engine YAMAHA CYGNUS 125 2006 User Guide

PRE-OPERATION CHECKS
1 Pre-operation checks6-1
2 Brake lever free travel6-2
3 Brake fluid6-2
4 Engine oil level6-2
5 Petrol level6-3
6 Throttle grip6-3
7 Tyre6-3
8 Lights and signal light6-3
9 Switches6-3

Before riding the motorcycle, you should check the following items:PRE-OPERATION CHECKS■ ■■ ■
■Pre-operation checksNOTE:
Carry out the pre-operation checks every time you ride the motorcycle. It takes only a little of time to inspect the items
listed above, but the value of consequent safety is much more than the time cost.
If you find any of the items listed above is not qualified or can not run well, clean up hazards before riding. Seek
help from your YAMAHA agency if necessary.
Front brake (disk brake)
(drum brake)
Rear brake
Throttle grip
Engine oil
Tires and tyre casing
The steel wires
Brake lever pivot
Center/side stand shaft
Tightness
Fuel tank
Lights and signal lights
ItemDescription
Action, free gap, brake fluid level and leakage, refuel if necessary
Action, free gap, adjust if necessary
Action, free gap, adjust if necessary
Operation, lubricate and adjust if necessary
Oil level, refuel if necessary
Tyre pressure, wear and deflection
Action, lubricate if necessary
Action, lubricate if necessary
Check the tightness of the bolts and nuts which connect the parts, tighten if necessary
Oil level, refuel if necessary
Action, repair if necessary
WARNING
6-1
Action, lubricate if necessary

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
1 Periodical maintenance7-1
2 Tool kits7-3
3 Replace engine oil7-3
4 Gear oil7-5
5 Air filter7-5
6 Crankcase filter7-6
7 Adjust mixing ratio7-6
8 Adjust idle speed7-7

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

■ ■■ ■
■Tool kitsService information included in this
manual and the tool kits provided will
help you perform the maintenance and
minor repairs. However, additional
tools such as a torque wrench to fas-
ten the nuts or screws may be neces-
sary for correctly performing certain
maintenance work.
WARNING

Modification without approval of
our company may affect the func-
tion of the motorcycle, and renderhazards.
MAINTENANCE
1.fuel drain plug 2.spring
3.filter screen 4.O-ringCAUTION:

When removing the drain plug, the
spring, the filter screen and O-ring
will fall out, do not lose any of thecomponents.
■ ■■ ■
■Replace engine oil1.Start the engine and warm the
vehicle for a few minutes, then shut
off the engine.
2.Place an oil pan under the engine
to collect the engine oil used.
3.Remove the drain bolt.
7-3
1. tool kits
12
4
1 3

CAUTION:

Before installing the drain plug,
make sure that the O-ring, springand filter screen is in position.Locking torque of drain bolt: 2.0kg.m
Locking torque of drain plug: 3.2kg.m4.Clean the filter screen.
5.Inspect the O-ring for damages, re-
place if necessary.
6.Tight the drain bolt and drain plug
according to the torque specification.Oil replaced periodicallyOil replaced periodically
(including the oil needed
for replacing filter element)Special engine oil used
for four-stroke motor-
cycleYAHAMA Four-stroke
YAMALUBE engine oil,
SAE 10W-30 combus-
tion engine oil (API) ,
Spec. SF1.0L
1.2LMAINTENANCE
CAUTION:

When re-fueling, make sure that no
foreign materials fall into the oil
tank.
7.Re-install the engine oil cap.
8.Start the engine, warm the vehicle
for a few minutes, and check for
leakage. While the engine oil leaking,
shut off the engine and inspect the
parts leaking.
9.Shut off the engine, check the oil
level. Re-install the oil cap.
7-4

Make sure that no foreign material
falls into gear box when refueling
or discharging gear oil. Prevent the
gear oil from adhering to the tyre.
4.Reinstall the refuel plug and check
the leakage of gear oil.
3.Reinstall the air filter cover and tight
the screws to prevent the un-filtered
air flowing into the engine.
MAINTENANCE
■ ■■ ■
■Gear oil1.Park the vehicle on a flat place, re-
move refuel plug and drain bolt to dis-
charge the gear oil.
2.Tight the drain bolt to 2.3kgm.
3.Refuel gear oil.Total capacity of gear oilWhile exchanging
Gear oil type150cc
130cc
YAHAMA special gear oil
YAHAMA special four-stroke engine oil
■ ■■ ■
■Air filter1.Loose the screws and remove the air
filter cover.
2.Take out the filter element, clean or
replace if necessary.
WARNING
7-5
refuel plug
drain bolt

■ ■■ ■
■Adjust mixing ratio1.Open the rubber cover which locates
under seat. 1. Remove the crankcase cover.
2. Take out the filter to clean.
■ ■■ ■
■Crankcase filterMAINTENANCE
WARNING

Use the specified solvent to clean
the parts, never use petrol or sol-
vent with low flash point which willcause fire or explosion.CAUTION:

Do not twist the filter element toavoid of damages.
3. Apply suitable engine oil (SAE 10W-
30) to the filter element after drying.
4.Install the filter element, crankcase
cover and kick-starter back.CAUTION:

To avoid fast wearing of the parts
in belt chamber, you should main-
tain the filter element in the belt
chamber as per time and mileagelisted in the Consumer Manual.2.Adjust the screw.
NOTE:
The mixing ratio pre-set should beoperated by local agency.
7-6
mixing ratio
adjustment
screw

CAUTION:

Before the motorcycle leaving factory,
we have already set the carburetor to
the standard position. Change the set-
ting at random will affect the engine
performance and increase the dis-charge of exhaust gas.■ ■■ ■
■Adjust throttle gripNOTE: Adjust idle speed before adjusting thefree gap of throttle grip.
1.Loose the fixing nut.
2.Turn the adjustor till the clearance
meets specification.
3.Fasten the fixing nut and recheck
the clearance whether meets the stan-
dard clearance. idle speed
adjusting
screw
MAINTENANCE
■ ■■ ■
■Adjust idle speedNOTE: Warm the engine before adjusting theidle speed.
1.Remove the small lid which locates
under the seat.
2.Turn the idle speed adjusting screw.
Turn clockwiseTurn counter-
clockwise
Idle speed
specificationSpeed up
Speed down
1700rpm 50rpm
Clearance: 0.7mm - 0.8mm
Model: C7ER
Clearance specified: 3 - 5mm
Adjusting direction of throttle grip clearance1. Remove the ignition plug to check
the clearance and model.■ ■■ ■
■Check ignition plug
7-7
vehicle idling adjustment
position3-5mm