Yamaha CYGNUS.X XC125 User manual

Model :
1WA281972000 *1F1281977000*
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XC125S
SERVICEMANUAL
©1985 by Yamaha Motor Co., Ltd.
1stEdition,August1985
All rights reserved. Any reprinting or
unauthorized use without the written
permission of YamahaMotor Co., Ltd.
isexpressly prohibited.
Printed in Japan
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NOTICE
Thismanual was written by theYamahaMotor Company primarily for useby Yamahadealers and
their qualified mechanics. It is not possible to put an entire mechanic's eductaion into one manual,
so it is assumed that presons using this bookto perform maintenance and repairs on Yamaha scooter
have a basic understanding of the mechanical concepts and procedures inherent in scooter repair
technology. Without such knowledge, attempted repairs or service to this model may render it unfit
to useand/or unsafe.
Yamaha Motor Company, Ltd. iscontinuallystriving to improve all models manufactured by Yamaha.
Modifications and significant changes in specifications or procedures will be forwarded to all
Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual.
TECHNICAL PUBLICATIONS
SERVICE DIVISION
MOTORCYCLE OPERATIONS
YAMAHA MOTOR CO.,LTD.
HOW TO USE THiS MANUAL
PARTICULARLY IMPORTANT INFORMATION
This material isdistinguished bythe following notation.
NOTE: A NOTE provides keyinformation to make procedures easier or clearer.
_A CAUTION indicates special procedures that must be followed to avoid damage to
the scooter.
IltJ_F_lTi_ll_r_jm A WARNING indicates special procedures that must befollowed to avoid injury to
a scooteroperator orperson inspecting or repairing the scooter.
MANUAL FORMAT
All ofthe procedures in this manual are organized in a sequential, step-by-step format.The informa-
tion has been compiled to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
In this revised format, the condition of a faulty compone_will precede an arrow symbol and the
course of action required will follow the symbol, e.g.,
Bearings
Pitting/Damage -_Replace.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section for ease in identifying
correct disassembly and assembly procedures.
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I LLUSTRATED SYMBOLS
Q Q (Refer to the illustration)
__] _[__ Symbols @ to (_ are designedasthumb tabsto
indicate the chaptersnumber and content.
(_ (_ (_ General information
L=_ _] _"__1 (_) Periodic inspection andadjustment(_Engine
(_) Cooling system
(_ Carburetion
(_ _ (_)Chassis
(_ Electrical
[CAFIB]l0 ] (_ Appendices
® ®
Symbols (_) to (_ are usedto identify the
@ -- (_ -- specificationsappearing in the text.
_ (_ Fillingfluid
__ __ (_) Lubricant
(_) Tightening
(_) Wear limit, clearance
(_ -- (_) _ (_) Engine speed
@ a,V,A
®__
Symbols (_) to (_ in the exploded diagram
l (_) _ (_) _ indicate gradeof lubricant and location of
== lubrication point.
_ _ (_ Apply engine oil
(_) Apply gear oil
@ (_) (_ (_) Apply molybdenum disulfideoil
Apply wheel bearing grease
_ _ (_) Apply lightweight lithium-soap basegrease
(_ Apply molybdenum disulfide grease
_) Apply locking agent (LOCTITE ®)
@
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iNDEX
GENERAL iNFORMATiON_E_R]j
PERIODIC INSPECTIONS
AND ADJUSTMENTS _Nsp;t:
=___ ADJ --
ENGINEOVERHAUL ENG_
CHASSISCHAS_
ELECTRICAL ELECr_
APPENDICES APpx_--J
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CHAPTE R 1.
GENERAL INFORMATION
SCOOTER iDENTIFiCATiON ...................................... 1=1
VEHICLE IDENTIFICATION NUMBER ........................... 1-1
ENGINE SERIAL NUMBER ..................................... 1-1
IMPORTANT INFORMATION ...................................... 1-2 /_
ALLREPLACEMENT PARTS ................................... 1-2
GASKETS, OIL SEALS, AND O-RINGS ........................... 1-2
LOCK WASHERS/PLATES AND COTTER PINS..................... 1-2
BEARINGS AND OIL SEALS ................................... 1-2
CIRCLIPS................................................... 1-3
SPECIALTOOLS ................................................ 1-3
FOR TUNE-UP ............................................... 1-3
FOR ENGINE SERVICE ....................................... 1-4
FOR CHASSISSERVICE ....................................... 1-7
FOR ELECTRICAL COMPONENTS .............................. 1-7
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I_GNEF_)I(_I_ SCOOTER IDENTIFiCATiON GENERAL INFORMATION
SCOOTER iDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number _isstamped
into the frame.
_:_: Starting Serial Number:
JYAlWA00 -_GA000101
NOTE:
The scooter identification number is used to
identify your scooter and may be used to
register your scooter with the licensing authority
in your state.
