Service / Technical
Single direction movement of the piston, When the piston moves up from BDC to TDC or TDC to BDC, the single direction movement of the Piston in one direction is called ‘Stroke’.
The bore is inside Diameter of Cylinder
Revolution per minutes
Effect of bore and stroke on engine performance : Engines of the same displacement vary in character depending on “bore and stroke”. Short stroke engines : Stroke is smaller than bore diameter. Square engines : Stroke and bore diameter are even. Long stroke engines : Str oke is larger than bore diameter.
Compared with a long stroke engine, the square or short stroke type is easy to raise the engine speed and develop high power. If the engine speeds are the same, the piston speed is slower and friction resistance can also be reduced. Among other merits are the lower overall height and compact design. Therefore, the square type and short stroke engines are dominant.
Displaced Volume: The compression ratio indicates to what extent the air – fuel mixture is compressed when piston is at TDC.
Combustion Chamber volume: The volume of space between the cylinder head and the piston at TDC is called “combustion chamber volume”.
Compression ratio: The compression ratio indicates to what extent the air – fuel mixture is compressed when piston is at TDC in compression stroke.
The higher Compression ratio is used for High speed Vehicles.
Compression Ratio :
Volume of Combustion chamber (v) + Displacement (v) divided by Volume of Combustion chamber (v)
Compression Torque :
The turning force exerted on rotating parts is called “torque”. Motorcycles are driven by the torque of the crankshaft.
Torque = Force × distance (kg•m N•m = kgN × m)
Change in torque (Primary and secondary reductions ,and speed reduction from the gear box).
The greater the number of gear teeth, the greater the torque. However, the rotational speed is reduced.
The “maximum torque” is indicated along with the engine speed at which maximum torque is delivered.
When a motorcycle is run at maximum torque, the rear wheel driving force is at the maximum.
Difference between BHP (Brake Horse power) & PS (Pfred Scale ) :
Both are the unit of Power 1 Bhp = 1.0143 Ps
Single Over Head Cam Shaft (SOHC) :
In this type of Cam Mechanism, Cam shaft is positioned in the cylinder head & driven by Cam Chain to operate Inlet & exhaust valve thru Rocker arms.
In this type mechanism Lesser parts are used to operate valves hence operation is stable even at high speed.
Trochoid Type Oil Pump :
Two rotors rotating at different Speeds causing variations in the volume between them. This Variation in volume causes oil flow in and out of the Pump. The Trochoid Pump is more commonly used due to its advantages and compact design.
Four Stroke Engine
Basic construction: A 4-stroke engine requires two complete revolution of the crankshaft (4 strokes of the piston) to complete a full cycle (Intake, Compression, Combustion and Exhaust).
Power stoke: A power stroke takes place on every other full rotation of the crankshaft. The cylinder head has two ports. An intake and an exhaust. Valves control the opening and closing of these ports. The opening and closing of the valves is timed to piston movement and location in its travel.
All air/fuel mixture compression takes place above the piston.
Advantages: Intake, compression, combustion and exhaust occur independently, so operation is more precise, efficient and very stable.Fuel loss caused by “stroke” over lap is less than 2-stroke. Fuel consumption is lower.
Single Axis Balancer
As engine runs, vibrations are caused from inertia force created by motion of engine Components (Piston & Connecting rod).
In order to lessen the vibration a balancer weight is added on a axis positioned at an angle above Crank Shaft and made to rotate in the opposite direction of Crank Shaft to reduce engine vibrations.
Wet Sump system :
Oil is stored in the oil sump in bottom of crank case, from here oil is pumped under pressure to various parts of the Engine. Oil is fed to both the Crank Shaft & Valve Train.
The Crank Shaft assembly is lubricated with the same oil used to lubricate the Transmission & Clutch .The oil is fed directly from the Oil Pump. The Cylinder & Piston are lubricated by splash oil that previously lubricated the Crank pin & connecting rods. The Valve Train is also lubricated by Pressure fed oil. After lubrication , the oil returns to the sump (Oil Chamber).
In this type of Frame the Engine is mounted at five locations (One at the top & two each at the front & rear of the Crank cases) and used as a stressed member of the frame for better stability, less vibrations & light weight The large size & thickness of the main pipe provide extra rigidity.
What is BS type Carburetor and what is the benefit of that for the user?
The BS carburetor ( ‘B’ stands for butterfly valve and ‘S’ for SU, designating the maker Skinner Union.)
In this type of the Carburetor, the air-fuel mixture is controlled by the regulation of the Engine Intake vacuum (negative pressure) which results in smooth operation of the vehicle, stable idling & good fuel economy.
Also due to this carburetor, the user gets smooth acceleration, even if the rider opens or closes the throttle sharply.
YTPS technology and its benefit:
Yamaha Throttle position sensor (YTPS) is a unit fitted on the carburettor on same axis of Butterfly valve.
It is adopted in order to control the ignition timing for each engine RPM. This helps to ensure excellent combustion efficiency and hence smooth throttle response, superior fuel economy and less emissions.
