oil YAMAHA CYGNUS 125 2000 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
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
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
brake levers.....................6-21
5ML-F8199-E0ch0.pmd2003/12/12, 16:02 5

3-2
1
2
3
4
5
6
7
8
9
INSTRUMENT AND CONTROL FUNCTIONS
EAU10980
Indicator lightsZAUM00**
12
ZAUM00**
12
1. High beam indicator light ”&”
2. Turn signal indicator light “5”
EAU11020
Turn signal indicator light “
5 55 5
5”
This indicator light flashes when the turn
signal switch is pushed to the left or right.
EAU11080
High beam indicator light “
& && &
&”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAUT1370
Oil change indicator
This indicator changes from green to red
every 3000 km (1800 mi) to indicate that
the engine oil should be changed.After changing the engine oil, reset the
oil change indicator switch by pushing
it in.
ZAUM00**
1
2
1. Oil change indicator
2. Reset switchIf the engine oil is changed before the
3000 km (1800 mi) interval, the indica-
tor must be reset after the oil change
for the next periodic oil change to be
indicated at the correct time.NOTE:
After resetting the oil change indicator
switch, the indicator changes from red
to green.
ECA10280
cCAfter 1000 km (600 mi) of operation,
the engine oil must be changed.
5ML-F8199-E0ch3re.pmd2003/12/12, 16:03 2

4-2
1
2
3
4
5
6
7
8
9
PRE-OPERATION CHECKS
EAU15602
Pre-operation check list
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
5ML-F8199-E0ch4.pmd2003/12/12, 16:03 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-E0ch5re.pmd2003/12/12, 16:03 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-E0ch6re.pmd2003/12/12, 16:04 4

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-E0ch6re.pmd2003/12/12, 16:04 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-E0ch6re.pmd2003/12/12, 16:04 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-E0ch6re.pmd2003/12/12, 16:04 10

6-11
1
2
3
4
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
ZAUM00**
1
1. Final transmission oil filler cap5. Install the final transmission oil
drain bolt, and then tighten it to the
specified torque.ZAUM00**
1
1. Final transmission oil drain bolt
Tightening torque:
Final transmission oil drain bolt:
23 Nm (2.3 m  kgf, 16.6 ft  lbf)
6. Add the specified amount of the
recommended final transmission
oil, and then install and tighten the
oil filler cap.
Recommended final transmission
oil:
See page 8-1.
Oil quantity:
0.13 L (0.14 US qt) (0.1 Imp.qt)
EWA11310
w8 88 8
8Make sure that no foreign mate-
rial enters the final transmission
case.
8 88 8
8Make sure that no oil gets on the
tire or wheel.7. Check the final transmission case
for oil leakage. If oil is leaking,
check for the cause.
EAUT1341
Air filter and V-belt case air fil-
ter elementsThe 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.
Cleaning the air filter element
1. Place the scooter on the
centerstand.
2. Remove the air filter case cover by
removing the screws.ZAUM00**
2(×6)
1
1. Air filter case cover
2. Screw3. Pull the air filter element out, and
5ML-F8199-E0ch6re.pmd2003/12/12, 16:04 11

6-13
1
2
3
4
5
6
7
8
9
PERIODIC MAINTENANCE AND MINOR REPAIR
ZAUM00**
1
1. V-belt case air filter element4. Apply oil of the recommended type
to the entire surface of the sponge
material, and then squeeze the ex-
cess oil out.NOTE:
The air filter element should be wet but
not dripping.
Recommended oil:
Engine oil
5. Insert the element into the air filter
case.
6. Install the filter element holder by
installing the screw.
EAU21300
Adjusting the carburetorThe 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. 7. Install the V-belt air filter case cover
by installing the screws.
5ML-F8199-E0ch6re.pmd2003/12/12, 16:04 13