Yamaha CYGNUS RAY ZR 2022 Manual

SUPPLEMENTARY
SERVICE MANUAL
LCG125
LCG125D
B2U-F8197-E1
2022
B2UF8197E1.book Page 1 Wednesday, October 6, 2021 4:38 PM

FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
RAY ZR125 (LCG125 & LCG125D) 2022. For complete service information procedures it is neces-
sary to use this Supplementary Service Manual together with the following manual.
FASCINO (LCX125) 2020 SERVICE MANUAL: B7J-F8197-E0
RAY ZR (LCG125 & LCG125D) 2022
SUPPLEMENTARY SERVICE MANUAL
©2022 by India Yamaha Motor Pvt. Ltd.
First edition, September 2021
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
India Yamaha Motor Pvt. Ltd.
is expressly prohibited.
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EAS200071
IMPORTANT
This manual was produced by the India Yamaha Motor Pvt. Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.
India Yamaha Motor Pvt. Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
TIP
Designs and specifications are subject to change without notice.
EAS20081
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal inju-
ry hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could result
in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to
the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
WARNING
NOTICE
TIP
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HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced. Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
1
7
3
5
4
6
2
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EAS20101
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine mounted Gear oil
Filling fluid Molybdenum disulfide oil
Lubricant Brake fluid
Special tool Wheel bearing grease
Tightening torque Lithium-soap-based grease
Wear limit, clearance Molybdenum disulfide grease
Engine speed Silicone grease
Electrical data Apply locking agent (LOCTITE®).
Engine oil Replace the part with a new one.
G
M
BF
B
T
R
.
.
LS
M
S
LT
E
New
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B2UF8197E1.book Page 5 Wednesday, October 6, 2021 4:38 PM

TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND
ADJUSTMENTS 3
CHASSIS 4
ELECTRICAL SYSTEM 5
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1
GENERAL INFORMATION
FEATURES..................................................................................................... 1-1
INDICATOR LIGHTS AND WARNING LIGHTS (for disc)........................ 1-1
INDICATOR LIGHTS AND WARNING LIGHTS (for drum) ...................... 1-2
SPECIAL TOOLS ........................................................................................... 1-3
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FEATURES
1-1
GEN
INFO
EAS00014
GENERAL INFORMATION
FEATURES
EAU4939J
INDICATOR LIGHTS AND WARNING LIGHTS
(for disc)
EAU11033
Turn signal indicator lights “ ” and “ ”
Each indicator light will flash when its corre-
sponding turn signal lights flash.
EAU11081
High beam indicator light “ ”
This indicator light comes on when the high
beam of the headlight is switched on.
EAUN0711
Eco indicator light “ECO”
This indicator light comes on when the vehicle is
being operated in an environmentally friendly,
fuel-efficient manner. The indicator light goes off
when the vehicle is stopped.
TIP
Consider the following tips to reduce fuel con-
sumption:
lAvoid high engine speeds during accelera-
tion.
lTravel at a constant speed.
EAU42778
Engine trouble warning light “ ”
This warning light comes on if a problem is de-
tected in the electrical circuit monitoring the en-
gine. If this occurs, have a Yamaha dealer check
the self-diagnostic system.
The electrical circuit of the warning light can be
checked by turning the vehicle on. The warning
light should come on for a few seconds, and
then go off.
If the warning light does not come on initially
when the vehicle is turned on, or if the warning
light remains on, have a Yamaha dealer check
the electrical circuit.
EAU76382
Stop and Start System indicator light “ ”
This indicator light comes on when the Stop and
Start System activates. The indicator light will
flash when the engine is automatically stopped
by the Stop and Start System.
TIP
Even if the Stop and Start Switch is set to “ ”,
this indicator light may not come on.
EAUE4570
Acceleration assist indicator light “ASST”
This vehicle is equipped with a Smart Motor
Generator (SMG) that not only starts the engine,
but also works in hybrid function to assist with
initial acceleration.
This indicator light comes on when the smart
motor generator is assisting with acceleration.
The indicator light goes off when the vehicle is
stopped.
TIP
When battery voltage is low, the smart motor
generator may not assist with acceleration.
1. Left turn signal indicator light “ ”
2. Eco indicator light “ECO”
3. Acceleration assist indicator light “ASST”
4. Right turn signal indicator light “ ”
5. High beam indicator light “ ”
6. Engine trouble warning light “ ”
7. Stop and Start System indicator light “ ”
143
567
2
ZAUE4431
ASST
A
A
A
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