Yamaha CRUX REV YD110-1 2016 User manual

DIC183
YD110-1
OWNER’S MANUAL
Read this manual carefully before operating this vehicle.
BY1-F8199-E0
[English (E)]

EAU46091
Readthis manual carefully before operatingthis vehicle. This manual shouldstay with this vehicle if it is sold.
UBY1E0E0.book Page 1 Monday, April 10, 2017 1:27 PM

Introduction
EAU10103
Welcome to the Yamaha world of motorcycling!
As the owner of the YD110-1, you are benefiting from Yamaha’s vast experience and newest technology regarding the de-
sign and manufacture of high-quality products, which have earned Yamaha a reputation for dependability.
Please take the time to read this manual thoroughly, so as to enjoy all advantages of your YD110-1. The Owner’s Manual
does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself
and others from trouble and injury.
In addition, the many tips given in this manual will help keep your motorcycle in the best possible condition. If you have any
further questions, do not hesitate to contact your Yamaha dealer.
The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most cur-
rent product information available at the time of printing, there may be minor discrepancies between your motorcycle and
this manual. If there is any question concerning this manual, please consult a Yamaha dealer.
WARNING
EWA10032
Please readthis manual carefully andcompletely before operatingthis motorcycle.
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Important manual information
EAU10134
Particularly important information is distinguished in this manual by the following notations:
*Product and specifications are subject to change without notice.
This is the safety alert symbol. It is usedto alert you to potential personal injury
hazards. Obey all safety messages that follow this symbol to avoidpossible injury
or death.
A WARNING indicates a hazardous situation which, if not avoided, couldresult in
death or serious injury.
A NOTICE indicates special precautions that must be taken to avoiddamage to the
vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
WARNING
NOTICE
TIP
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Important manual information
EAUE0011
YD110-1
OWNER’S MANUAL
©2016 by India Yamaha Motor Pvt. Ltd.
1st edition, August 2016
All rights reserved.
Any reprintingor unauthorizeduse
without the written permission of
India Yamaha Motor Pvt. Ltd.
is expressly prohibited.
Printedin India.
UBY1E0E0.book Page 2 Monday, April 10, 2017 1:27 PM

Table of contents
Location of important labels........... 1-1
Safety information............................ 2-1
Description ....................................... 3-1
Left view ......................................... 3-1
Right view....................................... 3-2
Controls and instruments ............... 3-3
Instrument andcontrol functions... 4-1
Main switch/steering lock............... 4-1
Indicator lights................................ 4-2
Speedometer unit........................... 4-2
Handlebar switches........................ 4-2
Clutch lever .................................... 4-3
Shift pedal ...................................... 4-3
Brake lever...................................... 4-4
Brake pedal .................................... 4-4
Fuel tank cap.................................. 4-4
Fuel................................................. 4-5
Fuel cock ........................................ 4-6
Starter (choke) lever ...................... 4-7
Kickstarter ...................................... 4-7
Seat ................................................ 4-8
Storage compartment .................... 4-9
Adjusting the shock absorber
assemblies .................................. 4-9
Carrier........................................... 4-10
Sidestand ..................................... 4-10
For your safety – pre-operation
checks ...............................................5-1
Operation andimportant riding
points .................................................6-1
Starting and warming up
a cold engine ...............................6-1
Starting a warm engine ...................6-2
Shifting ............................................6-2
Tips for reducing fuel
consumption................................6-3
Engine break-in...............................6-3
Parking ............................................6-4
Periodic maintenance and
adjustment ........................................7-1
Owner’s tool kit...............................7-1
Periodic maintenance chart for
the emission control system........7-2
General maintenance and
lubrication chart...........................7-3
Removing and installing panels ......7-7
Checking the spark plug.................7-9
Engine oil.......................................7-10
Servicing the air filter ....................7-12
Adjusting the carburetor ...............7-14
Adjusting the engine idling
speed.........................................7-15
Adjusting the throttle grip
free play .....................................7-15
Valve clearance.............................7-16
Tires .............................................. 7-16
