Yamaha YZF-R15 Manual de usuario

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SERVICE MANUAL

YZF-R15

20P-F8197-E0

YZF-R15

SERVICE MANUAL

All rights reserved.

Any reproduction or unauthorized use

without the written permission of

YAMAHA MOTOR INDIA SALES PVT. LTD.

is expressly prohibited.

NOTICE

This manual was produced by YMIS. primarily for use by YMIS dealers and their qualified mechanics. It

is not possible to include all the knowledge of a mechanic in one manual. 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 vehicle unsafe and unfit for use.

India Yamaha Motor Pvt. Ltd. is continually striving to improve all of its models. 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.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS

INVOLVED!

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.

A CAUTION indicates special precautions that must be taken to avoid damage to the

vehicle.

ANOTE provides key information to make procedures easier or clearer.

NOTE:

IMPORTANT MANUAL INFORMATION

NOTE :

CAUTION :

WARNING

YZF-R15

SERVICE MANUAL

All rights reserved.

Any reproduction or unauthorized use

without the written permission of

YAMAHA MOTOR INDIA SALES PVT. LTD.

is expressly prohibited.

NOTICE

This manual was produced by YMIS. primarily for use by YMIS dealers and their qualified mechanics. It

is not possible to include all the knowledge of a mechanic in one manual. 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 vehicle unsafe and unfit for use.

India Yamaha Motor Pvt. Ltd. is continually striving to improve all of its models. 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.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS

INVOLVED!

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.

A CAUTION indicates special precautions that must be taken to avoid damage to the

vehicle.

ANOTE provides key information to make procedures easier or clearer.

NOTE:

IMPORTANT MANUAL INFORMATION

NOTE :

CAUTION :

WARNING

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 section title

“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

disassembly 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

sequentially.

1

7

3

4

5

6

2

SYMBOLS

The following symbols are used in this manual for

easier understanding.

NOTE:

The following symbols are not relevant to every

vehicle.

1. Serviceable with engine mounted

2. Filling fluid

3. Lubricant

4. Special tool

5. Tightening torque

6. Wear limit, clearance

7. Engine speed

8. Electrical data

9. Engine oil

10. Gear oil

11. Molybdenum disulfide oil

12. Brake fluid

13. Wheel bearing grease

14. Lithium-soap-based grease

15 Molybdenum disulfide grease

16. Silicone grease

17 Apply locking agent (LOCTITE®).

18 Replace the part with a new one.

9 10

11 12

13 14

15 16

17 18

LT New

1 2 3

4 5 6

7 8

Clutch Hub Holder

YSST-733

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 section title

“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

disassembly 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

sequentially.

SYMBOLS

The following symbols are used in this manual for

easier understanding.

NOTE:

The following symbols are not relevant to every

vehicle.

1. Serviceable with engine mounted

2. Filling fluid

3. Lubricant

4. Special tool

5. Tightening torque

6. Wear limit, clearance

7. Engine speed

8. Electrical data

9. Engine oil

10. Gear oil

11. Molybdenum disulfide oil

12. Brake fluid

13. Wheel bearing grease

14. Lithium-soap-based grease

15 Molybdenum disulfide grease

16. Silicone grease

17 Apply locking agent (LOCTITE®).

18 Replace the part with a new one.

G

M

E

BLS

M

9 10

11 12

13 14

15 16

17 18

LT New

BF

S

T

R

.

.

