check engine YAMAHA CYGNUS 125 2005 Owners Manual

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

4-2
1
2
3
4
5
6
7
8
9
PRE-OPERATION CHECKS
ITEM CHECKS PAGE
Fuel Check fuel level in fuel tank.
 Refuel if necessary.
 Check fuel line for leakage.3-6
Engine oil Check oil level in engine.
 If necessary, add recommended oil to specified level.
 Check vehicle for oil leakage.6-8
Final transmission oil Check vehicle for oil leakage. 6-10
Front brake Check operation.
 If soft or spongy, have Yamaha dealer bleed hydraulic system.
 Check brake pads for wear.
 Replace if necessary.
 Check fluid level in reservoir.
 If necessary, add recommended brake fluid to specified level.
 Check hydraulic system for leakage.6-18, 6-19
Rear brake Check operation.
 Lubricate cable if necessary.
 Check lever free play.
 Adjust if necessary.6-18, 6-19
Throttle grip Make sure that operation is smooth.
 Check cable free play.
 If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.6-14, 6-21
Wheels and tires Check for damage.
 Check tire condition and tread depth.
 Check air pressure.
 Correct if necessary.6-15, 6-17
Brake levers Make sure that operation is smooth.
 Lubricate lever pivoting points if necessary.6-21
EAU15603
Pre-operation check list
5ML-F8199-E1ch4.pmd2004/10/04, 20:08 2

5-2
1
2
3
4
5
6
7
8
9
OPERATION AND IMPORTANT RIDING POINTS
EAU16780
Acceleration and decelerationZAUM00**
(a)(b)
The speed can be adjusted by opening
and closing the throttle. To increase the
speed, turn the throttle grip in direction
(a). To reduce the speed, turn the throttle
grip in direction (b).
EAU16760
Starting offNOTE:
Before starting off, allow the engine to
warm up.1. While pulling the rear brake lever
with your left hand and holding the
grab bar with your right hand, push
the scooter off the centerstand.
2. Sit astride the seat, and then ad-
just the rear view mirrors.
3. Switch the turn signal on.
4. Check for oncoming traffic, and
then slowly turn the throttle grip (on
the right) in order to take off.
5. Switch the turn signal off.
EAU16791
Braking1. Close the throttle completely.
2. Apply both front and rear brakes si-
multaneously while gradually in-
creasing the pressure.
EWA10300
w8 88 8
8Avoid braking hard or suddenly
(especially when leaning over to
one side), otherwise the scooter
may skid or overturn.
8 88 8
8Railroad 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 88 8
8Keep in mind that braking on a
wet road is much more difficult.
8 88 8
8Ride slowly down a hill, as brak-
ing downhill can be very difficult.
5ML-F8199-E1ch5.pmd2004/10/04, 20:08 2

5-3
1
2
3
4
5
6
7
8
9
OPERATION AND IMPORTANT RIDING POINTS
EAU16830
Engine break-inThere is never a more important period
in the life of your engine than the period
between 0 and 1000 km (600 mi). For
this reason, you should read the follow-
ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1000 km (600 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances. Dur-
ing this period, prolonged full-throttle
operation or any condition that might
result in engine overheating must be
avoided.
EAU16820
Tips for reducing fuel con-
sumptionFuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:
8Avoid high engine speeds during
acceleration.
8Avoid high engine speeds with no
load on the engine.
8Turn the engine off instead of let-
ting it idle for an extended length of
time (e.g., in traffic jams, at traffic
lights or at railroad crossings).
EAU16950
0~150 km (0~90 mi)
Avoid prolonged operation above 1/3
throttle.
After every hour of operation, stop the
engine, and then let it cool for five to
ten minutes.
Vary the engine speed from time to time.
Do not operate the engine at one set
throttle 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
cCAfter 1000 km (600 mi) of operation,
the engine oil must be changed and
the oil strainer cleaned.1000 km (600 mi) and beyond
Avoid prolonged full-throttle operation.
Vary the speed occasionally.
ECA10270
cCIf any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.
5ML-F8199-E1ch5.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

6-7
1
2
3
4
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
EAUT1170
Checking the spark plugThe spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked in
accordance with the periodic mainte-
nance and lubrication char t. In addition,
the condition of the spark plug can re-
veal the condition of the engine.
To remove the spark plug
1. Remove panel C. (See page 6-6.)
2. Remove the spark plug cap.
3. Remove the spark plug as shown,
with the spark plug wrench included
in the owner’s tool kit.ZAUM00**1
1. Spark 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 vehicle.2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if nec-
essary.
Specified spark plug:
CR7E (NGK)
To install the spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifi-
cation.
ZAUM00**
12(×4)
1. Panel B
2. ScrewTo install the panel
Place the panel in the original position,
and then install the screws.
5ML-F8199-E1ch6.pmd2004/10/04, 20:08 7

