Yamaha N MAX GPD150-A 2015 User manual

2015
SERVICE MANUAL
GPD150-A
2DP-F8197-E0

EAS20002
GPD150-A
SERVICE MANUAL
©2015 by PT Yamaha Indonesia Motor
Manufacturing
First edition, July 2015
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
PT Yamaha Indonesia Motor Manufacturing
is expressly prohibited.

EAS20003
IMPORTANT
This manual was produced by the PT Yamaha Indonesia Motor Manufacturing primarily for use by
Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a me-
chanic 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.
PT Yamaha Indonesia Motor Manufacturing is continually striving to improve all of its models. Modifi-
cations and significant changes in specifications or procedures will be forwarded to all authorized
Yamaha dealers and will appear in future editions of this manual where applicable.
T
IP
Designs and specifications are subject to change without notice.
EAS30001
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

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 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 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. This step explains removal and disassembly procedure only. For installation
and assembly procedure, reverse the steps.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
1
7
3
5
6
2
4

EAS20005
SYMBOLS
The following symbols are used in this manual for easier understanding.
T
IP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine mounted Gear oil
Filling fluid Molybdenum disulfide oil
Lubricant Brake fluid
Special tool Wheel bearing grease
Tightening torque Lithium-soap-based grease
Wear limit, clearance Molybdenum disulfide grease
Engine speed Silicone grease
Electrical data Apply locking agent (LOCTITE®).
Engine oil Replace the part with a new one.
Silicone fluid
G
M
BF
B
T
R
.
.
LS
M
S
LT
ENew
S

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

1
GENERAL INFORMATION
IDENTIFICATION ............................................................................................ 1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
ENGINE SERIAL NUMBER ......................................................................1-1
FEATURES...................................................................................................... 1-2
OUTLINE OF THE FI SYSTEM.................................................................1-2
FI SYSTEM................................................................................................ 1-3
OUTLINE OF THE ABS............................................................................. 1-4
ABS COMPONENT FUNCTIONS .............................................................1-8
ABS OPERATION ...................................................................................1-13
ABS WARNING LIGHT AND OPERATION.............................................1-16
INSTRUMENT FUNCTIONS ...................................................................1-18
IMPORTANT INFORMATION .......................................................................1-22
PREPARATION FOR REMOVAL AND DISASSEMBLY.........................1-22
REPLACEMENT PARTS.........................................................................1-22
GASKETS, OIL SEALS AND O-RINGS ..................................................1-22
LOCK WASHERS/PLATES AND COTTER PINS ...................................1-22
BEARINGS AND OIL SEALS ..................................................................1-23
CIRCLIPS ................................................................................................1-23
RUBBER PARTS.....................................................................................1-23
BASIC SERVICE INFORMATION.................................................................1-24
QUICK FASTENERS...............................................................................1-24
ELECTRICAL SYSTEM...........................................................................1-25
SPECIAL TOOLS ..........................................................................................1-30

IDENTIFICATION
1-1
EAS20007
IDENTIFICATION
EAS30002
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is stamped
into the frame.
EAS30004
ENGINE SERIAL NUMBER
The engine serial number “1” is stamped into the
crankcase.
1
1