brake YAMAHA YD110 2005 User Guide

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

1. Locknut
ykWduV
2. Adjusting Nut
,Mt¯LVx uV
3. Free play
Ýh&Iys
Clutch level free play
adjustment
Dyp&yhoj dh fcuk&Iys dh
,MtLVesaVThe clutch level 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.
Lora=k 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 YMI 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 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 increase free play and
direction è to decrease free play.
Ýh&Iys c<+kus ds fy, ,Mt¯LVx c¨YV
d¨ , dh fn'kk esa ?kqek,¡ rFkk Ýh&Iys
d¨ de djus ds fy, bls ch dh fn'kk
esa ?kqek,¡A
6.22
PERIODIC MAINTENANCE AND MINOR REPAIRlkef;d j[kj[kko rFkk ekewyh ejEer
12
çè
3
ç è
1
2
3
pg56_96.pmd2/25/2005, 9:59 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
YMI 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 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 YMI
dealer psrkouh;fn lgh rjhds ls ,MtLVesaV djuk
vlaHko yx jgk g¨ r¨ okbZñ,eñvkbZñ Mhyj
ls ckr djsaA
PERIODIC MAINTENANCE AND MINOR REPAIR
lkef;d j[kj[kko rFkk ekewyh ejEer
ç
è
1ç
pg56_96.pmd2/25/2005, 9:59 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 YMI 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 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
pg56_96.pmd2/25/2005, 9:59 AM 60

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

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
pg56_96.pmd2/25/2005, 9:59 AM 64

Brake and shift pedal
Greasingczsd rFkk f'k¶V&iSMy dh xzhft+axGrease the pivoting parts.vk/kkjh; Hkkxksa dks fpduk ¼xzht+½ djsaA
Recommended lubricant
izLrkfor xzht+ %20W40 Type SG
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 and sidestand
GreasinglsaVj rFkk lkbM LVSaM dk xzhft+axGrease the pivoting and mating
joints.
Check to see that the center and
sidestand move up and down
smoothly.vk/kkjh; vkSj vkil esa feyus okys tksM+ksa
dks xzht+ djsaA
;g ns[kus ds fy, tk¡p djsa fd chp okyk
rFkk lkbM ds LVS.M vkjke ls Åij pys
tk,a vkSj vkjke ls gh uhps tk tk,aA
6.30
Recommended lubricant
izLrkfor xzht+ %20W40 Type SG
PERIODIC MAINTENANCE AND MINOR REPAIRlkef;d j[kj[kko rFkk ekewyh ejEer
Recommended lubricant
izLrkfor xzht+
Multipurpose Grease
cgqmísf'k; xzht+
pg56_96.pmd2/25/2005, 9:59 AM 66

Front fork inspectionÝaV QksdZ dk fujh{k.k WARNINGSecurely support the Motorcycle
so there is no danger of it falling
over. psrkouhlqjf{kr rjhds ls eksVjlkbfdy dks lgkjk
nsa] ftlls blds fxjus dk [krjk u jgssA1. Visual check
Check for scratches or
damage on the inner tube and
traces if oil leakage from the
front fork.
n f"Vxr ¼us=kh;½ tk¡p %
vkxs yxs QksdZ esa ls vR;f/kd rsy
fjlko vkSj vanj dh V~;wc ij [kjksapks
rFkk blds {kfrxzLr gksus dh tk¡p
djsaA
2. Operation check
Place the Motorcycle on a level
place.
izfØ;k dh tk¡p %
eksVjlkbfdy dks ,d ysoy fd;s gq,
¼likV½ LFkku ij [kM+k djsaA
a. Hold the Motorcycle in an
upright position and apply the
front brake.
eksVjlkbfdy dks lh/kk Åij mBkdj
j[ksa vkSj vxyh czsd dk mi;ksx djsaA
b. Push down hard on the
handlebars several times and
check if the fork bounds
smoothly.
gSafMyckjksa dk dbZ ckj tksj ls uhps
dh vksj nck,a vkSj bl ckr dh tk¡p
djsa fd D;k QksdZ vkjke ls ^mNky*
ys ysrk gSA
6.31

