YAMAHA YD110 2005 Repair Manual

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
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ç
è
1ç
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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
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Inspect the drive chain when the
Motorcycle is on the centerstand.
Check the slack at the position
shown in the illustration. Normal
slack is approximately 20 ~ 30 mm.
If the slack exceeds 30 mm, adjust.Mªkbo psu dh tk¡p rHkh djsa tc
e¨Vj&lkbZfdy lsaVj LVSaM ij [kM+h g¨A
n'kkZ, x, fp=k ds vuqlkj gh psu dh
yxHkx
20 ls
30 feñehñ rd g¨rh gSA
;fn ;g
30 feñehñ ls Hkh vf/kd gS r¨ bls
O;ofLFkr djsaA
1. Wear limit line
oh;j fyfeV ykbu
2. Wear indicator
oh;j baMhdsVj
1. Free play
Ýh Iys
Drive chain slack checkMªkbo psu dh f'kfFkyrk dk fujh{k.kNOTE :
Spin the wheel several times and find
the tightest position of the chain.
Check and/or adjust the chain slack
while it’s in this tightest position.u¨V %ifg, d¨ dbZ ckj ?kqek,¡ v©j psu d¨
dlh gqbZ gkykr esa ys vk,¡A tc psu
dlh gqbZ voLFkk esa g¨ r¨ bldh f'kfFkyrk
¼ dj ysaA
6.25
PERIODIC MAINTENANCE AND MINOR REPAIR
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20~30 mm
1
2
1
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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
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1. Cotter pin
dkWVj fiu
6. Insert a new cotter pin into the axle
nut and bend the end of the cotter
pin as shown. If the notch in the
axle nut and the cotter pin hole do
not match, tighten the nut slightly
to align them.
,fDly ds uV esa ,d u;k dkWVj fiu
yxk,¡] v©j tSlk fd fp=k esa fn[kk;k
x;k gS] dkWVj fiu ds ,d fljs d¨ e¨M+
nsaA ;fn ,fDly uV dh u¨ad ¼ukWp½
rFkk dkWVj&fiu ds usd ds lkFk fey
ugh ikrh gS r¨ bUgs vkil esa feykus ds
fy, uV d¨ /khjs&/khjs dlsaA
WARNINGAlways use a new cotter pin on the
axle nut.
lko/kkuh %
psu dh f'kfFkyrk d¨ fo'ks"k #i ls
of.kZr fufnZ"V dh xbZ lhekv¨a esa gh
çfrikfnr ¼esauVsau½ djsaA

,fDly dh lgh ,ykbuesaV çfrikfnr
djus ds fy, ;g lqfuf'pr djsa fd
,MtLVj ij yxk gqvk fu'kku ckb±
rFkk nkb± v¨j ls ,d gh fpUg ¼fu'kku½
ij feyrh gSA
5. After adjusting, be sure to
tighten each chain adjusting
locknut. Then tighten the axle
nut to the specified torque.
,MtLVesaV djus ds ckn gj ,d psu
,Mt¯LVx ykWd uV d¨ vo'; dl
nsaA rRi'pkr~ ,fDly uV d¨ fu£n"V
VkdZ rd dl nsaA
Tightening torque
dlk x;k VkdZ
:
Axle nut
,fDly uV %
65 ft-lb (9.05 m-kg)
"kV~&isap ¼gsDl&LØ;w½ d¨ , dh fn'kk
esa ?kqek,¡ rFkk bls ,Mt¯LVx "kV~&isap ¼gsDl&LØ;w½ d¨
ch dh fn'kk esa ?kqek,¡ v©j ifg, ij
vkxs dh v¨j ncko MkysA ,Dly dh
lgh ,ykbuesaV ¼iafDrcðrk½ d¨
çfrikfnr ¼esauVsau½ djus ds fy, çR;sd
psu ,Mt¯LVx "kV&isap ¼gsDl&LØ;ww½
d¨ Bhd rjg ls leku nwjh rd
?kqek,¡A çR;sd psu iqyj ij fu'kku
yxs gq, gSA fiNys ifg, d¨ lgh
rjg ls yxkus ds fy, bu fpUg¨ dk
ç;¨x djsaA
CAUTION : Maintain chain slackness
within specified limits as per
specifications.
 To maintain correct axle
alignment, Ensure the notch
on the adjuster is on the same
Mark on Left and Right
Side.
