2005 YAMAHA YD110 steering wheel

Front fork inspection ...................................6-31vxys QksdZ dh tk¡pSteering inspection.....................................6-32LVs;¯jx dh tk¡pWheel bearings..........................................6-33ifg, dh cs;¯jxBattery .......................................................6-33cSV~jhFuse replacement.......................................6-36¶;wt+ dks cnyukHeadlight bulb replacement........................6-37gSM ykbV ds cYc dk cnyukTurn signal and taillight bulb replacement ...6-39eqM+us okys ¼VuZ½ flXuy rFkk ihNs dh ykbV ds cYc dks
cnyukFront wheel removal....................................6-40vxys ifg, dks gVkukFront wheel installaion................................6-41vxys ifg, dks yxkukRear wheel removal....................................6-42fiNys ifg, dks gVkukRear wheel installation...............................6-44fiNys ifg, dks yxkuk
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TABLE OF CONTENTS
Clutch lever free play adjustment..............6-22
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Front brake adjustment................... ......6-22vxyh czsd dh ,sM~tLVesaVRear brake adjustment............................6-23fiNyh cszd dh ,sM~tLVesaVBrake light switch adjustment..................6-24czsd ykbV cVu ¼fLop½ dh ,sM~tLVesaVChecking the brake shoes.......................6-24czsd 'kwt dh tk¡pDrive chain slack check...........................6-25MªkbZo pSu dh PG1_55.pmd2/25/2005, 10:04 AM 7

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

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so there is no danger of it falling
over. psrkouheksVjlkbfdy dks lqjf{kr rjhds ls lgkjk
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Steering inspectionLVs;¯jx dh tk¡pPeriodically inspect the condition
of the steering. Worm out or loose
steering bearings may be
dangerous. Place a stand under
the engine to raise the front wheel
off the ground. Hold the lower end
of the front forks and try to move
them forward and backward. If any
free play can be felt, ask a YMI
dealer to inspect and adjust the
steering. Inspection is easier if the
front wheel removed.le;≤ ij LVs;¯jx dh fLFkfr dk
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6.32
CAUTION :If any damage or unsmooth
movement is found with the front
fork, consult a YMI dealer. lko/kkuh %;fn vxys QksdZ dks dk;Z djus esa dksbZ
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pg56_96.pmd2/25/2005, 9:59 AM 68

JOBS TO BE CARRIED OUT DURING FIFTEENTH PAID SERVICE 1. Note down the customer’s observations.
2. Wash Motorcycle and blow it dry with compressed air.
3. Clean Spark Plug and reset the gap if necessary.
4. Check Valve clearance, adjust if necessary.
5. Clean and tune Carburettor, set the idle RPM, as recommended. Check for the easy operation of Choke Lever.
6. Open and clean Fuel Cock and Fuel Filter. Check for any cracks or damage on Fuel Hose.
7. Clean Air Filter Element and lubricate it with (4T) oil.
8. Replace Engine Oil and check for any leakages.
9. Wash Engine Oil Filter Screen with petrol.
10. Check operation of Front & Rear Brakes, adjust if necessary. Grease the Brake Cam.
11. For proper Clutch functioning, check alignement marks on Crank Case L.H., Adjust if necessary.
12. Check for Wheel Runout/Spokes looseness, repair if necessary.
13. Check Wheel Bearings (Front & Rear) for looseness, damage.
14. Check for Steering looseness / tightness, adjust if required.
15. Check Front Fork operation / oil leakages, repair if reqrired.
16. Check for Rear Shock Absorber operation.
17. Check Chain Slackness, alignment. Adjust if necessary. Clean and lubricate.
18. Clean Battery, check electrolyte level and proper routing of Breather Pipe.
19. Tighten all Nuts and Bolts. Specially, Cylinder Head, Engine Mounting, Rear Swing Fork, Front & Rear Wheel
Axles & Rear Shock Absorber Mountings to the specified torque.
20. Check all electrical operations.
21. Check and correct air pressure in Front and Rear Tyres.
22. Lubricate all the pivot points.
23. Check exhaust emission for ‘CO’ level at idling, correct if required.
24. Clean and polish Motorcycle after taking ROAD TEST.
10-2
DETGREEN.pmd2/25/2005, 10:00 AM 2