Spoke wheels ............................... 7-18
Adjusting the clutch lever
free play..................................... 7-18
Adjusting the brake lever
free play..................................... 7-19
Adjusting the brake pedal
free play..................................... 7-20
Brake light switches ..................... 7-20
Checking the front and rear
brake shoes............................... 7-21
Drive chain slack........................... 7-21
Cleaning and lubricating the
drive chain................................. 7-23
Checking and lubricating the
cables........................................ 7-24
Checking and lubricating the
throttle grip and cable end........ 7-24
Checking and lubricating the
brake and shift pedals............... 7-25
Checking and lubricating the
brake and clutch levers ............. 7-25
Checking and lubricating the
centerstand and sidestand........ 7-26
Lubricating the swingarm
pivots......................................... 7-27
Checking the front fork................. 7-27
Checking the steering................... 7-28
Checking the wheel bearings ....... 7-28
Battery .......................................... 7-28
Replacing the fuse........................ 7-30
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Table of contents
Replacing a headlight bulb............7-31
Replacing the tail/brake
light bulb ....................................7-32
Replacing a turn signal
light bulb ....................................7-32
Front wheel....................................7-33
Rear wheel.....................................7-35
Troubleshooting ............................7-37
Troubleshooting chart ...................7-39
Motorcycle care andstorage..........8-1
Matte color caution .........................8-1
Care.................................................8-1
Storage............................................8-3
Specifications....................................9-1
Consumer information ...................10-1
Identification numbers...................10-1
Index ................................................11-1
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Location of important labels
1-1
1
EAU10385
Read and understand all of the labels on your vehicle. They contain important information for safe and proper operation of
your vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement
label is available from your Yamaha dealer.
123
ZAUE2543
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Location of important labels
1-2
1
1 2
ZAUE2544
3
MAX . LOAD 3kg
100kPa=1bar kPa, psi kPa, psi
175, 25 225, 33
175, 25 280, 41
B44-F1668-00
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2-1
2
Safety information
EAU1028B
Be a Responsible Owner
As the vehicle’s owner, you are re-
sponsible for the safe and proper oper-
ation of your motorcycle.
Motorcycles are single-track vehicles.
Their safe use and operation are de-
pendent upon the use of proper riding
techniques as well as the expertise of
the operator. Every operator should
know the following requirements be-
fore riding this motorcycle.
He or she should:
zObtain thorough instructions from
a competent source on all aspects
of motorcycle operation.
zObserve the warnings and mainte-
nance requirements in this Own-
er’s Manual.
zObtain qualified training in safe
and proper riding techniques.
zObtain professional technical ser-
vice as indicated in this Owner’s
Manual and/or when made neces-
sary by mechanical conditions.
zNever operate a motorcycle with-
out proper training or instruction.
Take a training course. Beginners
should receive training from a cer-
tified instructor. Contact an autho-
rized motorcycle dealer to find out
about the training courses nearest
you.
Safe Riding
Perform the pre-operation checks
each time you use the vehicle to make
sure it is in safe operating condition.
Failure to inspect or maintain the vehi-
cle properly increases the possibility of
an accident or equipment damage.
See page 5-1 for a list of pre-operation
checks.
zThis motorcycle is designed to
carry the operator and a passen-
ger.
zThe failure of motorists to detect
and recognize motorcycles in traf-
fic is the predominating cause of
automobile/motorcycle accidents.
Many accidents have been
caused by an automobile driver
who did not see the motorcycle.
Making yourself conspicuous ap-
pears to be very effective in reduc-
ing the chance of this type of
accident.
Therefore:
• Wear a brightly colored jacket.
• Use extra caution when you are
approaching and passing
through intersections, since in-
tersections are the most likely
places for motorcycle accidents
to occur.
• Ride where other motorists can
see you. Avoid riding in another
motorist’s blind spot.
• Never maintain a motorcycle
without proper knowledge.
Contact an authorized motorcy-
cle dealer to inform you on ba-
sic motorcycle maintenance.
Certain maintenance can only
be carried out by certified staff.
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Safety information
2-2
2
zMany accidents involve inexperi-
enced operators. In fact, many op-
erators who have been involved in
accidents do not even have a cur-
rent motorcycle license.
