2005 YAMAHA YD110 torque

SALIENT FEATURES
CRUX S
1.4
ENGINE WITH ADVANCED
TECHNOLOGY Power - 7.60 BHP @7500 RPM
 Torque - 0.80 mkgf @ 6000 RPM
 Balanced, superior combination of
power and optimum fuel efficiency
thru improved carburetor
 Use of AIS to meet Emission
NormsFUEL TANK  Modern graphics
 With knee grip
LOCKABLE SIDE
COVER L.H.
 Modern Graphics
 SafeStorage of
- Toolkit
- First aid kit
- Registration paper
TRENDY MIRROR
 360º swivel to suit rider
preference
COLOURS
 Yamaha Black
 Candy Maroon
 Silver
IMPROVED TFF
 With double lip oil seal
 Comfortable suspensionBIG ROUND HEADLIGHT  Deep peneration & wider
illumination with multireflector.
 Easily adjustable
 Better aestetics
INTEGRAL FRONT
REGISTRATION PLATE
METER PANEL User friendlyMUDGUARD
 Better aesthetics
DOUBLE CRADLE
FRAME
For absolute
stabilityand ruggedness.
NEW MUFFLER ASSY. Meets 2005 Emission
Norms
 Smoother exhaust beats
 With protecor shield (safety)
 Use of Catalyst
DIGITAL CDI
 Digitally controlled ignition
for optimum combustion at
all speeds.TRENDY INDICATORS  Better aesthetics
DOUBLE SADDLE
 Extra long and cushined
 Comfort for rider and pillion
rider
PG1_55.pmd2/25/2005, 10:04 AM 13

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

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

1. Spark plug gap
LikdZ Iyx dk xSi
Spark plug inspection
LikdZ Iyx dk fujh{k.kThe spark plug is an important
engine component and is easy to
inspect. The condition of the spark
plug can indicate the condition of the
engine. The ideal color on the white
insulator around the center electrode
is a medium-to-light tan color for a
Motorcycle that is being ridden
Normally. Do not attempt to diagnose
any problems yourself. Instead, take
the Motorcycle to a YMI dealer. You
should periodically remove and
inspect the spark plug because heat
and deposits will cause the spark
plug to slowly break down and erode.
If electrode erosion becomes
excessive, or if carbon and otherBefore installing the spark plug,
measure the electrode gap with a
wire thickness gauge; adjust the gap
to specification as necessary.
LikdZ Iyx yxkus ds igys bysDVª¨M ds(xSi
) d¨ ok;j xst }kjk uki yasA tSlk
Hkh vko';d g¨ bl varj d¨ fu£n"Vuqlkj
(o£.kr&fof/k
) ls O;ofLFkr djsA
,-&LikdZ Iyx dk varj:
0.9feñehñ
(-0.2 feñehñ
)
When installing the plug, always
clean the gasket surface and use a
new gasket. Wipe off any grime from
the threads and tighten the spark
plug to the specified torque.Iyx yxkrs le; ges'kk xSlfdV ds ry
d¨ lkQ djs rFkk u;k xSlfdV yxk;saA
rarqv¨
(FkzSM~l
) ij yxh xanxh d¨ i¨aN Mkysa
v©j bls fu£n"V VkdZ rd dl nsA
Specified spark plug
fu£n"V fd;k x;k LikdZ Iyx %
P-RA7HC (Champion)
6.9A-Spark plug gap: 0.9mm(-0.2 mm)
deposits are excessive, you should
replace the spark plug with the
specified plug.LikdZ Iyx batu dk egÙoiw.kZ iqtkZ gS
rFkk bldh tk¡p djuk cgqr t#jh gSA
LikdZ Iyx dh fLFkfr ls batu dh gkyr
dk irk yxk;k tk ldrk gSA chp dh
bysDVª¨M ds pkj¨ rjQ lQsn balqysVj ds
Åij vkn'kZ jax] e/;e&gYdk Hkwjk gS t¨
;g n'kkZrk gS fd e¨VjlkbZfdy d¨
lkekU;r% lgh rjhds ls pyk;k tk jgk
gSA fdlh çdkj dh leL;kv¨a dk funku
djus ds fy, Lo;a ç;Ru u djsaA
e¨VjlkbZfdy d¨ okbZñ,eñvkbZñ Mhyj ds
ikl ys tk,¡A vkid¨ le;≤ ij
Iyx ckgj fudky dj mldh tk¡p djrs
jguk pkfg,] D;¨afd Å"ek rFkk tes gq,
d.k /khjs&/khjs LikdZ Iyx dh dk;Z&izzzzzzzðfr
d¨ [kjkc dj nsrs gS v©j bls u"V dj nsrs
gSA ;fn bysDVª¨M dk fljk
(Åij dk
fgLlk
) cgqr T;knk [kjkc g¨ tkrk gS
vFkok bl ij dkcZu rFkk nwljs tek d.kks
dh vf/kdrk c<+ tkrh gS r¨ vkid¨ bl
*LikdZ Iyx^ d¨ fu£n"V fd, x, Iyx ls
cny nsuk pkfg,A
PERIODIC MAINTENANCE AND MINOR REPAIR
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PG1_55.pmd2/25/2005, 10:04 AM 45

