service schedule YAMAHA YD110 2006 Owners Manual

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
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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 YMIS DEALER.
psrkouh
;fn vki e¨Vj&lkbZfdy dh *l£ol^ djus
ds rjhd¨ ls ifjfpr ugh gS r¨ ;g dk;Z
okbZñ,eñvkbZñ,lñ Mhyj d¨ gh djus nsaA
1. Tool kit
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Tool kit
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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
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1
PG1_55.pmd9/24/2005, 7:53 AM 37

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.pmd9/24/2005, 7:53 AM 39

6.4
1 4 . WHEEL BEARING
1 5 . STEERING BEARING
1 6 . FRONT FORKS
17.
1 8 . DRIVE CHAIN
19.
20.
21. 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
CENTER 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 YMIS 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.pmd9/24/2005, 7:53 AM 40

If the owner of the Vehicle does not comply with above legal requirement, the Vehicle may be
deregistered or penalty may be imposed by the authorities.;fn okgu&ekfyd mij¨Dr dkuwuh ek¡x d¨ Lohdkj ugh djrk gS r¨ okgu dk iathdj.k jí g¨ ldrk gS vFkok
ml ij tqekZuk yxk;k tk ldrk gSAThe following points may be checked and suitable corrective action if required, to ensure emission levels to remain
within acceptable limits.,eh'ku Lrjksa dks Lohdkjh; lhekvksa ds varxZr cuk;s j[kus ds fy, fuEufyf[kr rF;ksa dj tk¡p djsa o vko';d gks rks la'kks/ku
ds yh, dk;Zokgh djsaA1. Clean and oil Air Filter Element periodically and replace it when required.
le;≤ ij ,;j fQYVj ds ,syhesaV d¨ lkQ djsa v©j blesa rsy Mkyrs jgsa rFkk tc vko';drk iMs+ r¨ bls cny nsaA
2. Clean, inspect and adjust spark Plug Gap periodically.
le;≤ ij LikdZ Iyx dh tk¡p djsa] bls lkQ djsa v©j blds xSi ¼varj½ d¨ ,MtLV djsaA
3. Use only recommended Spark Plug. Replace it as per recommendations.
dsoy çLrkfor LikdZ Iyx dk gh ç;¨x djsaA çLrkfod ekin.M¨ ds vuq:i gh u;k Iyx yxk;saA
4. Use only recommended grade (SG) of genuine engine oil of superior quality.
dsoy mPp DokfyVh dk çLrkfor xzsM ¼
SG
½ dk vlyh batu rsy gh ç;¨x djsaA
5. Get your Vehicle serviced and tuned periodically as per recommended schedule.
çLrkfor f'kM~;wy ds eqrkfcd le;≤ ij vius okgu dh l£ol v©j V~;w¯ux djkrs jgsaA
6. Use unadulterated Petrol.
feykoV jfgr iSVª¨y dk ç;¨x djsaaA SAFETY NORMS
9.3
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pg97_103.pmd9/24/2005, 7:54 AM 97

WARRANTY
9.5
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Yamaha Motor India Sales Private Limited (hereinafter referred to as “YAMAHA”)
thank you for having purchased this YAMAHA Motorcycle. In the unlikely event of
your YAMAHA Motorcycle requiring warranty service please contact the nearest
authorized dealer. We advise that you read instruction manual carefully before
you get in touch with our Authorized Dealer to avoid any inconvenience.;kekgk eksVj bafM;k lsYl izkbZosV fyfefVM ¼blds ckn ß;kekgk fy[ksaxsa½ ;kekgk dh eksVjlkbZfdy
[kjhnus ij vkidks /kU;okn djrh gSA fdlh Hkh dfBu ifjfLFkfr;ksa esa vxj vkidks ;kekgk dh okjaVh
lsok;sa izkIr djuh gSa rks vius ut+nhd ds vf/kÑr Mhyj ls laidZ djsaA fdlh Hkh izdkj dh vlqfo/kk ls
cpus ds fy, vf/kÑr Mhyj ls laidZ djus ls iwoZ vki bl funsZ"k iqfLrdk dks Hkyh Hkkafr i<+ ysaAYAMAHA will replace or repair at its Authorised Dealership free of charge, those
parts which may be found on examination to have manufacturing defect, within 2
years from the date of sale of Motorcycle or first 30,000 kilometres of its operation,
whichever occurs first, to the purchaser.eksVjlkbZfdy dh foØ; frfFk ds nks lky vFkok
30000
fdyksehVj tks Hkh igys laiw.kZ gks tk;s ds
varxZr ;fn fdlh ikVZ esa fuekZ.kk/khu [kjkch ¼eSU;qQSDpfjax [kjkch½ ik;h tkrk gS rks ;kekgk vius xzkgd
dks ml ikVZ dks vius vf/kÑr Mhyjf'ki }kjk eq¶r cnysxh ;k Bhd djok dj nsxhA
YAMAHA warrants the products to be free from manufacturing defects for a period
of two (2) years from the date of sale of the Motorcycle or first 30,000 kilometres
of its operation, whichever occurs first. If during this period of warranty the
Motorcycle proves to be defective due to material or workmanship, YAMAHA through
its Authorised Dealers will repair the Motorcycle without charging the labour or
parts value as per the terms and conditions mentioned below:
VALIDITY OF WARRANTY
This warranty coverage on the Motorcycle shall be valid only if the
customer avails all Free and Paid Services from YAMAHA’S Authorised
Dealer as per Recommended Service Schedule, explained on page
10-39 to 10-42 of this Owner ’s Manual and only YAMAHA genuine
Spare parts must be used.
The customer shall ensure that each service is availed within 60 days
from the date of previous service or as per recommended service
schedule which ever is earlier.
pg97_103.pmd9/24/2005, 8:39 AM 99