• Make sure that you are qualified
and that you only lend your mo-
torcycle to other qualified oper-
ators.
• Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
• We recommend that you prac-
tice riding your motorcycle
where there is no traffic until you
have become thoroughly famil-
iar with the motorcycle and all of
its controls.
zMany accidents have been
caused by error of the motorcycle
operator. A typical error made by
the operator is veering wide on a
turn due to excessive speed or un-
dercornering (insufficient lean an-
gle for the speed).
• Always obey the speed limit and
never travel faster than warrant-
ed by road and traffic condi-
tions.
• Always signal before turning or
changing lanes. Make sure that
other motorists can see you.
zThe posture of the operator and
passenger is important for proper
control.
• The operator should keep both
hands on the handlebar and
both feet on the operator foot-
rests during operation to main-
tain control of the motorcycle.
• The passenger should always
hold onto the operator, the seat
strap or grab bar, if equipped,
with both hands and keep both
feet on the passenger footrests.
Never carry a passenger unless
he or she can firmly place both
feet on the passenger footrests.
zNever ride under the influence of
alcohol or other drugs.
zThis motorcycle is designed for
on-road use only. It is not suitable
for off-road use.
Protective Apparel
The majority of fatalities from motorcy-
cle accidents are the result of head in-
juries. The use of a safety helmet is the
single most critical factor in the pre-
vention or reduction of head injuries.
zAlways wear an approved helmet.
zWear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.
zThe use of a jacket, heavy boots,
trousers, gloves, etc., is effective
in preventing or reducing abra-
sions or lacerations.
zNever wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.
zAlways wear protective clothing
that covers your legs, ankles, and
feet. The engine or exhaust sys-
tem become very hot during or af-
ter operation and can cause
burns.
zA passenger should also observe
the above precautions.
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Safety information
2-3
2
AvoidCarbon Monoxide Poisoning
All engine exhaust contains carbon
monoxide, a deadly gas. Breathing
carbon monoxide can cause head-
aches, dizziness, drowsiness, nausea,
confusion, and eventually death.
Carbon Monoxide is a colorless, odor-
less, tasteless gas which may be
present even if you do not see or smell
any engine exhaust. Deadly levels of
carbon monoxide can collect rapidly
and you can quickly be overcome and
unable to save yourself. Also, deadly
levels of carbon monoxide can linger
for hours or days in enclosed or poorly
ventilated areas. If you experience any
symptoms of carbon monoxide poi-
soning, leave the area immediately, get
fresh air, and SEEK MEDICAL TREAT-
MENT.
zDo not run engine indoors. Even if
you try to ventilate engine exhaust
with fans or open windows and
doors, carbon monoxide can rap-
idly reach dangerous levels.
zDo not run engine in poorly venti-
lated or partially enclosed areas
such as barns, garages, or car-
ports.
zDo not run engine outdoors where
engine exhaust can be drawn into
a building through openings such
as windows and doors.
Loading
Adding accessories or cargo to your
motorcycle can adversely affect stabil-
ity and handling if the weight distribu-
tion of the motorcycle is changed. To
avoid the possibility of an accident, use
extreme caution when adding cargo or
accessories to your motorcycle. Use
extra care when riding a motorcycle
that has added cargo or accessories.
Here, along with the information about
accessories below, are some general
guidelines to follow if loading cargo to
your motorcycle:
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit.
Operation of an overloadedvehicle
couldcause an accident.
When loading within this weight limit,
keep the following in mind:
zCargo and accessory weight
should be kept as low and close to
the motorcycle as possible. Se-
curely pack your heaviest items as
close to the center of the vehicle
as possible and make sure to dis-
tribute the weight as evenly as
possible on both sides of the mo-
torcycle to minimize imbalance or
instability.
zShifting weights can create a sud-
den imbalance. Make sure that
accessories and cargo are se-
curely attached to the motorcycle
before riding. Check accessory
mounts and cargo restraints fre-
quently.
• Properly adjust the suspension
for your load (suspension-ad-
justable models only), and
check the condition and pres-
sure of your tires.
