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YZF-R15
Yamaha YZF-R15 Manuals
Manuals and User Guides for Yamaha YZF-R15. We have
2
Yamaha YZF-R15 manuals available for free PDF download: Service Manual, Owner's Manual
Yamaha YZF-R15 Service Manual (338 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 22.19 MB
Table of Contents
Table of Contents
6
Symbols
5
1 General Information
7
Identification
8
Vehicle Identification Number
8
Engine Serial Number
8
Features
9
Outline of the Fi System
9
Fi System
10
Multi-Function Display
11
Important Information
12
Preparation for Removaland Disassembly
12
Replacement Parts
12
Gaskets, Oil Seals and O-Rings
12
Lock Washers/Plates and Cotter Pins
12
Bearings and Oil Seals
13
Circlips
13
Checking the Connections
14
Special Tools
15
Specifications
19
General Specifications
20
Engine Specifications
21
Chassis Specifications
28
Electrical Specifications
31
Tightening Torques
34
General Tightening Torque Specifications
34
Engine Tightening Torques
35
Chassis Tightening Torques
39
Lubrication Points and Lubricant Types
41
Engine
41
Chassis
43
Lubrication System Chart and Diagrams
44
Engine Oil Lubrication Chart
44
Lubrication Diagrams
46
Cooling System Diagrams
50
Cable Routing
52
Periodic Checks and Adjustments
67
Periodic Maintenance
69
Introduction
69
Periodic Maintenance and Lubrication Intervals
69
Engine
71
Adjusting the Valve Clearance
71
Adjusting the Engine Idling Speed
72
Adjusting the Exhaust Gas Volume
73
Adjusting the Throttle Cable Free Play
74
Checking the Spark Plug
75
Checking the Ignition Timing
75
Measuring the Compression Pressure
76
Checking the Engine Oil Level
77
Changing the Engine Oil
78
Adjusting the Clutch Cable Free Play
79
Cleaning the Air Filter Element
80
Checking the Throttle Body Joint and Air Filter Case Joint
80
Checking the Fuel Line
81
Checking the Cylinder Head Breather Hose
81
Checking the Exhaust System
81
Checking the Coolant Level
81
Checking the Cooling System
82
Changing the Coolant
82
Chassis
85
Adjusting the Rear Disk Brake
85
Checking the Brake Fluid Level
85
Checking the Front Brake Pads
86
Checking the Rear Brake Pads
86
Checking the Front Brake Hose
86
Checking the Reart Brake Hose
87
Bleeding the Hydraulic Brake System
87
Adjusting the Drive Chain Slack
88
Lubricating the Drive Chain
89
Checking and Adjusting the Steering Head
89
Checking the Front Fork
90
Checking the Tyres
90
Checking the Wheels
92
Checking and Lubricating the Cables
92
Lubricating the Clutch Lever
92
Lubricating the Brake Lever
93
Lubricating the Pedals
93
Lubricating the Sidestand
93
Lubricating the Rear Suspension
93
Chassis
96
General Chassis
100
Installing the Air Filter Case
100
Front Wheel
101
Removing the Front Wheel
103
Disassembling the Front Wheel
103
Checking the Front Wheel
103
Assembling the Front Wheel
104
Adjusting the Front Wheel Static Balance
104
Installing the Front Wheel (Disc)
105
Rear Wheel
107
Removing the Rear Wheel (Disc)
110
Disassembling the Rear Wheel
110
Checking the Rear Brake Caliper Bracket
110
Checking and Replacing the Rear Wheel Sprocket
110
Assembling the Rear Wheel
111
Adjusting the Rear Wheel Static Balance
111
Installing the Wheel (Disc)
111
Front Brake
112
Introduction
115
Checking the Front Brake Disc
115
Replacing the Front Brake Pads
116
Removing the Front Brake Caliper
117
Disassembling the Front Brake Caliper
117
Checking the Front Brake Caliper
117
Assembling the Front Brake Caliper
118
Installing the Front Brake Caliper
118
Removing the Front Brake Master Cylinder
119
Checking the Front Brake Master Cylinder
119
Assembling the Front Brake Master Cylinder
119
Installing the Front Brake Master Cylinder
119
Rear Brake
122
Checking the Rear Brake Disc
127
Replacing the Rear Brakes Pads
127
Removing the Rear Brake Caliper
128
Disassembling the Rear Brake Caliper
129
Checking the Rear Brake Caliper
129
Assembling the Rear Brake Caliper
130
Installing the Rear Brake Caliper
130
Removing the Rear Brake Master Cylinder
131
Assembling the Rear Brake Master Cylinder
131
Installing the Rear Brake Master Cylinder
132
Handlebar
135
Removing the Handlebars
135
Checking the Handlebar
135
Installing the Handlebar
135
Front Fork
138
Removing the Front Fork Legs
141
Disassembling the Front Fork Legs
141
Checking the Front Fork Legs
142
Assembling the Front Fork Legs
142
Installing the Front Fork Legs
145
Steering Head
146
Removing the Lower Bracket
148
Checking the Steering Head
148
Installing the Steering Head
148
Rear Shock Absorber Assembly
151
Removing the Rear Shock Absorber Assembly
151
Checking the Rear Shock Absorber Assembly
151
Checking the Connecting Arm and Relay Arm
151
Installing the Relay Arm
151
Installing the Rear Shock Absorber Assembly
151
Swingarm
153
Removing the Swingarm
155
Checking the Swingarm
155
Installing the Swingarm
155
Chain Drive
157
Checking the Drive Chain
158
Installing the Drive Chain
159
Engine
160
Engine Removal
163
Installing the Engine
167
Cylinder Head
168
Removing the Cylinder Head
170
Checking the Cylinder Head
170
Checking the Camshaft Sprocket and Timing Chain Guide
171
Checking the Timing Chain Tensioner
171
Checking the Decompression System
172
Installing the Cylinder Head
172
Camshaft
175
Removing the Rocker Arms and Camshaft
176
Checking the Camshaft
176
Checking the Rocker Arms and Rocker Arm Shafts
176
Installing the Camshaft and Rocker Arms
177
Valves and Valve Springs
178
Removing the Valves
179
Checking the Valves and Valve Guides
179
Checking the Valve Seats
180
Checking the Valve Springs
181
Installing the Valves
182
Cylinder and Piston
184
Removing the Piston
185
Checking the Cylinder and Piston
185
Checking the Piston Rings
186
Checking the Piston Pin
187
Installing the Piston and Cylinder
187
Magneto and Starter Clutch
189
Removing the Starter Clutch
191
Checking the Starter Clutch
191
Installing the Starter Clutch
192
Installing the Magneto
192
Electric Starter
194
Disassembling the Starter Motor
196
Checking the Starter Motor
196
Assembling the Starter Motor
197
Clutch
198
Removing the Clutch
202
Checking the Friction Plates
202
Checking the Clutch Plates
202
Checking the Clutch Springs
203
Checking the Clutch Housing
203
Checking the Clutch Boss
203
Checking the Pressure Plate
203
Checking the Clutch Push Lever and Short Clutch Push Rod
203
Checking the Primary Drive Gear
203
Checking the Primary Driven Gear
204
Installing the Clutch
204
Oil Pump
207
Checking the Oil Pump
209
Assembling the Oil Pump
209
Installing the Oil Pump
210
Shift Shaft
211
Checking the Shift Shaft
212
Checking the Stopper Lever
212
Installing the Shift Shaft
212
Balancer Gear
213
Removing the Primary Drive Gear and Balancer Gears
215
Checking the Balancer Gears and Primary Drive Gear
215
Installing the Primary Drive Gear and Balancer Gears
215
Crankcase
217
Separating the Crankcase
220
Checking the Crankcase
220
Checking the Timing Chain and Timing Chain Guide
220
Checking the Oil Strainer
220
Checking the Bearings and Oil Seal
220
Installing the Bearing Retainer
221
Assembling the Crankcase
221
Crankshaft
222
Removing the Crankshaft
223
Checking the Crankshaft
223
Installing the Crankshaft
223
Transmission
225
Checking the Shift Forks
228
Checking the Shift Drum Assembly
228
Checking the Transmission
228
Checking the Clutch Push Rods
229
Assembling the Main Axle and Drive Axle
229
Installing the Shift Forks and Shift Drum Assembly
229
Cooling System
231
Radiator
232
Checking the Radiator
234
Installing the Radiator
234
Thermostat
235
Checking the Thermostat
236
Installing the Thermostat
236
Water Pump
237
Disassembling the Water Pump
239
Checking the Water Pump
239
Assembling the Water Pump
239
Installing the Water Pump
240
Fuel System
241
Fuel Tank
242
Removing the Fuel Tank
243
Removing the Fuel Pump
243
Checking the Fuel Pump Body
243
Installing the Fuel Pump
243
Installing the Fuel Tank
243
Throttle Body
247
Removing the Throttle Body
247
Checking the Fuel Injector
247
Checking the Throttle Body
247
Checking the Fuel Pressure
247
Installing the Throttle Body
247
Air Induction System
250
Checking the Air Induction System
253
Electrical System
255
Ignition System
258
Circuit Diagram
258
Troubleshooting
260
Electric Starting System
262
Circuit Diagram
262
Starting Circuit Cut-Off System Operation
264
Troubleshooting
266
Charging System
268
Circuit Diagram
268
Troubleshooting
270
Lighting System
272
Circuit Diagram
272
Troubleshooting
274
Signaling System
276
Circuit Diagram
276
Troubleshooting
278
Cooling System
282
Circuit Diagram
282
Troubleshooting
284
Fuel Injection System
286
Circuit Diagram
286
Ecu Self-Diagnostic Function
288
Self-Diagnostic Function Table
289
Troubleshooting Method
291
Diagnostic Mode
292
Troubleshooting Details
298
Fuel Pump System
308
Circuit Diagram
308
Troubleshooting
310
Electrical Components
312
Checking the Switches
314
Checking the Bulbs and Bulb Sockets
317
Checking and Charging the Battery
318
Checking the Fuse
318
Checking the Relays
321
Checking the Turn Signal Relay
322
Checking the Diode
323
Checking the Spark Plug Cap
323
Checking the Ignition Coil
324
Checking the Ignition Spark Gap
324
Checking the Crankshaft Position Sensor
325
Checking the Lean Angle Sensor
325
Checking the Rectifier/Regulator
326
Checking the Starter Motor Operation
326
Checking the Stator Coil
326
Checking the Fuel Sender
327
Checking the Horn
327
Checking the Coolant Temperature Sensor
328
Checking the Radiator Fan Motor
328
Checking the Throttle Body Sensor Assembly
329
Specifications
329
Checking the Speed Sensor
331
Troubleshooting
332
General Information
332
Incorrect Engine Idling Speed
333
Starting Failures
333
Faulty Clutch
334
Faulty Gear Shifting
334
Jumps out of Gear
334
Overheating
334
Poor Medium-And-High-Speed Performance
334
Shift Pedal Does Not Move
334
Faulty Front Fork Legs
335
Overcooling
335
Poor Braking Performance
335
Unstable Handling
335
Faulty Lighting or Signaling System
336
Wiring Diagram
337
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Yamaha YZF-R15 Owner's Manual (84 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 3.27 MB
Table of Contents
Important Manual Information
4
Important Manual Information
5
Table of Contents
6
Location of Important Labels
8
Safety Information
10
Description
15
Left View
15
Right View
16
Controls and Instruments
17
Instrument and Control Functions
18
Main Switch/Steering Lock
18
Indicator and Warning Lights
19
Tachometer
20
Multi-Function Display
20
Handlebar Switches
21
Clutch Lever
23
Shift Pedal
23
Brake Lever
23
Brake Pedal
24
Fuel Tank Cap
24
Fuel
25
Catalytic Converter
26
Seat
26
Helmet Holder
27
Sidestand
28
Ignition Circuit Cut-Off System
28
For Your Safety - Pre-Operation Checks
31
Operation and Important Riding Points
32
Starting the Engine
32
Shifting
33
Tips for Reducing Fuel Consumption
33
Engine Break-In
34
Parking
34
Periodic Maintenance and Adjustment
35
Owner's Tool Kit
35
Lubrication Chart
35
Removing and Installing the Cowlings and Panel
40
Checking the Spark Plug
41
Engine Oil and Oil Filter Element
43
Coolant
45
Adjusting the Engine Idling Speed
47
Adjusting the Throttle Cable Free Play
48
Valve Clearance
48
Tires
49
Cast Wheels
51
Adjusting the Clutch Lever Free Play
51
Checking the Front Brake Lever Free Play
52
Adjusting the Brake Pedal Free Play
53
Checking the Front and Rear Brake Pads
53
Checking the Brake Fluid Level
54
Changing the Brake Fluid
55
Drive Chain Slack
55
Cleaning and Lubricating the Drive Chain
56
Checking and Lubricating the Cables
57
Checking and Lubricating
57
Throttle Grip and Cable
57
Checking and Lubricating the Brake and Shift Pedals
58
Checking and Lubricating the Brake and Clutch Levers
58
Checking and Lubricating the
58
Lubricating the Swingarm Pivots
60
Checking the Front Fork
60
Checking the Steering
61
Checking the Wheel Bearings
61
Battery
62
Replacing the Fuse
63
Replacing a Headlight Bulb
64
Replacing the Tail/Brake Light Bulb
64
Replacing a Turn Signal Light Bulb
65
Replacing an Auxiliary Light Bulb
65
Supporting the Motorcycle
65
Front Wheel
66
Rear Wheel
68
Troubleshooting
69
Troubleshooting Charts
70
Motorcycle Care and Storage
72
Matte Color Caution
72
Care
72
Storage
75
Specifications
77
Consumer Information
80
Identification Numbers
80
Motorcycle Noise Regulation (for Australia)
81
Index
82
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