6-8
1
2
3
4
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIRZAUM00**
1
1. Spark plug gap
Spark plug gap:
0.6~0.7 mm (0.024~0.028 in)
2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
3. Install the spark plug with the spark
plug wrench, and then tighten it to
the specified torque.
Tightening torque:
Spark plug:
13 Nm (1.3m  kgf, 9.4ft  lbf)
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4~1/2 turn past
finger tight. However, the spark plug
should be tightened to the specified
torque as soon as possible.4. Install the spark plug cap.
5. Install the panel.
EAUT1350
Engine oil and oil strainerThe engine oil level should be checked
before each ride. In addition, the oil must
be changed and the oil strainer cleaned
at the intervals specified in the periodic
maintenance and lubrication chart. The
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 to the side can result in a
false reading.2. Start the engine, warm it up for sev-
eral minutes, and then turn it off.
3. Wait a few minutes until the oil
settles, remove the oil filler cap,
wipe the dipstick clean, inser t it
back into the oil filler hole (without
5ML-F8199-E1ch6.pmd2004/10/04, 20:08 8

6-9
1
2
3
4
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
screwing it in), and then remove it
again to check the oil level.
NOTE:
The engine oil should be between the
minimum and maximum level marks.ZAUM00**
1
2
1. Maximum level mark
1. Minimum level mark4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
5. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.To change the engine oil and clean
the oil strainer
1. Start the engine, warm it up for sev-
eral minutes, and then turn it off.
2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap and
drain bolts to drain the oil from the
crankcase.
ECA10410
cCWhen removing the engine oil drain
bolt, the O-ring, spring, and oil
strainer will fall out. Take care not to
lose these parts.ZAUM00**
1
1. Oil filler cap
ZAUM00**
1
1. Engine oil drain bolt AZAUM00**
1
1. Engine oil drain bolt B4. 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 the oil strainer, spring, O-ring
5ML-F8199-E1ch6.pmd2004/10/04, 20:08 9

6-10
1
2
3
4
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
and engine oil drain bolts, and then
tighten the drain bolts to the speci-
fied torque.
Tightening torque:
Engine oil drain bolt A:
20 Nm (2.0 m  kgf, 14.5ft  lbf)
Engine oil drain bolt B:
20 Nm (2.0 m  kgf, 14.5 ft  lbf)
NOTE:
Make sure that the O-ring is properly
seated.7. Add the specified amount of the
recommended engine oil, and then
install and tighten the engine oil filler
cap.
Recommended engine oil:
See page 8-1.
Oil change quantity:
0.9 L (0.98 US qt) (0.83 Imp.qt)
ECA11670
cC8 88 8
8Do not use oils with a diesel
specification of “CD” or oils of a
higher quality than specified. Inaddition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.
8 88 8
8Be sure no foreign material en-
ters the crankcase.
8. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off and
check for the cause.
9. Turn the engine off, and then check
the oil level and correct it if neces-
sary.
10. Reset the oil change indicator. (See
page 3-2 for reset procedures.)NOTE:
If the engine oil is changed before the
oil change indicator changes to red (i.e.
before the periodic oil change interval
has been reached), the indicator must
be reset after the oil change for the next
periodic oil change to be indicated at the
correct time.
EAU20060
Final transmission oilThe final transmission case must be
checked for oil leakage before each ride.
If any leakage is found, have a Yamaha
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.
1. Start the engine, warm it up by
riding the scooter for several min-
utes, and then stop the engine.
2. Place the scooter on the
centerstand.
3. Place an oil pan under the final
transmission case to collect the
used oil.
4. Remove the oil filler cap and drain
bolt to drain the oil from the final
transmission case.
5ML-F8199-E1ch6.pmd2004/10/04, 20:08 10

6-12
1
2
3
4
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
then blow the dirt out with com-
pressed air as shown.
ZAUM00**
1
1. Air filter element4. Check the air filter element for dam-
age and replace it if necessary.
5. Insert the air filter element into the
air filter case.
ECA10480
cC8 88 8
8Make sure that the air filter ele-
ment is properly seated in the air
filter case.
8 88 8
8The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
6. Install the air filter case cover by
installing the screws.
Cleaning the V-belt case air filter ele-
ment
1. Remove the V-belt air filter case
cover by removing the screws.ZAUM00**
21
1. Air filter case cover
2. Screw2. Remove the filter element holder by
removing the screw.
ZAUM00**
1
1. Air filter element holder3. Pull the air filter element out, and
then clean it with solvent. After
cleaning, remove the remaining
solvent by squeezing the element.
EWA10430
wUse 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
cCTo avoid damaging the air filter ele-
ment, handle it gently and carefully,
and do not twist it.
5ML-F8199-E1ch6.pmd2004/10/04, 20:08 12