8 8 8 Do not carry along loosely packed items which can shift during a ride Securely p...

Page 50: ...HIN EWA10470 w ve a Yamaha dealer replace cessively worn tires Besides ng illegal operating the ve le with excessively worn tires creases riding stability and n lead to loss of control e replacement of all wheel and ke related parts including the s should be left to aYamaha aler who has the necessary professional knowledge and ex perience 2003 12 12 16 04 ...

Page 51: ...er free play should mea 5 mm 0 12 0 2 in as shown cally check the brake lever free d if necessary have a Yamaha check the brake system EWA10640 w orrect brake lever free play in s a hazardous condition in the system Do not operate the ycle until the brake system has been checked or repaired by a Yamaha dealer 2003 12 12 16 04 ...

Page 52: ...for wear at the intervals specified in the periodic main tenance and lubrication chart EAU22420 Front brake pads ZAUM00 1 1 Brake pad wear indicator groove Each front brake pad is provided with a wear indicator groove which allows you to check the brake pad wear without having to disassemble the brake To check the brake pad wear check the wear indicator groove If a brake pad has worn to the point ...

Page 53: ...el make sure that the top of the master cyl inder is level by turning the handle bars 8 Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Recommended brake fluid DOT 4 8 Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance 8 Be careful...

Page 54: ...y four ars EAU23100 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and the cables and cable ends should be lubri cated if necessary If a cable is dam aged or does not move smoothly have aYamaha dealer check or replace it Recommended lubricant Engine oil EWA10720 w Damage to the outer sheath may in terfere w...

Page 55: ...ease all pur ose grease EAU23210 Checking and lubricating the centerstand and sidestand ZAUM00 The operation of the centerstand and sidestand should be checked before each ride and the pivots and metal to metal contact surfaces should be lubri cated if necessary EWA10740 w If the centerstand or sidestand does not move up and down smoothly have aYamaha dealer check or repair it Recommended lubrican...

Page 56: ...be checked as fol lows at the intervals specified in the periodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground EWA10750 w Securely support the motorcycle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them forward and backward If any free play can be felt have aYamaha dealer ch...

Page 57: ...nance There is no need to check the electrolyte or to add dis tilled water ECA10630 cC 8 8 8 8 8 Always keep the battery charged Storing a discharged battery can cause permanent battery dam age 8 8 8 8 8 To charge a sealed type MF bat tery a special constant voltage battery charger is required Us ing a conventional battery charger will damage the battery If you do not have access to a sealed type ...

Page 58: ...ry fully charge it and then ce it in a cool dry place e battery will be stored for more n two months check it at least ce a month and fully charge it if cessary ove the battery move the panel by removing the ew ZAUM00 1 1 Panel 2 Remove the battery holder bracket by removing the bolt ZAUM00 1 1 Bracket 3 Pull the battery out from the bat tery box and then disconnect the battery couplers 2003 12 12...

Page 59: ...ual circuits is located in age compartment See page 3 ZAUM00 1 2 3 4 5 6 1 Lid 2 Fuse box 3 Carburetor heater fuse 4 Ignition fuse 5 Headlight fuse 6 Signaling system fuse If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage 2003 12 12 16 04 ...

Page 60: ...r d then remove the defective bulb ZAUM00 1 1 Headlight bulb holder EWA10790 w Headlight bulbs get very hot There fore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down 5 Place a new headlight bulb into po sition and then secure it with the bulb holder ECA10660 cC Do not touch the glass part of the headlight bulb to keep it free from oil othe...

Page 61: ...e light lens by moving the screws move the defective bulb by push g it in and turning it counterclock se 1 sert a new bulb into the socket sh it in and then turn it clock se until it stops stall the lens by installing the rews ECA10680 cC Do not overtighten the screws other wise the lens may break 2003 12 12 16 04 ...