1 2 3

4 5 6

7 8

Clutch Hub Holder

YSST-733

TABLE OF CONTENTS

GENERAL INFORMATION 1

2

3

4

5

6

7

8

9

PERIODIC CHECKS AND

ADJUSTMENTS

SPECIFICATIONS

CHASSIS

ENGINE

COOLING SYSTEM

FUEL SYSTEM

ELECTRICAL SYSTEM

TROUBLESHOOTING

IDENTIFICATION

FEATURES

IMPORTANT INFORMATION

CHECKING THE CONNECTIONS

SPECIAL TOOLS

............................................................................................1-1

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

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

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

OUTLINE OF THE FI SYSTEM...................................................................1-2

FI SYSTEM.................................................................................................1-3

..........................................................................1-4

PREPARATION FOR REMOVALAND DISASSEMBLY...............................1-5

REPLACEMENT PARTS............................................................................1-5

GASKETS, OIL SEALS AND O-RINGS ......................................................1-5

LOCK WASHERS/PLATES AND COTTER PINS........................................1-5

BEARINGS AND OIL SEALS......................................................................1-6

CIRCLIPS...................................................................................................1-6

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

............................................................................................1-8

GENERAL INFORMATION

TABLE OF CONTENTS

GENERAL INFORMATION 1

2

3

4

5

6

7

8

9

PERIODIC CHECKS AND

ADJUSTMENTS

SPECIFICATIONS

CHASSIS

ENGINE

COOLING SYSTEM

FUEL SYSTEM

ELECTRICAL SYSTEM

TROUBLESHOOTING

IDENTIFICATION

FEATURES

IMPORTANT INFORMATION

CHECKING THE CONNECTIONS

SPECIAL TOOLS

............................................................................................1-1

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

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

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

OUTLINE OF THE FI SYSTEM...................................................................1-2

FI SYSTEM.................................................................................................1-3

..........................................................................1-4

PREPARATION FOR REMOVALAND DISASSEMBLY...............................1-5

REPLACEMENT PARTS............................................................................1-5

GASKETS, OIL SEALS AND O-RINGS ......................................................1-5

LOCK WASHERS/PLATES AND COTTER PINS........................................1-5

BEARINGS AND OIL SEALS......................................................................1-6

CIRCLIPS...................................................................................................1-6

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

............................................................................................1-8

GENERAL INFORMATION

IDENTIFICATION

IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER (FRAME

NO.)

ENGINE SERIAL NUMBER

NOTE:

The vehicle identification number “1”is stamped

into the frame.

The engine serial number “1”is stamped into the

crankcase.

Designs and specifications are subject to change

without notice.

1

FEATURES

OUTLINE OF THE FI SYSTEM

The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum

air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the

conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion

chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the

respective carburetor.

Despite the same volume of intake air, the fuel volume requirement varies by the engine operating

conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter

the fuel through the use of jets have been provided with various auxiliary devices, so that an optimum

airfuel ratio can be achieved to accommodate the constant changes in the operating conditions of the

engine.

As the requirements for the engine to deliver more performance and cleaner exhaust gases increase, it

becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To

accommodate this need, this model has adopted an electronically controlled fuel injection (FI) system, in

place of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required

by the engine at all times by using a microprocessor that regulates the fuel injection volume according to

the engine operating conditions detected by various sensors. The adoption of the FI system has resulted

in a highly precise fuel supply, improved engine response, better fuel economy, and reduced exhaust

emissions.

1. Engine trouble warning light

2. Spark plug

3. Ignition coil

4. Fuel pump

5. FID (fast idle solenoid)

6. Throttle body sensor assembly (consisting of

throttle position sensor, intake air pressure

sensor, intake air temperature sensor)

7. ECU (engine control unit)

8. Lean angle sensor

9. Crankshaft position sensor

10.Fuel injector

11.Coolant temperature sensor

1-1 1-2

1

xxxxxxx

FEATURES

IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER (FRAME

NO.)

ENGINE SERIAL NUMBER

NOTE:

The vehicle identification number “1”is stamped

into the frame.

The engine serial number “1”is stamped into the

crankcase.

Designs and specifications are subject to change

without notice.

FEATURES

OUTLINE OF THE FI SYSTEM

The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum

air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the

conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion

chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the

respective carburetor.

Despite the same volume of intake air, the fuel volume requirement varies by the engine operating

conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter

the fuel through the use of jets have been provided with various auxiliary devices, so that an optimum

airfuel ratio can be achieved to accommodate the constant changes in the operating conditions of the

engine.

