2005 YAMAHA YD110 wheel

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

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
fo"k; & lwph
TABLE OF CONTENTS
Clutch lever free play adjustment..............6-22
Dyp yhoj dh
,sM~tLVesaV
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

Owners are personally responsible for their vehicle’s condition. Your Motorcycle’s vital functions can start to deteriorate
quickly and unexpectedly-even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid
leakor loss of tyre pressure could have serious consequence Therefore’ it is very important that, in addition to a
thorough visual inspection, you check the following points before each ride.PRE-OPERATION CHECKS
PRE-OPERATION CHECK LIST
ITEMPAGE CHECKS
Front brake
Rear brake
Clutch
Throttle grip and housing
Engine oil
Drive chain
Wheels and tyres
Control and meter cable
Brake and shift pedal shafts
 Check tyre pressure, wear, damage and spoke tightness.
 Tighten spokes if necessary.  Check operation, condition and free play.
 Adjust if necessary.
 Check for smooth operation.
 Lubricate if necessary.
 Check oil level.
 Fill with oil if necessary.
 Check chain slack and condition.
 Lubricate if necessary.
 Adjust if necessary.
 Check for smooth operation.
 Lubricate if necessary.  Check for smooth operation.
 Lubricate if necessary.  Check operation, condition and free play.
 Adjust if necessary.  Check operation, condition and free play.
 Adjust if necessary.3-4, 6-22
3-4, 6-23
3-3-, 6-22
6-17, 6-29
6-11, 6-12
6-29
6-30 6-25, 6-26
6-18, 6-21
4.1
PG1_55.pmd2/25/2005, 10:04 AM 28

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

3. Ride at moderate speeds after
changing a tyre since the type
surface must first be broken in
for it to develop its optimal
characteristics.
Vk;j cnyus ds ckn e¨Vj&lkbZfdy
d¨ gYdh LihM+ ij pykuk pkfg,
ftlls fd Vk;j esa visf{kr fof'k"Vrkv¨a
dk lekos'k g¨us ds fy, fje esa te
tk;saA
Wheels
ifg,
To ensure maximum performance,
long service, and safe operation, note
the followingvR;kf/kd dk;Zdq'kyrk] nh?kZ&thou rFkk
lqjf{kr dk;Z lqfuf'pr djus ds fy,
fuEufyf[kr ckr¨a ij /;ku nsa %1. Always inspect the wheels
before a ride. Check for cracks,
bends or warpage of the wheel.
Be sure the spokes are tight and
undamaged. If any abnormal
condition exists in a wheel,
consult a YMI dealer. Do not
attempt even small repairs to the
wheel. If a wheel is deformed or
cracked, it must be replaced.
ges'kk e¨Vj&lkbZfdy pykus ls igys
ifg;¨a dh tk¡p dj ysaA ifg, esa
6.21
2.
iaDpj gqbZ V~;wc ij iS¯px ¼jcM+ ds
VqdMs½ yxkus d¨ çLrkfod ugh fd;k
x;k gSA ;fn ,slk djuk cgqr gh
vko';d g¨ tk,] r¨ csgn lko/kkuh
cjrsa v©j ftruh tYnh laHko g¨ bl
V~;wc d¨ ,d vPNh DokfyVh dh
V~;wc ls cny ysaAØSSDl iM+us] Vs ij dqN fyiVk g¨us dh tk¡p dj ysaA
lqfuf'pr dj ysa fd ifg, dh rhfy;k¡
dlh gqbZ g¨ v©j {kfr xzLr u g¨A
;fn ifg, esa d¨bZ vlkekU; fLFkfr
fn[kkbZ nsrh gS r¨] okbZñ,eñvkbZñ Mhyj
ls lykg ysaA ifg, esa ekewyh lh
ejEer dk dk;Z djus dk ç;Ru u
djsaA ;fn ifg;k foÑr g¨ x;k gS
vFkok pVd ¼ØSd½ x;k gS r¨ bls
cny nsuk pkfg,A
2. Tyre and wheels should be
balanced whenever either one is
changed or replaced. Failure to
have a wheel balanced can
result in poor performance,
adverse handling
characteristics, and shortened
tyre life.
tc Hkh Vk;j vFkok ifg;¨a esa fdlh
,d d¨ cnyk x;k g¨ r¨ Vk;j v©j
ifg, dk larqfyr g¨uk pkfg,A ifg,
dk ^cSysl^ u g¨uk] rqPN dk;Z {kerk]
foijhr gSaM¯yx fof'k"Vrkv¨a v©j Vk;j
dh fe;kn ¼mez½ de g¨us dk dkj.k
cu ldrk gSA
PERIODIC MAINTENANCE AND MINOR REPAIR
lkef;d j[kj[kko rFkk ekewyh ejEer
pg56_96.pmd2/25/2005, 9:59 AM 57

