Yamaha CRUX REV YD110-1 2016 Owner's Manual
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Yamaha CRUX REV YD110-1 2016 Owner's Manual

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Read this manual carefully before operating this vehicle.
OWNER'S MANUAL
YD110-1
BY1-F8199-E0

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Summary of Contents for Yamaha CRUX REV YD110-1 2016

  • Page 1 Read this manual carefully before operating this vehicle. OWNER’S MANUAL YD110-1 BY1-F8199-E0...
  • Page 2 EAU46091 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
  • Page 3 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.
  • Page 4 Important manual information EAU10134 Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
  • Page 5 Important manual information EAUE0011 YD110-1 OWNER’S MANUAL ©2016 by India Yamaha Motor Pvt. Ltd. 1st edition, August 2016 All rights reserved. Any reprinting or unauthorized use without the written permission of India Yamaha Motor Pvt. Ltd. is expressly prohibited. Printed in India.

  • Page 6: Table Of Contents

    Table of contents Location of important labels... 1-1 For your safety – pre-operation Tires ..........7-16 checks ..........5-1 Spoke wheels ....... 7-18 Safety information......2-1 Adjusting the clutch lever Operation and important riding free play........7-18 Description ........3-1 points ..........6-1 Adjusting the brake lever Left view .........
  • Page 7 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 and storage ..8-1 Matte color caution ......8-1 Care ..........8-1 Storage ..........8-3 Specifications........9-1 Consumer information ....10-1...

  • Page 8: Location Of Important Labels

    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. ZAUE2543...
  • Page 9 Location of important labels MAX . LOAD 3kg kPa, psi kPa, psi 100kPa=1bar 175, 25 225, 33 175, 25 280, 41 B44-F1668-00 ZAUE2544...

  • Page 10: Safety Information

    Safety information EAU1028B Never operate a motorcycle with- pears to be very effective in reduc- out proper training or instruction. ing the chance of this type of Take a training course. Beginners accident. Be a Responsible Owner should receive training from a cer- Therefore: As the vehicle’s owner, you are re- tified instructor.
  • Page 11 Safety information Many accidents involve inexperi- • Always signal before turning or Protective Apparel enced operators. In fact, many op- changing lanes. Make sure that The majority of fatalities from motorcy- erators who have been involved in other motorists can see you. cle accidents are the result of head in- accidents do not even have a cur- The posture of the operator and...
  • Page 12 Safety information Avoid Carbon Monoxide Poisoning Do not run engine outdoors where When loading within this weight limit, All engine exhaust contains carbon engine exhaust can be drawn into keep the following in mind: monoxide, a deadly gas. Breathing a building through openings such Cargo and accessory weight carbon monoxide can cause head- as windows and doors.
  • Page 13 Yamaha accessories, which are avail- performed to your vehicle that change lightweight as possible and able only from a Yamaha dealer, have any of the vehicle’s design or operation should be kept to a minimum. been designed, tested, and approved characteristics can put you and others •...
  • Page 14 Safety information operator and may limit control Check that the fuel cock (if ability, therefore, such accesso- equipped) is in the “OFF” position ries are not recommended. and that there are no fuel leaks. Use caution when adding electri- Point the front wheel straight cal accessories.

  • Page 15: Description

    Description EAU10411 Left view ZAUE2545 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)

  • Page 16: Right View

    Description EAU10421 Right view ZAUE2546 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)

  • Page 17: Controls And Instruments

    Description EAU10431 Controls and instruments 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)

  • Page 18: Instrument And Control Functions

    Instrument and control functions EAU10462 EWA10062 2. With the key in the “OFF” position, Main switch/steering lock WARNING push the key in and turn it to Never turn the key to “OFF” or “LOCK”. “LOCK” while the vehicle is moving. 3.

  • Page 19: Indicator Lights

    Instrument and control functions EAU10982 EAUT1822 EAU1234K Indicator lights Speedometer unit Handlebar switches Left 1 2 3 ZAUE2551 ZAUE2552 1. Neutral indicator light “ ” 1. Speedometer ZAUE2553 2. Turn signal indicator light “ ” 2. Odometer 1. Light switch “ / ”...

  • Page 20: Clutch Lever

    Instrument and control functions ter position. To cancel the turn signal EAU12852 EAU12872 Clutch lever Shift pedal 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 “...