With the use of YTPS technology, 3- dimensional digital mapping has been done among, engine revolution, ignition timing and throttle opening for optimum combustion their by ensuring maximum mileage.
India Yamaha Motor 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 advice that you read instruction manual carefully before you get in touch with our Authorized Dealer to avoid any inconvenience.
YAMAHA 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.
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:
The claim for replacement or repair of part (s) shall be considered only when:
1. The Customer ensures that immediately upon occurrence of the defect he approaches the nearest YAMAHA Authorised Dealer with the affected Motorcycle. The expenses if any, to bring the Motorcycle to YAMAHA’S Authorised Dealer shall be born by the customer.
2. The Customer produces the Owner’s Manual in original to enable YAMAHA’S Authorized Dealer to verify the Motorcycle details and servicing details. YAMAHA reserves the right to refuse warranty, if the Owner’s Manual is not presented or if the information contained in is incomplete or tempered.
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 in 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.
Claim of Proprietary Items
Warranty claims in respect of proprietary items like Tyres, Tubes, Battery and Spark Plug are warranted by their respective manufacturers and shall be claimed on directly by the customer as per their warranty terms. YAMAHA and its Authorised Dealers will give all assistance in taking up such claims with the manufacturer of said items.
Warranty Not Applicable
Normal maintenance operations such as Engine tune-up, Decarbonising, Fuel System Cleaning, Wheels, Breaks and Clutch adjustments as well as any other normal adjustment. Normal replacement of service wear and tear items, i.e. Break Shoes, Fasteners/Shims/Washers, Gaskets and Rubber or Plastic Components, ( other than tyres & tubes ) oil seals, Cables electrical wiring and Electrical Items like Bulbs, , filters, spark plugs, , Drive Chain, Sprocket, Clutch plate, Race Bearing & Element Air Cleaner and wheel rim misalignment or bend.
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.
Use of non-genuine parts, non-genuine oil and lubricants.
Parts of the Motorcycle getting rusty due to atmospheric effects because of Industrial Pollution. 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. 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).
Motorcycle used for any competition or race and/or for attempting to set up any kind of record. YAMAHA undertakes no liability in the matter of any consequential loss or damage caused due to failure of the part(s).
For motorcycles which have been used for any commercial purposes & Loading such as taxi etc. For normal phenomenon like noise, vibration, oil seepage, which do not affect the performance of the Motorcycle.
For maintenance repairs required due to misuse while driving or due to adulteration of oil, petrol or due to bad road conditions.
If any part of the vehicle is tampered / repaired by unauthorised persons/workshops etc. For consumables like oil, grease etc. used during free services or used during warranty repairs. If there is any damage due to modification or fitting of accessories other than the ones recommended by YAMAHA. For claims made for any consequential damage due to any previous malfunction. If there is any damaged caused due to usage of improper oil/grease, non genuine parts. This warranty does not cover the risks like accidents, lightening, water, fire other acts of God, improper handling or any external cause beyond the control of YAMAHA. This warranty does not affect the customer’s statutory rights under applicable Indian laws, nor the consumer’s rights against the Dealer arising from their sales/purchase contract. This Warranty is the entire written warranty given by YAMAHA for the Motorcycle and no other person, including the Authorized Dealer or his agent or employee is authorised to extend or enlarge terms or this Warranty.
GAUTAM BUDH NAGAR (NOIDA) COURTS SHALL HAVE EXCLUSIVE JURISDICTION TO ENTERTAIN ANY DISPUTES ARISING OUT OR IN ANY WAY TOUCHING OR CONCERNING THIS WARRANTY POLICY.
Free Services / Validity – Km/Days
|First||1||500 – 700 Kms / 30 Days|
|Second||2||2500 – 2700 Kms / 90 Days|
|Third||3||4500 – 5000 Kms / 180 Days|
|Fourth||4||6500 – 7000 Kms / 240 Days|
|Fifth||5||8500 – 9000 Kms / 300 Days|
|Sixth||6||10500 – 11000 Kms / 360 Days|
|Seventh||7||12500 – 13000 Kms|
|Eighth||8||14500 – 15000 Kms|
Bonus Free Services
|Ninth||9||16500 – 17000 Kms|
|Tenth||10||18500 – 19000 Kms|
|Eleventh||11||20500 – 21000 Kms|
|Twelth||12||22500 – 23000 Kms|
|Thirteen||13||24500 – 25000 Kms|
|Fourteen||14||26500 – 27000 Kms|
|Fifteen||15||28500 – 29000 Kms|
IT IS MANDATORY TO AVAIL ALL FREE SERVICES, BONUS FREE SERVICES & PAID SERVICES AS PER RECOMMENDED SERVICE SCHEDULE TO BE ELIGIBLE FOR THE WARRANTY BENEFITS. PLEASE ENSURE THAT EACH SERVICE IS AVAILED WITHIN 60 DAYS FROM THE DATE OF PREVIOUS SERVICE OR AS PER THE RECOMMENDED SCHEDULE, WHICH EVER IS EARLIER.
