brake YAMAHA CYGNUS 125 2011 User Guide

1
2
3
4
5
6
7
8
9
6-4
EAU1722A
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU17717
General maintenance and lubrication chartNO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK
1000 km
(600 mi)6000 km
(3500 mi)
12000 km
(7000 mi)18000 km
(10500 mi)24000 km
(14000 mi)
1 Air lter element• Replace.
√√√√
2*V-belt case air lter el-
ement• Clean.
• Replace if necessary.√√√√
3 * Front brake• Check operation, fl uid level and vehicle for fl uid leakage.
√√√√√ √
• Replace brake pads. Whenever worn to the limit
4 * Rear brake• Check operation and adjust brake lever free play.
√√√√√ √
• Replace brake shoes. Whenever worn to the limit
5 * Brake hose• Check for cracks or damage.
√√√√ √
• Replace. Every 4 years
6 * Wheels• Check runout and for damage.
√√√√
7 * Tires• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.√√√√ √
8 * Wheel bearings• Check bearing for looseness or damage.
√√√√
9 * Steering bearings• Check bearing assemblies for looseness.
• Moderately repack with lithium-soap-based grease every
12000 km (7000 mi) or 24 months.√√Re-
pack√Re-
pack√
10 * Chassis fasteners• Make sure that all nuts, bolts and screws are properly
tightened.√√√√ √
11Front brake lever pivot
shaft• Lubricate with silicone grease.
√√√√ √
2('KPFF
J`.,*f J`.,Q/f2J`.,`oJ`.,I\6"

1
2
3
4
5
6
7
8
9
6-5
EAU1722A
PERIODIC MAINTENANCE AND ADJUSTMENTNO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK
1000 km
(600 mi)6000 km
(3500 mi)
12000 km
(7000 mi)18000 km
(10500 mi)24000 km
(14000 mi)
12Rear brake lever pivot
shaft• Lubricate with lithium-soap-based grease.
√√√√ √
13 Sidestand, centerstand• Check operation.
• Lubricate.√√√√ √
14 * Sidestand switch• Check operation.
√√√√√ √
15 * Front fork• Check operation and for oil leakage.
√√√√
16 *Shock absorber as-
sembly• Check operation and shock absorber for oil leakage.
√√√√
17 Engine oil• Change. (See page 6-10.)
• Check oil level and vehicle for oil leakage.√Every 3000 km (1800 mi)
18 * Engine oil strainer• Clean.
√Every 6000 km (3500 mi)
19 Final transmission oil• Check vehicle for oil leakage.
• Change.√√√√√ √
20 * V-belt• Replace. Every 18000 km (10500 mi)
21 *Front and rear brake
switches• Check operation.
√√√√√ √
22Moving parts and ca-
bles• Lubricate.
√√√√ √
23 * Throttle grip• Check operation.
• Check throttle grip free play, and adjust if necessary.
• Lubricate cable and grip housing.√√√√ √
24 *Lights, signals and
switches• Check operation.
• Adjust headlight beam.√√√√√ √
2('KPFF
J`.,*f J`.,Q/f2J`.,`oJ`.,I\6"

1
2
3
4
5
6
7
8
9
6-6
EAU1722A
PERIODIC MAINTENANCE AND ADJUSTMENT
EAUT2710
TIP● Air fi lter and V-belt fi lter
• This model’s air fi lter is equipped with a disposable oil-coated paper element, which must not be cleaned with
compressed air to avoid damaging it.
• The air fi lter element needs to be replaced and V-belt fi lter needs to be serviced more frequently when riding in
unusually wet or dusty areas.● Hydraulic brake service
• After disassembling the brake master cylinder and caliper, always change the fl uid. Regularly check the brake
fl uid level and fi ll the reservoir as required.
• Every two years replace the internal components of the brake master cylinder and caliper, and change the brake
fl uid.
• Replace the brake hose every four years and if cracked or damaged.
2('KPFF
J`.,*f J`.,Q/f2J`.,`oJ`.,I\6"

