2005 YAMAHA YD110 maintenance

INTRODUCTION
Congratulations on your purchase of the CRUX S. This motorcycle has been produced using
the latest technology in our modern plant, to provide you a happy, enjoyable and safe riding
for many thousand kilometers and years. It represents the high degree of craftsmanship and
reliability that have made YMI a leader in these fields.
This Owner’s Manual will give you an understanding of the operation, inspection and basic
maintenance of this Motorcycle as recommended in this Owner’s manual. Always demand
only YMI Genuine Spare Parts and Yamalube oil. If you have any queries regarding the operation
or maintenance of your Motorcycle, please consult your YMI DEALER who will be too happy
to help you.
This Owner’s Manual also includes the GREEN BOOK containing Guidelines, DO’s and
DON’Ts to be followed by the Owner/User of the Motorcycle for keeping Environment Clean
and Green. You are requested to please read the GREEN BOOK carefully.
We provide,
YAMAHA MOTOR INDIA PVT. LTD.
19/6, Mathura Road,
Faridabad-121006 (India)
PG1_55.pmd2/25/2005, 10:04 AM 1

fo"k; & lwphTABLE OF CONTENTS 4
PRE-OPERATION CHECKS.................... 4-1vkWijs'ku ¼dk;Z½ ls iwoZ tk¡pPre-operation check list........................... 4-1vkWijs'ku iwoZ tk¡p lwph
5
OPERATION AND IMPORTANT RIDING
POINTS................................................. 5-1dk;Z rFkk lokjh ls tqM+s vko';d fcUnq%Starting and warming up a
cold engine............................................. 5-1BaMs batu dks pkyw djuk vkSj FkksM+k xeZ djukStarting a warm engine............................ 5-2xeZ batu dks pkyw djukShifting.................................................. 5-2f'¯¶VxTips for reducing fuel consumption............ 5-4b±/ku dh [kir dks de djus ds rjhdsRunning-in.............................................. 5-4fujarj :i ¼j¯ux bu½Parking.................................................. 5-5ik²dx
6
PERIODIC MAINTENANCE AND MINOR
REPAIR................................................. 6-1lkef;d j[kj[kko rFkk ekewyh fjis;j
Tool kit................................................... 6-1Vwy fdVPreventive maintenance schedule............. 6-3izfrca/kd ¼fizosafVo½ j[kj[kko dk 'ksM~;wyPanel removal and installation.................. 6-7iSuy dks gVkuk rFkk LFkkfir djuk ¼yxkuk½Spark plug and installation....................... 6-9LikdZ Iyx dh tk¡pEngine oil............................................... 6-11b±tu vkW;yAir filter...................................................6-14,vj fQYVjCarburetor adjustment.............................6-16dkWjC;wjsVj dks lsV djuk ¼,sM~tLVesaV½Idle speed adjustment..............................6-16vkbZMy ,sM~tLVesaVThrottle cable free play adjustment............6-18FkzkWVy dscy dh Ýh Iys ,sM~tLVesaVValve clearance adjustment......................6-18okYo fDy;jsal dh ,sM~tLVesaVTyres......................................................6-18Vk;jWheels..................................................6-21ifg,
PG1_55.pmd2/25/2005, 10:04 AM 6

Periodic inspection, adjustment and
lubrication will keep your Motorcycle
in the safest and most efficient
condition possible. Safety is an
obligation of the Motorcycle owner.
The maintenance and lubrication
schedule chart should be considered
strictly as a guide to general
maintenance and lubrication
intervals. YOU MUST TAKE
INTO CONSIDERATION THAT
WEATHER, TERRAIN,
GEOGRAPHICAL
LOCATIONS, AND A VARIETY
OF INDIVIDUAL USES ALL
TEND TO DEMAND THAT
EACH OWNER ALTER THIS
TIME SCHEDULE TO
SHORTER INTERVALS TO
MATCH THE ENVIRONMENT.
The most important points of
Motorcycle inspection, adjustment,
and lubrication are explained in the
following pages.le;≤ ij dh xbZ tk¡p] ,WMtLVesaV
¼rkyesay½] rFkk Y;wczhsdss'ku] vkidh
e¨VjlkbZfdy d¨ vfr lqjf{kr rFkk tgk¡
rd laHko g¨] l{ke voLFkk esa j[ksaxhAe¨VjlkbZfdy ds ekfyd dh viuh
ftEesnkjh gSA j[kj[kko] Y;wczhds'ku lwph
pkVZ d¨ lkekU; esaVhusal rFkk Y;wczhds'ku
O;oLFkk ds fy, xaHkhjrk ls ,d xkbM dh
rjg le>uk pkfg,A vkid¨ ;g ckrsa
/;ku esa j[kuh pkfg, fd e©le] Hkwfe]
Hk©x¨fyd LFkku rFkk O;fDr }kjk fHké rjhds
ls ç;¨x vkfn lHkh ;g ek¡x djrs gS fd
gj ,d e¨Vj&lkbZfdy ekfyd ekg©y d¨
,d tSlk cukus ds fy, le;&lwph d¨
Fk¨M+s ls Fk¨M+s le; ds varj ¼varjky½ esa
ifjo£rr djrk gSA e¨Vj&lkbZfdy dh
tk¡p] ,WMtLVesaV] rFkk Y;wczhsdss'ku ds vfr
egÙoiw.kZ dk;kZ±s dk o.kZu vxys i "B¨a ij
fd;k x;k gSA