All the below given points should be taken care in Free service/Paid service & Periodic service (after every 2000 kms).
|1||VALVES||Check valve clearances, adjust if necessary.|
|2||SPARK PLUG||Check condition, gap Clean and reset if necessary (Replace every 10000 Kms).|
|3||CARBURETOR||Check idle speed, Choke lever operation.|
|4||AIR FILTER||Clean, inspect & lubricate (replace if necessary).|
|5||FUEL LINE||Check fuel hose, for cracks or damage replace if necessary.|
|6||FUEL FILTER||Check for free flow of petrol, cleanliness of filter bowl, replace if necessary.|
|7||ENGINE OIL||Replace with recommended oil – Yamalube SG Grade (Warm engine before draining).|
|8||ENGINE OIL FILTER SCREEN||Wash with petrol.|
|9||BRAKE-FRONT & REAR BRAKE SHOES – FRONT & REAR (For Disc Brake Models Only)FRONT BRAKE||Check operation/Adjust if necessary. Grease the brake cam. Check for wear, replace if necessary.|
|10||BRAKE DISC BRAKE PADS MASTER CYLINDER & CALIPER||Check for scoring marks on disc Face and Run Out. Check for wear. Check for leakage.|
|11||CLUTCH||Check alignment marks on Push Lever and Crankcase LH Adjust if necessary.|
|12||REAR ARM PIVOT||Check Rear Arm assembly for looseness. Tighten with specified Torque if necessary.|
|13||WHEELS||Check run out, spoke tightness, damage; Correct it, if necessary.|
|14||WHEEL BEARING||Check Bearing assembly for looseness, damage, replace if necessary.(Repack grease every 10,000 kms.)|
|15||STEERING BEARING||Check Bearing assembly for looseness; correct if necessary.(Repack grease every 10,000 kms.)|
|16||FRONT FORKS||Check operation/Oil leakage. Repair if necessary.|
|17||REAR SHOCK ABSORBER||Check operation/oil leakage. Replace if necessary|
|18||DRIVE CHAIN||Check chain slack, alignment. Adjust if necessary, Clean periodically.|
|19||NUTS, BOLTS AND FASTENERS||Check all chassis fittings and fasteners for looseness. Tighten as per specification.|
|20||Check operation and lubricate if necessary|
|21||Check electrolyte level and top it up if necessary, Check Specific gravity and charge if required., Check breather pipe for blockage and routing.|
|21||CONTROL CABLES (Throttle, Clutch, Front Brake)||Check operation, free play, cable damage. Readjust or replace as required.|
* It is recommended that the above be serviced by authorised IYM dealer. Service more frequently when the vehicle is driven in dusty areas. * All the above points should be taken care of in free service, paid service & periodic services after every 2000 kms.
Self Maintenance Tips – Daily
|Component||To Check for||Symptoms||Action required|
|Front Brake||Check operation– If not ok||No proper Operation||Consult IYM Dealer|
|Brake Fluid level- if not Ok||No proper operation||Consult IYM Dealer|
|Free Play – If not OK (For non Disc Brake Models only )||No proper operation||Adjust|
|Rear Brake Pedal||Smooth operation & Free Play – If not OK||No proper operation||Adjust|
|Wheel||Tyre Pressure. If low If more||No proper maneuverability. Less road grip /Feeling of Jerks||Inflate as per specsDeflate with in specs|
|If more||Less road grip /Feeling of Jerks||Deflate with in specs|
|Tyre condition-If damaged||Frequent Puncture||Replace as per specs|
|Free movement of Wheel||Heavy||Consult IYM Dealer|
|Electricals (Horn, Lights, Fuel gauge)||Proper operation – If not ok||No proper operation||Consult IYM Dealer|
|Fuel tank/ Fuel lines||Any leakage Fuel Quantity – if less||Odour of fuel Starting Trouble||Consult IYM Dealer Fill fuel|
Self Maintenance Tips – Weekly
|Component||To Check for||Symptoms||Action required|
|Engine oil||Oil level – if low||Overheating/ Risk of damage to engine Parts||Consult IYM Dealer|
|Any leakage||Consult IYM Dealer|
|Battery||Check distilled Water level – If not ok||Problem in operation of Horn, Flasher, Brake ” Neutral light||Fill up to Max. Level/ Consult IYM dealer if battery is low charged|
|Nuts & Bolts||If Loose||Any noise ie. ratling||Consult IYM Dealer|
|Secondary Chain||Free Play||Noise from rear of side of the vehicle (This may lead to early wear of Chain ” sprockets)||Consult IYM Dealer|
|Clutch Lever||Free Play||Gear Shifting Hard ” Noisy||Consult IYM Dealer|
|If more||Clutch slippage/ Low Mileage (This leads to early wear of Clutch friction Plates)||Consult IYM Dealer|
|Throttle grip||Free Play – more||Feeling Lack of Power||Consult IYM Dealer|
|Smooth operation||Not proper operation||Consult IYM Dealer|
Self Maintenance Tips – Monthly
|Component||To Check for||Symptoms||Action required|
|Steering||Free Movement||No proper movement||Consult IYM Dealer|
|Spokes||Looseness||Shaky ride feel||Consult IYM Dealer|