ENGINE SERIAL NUMBER
The engineserial number _) isstamped intothe
elevated part of theleft rear section ofthe
transmission case.
NOTF-
The first threedigits of these numbers are for
model identifications; the remaining digits are
the unitproduction number.
iStarting Serial Number: ]
1WA-000101
NOTE:
Designs and specifications are subject to change
without notice.
1-1
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MPO.TAOTNFO.MATON
IMPORTANT INFORMATION
ALL REPLACEMENT PARTS
1. We recommend to use Yamaha genuine
parts for all replacements. Use oil and/or
grease recommended by Yamaha for assem-
blyand adjustment. |J
GASKETS, OIL SEALS, AND O-RINGS
1. All gaskets, seals, and O-rings should be
replaced when an engine is overhauled. All
gasket surfaces, oil seal lips, and O-rings
must be cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.
LOCK WASHERS/PLATES AND COTTER PINS
1. All lockwashers/plates (_and cotter pins
must be replaced when they are removed.
.__ Lock tab(s) should be bent along the bolt
//////////_or nut flat(s) after the bolt or nut hasbeen
properly tightened.
BEARINGS AND OIL SEALS
1. Install the bearing(s) (_and oil seal(s) (_)
with their manufacturer's marks or numbers
facing ou_tward.(In other words, the
stamped letters must be on the sideexposed
to view.) When installing oil seal(s), apply a
light coating of light-weight lithium base
grease to the seal lip(s). Oil the bearings
liberally when installing.
___ Do not use compressed air to spin the bearings
dry. This causes damage to the bearing surfaces.
1-2
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_GNE_) _ SPECIAL TOOLSCIRCLIPS
1.All circlips should be inspected carefully
f_t__
!l IJ(_)I_ P before reassembly. Always replace piston
(]_) pin clips after one use. Replace distorted
circlips. When installing a circlip(_), make
/_//__/_/_/sure that the sharp-edgedcorner (_ is
__ ////2 positioned opposite to the thrust (]_) it
receives. See the sectional view.
-- (_ Shaft
SPECIAL TOOLS
The proper special toolsare necessary for
complete and accurate tune-up and assembly.
Using the correct special tool will help pre-
vent damage caused by the use of improper
tools or improvised techniques.
FOR TUNE-UP
1. Inductive Tachometer
P/N YU-8036
This tool is needed for detecting engine rpm.
2.Timing Light
P/N YU-08037
This tool isnecessary for checking timing.
3.Compression Gauge
0
This gauge is used to measure engine compression.
1-3
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SPEC,ALTOOLS
4. Fuel Level Gauge
t P/NYM-01312-A
_1 This gaugeis usedto measurethe fuel level in the float
1
chamber.
I
I
I
5. Valve Adjusting Tool
P/N YM-08035
This tool is necessaryfor adjustingthe valveclearance.
FOR ENGINESERVICE
1. Rotor Holder
P/N YU-01235
This tool is used to hold the flywheel magneto when
removing or installing the flywheel magneto securing
nut.
2. Flywheel Magneto Puller
P/N YM-01189
This tool isusedto removethe flywheel.
3.Primary Sheave Holder
P/N YU-01701
This tool isusedwhenholding the clutch hub.
1-4
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GEN
INFOI( " I SPECIALTOOLS 4.Middle Drive Shaft Nut Wrench - (_)
P/N YM-04045-A
Locknut Wrench - (_)
P/N YM-4045-A
Thesetools are usedto removeand install the secondary
sheavenut.
5. Valve Spring Compresser
P/N YM-04019- (_
Adapter
PIN YM-4108 - (_)
Thesetoolsare used to remove and install the valve
assemblies.
6.Valve Seat Cutter
, _r=__ _ _ P/N YM-91043 -
_ 5 mm PilotP/N YM-91043-50- (_
T
=- [\ J[ JLJ_. _ Thesetools areusedto resurfacethe valveseat.
"=-@@o©
7.Valve Guide Remover
P/N YM-4097
Thistoolisneededto installthevalveguidesproperly.
8.Valve Guide Installer
P/N YM-4098
This toolis neededto install the valveguidesproperly.
1-5
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sPEoALTOOLS
9.Valve Guide Reamer
P/N YM-4099
This tool isusedto rebore the newvalveguide.
10. Clutch Spring Holder
P/N YS-28891
This tool is used to disassembly and assembly the
secondarysheave.
11. Cylinder Gauge
P/N 90890-03016
This tool isusedto measurescylinder bore.
12. Slide Hammer Set (M6)
P/N YU-01083
These tools are used to remove and install the rocker
arm shafts.
