Page 1
TROKE MOTOR OIL 0W40 ger Engine Life er Maintenance Cost OWNER'S MANUAL er Exhaust Smoke uces Wear and Tear 5P4-F8199-E1 5P4-F8199-E1 Starter Motor & Disc Brake Starter Motor & Disc Brake PRINTED IN INDIA 2Y16(OM-01)-271-08-06-E...
Page 2
WARNING PLEASE READ THIS MANUAL CAREFULLYAND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. OWNER'S MANUAL YAMAHA MOTOR INDIA PVT. LIMITED All rights reserved. Any reprinting or unauthorised use without the written permission of YAMAHA MOTOR INDIA PVT. LIMITED is expressly prohibited. TAKE NECESSARY PRECAUTIONS DURING RUNNING-IN PERIOD.
Page 3
Owner/ User of the Motorcycle for keeping Environment Clean and Green. You are requested to please read the GREEN BOOK carefully. We Provide At Your Caring Service, YAMAHA MOTOR INDIA PVT. LTD. A-3, Industrial Area, Noida Dadri Road Surajpur - 201 306 UP (India)
This manual should be considered a permanent part of this Motorcycle and should remain with it even if the Motorcycle is subsequently sold. • YAMAHA continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your Motorcycle and this manual.
ROAD SAFETY TIPS SAFE RIDING 1. Before riding, you should learn to ride your motorcycle properly and all the control functions should be known to you. 2. Remember that there are no legal “rights” when it comes to survival as far as Motorcyclists are concerned.
INSTRUMENT AND CONTROL FUNCTIONS WARNING Never turn the key to "LOCK" when the Motorcycle is moving. Push Main switch cum steering Release lock Turn LOCK: The main switch controls the ignition The steering is locked in this position and lighting systems. Its operation is and all electrical circuits are switched described below.
INSTRUMENT AND CONTROL FUNCTIONS Fuel Meter Turn indicator light “ ” Speedometer High beam indicator light “ ” Odometer Neutral indicator light “N” Fuel Meter Speedometer Indicator lights The fuel meter indicates the quantity The speedometer shows riding of the remaining petrol in the fuel tank. Turn indicator light "...
INSTRUMENT AND CONTROL FUNCTIONS Turn signal switch To signal a right-hand turn, push the switch to " ". To signal a left- hand turn, push the switch to " ". Once the switch is released it will return to the center position. To cancel the signal, push the switch in Press after it has returned to the center...
INSTRUMENT AND CONTROL FUNCTIONS Shift pedal Front brake lever Clutch lever Clutch lever Shift pedal Front brake lever The shift pedal is located on the left The front brake lever is located on The clutch lever is located on the left handlebar.
INSTRUMENT AND CONTROL FUNCTIONS NOTE : 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. WARNING WARNING Be sure the cap is properly installed and locked in place Rear brake pedal Open before riding the Motorcycle.
INSTRUMENT AND CONTROL FUNCTIONS WARNING Do not overfill the fuel tank. Avoid spilling fuel on the hot engine. Do not fill the fuel tank above the bottom of the filler tube to avoid Spillage CAUTION : Filler tube Arrow mark Always wipe off spilled fuel Fuel level Fuel cock...
INSTRUMENT AND CONTROL FUNCTIONS 1. Arrow mark 1. Arrow mark 1. Starter lever ON: With the fuel cock in this RES: This indicates reserve. If you Starter lever position, fuel flows to the run out of fuel while riding, set Starting a cold engine requires a carburettor.
INSTRUMENT AND CONTROL FUNCTIONS Kick starter Seat Holder Open (Bolt - 1 No.) Kick-starter Open (Bolt - 1 No.) Projection To install Raise the right Pillion footrest, and Opening of Seat rotate the kick starter away from the Insert the projection on the rear of To remove engine.
INSTRUMENT AND CONTROL FUNCTIONS Stan- Soft Hard dard Adjusting Position (Depends upon rider's requirement) WARNING A l w a y s a d j u s t e a c h s h o c k absorber to the same setting. 1.
• If necessry, add recommended brake fluid to specified level. 3-4, 6-18 Front brake • If soft or spongy, have YAMAHA dealer bleed hydraulic system. • Check fluid level in reservoir. • Check hydraulic system for leakage. • Check operation, condition and free play.
Page 22
PRE-OPERATION CHECKS ITEM CHECKS PAGE • Check for smooth operation. 6-22 Control and meter cable • Lubricate if necessary. • Check for smooth operation. Brake and shift pedal shafts 6-23 • Lubricate if necessary. • Check for smooth operation. Brake and clutch lever pivots 6-23 •...
OPERATION AND IMPORTANT RIDING POINTS CAUTION : Starting a warm engine. • Do not ride downhill with The Starter Lever may not be required Ignition Switch in “OFF” when the engine is warm. Position & in Neutral Gear. • Always ride motor cycle with CAUTION : Ignition Switch in “ON”...
