YAMAHA CYGNUS 125 2011 Workshop Manual

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EAU1722A
PERIODIC MAINTENANCE AND ADJUSTMENT
EAUT2142
TiresTo maximize the performance, dura-
bility, and safe operation of your ve-
hicle, note the following points regard-
ing the specifi ed tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
EWA10503
WARNING
Operation of this vehicle with im-
proper tire pressure may cause
severe injury or death from loss of
control.● The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the tempera-
ture of the tires equals the am-
bient temperature).● The tire air pressure must be
adjusted in accordance with
the riding speed and with the
total weight of rider, passen-
ger, cargo, and accessories ap-
proved for this model.
Tire air pressure (measured on cold
tires):
Up to 90 kg (198 lb):
Front:
175 kPa (1.75 kgf/cm
2, 25 psi)
Rear:
200 kPa (2.00 kgf/cm2, 29 psi)
90 kg (198 lb) to maximum load:
Front:
200 kPa (2.00 kgf/cm2, 29 psi)
Rear:
225 kPa (2.25 kgf/cm2, 33 psi)
Maximum load*:
157 kg (346 lb)
*Total weight of rider, passenger,
cargo and accessories
EWA10511
WARNING
Never overload your vehicle. Op-
eration of an overloaded vehicle
could cause an accident.
Tire inspectionZAUM00**
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1. Tire tread depth
2. Tire sidewallThe tires must be checked before
each ride. If the center tread depth
reaches the specifi ed limit, if the tire
has a nail or glass fragments in it, or if
the sidewall is cracked, have a Yama-
ha dealer replace the tire immediately.Minimum tire tread depth (front and
rear):
0.8 mm (0.03 in)TIPThe tire tread depth limits may differ
from country to country. Always com-
ply with the local regulations.
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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.
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6-18
EAU1722A
PERIODIC MAINTENANCE AND ADJUSTMENT
EAU22170
Adjusting the rear brake lever
free playZAUM00**
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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**
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(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.
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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**
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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**
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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**
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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.
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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.
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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.
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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
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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.
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EAU1722A
PERIODIC MAINTENANCE AND ADJUSTMENT
ZAUM00**
EAU23291
Checking the wheel bearingsThe front and rear wheel bearings
must be checked at the intervals
specifi ed 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.
EAUT1857
BatteryZAUM00**
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1. BatteryThis model is equipped with a VRLA
(Valve Regulated Lead Acid) battery.
There is no need to check the electro-
lyte or to add distilled water. However,
the battery lead connections need to
be checked and, if necessary, tight-
ened.TIPThe battery is located behind panel D.
(See page 6-8.)
EWA10760
WARNING
●
Electrolyte is poisonous and
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6-25
EAU1722A
PERIODIC MAINTENANCE AND ADJUSTMENT
dangerous since it contains
sulfuric acid, which causes se-
vere burns. Avoid any contact
with skin, eyes or clothing and
always shield your eyes when
working near batteries. In case
of contact, administer the fol-
lowing FIRST AID.
• EXTERNAL: Flush with plen-
ty of water.
• INTERNAL: Drink large quan-
tities of water or milk and im-
mediately call a physician.
• EYES: Flush with water for
15 minutes and seek prompt
medical attention.
●
Batteries produce explosive
hydrogen gas. Therefore, keep
sparks, ames, cigarettes, etc.,
away from the battery and pro-
vide suf cient ventilation when
charging it in an enclosed
space.
●
KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
To charge the battery
Have a Yamaha dealer charge the
battery as soon as possible if it seems
to have discharged. Keep in mind that
the battery tends to discharge more
quickly if the vehicle is equipped with
optional electrical accessories.
ECA16520
NOTICETo charge a VRLA (Valve Regulated
Lead Acid) battery, a special (con-
stant-voltage) battery charger is
required. Using a conventional bat-
tery charger will damage the bat-
tery. If you do not have access to a
constant-voltage battery charger,
have a Yamaha dealer charge your
battery.
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.
NOTICE:
When removing the
battery, be sure the key is
turned to “OFF”, then discon-
nect the negative lead before
disconnecting the positive
lead.
[ECA16302]
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.
3. Fully charge the battery before
installation.
4. Before installation, make sure
that the battery leads are properly
connected to the battery termi-
nals.
ECAT1053
NOTICE●
Always keep the battery
charged. Storing a discharged
battery can cause permanent
battery damage.
●
After installing the battery, be
sure to turn the main switch
from “ON” to “OFF” three
times in 3 seconds intervals to
initialize the idle speed control
system.
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