  • Page 21: Brake Lever

    Instrument and control functions EAU12892 EAU12944 EAUE0041 Brake lever Brake pedal Fuel tank cap ZAUE2557 ZAUE2556 ZAUE2558 1. Brake lever 1. Brake pedal 1. Arrow mark 2. Fuel tank cap The brake lever is located on the right The brake pedal is located on the right 3.

  • Page 22: Fuel

    Instrument and control functions 2. Turn the key counterclockwise to EAU13213 Fuel the original position, and then re- Make sure there is sufficient gasoline in move it. the tank. EWA10882 WARNING The fuel tank cap cannot be installed unless the key is in the lock. In addi- Gasoline and gasoline vapors are tion, the key cannot be removed if the extremely flammable.

  • Page 23: Fuel Cock

    Instrument and control functions ately. If gasoline spills on your skin, EAU13562 Fuel cock wash with soap and water. If gaso- The fuel cock supplies fuel from the line spills on your clothing, change tank to the carburetor while filtering it your clothes.

  • Page 24: Starter (Choke) Lever

    Instrument and control functions This indicates reserve. If you run out of EAU13591 EAUE3321 Starter (choke) lever “ ” Kickstarter fuel while riding, move the lever to this position. Fill the tank at the first oppor- tunity. Be sure to set the lever back to “ON”...

  • Page 25: Seat

    Instrument and control functions EAUE2670 Tightening torque: Seat Bolt: 8 N·m (0.8 kgf·m, 5.8 lb·ft) To remove the seat 1. Remove panels A and B. (See 3. Install the panels. page 7-7.) 2. Remove the bolts. Make sure that the seat is properly se- cured before riding.

  • Page 26: Storage Compartment

    Instrument and control functions EAU14883 EAUE3110 Storage compartment Adjusting the shock absorber assemblies EWA10211 WARNING Always adjust both shock absorber assemblies equally, otherwise poor handling and loss of stability may re- sult. Each shock absorber assembly is 1. Hook equipped with a spring preload adjust- 2.

  • Page 27: Carrier

    Instrument and control functions Align the appropriate notch in the EAU15113 EAU37491 Carrier Sidestand adjusting ring with the position in- The sidestand is located on the left EWA10172 dicator on the shock absorber. WARNING side of the frame. Raise the sidestand Do not exceed the load limit of 3 or lower it with your foot while holding kg (6.6 lb) for the carrier.

  • Page 28: For Your Safety - Pre-Operation Checks

    Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage. Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicle, check the following points:...
  • Page 29 • Make sure that operation is smooth. • Check throttle grip free play. Throttle grip 7-15, 7-24 • If necessary, have Yamaha dealer adjust throttle grip free play and lubricate ca- ble end and grip housing. • Make sure that operation is smooth. Control cables 7-24 •...

  • Page 30: Operation And Important Riding Points

    The neutral indi- WARNING cator light should come on. If not, Failure to familiarize yourself with ask a Yamaha dealer to check the the controls can lead to loss of con- electrical circuit. trol, which could cause an accident 4.

  • Page 31: Starting A Warm Engine

    Operation and important riding points EAU16641 EAUE2280 ECA10261 Starting a warm engine Shifting NOTICE Follow the same procedure as for Even with the transmission in starting a cold engine with the excep- the neutral position, do not tion that the starter (choke) is not re- coast for long periods of time quired when the engine is warm.

  • Page 32: Tips For Reducing Fuel Consumption

    If any engine trouble should occur during the engine break-in period, 0–150 km (0–90 mi) immediately have a Yamaha dealer Avoid prolonged operation above 1/3 check the vehicle. throttle. After every hour of operation, stop the engine, and then let it cool for five to ten minutes.

  • Page 33: Parking

    Operation and important riding points EAU17172 Parking When parking, stop the engine, re- move the key from the main switch, and then turn the fuel cock lever to “OFF”. EWA10312 WARNING Since the engine and exhaust system can become very hot, park in a place where pedestri- ans or children are not likely to touch them and be burned.

  • Page 34: Periodic Maintenance And Adjustment

    If If you do not have the tools or experi- you are not familiar with vehicle ser- ence required for a particular job, have vice, have a Yamaha dealer perform a Yamaha dealer perform it for you. service.

  • Page 35: Periodic Maintenance Chart For The Emission Control System

    The annual checks must be performed every year, except if a kilometer-based maintenance is performed in- stead. From 20000 km, repeat the maintenance intervals starting from 4000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and tech- nical skills. EAU67781...