WARNING
If you are not familiar with
Motorcycle service, this work
should be done by a YMI DEALER.
psrkouh
;fn vki e¨Vj&lkbZfdy dh *l£ol^ djus
ds rjhd¨ ls ifjfpr ugh gS r¨ ;g dk;Z
okbZñ,eñvkbZñ Mhyj d¨ gh djus nsaA
1. Tool kit
Vwy&fdV
Tool kit
Vwy&fdV
The service information included in
this manual is intended to provide
you, the owner, with the necessary
information for completing some of
your own preventive maintenance
and minor repairs. The tools
provided in the owner’s tool kit are to
assist you in the performance of
periodic maintenance. However,
some other tools such as a torque
wrench are also necessary to
perform the maintenance correctly.bl xzkgd&iqfLrdk ds lkFk l£ol dh
lwpuk g¨us dk vFkZ gS& vkid¨
e¨VjlkbZfdy ds ekfyd d¨ t:jh lwpuk
miyC/k djkuk rkfd ekewyh fjis;j rFkk
dqN fçosafVo esaVhusal ¼çfrca/kd j[kj[kko½
6.1
PERIODIC MAINTENANCE AND MINOR REPAIR
lkef;d j[kj[kko rFkk ekewyh ejEer
1
PG1_55.pmd2/25/2005, 10:04 AM 37

ds dk;Z d¨ iwjk fd;k tk ldsA
e¨Vj&lkbZfdy ekfyd dh Vwy&fdV esa
çnku fd, x, v©t+kj vkid¨ le;cð
j[kj[kko d¨ vatke nsus esa lgk;rk djrs
gSA tcfd esaVhusal ¼j[kj[kko½ d¨ lgh
rjhds ls iwjk djus ds fy, ÞVkdZ&jsapß
tSls nwljs v©t+kj g¨uk Hkh t#jh gSA
NOTE :If you do not have necessary tools
required during a service operation,
take your Motorcycle to a YMI dealer
for service.u¨V %;fn l£ol&dk;Z ds fy, vkids ikl
vko';d v©t+kj ¼;a=k½ ugh gS r¨ vki
e¨Vj&lkbZfdy d¨ okbZñ,eñvkbZñ Mhyj
ds ikl ys tk,¡A
KEEP YOUR MOTORCYCLE TUNED IN PERFECT CONDITION
viuh e¨Vj&lkbZfdy d¨ gj rjg ls vPNh gkyr esa j[ksaA
WARNINGModifications to this Motorcycle not
approved by YMI may cause loss of
performance, and render it unsafe
for use. Consult a YMI dealer before
attempting any changes. psrkouhokbZñ,eñvkbZñ Mhyj dh LohÑfr ds fcuk
e¨Vj&lkbZfdy esa fdlh rjg dk cnyko
djuk dk;Zdq'kyrk ds fy, gkfudkjd g¨
ldrk gSA fdlh Hkh rjg ds ifjorZu
djus ls igys okbZñ,eñvkbZñ Mhyj ls
ijke'kZ ysaA
6.2
PERIODIC MAINTENANCE AND MINOR REPAIRlkef;d j[kj[kko rFkk ekewyh ejEer
PG1_55.pmd2/25/2005, 10:04 AM 38

