YAMAHA YD110 2005 Service Manual

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
•••
••
••• ••
••• ••
••• ••
••• ••
••• ••
••• ••
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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
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6.5
fçosafVo esafVusal ¼çfrca/k j[kj[kko½ lwph
1.
okYo
2.
LikdZ Iyx
3.
dkc¨ZjsVj
4.
,;j fQYVj *
5.
¶;wy ykbu
6.
¶;wy fQYVj
7.
batu vkW;y
8.
9.
10.
11.
Dyp
12.
13.
ifg,
okYo dh Dyh;jsal dh tk¡p djsaA
;fn vko';d g¨ r¨ O;ofLFkr djsaA
fLFkfr ,oa xSi dh tk¡p djsaA
;fn vko';d g¨ r¨ lkQ djsaA
pkWd yhoj dk dk;Z rFkk vkn'kZ xfr dh tk¡p djsaA
;fn vko';d g¨ r¨ lgh djsaA
,;j fQYVj dks tk¡p djsa] lQkbZ djsa o Y;wczhdsV djsa
;fn vko';d g¨ r¨ cny nssaA
¶;wy g©t+ d¨ {kfr rFkk njkj¨a ds fy, tk¡psA
;fn vko';d g¨ r¨ cny nssaA
dk;Z dh tk¡p djsaA ;fn vko';d g¨ r¨ O;ofLFkr djsaA(czsd dh dSe ij xzhl yxk,¡A
)
iSVª¨y ls /k¨,¡A
fiNyh rjQ dh ihNs okyh vkeZ vlsacyh ds ;fn vko';d g¨ r¨ fu£n"V VkdZ ij dl nsaA f?klko ds fy, ns[ksaA
;fn vko';d g¨ r¨ cny nssaA
ckb± v¨j ds Ø®d dsl rFkk iq'k yhoj ij i¯Drcð ¼,ykbuesaV½
fpUg¨a dh tk¡p djsaA ;fn vko';d g¨ r¨ O;ofLFkr djsaA
ju vkÅV] rhyh;¨a ds dlko rFkk {kfr dh tk¡p djsaA
;fn vko';d g¨ r¨ Bhd djsaAiSVªksy ds cgko] fQYVj ckWÅy dh lkQkbZ dh tk¡p djsaA
;fn vko';d g¨ r¨ cny nsaaA
batu vkW;y
fQYVj LØhu
fiNyh rFkk
vxyh czsd
vxys ,oa
fiNys czsd 'kwt+
fiNyh
vkeZ fioV
çR;sd
10,000
fdñehñ ij cny nsa
•• • ••
çLrkfod rsy ls cny nsaA
¼igys ds rsy d¨ cgkus ls igys bat+u d¨ Fk¨M+k xeZ djsa½
I-VIVII-VIII
lsok,¡
eq¶r
çR;sd2000fdñehñ ij
IX-X XI-XV
Hkqxrku
c¨ul eq¶r
Hkqxrku
•• • ••
•• • ••
•• • ••
•• • ••
•• • ••
•• • ••
•• • ••
•• • ••
•• • ••
•• • ••
•• • ••
•• • ••
oLrqdk;Z ¼vkWijs'ku½ Øe
la[;k
PERIODIC MAINTENANCE AND MINOR REPAIR
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14.
ifg, ds cS¯jx
15.
LVh¯jx ds cS¯jx
16.
vxys QkWdZ
18.
Mªkbo psu
19.
20.
21.
cSVjh
22.
