service YAMAHA YD110 2005 Owners Manual

2
4
MONT
HS
/
30,
000
KMS
(8 FREE SERVICES)
OWNER'S MANUAL OWNER'S MANUAL

TABLE OF CONTENTSfo"k; & lwph
Troubleshooting.............................................6-45leL;k lek/kku ¼Vªcy'kw¯Vx½Troubleshooting chart............................... ..6-46rhoz leL;k lek/kku dk pkVZ
7
CLEANING AND STORAGE.......................... 7-1lQkbZ rFkk HkaMkj.kA. Cleaning.................................................... 7-1¼,½ lQkbZB. Storage ..................................................... 7-3¼ch½ HkaMkj.k ¼LVksjst+½

8
SPECIFICATIONS ......................................... 8-1fooj.k
9 ............................................................
9 ...................................................................
CUSTOMER INFORMATION................................. 9-1
xzkgd lwpukKey identification number.............................. 9-1pkWch dk igpku uañFrame serial number..................................... 9-1Ýse dk lhfj;y uacjEngine serial number..................................... 9-1batu dk lhfj;y uacjFacts related with Exhaust emission control . 9-2çokg&fu;a=k.k ls lacf/kr rF;Safety norms ................................................. 9-3
Warranty 9 - 5okjaVh
10
DETACHMENTSvyxko ¼fMVspesaV½Fifteenth paid service coupon...............10-1iaægok¡ Hkqxrku lfoZl dwiuFourteenth paid service coupon............10-3p©ngok¡ Hkqxrku lfoZl dwiuThirteenth pad service coupon..............10-5rsjgok¡ Hkqxrku lfoZl dwiuTwelveth paid service coupon...............10-7ckjgok¡ Hkqxrku lfoZl dwiuEleventh paid service coupon...............10-9X;kjgok¡ Hkqxrku lfoZl dwiuTenth bonus free service coupon..........10-11nlok¡ c¨ul&Ýh lfoZl dwiuNinth bonus free service coupon...........10-13uok¡ c¨ul&Ýh lfoZl dwiuEighth paid service coupon...................10-15vkBok¡ Hkqxrku lfoZl dwiuSeventh paid service coupon................10-17lkrok¡ Hkqxrku lfoZl dwiuSixth free service coupon......................10-19NBk eq¶r&lfoZl dwiu
PG1_55.pmd2/25/2005, 10:04 AM 8

Fifth free service coupon.......................10-21ik¡pok¡ eq¶r&lfoZl dwiuFourth free service coupon....................10-23p©Fkk eq¶r&lfoZl dwiuThird free service coupon.......................10-25rhljk eq¶r&lfoZl dwiuSecond free service coupon...................10-27nwljk eq¶r&lfoZl dwiuFirst free service Coupon.......................10-29igyk eq¶r&lfoZl dwiuPre-delivery inspection..........................10-31fMyojh iwoZ&fufj{k.kInstallation.............................................10-35baLVkys'kuDelivery certificate.................................10-37fMyojh lfVZfQdsV~l ¼çek.k&i=k½Service record........................................10-39lfoZl ¼lsok½ fjdkMZ
GREEN BOOKgjh&iqfLrdkAddress of Area Officeseq[; dk;Zky;kssa dk irk
fo"k; & lwph
TABLE OF CONTENTS
ALWAYS KEEP THE ENVIRONMENT CLEAN
okrkoj.k d¨ lnk LoPN j[¨A
PG1_55.pmd2/25/2005, 10:04 AM 9

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

Periodic inspection, adjustment and
lubrication will keep your Motorcycle
in the safest and most efficient
condition possible. Safety is an
obligation of the Motorcycle owner.
The maintenance and lubrication
schedule chart should be considered
strictly as a guide to general
maintenance and lubrication
intervals. YOU MUST TAKE
INTO CONSIDERATION THAT
WEATHER, TERRAIN,
GEOGRAPHICAL
LOCATIONS, AND A VARIETY
OF INDIVIDUAL USES ALL
TEND TO DEMAND THAT
EACH OWNER ALTER THIS
TIME SCHEDULE TO
SHORTER INTERVALS TO
MATCH THE ENVIRONMENT.
The most important points of
Motorcycle inspection, adjustment,
and lubrication are explained in the
following pages.le;≤ ij dh xbZ tk¡p] ,WMtLVesaV
¼rkyesay½] rFkk Y;wczhsdss'ku] vkidh
e¨VjlkbZfdy d¨ vfr lqjf{kr rFkk tgk¡
rd laHko g¨] l{ke voLFkk esa j[ksaxhAe¨VjlkbZfdy ds ekfyd dh viuh
ftEesnkjh gSA j[kj[kko] Y;wczhds'ku lwph
pkVZ d¨ lkekU; esaVhusal rFkk Y;wczhds'ku
O;oLFkk ds fy, xaHkhjrk ls ,d xkbM dh
rjg le>uk pkfg,A vkid¨ ;g ckrsa
/;ku esa j[kuh pkfg, fd e©le] Hkwfe]
Hk©x¨fyd LFkku rFkk O;fDr }kjk fHké rjhds
ls ç;¨x vkfn lHkh ;g ek¡x djrs gS fd
gj ,d e¨Vj&lkbZfdy ekfyd ekg©y d¨
,d tSlk cukus ds fy, le;&lwph d¨
Fk¨M+s ls Fk¨M+s le; ds varj ¼varjky½ esa
ifjo£rr djrk gSA e¨Vj&lkbZfdy dh
tk¡p] ,WMtLVesaV] rFkk Y;wczhsdss'ku ds vfr
egÙoiw.kZ dk;kZ±s dk o.kZu vxys i "B¨a ij
fd;k x;k gSA

