clutch YAMAHA YD110 2005 User Guide

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.
e¨Vj&lkbZfdy dh xfr c<+us ds n©jku
xh;j rst+h ls cnys rFkk batu dh rst+
LihM+ ls cpsaA
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.pmd2/25/2005, 10:04 AM 35

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

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

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

SPECIFICATIONS
ModelCRUX S
Dimensions:
Overall length2,000 mm
Overall width 735 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 power7.60BHP(5.59kw) @ 7500 RPM
Maximum torque 0.8 Mkg @ 6000 RPM
EngineOil
Type:
CAUTION :
Be sure to use motor oils that do not contain
antifrication 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 0.9 L
Total amount 1.1 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.pmd2/25/2005, 9:59 AM 88

Spark plug :
Type/Manufacture P-RA7HC (Champion)
Spark plug gap 0.9 mm (-0.2mm)
Clutch type :Wet, multiple-disk
Transmission :
Primary reduction systemSpur gear
Primary reduction ratio3.722 (67/18)
Secondary reduction systemChain drive
Secondary reduction ratio3.143 (44/14)
Transmission type Constant mesh 4
speed
OperationLeft foot operation
Gear ratio 1st3.000
2nd 1.688
3rd 1.200
4th 0.875
Chassis:
Frame typeDouble Cradle
Caster angle 26.4 degTyre with Tube
Size
Front2.50 ~ 18” 4PR
Rear2.75 ~ 18” 6PR
Air pressure (cold tyre):
Single Rider
Front 25 psi (1.75 Kgf/cm²)
Rear 32 psi (2.25 Kgf/cm²)
With Pillion and rider
Front 25 psi (1.75 Kgf/cm²)
Rear 32 psi (2.25 Kgf/cm²)
8.3
SPECIFICATIONSfo'ks"k fooj.k
pg56_96.pmd2/25/2005, 9:59 AM 90

WARRANTY
9.6
okjaVh
The claim for exchange or repair of part (s) shall be considered only when:ikVZl d¨ cnyus vFkok budh fjis;j djus ds Dyse ij rHkh fopkj fd;k tk,xk tc %1. Customer ensures that immediately upon discovery of the defect he
approaches the nearest YMI Authorised Dealership with the affected
Motorcycle.
The expenses if any, to bring the Motorcycle to the YMI Authorised
Dealership shall be borne by the customer.
miHkksDrk ;g vk'oklu nsrk gS fd n¨"k dk irk yxus ds rqqjUr ckn og e¨VjlkbZfdy
ds lkFk utnhd ds okbZñ,eñvkbZñ Mhyj ds ikl igq¡p tk,xkA
e¨VjlkbZfdy dks vf/kÎÑr Mhyj ds ikl ys tkus dk fdlh rjg dk [kpZ] miHkksDrk
}kjk Lo;a lgu fd;k tk,xkA
2. Customer produces the Owner’s Manual in original to enable the YMI
Dealer to verify the Motorcycle details and servicing details.
eksVjlkbZfdy v©j mldh *l£o¯lx^ dh foLr r tkudkjh nsus ds fy, miHkksDrk dks
okbZñ,eñvkbZñ Mhyj d¨ vksulZ eSuqvy dh ewy izrh çLrqr djuh gksxhA
THIS WARRANTY IS NOT APPLICABLE TO;g *okjaVh^ mu ifjfLFkfr;ksa esa vuqdwy ugh jgsaxh tSls %1. Normal maintenance operations such as Engine tune-up, Decarbonising,
Fuel System Cleaning, Wheels, Brakes and Clutch adjustments as
well as any other normal adjustment.
;g okjaVh dojst dsoy rHkh ykxw gksxk tc eksVjlkbZfdy dks vf/kÑr Mhyj
}kjk lHkh eq¶r l£ol] cksul Ýh l£ol v©j isM l£ol çLrkfod l£ol varjky
esa djokbZ xbZ gks tks fd bl iqfLrdk ds i "B
10-39 ls 10-41 esa fn;k x;k
gS rFkk dsoy okbZñ,eñvkbZñ ds vf/kÑr&ikVZl~ o ;kekY;wc dk ç;ksx fd;k x;k
gksA ÑI;k ;g lqfuf'pr djsa fd çR;sd l£ol] fiNyh l£ol dk
60 fnu ds
varjky ;k çLrkfod le;kuqlkj ;k tks Hkh igys gks djokuh pkfg,A
okjaVh dh oS/krk
pg97_103.pmd2/25/2005, 9:59 AM 100