  • Page 36: General Maintenance And Lubrication Chart

    Periodic maintenance and adjustment EAU67791 General maintenance and lubrication chart ODOMETER READING (whichever comes first) ANNUAL 1000 km 4000 km 8000 km 12000 km 16000 km ITEM CHECK OR MAINTENANCE JOB CHECK 12 months 16 months 1 month 4 months 8 months Primary air filter ele- √...
  • Page 37 Periodic maintenance and adjustment ODOMETER READING (whichever comes first) ANNUAL 1000 km 4000 km 8000 km 12000 km 16000 km ITEM CHECK OR MAINTENANCE JOB CHECK 1 month 4 months 8 months 12 months 16 months • Check bearing for looseness or √...
  • Page 38 Periodic maintenance and adjustment ODOMETER READING (whichever comes first) ANNUAL 1000 km 4000 km 8000 km 12000 km 16000 km ITEM CHECK OR MAINTENANCE JOB CHECK 1 month 4 months 8 months 12 months 16 months • Check operation. Sidestand, center- √...
  • Page 39 Periodic maintenance and adjustment EAUE2910 Air filter This model’s air filter has two filter elements. The sponge-type primary filter element can be cleaned, lubricated, and re-used. The secondary filter element is an oil-coated paper type which must only be replaced. To avoid damaging the air filter elements, do not attempt to clean it with compressed air, by tapping it.

  • Page 40: Removing And Installing Panels

    Periodic maintenance and adjustment EAU18773 Removing and installing pan- The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. ZAUE2575 ZAUE2574 1.
  • Page 41 Periodic maintenance and adjustment To install the panel 1. Secure the rear of the panel first, then push the front of the panel in to insert the projection into the hole. ZAUE2578 1. Panel B 1. Hole 2. Screw 2. Projection 3.

  • Page 42: Checking The Spark Plug

    Do not attempt to 1. Spark plug gap diagnose such problems yourself. In- ZAUE2580 Spark plug gap: stead, have a Yamaha dealer check 1. Spark plug cap 0.6–0.7 mm (0.024–0.028 in) the vehicle. 2. Remove the spark plug as shown, with the spark plug wrench includ- ed in the owner’s tool kit.

  • Page 43: Engine Oil

    Periodic maintenance and adjustment To install the spark plug EAUE2870 Engine oil 1. Clean the surface of the spark The engine oil level should be checked plug gasket and its mating sur- before each ride. In addition, the oil face, and then wipe off any grime must be changed and the oil strainer from the spark plug threads.
  • Page 44 Periodic maintenance and adjustment 4. If the engine oil is below the mini- ECA11621 NOTICE mum level mark, add sufficient oil of the recommended type to raise In order to prevent clutch slip- it to the correct level. page (since the engine oil also 5.

  • Page 45: Servicing The Air Filter

    Periodic maintenance and adjustment EAUE2931 ment to remove the excess kero- Servicing the air filter sene or diesel. WARNING! Use This model’s air filter has two filter ele- only a dedicated parts cleaning ments. The sponge-type primary filter solvent. To avoid the risk of fire element can be cleaned, lubricated, or explosion, do not use gaso- and re-used.
  • Page 46 Periodic maintenance and adjustment ZAUE2586 ZAUE2585 1. Air filter check hose 1. Air filter case cover 2. Screw 7. Install the air filter case cover by The primary air filter element should be 3. Remove the secondary air filter el- installing the screws.

  • Page 47: Adjusting The Carburetor

    Yamaha dealer, who has the nec- The air filter element needs and/or cylinder(s) may become essary professional knowledge and ex- more frequent replacement if excessively worn.

  • Page 48: Adjusting The Engine Idling Speed

    Yamaha dealer make the adjustment. and, if necessary, adjust it as follows. 2. Check the engine idling speed and, if necessary, adjust it to...

  • Page 49: Valve Clearance

    Therefore, it rection (b). must be adjusted by a Yamaha dealer is essential to maintain the tires in good at the intervals specified in the periodic condition at all times and replace them maintenance and lubrication chart.
  • Page 50 * Total weight of rider, passenger, car- nail or glass fragments in it, or if the very carefully and replace it as go and accessories sidewall is cracked, have a Yamaha soon as possible with a high- dealer replace the tire immediately. quality product.

  • Page 51: Spoke Wheels

    WARNING before each ride. If any damage is The front and rear tires should be of found, have a Yamaha dealer re- the same make and design, other- ZAUE2592 place the wheel. Do not attempt wise the handling characteristics of 1.