WARNING
If you are not familiar with
Motorcycle service, this work
should be done by a YMI DEALER.
psrkouh
;fn vki e¨Vj&lkbZfdy dh *l£ol^ djus
ds rjhd¨ ls ifjfpr ugh gS r¨ ;g dk;Z
okbZñ,eñvkbZñ Mhyj d¨ gh djus nsaA
1. Tool kit
Vwy&fdV
Tool kit
Vwy&fdV
The service information included in
this manual is intended to provide
you, the owner, with the necessary
information for completing some of
your own preventive maintenance
and minor repairs. The tools
provided in the owner’s tool kit are to
assist you in the performance of
periodic maintenance. However,
some other tools such as a torque
wrench are also necessary to
perform the maintenance correctly.bl xzkgd&iqfLrdk ds lkFk l£ol dh
lwpuk g¨us dk vFkZ gS& vkid¨
e¨VjlkbZfdy ds ekfyd d¨ t:jh lwpuk
miyC/k djkuk rkfd ekewyh fjis;j rFkk
dqN fçosafVo esaVhusal ¼çfrca/kd j[kj[kko½
6.1
PERIODIC MAINTENANCE AND MINOR REPAIR
lkef;d j[kj[kko rFkk ekewyh ejEer
1
PG1_55.pmd2/25/2005, 10:04 AM 37

ds dk;Z d¨ iwjk fd;k tk ldsA
e¨Vj&lkbZfdy ekfyd dh Vwy&fdV esa
çnku fd, x, v©t+kj vkid¨ le;cð
j[kj[kko d¨ vatke nsus esa lgk;rk djrs
gSA tcfd esaVhusal ¼j[kj[kko½ d¨ lgh
rjhds ls iwjk djus ds fy, ÞVkdZ&jsapß
tSls nwljs v©t+kj g¨uk Hkh t#jh gSA
NOTE :If you do not have necessary tools
required during a service operation,
take your Motorcycle to a YMI dealer
for service.u¨V %;fn l£ol&dk;Z ds fy, vkids ikl
vko';d v©t+kj ¼;a=k½ ugh gS r¨ vki
e¨Vj&lkbZfdy d¨ okbZñ,eñvkbZñ Mhyj
ds ikl ys tk,¡A
KEEP YOUR MOTORCYCLE TUNED IN PERFECT CONDITION
viuh e¨Vj&lkbZfdy d¨ gj rjg ls vPNh gkyr esa j[ksaA
WARNINGModifications to this Motorcycle not
approved by YMI may cause loss of
performance, and render it unsafe
for use. Consult a YMI dealer before
attempting any changes. psrkouhokbZñ,eñvkbZñ Mhyj dh LohÑfr ds fcuk
e¨Vj&lkbZfdy esa fdlh rjg dk cnyko
djuk dk;Zdq'kyrk ds fy, gkfudkjd g¨
ldrk gSA fdlh Hkh rjg ds ifjorZu
djus ls igys okbZñ,eñvkbZñ Mhyj ls
ijke'kZ ysaA
6.2
PERIODIC MAINTENANCE AND MINOR REPAIRlkef;d j[kj[kko rFkk ekewyh ejEer
PG1_55.pmd2/25/2005, 10:04 AM 38

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


,;j&fQYVj dks yxk, fcuk batu
dHkh Hkh ugh pykuk pkfg,A blds
dkj.k fiLVu v©j flysaMj dk f?klko
vf/kd gks ldrk gSA

/kwy feêh ls Hkjs xans Þ,yhesaV ,;j
Dyhujß ls rsy dh [kir cgqr c<+
tkrh gS rFkk 'kfDr ¼ikWoj½ dh {kfr
gksrh gSA

