YAMAHA CYGNUS 125 2005 Workshop Manual

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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU21960
Cast wheelsTo maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points regard-
ing the specified wheels.
8The wheel rims should be checked
for cracks, bends or warpage be-
fore each ride. If any damage is
found, have a Yamaha dealer re-
place the wheel. Do not attempt
even the smallest repair to the
wheel. A deformed or cracked wheel
must be replaced.
8The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in poor
performance, adverse handling
characteristics, and a shortened
tire life.
8Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
EAUT1220
Checking the front brake lever
free play
1
ZAUM01071. Brake lever free playThe brake lever free play should mea-
sure 3~5 mm (0.12~0.2 in) as shown.
Periodically check the brake lever free
play and, if necessary, have a Yamaha
dealer check the brake system.
EWA10640
wAn incorrect brake lever free play in-
dicates a hazardous condition in the
brake system. Do not operate the
motorcycle until the brake system hasbeen checked or repaired by a
Yamaha dealer.
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU22170
Adjusting the rear brake lever
free play1ZAUM01081. Brake lever free playThe 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)
ZAUM03201. Adjusting nut
EWA10650
wIf proper adjustment cannot be ob-
tained as described, have a Yamaha
dealer make this adjustment.
EAU22380
Checking the front brake pads
and rear brake shoesThe front brake pads and the rear brake
shoes must be checked for wear at the
intervals specified in the periodic main-
tenance and lubrication char t.
EAU22420
Front brake padsZAUM00**
1
1. Brake pad wear indicator grooveEach 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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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU22540
Rear brake shoes
1
2
ZAUM00591. Wear indicator
2. Wear limit lineThe rear brake is provided with a wear
indicator, which allows you to check the
brake shoe wear without having to dis-
assemble the brake. To check the brake
shoe wear, check the position of the
wear indicator while applying the brake.
If a brake shoe has worn to the point
that the wear indicator reaches the wear
limit line, have a Yamaha dealer replace
the brake shoes as a set. groove has almost disappeared, have a
Yamaha dealer replace the brake pads
as a set.
EAU32343
Checking the front brake fluid
levelZAUM00**
1
1. MInimum level markInsufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads and/
or brake system leakage. If the brake
fluid level is low, be sure to check the
brake pads for wear and the brake sys-
tem for leakage.
Observe these precautions:8When checking the fluid level, make
sure that the top of the master cyl-
inder is level by turning the handle-
bars.
8Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.
Recommended brake fluid:
DOT 4
8Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and lead
to poor braking performance.
8Be careful that water does not en-
ter the master cylinder when refill-
ing. Water will significantly lower the
boiling point of the fluid and may
result in vapor lock.
8Brake fluid may deteriorate painted
surfaces or plastic parts. Always
clean up spilled fluid immediately.
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU22720
Changing the brake fluidHave a Yamaha dealer change the brake
fluid at the intervals specified in the
NOTE after the periodic maintenance
and lubrication chart. In addition, have
the oil seals of the brake master cylin-
der and caliper as well as the brake hose
replaced at the intervals listed below or
whenever they are damaged or leaking.
8Oil seals: Replace every two years.
8Brake hose: Replace every four
years.
EAU23100
Checking and lubricating the
cablesThe 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
a Yamaha dealer check or replace it.
Recommended lubricant:
Engine oil
EWA10720
wDamage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to rust.
Replace a damaged cable as soon as
possible to prevent unsafe condi-
tions.
8As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer check
the cause.
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23110
Checking and lubricating the
throttle grip and cableThe operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated or
replaced at the intervals specified in the
periodic maintenance chart.
EAU23170
Lubricating the front and rear
brake leversZAUM00**The pivoting points of the front and rear
brake levers must be lubricated at the
intervals specified in the periodic main-
tenance and lubrication chart.
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
EAU23210
Checking and lubricating the
centerstand and sidestandZAUM00**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
wIf the centerstand or sidestand does
not move up and down smoothly,
have a Yamaha dealer check or repair
it.
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23271
Checking the front forkThe condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
EWA10750
wSecurely support the motorcycle so
that there is no danger of it falling
over.Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the motorcycle on a level sur-
face and hold it in an upright posi-
tion.
2. While applying the front brake, push
down hard on the handlebars sev-
eral times to check if the front fork
compresses and rebounds
smoothly.