Tighten torque
dlk gqvk VkdZ
:
Spark plug
LikdZ Iyx
:
12 ft-lb (1.75 m-kg)
NOTE :
If a torque wrench is not available
when you are installing a spark plug,
a good estimate of the correct torque
is 1/4 to 1/2 turn past finger using a
box spanner.
u¨V %
LikdZ Iyx yxkrs le; ;fn VkdZ jsap
miyC/k u r¨ gkFk ls iwjk dlus d ckn
ckWDl&Lisuj ls ,d p©FkkbZ ls vk/kh pwM+h
rd ?kqek,¡A
ALWAYS USE ONLY THE STANDARD RECOMMENDED MAKE AND TYPE OF SPARK PLUG.gess'kk dsoy çLrkfod çekf.kd uke ds cus rFkk vkn'kZ LikdZ Iyx gh ç;¨x djsA
6.10
PERIODIC MAINTENANCE AND MINOR REPAIRlkef;d j[kj[kko rFkk ekewyh ejEer
PG1_55.pmd2/25/2005, 10:04 AM 46

1. Engine oil drain plug
batu vkW;y Mªsu Iyx
c. Remove the drain plug and drain
the oil.
Mªsu Iyx dks [kksy dj ckgj fudky
ysa v©j rsy dks fudyus nsaA
d. Reinstall the drain plug and
tighten it to the specified torque.
Mªsu Iyx dks fQj ls yxk nsa v©j bls
fu£n"V VkdZ rd dl nsaaA
f. Start the engine and warm up for
a few minutes. While warming
up, check for oil leakage. If oil
leakage is found, stop the engine
immediately and check for the
cause.
batu dks pkyw djsa v©j dqN feuVksa
ds fy, FkksM+k xeZ djrs le; rsy ds
fjlko dh tk¡p dj ysaA ;fn rsy
*yhd^ dj jgk gks rks batu dks rqjar
can dj nsa vkSj dkj.k dh tk¡p djsaA
ALWAYS CHANGE ENGINE OIL AT RECOMMENDED GRADE OF ENGINE OIL
ges'kk dsoy çLrkfod xzsM dk batu&vkW;y gh ç;ksx djsaA
e. Fill engine with oil and install the
dipstick.
batu dks rsy ls Hkj ysa v©j fMikfLVd
dks mlesa yxk nsaA
Tightening torque
dlk x;k VkdZ %
Drain plug
Mªsu Iyx %
14.5 Lt.-lb (2.0 m-kg)
Recommended oil:
YAMALUBE 4 stroke motor oil
(20 W 40 type SG) or equivalent.
Oil quantity:
Total amount : 1.1 L
Periodic oil change :0.9 L
6.13
çLrkfod rsy %
;kekY;wc&
4 LVªksd eksVj vkW;y
¼
20
M~CY;w
40
Vkbi ,l th½ vFkok
mlds leku½
rsy dh ek=kk %
dqy ek=kk %
1.1
fyñ
le;≤ ij rsy esa
ifjorZu %
0.9
fyñ
PERIODIC MAINTENANCE AND MINOR REPAIR
lkef;d j[kj[kko rFkk ekewyh ejEer
1
PG1_55.pmd2/25/2005, 10:04 AM 49

