check oil YAMAHA CYGNUS 125 2006 Owners Manual

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

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

*: Recommended to be finished by a YAMAHA specified maintenance station.
**: Use lithium grease.
Replace brake fluid:
1.Replace brake fluid when disassembling the main cylinder or cartridge style cylinder. Check the liquid level
in normal condition, re-fuel if necessary.
2.It's recommended that you should replace the oil seals in the main cylinder and cartridge style cylinder
every 2 years.
3.It's recommended to change brake tube every 4 years, or replace it when found crackles.Steering bearing*
Front fork*Rear shock absorber *V belt
Check the fastening degree of bearing assembly, modify and re-lubricate if necessary.**Check action/leakage, repair if necessary.
Check action/leakage, repair if necessary.
Check the wear and damages, replace if necessary.Check the accessories and fasteners in the chassis. Modify if necessary. Accessory/Fastener*
Center/side stand* Check action, repair if necessary.
Items
1,500km or 2 months
DescriptionRunning-in
500km
1,500km or 2 months
At the firstEvery
MAINTENANCECAUTION:
7-2

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

Front brake (drum brake)
1.Hold the brake lever, check whether
the wear indicator 1 reaches wear
margin 2.
2.If the indicator points to the wear
margin, ask your agency to replace the
brake block.
WARNING

1.Use the specified brake fluid,
otherwise, the rubber seal ring will
distort and cause leakage, thus ren-
der brake failure.
2.Refuel the same model of brake
fluid. Mix different brake fluid will
cause hazard chemical reaction
and render brake failure.
3.Avoid water going into the main
cylinder when refueling, it will de-
crease the boiling point of the brakeMAINTENANCE■ ■■ ■
■Check front/rear brakeFront brake (dish brake)
Hold the front brake lever, if the wear
indicator of brake block touches the
brake disc, ask your agency to replace
the brake block.
Brake fluid: YAHAMA brake fluid
DOT #3 or DOT #4. fluid and arise air bind.
4.The brake fluid will erode the
varnish surface and plastic
components, clean the fluid imme-
diately if splashed.
5.If you cannot refuel the brake fluid
to the standard level, seek assis-
tance from your agency.Rear brake
1.Hold the brake lever, check whether
the wear indicator reaches wear margin.
1. wear indicator 2. wear margin2.If the indicator points to the wear
margin, ask your agency to replace the
brake block.
7-8
wear indicator
brake disc
1
2
21

MAINTENANCE
■ ■■ ■
■Check front forkThe motorcycle shall be securely
supported when being checked, so
that it would not fall over.1.Visual examination
Check the inner tubes for scratches,
damages or oil leakage.
2.Action examination
Pull the motorcycle to a flat place.
a.Hold the handlebar and keep the
motorcycle upright, grasp the front and
rear brake lever to avoid slipping when
checking.
b.Actuate the handlebar up and right
for several times to check the action
of front fork.
CAUTION:

If you find any damage, oil leakage
or malfunction, ask your agency tocheck it.■ ■■ ■
■Check steering systemWorn or loose steering bearings may
cause danger. Place a stand under the
engine to raise the front wheel off
ground. Hold the lower ends of the
front fork and move them forward and
backward. If any free play can be felt,
ask your agency to check it.
WARNING

Make sure that the motorcycle
stands steadily when checking thesteering system to avoid hazard.Fuse specification: 15A
■ ■■ ■
■Replace fuse1.Remove the cover of accumulator.
2.Remove the negative terminal (-) and
positive terminal (+), then you can
take out the fuse.
3.Replace the blown fuse.CAUTION:

Do not use fuses of a higher amper-
age rating than recommended to
avoid extensive damages to the elec-
trical system, which may result infire.
WARNING
7-9

MAINTENANCE2.Remove the negative terminal (-) and
positive terminal (+), and you can take
off the battery.
3.Clean the connector.
Use steel brush to clean the rust and
dirt on the connector, after coating thin
grease to the connector, assemble the
parts reversely.CAUTION:

1.The accumulator equipped is free
of maintenance (do not need to add
water), you have to use the sealed
charger (constant voltage/current
value or constant voltage value)
Electrolyte is poisonous and dan-
gerous and will cause severe burn
injury. It contains strong acid;
avoid any contact with skin, eyes
or clothing. In case of contact, the
procedure is as per following:
External: Flush with water. Internal:
Drink large amount of boiled water
or milk, and drink milk of magnesia,
eggs mixture or vegetable oil, and
promptly consult for medical atten-
tion immediately.
Eyes: Flush with water for 15 min-
utes and seek prompt medical
attention. Batteries may produce
explosive gases. Therefore, keep
fire source (sparks, flames,
cigarettes, etc.) away from batter-
ies and provide sufficient ventila-
tion when charging or using the
battery in an enclosed space. Take
care of your eyes while working
around the battery.
Anyway, keep children away frombattery.
■ ■■ ■
■Accumulator·Disassembly of the accumulator
1.Remove the battery cover.
CAUTION:

1 11 1
1 Never attempt to remove the cov-
ers on the accumulator.
2 22 2
2 If the motorcycle will not be used
for more than 15 days, you should
charge the battery before riding.
3 33 3
3 If the motorcycle is always ser-
viced in low speed and short
distance, and will be started
frequently, you should check the
battery regularly and charge it ifnecessary. specified for the accumulator,
otherwise, it will shorten the service
lift of accumulator.
2.Before using the battery for the
first time, you should charge it for
about 1-2 hours to extend the ser-vice life.
WARNING
7-10
accumulator
connector