YAMAHA YD110 2005 Owners Manual

CLAIMABLE
This coupon entitles the owner to the paid service as detailed overleaf
and is mandatory for
eligibility of warranty benefits.
Cost of Oil & Gaskets will be chargeable at actuals.
No.
SELLING DLR'S STAMP, SIGN & CODESERVICING DLR'S STAMP, SIGN & CODE
CUSTOMER'S CERTIFICATION
The jobs as detailed overleaf have been
executed to my entire satisfaction.
Sig. :
Name :FRAME NO. :
ENGINE NO. :
DATE OF SALE :JOB CARD NO :SERVICE DATE :KILOMETERS :
SECOND FREE SERVICE COUPON
VALIDITY : WITHIN 2500-2700 KMS OR 90 DAYS FROM THE DATE OF
PURCHASE OF MOTORCYCLE WHICHEVER IS EARLIER.
2
SERVICING DEALER TO ENSURE THAT SERVICE RECORD IS DULY ENTERED ON PAGE 10-39.
10-27
DETWHITE.pmd2/25/2005, 10:01 AM 13

JOBS TO BE CARRIED OUT DURING SECOND FREE 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.
10-28
DETWHITE.pmd2/25/2005, 10:01 AM 14

CLAIMABLE
This coupon entitles the owner to the paid service as detailed overleaf
and is mandatory for
eligibility of warranty benefits.
Cost of Oil & Gaskets will be chargeable at actuals.
No.
SELLING DLR'S STAMP, SIGN & CODESERVICING DLR'S STAMP, SIGN & CODE
CUSTOMER'S CERTIFICATION
The jobs as detailed overleaf have been
executed to my entire satisfaction.
Sig. :
Name :FRAME NO. :
ENGINE NO. :
DATE OF SALE :JOB CARD NO :SERVICE DATE :KILOMETERS :
FIRST FREE SERVICE COUPON
VALIDITY : WITHIN 500-700 KMS OR 30 DAYS FROM THE DATE OF
PURCHASE OF MOTORCYCLE WHICHEVER IS EARLIER.
1
SERVICING DEALER TO ENSURE THAT SERVICE RECORD IS DULY ENTERED ON PAGE 10-39.
10-29
DETWHITE.pmd2/25/2005, 10:01 AM 15

JOBS TO BE CARRIED OUT DURING FIRST FREE 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.
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DETWHITE.pmd2/25/2005, 10:01 AM 16

10-31
1. Check for any missing item(s), scratches in painted/plated part(s), saddle or other external
visual damages and take corrective action.
Check each of the following items individually and mention the corrective action (as per the
recommended specifications) in the boxes provided.2. Check for missing part(s), if any.A. FRAME
a. Brakes
Front :Free Play at Lever End (10 ~ 15 mm)
Rear :Free Play at Rear Brake (20 ~ 30 mm)
b. Clutch :Free Play at Lever End (10 ~ 15 mm)c. Throttle :Free Play at Throttle Grip (3 ~7 mm)d. Steering :Check for Free Movemente. Suspension
Front Fork : Check for any sticky movement
Rear Shock Abs : For Free Stroking
(To be filled in by the Dealer on receipt of the Motorcycle from YMI)
Odo-Meter
ReadingDate of
Inspection
Frame
No.Engine
No.Date of
SaleFound OK
Set RightReplaced
Cleaned
Lubricated
RCL
S
PRE-DELIVERY INSPECTION REPORT
No.
SERVICE2.pmd2/25/2005, 10:01 AM 1

PRE-DELIVERY INSPECTION REPORT
f. Wheels
Tyre :Tyre pressure Solo Double
(PSI)
Front 25 25
Rear 32 32
R i m : Runout - Radial - 1.5 mm (Max)
- Lateral - 1.5 mm (Max)
Spokes : No loosenes
g. Locks Operation : • Ignition
 Steering Fuel Tank Cap Side Cover (L.H.)
h. Fasteners Specified Torque
(Ft-Lb)
1. Front Wheel Axle Nuts25-40
2. Front Fork (Crown Handle & Inner Tube)13-202. Front Fork under Bracket Stem Nut18-223. Handle Bar Mounting Bolts13-204. Rear Shock Absorber Mounting Bolts22-355. Rear Swing Arm Pivot Shaft Nut32-526. Rear Wheel Axle/Sprocket. Shaft Nuts60-70
B. ENGINE
a. Engine Oil :  Oil Level (For checking - Refer Pg. 6-11)
 Check for any Leakages
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SERVICE2.pmd2/25/2005, 10:01 AM 2