,yhesaV ,;j Dyhuj dks çR;sd
2000
fdñehñ ds ckn lkQ djsaA

;fn eksVjlkbZfdy dks cgqr /kwy&feêh
;qDr fLFkfr;ksa esa pyk;k tkrk gS rks
,yhesaV ,;j Dyhuj dh lQkbZ rFkk
Y;qczhdsa'ku T;knk 'kh?kzrk ls gksuk
pkfg, ¼çR;sd
1000
fdñehñ ij½A
Carburetor adjustmentdkc¨ZjsVj dks lSV djukThe carburetor is a vital part of the
engine and requires very
sophisticated adjustments. Most
adjustments should be left to a YMI
dealer who has the professional
knowledge and experience to do so.
However, the following may be
serviced by the owner as part of
routine maintenance.
dkc¨ZjsVj batu dk ,d egÙoiw.kZ Hkkx
g¨rk gS v©j bldh ,MtLVesaV feys&tqys
rjhd¨ ls djuh iM+rh gSA cgqr lh
,MtLVesaVl ¼rky&esy½ d¨ okbZñ,eñvkbZñ
Mhyj ds Åij N¨M+ nsuk pkfg,] ftUgs
bl rjg dk dke djus dk i;kZIr vuqHko
rFkk O;olkf;d Kku gSA tcfd
fuEufyf[kr dks e¨VjlkbZfdy dk ekfyd
vke ejEer dh rjg dj ldrk gSSA
6.16
CAUTION :
The carburetor is set at the YMI
factory after many tests. If the
settings are changed, poor engine
performance and damage may
result. lko/kkuh
:
vusd¨ VsLV djus ds ckn dkc¨ZjsVj d¨
dkj[kkus esa O;ofLFkr fd;k tkrk gSA
;fn bldh *lS¯Vx^ esa ifjorZu yk;k
tkrk gS r¨ ;g batu dh rqPN dk;Z{kerk
v©j {kfr dk dkj.k cu ldrh gSA
Idle speed adjustmentvkn'kZ xfr dh ,MtLVesaVNOTE :
A diagnostic tachometer must be
used for this procedure.u¨V
:
bl çfd;k ds fy, ,d *Mk;xu¨fLVd
VSd¨ehVj^ dk ç;¨x fd;k tkuk pkfg,A1. Attach the tachometer. Start the
engine and warm it up for a few
minutes at approximately 1,000
to 1,500 r/min. Occasionally rev
the engine to 4,000 to 5,000 r/
min. The engine is warm when it
quickly responds to the throttle.
VSd¨ehVj yxk;sa] batu d¨ pkyw djsa
v©j dqN feuVks ds fy, xeZ djsa rkfd
bldh xfr
1,000
ls
1,500
pDdj
çfr feuV rd igq¡p tk;saA dHkh&dHkh
bls
4,000
ls
5,000
pDdj çfr
feuV ij Hkh ysa tk;saA tc batu
'kh?kzrk ls FkzkWVy ds vuqdwy dk;Z
djrk gS r¨ ;g xeZ g¨rk gSA
PERIODIC MAINTENANCE AND MINOR REPAIRlkef;d j[kj[kko rFkk ekewyh ejEer
PG1_55.pmd2/25/2005, 10:04 AM 52

1. Tread depth
VsªªM MsIFk
2. Side wall
lkbM okWy
Tyres
Vk;j
To ensure maximum performance, long
service and safe operation, note the
following:vR;f/kd dk;Z{kerk] nh?kZ l£ol v©j lqjf{kr
dk;Z ds fy, fuEufyf[kr ij /;ku nsa %1. Tyre air pressure
Always check and correct the tyre
pressure before operating the
Motorcycle.
Vk;j esa gok dk ncko
e¨Vj&lkbZfdy pykus ls igys ges'kk Vk;j
esa gok ds ncko d¨ tk¡p ys v©j bls
O;ofLFkr djasA
1. Free play
Ýh Iys
2. Locknut
ykWd uV
3. Adjusting nut
,Mt¯LVx uV
1. Loosen the locknut.
ykWd uV dks 2. Turn the adjusting nut in direction
ç to increase free play and in
direction è to decrease free play.
Ýh Iys d¨ c<+kus ds fy, ,Mt¯LVx uV
d¨ , dh fn'kk esa ?kqek,¡ rFkk Ýh Iys d¨
de djus ds fy, bls ch fn'kk esa ?kqek,¡A
3. Tighten the locknut.
ykWd uV d¨ dl nsaA
Valve clearance adjustment:okYo dh Dyh;jsal dk rkyesy %The correct valve clearance changes
with use, resulting in improper fuel/
air supply or engine noise. To prevent
this, the valve clearance must be
adjusted regularly. This adjustment
however, should be left to a YMI
dealer.mfpr okYo Dyh;jsal t¨ fd batu ds ç;¨x
ds lkFk cnyrk jgrk gS] vuqfprb±/ku@gok
dh lIykbZ vFkok batu esa 'k¨j dk dkj.k curk
gSA blds cpus ds fy, okYo ds Dyh;jsal d¨
yxkrkj O;ofLFkr djrs jguk pkfg,A oSls bl
rjg ds ,MtLVesaV ¼ rkyesy½ d¨ okbZñ,eñvkbZñ
Mhyj }kjk gh djok;k tkuk pkfg,A
KEEP RECOMMENDED TYRE PRESSURE IN BOTH THE TYRES
n¨u¨ Vk;j¨a esa vuqe¨fnr ok;q&ncko gh j[ksaA
6.18
PERIODIC MAINTENANCE AND MINOR REPAIRlkef;d j[kj[kko rFkk ekewyh ejEer
1
2
3ç è
PG1_55.pmd2/25/2005, 10:04 AM 54