Yamaha GLADIATOR Ower'S Manual Download

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1. Locknut
2. Adjusting Bolt
3. Free play (10~15 mm)

Clutch lever free play
adjustment

The clutch lever free play should be
adjusted to 10 ~ 15 mm. If the free
play is incorrect, adjust as follows.

1 . Loosen the locknut.

2. Turn the adjusting bolt at the

clutch lever in direction b to
increase free play or in direction a
to decrease free play.

3. Tighten the locknut.

If proper adjustment cannot be
obtained or the clutch does not work
correctly, ask a

dealer to

i n s p e c t

t h e

i n t e r n a l

c l u t c h

mechanism.

YAMAHA

PERIODIC MAINTENANCE AND MINOR REPAIR

6-16

NOTE :

Summary of Contents for GLADIATOR

Page 1: ...e Cost er Exhaust Smoke uces Wear and Tear PRINTED IN INDIA 2Y16 OM 01 271 08 06 E Starter Motor Disc Brake G G TROKE MOTOR OIL 0W40 4 Starter Motor Disc Brake Starter Motor Disc Brake OWNER S MANUAL 5P4 F8199 E1 5P42 5P4 F8199 E1 ...

Page 2: ...MANUAL YAMAHA MOTOR INDIA PVT LIMITED All rights reserved Any reprinting or unauthorised use without the written permission of YAMAHA MOTOR LIMITED is expressly prohibited INDIA PVT WARNING PLEASEREADTHISMANUALCAREFULLYANDCOMPLETELYBEFOREOPERATINGTHISMOTORCYCLE ...

Page 3: ...ease take due care and ensure proper maintenance of your Motorcycle as recommended in this Owner s Manual Always demand only Genuine Spare Parts and Yamalube oil If you have any queries regarding the operation or maintenance of your Motorcycle please consult your DEALER who will be too happy to help you This Owner s Manual also includes the GREEN BOOK containing Guidelines DO s and DON Ts to be fo...

Page 4: ... 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 your dealer YAMAHA YAMAHA The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED NOTE CAUTION WARNING Failure to follow WARNING instructions to the Motorcycle operator a bystander or a person inspecting or repairing t...

Page 5: ...er 3 7 Kick starter 3 8 Seat 3 8 Storage compartment 3 9 Rear shock absorber adjustment 3 9 Handle Seat Stay Lock 3 10 PRE OPERATION CHECKS 4 1 Pre operation check list 4 1 OPERATION AND IMPORTANT RIDING POINTS 5 1 Starting and warming up a cold engine 5 1 Starting a warm engine 5 2 Shifting 5 2 Tips for reducing fuel consumption 5 3 Running in 5 3 Parking 5 4 PERIODIC MAINTENANCE AND MINOR REPAIR...

Page 6: ... Brake and shift pedal lubrication 6 23 Brake and clutch lever lubrication 6 23 Center and sidestand lubrication 6 23 Front fork inspection 6 24 Steering inspection 6 24 Wheel bearings 6 25 Battery 6 25 Fuse replacement 6 27 Headlight bulb replacement 6 28 Turn signal and taillight bulb replacement 6 29 Front wheel removal 6 29 Front wheel installation 6 30 Rear wheel removal 6 31 Rear wheel insta...

Page 7: ...o know its capabili ties and limitations 5 Right thoughtfully planning your route well in advance 6 Give proper Signals and use Horn and Headlights judiciously 7 Don t ride in another motorist s blind spot 8 Always make pre ride safety checks before you start the Engine SAFE BRAKING Use the basic methods of braking effectively 1 Engine Brake When the Throttle is released compression backs up and a...

Page 8: ...hain free play check window page 6 19 9 Side panel L H lock page 6 5 10 Shift pedal page 3 4 1 Fuel cock page 3 6 2 Starter Lever page 3 7 3 Fuse page 6 26 4 Battery page 6 24 5 Storage Compartment page 3 9 STANDARD VEHICLE 2 6 5 4 3 7 8 9 1 10 fazer5yy8 pmd 8 28 2006 11 51 AM 4 ...