WARNING
If the center and/or sidestand does
not move smoothly, consult a YMI
dealer. psrkouh;fn eksVjlkbfdy ds chp okyk rFkk
lkbM dk LVS.M vkjke ls ¼fcuk fdlh
:dkoV½ ds dke ugha djrs gksa rks
okbZñ,eñvkbZñ Mhyj ls laidZ djsaA
PERIODIC MAINTENANCE AND MINOR REPAIR
lkef;d j[kj[kko rFkk ekewyh ejEer
pg56_96.pmd2/25/2005, 9:59 AM 67

1. Brake cable adjusting nut
czsd dh rkj dk ,M~t¯LVx uVA
1. Place the Motorcycle on the
centerstand.eksVjlkbfdy dks chp okys LVS.M ij
yxkdj [kM+k djsaA
2. Fully loosen the brake cable
adjusting nut at the wheel hub
and remove the cable from the
brake cam lever.
ifg, ds gc ij yxs czsd dh rkj ds
,M~t¯LVx uV dks iwjk [kksy ysa vkSj
rkj ¼dscy½ dks cszd ds dSe yhoj esa
ls ckgj fudky ysaA
Front wheel removalvxys ifg, dks gVkuk WARNING It is advisable to have a YMI
dealer service the wheel.
 Securely support the
Motorcycle so there is no
danger of it falling over. psrkouh
mi;qDr ;gh gS fd okbZñ,eñvkbZñ Mhyj
ls gh ifg, dh ^l£ol* djkbZ tk,A

eksVjlkbfdy dks lqjf{kjr rjhds ls
lgkjk nsa rkfd bls iyV dj fxjus
dk [krjk u jgsA
6.40
PERIODIC MAINTENANCE AND MINOR REPAIRlkef;d j[kj[kko rFkk ekewyh ejEer
1
pg56_96.pmd2/25/2005, 9:59 AM 76

1. Stopper
LVkWij
Front wheel installationvxys ifg, dks yxkukWhen installing the front wheel,
reverse the removal procedure.tc vxys ifg, dks yxkuk gks rks ifg;k
gVkus dh ^izfØ;k* dks myV nsaA
fuEufyf[kr rF;ksa ij /;ku nsaA1. Make sure the slot in the brake
shoe plate fits over the stopper
on the front fork outer tube.
;g lqfuf'pr dj ysa fd czsd dh
'kw&IysV esa cuk gqvk LykWV] vxys
QksdZ dh ckgjh V~; c ij yxs LVkWij
ds lkFk ^fQV* ¼Bhd rjg ls cSB tk,½
gks tk,A
1. Cotter pin
dkWij fiu
2. Axle nut
,Dly uV
5. Remove the cotter pin and axle
nut.
dkWVj fiu rFkk ,Dly uV dks [kkssydj
ckgj fudky ysaA
6. Remove the wheel axle. Make
sure the Motorcycle is properly
supported.
ifg, ds ,Dly dks ckgj fudky ysaA
lqfuf'pr djsa fd eksVjlkbZfdy dks
mfpr lgkjk feyrk jgsA
1. Clip
fDyi
2. Speedometer cable
LihM+¨ehVj dscy
4. Remove the speedometer
cable from the front wheel side.
First remove the clip and then
pull the cable out.
LihM+¨ehVj dscy d¨ vxys ifg;s
ls gVk;saA igys fDyi d¨ gVk;sa
v©j mlds ckn dscy d¨ [khpsaA
6.41
PERIODIC MAINTENANCE AND MINOR REPAIR
lkef;d j[kj[kko rFkk ekewyh ejEer
2
1
2
1
1
pg56_96.pmd2/25/2005, 9:59 AM 77