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
such use prematurely affects the performance and reliability of the motorcycle.
eksVjlkbZfdy ds ikV~Zl ftudk nq:i;ksx fd;k x;k gks] nq?kZVuk ls [kjkc gq, gks ;k ykijokgh&NsM+ NkM+ dh xbZ gks vFkok ftUgs nwljs
ikVZ~l rFkk midj.kks ds lkFk tksM+ dj ç;ksx fd;k x;k gks ftUgsa ;kekgk }kjk çLrkfor vFkok fu£er ugh fd;k x;k gks] bl rjg ls bu
ikVZl dk vlkef;d nqji;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 ikVZ~l tks fd v©|ksfxd çnw
"k.k ds dkj.k gksus okys 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 affects its performance and reliability.
eksVjlkbZfdy ds os ikVZ~l ftUgs vuf/kÑr :i ls ifjo£rr fd;k x;k gks] lq/kkjk x;k gks vFkok cnyk x;k gks v©j tks ;kekgk ds fu.kZ;
ds varxZr eksVjlkbZfdy dh dk;Zdq
'kyrk rFkk fo
'oluh;rk ij çHkko Mkyrs gksaA
7. Motorcycle that has not been got serviced by YAMAHA’S Authorised Dealers as per the service schedule
described in this Owner’s Manual vide the 6 Free Services, 2 Bonus Services and 7 Paid Service Coupons
(attached in this book) or which has not been operated or maintained in accordance with the instructions
mentioned in this Manual (especially during Running in Period).
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6 Ýh l£ol dwiuksa]
2 cksul Ýh l£ol dwiuks v©j
7 Hkqxrku l£ol dwiuks ¼tks bl iqfLrdk ds lkFk layXu gS½
vFkok bl eSuqvy ¼fo'ks"k :i ls Þj¯ux&buß ihfj;M+ esa½ esa fn, lfoZl ds fu/kkZfjr le; ds vuqlkj lkekU; ,oa ejEer ds dk;Z ds fy,
;fn eksVjlkbZfdy dks ;kekgk ds vf/kÑr Mhyj ls *l£ol^ ugh djk;k x;k gksA
WARRANTY
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pg97_103.pmd9/24/2005, 8:39 AM 102

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
SERVICE2.pmd9/24/2005, 8:01 AM 6

SERVICE RECORD
10-42
(i) Cost of Oil for the Free Services will be Chargeable at actuals and to be borne by
the Customer.
(ii) Please ensure that the Servicing Dealer Column is duly Stamped & signed by the
Servicing Dealer.
(iii)For the validity of "Warranty" benefits, It is mandatory that all Services, Bonus
Free Services and Paid Services are availed by the customer as per the
recommended Schedule, as given in the Owner's Manual.
(iv)Please ensure that each service is availed within 60 days from date of previous
service or as per the recomended service schedule whichever is earlier.
I
M
P
O
R
T
A
N
T
SERVICE2.pmd9/24/2005, 8:01 AM 12

3.6 KEEP OUR ENVIRONMENT CLEAN.
Please follow simple steps
DO’S (
)


1
Always use genuine ‘spare parts’ purchased from
YMIS
Authorised Dealers.


2
Always use only genuine oils
 4T - 20W/40 SG grade - YAMALUBE 4T


3 Always keep your engine well tuned. Save environment and also improve Fuel Efficiency


4  ALWAYS GET YOUR MOTORCYCLE REPAIRED AND MAINTAINED ONLY AT YMIS AUTHORISED
DEALER.
 YMIS serves you through a large network of Authorised Dealers.


5.Check the Following at every scheduled service:-
a) Spark Plug : Check/Reset Gap/Replace as per the recommendations
in this Owner’s Manual (page no 6-7)
b) Carburetor : Cleaning/Adjustment Every 4500 kmsc) Air Filter : Clean every 2000 kms as per the environment conditions.
d) Piston/Rings/Cylinder : Check / Clean / Replace if necessary
e) Exhaust System : Check / Replace if necessary
f) Valve Timing : Check / Adjust every 4500 kms
g) Compression pressure : Check / Diagnose.
DO’S AND DON’TS FOR THE MOTORCYCLE
2
greenbook.pmd9/24/2005, 8:00 AM 4