• Never attach any large or heavy
items to the handlebar, front
fork, or front fender. These
items, including such cargo as
sleeping bags, duffel bags, or
Maximum load:
155 kg (342 lb)
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Safety information
2-4
2
tents, can create unstable han-
dling or a slow steering re-
sponse.
zThis vehicle is not designedto
pull a trailer or to be attachedto
a sidecar.
Genuine Yamaha Accessories
Choosing accessories for your vehicle
is an important decision. Genuine
Yamaha accessories, which are avail-
able only from a Yamaha dealer, have
been designed, tested, and approved
by Yamaha for use on your vehicle.
Many companies with no connection
to Yamaha manufacture parts and ac-
cessories or offer other modifications
for Yamaha vehicles. Yamaha is not in
a position to test the products that
these aftermarket companies produce.
Therefore, Yamaha can neither en-
dorse nor recommend the use of ac-
cessories not sold by Yamaha or
modifications not specifically recom-
mended by Yamaha, even if sold and
installed by a Yamaha dealer.
Aftermarket Parts, Accessories, and
Modifications
While you may find aftermarket prod-
ucts similar in design and quality to
genuine Yamaha accessories, recog-
nize that some aftermarket accesso-
ries or modifications are not suitable
because of potential safety hazards to
you or others. Installing aftermarket
products or having other modifications
performed to your vehicle that change
any of the vehicle’s design or operation
characteristics can put you and others
at greater risk of serious injury or
death. You are responsible for injuries
related to changes in the vehicle.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.
zNever install accessories or carry
cargo that would impair the per-
formance of your motorcycle.
Carefully inspect the accessory
before using it to make sure that it
does not in any way reduce
ground clearance or cornering
clearance, limit suspension travel,
steering travel or control opera-
tion, or obscure lights or reflec-
tors.
• Accessories fitted to the han-
dlebar or the front fork area can
create instability due to improp-
er weight distribution or aerody-
namic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.
• Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerody-
namic effects. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become
unstable in cross winds. These
accessories may also cause in-
stability when passing or being
passed by large vehicles.
• Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the
freedom of movement of the
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Safety information
2-5
2
operator and may limit control
ability, therefore, such accesso-
ries are not recommended.
zUse caution when adding electri-
cal accessories. If electrical ac-
cessories exceed the capacity of
the motorcycle’s electrical sys-
tem, an electric failure could re-
sult, which could cause a
dangerous loss of lights or engine
power.
Aftermarket Tires andRims
The tires and rims that came with your
motorcycle were designed to match
the performance capabilities and to
provide the best combination of han-
dling, braking, and comfort. Other
tires, rims, sizes, and combinations
may not be appropriate. Refer to page
7-16 for tire specifications and more in-
formation on replacing your tires.
Transportingthe Motorcycle
Be sure to observe following instruc-
tions before transporting the motorcy-
cle in another vehicle.
zRemove all loose items from the
motorcycle.
zCheck that the fuel cock (if
equipped) is in the “OFF” position
and that there are no fuel leaks.
zPoint the front wheel straight
ahead on the trailer or in the truck
bed, and choke it in a rail to pre-
vent movement.
zShift the transmission in gear (for
models with a manual transmis-
sion).
zSecure the motorcycle with tie-
downs or suitable straps that are
attached to solid parts of the mo-
torcycle, such as the frame or up-
per front fork triple clamp (and not,
for example, to rubber-mounted
handlebars or turn signals, or
parts that could break). Choose
the location for the straps carefully
so the straps will not rub against
painted surfaces during transport.
zThe suspension should be com-
pressed somewhat by the tie-
downs, if possible, so that the mo-
torcycle will not bounce exces-
sively during transport.