PREVENTIVE MAINTENANCE SCHEDULE
S.NO.ITEM OPERATION
1. VALVES
2. SPARK PLUG
3 . CARBURETOR
4. AIR FILTER*
5. FUEL LINE
6 . FUEL FILTER
7. ENGINE OIL
8.
9.
10.
11. CLUTCH
12.
1 3 . WHEELS
Check valve clearances, adjust if necessary.
Check condition, gap;
Clean and reset if necessary.
Check idle speed, Choke lever operation.
Clean, inspect & lubricate. (Replace if necessary)
Check fuel hose, for cracks or damage.
Replace if necessary.
Replace with recommended oil - Yamalube SG Grade
(Warm engine before draining)
Wash with petrol
Check operation./Adjust if necessary.
Grease the brake cam.
Check for wear, replace if necessary.
Check alignment marks on Push Lever and
Crankcase L.H. Adjust if necessary.
Check Rear Arm assembly for looseness.
Tighten with specified Torque if necessary.
Check runout, spoke tightness, damage;
Correct it, if necessary.Check for free flow of petrol, cleanliness of filter bowl,
Replace if necessary.
ENGINE OIL
FILTER SCREEN
BRAKE FRONT
& REAR
BRAKE SHOES-
FRONT & REAR
REAR ARM
PIVOT
REPLACE EVERY 10,000 km
•••
••
SERVICE
FREE
PAIDEVERY
2000
KM I-VIVII-VIIIIX-XXI-XV
BONUS
FREEPAID
6.3
PERIODIC MAINTENANCE AND MINOR REPAIR
lkef;d j[kj[kko rFkk ekewyh ejEer
•••
••
••• ••
••• ••
••• ••
••• ••
••• ••
••• ••
••• ••
••• ••
••• ••
••• •• ••• ••
PG1_55.pmd2/25/2005, 10:04 AM 39

6.4
1 4 . WHEEL BEARING
1 5 . STEERING BEARING
1 6 . FRONT FORKS
17.
1 8 . DRIVE CHAIN
19.
20.
2 1 . BATTERY
22.S.NO.ITEM OPERATION
SERVICE
FREE
PAIDEVERY
2000
KM
Check Bearing assembly for looseness, damage;
Replace if necessary.
Check Bearing assembly for looseness;
Correct if necessary.
Check operation/oil leakage. Repair if necessary.
Check all Chassis fittings and fasteners for looseness
Tighten as per specification.
Check operation and lubricate if necessary.
Check electrolyte level and top it up if necessary.
Check specific gravity and charge if required.
Check breather pipe for blockage and routing.
Check operation, free play, cable damage
Readjust or replace as required.Check chain slack, alignment. Adjust if necessary.
Clean & lubricate periodically.
CONTROL CABLES
-THROTTLE
-CLUTCH
-FRONT BRAKE
EVERY 10,000 km
••• ••
ABSORBER REAR SHOCK
NUTS, BOLTS AND
FASTENERS
CENTERSTAND AND
SIDE STAND
Replace grease
Replace grease
Replace oil
EVERY 10,000 km
EVERY 10,000 km
EVERY MONTH
PREVENTIVE MAINTENANCE SCHEDULE
IT IS RECOMMENDED THAT THE ABOVE BE SERVICED BY AUTHORIZED YMI DEALER.
SERVICE MORE FREQUENTLY WHEN THE VEHICLE IS DRIVEN IN DUSTY AREAS.
I-VIVII-VIIIIX-X XI-XV
BONUS
FREEPAID••• ••
••• ••
••• ••
••• ••
••• ••
••• ••
••• ••
Check operation/oil leakage. Repair if necessary.
*
PERIODIC MAINTENANCE AND MINOR REPAIRlkef;d j[kj[kko rFkk ekewyh ejEer
PG1_55.pmd2/25/2005, 10:04 AM 40

6.5
fçosafVo esafVusal ¼çfrca/k j[kj[kko½ lwph
1.
okYo
2.
LikdZ Iyx
3.
dkc¨ZjsVj
4.
,;j fQYVj *
5.
¶;wy ykbu
6.
¶;wy fQYVj
7.
batu vkW;y
8.
9.
10.
11.
Dyp
12.
13.
ifg,
okYo dh Dyh;jsal dh tk¡p djsaA
;fn vko';d g¨ r¨ O;ofLFkr djsaA
fLFkfr ,oa xSi dh tk¡p djsaA
;fn vko';d g¨ r¨ lkQ djsaA
pkWd yhoj dk dk;Z rFkk vkn'kZ xfr dh tk¡p djsaA
;fn vko';d g¨ r¨ lgh djsaA
,;j fQYVj dks tk¡p djsa] lQkbZ djsa o Y;wczhdsV djsa
;fn vko';d g¨ r¨ cny nssaA
¶;wy g©t+ d¨ {kfr rFkk njkj¨a ds fy, tk¡psA
;fn vko';d g¨ r¨ cny nssaA
dk;Z dh tk¡p djsaA ;fn vko';d g¨ r¨ O;ofLFkr djsaA(czsd dh dSe ij xzhl yxk,¡A
)
iSVª¨y ls /k¨,¡A
fiNyh rjQ dh ihNs okyh vkeZ vlsacyh ds ;fn vko';d g¨ r¨ fu£n"V VkdZ ij dl nsaA f?klko ds fy, ns[ksaA
;fn vko';d g¨ r¨ cny nssaA
ckb± v¨j ds Ø®d dsl rFkk iq'k yhoj ij i¯Drcð ¼,ykbuesaV½
fpUg¨a dh tk¡p djsaA ;fn vko';d g¨ r¨ O;ofLFkr djsaA
ju vkÅV] rhyh;¨a ds dlko rFkk {kfr dh tk¡p djsaA
;fn vko';d g¨ r¨ Bhd djsaAiSVªksy ds cgko] fQYVj ckWÅy dh lkQkbZ dh tk¡p djsaA
;fn vko';d g¨ r¨ cny nsaaA
batu vkW;y
fQYVj LØhu
fiNyh rFkk
vxyh czsd
vxys ,oa
fiNys czsd 'kwt+
fiNyh
vkeZ fioV
çR;sd
10,000
fdñehñ ij cny nsa
•• • ••
çLrkfod rsy ls cny nsaA
¼igys ds rsy d¨ cgkus ls igys bat+u d¨ Fk¨M+k xeZ djsa½
I-VIVII-VIII
lsok,¡
eq¶r
çR;sd2000fdñehñ ij
IX-X XI-XV
Hkqxrku
c¨ul eq¶r
Hkqxrku
•• • ••
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•• • ••
•• • ••
•• • ••
•• • ••
•• • ••
•• • ••
oLrqdk;Z ¼vkWijs'ku½ Øe
la[;k
PERIODIC MAINTENANCE AND MINOR REPAIR
lkef;d j[kj[kko rFkk ekewyh ejEer
PG1_55.pmd2/25/2005, 10:04 AM 41

