YAMAHA R15 SERVICE MANUAL PDF
View and Download Yamaha YZF-R15 service manual online. YZF-R15 Motorcycle pdf manual download. YZF-R SERVICE MANUAL. All rights reserved. Any reproduction or unauthorized use without the written permission of. YAMAHA MOTOR INDIA SALES PVT. Yamaha YZF-R15 Service Manual (English) - Ebook download as PDF File .pdf), Text File .txt) or read book online. Yamaha YZF-R15 Service Manual (English).
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Yamaha R15 v1 service manual is a necessity for all the bikers who own this sporty looking bike. Click here to read more this service manual of. Note that the illustrations for reference in finding parts numbers are not to be used for assembling. When assembling, please use the applicable service manual. YZF-R15 Motorcycle pdf manual download. - Thu, 07 Mar GMT Yamaha YZF-R15 Manuals Yamaha R15 Yzf. Service Manual | Yamaha T
To increase your chances of winning, try raising your bid. You're the first bidder. Good Luck! You're still the highest bidder! You increased your max bid to Please enter your bid again. Enter a valid amount for your bid. Enter a bid that is the minimum bid amount or higher. You have to bid at least Sorry, you can't lower your maximum bid once it's placed. Therefore, anyone who uses this book to perform maintenance and repairs onYamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. India Yamaha Motor Pvt. Modifications and significant changes in specifications or procedures will be forwarded to all authorized YMIS dealers and will appear in future editions of this manual where applicable.
Designs and specifications are subject to change without notice. Particularly important information is distinguished in this manual by the following.
Failure to follow WARNING instructions could result in severe injury or death to the vehicle operator, a bystander or a person checking or repairing the vehicle. Calculate the piston-to-cylinder clearance with the following formula. Level the piston ring into the cylinder with the piston crown.
Before measuring the piston ring side clearance. D3 or D5. Piston ring Top ring Ring side clearance 0. Piston-to-cylinder clearance 0. Limit Piston-pin-to-piston-pin-bore clearance 0. The oil ring expander spacer end gap cannot be measured. Piston pin bore inside diameter Be sure to install the piston rings so that the manufacturer marks or numbers face up.
If the oil ring rail gap is excessive. Top ring Oil ring expander Upper oil ring rail Lower oil ring rail 2nd ring exhaust side. To protect the end of the crankshaft, place an appropriate sized socket between the flywheel puller set center bolt and the crankshaft. Make sure the magneto puller is centered over the magneto rotor. Magneto puller YSST Measure the armature assembly resistances with the multimeter.
Before disassembling the starter motor.
Yamaha YZF-R15 Service Manual (English).pdf - 2008 SERVICE...
Mica undercut depth 1. If any resistance is out of specification. Brush spring force 3. Order LS 10 Nm 1. Straighten the lock washer tab. Measure the friction plate at four places. Friction plate 1 B. Friction plate 1 thickness 2. Pitting on the clutch boss splines will cause erratic clutch operation.
Clutch spring free length Pitting on the clutch housing dogs will cause erratic clutch operation. Clutch hub holder YSST 2. Clutch spring bolt 12 Nm 1. Recommended lubricant Engine oil 7. Bend the lock washer tab along a flat side of the nut.
Tighten the clutch cover bolts in the proper tightening sequence as shown. Clutch cover bolt 10 Nm 1. Oil pump housing Recommended lubricant Engine oil 2. When installing the inner rotor. Outer rotor 3. Inner rotor 2. Inner-rotor-to-outer-rotor-tip clearance Less than 0. After tightening the screws. Oil pump assembly screw 4 Nm 0. Order 10 Nm 1. Install the dowel pins and springs alternately as shown as.
Balancer driven gear nut 50 Nm 5.
Thoroughly clean all the gasket surfaces and crankcase mating surfaces. Work slowly and carefully and make sure the crankcase halves separate evenly. Thoroughly wash the crankcase halves in a mild solvent. Right crankcase B. Tap on one side of the crankcase with a softface hammer.