JOBS TO BE CARRIED OUT DURING FOURTEENTH PAID SERVICE 1. Note down the customer’s observations.
2. Wash Motorcycle and blow it dry with compressed air.
3. Clean Spark Plug and reset the gap if necessary.
4. Check Valve clearance, adjust if necessary.
5. Clean and tune Carburettor, set the idle RPM, as recommended. Check for the easy operation of Choke Lever.
6. Open and clean Fuel Cock and Fuel Filter. Check for any cracks or damage on Fuel Hose.
7. Clean Air Filter Element and lubricate it with (4T) oil.
8. Replace Engine Oil and check for any leakages.
9. Wash Engine Oil Filter Screen with petrol.
10. Check operation of Front & Rear Brakes, adjust if necessary. Grease the Brake Cam.
11. For proper Clutch functioning, check alignement marks on Crank Case L.H., Adjust if necessary.
12. Check for Wheel Runout/Spokes looseness, repair if necessary.
13. Check Wheel Bearings (Front & Rear) for looseness, damage.
14. Check for Steering looseness / tightness, adjust if required.
15. Check Front Fork operation / oil leakages, repair if reqrired.
16. Check for Rear Shock Absorber operation.
17. Check Chain Slackness, alignment. Adjust if necessary. Clean and lubricate.
18. Clean Battery, check electrolyte level and proper routing of Breather Pipe.
19. Tighten all Nuts and Bolts. Specially, Cylinder Head, Engine Mounting, Rear Swing Fork, Front & Rear Wheel
Axles & Rear Shock Absorber Mountings to the specified torque.
20. Check all electrical operations.
21. Check and correct air pressure in Front and Rear Tyres.
22. Lubricate all the pivot points.
23. Check exhaust emission for ‘CO’ level at idling, correct if required.
24. Clean and polish Motorcycle after taking ROAD TEST.
10-4
DETGREEN.pmd2/25/2005, 10:00 AM 4

JOBS TO BE CARRIED OUT DURING THIRTEENTH PAID SERVICE 1. Note down the customer’s observations.
2. Wash Motorcycle and blow it dry with compressed air.
3. Clean Spark Plug and reset the gap if necessary.
4. Check Valve clearance, adjust if necessary.
5. Clean and tune Carburettor, set the idle RPM, as recommended. Check for the easy operation of Choke Lever.
6. Open and clean Fuel Cock and Fuel Filter. Check for any cracks or damage on Fuel Hose.
7. Clean Air Filter Element and lubricate it with (4T) oil.
8. Replace Engine Oil and check for any leakages.
9. Wash Engine Oil Filter Screen with petrol.
10. Check operation of Front & Rear Brakes, adjust if necessary. Grease the Brake Cam.
11. For proper Clutch functioning, check alignement marks on Crank Case L.H., Adjust if necessary.
12. Check for Wheel Runout/Spokes looseness, repair if necessary.
13. Check Wheel Bearings (Front & Rear) for looseness, damage.
14. Check for Steering looseness / tightness, adjust if required.
15. Check Front Fork operation / oil leakages, repair if reqrired.
16. Check for Rear Shock Absorber operation.
17. Check Chain Slackness, alignment. Adjust if necessary. Clean and lubricate.
18. Clean Battery, check electrolyte level and proper routing of Breather Pipe.
19. Tighten all Nuts and Bolts. Specially, Cylinder Head, Engine Mounting, Rear Swing Fork, Front & Rear Wheel
Axles & Rear Shock Absorber Mountings to the specified torque.
20. Check all electrical operations.
21. Check and correct air pressure in Front and Rear Tyres.
22. Lubricate all the pivot points.
23. Check exhaust emission for ‘CO’ level at idling, correct if required.
24. Clean and polish Motorcycle after taking ROAD TEST.
10-6
DETGREEN.pmd2/25/2005, 10:00 AM 6