b. Spark Plug :Recommended No. (P-RA7HC - Champion)
Gap 0.9 ±0.2 mm
c. Valve Clearance : (Cold condition)
(If required)Inlet0.08 ~ 0.12 mm
Exhaust0.10 ~ 0.14 mm
(After matching of the mark on sprocket cam chain with mark on Cylinder
Head Casting and ensuring the Piston at TDC of compression stroke.)
d. Kick Operation :For free Movement
e. Carburetor :  Idle RPM
In warmed up condition
(1300~1500 RPM)
 Check for Overflow
f. Drive Chain :  Alignment
 Slackness (20 ~ 30 mm)
g. Fasteners Specified Torque
(Ft-Lb)
1. Cylinder Head Bolts14-17
2. Engine Mounting
a) Engine Mounting Front and Stay Front25-29
b) Stay Engine Front and Frame25-29c) Engine Mounting Rear and Frame25-29d) Engine Mounting Upper &
Stay Engine Upper25-29e) Stay Engine Upper and Frame25-29f) Engine Mounting Front Lower and Frame25-29
3. Front and Rear Silencer Mounting Nut9-124. Crown Handle Centre Bolt20-31
PRE-DELIVERY INSPECTION REPORT10-33
SERVICE2.pmd2/25/2005, 10:01 AM 3

PRE-DELIVERY INSPECTION REPORT
10-34
C. ELECTRICAL
a. Ignition Switch Operation
b. Left Hand Switch Operation & Pass Beam
 Horn
 Indicator Head Light
c. All Bulbs - Functioningd. Battery
 Electrolyte Level
 Specific Gravity Routing of Breather Pipe Fuse Routing of Positive Wire (Red) Below Breather Pipe
D. ROAD TEST
a. Starting
b. Gear Shifting Operationc. Clutch Operationd. Application of Brakes (Front and Rear)e. Speedo/ Odo Meter OperationEXPLAINED BY:SIGNATURE :NAME :
MAIN SELLING DLR'S STAMP, SIGN & CODE
CUSTOMER’S SIGNATURE:
SERVICE2.pmd2/25/2005, 10:01 AM 4

10-35
1. Operation of all the locks (Ignition, Steering, Fuel Tank Cap, Side Cover L.H.).
2. Fuel Cock Lever Operation and its reserve position; Fuel Tank Capacity including reserve.
3. Operation and function of Choke Lever.
4. Operation of Kick Lever.
5. Operation of Throttle.
6. Operation of Handle Bar Switches, their Functions and Pass Beam.
7. Disadvantages of riding on half Clutch (Never ride with clutch pressed).
8. Gear shifting pattern.
9. Tyre inflation pressure :Front - 25 Psi Rear - 32 Psi (Solo), 32 Psi (Double)
10. Never give sudden acceleration; always accelerate gradually
11. Simultaneous use of Front and Rear Brakes.
12. Never ride with your foot on Rear brake Pedal.
13. Whenever parking the Motorcycle on the Side Stand, ensure that the Fuel Cock Lever is in closed
position.
INSTALLATION
Procedures to be explained to the customer on delivery of the Motorcycle by the Dealer's
Representative.
SERVICE2.pmd2/25/2005, 10:01 AM 5

14. Location of Storage and Tool Kit compartments and their use.
15. Procedure of opening and closing of L. H. Side Panel.
16. Battery Maintenance : Checking of electrolyte level (
To add only distilled water if required &
to maintain its Specified Level
)
17. Correct Drive Chain Slackness (20 ~30 mm).
18. Correct type of Spark Plug and Spark Plug gap.
19. Engine Oil (in Gear Box), level checking and explaining the importance of
replacing the Engine
Oil after every 2000 KMS Always use YAMALUBE 4T OIL SG Grade.
20. TFF oil to be replaced after every 10000 Kms.
21. Running- In Period/ Preventive Maintenance Schedule Instructions
22. Information of emission and safety norms alongith Catcon & AIS.
23. Importance and schedule of Free Services
24. Warranty Terms and Conditions.
INSTALLATION
IMPORTANT CAUTION
EXPLAINED BY:SIGNATURE :NAME :
MAIN SELLING DLR'S STAMP, SIGN & CODE
CUSTOMER’S SIGNATURE:10-36
SERVICE2.pmd2/25/2005, 10:01 AM 6