I-VIVII-VIII
{kfr ,oa ;fn vko';d g¨ r¨ cny djsaA
f'kfFkyrk ds fy, cS¯jx vlsacyh dh tk¡p djsaA
;fn vko';d g¨ r¨ Bhd djsaA
QkWdZ ds dk;Z vFkok rsy ds fjlko dh tk¡p djsaA
;fn vko';d g¨ r¨ bldh ejEer djsaA
'kkWd&vCt+kcZj ds dk;Z vFkok
rsy ds fjlko dh tk¡p djsaA
;fn vko';d g¨ r¨ bldh ejEer djsaA
psfll dh lHkh fQ¯Vx v©j QkLVulZ d¨ f'kfFkyrk ds fy, tk¡psA
ekun.M¨a ds vuqlkj dl nsaA
dk;Z dh tk¡p djsaA
;fn vko';d g¨ r¨ yqczhdsV djsaA
bySDVª¨ykbV ds Lrj ¼ysoy½ dh tk¡p djsaA ;fn vko';d g¨ r¨
bls Åij ds Lrj rd Hkj nsaA vkisf{kr ?kuRo dh tk¡p djsaA;fn
vko';d g¨ r¨ bls pktZ dj ysaA ok;q uyh ¼czhnj ikbi½ dk
#dkoV ,oa lgh ekxZ ds fy, fufj{k.k djsaA
psu dh f'kfFkyrk] iafDrcðrk d¨ tk¡psA
lkQ djsa v©j yqczhdsV djsaA
fu;a=k.k dsoy
& FkzkWVy
& Dyp
& vxyh czsd
••• ••
fiNys 'kkWd&vCt+kcZj
uV] c¨YV rFkk
QkLVulZ
lsaVj vkSj
lkbZM LVSaM
fQj ls xzhl HkjsaA
fQj ls xzhl HkjsaA
rsy cnysaA
çR;sd ekl
;g çLrkfor fd;k tkrk gS fd mij¨Dr lHkh lsok,¡ vf/kÑr okbZñ,eñvkbZñ Mhyj }kjk gh yh tkuh pkfg;sA
okgu ¼e¨Vj&lkbZfdy½ d¨ jsrhys bykd¨a esa pykus ij vf/kd 'kh?kzrk ls *l£ol^ djk,¡AfçosafVo esafVusal ¼çfrca/k j[kj[kko½ lwph
oLrq dk;Z ¼vkWijs'ku½lsok,¡
eq¶r
çR;sd2000fdñehñ ij
Øela[;k
{kfr] Ýh&Iys] ,oa dk;Z dh tk¡p djsaA
ek¡x ds vuq:i djsa vFkok cny MkysaA
çR;sd
10,000
fdñehñ ij
çR;sd
10,000
fdñehñ ij
*
IX-X XI-XV
Hkqxrku Hkqxrku
c¨ul eq¶r
••• ••
••• ••
••• ••
••• ••
••• ••
••• ••
••• ••
6.6
PERIODIC MAINTENANCE AND MINOR REPAIRlkef;d j[kj[kko rFkk ekewyh ejEer
çR;sd
10,000
fdñehñ ij
17.
PG1_55.pmd2/25/2005, 10:04 AM 42

1. Panel A
iSuy &,
Panel removal and
installationiSuy d¨ gVkuk rFkk yxkukThe panels illustrated need to be
removed to perform some of the
maintenance described in this
manual. Refer to this section each
time a panel has to be removed or
reinstalled.n'kkZ, x, fp=k¨ ds vuqlkj bl
xzkgd&iqfLrdk esa j[kj[kko ds fo"k; esa
t¨ dqN Hkh crk;k x;k gS mlds fy,
iSuy¨a d¨ gVkus dh t#jr iM+rh gSA
tc Hkh iSuy d¨ gVkuk gks rks bl [kaM dh
lgk;rk ysaA
1. Panel B
iSuy&ch
1. Lug
yx
2. Panel A
iSuy&,
3. Panel Lock
iSuy dk ykWd ¼rkyk½
Removal of Panel AiSuy *,^ d¨ gVkukUnlock the panel.
Pull the lug 1 towards you to remove
it from the fuel tank.
Slide the panel A towards the rear
end of the motorcycle for removing
the lug 2 to free the panel.iSuy ds ykWd ¼rkys½ d¨ [k¨ysaA b±/ku dh
Vadh ls vyx gVkus ds fy, yx uañ
1 d¨
viuh rjQ [khpsaA yx uañ
2 d¨ gVkus
,oa iSuy d¨ Lora=k :i ls vyx djus
ds fy, iSuy&, d¨ e¨VjlkbZfdy dh
fiNyh rjQ f[kldk,¡A
6.7
PERIODIC MAINTENANCE AND MINOR REPAIR
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1
2
2
13
PG1_55.pmd2/25/2005, 10:04 AM 43

1. Lug
yx
2. Panel B
iSuy&ch
Removal of Panel BiSuy&ch d¨ gVkukLoosen screw and follow the same
procedure as for removing panel A.isap d¨ viuk,¡] ftls iSuy ^,^ d¨ gVkus esa ç;qDr
fd;k gSA
1. Lug
yx
2. Lug
yx
Installation of Panel AiSuy *,^ d¨ yxkukSlide the panel towards the front of
the motorcycle for inserting the lug
¿ in the slot given in the frame.