In this position. Left crankcase 2. Tap only on reinforced portions of the crankcase. Bearing retainer bolt 7 Nm 0. Crankcase bolt 10 Nm 1. Do not allow any sealant to come into contact with the oil gallery. Thoroughly clean all the gasket mating surfaces and crankcase mating surfaces.
Crankcase 1 Balancer 1 2 Crankshaft 1 For installation. Big end side clearance D 0. Width A Runout limit C 0. Turn the crankshaft slowly. Turn the crankshaft installer bolt until the crankshaft bottoms against the bearing. To avoid scratching the crankshaft and to ease the installation procedure. Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installer bolt with the other.
Shift fork guide bar Roll the shift fork guide bar on a flat surface.
Before assembling the crankcase. The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence: Coolant reservoir breather hose 1 2 Coolant reservoir hose 1 3 Coolant reservoir cap 1 4 Coolant reservoir 1 5 Radiator fan coupler 1 6 Water pump breather hose 1 7 Radiator outlet hose 1 8 Radiator inlet hose 1 9 Radiator cap 1 6.
Yamaha YZF-R15 Service Manual (English).pdf - 2008 SERVICE...
Apply the specified pressure for ten seconds and make sure there is no drop in pressure. Radiator cap opening pressure Apply compressed air to the rear of the radiator. Radiator cap tester 6. Straighten any flattened fins with a thin.
Fully open NOTE: If the accuracy of the thermostat is in doubt. Replace any part that was dropped or subjected to a strong impact. Use extreme care when handling the coolant temperature sensor. While stirring the water. Coolant temperature sensor 18 Nm 1. Fully closed B.
A faulty thermostat could cause serious overheating or overcooling. Clutch cable engine side Disconnect.
Push down 3. Remove the water pump seal from the inside of the water pump housing. Never lubricate the water pump seal surface with oil or grease. Mechanical seal installer 4.
Seat 1 Fuel pump coupler 1 Disconnect. Residual pressure in the fuel lines could cause fuel to spurt out when removing the hoses. Be sure to lean the fuel tank against a wall or the like.
Do not set the fuel tank down on the installation surface of the fuel pump. Extract the fuel in the fuel tank through the fuel tank cap with a pump. Order LT 2 Nm 0. Remove the seat. Measure the fuel pressure. Wash the throttle body in a petroleum. Do not use any caustic carburetor cleaning solution. Blow out all of the passages with compressed air. Air cut-off valve 7. Air induction system hose 3-way joint to air cut-off valve 4. Air induction system vacuum hose 6.
Air induction system hose 3-way joint to resonator 3. Air induction system hose air filter case to 3way joint 5. Resonator 2. Air induction system hose 3-way joint to resonator 1 2 Resonator 1 3 Air induction system hose air filter case to 3way joint 1 4 Air induction system hose 3-way joint to air cutoff valve 1 5 Air induction system vacuum hose 1 6 Air cut-off valve 1 7 Reed valve assembly 1 8 Reed valve plate 1 1 Remarks For installation.
Air cut-off valve The air cut-off valve is operated by the intake gas pressure through the piston valve diaphragm. From the air filter case B. Air cut-off valve opens Perform step b. During sudden deceleration the throttle valve suddenly closes. Air cut-off valve closes Replace the air cut-off valve. Blow air through the end of the air induction system hose 3-way joint to air cut-off valve and check that air does not flow and out through the air cut-off valve to cylinder head side.
Blow air through the end of the air induction system hose 3-way joint to air cut-off valve and check that air flows from the air cut-off valve to cylinder head side.
To the intake manifold 1. To the cylinder head C. When there is negative pressure at the exhaust port. Air cut-off valve closes Air cut-off valve is OK. Seat 2. Fuel tank 3. Right front panel. Check the battery. Check the ignition spark gap. Check the spark plug cap.
Check the crankshaft position sensor.