13.Dial Gauge
P/N YU-03097
1-6
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_EN)_-SPECIAL TOOLS FOR CHASSIS SERVICE
1. RingNut Wrench
P/N YU-01268- (_
P/N YU-33975 -
These tools are used to loosen and tighten the steering
ring nut.
FOR ELECTRICAL COMPONENTS
1. Pocket Tester
P/N YU-03112
This instrument is invaluablefor electricalsystem
inspectionand adjustment.
°2. Electro Tester
P/N YU-33260
This instrument is necessary for ignition system in-
spection.
1-7
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l'"sPl lAoJ
CHAPTER2.
PERiODiC iNSPECTiON AND ADJUSTMENTS
INTRODUCTION .............................................. 2-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ............. 2-1
REMOVING THE COVERSAND PANELS .......................... 2-2
SIDE COVER .............................................. 2-2
FRONT COVER ............................................ 2-2
FOOTREST BOARD ........................................ 2-3
FRONT AND REAR LEG SHIELD ............................. 2-3i_lp" _lmimm
FRONT AND REAR HANDLEBAR COVERS ..................... 2-4 _IIPJ
ENGINE ..................................................... 2-4
VALVE CLEARANCE ADJUSTMENT .......................... 2-4
THROTTLE CABLE ADJUSTMENT ............................ 2-6
IDLE SPEEDADJUSTMENT .................................. 2-6
IGNITION TIMING CHECK ................................... 2-7
FUEL LINE INSPECTION .................................... 2-8
ENGINE OIL LEVEL INSPECTION............................. 2-8
ENGINE OIL REPLACEMENT ................................ 2-8
FINAL GEAR OIL (SUB TRANSMISSION OIL) REPLACEMENT ..... 2-9
AIR FILTER AND CRANKCASE FILTER CLEANING ............. 2-10
V-BELT INSPECTION ....................................... 2-11
COMPRESSION PRESSUREMEASUREMENT .................... 2-11
SPARK PLUG INSPECTION .................................. 2-12
CHASSIS..................................................... 2-13
BRAKE LINING INSPECTION ................................ 2-13
FRONT BRAKE ADJUSTMENT ............................... 2-13
REAR BRAKE ADJUSTMENT ................................ 2-14
TIRES AND CAST WHEELS CHECK............................ 2-14
STEERING HEAD INSPECTION ............................... 2-16
STEERING HEAD ADJUSTMENT .............................. 2-16
ELECTRICAL ................................................. 2-17
BATTERY INSPECTION ..................................... 2-17
HEADLIGHT BULB REPLACEMENT ........................... 2-18
HEADLIGHT BEAM ADJUSTMENT ............................ 2-19
FUSE INSPECTION ......................................... 2-20
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__1 iNTRODUCTION/
PERIODIC MAINTENANCE/LUBRICATION INTERVALS
PERiODiC iNSPECTiONSAND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessaryto perform recommended inspections and adjustments.
These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and
a longer service life.The need for costly overhaul workwill be greatly reduced. This information
applies to vehicles alreadyin service as well as new vehicles that are being prepared for sale.All service
technicians should be familiarwith this entire chapter.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS Unit: km (miles)
-- EVERY
BREAK-IN 6,000 12,000
ITEM REMARKS 1,000 (600) (4,000) or (8,000) or
-- 6months 12 months
Valve(s)* Checkvalveclearance. Adjust if necessary,o o o
Spark plug(s) Check condition. Cleanor replace if necessary,ooo
Air filter Clean.Replace if necessary,o o
Crankcase filter Clean. Replace if necessary, o
Carburetor*Checkidle speed/starter operation,ooo
Adjust if necessary.
Fuelline _ Check fuelhose and vacuum pipe forcrackso o
or damage. Replace if necessary.
Engineoil Replace (Warm enginebefore draining), o o o
Check oil level/oil leakage. REPLACE o o
Final gear oil Replace every 24,000 (16,000) or 24 months.
Brake Checkoperation.Adjustif necessary. © o
Clutch Check operation.Adjust if necessary,o ©
Front brake tensionbar
pivots and bottomApply until newgreaseshows.*** o o
link pivots li "-' ***
Front axle Applygreasegnuy.© o
Wheels* Check balance/damage/runout,o o
Repair if necessary.
Check bearings assembly for looseness/damage,o o
Wheel bearings* Replace if damaged.
Check bearingsassembly for looseness.
Steeringbearing*Correct if necessary.Moderately repack o o
every 24,000 (16,000) or 24 months.**
Front forks* Check operation/oil leakage.Repair if necessary, o o
Rear shock absorber* Checkoperation/oil leakage.Repair if necessary.© o
V-belt Check damage and wear.Replace if necessary,o o
Replace every 18,000 km (12,000 mi).
Fittings/Fasteners* Check all chassisfittingsand fasterners.