6.27
PERIODIC MAINTENANCE AND MINOR REPAIR
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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
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Throttle cable and grip
lubricationFkzkWVy dscy v©j fxzi Y;wczhdsV
djukAThe throttle twist grip assembly
should be greased at the time that
the cable is lubricated, since the
grip must be removed to get at the
end of the throttle cable. After
removing the screws, hold the end
of the cable up in the air and put in
several drops of lubricant. With the
throttle grip disassembled, coat the
metal surface of the grip assembly
with a suitable all purpose grease.ftl le; dscy dks Y;wczhdsaV fd;k tkrk
gS mlh le; ^FkzkWVy V~foLV fxzi vlsEcyh*rkj¨a d¨ tax&çfrj¨/kh rsy rFkk dscy ds
fdukj¨a ls yqczhdsV djsaA ;fn dscy lgh
rjhds ls dke ugh dj jgh g¨ r¨ okbZñ,eñvkbZñ
Mhyj ls bls cnyrs d¨ dgsaA
dh fxzlhax Hkh dh tkuh pkfg,] D;ksafd
fxzi dks FkzkVy dh dscy ds fljs rd ykus
ds fy,] bls ckgj fudky ysuk pkfg,A
isap gVkus ds ckn rkj ¼dscy½ ds ,d
fljs ¼fdukjs½ dks gok esa idM+s jgsa vkSj
ml ij Y;wczhdsaV dh cgqr lh cwansa MkysaA
FkzkWVy fxzi dks [kksyus ¼vyx&vyx djus½
ds lkFk fxzi vlsEcyh dks /kkrq ds ry ij
;Fkk;ksX;] cgqmís'kh; ¼vkWy ijit+½ xzhl
dh dks¯Vx dj nsaA
Cable inspection and
lubricationdscy dk fujh{k.k ,oa Y;wczhds'ku WARNINGDamage to the outer housing of
cables may lead to internal
rusting and interfere with the
cable movement. Replace
damaged cables as soon as
possible to prevent unsafe
conditions. psrkouhdscy ¼rkj¨a½ dh ckgjh gkůlx ds
{kfrxzLr g¨us ls ;g vanj ls tax idM+
ldrh gS v©j blls dscy d¨ Åij uhps
ewoesaV djus esa eqf'dy vk ldrh gSA
vlqjf{kr fLFkfr;¨a ¼gkykr¨aa½ ls cpus ds
fy, {kfrxzLr rkj¨a ¼dscy½ d¨ ftruh
tYnh g¨ lds cny nsaALubricate the cables and cable
ends with anticorrosive oil . If a
cable does not operate smoothly,
ask a YMI dealer to replace it.Recommended lubricant
çLrkfod yqczhdsVj %20W40 Type SG
6.29
PERIODIC MAINTENANCE AND MINOR REPAIR
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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
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fy, batu ds uhps ,d LVS.M yxk ysaaA
vxys QksdsZa ds fupys fljs dks idM+ dj
j[ksa vkSj mUgsa vkxs rFkk ihNs dh vksj
pykus dk iz;Ru djsaA ;fn fdlh rjg
dk Lora=k ¼Ýh½ Iys eglwl fd;k tk jgk
gks rks okbZñ,eñvkbZñ Mhyj ls LVs;¯jx dh
tk¡p djus vkSj ^,MtLV* djus dks dgsaA
;fn vkxs dk ifg;k gVk fn;k tk, rks
tk¡p djuk vklku gks tkrk gSA WARNINGSecurely support the Motorcycle
so there is no danger of it falling
over. psrkouheksVjlkbfdy dks lqjf{kr rjhds ls lgkjk
nsdj j[ksa rkfd blds iyV dj fxjus
dk [krjk u jgsA
Steering inspectionLVs;¯jx dh tk¡pPeriodically inspect the condition
of the steering. Worm out or loose
steering bearings may be
dangerous. Place a stand under
the engine to raise the front wheel
off the ground. Hold the lower end
of the front forks and try to move
them forward and backward. If any
free play can be felt, ask a YMI
dealer to inspect and adjust the
steering. Inspection is easier if the
front wheel removed.le;≤ ij LVs;¯jx dh fLFkfr dk
fujh{k.k djrs jgasA LVs;¯jx dh f?klh gqbZ
vFkok vxys ifg, dks t+ehu ls Åij mBkus ds
6.32
CAUTION :If any damage or unsmooth
movement is found with the front
fork, consult a YMI dealer. lko/kkuh %;fn vxys QksdZ dks dk;Z djus esa dksbZ
:dkoV vk jgh gS vFkok ;g dgha ls
{kfrxzLr gk x;k gS rks okbZñ,eñvkbZñ
Mhyj ls ijke'kZ ysaAPERIODIC MAINTENANCE AND MINOR REPAIRlkef;d j[kj[kko rFkk ekewyh ejEer
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