1. Cotter pin
dkWVj fiu
6. Insert a new cotter pin into the axle
nut and bend the end of the cotter
pin as shown. If the notch in the
axle nut and the cotter pin hole do
not match, tighten the nut slightly
to align them.
,fDly ds uV esa ,d u;k dkWVj fiu
yxk,¡] v©j tSlk fd fp=k esa fn[kk;k
x;k gS] dkWVj fiu ds ,d fljs d¨ e¨M+
nsaA ;fn ,fDly uV dh u¨ad ¼ukWp½
rFkk dkWVj&fiu ds usd ds lkFk fey
ugh ikrh gS r¨ bUgs vkil esa feykus ds
fy, uV d¨ /khjs&/khjs dlsaA
WARNINGAlways use a new cotter pin on the
axle nut.
lko/kkuh %
psu dh f'kfFkyrk d¨ fo'ks"k #i ls
of.kZr fufnZ"V dh xbZ lhekv¨a esa gh
çfrikfnr ¼esauVsau½ djsaA

,fDly dh lgh ,ykbuesaV çfrikfnr
djus ds fy, ;g lqfuf'pr djsa fd
,MtLVj ij yxk gqvk fu'kku ckb±
rFkk nkb± v¨j ls ,d gh fpUg ¼fu'kku½
ij feyrh gSA
5. After adjusting, be sure to
tighten each chain adjusting
locknut. Then tighten the axle
nut to the specified torque.
,MtLVesaV djus ds ckn gj ,d psu
,Mt¯LVx ykWd uV d¨ vo'; dl
nsaA rRi'pkr~ ,fDly uV d¨ fu£n"V
VkdZ rd dl nsaA
Tightening torque
dlk x;k VkdZ
:
Axle nut
,fDly uV %
65 ft-lb (9.05 m-kg)
"kV~&isap ¼gsDl&LØ;w½ d¨ , dh fn'kk
esa ?kqek,¡ rFkk bls ,Mt¯LVx "kV~&isap ¼gsDl&LØ;w½ d¨
ch dh fn'kk esa ?kqek,¡ v©j ifg, ij
vkxs dh v¨j ncko MkysA ,Dly dh
lgh ,ykbuesaV ¼iafDrcðrk½ d¨
çfrikfnr ¼esauVsau½ djus ds fy, çR;sd
psu ,Mt¯LVx "kV&isap ¼gsDl&LØ;ww½
d¨ Bhd rjg ls leku nwjh rd
?kqek,¡A çR;sd psu iqyj ij fu'kku
yxs gq, gSA fiNys ifg, d¨ lgh
rjg ls yxkus ds fy, bu fpUg¨ dk
ç;¨x djsaA
CAUTION : Maintain chain slackness
within specified limits as per
specifications.
 To maintain correct axle
alignment, Ensure the notch
on the adjuster is on the same
Mark on Left and Right
Side.
6.27
PERIODIC MAINTENANCE AND MINOR REPAIR
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pg56_96.pmd2/25/2005, 9:59 AM 63

Rear wheel removalfiNys ifg, dks gVkuk
WARNING
 It is advisable to service the
wheel by YMI dealer.
 Securely support the
Motorcycle so there is no
danger of it falling over. psrkouh
mi;qDr ;gh gS fd ifg, dh ^l£ol*
okbZñ,eñvkbZñ Mhyj ls gh djkbZ tk,A

eksVjlkbfdy dk lqjf{kr rjhds ls
lgkjk nsdj [kM+k djsaA rkfd bls
iyV dj fxjus dk [krjk u jgsA
Axle nut torque
,Dly ds uV dk VkdZ %
33 ft.-lb (4.55 m-kg)
2. Make sure the axle nut is
properly torqued and a new
cotter pin is installed.
;g lqfuf'pr djsa fd ,Dly ds uV
dks lgh rjhds ls dlk
gqvk gks vkSj
ml ij u;k dkWVj fiu yxk gksA
WARNINGAlways use a new cotter pin. psrkouhges'kk dkWVj fiu dk iz;ksx djsaA3. Adjust the free play in the brake
lever.
czsd yhoj ds Ýh&Iys dks ,M~tLV
djsaA
1. Nut
uV
2. Cotter pin
dkWVj fiu
3. Tension bar
Vsa'ku ckj
1. Place the Motorcycle on the
centerstand.
eksVjlkbfdy dks chp ds LVS.M ij
[kM+k djsaA
2. Remove the cotter pin and nut.
Then remove the tension bar
from the brake shoes plate.
dkWVj fiu vkSj uV dks gVk nsaA mlds
ckn 'kw&IysV esa ls ^Vsa'ku&ckj* dks
ckgj fudky ysaA
6.42
PERIODIC MAINTENANCE AND MINOR REPAIRlkef;d j[kj[kko rFkk ekewyh ejEer
2
1
3
pg56_96.pmd2/25/2005, 9:59 AM 78