OPERATION AND IMPORTANT RIDING POINTS 8. Avoid frequent braking. Tips for reducing fuel CAUTION : consumption 9. Always maintain your tyre Be sure to replace the engine oil as pressure as per recommendation per recommended schedule. Your Motorcycle's fuel consumption 10.
OPERATION AND IMPORTANT RIDING POINTS Parking When parking the Motorcycle, stop the engine and remove the ignition key. Turn the fuel cock to "OFF" whenever stopping the engine. WARNING The exhaust system is hot. Park the Motorcycle in a place where pedestrians or children are not likely to touch the Motorcycle.
If you are not familiar with in the safest and most efficient Motorcycle service, this work condition possible. Safety is an should be done by a YAMAHA obligation of the Motorcycle owner. dealer. The maintenance and lubrication schedule chart should be considered...
Page 28
PERIODIC MAINTENANCE AND MINOR REPAIR NOTE : If you do not have necessary tools required during a service operation, take your Motorcycle to a YAMAHA dealer for service. WARNING Modifications to this Motorcycle not approved by YAMAHA may cause loss of performance, and render it unsafe for use.
PERIODIC MAINTENANCE AND MINOR REPAIR PREVENTIVE MAINTENANCE SCHEDULE DURING SERVICE DAYS OR KMS AFTER WHICHEVE OCCURS FIRST ITEM OPERATION 90 DAYS OR 180 DAYS OR 30 DAYS OR 2000 KMS 4500~5000 KMS 500~700 KMS 2500~2700 KMS Check valve clearances, adjust if necessary. VALVES Check condition, gap;...
Page 30
PERIODIC MAINTENANCE AND MINOR REPAIR PREVENTIVE MAINTENANCE SCHEDULE DURING SERVICE DAYS OR KMS AFTER ITEM OPERATION WHICHEVE OCCURS FIRST S.NO 30 DAYS OR 90 DAYS OR 180 DAYS OR 2000 KMS 4500~5000 KMS 500~700 KMS 2500~2700 KMS Check alignment marks on Push Lever and CLUTCH Crankcase L.H.
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Panel A 1. Lug 2. Panel B 2. Panel A Panel removal and installa- 3. Lug tion Removal of Panel A The panels illustrated need to be Unlock the panel. removed to perform some of the maintenance described in this Pull the lug 1 towards you to remove manual.
Page 32
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Lug 1. Lug 1. Lug. 2. Lug 2. Lug 2. Lug 3. Lug 3. Lug Removal of Panel B Installation of Panel A Installation of Panel B Loosen screw completely and follow Slide the panel towards the Rear of Follow the same procedure as given t h e s a m e p r o c e d u r e a s f o r the motorcycle for inserting the lug...
Do not attempt to diagnose A.- Spark plug gap: 0.6-0.7 mm any problems yourself. Instead, take the Motorcycle to a YAMAHA dealer. When installing the plug, always You should periodically remove and clean the gasket surface and use a inspect the spark plug because heat new gasket.
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Engine oil filler cap 1. Dipstick Maximum level Minimum level 2. Engine oil replacement Engine oil a. Warm up the engine for a few 1. Oil level measurement NOTE : minutes. a. Place the Motorcycle on the Wait a few minutes until the oil level b.
Page 35
PERIODIC MAINTENANCE AND MINOR REPAIR Start the engine and warm up Tightening torque: for a few minutes. While Drain plug: warming up, check for oil leak- 14.5 It-lb (2.0 m-kg) age. If oil leakage is found, stop the engine immediately and e.
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Air filter element Air filter case cover Air filter element 2. Frame Screw(4 Nos) Lockable SpringWire 6. Dip the Air Filter Elements in Air filter recommended oil squeeze out the The air filter should be cleaned at 3.
Most adjust- 7. Pull the air filter elements over • The engine should never be run ments should be left to a YAMAHA the frame and install the air filter without the air filter installed. dealer who has the professional in the case.
1. Do not Tamper/Adjust with TPS NOTE : (Throttle Position Sensor) If the specified idle speed cannot be 2. Do not Open BS (Butterfly Slide) obtained by performing the above Valve Screws. adjustment, consult a YAMAHA Please refer Page 6.3 dealer. 6-12...
This adjustment however, should be left to a YAMAHA dealer. 1. Tread depth 1. Free play 2.
Page 40
Do not carry loosely or if the side wall is cracked, packed items that can shift. ed according to total weight of contact a YAMAHA dealer cargo, rider, passenger, and Securely pack your heaviest items immediately and have the tyre...
If proper adjustment cannot be obtained or the clutch does not work correctly, ask a YAMAHA 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.