1
2
3
4
5
6
7
8
9
6-17
EAU1722A
PERIODIC MAINTENANCE AND ADJUSTMENTTire information
This model is equipped with tubeless
tires.
After extensive tests, only the tires
listed below have been approved for
this model by Yamaha Motor Co., Ltd.Front tire:
Size:
110/70-12 47L
Manufacturer/model:
CHENG SHIN/C-922N
Rear tire:
Size:
120/70-12 58L
Manufacturer/model:
CHENG SHIN/C-6007
EWA10470
WARNING
● Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
vehicle with excessively worn
tires decreases riding stability
and can lead to loss of control.● The replacement of all wheel
and brake related parts, includ-
ing the tires, should be left to
a Yamaha dealer, who has the
necessary professional knowl-
edge and experience.
EAU21962
Cast wheelsTo maximize the performance, dura-
bility, and safe operation of your ve-
hicle, note the following points regard-
ing the specifi ed wheels.● The wheel rims should be
checked for cracks, bends, warp-
age or other damage before each
ride. If any damage is found,
have a Yamaha dealer replace
the wheel. Do not attempt even
the smallest repair to the wheel.
A deformed or cracked wheel
must be replaced.● The 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.
2('KPFF
J`.,*f J`.,Q/f2J`.,`oJ`.,I\6"

1
2
3
4
5
6
7
8
9
6-18
EAU1722A
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU22170
Adjusting the rear brake lever
free playZAUM00**
1
1. Rear brake lever free playThe brake lever free play should mea-
sure 10 ~ 20 mm (0.039 ~ 0.079 in) as
shown. Periodically check the brake
lever free play and, if necessary, ad-
just it as follows.
To increase the brake lever free play,
turn the adjusting nut at the brake
shoe plate in direction (a). To de-
crease the brake lever free play, turn
the adjusting nut in direction (b).
ZAUM00**
1
(a)(b)
1. Adjusting nut
EWA10650
WARNING
If proper adjustment cannot be ob-
tained as described, have a Yama-
ha dealer make this adjustment.
EAU37913
Checking the brake lever free
playThere should be no free play at the
brake lever end. If there is free play,
have a Yamaha dealer inspect the
brake system.
EWA14211
WARNING
A soft or spongy feeling in the
brake lever can indicate the pres-
ence of air in the hydraulic system.
If there is air in the hydraulic sys-
tem, have a Yamaha dealer bleed
the system before operating the
vehicle. Air in the hydraulic system
will diminish the braking perfor-
mance, which may result in loss of
control and an accident.
2('KPFF
J`.,*f J`.,Q/f2J`.,`oJ`.,I\6"

1
2
3
4
5
6
7
8
9
6-19
EAU1722A
PERIODIC MAINTENANCE AND 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 specifi ed in the
periodic maintenance and lubrication
chart.
EAU22420
Front brake padsZAUM00**
1
1. Brake pad wear indicator grooveEach front brake pad is provided with
a wear indicator groove, which al-
lows 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 groove has almost disappeared, have a Yamaha dealer
replace the brake pads as a set.
EAU22540
Rear brake shoesZAUM00**
2
1
1. 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
disassemble 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.
EAU32344
Checking the brake uid levelZAUM00**
1
1. Minimum level markInsuffi cient brake fl uid may allow air
to enter the brake system, possibly
causing it to become ineffective.
Before riding, check that the brake
fl uid is above the minimum level mark
and replenish if necessary. A low
brake fl uid level may indicate worn
brake pads and/or brake system leak-
age. If the brake fl uid level is low, be
sure to check the brake pads for wear
and the brake system for leakage.
2('KPFF
J`.,*f J`.,Q/f2J`.,`oJ`.,I\6"