As the requirements for the engine to deliver more performance and cleaner exhaust gases increase, it

becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To

accommodate this need, this model has adopted an electronically controlled fuel injection (FI) system, in

place of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required

by the engine at all times by using a microprocessor that regulates the fuel injection volume according to

the engine operating conditions detected by various sensors. The adoption of the FI system has resulted

in a highly precise fuel supply, improved engine response, better fuel economy, and reduced exhaust

emissions.

1. Engine trouble warning light

2. Spark plug

3. Ignition coil

4. Fuel pump

5. FID (fast idle solenoid)

6. Throttle body sensor assembly (consisting of

throttle position sensor, intake air pressure

sensor, intake air temperature sensor)

7. ECU (engine control unit)

8. Lean angle sensor

9. Crankshaft position sensor

10.Fuel injector

11.Coolant temperature sensor

1-1 1-2

1

xxxxxxx

91011

1 2 3 4 5,6 7 8

FEATURES

FI SYSTEM

The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel

pressure that is applied to the fuel injector at only 250 kPa (2.50 kg/cm², 35.6 psi). Accordingly, when the

energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be

injected into the intake manifold only during the time the passage remains open. Therefore, the longer the

length of time the fuel injector is energized (injection duration), the greater the volume of fuel that is

supplied. Conversely, the shorter the length of time the fuel injector is energized (injection duration), the

lesser the volume of fuel that is supplied.

The injection duration and the injection timing are controlled by the ECU. Signals that are input from the

throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake air temperature

sensor, lean angle sensor and coolant temperature sensor enable the ECU to determine the injection

duration. The injection timing is determined through the signals from the crankshaft position sensor. As a

result, the volume of fuel that is required by the engine can be supplied at all times in accordance with the

driving conditions.

1. Fuel pump

2. Fuel injector

3. Ignition coil

4. Coolant temperature sensor

5. ECU (engine control unit)

6. Lean angle sensor

7. Crankshaft position sensor

8. FID (fast idle solenoid)

9. Air filter case

10. Throttle body

11. Throttle body sensor assembly

12. Intake air temperature sensor

13. Throttle position sensor

14. Intake air pressure sensor

A. Fuel system

B. Air system

C. Control system

12

14

10

9

1

2

34

6

5

7

8

11

13

The multi-function display is equipped with the

following:

•a speedometer (which shows the riding speed)

•an odometer (which shows the total distance

traveled)

•two tripmeters (which show the distance

traveled since they were last set to zero)

•a fuel reserve tripmeter (which shows the

distance traveled since the fuel level warning

light came on)

•a fuel meter

1. Multi-function display

2. “RESET/SELECT”button

Odometer and tripmeter modes

( )

“ /

“

“ 1” “ 2”

:

→ 1 → 2 →

1.

,

“ -

,

. ,

“ /

:

- → 1 → 2 → → -

A brief push less than one second on the

RESET SELECT”button switches the display

between the odometer mode ODO”and the

tripmeter modes TRIP and TRIP in the

following order

ODO TRIP TRIP ODO

When approximately 9 L of fuel remains in the

fuel tank the odometer display will automatically

change to the fuel reserve tripmeter mode F

TRIP”and start counting the distance traveled

from that point and the last segment of the fuel

meter will start flashing In that case pushing the

RESET SELECT”button switches the display

between the various tripmeter and odometer

modes in the following order

F TRIP TRIP TRIP ODO F TRIP

1-3 1-4

Tripmeter will reset itself automatically and the

display will return to the prior mode after refueling

and traveling 5 km (3 mi).

The fuel meter indicates the amount of fuel in the

fuel tank. The display segments of the fuel meter

disappear towards “E”(Empty) as the fuel level

decreases. When the last fuel meter segment

starts flashing, refuel as soon as possible.

1. Fuel meter