1- lkekU; ejEer ds dk;Z] tSls fd batu dh V~;w¯ux] fMdkcksZukb¯tx] b±/ku dh lQkbZ&ç.kkyh] ifg;¨a]czsdksa v©j Dyp dh
,MtLVesaV ds lkFk&lkFk dksbZ nwljh lk/kkj.k ,MtLVesaVA2. Normal replacement of service wear and tear items, i.e., Brake Shoes, Fasteners/Shims/Washers, Gaskets
and Rubber or Plastic Components, Cable and Electrical Items like Bulbs, Drive Chain, Sprocket, Clutch
plate, Race Bearing & Element Air Cleaner.
dk;Z ds n©jku f?kls rFkk [kjkc gq, ikVZl mnkgj.kr% czsd 'kwt+] QkLVulZ@f'kel@ok'klZ] xSldV rFkk jcM+ ;k IykfLVd
ds daiksusaV] rkjsa v©j bysDVªhdy vkbVe&tSls fd cYc] Mªkbo&psu] LçkWfdV v©j Dyp IysV~l] jsl cs;¯jx vkSj ,yhesaV ,;j
Dyhuj dks lk/kkj.kr% cny dj nsukA]
3. Part(s) of the Motorcycle that have been subjected to misuse, accident, negligent treatment or which have
been used in conjunction with parts and equipment not manufactured or recommended for use by Yamaha
Motor India Pvt. Ltd., if in the sole judgement of Yamaha Motor India Pvt. Ltd. such use prematurely affects
the performance and reliability of the motorcycle.
vf/kÎdj.k fd, gq, eksVjlkbZfdy ds ikVZl tks fd nq:i;ksx] nq?kZVuk] ykijokgh ls Bhd fd, x, vFkok ftUgs nwljs ikVZl
rFkk midj.kks ds lkFk tksM+ dj ç;ksx fd;k x;k gS ysfdu ;kekgk e¨VjlkbZfdy bafM;k çkñ fyñ çLrkfod vFkok fu£er ugh
fd;k x;k gS] ;fn ;kekgk e¨VjlkbZfdy bafM;k çkñ fyñds fuekZ.k ds varxZr vkrs gS] bl rjg ls mu vkbVedk vlkef;d
ç;ksx eksVjlkbZfdy dh dk;Zdq'kyrk v©j fo'oluh;rk dks çHkkfor djrk gSA
4. Use of non-genuine parts, non-genuine oil and lubricants.
udyh Y;qczhdsaVl] rsy rFkk udyh ikVZl dk ç;ksxA
5. Parts of the Motorcycle getting rusty due to atmospheric effects because of Industrial Pollution.
eksVjlkbZfdy ds os ikVZl tks fd v©|ksfxd çnw"k.k ds dkj.k rFkk okrkoj.k ds çHkkoksa dh otg ls tax idM+ ysrs gSA
6. Parts of Motorcycle that have been altered and modified or replaced in unauthorised manner and which in
the sole judgement of Yamaha Motor India Pvt. Ltd. affects its performance and reliability.
eksVjlkbZfdy ds os ikVZl ftUgs vukf/kÑr :i ls ifjo£rr fd;k x;k gS] lq/kkjk x;k gS vFkok cnyk x;k gS v©j tks ;kekgk
e¨VjlkbZfdy bafM;k çkñ fyñ ds lksy&fu.kZ; ds varxZr eksVjlkbZfdy dh dk;Zdq'kyrk rFkk fo'oluh;rk ij çHkko Mkyrs gSA
WARRANTY
9.7
okjaVh
pg97_103.pmd2/25/2005, 9:59 AM 101

JOBS TO BE CARRIED OUT DURING FIFTEENTH PAID 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.
10-2
DETGREEN.pmd2/25/2005, 10:00 AM 2