Insert and push the lug À in the fuel
tank ensuring proper seating.
After proper seating of the panel A,
lock it.Ýse esa fn, x, [kk¡psa ¼Ly¨V½ esa yx uañ ¿
d¨ cSBkus ds fy, iSuy d¨ e¨Vj&lkbZfdy
ds lkeus dh v¨j [khapsaA
lgh rjg ls cSBus ds fy, yx À d¨
b ±/ku dh Vadh esa cSBk,¡ v©j uhps dh v¨j
nck bls *ykWd^ dj nsaA
iSuy *,^ ds lgh ykWd dj nsaA
1. Lug
yx
2. Lug
yx
Installation of Panel BiSuy *ch^ d¨ yxkukFollowing the same procedure as
given for installation of panel A and
tighten the screw for locking.iSuy *,^ d¨ yxkus ds fy, t¨ rjhdk
viuk;k gS] iSuy *ch^ ds fy, mlh rjhds
dks viuk;sa vkSj isp d¨ dl nsaA
6.8
PERIODIC MAINTENANCE AND MINOR REPAIRlkef;d j[kj[kko rFkk ekewyh ejEer
1
2
1
2
1
2
PG1_55.pmd2/25/2005, 10:04 AM 44

1. Spark plug gap
LikdZ Iyx dk xSi
Spark plug inspection
LikdZ Iyx dk fujh{k.kThe spark plug is an important
engine component and is easy to
inspect. The condition of the spark
plug can indicate the condition of the
engine. The ideal color on the white
insulator around the center electrode
is a medium-to-light tan color for a
Motorcycle that is being ridden
Normally. Do not attempt to diagnose
any problems yourself. Instead, take
the Motorcycle to a YMI dealer. You
should periodically remove and
inspect the spark plug because heat
and deposits will cause the spark
plug to slowly break down and erode.
If electrode erosion becomes
excessive, or if carbon and otherBefore installing the spark plug,
measure the electrode gap with a
wire thickness gauge; adjust the gap
to specification as necessary.
LikdZ Iyx yxkus ds igys bysDVª¨M ds(xSi
) d¨ ok;j xst }kjk uki yasA tSlk
Hkh vko';d g¨ bl varj d¨ fu£n"Vuqlkj
(o£.kr&fof/k
) ls O;ofLFkr djsA
,-&LikdZ Iyx dk varj:
0.9feñehñ
(-0.2 feñehñ
)
When installing the plug, always
clean the gasket surface and use a
new gasket. Wipe off any grime from
the threads and tighten the spark
plug to the specified torque.Iyx yxkrs le; ges'kk xSlfdV ds ry
d¨ lkQ djs rFkk u;k xSlfdV yxk;saA
rarqv¨
(FkzSM~l
) ij yxh xanxh d¨ i¨aN Mkysa
v©j bls fu£n"V VkdZ rd dl nsA
Specified spark plug
fu£n"V fd;k x;k LikdZ Iyx %
P-RA7HC (Champion)
6.9A-Spark plug gap: 0.9mm(-0.2 mm)
deposits are excessive, you should
replace the spark plug with the
specified plug.LikdZ Iyx batu dk egÙoiw.kZ iqtkZ gS
rFkk bldh tk¡p djuk cgqr t#jh gSA
LikdZ Iyx dh fLFkfr ls batu dh gkyr
dk irk yxk;k tk ldrk gSA chp dh
bysDVª¨M ds pkj¨ rjQ lQsn balqysVj ds
Åij vkn'kZ jax] e/;e&gYdk Hkwjk gS t¨
;g n'kkZrk gS fd e¨VjlkbZfdy d¨
lkekU;r% lgh rjhds ls pyk;k tk jgk
gSA fdlh çdkj dh leL;kv¨a dk funku
djus ds fy, Lo;a ç;Ru u djsaA
e¨VjlkbZfdy d¨ okbZñ,eñvkbZñ Mhyj ds
ikl ys tk,¡A vkid¨ le;≤ ij
Iyx ckgj fudky dj mldh tk¡p djrs
jguk pkfg,] D;¨afd Å"ek rFkk tes gq,
d.k /khjs&/khjs LikdZ Iyx dh dk;Z&izzzzzzzðfr
d¨ [kjkc dj nsrs gS v©j bls u"V dj nsrs
gSA ;fn bysDVª¨M dk fljk
(Åij dk
fgLlk
) cgqr T;knk [kjkc g¨ tkrk gS
vFkok bl ij dkcZu rFkk nwljs tek d.kks
dh vf/kdrk c<+ tkrh gS r¨ vkid¨ bl
*LikdZ Iyx^ d¨ fu£n"V fd, x, Iyx ls
cny nsuk pkfg,A
PERIODIC MAINTENANCE AND MINOR REPAIR
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Tighten torque
dlk gqvk VkdZ
:
Spark plug
LikdZ Iyx
:
12 ft-lb (1.75 m-kg)
NOTE :
If a torque wrench is not available
when you are installing a spark plug,
a good estimate of the correct torque
is 1/4 to 1/2 turn past finger using a
box spanner.
