2006 YAMAHA YD110 brake

4.2
PRE-OPERATION CHECKS
IF WAITING AT TRAFFIC SIGNAL IS FOR LONG, SWITCH OFF THE ENGINE TO PROTECT
THE ENVIRONMENT AND TO LOWER FUEL CONSUMPTION
NOTE :Pre-operator checks should be made each time the Motorcycle is used. Such an inspection can be accomplished
in a very short time; and the added safety it assures is more than worth the time involved. WARNINGIf any item in the Pre-Operation Check is not working properly, have it inspected and repaired before operating
the Motorcycle.
ITEMPAGE CHECKS
Brake and clutch lever pivots
Center stand pivot
Chassis fasteners
Fuel Tank
Lights, signals and switches
Battery
 Check for smooth operation.
 Lubricate if necessary.
 Check for proper operation.  Make sure that all nuts, bolts, and screws are properly tightened
 Tighten if necessary.
 Check fuel level.
 Fill with fuel if necessary.6-30
6-30
-
3-5, 3.6
3-2, 6-37
6-33 – 6-35 Check for smooth operation.
 Lubricate if necessary.
 Check fluid level.
 Fill with distilled water if necessary.
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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
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•••
••
••• ••
••• ••
••• ••
••• ••
••• ••
••• ••
••• ••
••• ••
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6.4
1 4 . WHEEL BEARING
1 5 . STEERING BEARING
1 6 . FRONT FORKS
17.
1 8 . DRIVE CHAIN
19.
20.
21. 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
CENTER 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 YMIS 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.
*
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1. Locknut
ykWduV
2. Adjusting Nut
,Mt¯LVx uV
3. Free play
Ýh&Iys
Clutch lever free play
adjustment
Dyp&yhoj dh Ýh&Iys dh
,MtLVesaVThe clutch lever free play should
be adjusted to 10 ~ 15 mm. If the
free play is incorrect, adjust as
follows.Dyp yhoj dh Ýh Iys d¨
10
ls
15
feñehñ rd ,MtLV djuh pkfg,A ;fn
Ýh&Iys lgh u vk jgh g¨ r¨ bls uhps fn,
x, rjhds ls ,MtLV djsa %1. Loosen the locknut.
ykWd uV d¨ 2. Turn the adjusting bolt at the
clutch lever in direction ç toincrease free play or in direction
è to decrease free play.
Ýh&Iys c<+kus ds fy, Dyp yhoj ds
,Mt¯LVx c¨YV d¨ , dh fn'kk esa
?kqek,¡ vFkok Lora=k ¼Ýh½ Iys d¨ ?kVkus
ds fy, yhoj ds c¨YV d¨ ch dh
fn'kk esa ?kqek,¡A
3. Tighten the locknut.
ykWd uV d¨ dl nsaA
NOTE :
If proper adjustment cannot be
obtained or the clutch does not work
correctly, ask a YMIS dealer to inspect
the internal clutch mechanism.u¨V %;fn lgh jgh g¨ vFkok Dyp lqpk: rjhds ls dke
u djrk g¨ r¨ okbZñ,eñvkbZñ,lñ Mhyj
ls vkarfjd Dyp eSdsfuTe dh tk¡p djus
d¨ dgsaA
1. Locknut
ykWduV
2. Adjusting Bolt
,Mt¯LVx c¨YV
3. Free play
Ýh&Iys
Front brake adjustment
vxyh czsd dh ,MtLVesaVThe front brake level free play should
be adjusted to 10 ~ 15 mm.vxys czsd yhoj dh Ýh Iys d¨
10 ls
15
feñehñ rd ,MtLV djuk pkfg,A1. Loosen the locknut
ykWduV d¨ 2. Turn the adjusting bolt in direction
ç to decrease free play and
direction è to increase free play.
Ýh&Iys de djus ds fy, ,Mt¯LVx
c¨YV d¨ , dh fn'kk esa ?kqek,¡ rFkk
Ýh&Iys d¨ c<+kus ds fy, bls ch dh
fn'kk esa ?kqek,¡A
6.22
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çè
3
ç è
1
2
3
pg56_96.pmd9/24/2005, 7:53 AM 58

1. Adjusting Nut
,Mt¯LVx uV
Rear brake adjustment
fiNyh czsd dh ,MtLVesaVThe rear brake pedal free play
should be adjusted to 20 ~ 30 mm
at the brake pedal end. Turn the
adjusting nut in direction ç to
increase free play and in direction
è to decrease free play.czsd iSMy ds fdukjs ij fiNys czsd iSMy
dh Ýh Iys ¼ 20
ls
30
feñehñ
rd ,MtLV djuh pkfg,A Ýh Iys
¼ uV d¨ , dh fn'kk esa ?kqek,¡ v©j Ýh Iys
¼ ch dh fn'kk esa ?kqek,¡A
a. Freeplay
Ýh Iys

WARNING• When it is impossible to make
the proper adjustment, ask a
YMIS dealer.
 Check the operation of the
brake light after adjusting the
rear brake. psrkouh
tc lgh rjhds ls lkaetL;
¼,MtLVesaV½ LFkkfir djuk vlaHko
yx jgk g¨ r¨ okbZñ,eñvkbZñ,lñ Mhyj
ls ijke'kZ djsaA

fiNyh czsd d¨ ,MtLVesaV djus ds
ckn czsd ykbV dh çfØ;k dh tk¡p
djsaA
6.23
3. Tighten the locknut.
ykWd uV d¨ dl nsaA
WARNINGWhen it is impossible to make the
proper adjustment, ask a YMIS
dealer psrkouh;fn lgh rjhds ls ,MtLVesaV djuk
vlaHko yx jgk g¨ r¨ okbZñ,eñvkbZñ,lñ
Mhyj ls ckr djsaA
PERIODIC MAINTENANCE AND MINOR REPAIR
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ç
è
1ç
pg56_96.pmd9/24/2005, 7:53 AM 59