Yamaha Corporation Yzf R15 Version 2 0 2015 User Manual
Replace the right handlebar switch. Check the entire ignition system wiring. Check the lean angle sensor. Check the engine stop switch. Battery Starter motor Starter relay Starting system cut off relay. The starting circuit cut-off relay prevents the starter motor from operating when neither of these conditions has been met. In this instance. When at least one of the above conditions has been met.
Check the fuse. Check the starting circuit cut-off relay. Check the starter relay. Perform the electric starting system troubleshooting. Check the diode. Right side panel 1. Check the starter motor. Check the starter motor operation. Check the main switch. Check the start switch. Check the entire starting system wiring. Check the neutral switch. Check the clutch switch.
Check the stator coil. Check the entire charging system wiring.
Choose your model
Check the dimmer switch. Check the entire lighting system wiring.
Replace the left handlebar switch. Check the pass switch. Headlight 1. Check the each bulbs and bulb sockets condition. Rear Flasher light L Turn signal switch Neutral switch Fuse Front Flasher light L Tail light Front Flasher light R Speed sensor Main switch Fuel sender ECU engine control unit Check the signaling system The horn fails to sound. Check the entire signaling system wiring. Check the horn switch. Check the horn. The turn signal light. Check the rear brake light switch.
Check the front brake light switch. Check the turn signal indicator light bulb and socket. Check the turn signal light bulb and socket. Check the turn signal switch. The neutral indicator light fails to come on. Check the neutral indicator light bulb and socket. Check the turn signal relay. Check the fuel sender. The fuel gauge fails to operate. Check the coolant temperature sensor. Check the radiator fan motor relay. Check the radiator fan motor. Check the entire cooling system wiring.
Headlight lens unit 1. Left and right front panel 3. Self-diagnosis signal connector Vehicle speed sensor Radiator fan motor FID fast idle solenoid device Lean Angle Sensor Engine stop switch Coolant temperature sensor Fuel pump Stop Switch Spark plug Sensor Module Radiator fan motor relay Ignition coil Digit of 1: Cycles of 0.
If this function detects a malfunction in the system. Once a malfunction has been detected. ON and 1. Engine trouble warning light Engine trouble warning light fault code indication Digit of Cycles of 1 sec. ON and 0. It remains stored in the memory of the ECU until it is deleted. Lean angle sensor Lean angle sensor Faulty ignition Fuel injector open or short circuit Engine trouble warning light on for 3 seconds a. When an abnormal signal is received from a sensor.
If the warning light does not come on under these conditions. Engine trouble warning light off NOTE: Engine unable to start under following conditions. Engine trouble warning light flashes when the start switch is pushed.
Able Able 46 Vehicle system power supply Monitoring voltage Power supply to the fuel injection system is not normal.
Unable Unable 13 Intake air pressure sensor open or short circuit Intake air pressure sensor: Able Able 30 Lean angle sensor latch up detected No normal signal is received from the lean angle sensor.
Unable 42 Start unable warning Able Able 16 Throttle position sensor stuck Throttle position sensor is stuck Able Able 21 Coolant temperature sensor Coolant temperature sensor: Able Able 14 Intake air pressure Intake air pressure sensor: Able 22 Intake air temperature sensor open or short circuit Intake air temperature sensor: Unable Unable 33 Ignition coil open circuit Primary lead of the ignition coil: Unable Unable 41 Lean angle sensor open or short circuit Lean angle sensor: Unable Unable 39 Fuel injector Fuel injector: Check and repair.
Monitor the operation of the sensors and actuators in the diagnostic mode. Check the operation of following sensors and actuators in the Diagnostic mode. If a malfunction is detected in the sensors or actuators. Check the fault code number displayed on the FI diagnostic tool or Meter. No fault code No. Fault code No. Perform Fuel Injection System reinstatement action.
If fault codes are displayed. Identify the probable cause of the malfunction. Erase the malfunction history in the diagnostic mode. Check and repair the probable cause of malfunction.
Identify the faulty system with the fault code. If no malfunction is detected in the sensors and actuators. The engine speed.