  • Page 52: Adjusting The Brake Lever Free Play

    WARNING 3. Tighten the locknut. If proper adjustment cannot be ob- ZAUE2594 tained as described, have a Yamaha If the specified free play cannot be ob- 1. Brake lever free play dealer make this adjustment. tained as described above or if the...

  • Page 53: Adjusting The Brake Pedal Free Play

    Periodically check the brake pedal free Yamaha dealer make this ad- adjusted by a Yamaha dealer. play and, if necessary, adjust it as fol- justment.

  • Page 54: Checking The Front And Rear Brake Shoes

    3. To check the drive chain slack, re- Yamaha dealer replace the brake move the cover by pulling it out- ZAUE2599 shoes as a set.
  • Page 55 (b), EAUN1071 To adjust the drive chain slack and then push the rear wheel for- Consult a Yamaha dealer before ad- ward. justing the drive chain slack. 7-22...

  • Page 56: Cleaning And Lubricating The Drive Chain

    Periodic maintenance and adjustment EWA10661 EAUE2350 Cleaning and lubricating the WARNING Using the alignment marks on each drive chain After adjusting the brake pedal free side of the swingarm, make sure that The drive chain must be cleaned and play, check the operation of the both washer edges are in the same po- lubricated at the intervals specified in brake light.

  • Page 57: Checking And Lubricating The Cables

    Yamaha dealer at the inter- sary. If a cable is damaged or does not vals specified...

  • Page 58: Checking And Lubricating The Brake And Shift Pedals

    Periodic maintenance and adjustment EAU44276 EAU43612 Recommended lubricant: Checking and lubricating the Checking and lubricating the Lithium-soap-based grease brake and shift pedals brake and clutch levers The operation of the brake and shift Brake lever pedals should be checked before each ride, and the pedal pivots should be lu- bricated if necessary.

  • Page 59: Checking And Lubricating The Centerstand And Sidestand

    EWA10742 WARNING If the centerstand or sidestand does not move up and down smoothly, have a Yamaha dealer check or re- pair it. Otherwise, the centerstand or sidestand could contact the ground and distract the operator, resulting in a possible loss of control.

  • Page 60: Lubricating The Swingarm Pivots

    The swingarm pivots must be lubricat- at the intervals specified in the periodic ed by a Yamaha dealer at the intervals maintenance and lubrication chart. specified in the periodic maintenance and lubrication chart.

  • Page 61: Checking The Steering

    If any free skin, eyes or clothing and al- hub or if the wheel does not turn play can be felt, have a Yamaha ways shield your eyes when smoothly, have a Yamaha dealer dealer check or repair the steer- working near batteries.
  • Page 62 Periodic maintenance and adjustment Batteries produce explosive hy- To store the battery drogen gas. Therefore, keep 1. If the motorcycle will not be used The electrolyte should be between the sparks, flames, cigarettes, etc., for more than one month, remove minimum and maximum level marks.

  • Page 63: Replacing The Fuse

    Periodic maintenance and adjustment If the breather hose is posi- EAUE3120 Replacing the fuse tioned in such a way that the The fuse holder is located behind panel frame is exposed to electrolyte A. (See page 7-7.) or gas expelled from the bat- If the fuse is blown, replace it as fol- tery, the frame could suffer lows.

  • Page 64: Replacing A Headlight Bulb

    If a headlight bulb possibly a fire. [EWA15132] burns out, have a Yamaha dealer re- place it and, if necessary, adjust the headlight beam. ZAUE2617 1. Fuse 2. Spare fuse Specified fuse: 10.0 A...

  • Page 65: Replacing The Tail/Brake Light Bulb

    Periodic maintenance and adjustment EAU24135 EAU24205 Replacing the tail/brake light Replacing a turn signal light bulb bulb 1. Remove the tail/brake light lens by 1. Remove the turn signal light lens removing the screws. by removing the screw. ZAUE2619 1. Bulb 3.

  • Page 66: Front Wheel

    Periodic maintenance and adjustment EAU24361 Front wheel EAUE2880 To remove the front wheel EWA10822 WARNING To avoid injury, securely support the ZAUE2621 ZAUE2622 vehicle so there is no danger of it 1. Bulb 1. Front brake lever free play adjusting nut falling over.
  • Page 67 Periodic maintenance and adjustment When tightening the axle nut, hold the wheel axle with a wrench to keep it from turning. 5. Install the brake cable to the brake shoe plate, and then connect the cable to the brake camshaft lever by installing the brake lever free ZAUE2624 ZAUE2625...