Page 9: ...Rear shock absorber page 3 9 12 Air filter page 6 10 13 Kick starter page 3 7 14 Seat page 3 8 15 Engine oil filler cap page 6 8 16 Rear brake pedal page 3 4 6 17 STANDARD VEHICLE 15 11 12 13 14 16 fazer5yy8 pmd 8 28 2006 11 51 AM 5 ...

Page 10: ...g Lock Page 3 1 21 Fuel Gauge page 3 2 22 Front Brake Lever page 3 4 6 16 23 Throttle Grip page6 12 24 Fuel Tank Cap page 3 5 25 Turn Indicator Switch page 3 2 26 Starter Kill Switch page 3 3 17 18 19 20 21 23 24 25 Controls Instruments DESCRIPTION 22 STANDARD VEHICLE 2 3 26 fazer5yy8 pmd 8 28 2006 11 51 AM 6 ...

Page 11: ... be removed in this position 1 Push 2 Release 3 Turn LOCK The steering is locked in this position and all electrical circuits are switched off The key can be removed in this position To lock the steering turn the handle bars all the way to the left or right With the key at OFF push it into the main switch and release it turn it counter clockwise to LOCK and remove it To release the lock turn the k...

Page 12: ...ator comes on when the transmission is in neutral This indicator comes on when the headlight high beam is used 1 Speedometer 2 Odometer Speedometer The speedometer shows riding speed This speedometer is equipped with an odometer 1 Fuel Meter The fuel meter indicates the quantity of the remaining petrol in the fuel tank The gauge needle moves from F Full to E Empty as the fuel level decreases When ...

Page 13: ... the headlight on also INSTRUMENT AND CONTROL FUNCTIONS 3 3 1 PassSwitch 2 Dimmer Switch 3 Light switch 4 Turn signal cum cancellation switch 5 Horn switch Handlebar switches Dimmer switch Turn the switch to for the high beam and to for the low beam Pass switch Press the switch to operate the Passing Light 1 Starter Switch 2 Kill Switch Starter Switch Press the button to start the bike Vehicle sho...

Page 14: ... your toe to shift down 1 Front brake lever Front brake lever The front brake lever is located on the right handlebar Pull it toward the handlebar to apply the front brake 1 1 1 1 Clutch lever Clutch lever The clutch lever is located on the left handlebar Pull the clutch lever to the handlebar to disengage the clutch and release the lever to engage the clutch The lever should be pulled rapidly and...

Page 15: ...th the key inserted To remove the key turn it counterclockwise to the original position Ensure the arrow on fuel tank is towards the Front of the bike when inserting Fuel Tank Cap in Fuel Tank 1 This tank cap cannot be closed unless the key is in the lock The key cannot be removed if the cap is not locked properly Be sure the cap is properly installed and locked in place before riding the Motorcyc...

Page 16: ...with a dry and clean soft cloth Fuel may deteriorate painted surfaces or plastic parts Recommended Fuel Fuel tank capacity Regular gasoline Petrol Total 13 0 L Reserve 1 2 L CAUTION IT IS A GOOD PRACTICE TO RETURN THE FUEL COCK LEVER TO Off POSITION WHEN ENGINE IS NOT RUNNING 1 Filler tube 2 Fuel level Fuel Make sure there is sufficient fuel in the tank Fill the fuel tank to the bottom of the fill...

Page 17: ...tes reserve If you run out of fuel while riding set the fuel cock to this position Fill the tank at the first opportunity Be sure to set the fuel cock back to ON after refueling 1 Starter lever Starter lever Starting a cold engine requires a richer air fuel mixture A separate starter circuit supplies this mixture Move the Starter Lever in Direction a toTurn on the Starter Move the Starter Lever in...