Malfunction in FI diagnostic tool. Stop the engine. If a malfunction is detected in the system.
And also. Malfunction in ECU. Disconnect the FI diagnostic tool and connect the self-diagnosis signal connector. Verify the operation of the sensor or actuator. FI Diagnostic Tool D Setting the diagnostic mode 1. Throttle position sensor: Lean angle sensor: Intake air temperature sen. Fault code table Fault code No.
Symptom Probable cause of malfunction Diagnostic code No. The CO adjustment value and throttle valve fully closed notifica60 tion valve are not properly written on or read from the internal memory. Fuel system voltage battery voltage Approximately Refer jection system is not normal. If the battery voltage is lower. Diagnostic Code Table Diagnostic code No.
Compare the actually measured air temperature with the display value. If the display value changes. When this malfunction is detected in the ECU. The number is cumulative and does not reset each. Check that the number increase when the front wheel is rotated. The program and data are not properly written on or read from the — internal memory. Check the spark five times. Check the operating sound of the injector five times. ON 2 seconds. Radiator fan motor relay Actuates the radiator fan motor relay for five cycles every Check the operating sound five-second.
CO adjustment value is detected. Illuminates the engine trouble warning light. When all code numbers are shown. Control number 0— — Fault code number displayed on the FI diagnostic tool when the engine failed to work normally. Diagnostic code number to be used when the diagnostic mode is operated.
After the check and service of the malfunctioning part has been completed. Diagnostic code No. Cranking the engine. Symptom No normal signals are received from the crankshaft position sensor. Check for looseness or pinching. Check and service the items or components that are the probable cause of the malfunction following the order given.
Code No. Symptom Intake air pressure sensor: Do not remove the sensor module throttle body sensor assembly from the throttle body. Do not remove the throttle body sensor assembly from the throttle body. Defective intake air pressure sensor. Starting the engine and operating it at rpm and above. Symptom Throttle position sensor: Symptom Coolant temperature sensor-open or short circuit detected. Check the installed area for ture sensor looseness or pinching.
Symptom Throttle position sensor is stuck. Symptom Intake air temperature sensor: Symptom Primary lead of the ignition coil: Symptom Rollover signal is received from the lean angle sensor. Raise the vehicle upright. Symptom Open or short circuit detected in injector. Reinstatement method Symptom Lean angle sensor: Symptom Faulty ECU memory. Symptom Power supply to the fuel injection system is not normal.
Repair or replace if there is an open or short circuit. Adjust the exhaust gas volume refer to page no. Starting the engine. Symptom No normal signals are received from the speed sensor.
Stop switch Check the fuel pump. Check the entire fuel pump system wiring. Fuel tank 1. Main switch Clutch switch Front brake light switch Ignition coil Throttle body sensor assembly intake air pressure sensor.
Always insert the probes from the opposite end of the coupler. Multimeter NOTE: If the continuity reading is incorrect. The switches and their terminal connections are illustrated as in the following example of the main switch. When checking for continuity. There is continuity between red. The continuity i. If either of the readings indicate no continuity.
The majority of these types of bulbs can be removed from their respective socket by turning them counterclockwise. Before checking for continuity. Types of bulbs The bulbs used on this vehicle are shown in the illustration on the left. Never pull the lead. If the fuse immediately blows again. Connect the multimeter to the fuse and check the continuity. Check each bulb socket for continuity in the same manner as described in the bulb section.
Check the bulb socket for continuity. If any of the readings indicate no continuity. Set on the switches to verify if the electrical circuit is operational. Multimeter b. Install a good bulb into the bulb socket. Install a new fuse of the correct amperage rating. Connect the multimeter probes to the respective leads of the bulb socket. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system.
If the battery is overcharged. Connect a multimeter to the battery terminals.Be sure to tighten the camshaft sprocket bolt to the specified torque to avoid the possibility of the bolt coming loose and damaging the engine. Install the fuse box. Connect a battery 12 V to the horn. Try raising your max bid. Warpage limit 0. If the brake disc deflection cannot be brought within specification.
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