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Description
3-1
3
EAU10411
Left view
ZAUE2545
12 345
876
1. Fuel cock (page 4-6)
2. Starter (choke) lever (page 4-7)
3. Battery (page 7-28)
4. Fuse (page 7-30)
5. Seat (page 4-8)
6. Owner’s tool kit (page 7-1)
7. Panel lock
8. Shift pedal (page 4-3)
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Description
3-2
3
EAU10421
Right view
ZAUE2546
123
4
5
6
1. Rear shock absorber (page 4-9)
2. Air filter (page 7-12)
3. Kickstarter (page 4-7)
4. Engine oil filler cap (page 7-10)
5. Brake pedal (page 4-4)
6. Rear brake light switch (page 7-20)
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Description
3-3
3
EAU10431
Controls andinstruments
1. Clutch lever (page 4-3)
2. Left handlebar switches (page 4-2)
3. Speedometer (page 4-2)
4. Main switch/steering lock (page 4-1)
5. Fuel tank cap (page 4-4)
6. Throttle grip (page 7-15)
7. Brake lever (page 4-4)
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Instrument andcontrol functions
4-1
4
EAU10462
Main switch/steeringlock
The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering. The various
positions are described below.
EAUE0021
ON
All electrical systems are supplied with
power, the meter lighting comes on
and the engine can be started. The key
cannot be removed.
EAU10662
OFF
All electrical systems are off. The key
can be removed.
WARNING
EWA10062
Never turn the key to “OFF” or
“LOCK” while the vehicle is moving.
Otherwise the electrical systems will
be switchedoff, which may result in
loss of control or an accident.
EAU10696
LOCK
The steering is locked and all electrical
systems are off. The key can be re-
moved.
To lock the steering
1. Turn the handlebars all the way to
the left or right.
2. With the key in the “OFF” position,
push the key in and turn it to
“LOCK”.
3. Remove the key.
TIP
If the steering will not lock, try turning
the handlebars back to the right or left
slightly.
To unlock the steering
From the “LOCK” position, push the
key and turn it to “OFF”.
ZAUE2548
OFF(push)
LOCK
OFF
LOCK(push)
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Instrument andcontrol functions
4-2
4
EAU10982
Indicator lights
EAU11022
Turn signal indicator light “ ”
This indicator light flashes when a turn
signal light is flashing.
EAU11061
Neutral indicator light “ ”
This indicator light comes on when the
transmission is in the neutral position.
EAU11081
High beam indicator light “ ”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAUT1822
Speedometer unit
The speedometer unit is equipped with
a speedometer and an odometer. The
speedometer shows the riding speed.
The odometer shows the total distance
traveled.
EAU1234K
Handlebar switches
Left
EAU12401
Dimmer switch “ / ”
Set this switch to “ ” for the high
beam and to “ ” for the low beam.
EAU12461
Turn signal switch “ / ”
To signal a right-hand turn, push this
switch to “ ”. To signal a left-hand
turn, push this switch to “ ”. When
released, the switch returns to the cen-
1. Neutral indicator light “ ”
2. Turn signal indicator light “ ”
3. High beam indicator light “ ”
ZAUE2551
60
20
80
100
120
140
km/h
km
40
0
000031
123
1. Speedometer
2. Odometer
ZAUE2552
60
20
80
100
120
140
km/h
km
40
0
000031
12
1. Light switch “ / ”
2. Dimmer switch “ / ”
3. Turn signal switch “ / ”
4. Horn switch “ ”
1
2
3
4
ZAUE2553
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Instrument andcontrol functions
4-3
4
ter position. To cancel the turn signal
lights, push the switch in after it has re-
turned to the center position.
EAU12501
Horn switch “ ”
Press this switch to sound the horn.
EAUE3090
Light switch “ / ”
Set the switch to “ ” to turn on the
headlight and taillight. Set the switch
to “ ” to turn off all the lights.
EAU12852
Clutch lever
The clutch lever is located on the left
side of the handlebar. To disengage
the clutch, pull the lever toward the
handlebar grip. To engage the clutch,
release the lever. The lever should be
pulled rapidly and released slowly for
smooth clutch operation.
EAU12872
Shift pedal
The shift pedal is located on the left
side of the motorcycle and is used in
combination with the clutch lever when
shifting the gears of the 4-speed con-
stant-mesh transmission equipped on
this motorcycle.
1. Clutch lever
ZAUE2554
1
1. Shift pedal
1
ZAUE2555
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