Yamaha YBR 125 GLADIATOR, YBR125 User Manual

Starter Motor & Disc Brake

ROKE MOTOR OIL

Starter Motor & Disc Brake

OWNER'S MANUAL

W40

er Engine Life

r Maintenance Cost r Exhaust Smoke

ces Wear and Tear

5P4-F8199-E1

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

(Starter Motor & Disc Brake)

5P42

5P4-F8199-E1

WARNING

PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THISMOTORCYCLE.

OWNER'S MANUAL

YAMAHA MOTOR INDIA PVT. LIMITED

permission of

YAMAHA MOTOR LIMITED is

expressly prohibited.

INDIA PVT.

TAKE NECESSARY PRECAUTIONS DURING RUNNING-IN PERIOD.

INTRODUCTION

Congratulations on yourpurchase of the . This motorcycle hasbeen produced using the 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

YAMAHA

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 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 toohappyto 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 please read theGREENBOOK carefully.

We Provide

At Your CaringService,

a leader in these fields.

GLADIATOR

YAMAHA

YAMAHA MOTOR INDIA PVT.LTD.

A-3, Industrial Area, Noida Dadri Road Surajpur - 201 306 UP (India)

IMPORTANT MANUAL INFORMATION

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

The SafetyAlert Symbol meansATTENTION ! BECOME ALERT ! YOUR SAFETY IS INVOLVED !

WARNING

CAUTION :

NOTE :

Failure to follow WARNING instructions to the Motorcycle operator, a bystander or a person inspecting orrepairingthe Motorcycle.

A CAUTION indicates specialprecautions that must be taken to avoid damage to the Motorcycle.

ANOTE provides key information to make procedures easierorclearer.

could result in severe injury

NOTE :

•

This manual should be considered a permanent part of this Motorcycle and should remain with it even iftheMotorcycle is subsequently sold.

•

YAMAHA

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. If there is any question concerningthismanual, please consult your dealer.

continually seeks advancements in product design and quality. Therefore,

YAMAHA

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

T ABLE OF CONTENTS

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 IMPORT ANT 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 ............................................................ 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

fazer5yy8.pmd 8/28/2006, 11:51 AM1

TABLE 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. S torage ...................................................... 7-2

SPECIFICATIONS ........................................... 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

fazer5yy8.pmd 8/28/2006, 11:51 AM2

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.

CAUTION :

• 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.

fazer5yy8.pmd 8/28/2006, 11:51 AM3

1-1

DESCRIPTION

Left view

STANDARD VEHICLE

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)

6543 7

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)

fazer5yy8.pmd 8/28/2006, 11:51 AM4

2-1

Right view

STANDARD VEHICLE

DESCRIPTION

12 1314

11. Rear shock absorber (page 3-9)

12. Air filter (page 6-10)

13. Kick starter (page 3-7)

fazer5yy8.pmd 8/28/2006, 11:51 AM5

14. Seat (page 3-8)

15. Engine oil filler cap (page 6-8)

16. Rear brake pedal (page 3-4,6-17)

2-2

DESCRIPTION

Controls / Instruments

19 20 21

STANDARD VEHICLE

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)

fazer5yy8.pmd 8/28/2006, 11:51 AM6

23 26

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)

2-3

INSTRUMENT AND CONTROL FUNCTIONS

WARNING

Never turn the key to "LOCK" when the Motorcycle is moving.

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 removed in thisposition.

OFF: Engine will be shut off. All electrical

circuits are switched off. The key can 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 handlebars all the way to the left or right. With the key at "OFF", push it into the main switch and release it, turn it counterclockwise to "LOCK" and removeit. To release the lock, turn the key to "OFF".

3-1

INSTRUMENT AND CONTROL FUNCTIONS

1. Speedometer

2. Odometer

Speedometer

The speedometer shows riding speed.

This speedometer is equipped with an odometer.

1. Fuel Meter

Fuel Meter

The fuel meter indicates the quantity of the remaining petrol inthe 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.

1. Turn indicator light “ ”

2. High beam indicator light “ ”

3. Neutral indicator light “N”

Indicator lights

Turn indicatorlight " "

The indicator flashes when the turn switch is moved to theleft or right. .

Neutral indicator light "N"

This indicator comes on when the transmission is in neutral.

High beam indicator light " "

This indicator comes on when the headlight high beam is used.

3-2

INSTRUMENT AND CONTROL FUNCTIONS

Turn signalswitch

To signal a right-hand turn, push the switch to " ". To signal a lefthand turn, push the switch to " ".

OFF

Once the switch is released it will return to the center position. To cancel the signal, push the switch in

1. PassSwitch " "

2. Dimmer Switch

3. Light switch

4. Turn signal cum cancellation switch“ “

5. Horn switch

Handlebar switches

Pass switch ""

Press the switch to operate the Passing Light.

Dimmer switch

after it has returned to the center position.

Horn switch " "

Press the switch to sound the horn.

Lights switch

Turning the light switch to " ", turns on the meter light and tail-light. Turning the light switch to “ ", turns the headlight on also.