ZAUM00**
ECA10590
cCIf any damage is found or the front
fork does not operate smoothly, have
a Yamaha dealer check or repair it.
EAU23280
Checking the steeringWorn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must 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
wSecurely 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 a Yamaha dealer check
or repair the steering.
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PERIODIC MAINTENANCE AND MINOR REPAIR
ZAUM00**
EAU23290
Checking the wheel bearingsThe front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrication
chart. If there is play in the wheel hub or
if the wheel does not turn smoothly,
have a Yamaha dealer check the wheel
bearings.
EAUT1401
BatteryThis model is equipped with a sealed-
type (MF) battery, which does not re-
quire any maintenance. There is no need
to check the electrolyte or to add dis-
tilled water.
ECA10630
cC8 88 8
8Always keep the battery charged.
Storing a discharged battery can
cause permanent battery dam-
age.
8 88 8
8To 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 (MF) battery charger,
have a Yamaha dealer charge
your battery.
EWA10760
w8 88 8
8Electrolyte is poisonous and dan-
gerous since it contains sulfuric
acid, which causes severe burns.
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PERIODIC MAINTENANCE AND MINOR REPAIR
Avoid any contact with skin, eyes
or clothing and always shield
your eyes when working near
batteries. In case of contact, ad-
minister the following FIRST AID.
9 99 9
9EXTERNAL: Flush with
plenty of water.
9 99 9
9INTERNAL: Drink large
quantities of water or milk
and immediately call a
physician.
9 99 9
9EYES: Flush with water for
15 minutes and seek prompt
medical attention.
8 88 8
8Batteries produce explosive hy-
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro-
vide sufficient ventilation when
charging it in an enclosed space.
8 88 8
8KEEP THIS AND ALL BATTERIES
OUT OF THE REACH OF CHIL-
DREN.
To charge the battery
Have a Yamaha dealer charge the bat-
tery as soon as possible if it seems tohave discharged. Keep in mind that the
battery tends to discharge more quickly
if the vehicle is equipped with optional
electrical accessories.
To store the battery
1. If the vehicle will not be used for
more than one month, remove the
battery, fully charge it, and then
place it in a cool, dry place.
2. If the battery will be stored for more
than two months, check it at least
once a month and fully charge it if
necessary.
To remove the battery
1. Remove the panel by removing the
screw.
ZAUM00**
1
1. Panel2. Remove the battery holder bracket
by removing the bolt.ZAUM00**
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1. Bracket3. Pull the battery out from the bat-
tery box, and then disconnect the
battery couplers.
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PERIODIC MAINTENANCE AND MINOR REPAIR
ZAUM00**
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1. BatteryTo install the battery
1. Connect the battery couplers, and
then place the battery in the origi-
nal position.
2. Install the battery holder bracket by
installing the bolt.
3. Install the panel by installing the
screw.
4. Fully charge the battery before in-
stallation.
EAUT1431
Replacing the fusesThe main fuse box is located behind
panel B. (See page 6-6.)ZAUM00**
1
1. Main fuseThe fuse block, which contains the fuses
for the individual circuits, is located in
the storage compartment. (See page 3-
8.)
ZAUM00**
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1. Lid
2. Fuse box
3. Carburetor heater fuse
4. Ignition fuse
5. Headlight fuse
6. Signaling system fuseIf 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.
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PERIODIC MAINTENANCE AND MINOR REPAIR
Specified fuses:
Main fuse:
30 A
Headlight fuse:
15 A
Signaling system fuse:
15 A
Ignition fuse:
7.5 A
Carburetor heater fuse:
7.5 A
ECA10640
cCDo not use a fuse of a higher amper-
age rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire.3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows again,
have a Yamaha dealer check the
electrical system.
EAU23710
Replacing a headlight bulbThis model is equipped with quartz bulb
headlights. If a headlight bulb burns out,
replace it as follows.
1. Place the vehicle on the
centerstand.
2. Remove panel B. (See page 6-6.)
3. Disconnect the headlight coupler,
and then remove the bulb cover.ZAUM00**
1
1. Bulb cover4. Unhook the headlight bulb holder,
and then remove the defective bulb.
ZAUM00**
1
1. Headlight bulb holder
EWA10790
wHeadlight 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
cCDo not touch the glass part of the
headlight bulb to keep it free from oil,
otherwise the transparency of the
glass, the luminosity of the bulb, and
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