Yamaha GLADIATOR Ower's Manual

er Engine Life

r Maintenance Cost r Exhaust Smoke

ces Wear and Tear

PRINTED IN INDIA 2Y16(OM-01)-271-08-06-E

Starter Motor & Disc Brake

ROKE MOTOR OIL

W40

Starter Motor & Disc Brake

(Starter Motor & Disc Brake)

OWNER'S MANUAL

5P4-F8199-E1

5P42

5P4-F8199-E1

TAKE NECESSARY PRECAUTIONS DURING RUNNING-IN PERIOD.

OWNER'S MANUAL

YAMAHA MOTOR INDIA PVT. LIMITED

permission of

YAMAHA MOTOR LIMITED is

expressly prohibited.

INDIA PVT.

WARNING

PLEASE READ THIS MANUAL CAREFULLYAND COMPLETELYBEFORE OPERATING THIS MOTORCYCLE.

INTRODUCTION

Congratulations onyour purchase of the . This motorcyclehas been produced usingthe latest technology in our modern plant, to provide you a happy, enjoyable and safe riding for many thousand kilometers and years. It represents the high degree of craftsmanship and reliability that have made

a leader inthese fields.

This Owner's Manual will give you an understanding of the operation, inspection and basic maintenance of this Motorcycle. To ensure a long trouble free performance, please take due care and ensure proper maintenance of your Motorcycleas recommended in this Owner's Manual. Always demandonly Genuine Spare Parts and Yamalube oil. If you have any queries regarding the operation or maintenance of your Motorcycle, pleaseconsult your DEALER who willbe too happy to help you.

This Owner's Manual also includes the GREEN BOOK containing Guidelines, DO's and DON'Ts to be followed by the Owner/ User of the Motorcycle for keeping Environment Clean and Green. You are requested to pleaseread the GREEN BOOK carefully.

We Provide

At YourCaring Service,

GLADIATOR

YAMAHA

YAMAHA MOTOR INDIA PVT.LTD.

A-3, Industrial Area, Noida Dadri Road Surajpur - 201306 UP (India)

Particularly important information is distinguished in this manual by the following notations:

IMPORTANT MANUAL INFORMATION

•

This manual should be considered a permanent part of this Motorcycle and should remain with iteven if the Motorcycle is subsequentlysold.

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 betweenyour Motorcycle and this manual.If there is anyquestion concerning this manual, please consultyour dealer.

YAMAHA

The SafetyAlert Symbol means ATTENTION! BECOME ALERT ! YOUR SAFETY IS INVOLVED !

NOTE :

CAUTION :

WARNING

Failure to follow WARNING instructions to the Motorcycle operator, a bystander or aperson inspecting or repairing the Motorcycle.

could result in severe injury

A CAUTION indicates special precautions that mustbe taken toavoid damage tothe Motorcycle.

ANOTE provides key information tomake procedures easier or clearer.

NOTE :

ROAD SAFETY TIPS ....................................... 1-1

DESCRIPTION ................................................ 2-1

Left view ........................................................ 2-1

Right view ...................................................... 2-2

Controls/Instruments ................................... 2-3

INSTRUMENT AND CONTROL

FUNCTIONS.................................................... 3-1

Main switch cum steering lock ..................... 3-1

Speedometer ................................................ 3-2

Fuel Meter ..................................................... 3-2

Indicator lights .............................................. 3-2

Handlebar switches/Kill Switch ................... 3-3

Starter Switch

Clutch lever ................................................... 3 -4

Shift pedal ..................................................... 3- 4

Front brake lever ........................................... 3- 4

Rear brake pedal .......................................... 3- 5

Fuel tank cap ................................................ 3- 5

Fuel ............................................................... 3-5

Fuel cock ....................................................... 3- 6

Starter Lever.................................................. 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