Page 18: ...wn on front of the seat and tighten the bolts on the left and right hand side of the seat ALWAYS USE A HELMET WHILE RIDING FOR YOUR SAFETY 1 Kick starter Kick starter Raise the right Pillion footrest and rotate the kick starter away from the engine Push the starter down lightly with your foot Kick until the gears engage then kick smoothly and forcefully to start the engine This model has a primary...

Page 19: ...Turn the adjusting ring in direction a to increase spring preload and in direction b to decrease spring preload Make sure that the appropriate notch in the adjusting ring is aligned with the position indicator on the rear shock absorber Always adjust each shock absorber to the same setting Uneven adjustment can cause poor handling and loss of stability INSTRUMENT AND CONTROL FUNCTIONS 3 9 WARNING ...

Page 20: ...INSTRUMENT AND CONTROL FUNCTIONS 3 10 1 HandleSeat 1 Stay Lock on Saree Guard Stay Lock For mounting Helmet Lock 1 1 ...

Page 21: ...grip and housing Rear brake Front brake Lubricate if necessary Check tyre pressure wear damage and spoke tightness Tighten spokes if necessary Adjust if necessary 6 13 6 15 6 19 6 20 Check oil level Fill with oil if necessary Check chain slack and condition Check operation condition and free play Adjust if necessary Lubricate if necessary Check for smooth operation Adjust if necessary Check operat...

Page 22: ...eners Center and sidestand pivot Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Check fuel level Fill with fuel if necessary Fill with distilled water if necessary Check fluid level Check for proper operation 6 25 6 26 3 3 6 28 6 29 3 5 3 6 Lubricate if necessary Check for smooth operation Lubricate if necessary Check for smooth operation ITEM CHECKS 6 23 PAGE...

Page 23: ...rner Starting and warming up a cold engine 1 Turn the fuel cock to ON 2 Turn the main switch to ON 3 Shift the transmission into neutral When the transmission is in neutral the neutral indicator light should be on If the light does not come on ask a YAMAHA dealer to inspect it 4 Fully open the Starter Lever and completely close the throttle grip 5 Kick the kick starter to start the engine 6 After ...

Page 24: ...se of the shift pedal is shown in the illustration To shift into neutral depress the shift pedal repeatedly until it reach es the end of its travel then raise the pedal slightly Do not ride downhill with Ignition Switch in OFF Position in Neutral Gear Always ride motor cycle with Ignition Switch in ON Position in Neutral Gear Always use the clutch when changing gears The engine transmission and dr...

Page 25: ...rossings 6 Do not drive with excessive load on the Motorcycle 7 Plan your route in advance Running in There is never a more important period in the life of your Motorcycle than the period between zero and 1 000 km For this reason we ask that you carefully read the following material Because the engine is brand new you must not put an excessive load on it for the first 1 000 km The various parts in...

Page 26: ...whenever stopping the engine The exhaust system is hot Park the Motorcycle in a place where pedestrians or children are not likely to touch the Motorcycle Do not park the Motorcycle on a slope or soft ground the Motorcycle may overturn IT IS NOT RECOMMENDED TO RIDE THE MOTORCYCLE WITH CONSTANT THROTTLE OPENING FOR VERY LONG DISTANCE 5 4 WARNING ...

Page 27: ...AT EACH OWNER ALTER THIS TIME SCHEDULE TO SHORTER INTERVALS TO MATCH THE ENVIRONMENT The most impor tant points of Motorcycle inspection adjustment and lubrication are explained in the following pages If you are not familiar with Motorcycle service this work should be done by a YAMAHA dealer 1 Tool kit Tool kit The service information included in this manual is intended to provide you the owner wi...

Page 28: ...ou do not have necessary tools required during a service operation take your Motorcycle to a YAMAHA dealer for service Modifications to this Motorcycle not approved by YAMAHA may cause loss of performance and render it unsafe for use Consult a YA M A H A d e a l e r b e f o r e attempting any changes 6 2 ...