Inspect the drive chain when the
Motorcycle is on the centerstand.
Check the slack at the position
shown in the illustration. Normal
slack is approximately 20 ~ 30 mm.
If the slack exceeds 30 mm, adjust.Mªkbo psu dh tk¡p rHkh djsa tc
e¨Vj&lkbZfdy lsaVj LVSaM ij [kM+h g¨A
n'kkZ, x, fp=k ds vuqlkj gh psu dh
yxHkx
20 ls
30 feñehñ rd g¨rh gSA
;fn ;g
30 feñehñ ls Hkh vf/kd gS r¨ bls
O;ofLFkr djsaA
1. Wear limit line
oh;j fyfeV ykbu
2. Wear indicator
oh;j baMhdsVj
1. Free play
Ýh Iys
Drive chain slack checkMªkbo psu dh f'kfFkyrk dk fujh{k.kNOTE :
Spin the wheel several times and find
the tightest position of the chain.
Check and/or adjust the chain slack
while it’s in this tightest position.u¨V %ifg, d¨ dbZ ckj ?kqek,¡ v©j psu d¨
dlh gqbZ gkykr esa ys vk,¡A tc psu
dlh gqbZ voLFkk esa g¨ r¨ bldh f'kfFkyrk
¼ dj ysaA
6.25
PERIODIC MAINTENANCE AND MINOR REPAIR
lkef;d j[kj[kko rFkk ekewyh ejEer
20~30 mm
1
2
1
pg56_96.pmd2/25/2005, 9:59 AM 61

1. Chain joint
psu&t¨M
If the chain is disassembled, be
sure the chain lock is placed in the
correct direction when installing.
;fn psu d¨ [k¨y dj vyx dj fn;k
x;k gS r¨ ;g lqfuf'pr djsa fd bls fQj
ls yxkrs le; psu ykWd d¨ lgh fn'kk esa
yxk;k tk,A
1. Adjusting nut
,Mt¯LVx uV
2. Cotter pin
dkWVj fiu
3. Axle nut
,fDly dk uV
Driven chain slack adjustmentMªkbo&psu dh ¼,MtLVesaV½1. Loosen the rear brake pedal
free play adjusting nut.
fiNyh czsd ds iSMy ds Ýh&Iys
,Mt¯LVx uV d¨ 2. Remove the cotter pin from the
axle nut.
,Dly uV ls dkWVj&fiu d¨ vyx
gVk ysaA
3. Loosen the axle nut.
,Dly uV d¨ 6.26
1. Locknut
ykWd uV
2. Adjusting hex screw
,Mt¯LVx gsDl&isap
4. Loosen the chain adjusting
locknuts on each chain puller.
To tighten the chain, turn the
chain adjusting hex screw in
direction(a). To loosen the
chain, turn the chain and push
the wheel forward. Turn each
chain adjusting hex screw
exactly the same amount to
maintain correct axle
alignment. There are marks on
each chain puller. Use these
makes to align the rear wheel.
çR;sd psu&iqyj ij yxs ,Mt¯LVx
ykWd uV¨a ¼isp¨a½ d¨ psu d¨ dlus fy,] psu ,Mt¯LVx
PERIODIC MAINTENANCE AND MINOR REPAIRlkef;d j[kj[kko rFkk ekewyh ejEer
12
3ç
è
2
1
pg56_96.pmd2/25/2005, 9:59 AM 62