REPA IR ............................................................ 6-1

Tool kit ........................................................... 6 -1

Preventive maintenance schedule .............. 6-3

Panel removal and installation .................... 6 -5

Spark plug inspection .................................. 6-7

Engine Oil ..................................................... 6-8

TABLE OF CONTENTS

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T ABLE OF CONTENTS

Air filter........................................................... 6-10

Carburetor adjustment ................................. 6-11

Idle speed adjustment ................................. 6-12

Throttle cable free play adjustment ............. 6-12

Valve clearance adjustment ......................... 6-13

Tyres.............................................................. 6-13

Wheels.......................................................... 6-15

Clutch lever free play adjustment ................ 6-16

Rear brake adjustment ................................ 6-17

Brake light switch adjustment ..................... 6-17

Checking front Brake Pads &

rear brake shoes .......................................... 6-18

Checking brake fluid level ............................ 6-18

Drive chain slack check ................................ 6-19

Drive chain slack adjustment ...................... 6-20

Drive chain lubrication .................................. 6-22

Cable inspection and lubrication ................. 6-22

Throttle cable and grip lubrication ............... 6-22

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 installation ................................ 6-33

Troubleshooting ........................................... 6-33

Troubleshooting chart .................................. 6-34

CLEANING & STORAGE................................. 7-1

A. Cleaning ................................................... 7-1

B. Storage ...................................................... 7-2

SPECIFICATIO NS ........................................... 8-1

CUSTOMER INFORMATION........................... 9-1

Key identification number ............................. 9- 1

Frame serial number ................................... 9-1

Engine serial number .................................. 9-1

DETATCHMENTS

Pre-Delivey Inspection.................................... 10-1

Installation....................................................... 10-5

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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. The fact that you may be well within your rights is no guarantee that you will avoid a collision with a bigger vehicle whose driver fails to see you. Always ride defensively and take nothing on road for granted.

3. Develop the ability to react swiftly to any unexpected road hazards or emergencies giving yourself time to spare for appropriate response.

4. Develop the ability to get the most out of your Motorcycle, But at the same time get to 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 acts as the Engine Brake. If the riding condition allows, reduce speed by shifting the Gear down.

2. Front and Rear Brakes : It is important to apply equal force to the Front and Rear Brakes simultaneously.

• Use Front and Rear Brakes simultaneously.

• Be sure not to disengage the clutch while braking.

• While riding downhill always use Engine as a Brake and never ride in Neutral Gear.

• While riding down hill do not switch off ignition while Engine is in gear.

CAUTION :

1-1

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DESCRIPTION

2-1

Left view

6. Toolkit (page 6-1)

7. Handle Seat (page 3-10)

8. Drive chain 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

6543 7

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DESCRIPTION

2-2

Right view

11. 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

12 1314

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17. Clutch Lever (page 3-3, 6-16)

18. Left Hand Switch (page 3-3)

19. Speedometer (page 3-2)

20. Main switch Cum Steering 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)

19 20 21

Controls / Instruments

DESCRIPTION

STANDARD VEHICLE

2-3

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Main switch cum steering lock

The main switch controls the ignition and lighting systems. Its operation is described below.

ON: Electrical circuits are switched on. The engine can be started. The key cannot be removedin this position.

OFF: Engine will be shut off. All electrical circuits are switched off. The key can be removed inthis 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 handlebars all theway to theleft or right. With the key at "OFF", push it into the main switch and release it, turn it counterclockwise to "LOCK"and remove it. To release the lock, turn the key to "OFF".

INSTRUMENT AND CONTROL FUNCTIONS

WARNING

Never turn the keyto "LOCK" when the Motorcycle ismoving.

3-1

INSTRUMENT AND CONTROL FUNCTIONS

3-2

1. Turn indicator light “ ”

2. High beam indicator light “ ”

3. Neutral indicator light “N”

Indicator lights

Turnindicator light " "

Neutral indicator light"N"

High beam indicatorlight " "

The indicator flashes when the turn switch is movedto the left or right..