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

Kill switch is an emergency switch to

Press

cut "OFF" engine & should always

Turn the switch to" " for the high beam and to " " for thelow beam.

3-3

be in "ON" positon at the time of starting the vehicle.

INSTRUMENT AND CONTROL FUNCTIONS

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.

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 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.

USE BOTH BRAKES SIMULTANEOUSLY

3-4

1 Rear brake pedal

Rear brake pedal

The rear brake pedal is on the right side of the Motorcycle. Press down on the brake pedal to apply the rear brake.

INSTRUMENT AND CONTROL FUNCTIONS

WARN

ING

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.

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

Be sure the cap is properly installed and locked in place before riding the Motorcycle.

WARNING

Before you operate this vehile read the Owner's Manual.

1. Arrow

3-5

INSTRUMENT AND CONTROL FUNCTIONS

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 filler tube as shown in the illustration.

IT IS A GOOD PRACTICE TO RETURN THE FUEL COCK LEVER TO

"Off" POSITION WHEN ENGINE IS NOT RUNNING

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 :

Always wipe off spilled fuel immediately with a dry and clean soft cloth. Fuel may deteriorate painted surfaces or plastic parts.

Recommended Fuel :

Regular gasoline (Petrol)

Fuel tank capacity :

Total :

13.0 L

Reserve :

1.2 L

OFF

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.

3-6

INSTRUMENT AND CONTROL FUNCTIONS

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 while riding.

RES

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

NEVER MIX OIL IN PETROL

3-7

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 theStarter

Move the Starter Lever in Direction b to Turn Off the Starter

INSTRUMENT AND CONTROL FUNCTIONS

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. 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

3-8

INSTRUMENT AND CONTROL FUNCTIONS

Stan-

Soft

Adjusting Position

(Depends upon rider's requirement)

12345

WARNING

Always adjust each shock

1. Storage compartment

Storage compartment

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

1. Spring preload adjusting ring

2. Position indicator

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.

absorber to the same setting. Uneven adjustment cancause poor handling and loss of stability.

dard

Hard

3-9

INSTRUMENT AND CONTROL FUNCTIONS

1. HandleSeat

1. Stay Lock on Saree Guard

Stay Lock

For mounting Helmet Lock

3-10

PRE-OPERATION CHECKS

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

ITEM CHECKS

Front brake

Rear brake

Clutch

Throttle grip and housing

Engine oil

Drive chain

Wheels and tyres

• Check operation, condition and free play.

• Adjust if necessary.

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

• 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.

• Adjust if necessary.

• Check operation, condition and free play.

• Adjust if necessary.

• Check for smooth operation.

• Lubricate if necessary.

• Check oil level.

• Fill with oil if necessary.

• Check chain slack and condition.

• Lubricate if necessary.

• Adjust if necessary.

• Check tyre pressure, wear, damage and spoke tightness.

• Tighten spokes if necessary.

4-1

PAGE

3-4, 6-18

3-5, 6-17

3-4, 6-16

6-12, 6-22

6-8 ~ 6-9

6-19 ~ 6-20

6-13 ~ 6-15

PRE-OPERATION CHECKS

ITEM CHECKS

Control and meter cable

Brake and shift pedal shafts

Brake and clutch lever pivots

Center and sidestand pivot

Chassis fasteners

Fuel Tank

Lights, signals and switches

Battery

• Check for smooth operation.

• Lubricate if necessary.

• Check for smooth operation.

• Lubricate if necessary.

• Check for smooth operation.

• Lubricate if necessary.

• Check for smooth operation.

• Lubricate if necessary.

• Make sure that all nuts, bolts, and screws are properly tightened.

• Tighten if necessary.

• Check fuel level.

• Fill with fuel if necessary.

• Check for proper operation.

• Check fluid level.

• Fill with distilled water if necessary.

PAG E

6-22

6-23

3-5 ~ 3-6

3-3, 6-28 ~ 6-29

6-25 ~ 6-26

WARNING

If any item in the Pre-Operation Check is not working properly, have it inspected and repaired before operating the Motorcycle.

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

TO PROTECT THE ENVIRONMENT AND TO LOWER FUEL CONSUMPTION

4-2

OPERATION AND IMPORTANT RIDING POINTS

WARNING

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 a corner.

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.

NOTE :

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

4 Fully open the Starter Lever and

completely close the throttle grip.

5. Kick the kick starter to start the

engine.

6. After starting the Engine, turn back

the Starter Lever to the Warmingup Position (About Half way)

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

NOTE :

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

NOTE :

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

5-1

OPERATION AND IMPORTANT RIDING POINTS

Starting a warm engine.

The Starter Lever may not be required when the engine is warm.

CAUTION :

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

NEVER RIDE MOTORCYCLE WITH CLUTCH PARTIALLY ENGAGED.

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.

CAUTION :

• 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 driveline are not designed to withstand the shock of forced shifting and can be damaged by shifting without using the clutch.

5-2

+ 53 hidden pages