Page 29: ... 1 2 3 FUEL LINE 5 AIR FILTER 4 FUEL FILTER 6 ENGINE OIL 7 ENGLINE OIL FILTER SCREEN 8 BRAKE REAR 9 BRAKE FLUID LEVEL 11 BRAKE SHOES REAR 10 Check for wear replace if necessary Check Level Refill if necessary 30 DAYS OR 500 700 KMS AFTER DURING SERVICE DAYS OR KMS WHICHEVE OCCURS FIRST REPLACE EVERY 10 000 km 1 TPS Throttle Position Sensor 2 BS Butterfly Slide Valve Screws CAUTION 1 Do not Tamper ...

Page 30: ...sary Check specific gravity and charge if required Check breather pipe for blockage and routing 26 BATTERY CONTROL CABLES THROTTLE CLUTCH FRONT BRAKE 27 Readjust or replace as required Check operation free play cable damage EVERY MONTH IT IS RECOMMENDED THAT THE ABOVE BE SERVICED BY AUTHORIZED YMI DEALER SERVICE MORE FREQUENTLY WHEN THE VEHICLE IS DRIVEN IN DUSTY AREAS EVERY 10 000 KMS WHEEL BEARI...

Page 31: ...efer to this section each time a panel has to be removed or reinstalled 2 Panel B PERIODIC MAINTENANCE AND MINOR REPAIR 6 5 1 Lug 2 Panel A 3 Lug Removal of Panel A Unlock the panel Pull the lug 1 towards you to remove it from the fuel tank Slide the panel A 2 towards the Front of the motorcycle for removing the lug 3 to free the panel 1 2 2 3 1 ...

Page 32: ...anel A Slide the panel towards the Rear of the motorcycle for inserting the lug 2 in the slot given in the frame Insert and push the lug 1 in the fuel tank ensuring proper seating After proper seating of the panel A lock it 1 Lug 2 Lug 3 Lug Installation of Panel B Follow the same procedure as given for installation of panel A and tighten the screw for locking 2 1 1 2 1 2 3 3 1 2 3 2 1 ...

Page 33: ...ces sive or if carbon and other deposits are excessive you should replace the spark plug with the specified plug Specified spark plug CR7HSA NGK Before installing the spark plug measure the electrode gap with a wire thickness gauge adjust the gap to specification as necessary PERIODIC MAINTENANCE AND MINOR REPAIR 6 7 A Spark plug gap 0 6 0 7 mm When installing the plug always clean the gasket surf...

Page 34: ...tilt toward the side can result in false readings 1 Maximum level 2 Minimum level Wait a few minutes until the oil level settles before checking B Unscrew the dipstick and rest it on the threads of the oil filler hole The oil level should be between the minimum and maximum mark on the dip stick If the level is low add oil to raise it to the specified level PERIODIC MAINTENANCE AND MINOR REPAIR 6 8...

Page 35: ...Drain plug 14 5 It lb 2 0 m kg e Fill engine with oil and install the dipstick Recommended oil YAMALUBE 4 stroke motor oil 20W40 type SG Oil quantity Total amount 1 2 L Periodic oil change 1 0 L PERIODIC MAINTENANCE AND MINOR REPAIR 6 9 f Start the engine and warm up for a few minutes While warming up check for oil leak age If oil leakage is found stop the engine immediately and check for the caus...

Page 36: ...installation procedures 2 Remove the air filter case fitting screws and the air filter case cover 1 Air filter element 2 Lockable SpringWire PERIODIC MAINTENANCE AND MINOR REPAIR 6 10 3 Remove the air filter from the case 4 Unlock the spring wire 2 1 2 1 1 Air filter element 2 Frame 6 Dip the Air Filter Elements in recommended oil squeeze out the excess oil They should be wet but not dripping Reco...

Page 37: ... Cleaner should be cleaned and lubricated more frequently every 1000 kms if Motorcycle is operated in very dusty e g unpaved dust laden roads conditions Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisti cated adjustments Most adjust ments should be left to a YAMAHA dealer who has the professional knowledge and experience to do so However the following ma...