This indicator comes on when the transmission is inneutral.

This indicator comes on when the headlight high beamis 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 remainingpetrol in the fuel tank.

The gauge needle moves from “F” (Full) to"E”(Empty) as the fuel level decreases.

When the needle comes below “E” please refill the fuel tank at the earliest.

Fuel Meter

Turnsignal switch

Horn switch " "

Lights switch

To signal a right-hand turn, push the switch to " ". To signal a lefthand 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 after it has returned to the center position.

Press the switch to sound the horn.

Turning the light switch to " ", turns on the meter light and tail-light. Turning the light switch to “ ", turns 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 should be in

1) Neutral Position

2) If in Gear clutch lever to be pressed

Kill switch is an emergency switch to cut "OFF" engine & should always be in "ON" positon at the time of starting the vehicle.

Kill Switch

Press

OFF

INSTRUMENT AND CONTROL FUNCTIONS

USE BOTH BRAKES SIMULTANEOUSLY

3-4

1. Shift pedal

Shift pedal

The shift pedal is located on the left side of the engine and is used in combination with the clutch when shifting. Use your toe or heel to shift up and your toe toshift 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. 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 released slowly for smooth clutch operation.

INSTRUMENT AND CONTROL FUNCTIONS

3-5

1 Rear brake pedal

Rear brake pedal

The rear brake pedal is on the right side ofthe Motorcycle. Pressdown on the brake pedal to apply the rear brake.

1. Open

Fuel tank cap

TO OPEN: Insert the key and turn it 1/4 turn clockwise. The lock will be released and the cap can be opened.

TO CLOSE: Push the tank cap into position with 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.

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 theMotorcycle.

WARNING

NOTE :

WARNING

WARN

ING

r '

1. Arrow

WARNING

Beforeyou operate this vehile readthe Owner's Manual.

1. Arrow mark

Fuel cock

The fuel cock supplies fuel from the tank to the carburetor while filtering it also.

The fuel cock has three positions, which should be set as shown in the illustrations.

OFF: With the fuel cock in this

position, fuel will not flow. Always set the fuel cock to this position when the engine is not running.

INSTRUMENT AND CONTROL FUNCTIONS

3-6

Always wipe off spilled fuel immediately with a dry and clean soft cloth. Fuel may deteriorate painted surfaces orplastic 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 surethere is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown in the illustration.

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

OFF

INSTRUMENT AND CONTROL FUNCTIONS

3-7

NEVER MIX OIL IN PETROL

1. Arrow mark

ON: With the fuel cock in this

position, fuel flows to the carburettor. Set the fuel cock to this position when starting the engine and whileriding.

1. Arrow mark

RES: This indicates 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 to Turn on the Starter Move the Starter Lever in Direction b to Turn Off theStarter

RES

3-8

INSTRUMENT AND CONTROL FUNCTIONS

1. Open (Bolt - 1 No.)

2. Open (Bolt - 1 No.)

Opening of Seat

To remove

Open side panels as per instructions on page 6-5. Remove the two bolts 1 and 2 as shown in figure. Lift the front of the seat and slide forward to remove.

1. Seat Holder

2. Projection

To install

Insert the projection on the rear of seat in to seat holder. Then push down 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-coupled kick starter so the engine can be started in any gear if the clutch is disengaged. However, shifting to neutral before starting is recommended.

kick

1. Storage compartment

Storage compartment

The storage compartment is located inside the L.H.Side Cover

1. Spring preload adjusting ring

2. Positionindicator

Rear shock absorber adjustment

Each shock absorber is equipped with a spring preload adjusting ring. Adjust spring preload as follows. 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 lossof stability.

