service YAMAHA YD110 2006 Workshop Manual

10-31
1. Check for any missing item(s), scratches in painted/plated part(s), saddle or other external
visual damages and take corrective action.
Check each of the following items individually and mention the corrective action (as per the
recommended specifications) in the boxes provided.2. Check for missing part(s), if any.A. FRAME
a. Brakes
Front :Free Play at Lever End (10 ~ 15 mm)
Rear :Free Play at Rear Brake (20 ~ 30 mm)
b. Clutch :Free Play at Lever End (10 ~ 15 mm)c. Throttle :Free Play at Throttle Grip (3 ~7 mm)d. Steering :Check for Free Movemente. Suspension
Front Fork : Check for any sticky movement
Rear Shock Abs : For Free Stroking
(To be filled in by the Dealer on receipt of the Motorcycle from YMI)
Odo-Meter
ReadingDate of
Inspection
Frame
No.Engine
No.Date of
SaleFound OK
Set RightReplaced
Cleaned
Lubricated
RCL
S
PRE-DELIVERY INSPECTION REPORT
No.
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PRE-DELIVERY INSPECTION REPORT
f. Wheels
Tyre :Tyre pressure Solo Double
(PSI)
Front 25 25
Rear 32 32
R i m : Runout - Radial - 1.5 mm (Max)
- Lateral - 1.5 mm (Max)
Spokes : No loosenes
g. Locks Operation : • Ignition
 Steering Fuel Tank Cap Side Cover (L.H.)
h. Fasteners Specified Torque
(Ft-Lb)
1. Front Wheel Axle Nuts25-40
2. Front Fork (Crown Handle & Inner Tube)13-202. Front Fork under Bracket Stem Nut18-223. Handle Bar Mounting Bolts13-204. Rear Shock Absorber Mounting Bolts22-355. Rear Swing Arm Pivot Shaft Nut32-526. Rear Wheel Axle/Sprocket. Shaft Nuts60-70
B. ENGINE
a. Engine Oil :  Oil Level (For checking - Refer Pg. 6-11)
 Check for any Leakages
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b. Spark Plug :Recommended No. (P-RA7HC - Champion)
Gap 0.9 ±0.2 mm
c. Valve Clearance : (Cold condition)
(If required)Inlet0.08 ~ 0.12 mm
Exhaust0.10 ~ 0.14 mm
(After matching of the mark on sprocket cam chain with mark on Cylinder
Head Casting and ensuring the Piston at TDC of compression stroke.)
d. Kick Operation :For free Movement
e. Carburetor :  Idle RPM
In warmed up condition
(1300~1500 RPM)
 Check for Overflow
f. Drive Chain :  Alignment
 Slackness (20 ~ 30 mm)
g. Fasteners Specified Torque
(Ft-Lb)
1. Cylinder Head Bolts14-17
2. Engine Mounting
a) Engine Mounting Front and Stay Front25-29
b) Stay Engine Front and Frame25-29c) Engine Mounting Rear and Frame25-29d) Engine Mounting Upper &
Stay Engine Upper25-29e) Stay Engine Upper and Frame25-29f) Engine Mounting Front Lower and Frame25-29
3. Front and Rear Silencer Mounting Nut9-124. Crown Handle Centre Bolt20-31
PRE-DELIVERY INSPECTION REPORT10-33
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PRE-DELIVERY INSPECTION REPORT
10-34
C. ELECTRICAL
a. Ignition Switch Operation
b. Left Hand Switch Operation & Pass Beam
 Horn
 Indicator Head Light
c. All Bulbs - Functioningd. Battery
 Electrolyte Level
 Specific Gravity Routing of Breather Pipe Fuse Routing of Positive Wire (Red) Below Breather Pipe
D. ROAD TEST
a. Starting
b. Gear Shifting Operationc. Clutch Operationd. Application of Brakes (Front and Rear)e. Speedo/ Odo Meter OperationEXPLAINED BY:SIGNATURE :NAME :
MAIN SELLING DLR'S STAMP, SIGN & CODE
CUSTOMER’S SIGNATURE:
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10-35
1. Operation of all the locks (Ignition, Steering, Fuel Tank Cap, Side Cover L.H.).
2. Fuel Cock Lever Operation and its reserve position; Fuel Tank Capacity including reserve.
3. Operation and function of Choke Lever.
4. Operation of Kick Lever.
5. Operation of Throttle.
6. Operation of Handle Bar Switches, their Functions and Pass Beam.
7. Disadvantages of riding on half Clutch (Never ride with clutch pressed).
8. Gear shifting pattern.
9. Tyre inflation pressure :Front - 25 Psi Rear - 32 Psi (Solo), 32 Psi (Double)
10. Never give sudden acceleration; always accelerate gradually
11. Simultaneous use of Front and Rear Brakes.
12. Never ride with your foot on Rear brake Pedal.
13. Whenever parking the Motorcycle on the Main Stand, ensure that the Fuel Cock Lever is in closed
position.