Page 38: ... to increase engine speed and in direction b to decrease engine speed Standard idle speed 1 300 1 500 r min If the specified idle speed cannot be obtained by performing the above adjustment consult a dealer YAMAHA Throttle cable free play adjustment Before checking the throttle cable free play the engine idling speed should be adjusted Adjust the throttle cable by turning the adjusting nut so that...

Page 39: ...ct valve clearance changes with use resulting in improper fuel air supply or engine noise To prevent this the valve clearance must be adjusted regularly This adjustment however should be left to a YAMAHA dealer 1 Tread depth 2 Side wall Tyres To ensure maximum performance long service and safe operation note the following 1 Tyre air pressure Always check and adjust the tyre pressure before operati...

Page 40: ...ems that can shift Securely pack your heaviest items close to the center of the Motorcy cle and distribute the weight evenly from side to side Properly adjust the suspension for your load and check the condition and pressure of your tyres NEVER O V E R L O A D Y O U R MOTORCYCLE Make sure the total weight of the cargo rider passenger and accessories fairing saddlebags etc approved for this model d...

Page 41: ...maged If any abnormal condition exists in a wheel consult a YAMAHA dealer Do not attempt even small repairs to the wheel If a wheel is deformed or cracked it must be replaced 2 Tyres and wheels should be balanced whenever either one is changed or replaced Failure to have a wheel balanced can result in poor performance adverse handling characteristics and shortened tyre life 3 Ride at moderate spee...

Page 42: ...st as follows 1 Loosen the locknut 2 Turn the adjusting bolt at the clutch lever in direction b to increase free play or in direction a to decrease free play 3 Tighten the locknut If proper adjustment cannot be obtained or the clutch does not work correctly ask a dealer to inspect the internal clutch mechanism YAMAHA PERIODIC MAINTENANCE AND MINOR REPAIR 6 16 NOTE a b 1 2 3 ...

Page 43: ...e rear brake 1 Brake light switch 2 Adjusting nut Brake light switch adjustment The rear brake light switch is acti vated by the brake pedal and is properly adjusted when the brake light comes on just before braking takes effect To adjust the rear brake light switch hold the switch body so it does not rotate while turning the adjusting nut Turn the adjusting nut in direction a to make the brake li...

Page 44: ...e wear without having to disassemble the brake To check the brake shoe wear check the position of the wear indicator while applying the brake If a brake shoe has worn to thepoint that the wear indicator reaches the wear limit line have a YAMAHA dealer replace the brake shoes as a 1 Minimum Level Mark Checking the brake fluid level Insufficient brake fluid may allow air to enter th brake system pos...

Page 45: ...boiling point of the fluid and may result in vapour lock Brake fluid may deteriorate painted surfaces or plastic parts Always clean up spilled fluid immediately As the brake pads wear it is normal Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and l e a d t o p o o r b r a k i n g performance or the brake fluid level to gradually go down However if...

Page 46: ... axle nut 1 Locknut 2 Adjusting hex screw 4 Loosen the chain adjusting locknuts on each chain puller To tighten the chain turn the chain adjusting hex screw in direction b to loosen the chain turn the chain adjusting hex screw in direction a and push the wheel forward Turn each chain adjusting hex screw exactly the same amount to maintain correct axle alignment There are marks on each chain puller...

Page 47: ... Left and Right Side Tightening torque Axle nut 65 ft lb 9 05 m kg 1 Cotter pin 6 Insert a new cotter pin into the axle nut and bend the end of the cotter pin as shown If the notch in the axle nut and the cotter pin hole do not match tighten the nut slightly to align them Always use a new cotter pin on the axle nut 7 Adjust the free play in the brake pedal Check the operation of the brake light af...

Page 48: ... Cable inspection and lubrication Damage to the outer housing of cables may lead to internal rusting and interfere with the cable movement Replace damaged cables as soon as possible to prevent unsafe conditions Lubricate the cables with anti corrosive oil and cable ends If a cable does not operate smoothly ask a YAMAHA dealer to replace it Recommended lubricant YAMALUBE 20W40Type SG Throttle cable...

Page 49: ...ing parts MULTIPURPOSE Recommended Grease Center and sidestand lubrication Lubricate the pivoting and mating joints Check to see that the center and sidestand move up and down smoothly If the center and or sidestand does not move smoothly consult a YAMAHAdealer PERIODIC MAINTENANCE AND MINOR REPAIR 6 23 WARNING ...

Page 50: ... and check if the fork rebounds smoothly If any damage or unsmooth movement is found with the front fork consult aYAMAHAdealer Steering inspection Periodically inspect the condition of the steering Worn out or loose steering bearings may be danger ous Place a stand under the engine to raise the front wheel off the ground Hold the lower end of the front forks and try to move them forward and backwa...

Page 51: ...the wheel bearings 1 Maximum level mark 2 Minimum level mark Battery 1 Battery is located inside the L H side panel for removal installation of L H side panel please refer page 6 5 2 Open the lid 3 Check the level of the battery electrolyte and make sure that the terminals are tight Top up with distilled water if the electrolyte level is low PERIODIC MAINTENANCE AND MINOR REPAIR 6 25 WARNING 1 2 M...

Page 52: ...sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield your eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Replenishing the battery fluid Normal tap water contains minerals which are harmful to a battery therefore refill only with distilled water Take care not to spill battery fluid on the chain Battery fluid may weaken the chain causin...

Page 53: ... the breather hose is properly connected and is not damaged or obstructed 1 Main fuse Fuse replacement The fuse is located behind panel A See page 6 6 for panel removal and installation procedures If the fuse is blown turn off the main switch and the switch of the circuit in question Install a new fuse of proper amperage Turn on the switches and see if the electrical device operates If the fuse im...

Page 54: ...holder 1 Nos 1 Parking Bulb 1 No Keep flammable products and your hands away from the bulb while it is on as it is hot Do not touch the bulb until it cools down 5 Put a new bulb into position and secure it in place with the bulb holder as the case may be 6 Install the head light assy 7 If the headlight beam adjustment is necessary ask a YAMAHA dealer to make adjustment WARNING 1 2 1 1 1 Head Light...

Page 55: ...n it clockwise until it engages into the socket 4 Install the lense and the screws 1 Integral Tail lamp Screws Nos Do not over tighten the screws as the lense may break 2 with Indicators Front wheel removal It is advisable to have a YAMAHA dealer service the wheel S e c u r e l y s u p p o r t t h e Motorcycle so there is no danger of it falling over PERIODIC MAINTENANCE AND MINOR REPAIR 6 29 WARN...

Page 56: ...the Speedometer cable Nut 1 pull the cable 2 out from the Front Wheel 1 Cotter Pin 2 Axle Nut 3 Remove the cotter pin 1 and axle nut 2 4 Remove the wheel make sure the Motorcycle is properly supported 5 Remove the Front Wheel PERIODIC MAINTENANCE AND MINOR REPAIR 6 30 1 1 2 2 1 ...

Page 57: ...pper on the front fork outer tube 2 Make sure the axle nut is properly torqued and a new cotter pin is installed Always use a new cotter pin Axle nut torque 33 ft lb 4 55 m kg PERIODIC MAINTENANCE AND MINOR REPAIR 6 31 WARNING Rear wheel removal It is advisable to have a YAMAHA dealer service the wheel S e c u r e l y s u p p o r t t h e Motorcycle so there is no danger of it falling over WARNING ...

Page 58: ...ake shoe plate 1 Axle nut 2 Cotter pin 3 Brake rod 4 Brake adjusting nut 3 Remove the brake adjusting nut and brake rod from the brake cam lever 4 Remove the axle nut cotter pin and the axle nut 1 Rear axle 5 Pull out the rear axle 6 Remove the wheel assembly PERIODIC MAINTENANCE AND MINOR REPAIR 6 32 ALWAYS USE YAMAHA GENUINE SPARE PARTS 1 2 3 4 ...

Page 59: ...t the rear brake pedal free play See page 6 17 Troubleshooting Although YAMAHA Motorcycles receive a rigid inspection before shipment from the factory trouble may occur during operation Any problem in the fuel compression or ignition systems can cause poor starting and loss of power The troubleshooting chart describes a quick easy procedure for making checks If your Motorcycle requires any repair ...

Page 60: ...ition check Enough fuel No fuel Go to compression check in the fuel tank Check if there is fuel Supply fuel Open the throttle half way and start the engine or replace spark plug WARNING Never Check the fuel system while smoking or in the vicinity of an open flame PERIODIC MAINTENANCE AND MINOR REPAIR 6 34 Ask YAMAHA dealer to inspect Troubleshooting chart For Starting 1 Fuel 2 Compression 3 Igniti...

Page 61: ... Fork Brakes Transmission Seals Electrical Parts there by leading to its Detorioration CLEANING AND STORAGE Improper cleaning can damage the cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any harsh chemical products on plastic parts Alaways use clean cloth or sponge for cleaning the Motorcycle CAUTION 4 After ...

Page 62: ... tank 3 Remove the spark plug pour about one tablespoon of SAE 10W30 or 20W40 motor oil in the spark plug hole and reinstall the spark plug Kick the engine over several times with the ignition off to coat the cylinder wall with oil 4 Remove the drive chain Thoroughly clean the chain with solvent and lubricate it Reinstall the chain or store it in a plastic bag tied to frame for safe keeping 5 Lubr...

Page 63: ...C Forward inclined single cylinder 123 7 cm mm Kick Self starter Wet sump 3 10 8 BHP 7500 RPM 1 06 Kgfm 6500 RPM EngineOil Capacity Air filter Fuel Carburettor Type Periodic oil change 1 0 Total amount 1 2 Type Regular Gasoline Petrol Fuel tank capacity 13 0 Reserve amount Type BS25 Manufacturer M S UCAL Fuel System Be sure to use motor oils that do not contain antifriction modifiers Passenger car...

Page 64: ...14 Transmission type Constant mesh 5 speed Operation Gear ratio 1st 33 11 3 0 1 2nd 32 18 1 77 1 3rd 25 19 1 31 1 4th 23 12 1 04 1 5th 21 24 0 875 1 Frame type Diamond Type Caster angle 26 40 Wet multiple disc Left foot operation Size Front Rear 3 00 Air pressure cold tyre Single Rider Front Rear 32 With Pillion and rider Front Rear Tyre with Tube 2 75 x18 4PR RIBBED X18 6PR UNIVERSAL 25 psi 1 75 ...

Page 65: ...l travel Electrical Bulb voltage Wattage x Quantity Fuse Front 120 mm Rear 90 mm Ignition system DC CDI Digitally Timing Generator system Type Standard output 12V Battery Type Voltage capacity Headlight Tail Brake light Front flasher light Rear flasher light Meter light Neutral indicator light High beam indicator light Turn indicator light Main Advanced Flywheel magneto Lead acid 12V 5 0 AH 12V 35...

Page 66: ... the space provided and use it for reference when obtaining a new key 1 Frame serial number The frame serial number is stamped into the steering head pipe on right hand side Frame serial number 1 Engine serial number The engine serial number is stamped into the right hand crankcase Engine serial number CUSTOMER INFORMATION 9 1 ...

Page 67: ...kes 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 Movement e Suspension Front Fork Check for any sticky movement Rear Shock Abs For Free Stroking Setting on both To be filled in by the Dealer on receipt of the Motorcycle from YAMAHA Odo Meter Reading Date of Inspection Frame No Engine No Date of...

Page 68: ...H h Fasteners Specified Torque Ft Lb 1 Front Wheel Axle Nuts 25 40 2 Front Fork Crown Handle Inner Tube 13 20 2 Front Fork under Bracket Stem Nut 18 22 3 Handle Bar Mounting Bolts 13 20 4 Rear Shock Absorber Mounting Bolts 22 35 5 Rear Swing Arm Pivot Shaft Nut 32 52 6 Rear Wheel Axle Sprocket Shaft Nuts 60 70 B ENGINE a Engine Oil Oil Level For checking Refer Pg 6 8 Check for any Leakages 10 2 SE...