The rear brake light switch is acti- the proper adjustment, ask a (Instruction 2, a ) at the brake pedal vated by the brake pedal and is YAMAHA dealer. end. Turn the adjusting nut in properly adjusted when the brake •...
If the brake fluid level is low, have a YAMAHA dealer replace the wear limit line, have a YAMAHA be sure to check the brake pads for brake pads as a set.
Have a YAMAHA dealer check the l e a k a g e a n d p o o r b r a k i n g brake fluid at the intervals specified in performance the periodic maintenance.
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Chain joint 1. Locknut Adjusting nut 2. Adjusting hex screw Cotter pin If the chain is disassembled, be sure Axle nut 4. Loosen the chain adjusting the chain lock is placed in the Drive chain slack adjust- locknuts on each chain puller.
Page 47
PERIODIC MAINTENANCE AND MINOR REPAIR Adjust the free play in the CAUTION : brake pedal. • Maintain chain slackness within specified limits as per specifications. WARNING Check the operation of the brake • To maintain correct axle light after adjusting the rear alignment, Ensure the notch brake.
Lubricate the pivoting and mating Lubricate the pivoting parts. joints. Recommended Grease : Check to see that the center and MULTIPURPOSE sidestand move up and down smoothly. WARNING If the center and/or sidestand does not move smoothly, consult a YAMAHA dealer. 6-23...
Check for scratches or damage forward and backward. If any free on the inner tube and excessive play can be felt, ask a YAMAHA oil leakage from the front fork. dealer to inspect and adjust the steering. Inspection is easier if the front wheel is removed.
If there is play in the front or rear so there is no danger of it falling wheel hub or if the wheel does not over. turn smoothly, have a YAMAHA dealer inspect the wheel bearings. 1. Maximum level mark 2. Minimum level mark...
Page 52
PERIODIC MAINTENANCE AND MINOR REPAIR CAUTION : Antidote: Replenishing the battery fluid EXTERNAL: Flush with water. A poorly maintained battery will When inspecting the battery, be corrode and discharge quickly. The sure the breather hose is routed INTERNAL: Drink large quantities battery fluid should be checked at correctly.
Install a new fuse of proper connected and is not damaged or amperage. Turn on the switches and obstructed. see if the electrical device operates. If the fuse immediately blows again, consult a YAMAHA dealer. 6-27...
4. Remove the defective head light 7. If the headlight beam adjustment 3. Slide head light forward. bulb from the bulb holder, if is necessary, ask a YAMAHA fused. dealer to make adjustment. 5. Remove the parking bulb if fused.
PERIODIC MAINTENANCE AND MINOR REPAIR Front wheel removal WARNING • 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.
Page 56
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Cotter Pin 2. Axle Nut Speedometer Cable 3. Remove the cotter pin '1' and axle 1. Place the Motorcycle on the nut '2'. centerstand. 4. Remove the wheel, make sure 2. Loosen the Speedometer cable the Motorcycle is properly Nut '1', &...
Rear wheel removal Always use a new cotter pin. WARNING • It is advisable to have a YAMAHA dealer service the Axle nut torque: wheel. 33 ft-lb (4.55 m-kg) • 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.
Page 58
2. Remove the cotter pin and nut. lever. Then remove the tension bar 4. Remove the axle nut cotter pin from the brake shoe plate. and the axle nut. ALWAYS USE YAMAHA GENUINE SPARE PARTS 6-32...
If your Motorcycle requires tightening torque. any repair, bring it to a YAMAHA 5. Take the Motorcycle off the dealer. The skilled technicians at a centerstand. YAMAHA dealership have the tools, 6.
2. Compression There is compression Go to Ignition check. Use kick starter. No compression. Ask YAMAHA dealer to inspect. 3. Ignition Wipe clean with dry cloth Open the throttle half-way and correct spark plug and start the engine.
CLEANING AND STORAGE A. CLEANING 1. Before cleaning the Motorcycle: CAUTION : a. Block off the end of the exhaust Direct excessive Hose Pressure Frequent, thorough cleaning of your pipe to prevent water entry; a may cause water Entry Into Wheel Motorcycle will not only enhance its plastic bag and strong rubber Bearing, Front Fork Brakes,...
CLEANING AND STORAGE 8. Clean the seat with a vinyl B. STORAGE solvent and lubricate it. Reinstall upholstery cleaner to keep the the chain or store it in a plastic bag Long term storage (60 days or more) cover pliable and glossy. (tied to frame for safe-keeping).
SPECIFICATIONS Specifications EngineOil: Type: YAMALUBE 4-Stroke motor Model GLADIATOR oil (20W40 type SG) Dimensions Overall length 2065 mm CAUTION : Overall width 730 mm Be sure to use motor oils that do not contain Overall height 1100 mm antifriction modifiers. Passenger car motor oils (often...
