2005 YAMAHA YD110 service

2
4
MONT
HS
/
30,
000
KMS
(8 FREE SERVICES)
OWNER'S MANUAL OWNER'S MANUAL

TABLE OF CONTENTSfo"k; & lwph
Troubleshooting.............................................6-45leL;k lek/kku ¼Vªcy'kw¯Vx½Troubleshooting chart............................... ..6-46rhoz leL;k lek/kku dk pkVZ
7
CLEANING AND STORAGE.......................... 7-1lQkbZ rFkk HkaMkj.kA. Cleaning.................................................... 7-1¼,½ lQkbZB. Storage ..................................................... 7-3¼ch½ HkaMkj.k ¼LVksjst+½

8
SPECIFICATIONS ......................................... 8-1fooj.k
9 ............................................................
9 ...................................................................
CUSTOMER INFORMATION................................. 9-1
xzkgd lwpukKey identification number.............................. 9-1pkWch dk igpku uañFrame serial number..................................... 9-1Ýse dk lhfj;y uacjEngine serial number..................................... 9-1batu dk lhfj;y uacjFacts related with Exhaust emission control . 9-2çokg&fu;a=k.k ls lacf/kr rF;Safety norms ................................................. 9-3
Warranty 9 - 5okjaVh
10
DETACHMENTSvyxko ¼fMVspesaV½Fifteenth paid service coupon...............10-1iaægok¡ Hkqxrku lfoZl dwiuFourteenth paid service coupon............10-3p©ngok¡ Hkqxrku lfoZl dwiuThirteenth pad service coupon..............10-5rsjgok¡ Hkqxrku lfoZl dwiuTwelveth paid service coupon...............10-7ckjgok¡ Hkqxrku lfoZl dwiuEleventh paid service coupon...............10-9X;kjgok¡ Hkqxrku lfoZl dwiuTenth bonus free service coupon..........10-11nlok¡ c¨ul&Ýh lfoZl dwiuNinth bonus free service coupon...........10-13uok¡ c¨ul&Ýh lfoZl dwiuEighth paid service coupon...................10-15vkBok¡ Hkqxrku lfoZl dwiuSeventh paid service coupon................10-17lkrok¡ Hkqxrku lfoZl dwiuSixth free service coupon......................10-19NBk eq¶r&lfoZl dwiu
PG1_55.pmd2/25/2005, 10:04 AM 8

Fifth free service coupon.......................10-21ik¡pok¡ eq¶r&lfoZl dwiuFourth free service coupon....................10-23p©Fkk eq¶r&lfoZl dwiuThird free service coupon.......................10-25rhljk eq¶r&lfoZl dwiuSecond free service coupon...................10-27nwljk eq¶r&lfoZl dwiuFirst free service Coupon.......................10-29igyk eq¶r&lfoZl dwiuPre-delivery inspection..........................10-31fMyojh iwoZ&fufj{k.kInstallation.............................................10-35baLVkys'kuDelivery certificate.................................10-37fMyojh lfVZfQdsV~l ¼çek.k&i=k½Service record........................................10-39lfoZl ¼lsok½ fjdkMZ
GREEN BOOKgjh&iqfLrdkAddress of Area Officeseq[; dk;Zky;kssa dk irk
fo"k; & lwph
TABLE OF CONTENTS
ALWAYS KEEP THE ENVIRONMENT CLEAN
okrkoj.k d¨ lnk LoPN j[¨A
PG1_55.pmd2/25/2005, 10:04 AM 9

OPERATION AND IMPORTANT RIDING POINTS
Tips for reducing fuel
consumptionb±/ku dh [kir de djus ds fVIlYour Motorcycle’s fuel consumption
depends to a large extent on your
riding style.vkidh e¨Vj&lkbZfdy esa b±/ku dh [k+ir]
vkids pykus ds rjhds ij fuHkZj djrh gSAThe following tips can help reduce fuel
consumption :uhps fn, x, fVIl ¼fof/k;k¡½ b±/ku dh [k+ir
d¨ de djus esa lgk;d g¨ ldrs gS
:
1. Warm up the engine before riding.
e¨Vj&lkbZfdy pykus ls igys batu
d¨ FkksM+k xeZ djsaA
2. Lift up the Choke Lever as soon
as possible.
ftruh tYnh laHko g¨ *pkWd yhoj^ d¨
Åij dh rjQ mBk ysaA
3. Shift up swiftly and avoid high
engine speeds during
acceleration.
e¨Vj&lkbZfdy dh xfr c<+us ds n©jku
xh;j rst+h ls cnys rFkk batu dh rst+
LihM+ ls cpsaA
4. Do not double-clutch or rev the
engine while shifting down and
avoid high engine speeds with
no load on the engine.
xkM+h d¨ fupys xh;j esa ykrs le;
Mcy Dyp dk ç;¨x u djsaA rFkk
batu ij y¨M u g¨us dh fLFkfr esa
batu ds rhoz osx ls cpsaA
5. Turn off the engine instead of
letting it idle for an extended
length of time, i.e. in traffic jams,
at traffic lights or rail-road
crossings.
tc vki T;knk nsj rd [kM+s gks rks
batu dk vkbZMy ij pyrs jgus dh
vis{kk mls can dj nsaA
mnkgj.k% VªSfQd tke esa]yky cÙkh
ij] jsyos Øk£lx ij bR;kfnA
6. Do not drive with excessive load
on the Motorcycle.
vR;kf/kd ot+u ds lkFk
e¨Vj&lkbZfdy u pyk,¡A
7. Plan your route in advance.
vius ;k=kk&ekxZ dh ;¨t+uk igys ls
gh cuk ysaA
8. Avoid frequent braking.
ckj&ckj czsd yxkus ls cpsaA
9. Always maintain your tyre
pressure as per
recommendation.
tSlk fd çLrkfor ¼flQkfj'k½ fd;k
x;k gS] ges'kk vius Vk;j esa gok ds
ncko d¨ cuk dj j[¨saA
10.Get your motorcycle serviced
periodically after every 2000 kms.
çR;sd
2000
fdñehñ ds varjky esa
lkef;d #i ls e¨Vj&lkbZfdy dh
lfoZl djok,¡A
Running-in
jfuax&bu
There is never a more important period
in the life of your Motorcycle than the
period between zero and 1,000 km.
For this reason we ask that you
carefully read the following material.
Because the engine is brand new, you
must not put an excessive load on it
for the first 1,000 km. The various
parts in the engine wear and polish
themselves to the correct operating
clearances. During this period,
prolonged full throttle operation, or any
condition which might result in
excessive heating of the engine, must
be avoided.
5.4
dk;Z rFkk lokjh ls tqM+s vko';d rF;
PG1_55.pmd2/25/2005, 10:04 AM 35

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
•••
••
••• ••
••• ••
••• ••
••• ••
••• ••
••• ••
••• ••
••• ••
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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
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