INSTRUMENT AND CONTROL FUNCTIONS

3-9

WARNING

Adjusting Position

Soft

12345

Hard

Standard

(Depends upon rider's requirement)

INSTRUMENT AND CONTROL FUNCTIONS

3-10

1. HandleSeat

1. Stay Lock on Saree Guard

Stay Lock

For mounting Helmet Lock

PRE-OPERATION CHECKS

4-1

Owners are personally responsible for their vehicle's condition. Your Motorcycle's vital functions can start to deteriorate quickly and unexpectedly- even if it remains unused (for instance, if it is exposed to the elements). Any damage. fluid leak or loss of tyre pressure could have serious consequence Therefore' it is very important that, in addition to a thorough visual inspection, you check the following points before each ride.

PRE - OPERATION CHECK LIST

Engine oil

Wheels and tyres

Drive chain

Clutch

Throttle 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 operation, condition and free play.

• Adjust if necessary.

• Check operation, condition and free play.

ITEM CHECKS

6-8 ~ 6-9

6-12, 6-22

3-4, 6-16

3-5, 6-17

3-4, 6-18

PAGE

• If soft or spongy, have YAMAHA dealer bleed hydraulic system.

• Check fluid level in reservoir.

• If necessry, add recommended brake fluid to specified level.

• Check hydraulic system for leakage.

PRE-OPERATION CHECKS

4-2

IF WAITING AT TRAFFIC SIGNAL IS FOR LONG, SWITCH OFF THE ENGINE

TO PROTECT THE ENVIRONMENT AND TO LOWER FUEL CONSUMPTION

If anyitem in the Pre-Operation Check is not workingproperly, haveit inspected and repaired beforeoperating the Motorcycle.

WARNING

Fuel Tank

Brake and clutch lever pivots

Battery

Lights, signals and switches

Chassis fasteners

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

PAG E

6-23

Brake and shift pedal shafts

Control and meter cable

• Lubricate if necessary.

• Check for smooth operation.

• Lubricate if necessary.

• Check for smooth operation.

6-22

6-23

OPERATION AND IMPORTANT RIDING POINTS

1. Before riding this Motorcycle, become thoroughly familiar with all operating controls and their functions. Consult a YAMAHA dealer regarding any control or function that you do not thoroughly understand.

2. Never start your engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and can cause loss of consciousness. Always operate your Motorcycle in an area with adequate ventilation.

3. Before starting out, always be sure the side stand is up. Failure to retract the side stand completely can result in a serious accident when you try to turn acorner.

Starting and warming up a cold engine

1. Turn the fuelcock to "ON"

2. Turn the mainswitch to "ON."

3. Shift the transmission into neutral.

When the transmission is in neutral, the neutral indicator light should beon. If the light does not come on, ask a YAMAHA dealer toinspect it.

4 Fully open the Starter Lever and

completely close thethrottle grip.

5. Kick the kick starter to start the

engine.

6. After starting the Engine, turn back

the Starter Lever to the Warmingup Position (AboutHalf way)

7. After Warming-up the Engine, turn off the Starter Lever completely.

For better engine performance always warm up the engine. before take off. Never open throttle fully when engine is cold, otherwise engine tends tostop.

The engine is warm when it responds normally to the throttle with the Starter Lever in “OFF” direction.

5-1

WARNING

NOTE :

OPERATION AND IMPORTANT RIDING POINTS

Starting a warm engine.

The Starter Lever maynot be required when the engineis warm.

See the "Running-in" section prior to operating the Motorcycle for the first time.

a. Shift pedal

N. Neutral, 1,2,3,4,5 Gear Shift Patterns

Shifting

The transmission lets you control the amount of power you have available at a given speed for starting, accelerating, climbing hills, etc. The use 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 & inNeutral Gear.

• Always ride motor cycle with Ignition Switch in “ON” Position & inNeutral Gear.

• Always use the clutch when changing gears. The engine, transmission, and driveline are not designed to withstand the shock of forced shifting and can be damaged by shifting without using theclutch.

5-2

CAUTION :

NEVER RIDE MOTORCYCLE WITH CLUTCH PARTIALLY ENGAGED.

N 1

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Yamaha GLADIATOR Ower's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual