Yamaha R15 2022 Manual de usuario

2022

SERVICE MANUAL

BCW-F8197-E0

YZF155D-A

YZF155-A

BCWF8197E0.book Page 1 Thursday, November 18,2021 9:18 AM

EAS200071

IMPORTANT

This manual was produced by the India Yamaha Motor Pvt. Ltd. primarily for use by Yamaha dealers

and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-

ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha 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 vehi-

cle unsafe and unfit for use.

India Yamaha Motor Pvt. Ltd. is continually striving to improve all of its models. Modifications and sig-

nificantchanges in specifications orprocedures willbeforwarded to allauthorized Yamaha dealers and

will appear in future editions of this manual where applicable.

TIP

Designs and specifications are subject to change without notice.

EAS20081

IMPORTANT MANUAL INFORMATION

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

This is the safety alert symbol. It is used to alert you to potential personal inju-

ry hazards. Obey all safety messages that follow this symbol to avoid possible

injury or death.

A WARNING indicates a hazardous situation which, if not avoided, could result

in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid damage to

the vehicle or other property.

A TIP provides key information to make procedures easier or clearer.

WARNING

NOTICE

TIP

EAS00000

YZF155D-A & YZF155-A

SERVICE MANUAL

First edition, September 2021

Any reproduction or unauthorized use

without the written permission of

India Yamaha Motor Pvt. Ltd.

is expressly prohibited.

BCWF8197E0.book Page 1 Thursday, November 18,2021 9:18 AM

EAS20004

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid

out with the individual steps in sequential order.

• The manual is divided into chapters and each chapter is divided into sections. The current sectiontitle

“1” is shown at the top of each page.

• Sub-section titles “2” appear in smaller print than the section title.

• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each

removal and disassembly section.

• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-

sembly step.

• Symbols “5” indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-

tially.

BCWF8197E0.book Page 2 Thursday, November 18,2021 9:18 AM

EAS20005

SYMBOLS

The following symbols are used in this manual for easier understanding.

TIP

The following symbols are not relevant to every vehicle.

SYMBOL DEFINITION SYMBOL DEFINITION

Serviceable with engine mounted Molybdenum disulfide oil

Filling fluid Brake fluid

Lubricant Wheel bearing grease

Special tool Lithium-soap-based grease

Tightening torque Molybdenum disulfide grease

Wear limit, clearance Silicone grease

Engine speed Apply locking agent (LOCTITE®).

Electrical data Replace the part with a new one.

Engine oil

New

BCWF8197E0.book Page 3 Thursday, November 18,2021 9:18 AM

EAS10003 TABLE OF CONTENTS

GENERAL INFORMATION 1

SPECIFICATIONS 2

PERIODIC CHECKS AND

ADJUSTMENTS 3

CHASSIS 4

ENGINE 5

COOLING SYSTEM 6

FUEL SYSTEM 7

ELECTRICAL SYSTEM 8

TROUBLESHOOTING 9

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BCWF8197E0.book Page 2 Thursday, November 18,2021 9:18 AM

GENERAL INFORMATION

IDENTIFICATION ...........................................................................................1-1

VEHICLE IDENTIFICATION NUMBER ....................................................1-1

ENGINE SERIAL NUMBER .....................................................................1-1

FEATURES .....................................................................................................1-2

OUTLINE OF THE TCS (Traction Control System) ..................................1-2

OUTLINE OF THE FI SYSTEM ................................................................1-6

FEATURES ..............................................................................................1-7

OUTLINE OF THE ABS ............................................................................1-8

ABS COMPONENT FUNCTIONS ..........................................................1-12

ABS OPERATION ..................................................................................1-18

ABS WARNING LIGHT AND OPERATION ............................................1-21

CCU (Communication Control Unit) .......................................................1-22

HANDLEBAR SWITCHES ......................................................................1-23

INDICATOR LIGHTS AND WARNING LIGHTS .....................................1-24

DISPLAY ................................................................................................1-25

MENU MODE .........................................................................................1-31

IMPORTANT INFORMATION ......................................................................1-34

PREPARATION FOR REMOVAL AND DISASSEMBLY ........................1-34

REPLACEMENT PARTS ........................................................................1-34

GASKETS, OIL SEALS AND O-RINGS .................................................1-34

LOCK WASHERS/PLATES AND COTTER PINS ..................................1-34

BEARINGS AND OIL SEALS .................................................................1-35

CIRCLIPS ...............................................................................................1-35

RUBBER PARTS ....................................................................................1-35

BASIC SERVICE INFORMATION ................................................................1-36

QUICK FASTENERS ..............................................................................1-36

ELECTRICAL SYSTEM ..........................................................................1-37

SPECIAL TOOLS .........................................................................................1-42

BCWF8197E0.book Page 0 Thursday, November 18,2021 9:18 AM

1-1

GEN

INFO

IDENTIFICATION

EAS20007

IDENTIFICATION

EAS30002

VEHICLE IDENTIFICATION NUMBER

The vehicleidentification number “1” is stamped

into the steering head pipe.

EAS30004

ENGINE SERIAL NUMBER

Theengineserialnumber“1”isstampedintothe

crankcase.

XXXXXXXX

BCWF8197E0.book Page 1 Thursday, November 18,2021 9:18 AM

1-2

FEATURES

GEN

INFO

EAS20008

FEATURES

EAS30855

OUTLINE OF THE TCS (Traction Control System)

The traction control system controls excessive spinning (slipping) of the rear wheel when accelerating

on slippery surfaces, such as unpaved or wet roads.

The ECU monitors the front and rear wheel speeds using the signals from the front and rear wheel sen-

sors, and detects rear wheel slipping according to the difference between the wheel speeds. If the slip-

ping exceeds the preset value, the ECU controls the slipping using integrated control of the ignition

timing and fuel cut-off.

The traction control system can be set to “ON” operation modes or turned “OFF”.

TCS (Traction control system) layout

1. Traction control system indicator light

2. Trip / information switch (To “ON” or “OFF”

TCS mode)

3. ABS ECU

4. ECU (Engine Control Unit)

5. Rear wheel sensor

6. Fuel injector

7. Spark plug

8. Front wheel sensor

9. Ignition coil

BCWF8197E0.book Page 2 Thursday, November 18,2021 9:18 AM

1-3

GEN

INFO

FEATURES

TCS (Traction control system) block diagram

The signals from the front and rear wheel sensors are sent to the ECU through the ABS ECU, and the

ECU calculates the amount of slip according to the difference between the detected front and rear

wheel speeds.

If the amount of slip exceeds the preset value, the ECU controls the ignition timing and fuel cut-off so

that the amount of slip is less than the preset value. The traction control system indicator light in the

meter assembly flashes when the traction control system has activated.

1. Front wheel sensor

2. Rear wheel sensor

3. ABS ECU

4. Trip / information switch (To “ON” or “OFF”

TCS mode)

5. ECU

A. Signal conversion

B. Slip amount calculation

C. Exceeds preset value

D. Actuator control

E. Fuel cut-off

F. Ignition timing (retarded)

G. Traction control system indicator light

(flashes)

BCWF8197E0.book Page 3 Thursday, November 18,2021 9:18 AM

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