Page 62: ...rn it clock e until it stops all the socket together with the b by turning it clockwise tall the panel EAUT1330 Rear turn signal light bulb If a rear turn signal light does not come on have a Yamaha dealer check the electrical circuit or replace the bulb 2003 12 12 16 04 ...

Page 63: ...6 29 1 2 3 4 5 6 7 8 9 PERIODIC MAINTENANCE AND MINOR REPAIR 2003 12 12 16 04 ...

Page 64: ...ve a Yamaha dealer check the vehicle y cloth and correct the r replace the spark plug dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery he battery is good heck the battery lead connections nd charge the battery if necessary Open the throttle halfway and operate the electric starter 2003 12 12 16 04 ...

Page 65: ...in contact with rong or abrasive cleaning prod ucts solvent or thinner fuel gasoline rust removers or in hibitors brake fluid antifreeze or electrolyte 8 8 8 8 8 Do not use high pressure wash ers or steam jet cleaners since they cause water seepage and deterioration in the following ar eas seals of wheel and swingarm bearings fork and brakes electric components couplers connectors instru ments swi...

Page 66: ...pray oil as a universal cleaner emove any remaining dirt 5 Touch up minor paint damage caused by stones etc 6 Wax all painted surfaces 7 Let the scooter dry completely be fore storing or covering it EWA10940 w 8 8 8 8 8 Make sure that there is no oil or wax on the brakes or tires If nec essary clean the brake discs and brake linings with a regular brake disc cleaner or acetone and wash the tires w...

Page 67: ...t fuel deposits from building Pour the drained fuel into the el tank 3 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 4 Perform the following steps to pro tect the cylinder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install ...

Page 68: ...7 4 E or more than 30 C 90 F For re information on storing the tery see page 6 23 ny necessary repairs before stor scooter 2003 12 12 16 04 ...

Page 69: ...ar unleaded gasoline only ank capacity L Carburetor Manufacturer Taiwan KEI HIN Type x quantity CVK24 x 1 Spark plug s Manufacturer model NGK CR7E Spark plug gap 0 6 0 7 mm Clutch Clutch type Dry centrifugal automatic Transmission Primary reduction system Helical gear Primary reduction ratio 38 13 2 923 Secondary reduction system Helical gear Secondary reduction ratio 40 12 3 333 Transmission type...

Page 70: ...nition system C D I Charging system A C magneto Battery Model YTX7A BS Voltage capacity 12 V 6 0 Ah Headlight Bulb type Halogen bulb Bulb voltage wattage x quantity Headlight 12 V 60 W 55 0 W x 1 Tail brake light 12 V 5 0 21 0 W x 1 Front turn signal light 12 V 10 0 W x 2 Rear turn signal light 12 V 16 0 W x 2 Auxiliary light 12 V 5 0 W x 1 Meter lighting 12 V 1 7 W x 3 High beam indicator light 1...

Page 71: ...8 3 1 2 3 4 5 6 7 8 9 SPECIFICATIONS 2003 12 12 16 04 ...

Page 72: ... NOTE The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your area EAU26381 ntification number 1 entification number y identification number is d into the key tag this number in the space pro nd use it for reference when or a new key 2003 12 12 16 05 ...

Page 73: ...9 2 1 2 3 4 5 6 7 8 9 CONSUMER INFORMATION 2003 12 12 16 05 ...

Page 74: ... Spark plug checking 6 7 Specifications 8 1 Speedometer unit 3 3 Start switch 3 4 Starting a cold engine 5 1 Starting off 5 2 Storage 7 3 Storage compartment 3 8 T Tail brake light bulb replacing 6 27 Throttle cable free play adjusting 6 14 Throttle grip and cable checking and lubricat ing 6 21 Tires 6 15 Tool kit 6 1 Troubleshooting 6 29 Troubleshooting chart 6 30 Turn signal indicator light 3 2 ...

Page 75: ...2003 12 12 14 37 ...

Page 76: ...PRINTED IN TAIWAN E 2003 12 0 3 1 YAMAHA MOTOR TAIWAN CO LTD ...

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