u¨V %
LikdZ Iyx yxkrs le; ;fn VkdZ jsap
miyC/k u r¨ gkFk ls iwjk dlus d ckn
ckWDl&Lisuj ls ,d p©FkkbZ ls vk/kh pwM+h
rd ?kqek,¡A
ALWAYS USE ONLY THE STANDARD RECOMMENDED MAKE AND TYPE OF SPARK PLUG.gess'kk dsoy çLrkfod çekf.kd uke ds cus rFkk vkn'kZ LikdZ Iyx gh ç;¨x djsA
6.10
PERIODIC MAINTENANCE AND MINOR REPAIRlkef;d j[kj[kko rFkk ekewyh ejEer
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1. Engine oil filter cap
batu vkW;y fQYVj dSi
Engine oilbatu dk rsy1. Oil level measurement
rsy ds Lrj dks ukiukA
a. Place the Motorcycle on the
centerstand. Warm up the engine
for several minutes., - e¨VjlkbZfdy d¨ lSaVj LVSaM ij [kM+k
dj nsaA batu d¨ dbZ feuV¨a rd /
khjs&/khjs xeZ djsaA
1. Maximum level
mPpre Lrj
2. Minimum level
fuEure Lrj
NOTE :Wait a few minutes until the oil level
settles before checking.u¨V %tk¡p djus ls igys tc rd vWk;y dk
Lrj ¼ysoy½ fLFkj u g¨ tk, rc rd
dqN feuV¨a ds fy, çrh{kk djsA
NOTE :
Be sure the Motorcycle is positioned
straight up when checking the oil
level. A slight tilt toward the side can
result in false readings.u¨V %;g lqfuf'pr djs fd rsy dk Lrj ns[krs
le; e¨Vj&lkbZfdy viuh txg ij lh/kh
[kM+h jgsA ,d rjQ d¨ Fk¨M+k lk Hkh
>qdko jgus ls jh¯Mx xyr g¨ ldrh gSA
ALWAYS CHANGE ENGINE OIL AT RECOMMENDED INTERVALS
FOR OPTIMUM ENGINE PERFORMANCE AND ENGINE LIFE
6.11
PERIODIC MAINTENANCE AND MINOR REPAIR
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PG1_55.pmd2/25/2005, 10:04 AM 47

b. Unscrew the dipstick and rest it
on the threads of the oil filler hole.
The oil level should be between
the minimum and maximum
mark on the dipstick. If the level
is low, add oil to raise it to the
specified level.ch- fMikfLVd d¨ [k¨y ysa v©j bls
fQyj ds Nsn ij fVdk nsaA vkW;y
dk ysoy fMikfLVd ds fuEure o
mPpre fu'kku ds e/; esa g¨uk pkfg,A
;fn ysoy de yxs r¨ bls c<+kus ds
fy, fu£n"V Lrj rd rsy MkysaA
1. Dipstick
fMifLVd
2. Engine oil replacement
batu&rsy d¨ cnyuk
a. Warm up the engine for a few
minutes.
dqN feuV¨ ds fy, batu d¨ xeZ
djsaA
b. Stop the engine. Place an oil pan
under the engine and remove
the dipstick.
batu d¨ can dj nsA batu ds uhps
,d vkW;y iSu ¼crZu½ j[k ysa rFkk
fMikfLVd d¨ ckgj fudky ysaA
batu dh vf/kd dk;Z{kerk rFkk nh?kZ thou ds fy, batu&vkW;y d¨ ges'kk çLrkfor
varjky¨ ij cnyrs jgsaA
6.12
PERIODIC MAINTENANCE AND MINOR REPAIRlkef;d j[kj[kko rFkk ekewyh ejEer
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