Page 69: ...M Check for Overflow f Drive Chain Alignment Slackness 20 30 mm g Brake Fluid Fluid Level Refer Page 6 18 h Fasteners Specified Torque Ft Lb 1 Cylinder Head Bolts 14 17 2 Engine Mounting a Engine Mounting Front and Stay Front 25 29 b Stay Engine Front and Frame 25 29 c Engine Mounting Rear and Frame 25 29 d Engine Mounting Upper Stay Engine Upper 25 29 e Stay Engine Upper and Frame 25 29 3 Front a...

Page 70: ...Specific Gravity Routing of Breather Pipe Fuse Routing of Positive Wire Red Below Breather Pipe e Starter Switch Kill Switch D ROAD TEST a Starting b Gear Shifting Operation c Clutch Operation d Application of Brakes Front and Rear e Speedo Odo Meter Operation f Fuel Meter Operation MAIN SELLING DLR S STAMP SIGN CODE EXPLAINED BY SIGNATURE NAME CUSTOMER S SIGN SERVICE2 PMD 8 28 2006 2 23 PM 4 ...

Page 71: ...h pressed 9 Gear shifting pattern 10 Tyre inflation pressure Front 25 Psi Rear 32 Psi Solo 36 Psi Double 11 Never give sudden acceleration always accelerate gradually 12 Simultaneous use of Front and Rear Brakes 13 Checking of Brake Fluid at regular intervals 14 Never ride with your foot on Rear brake Pedal 15 Whenever parking the Motorcycle on the Side Stand ensure that the Fuel Cock Lever is in ...

Page 72: ... 20 30 mm 21 Correct type of Spark Plug and Spark Plug gap 22 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 23 TFF oil to be replaced after every 10000 Kms 24 Running In Period Preventive Maintenance Schedule Instructions INSTALLATION 10 6 MAIN SELLING DLR S STAMP SIGN CODE EXPLAINED BY SIGNA...

Page 73: ... List of Components impacting Emission 3 CONTENTS DO S DON TS for the Motorcycle 1 Procedure for measurement of CO Emission Level 3 greenbook PMD 8 28 2006 2 24 PM 1 ...

Page 74: ...A serves you through a wide 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 kms c Air Filter Clean every 2000 kms as per the environment conditions d Piston Rings Cylinder Check Clean Replace if necessary e Exhaust System Chec...

Page 75: ...Get emission of your Motorcycle inspected at least once every 3 months 11 Please follow good driven habits in varying traffic conditions 12 Switch OFF the engine while waiting at signal point DON TS 1 Don t overload overspeed your Motorcycle 2 Don t alter or modify your Motorcycle 3 Never drive with Ignition OFF while moving down a slope 4 Don t turn off the Engine or interrupt the Ignition when t...

Page 76: ...Gas Analyser inside the Exhaust Muffler of the Motorcycle 2 7 If the reading is within specified limits then it is acceptable If the reading exceeds the norm of 3 5 by volume have it adjusted by YAMAHA Authorised Dealer CO EMISSION LEVEL MEASUREMENT 3 MODEL IDLE R P M 1300 1500 RPM GLADIATOR 3 LIST OF COMPONENTS IMPACTING EMISSION a Air Filter e Cylinder Head i Valve Seals m Spark Plug b Carbureto...

Page 77: ...uces Wear and Tear YAMAHA MOTOR INDIA PRIVATE LIMITED A 3 SURAJPUR INDUSTRIAL AREA NOIDA DADRI ROAD SURAJPUR 201 306 UP INDIA PRINTED IN INDIA 2Y16 OM 01 271 08 06 E SG 4 STROKE MOTOR OIL 20W40 4 Parts Accessories Always use Starter Motor Disc Brake 5P42 5P4 F8199 E1 ...

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