JOBS TO BE CARRIED OUT DURING TWELVETH PAID SERVICE 1. Note down the customer’s observations.
2. Wash Motorcycle and blow it dry with compressed air.
3. Clean Spark Plug and reset the gap if necessary.
4. Check Valve clearance, adjust if necessary.
5. Clean and tune Carburettor, set the idle RPM, as recommended. Check for the easy operation of Choke Lever.
6. Open and clean Fuel Cock and Fuel Filter. Check for any cracks or damage on Fuel Hose.
7. Clean Air Filter Element and lubricate it with (4T) oil.
8. Replace Engine Oil and check for any leakages.
9. Wash Engine Oil Filter Screen with petrol.
10. Check operation of Front & Rear Brakes, adjust if necessary. Grease the Brake Cam.
11. For proper Clutch functioning, check alignement marks on Crank Case L.H., Adjust if necessary.
12. Check for Wheel Runout/Spokes looseness, repair if necessary.
13. Check Wheel Bearings (Front & Rear) for looseness, damage.
14. Check for Steering looseness / tightness, adjust if required.
15. Check Front Fork operation / oil leakages, repair if reqrired.
16. Check for Rear Shock Absorber operation.
17. Check Chain Slackness, alignment. Adjust if necessary. Clean and lubricate.
18. Clean Battery, check electrolyte level and proper routing of Breather Pipe.
19. Tighten all Nuts and Bolts. Specially, Cylinder Head, Engine Mounting, Rear Swing Fork, Front & Rear Wheel
Axles & Rear Shock Absorber Mountings to the specified torque.
20. Check all electrical operations.
21. Check and correct air pressure in Front and Rear Tyres.
22. Lubricate all the pivot points.
23. Check exhaust emission for ‘CO’ level at idling, correct if required.
24. Clean and polish Motorcycle after taking ROAD TEST.
10-8
DETGREEN.pmd2/25/2005, 10:00 AM 8

JOBS TO BE CARRIED OUT DURING ELEVENTH PAID SERVICE 1. Note down the customer’s observations.
2. Wash Motorcycle and blow it dry with compressed air.
3. Clean Spark Plug and reset the gap if necessary.
4. Check Valve clearance, adjust if necessary.
5. Clean and tune Carburettor, set the idle RPM, as recommended. Check for the easy operation of Choke Lever.
6. Open and clean Fuel Cock and Fuel Filter. Check for any cracks or damage on Fuel Hose.
7. Clean Air Filter Element and lubricate it with (4T) oil.
8. Replace Engine Oil and check for any leakages.
9. Wash Engine Oil Filter Screen with petrol.
10. Check operation of Front & Rear Brakes, adjust if necessary. Grease the Brake Cam.
11. For proper Clutch functioning, check alignement marks on Crank Case L.H., Adjust if necessary.
12. Check for Wheel Runout/Spokes looseness, repair if necessary.
13. Check Wheel Bearings (Front & Rear) for looseness, damage.
14. Check for Steering looseness / tightness, adjust if required.
15. Check Front Fork operation / oil leakages, repair if reqrired.
16. Check for Rear Shock Absorber operation.
17. Check Chain Slackness, alignment. Adjust if necessary. Clean and lubricate.
18. Clean Battery, check electrolyte level and proper routing of Breather Pipe.
19. Tighten all Nuts and Bolts. Specially, Cylinder Head, Engine Mounting, Rear Swing Fork, Front & Rear Wheel
Axles & Rear Shock Absorber Mountings to the specified torque.
20. Check all electrical operations.
21. Check and correct air pressure in Front and Rear Tyres.
22. Lubricate all the pivot points.
23. Check exhaust emission for ‘CO’ level at idling, correct if required.
24. Clean and polish Motorcycle after taking ROAD TEST.
10-10
DETGREEN.pmd2/25/2005, 10:00 AM 10