  • Page 68: Rear Wheel

    Periodic maintenance and adjustment EAU25081 4. Unhook the drive chain case lock Rear wheel and remove the drive chain case. EAUE2661 To remove the rear wheel EWA10822 WARNING To avoid injury, securely support the ZAUE1520 vehicle so there is no danger of it 1.
  • Page 69 Periodic maintenance and adjustment ZAUE2629 ZAUE2630 1. Brake camshaft lever 1. Wheel axle 1. Drive chain 2. Drive chain puller locknut 2. Collar 3. Drive chain slack adjusting bolt 4. Axle nut and washer The drive chain does not need to be 5.

  • Page 70: Troubleshooting

    However, should your motorcycle Tightening torques: require any repair, take it to a Yamaha Axle nut: 75 N·m (7.5 kgf·m, 54 lb·ft) dealer, whose skilled technicians have Brake torque rod nut: the necessary tools, experience, and 19 N·m (1.9 kgf·m, 13 lb·ft)
  • Page 71 Periodic maintenance and adjustment heaters or furnaces. Gasoline or gasoline vapors can ignite or ex- plode, causing severe injury or prop- erty damage. 7-38...

  • Page 72: Troubleshooting Chart

    Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Check the compression. 3. Compression The engine does not start. There is compression.

  • Page 73: Motorcycle Care And Storage

    Rust and corrosion can develop matte colored finished parts. Be Cleaning even if high-quality components are sure to consult a Yamaha dealer for ECA10773 NOTICE used. A rusty exhaust pipe may go un- advice on what products to use be- noticed on a car, however, it detracts fore cleaning the vehicle.
  • Page 74 Motorcycle care and storage off any detergent residue using shield. Test the product on a plenty of water, as it is harmful small hidden part of the wind- Salt sprayed on roads in the winter to plastic parts. shield to make sure that it does may remain well into spring.

  • Page 75: Storage

    WARNING ing it with a tarp, while it is still Contaminants on the brakes or tires Consult a Yamaha dealer for ad- wet, will allow water and humid- can cause loss of control. vice on what products to use.
  • Page 76 Motorcycle care and storage 2. Turn the fuel cock lever to the off e. Remove the spark plug cap than 0 °C (30 °F) or more than 30 position. from the spark plug, and then °C (90 °F)]. For more information 3.

  • Page 77: Specifications

    Specifications Dimensions: Starting system: Clutch: Kickstarter Overall length: Clutch type: Lubrication system: 2020 mm (79.5 in) Wet, multiple-disc Wet sump Overall width: Drivetrain: Engine oil: 740 mm (29.1 in) Primary reduction ratio: Overall height: Recommended brand: 3.421 (65/19) 1045 mm (41.1 in) YAMALUBE Final drive: Seat height:...
  • Page 78 Specifications Manufacturer/model: Rim size: Battery: TVS/ATT625 17 M/C x 1.60 Model: Rear tire: Front brake: AB2.5L-C-4 Type: Type: Model: With tube Mechanical leading trailing drum brake 12MX2.5L-C-5 Size: Rear brake: Voltage, capacity: 3.00-17 50P 12 V, 2.5 Ah (10 HR) Type: Manufacturer/model: Voltage, capacity:...

  • Page 79: Consumer Information

    Record the vehicle identification num- ber and the engine serial number in the spaces provided below for assistance xxxxxxxx when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. VEHICLE IDENTIFICATION NUMBER: ZAUE2632 1. Vehicle identification number 1.

  • Page 80: Index

    Index Air filter, servicing .........7-12 Front fork, checking ......7-27 Safety information........2-1 Fuel............4-5 Seat............4-8 Fuel cock ..........4-6 Shifting ............6-2 Battery ..........7-28 Fuel consumption, tips for reducing ..6-3 Shift pedal..........4-3 Brake and clutch levers, Fuel tank cap.......... 4-4 Shock absorber assemblies, checking and lubricating ....7-25 Fuse, replacing ........
  • Page 81 Index Wheel bearings, checking ....7-28 Wheel (front) ......... 7-33 Wheel (rear)........... 7-35 Wheels..........7-18 11-2...
  • Page 82 BY1-F8199-E0 2Y121(OM-01)919-07-16-E PRINTED IN INDIA...

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