1
2
3
4
5
6
7
8
9
6-20
EAU1722A
PERIODIC MAINTENANCE AND ADJUSTMENT
Observe these precautions:● When checking the fl uid level,
make sure that the top of the
master cylinder is level by turning
the handlebars.● Use only the recommended qual-
ity brake fl uid, otherwise the
rubber seals may deteriorate,
causing leakage and poor braking
performance.Recommended brake uid:
DOT 4● Refi ll with the same type of brake
fl uid. Mixing fl uids may result in
a harmful chemical reaction and
lead to poor braking performance.● Be careful that water does not en-
ter the master cylinder when refi ll-
ing. Water will signifi cantly lower
the boiling point of the fl uid and
may result in vapor lock.● Brake fl uid may deteriorate
painted surfaces or plastic parts.
Always clean up spilled fl uid im-
mediately.● As the brake pads wear, it is normal for the brake fl uid level to
gradually go down. However, if
the brake fl uid level goes down
suddenly, have a Yamaha dealer
check the cause.
EAU22721
Changing the brake uidHave a Yamaha dealer change the
brake fl uid at the intervals specifi ed in
the TIP after the periodic maintenance
and lubrication chart. In addition, have
the oil seals of the brake master cyl-
inder and caliper as well as the brake
hose replaced at the intervals listed
below or whenever they are damaged
or leaking.● Oil seals: Replace every two
years.● Brake hose: Replace every four
years.
2('KPFF
J`.,*f J`.,Q/f2J`.,`oJ`.,I\6"

1
2
3
4
5
6
7
8
9
6-21
EAU1722A
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU43641
Lubricating the front and rear
brake leversZAUM00**ZAUM00**
The pivoting points of the front and
rear brake levers must be lubricated
at the intervals specifi ed in the period-
ic maintenance and lubrication chart.
EAU23095
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
lubricated if necessary. If a cable is
damaged or does not move smoothly,
have a Yamaha dealer check or re-
place it.
WARNING! Damage to the outer
housing of cables may result in
internal rusting and cause inter-
ference with cable movement.
Replace damaged cables as soon
as possible to prevent unsafe
conditions.
[EWA10711]
Recommended lubricant:
Yamaha Chain and Cable Lube or
engine oil
EAU23114
Checking and lubricating the
throttle grip and cableThe operation of the throttle grip
should be checked before each ride.
In addition, the cable should be lubri-
cated by a Yamaha dealer at the inter-
vals specifi ed in the periodic mainte-
nance chart.
The throttle cable is equipped with a
rubber cover. Make sure that the cov-
er is securely installed. Even though
the cover is installed correctly, it does
not completely protect the cable from
water entry. Therefore, use care not to
pour water directly onto the cover or
cable when washing the vehicle. If the
cable or cover becomes dirty, wipe
clean with a moist cloth.
2('KPFF
J`.,*f J`.,Q/f2J`.,`oJ`.,I\6"

1
2
3
4
5
6
7
8
9
6-22
EAU1722A
PERIODIC MAINTENANCE AND ADJUSTMENT
Recommended lubricants:
Front brake lever:
Silicone grease
Rear brake lever:
Lithium-soap-based grease
EAU23213
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
lubricated if necessary.
EWA10741
WARNING
If the centerstand or sidestand
does not move up and down
smoothly, have a Yamaha dealer
check or repair it. Otherwise, the
centerstand or sidestand could
contact the ground and distract the
operator, resulting in a possible
loss of control.
Recommended lubricant:
Lithium-soap-based grease
2('KPFF
J`.,*f J`.,Q/f2J`.,`oJ`.,I\6"

1
2
3
4
5
6
7
8
9
6-23
EAU1722A
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU23272
Checking the front forkThe condition and operation of the
front fork must be checked as follows
at the intervals specifi ed in the period-
ic maintenance and lubrication chart.
To check the condition
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level sur-
face and hold it in an upright
position. WARNING! To avoid
injury, securely support the ve-
hicle so there is no danger of it
falling over.
[EWA10751]
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
ZAUM00**
ECA10590
NOTICEIf any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU45511
Checking the steeringWorn or loose steering bearings may
cause danger. Therefore, the opera-
tion of the steering must be checked
as follows at the intervals specifi ed in
the periodic maintenance and lubrica-
tion chart.
1. Place the vehicle on the cen-
terstand. WARNING! To avoid
injury, securely support the ve-
hicle so there is no danger of it
falling over.
[EWA10751]
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 steer-
ing.
2('KPFF
J`.,*f J`.,Q/f2J`.,`oJ`.,I\6"