Yamaha CYGNUS RAY ZR 2022 Handbuch

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

First edition, September 2021

Any reproduction or unauthorized use

without the written permission of

India Yamaha Motor Pvt. Ltd.

is expressly prohibited.

B2UF8197E1.book Page 1 Wednesday, October 6, 2021 4:38 PM

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

B2UF8197E1.book Page 2 Wednesday, October 6, 2021 4:38 PM

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.

B2UF8197E1.book Page 3 Wednesday, October 6, 2021 4:38 PM

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.

New

B2UF8197E1.book Page 4 Wednesday, October 6, 2021 4:38 PM

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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B2UF8197E1.book Page 2 Wednesday, October 6, 2021 4:38 PM

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

B2UF8197E1.book Page 0 Wednesday, October 6, 2021 4:38 PM

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

ZAUE4431

ASST

B2UF8197E1.book Page 1 Wednesday, October 6, 2021 4:38 PM

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