14.
ifg, ds cS¯jx
15.
LVh¯jx ds cS¯jx
16.
vxys QkWdZ
18.
Mªkbo psu
19.
20.
21.
cSVjh
22.
I-VIVII-VIII
{kfr ,oa ;fn vko';d g¨ r¨ cny djsaA
f'kfFkyrk ds fy, cS¯jx vlsacyh dh tk¡p djsaA
;fn vko';d g¨ r¨ Bhd djsaA
QkWdZ ds dk;Z vFkok rsy ds fjlko dh tk¡p djsaA
;fn vko';d g¨ r¨ bldh ejEer djsaA
'kkWd&vCt+kcZj ds dk;Z vFkok
rsy ds fjlko dh tk¡p djsaA
;fn vko';d g¨ r¨ bldh ejEer djsaA
psfll dh lHkh fQ¯Vx v©j QkLVulZ d¨ f'kfFkyrk ds fy, tk¡psA
ekun.M¨a ds vuqlkj dl nsaA
dk;Z dh tk¡p djsaA
;fn vko';d g¨ r¨ yqczhdsV djsaA
bySDVª¨ykbV ds Lrj ¼ysoy½ dh tk¡p djsaA ;fn vko';d g¨ r¨
bls Åij ds Lrj rd Hkj nsaA vkisf{kr ?kuRo dh tk¡p djsaA;fn
vko';d g¨ r¨ bls pktZ dj ysaA ok;q uyh ¼czhnj ikbi½ dk
#dkoV ,oa lgh ekxZ ds fy, fufj{k.k djsaA
psu dh f'kfFkyrk] iafDrcðrk d¨ tk¡psA
lkQ djsa v©j yqczhdsV djsaA
fu;a=k.k dsoy
& FkzkWVy
& Dyp
& vxyh czsd
••• ••
fiNys 'kkWd&vCt+kcZj
uV] c¨YV rFkk
QkLVulZ
lsaVj vkSj
lkbZM LVSaM
fQj ls xzhl HkjsaA
fQj ls xzhl HkjsaA
rsy cnysaA
çR;sd ekl
;g çLrkfor fd;k tkrk gS fd mij¨Dr lHkh lsok,¡ vf/kÑr okbZñ,eñvkbZñ Mhyj }kjk gh yh tkuh pkfg;sA
okgu ¼e¨Vj&lkbZfdy½ d¨ jsrhys bykd¨a esa pykus ij vf/kd 'kh?kzrk ls *l£ol^ djk,¡AfçosafVo esafVusal ¼çfrca/k j[kj[kko½ lwph
oLrq dk;Z ¼vkWijs'ku½lsok,¡
eq¶r
çR;sd2000fdñehñ ij
Øela[;k
{kfr] Ýh&Iys] ,oa dk;Z dh tk¡p djsaA
ek¡x ds vuq:i djsa vFkok cny MkysaA
çR;sd
10,000
fdñehñ ij
çR;sd
10,000
fdñehñ ij
*
IX-X XI-XV
Hkqxrku Hkqxrku
c¨ul eq¶r
••• ••
••• ••
••• ••
••• ••
••• ••
••• ••
••• ••
6.6
PERIODIC MAINTENANCE AND MINOR REPAIRlkef;d j[kj[kko rFkk ekewyh ejEer
çR;sd
10,000
fdñehñ ij
17.
PG1_55.pmd2/25/2005, 10:04 AM 42