Page 64
SPECIFICATIONS Spark plug : Type/Manufacturer CR7HSA (NGK) Tyre with Tube Spark plug gap 0.6-0.7 mm Size Clutch type : Wet, multiple-disc Front 2.75 x18” 4PR (RIBBED) Transmission : Primary reduction system Helical gear Rear 3.00 X18” 6PR (UNIVERSAL) Primary reduction ratio 3.4 (68/20) Air pressure (cold tyre ): Secondary reduction system...
Page 65
SPECIFICATIONS Wheels: Wheel travel: Type: Front 120 mm Front Spoke wheel Rear: 90 mm Rear Spoke wheel Electrical: Size: Ignition system: DC-CDI (Digitally Timing Front 1.60 X 18 Advanced) Rear 1.60 X 18 Generator system: Brakes: Type Flywheel magneto Front : Standard output Type Single Disc Brake...
CUSTOMER INFORMATION Key identification number Frame serial number Engine serial number Key identification number Frame serial number Engine serial number The key identification number is The frame serial number is stamped The engine serial number is stamped on the key. into the steering head pipe on right stamped into the right hand hand side.
Page 67
PRE-DELIVERY INSPECTION REPORT (To be filled in by the Dealer on receipt of the Motorcycle from YAMAHA) Frame Engine Odo-Meter Date of Date of Reading Inspection Sale 1. Check for any missing item(s), scratches in painted/plated part(s), saddle or other external visual damages and take corrective action.
Page 68
PRE-DELIVERY INSPECTION REPORT f. Wheels Tyre Tyre pressure Solo Double (PSI) Front Rear Runout - Radial - 1.5 mm (Max) - Lateral - 1.5 mm (Max) Spokes No loosenes g. Locks Operation • Ignition • Steering • Fuel Tank Cap •...
Page 69
PRE-DELIVERY INSPECTION REPORT b. Spark Plug Recommended No. (CR7HSA-NGK) 0.6-0.7 mm c. Valve Clearance (Cold condition) (If required) Inlet 0.08 ~ 0.12 mm Exhaust 0.10 ~ 0.14 mm (After matching of the mark on sprocket cam chain with mark on Cylinder Head Casting and ensuring the Piston at TDC of compression stroke.) d.
Page 70
PRE-DELIVERY INSPECTION REPORT C. ELECTRICAL a. Ignition Switch Operation b. Left Hand Switch Operation & Pass Beam • Horn • Indicator • Head Light c. All Bulbs - Functioning d. Battery • Electrolyte Level • Specific Gravity • Routing of Breather Pipe •...
INSTALLATION Procedures to be explained to the customer on delivery of the Motorcycle by the Dealer's Representative. Operation of all the locks (Ignition, Steering, Fuel Tank Cap, Side Cover L.H.). Fuel Cock Lever Operation and its reserve position; Fuel Tank Capacity including reserve. Operation and function of Starter Lever.
Page 72
INSTALLATION Location of Storage and Tool Kit compartments and their use. Procedure of opening and closing of L. H. Side Panel. Battery Maintenance : Checking of electrolyte level (To add only distilled water if required & to maintain its Specified Level) Correct Drive Chain Slackness (20 ~30 mm).
Page 73
CONTENTS • DO’S & DON’TS for the Motorcycle • Procedure for measurement of ‘CO’ Emission Level. • List of Components impacting Emission greenbook.PMD 8/28/2006, 2:24 PM...
Page 74
• 4T - 20W/40 SG grade - YAMALUBE 4T Always keep your engine well tuned. Save environment and also improve Fuel Efficiency • ALWAYS GET YOUR MOTORCYCLE REPAIRED AND MAINTAINED ONLY AT YAMAHA AUTHORISED DEALER. • YAMAHA serves you through a wide network of Authorised Dealers.
Page 75
DO’S AND DON’TS FOR THE MOTORCYCLE 6 Always drive with Starter Lever in OFF position. 7 Use Starter Lever for minimum possible period (1 to 2 minutes) only to start and warm up Engine (may be required only in winter) 8 If misfiring, get your Motorcycle diagnosed &...
Page 76
Insert the Sampling probe of the Exhaust Gas Analyser inside the Exhaust Muffler of the Motorcycle. • 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. 3. LIST OF COMPONENTS IMPACTING “EMISSION”...
Page 77
• Longer Engine Life • Lower Maintenance Cost • Lower Exhaust Smoke • Reduces Wear and Tear 5P4-F8199-E1 YAMAHA MOTOR INDIA PRIVATE LIMITED A-3, SURAJPUR INDUSTRIAL AREA, NOIDA DADRI ROAD PRINTED IN INDIA SURAJPUR - 201 306 (UP) INDIA 2Y16(OM-01)-271-08-06-E...
Need help?
Do you have a question about the GLADIATOR and is the answer not in the manual?
Questions and answers