Correct if necessary, o o ©
Center and sidestand* Check operation.Repair if necessary,o o o
Sidestand switch* Check operation.Clean or replace if necessary,o o o
Battery* Check specific gravity.Check breather pipe for
proper operation. Correct if necessary. © ©
*: It is recommended that these items be serviced by aYamaha dealer.
**" Medium weight wheel bearing grease.
***: Lithium soap basegrease.
2-1
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,.sPli l •
REMOVINGTHE COVERSAND PANELSADJ
REMOVING THE COVERS AND PANELS
(_ Side covers(Right/Left)
(_) Front cover
(_ Footrest board
(_ Front and rearlegshield
(_ Front andrearhandlebarcover
*Beforeremoving the cover(s),make sure
thatall hooks are free.
®After installing the cover(s), make sure
thatall hooks are securely fitted.
SIDE COVER (Right/Left)
1. Remove:
o Screws (Side cover)(_)
2. Unhook"
o Hooks (_
3. Remove:
® Side cover (_
I
__@ FRONT COVER
1. Open the seat.
2. Remove:
e Screws (Front cover) (_
oBolts (Front cover)
3. Close the seat.
4. Remove:
®Front cover (_
2-2
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INSP 1
ADJ /'l_l REMOVINGTHECOVERSANDPANELS
.emove:
® Side covers (Right/Left)
• Front cover
• Footrest mat
•Bolts (Footrest board)
• Footrest board
FRONT AND REAR LEG SHIELD
Front LegShield
1. Remove:
-- e Nuts(Legshield)
2.Remove:
_J_-___ • Screws(Leg shield)
• Bolts (Footrest board)
•Front legshield
RearLegShield
1. Remove:
®Footrest board
• Front legshield
®Screws(Rear legshield)
•Nut (Rear legshield)
®Main switchcap (_
Turn counterclockwiseand pull off.
2. Loosen:
®Rearbrakeadjuster
3.Apply the rear brake fully, move the leg
_"shieldthen removethe legshield.
4. Remove:
eRearlegshield
2-3
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INSP
VALVECLEARANCE ADJUSTMENT ADJ
FRONT AND REAR HANDLEBAR COVERS
_ _ Front Handlebar Cover
',!ll \ _, I1'1.Remove:
° • Rear viewmirrors
__.A#_ _ o Screws (Handlebar cover)
2. Remove:
® Front handlebar cover
RearHandlebarCover
emove:
2.Disconnect:
1__ "_____ •Speedometer cable _
_;_ _,__ 3. Remove:
o Screws (Handlebar cover)
_ ® Rear handlebar cover
ENGINE
VALVE CLEARANCE ADJUSTMENT
NOTE:
Valve clearance must be measured when the
engine is cool to the touch.
1.Remove:
® Side cover (Right)
•Frontcover
=Valve covers (_ (Intake/Exhaust)
eSparkplug
®Timing check window plug (_)
_: 2. Measure:
•Valve clearance
_i:_:_:i:: :: _i_ By the following measurement steps.
_: Valve clearance measurement steps:
o Align the "T" mark (_) on the flywheel
with the stationary pointer (_ on the
crankcase.When the "T" mark is aligned
with the stationary pointer, the piston is
at Top Dead Center (TDC). 2-4
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vALvECLEA.ANCEAO,OSTMENT
'_' ® Measure the valve clearance usinga Feeler
__ ili_ii Gauge@.
\ ,_ Out of specification _ Adjust clearance.
i :, Intake Valve (Cold):
__. _.0.08~0.12 mm(0.003 ~0.005 in)
Exhaust Valve (Cold):
i0.10~0.14mm(0.004 ~0.006in)
3. Adjust:
Valve clearance
By the following adjustment steps.
Valve clearance adjustment steps:
• Loosen the Iocknut (_).
• Insert a Feeler Gauge (_) between the ad-
juster end and the valve end.
_-_i_ • Turn the adjuster @ clockwiseor counter-
clockwise with the Valve Adjusting 'Tool
(_ (YM-08035) until proper clearance is
attained.
Intake Valve(Cold):
0.08~0.12 mrn (0.003 ~0.005 in)
Exhaust Valve(Cold):
0.10 ~ 0.14 mm (0.004 _0.006 in)
• Hold the adjuster to prevent it from
moving and thoroughly tighten the lock-
nut.
ValveClearance Adjusting Locknut:
7 Nm (0.7 m.kg,5.1 ft.lb)
® Measure the valve clearance.
®Ifthe clearance is incorrect, repeat above
steps until the proper clearance is obtained.
4. Install:
Reverse the applicable removal steps. (See
page 2-4)
_Spark Plug:
12.5 Nrn (1.25 rn.kg, 9.0 ft. lb)
Valve Cover (Intake/Exhaust):
7 Nm(0.7 m. kg, 5.1ft. Ib)
2-5
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