INSTALLATION
Procedures to be explained to the customer on delivery of the Motorcycle by the Dealer's
Representative.
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14. Location of Storage and Tool Kit compartments and their use.
15. Procedure of opening and closing of L. H. Side Panel.
16. Battery Maintenance : Checking of electrolyte level (
To add only distilled water if required &
to maintain its Specified Level
)
17. Correct Drive Chain Slackness (20 ~30 mm).
18. Correct type of Spark Plug and Spark Plug gap.
19. Engine Oil (in Gear Box), level checking and explaining the importance of
replacing the Engine
Oil after every 2000 KMS Always use YAMALUBE 4T OIL SG Grade.
20. TFF oil to be replaced after every 10000 Kms.
21. Running- In Period/ Preventive Maintenance Schedule Instructions
22. Information of emission and safety norms alongith Catcon & AIS.
23. Importance and schedule of Free Services
24. Warranty Terms and Conditions.
INSTALLATION
IMPORTANT CAUTION
EXPLAINED BY:SIGNATURE :NAME :
MAIN SELLING DLR'S STAMP, SIGN & CODE
CUSTOMER’S SIGNATURE:10-36
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DELIVERY CERTIFICATE
(To be filled in at the time of delivery of Motorcycle)CUSTOMER’S NAME
ADDRESS
No.Please Tick

against
appropriate Nos.
Engine No.
1. Colour : Date of sale :
9. Vehicle Owned : 2. Marital Status :
3. Age Group :
4. Family Income (PM) :
5. Education :
6. Occupation :
7. Mode of Purchase :
8. What Prompted you to :
Purchase Vehicle
Frame No. :
Dealer
SSO Sub DealerBranchConsultant
DDMMYYYY
1 Single
Married 2
1 18-24
2
25-29 3
30-34 4
35-39 >405
1 <5000
2
5000-10000
10000-15000 3
15000-20000 >20000
4
5
1 High School
Under Graduate
2
GraduatePost Graduate 3
4
Student 1
Business
2 ServiceAgriculture 34
Cash 1
Finance
2 Institutional3
News Paper/Magazine 1
Friends
Hoarding
2
3
Mechanics 4
5
TV 5
1
Black
2 White 3 Red 4BrownBlue / Dark Blue
6 Gold 7 Green
8 Silver / Gray
1 0 Other
9 Maroon
1
234 5Sold by :
First 2 Wheeler 1
Previous 2 wheeler
1
2
23 H H TVSBAJAJ LML
4
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10-38
CUSTOMER CERTIFICATION :
1. This is to certify that I have taken possession of CRUX motorcycle with the Tool Kit and “First Aid Kit”.
The Dealer Representative has explained and demonstrated the Important Functions and Company Policy
also.
SELLING DLR’S STAMP, SIGN & CODE
10. Which Motorcycle :
you considered
before buying Yamaha
12. Main uses of :
Commuting 1
2
Business 3
Leisure Ride 4
Shopping
Single Riding 1
2
Pillion Riding
13. Usage Pattern :%%
motorcycle 11. What influenced the :
Purchase
(Choose any Three)Styling 1
Coloring
2
3 Fit and Finish 4
Price 5
Fuel consumption
Engine performance 6
7 Engine CC size 8
Handling
9 Rider comfort
Riding Position 10
11 Passenger comfort 1 2
Availability 1 3
Physical size
Reliability / Durability 14 15
Resale value 1 6
Dealer
17
New Model
Reputation by friend/magazine 18
19
Brand Reputation 2 0
Other
DELIVERY CERTIFICATE
Model
2H H TVSBAJAJ LML
1342
CUSTOMER’S SIGNATURE:
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*
Service to be availed within specified kms from date of Purchase or 60 days after
previous service.
CUSTOMER'S NAME & ADDRESS
MOTORCYCLE IDENTIFICATION
DATE OF SALE OF MOTORCYCLE
30
90
180 SERVICE/WARRANTY RECORD
500-
700
2500-
2700
4500-
5000
S.
NO.SERVICED AT
KMS / ON DATESERVICING DLR'S
NAME & ADDRESS JOB DETAILS/
CARD NO
SELLING DLR'S
STAMP, SIGN & CODE
VALIDITY*
KMS / DAY DATE
FRAME NO. :
ENGINE NO. :1
2
3
No.
FREE SERVICE RECORD
SERVICE RECORD
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SERVICE RECORD
240
300
360 6500-
7000
8500-
9000
10500-
11000
S.
NO.SERVICED AT
KMS / ON DATESERVICING DLR'S
NAME & ADDRESS JOB DETAILS/
CARD NO VALIDITY*
KMS / DAY DATE4
5
6
12500-13000
14500 -15000
SERVICED AT
KMS / ON DATESERVICING DLR'S
NAME & ADDRESS JOB DETAILS/
CARD NO VALIDITY*
KMS DATE
*
Service to be availed within specified kms from date of Purchase or 60 days after
previous service.S.
NO.7
8
FREE SERVICE RECORD PAID SERVICE RECORD
10-40
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