1. Wear limit line
oh;j fyfeV ykbu
2. Wear indicator
oh;j baMhdsVj
Checking the brake shoes
czsd 'kwt+ dh tk¡pA wear indicator is provided on each
brake. This indicator allows
inspection of shoe wear without
disassembling the brake. Apply the
brake and inspect the position of the
indicator reaches to the wear limit
line, ask a YMIS dealer to replace
the shoes.gj ,d czsd ds fy, ,d oh;j&baMhdsVj
yxk;k x;k gSA ;g bafMdsVj czsd d¨ fcuk
[k¨ys gq,] czsd 'kwW dh tk¡p esa lgk;d g¨rk
gSA czsd yxk,¡ v©j baMhdsVj dh voLFkk
dk fujh{k.k djsaA ;fn baMhdsVj oh;j dh
lhek&js[kk rd igq¡p tkrk gS r¨
okbZñ,eñvkbZñ,lñ Mhyj ls bu 'kwt+ d¨
cnyrs d¨ dgsaA
1. Brake light switch
czsd ykbV dk fLop
2. Adjusting nut
,Mt¯LVx uV
Brake light switch adjustment
czsd ykbV ds fLop dh ,MtLVesaVThe rear brake light switch is
activated by the brake pedal and is
properly adjusted when the brake
light comes on just before braking
takes effect. To adjust the rear brake
light switch, hold the switch body so
it does not rotate while turning the
adjusting nut.
Turn the adjusting nut in direction ç
to make the brake light come on
earlier.
Turn the adjusting nut in direction è
to make the brake light come on later.
fiNyh czsd dh ykbV dk fLop ¼cVu½
czsd iSMy ls fØ;kfUor g¨rk gS v©j bl
rjg ls ,MtLV fd;k tkrk gS fd czsd
yxus dk çHkko fn[kus ls igys gh czsd dh
cÙkh ¼ykbV½ ty mBrh gSA fiNyh czsd
ds cVu ¼fLop½ d¨ ,MtLV djus ds fy,
fLop d¨ bl rjg ls idMsa rkfd
,Mt¯LVx uV d¨ [k¨yrs le; fLop ?kwe
u ldsA
czsd ykbV d¨ 'kh?kzrk ls igys tykus ds
fy, ,Mt¯LVx uV d¨ , dh fn'kk esa
?kqek,¡A
czsd ykbV d¨ ckn esa tykus ds fy,
,Mt¯LVx uV d¨ ch dh fn'kk esa ?kqek,¡A
6.24
PERIODIC MAINTENANCE AND MINOR REPAIRlkef;d j[kj[kko rFkk ekewyh ejEer
ç
è1
2
21
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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 adjusting
hex screw in direction (B) 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
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3ç
è
2
1
pg56_96.pmd9/24/2005, 7:53 AM 62

psrkouh
,fDly uV ds fy, ges'kk u, dkWVj fiu
dk gh ç;¨x djsaA7. Adjust the free play in the brake
pedal.
czsd iSMy ds Ýh Iys d¨ ,MtLV
djsaA
p
WARNINGCheck the operation of the brake
light after adjusting the rear brake. psrkouhfiNyh czsd d¨ ,MtLV djus ds ckn
czsd dh cÙkh ¼ykbV½ dh çfØ;k d¨ tk¡p
ysaA
6.28
Drive chain lubricationMªkbo&psu dh Y;wczhds'kuThe chain consists of many parts
which work with each other. If the
chain is not maintained properly, it
will wear out quickly. Therefore, the
chain must be serviced regularly.
This service is especially
necessary when riding in dusty
areas.psu esa cgqr ls fgLls g¨rs gS t¨ ,d&nwljs
ds fy, dke djrs gSA ;fn psu dh
ns[kHkky lgh rjg ls u dh tk, r¨ ;g
tYnh f?kl tkrh gSA blfy, yxkrkj
bldh l£ol dk /;ku j[kuk pkfg,A
jsrhys bykd¨ esa e¨Vj&lkbZfdy pykrs
le; bl rjg dh l£ol djkuk cgqr
t#jh g¨ tkrk gSA1. The drive chain should be
lubricated every 5,000 km.
Mªkbo&psu d¨ çR;sd
5,000
fdñehñ
ds ckn Y;wczhdsV dj nsuh pkfg,A
2. To clean the chain thoroughly,
remove it from the Motorcycle,
dip it in solvent, and clean outas much dirt as possible.
Then, take the chain out of the
solvent to dry it, and then dip
the chain in oil of 20W40.
Remove the chain and hang it
on a peg for a while till the
excess oil drips down
completely. Then using a clean
cloth wipe the chain.
psu d¨ iw.kZr;k lkQ djus ds fy,
bls e¨Vj&lkbZfdy ls mrkj ysa] ækod
¼lkWyosaV½ esa Mqc¨ nsa v©j ftruk T;knk
laHko g¨ /kwy&feêh d¨ lkQ dj ysaA
mlds ckn psu d¨ lq[kkus ds fy,
ækod ls ckgj fudky ysa v©j fQj ls20W40
czkaM ds ¼vkW;y½ rsy esa iwjh
fHkx¨ nsaA rRi'pkr~ psu d¨ ckgj
fudky dj rc rd [kq¡Vh ij Vk¡x nsa]
tc rd fd Qkyrw rsy blesa ls iwjh
rjg fupqM+ u tk,A rc psu d¨ ,d
lkQ diM+s ls i¨aN ysaA
PERIODIC MAINTENANCE AND MINOR REPAIRlkef;d j[kj[kko rFkk ekewyh ejEer
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