2007 YAMAHA YD110 clutch

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.
PG1_55.pmd10/15/2006, 9:15 AM 31

xh;j d¨ U;wVªy esa ykus ds fy,
f'k¶V&iSMy d¨ rc rd uhps dh v¨j
nckrs jgs tc rd fd ;g vius vafre
iM+ko rd u igq¡p tk,A mlds ckn
iSMy d¨ Fk¨M+k Åij dh v¨j mBk ysaA CAUTION :1. Do not ride down hill with
ignition switch in “OFF” position
and in neutral gear. Always ride
motorcycle with ignition switch
in “ON’ Position & while engine
is in gear.
2. Always use the clutch when
changing gears. The engine,
transmission, and driveline are
not designed to withstand the
shock of forced shifting and
can be damaged by shifting
without using the clutch.OPERATION AND IMPORTANT RIDING POINTS
lko/kkuh %1.
u djsa ¼bXuh'ku Lfop dks vkWQ
ikst+h'ku ij½ o eksVjlkbZdy U;wVªy
esa Hkh u djsaA
dks pkyw j[ksa ¼bXuh'ku Lfop dks vkWu
ikst+h'ku ij½ o eksVjlkbZdy dks
xh;j esa j[ksaA
2.
xh;j cnyrs le; ges'kk Dyp dk
ç;¨x djasA batu] V ªkaleh'ku rFkk
M ªkbo ykbu bl rjg ls fMt+kbu
ugh fd, x, gS fd ;g cnyrs gq,
vR;kf/kd ncko¨a d¨ lgu dj ldus
dh fLFkfr esa g¨rs gS rFkk f'k¯¶Vx
djrs le; Dyp ds ç;¨x u djus
ls ;s {kfrxzLr g¨ ldrs gSA
NEVER RIDE MOTORCYCLE WITH CLUTCH PARTIALLY ENGAGED.*Dyp^ ds vkaf'kd #i ls tqM+s g¨us dh fLFkfr esa e¨Vj&lkbZfdy dHkh u pyk,¡A
5.3
dk;Z rFkk lokjh ls tqM+s vko';d rF;
PG1_55.pmd10/15/2006, 9:15 AM 36

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.
xh;j rst+h ls cnys vkSj xfr cM+krs
le; batu dks t+:jr ls vf/kd LihM+
u nsaA
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.pmd10/15/2006, 9:15 AM 37

PREVENTIVE MAINTENANCE SCHEDULE
S.NO. ITEMOPERATION
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.pmd10/15/2006, 9:15 AM 41

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
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.
*
PERIODIC MAINTENANCE AND MINOR REPAIRlkef;d j[kj[kko rFkk ekewyh ejEer
PG1_55.pmd10/15/2006, 9:15 AM 42

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
6.22
PERIODIC MAINTENANCE AND MINOR REPAIRlkef;d j[kj[kko rFkk ekewyh ejEer
32
1
12
pg56_96.pmd10/15/2006, 8:53 AM 58

Brake and shift pedal
Greasingczsd rFkk f'k¶V&iSMy dh xzhft+axGrease the pivoting parts.vk/kkjh; Hkkxksa dks fpduk ¼xzht+½ djsaA
Brake and clutch lever
Greasingczsd rFkk f'k¶V&iSMy dh xzhft+axGrease the pivoting parts.vk/kkjh; Hkkxksa dks fpduk ¼xzht+½ djsaA
Center stand GreasinglsaVj LVSaM dk xzhft+axGrease the pivoting and mating
joints.
Check to see that the center stand
move up and down smoothly.vk/kkjh; vkSj vkil esa feyus okys tksM+ksa
dks xzht+ djsaA
tk¡p djsa fd lsaVj LVS.M Åij vkSj uhps
gks vkjke ls tk,A
6.30
PERIODIC MAINTENANCE AND MINOR REPAIRlkef;d j[kj[kko rFkk ekewyh ejEer
Recommended lubricant
izLrkfor xzht+
Multipurpose Grease
cgqmísf'k; xzht+
pg56_96.pmd10/15/2006, 8:53 AM 66

SPECIFICATIONS
ModelCRUX
Dimensions:
Overall length2,000 mm
Overall width735 mm
Overall height1,075 mm
Seal height 780 mm
Wheelbase1,260 mm
Ground clearance160 mm
Minimum turning radius 2,000 mm
Weight : ( With oil & 90% fuel ) 113 kg
Engine :Engine type Air cooled 4-stroke,
SOHC
Cylinder arrangement Forward inclined
single cylinder
Displacement105.6 cm
3
Boer × Stroke49×56 mm
Compression ratio9.0 : 1
Starting systemKick starter
Lubrication systemWet sump
Maximum power7.60 PS(5.59kw) @ 7500 RPM
Maximum torque 0.8 Mkg @ 6000 RPM
EngineOil
Type:
CAUTION :
Be sure to use motor oils that do not contain
antifriction modifiers. Passenger car motor oils
(often labelled Energy conserving) contain anti-
friction additives which will cause clutch/or
starter clutch slippage, resulting in reduced
component life and poor engine performance.
Capacity :
Periodic oil change 1.0 L
Total amount 1.2 L
Air filter:Foam type element
Fuel :
Type Regular gasoline
(petrol)
Fuel tank capacity 11.0 Litres
Reserve amount1.4 Litres
Carburetor:
Type VM17SH
ManufactureMIKUNI
SPECIFICATIONSfo'ks"k fooj.k
8.1
YAMALUBE
4-Stroke motor oil (20W40)
Type SG
pg56_96.pmd10/15/2006, 8:53 AM 88