Yamaha R15 2022 User manual

2022
SERVICE MANUAL
BCW-F8197-E0
YZF155D-A
YZF155-A
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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
©2022 by India Yamaha Motor Pvt. Ltd.
First edition, September 2021
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
India Yamaha Motor Pvt. Ltd.
is expressly prohibited.
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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.
3
4
5
6
1
2
7
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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
M
BF
B
LS
T
R
.
.
M
S
LT
New
E
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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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1
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
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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
1
1
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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
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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.
1A
B
D
G
E
F
5
C
A
4
3
2
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)
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1-4
FEATURES
GEN
INFO
Traction control system
The tractioncontrol system (TCS) helps maintaintractionwhen accelerating onslippery surfaces, such
as unpaved or wet roads. If sensors detect that the rear wheel is starting to slip (uncontrolled spinning),
the traction control system assists by regulating engine power as needed until traction is restored.
WARNING
EWA15433
The traction control system is not a substitute for riding appropriately for the conditions. Trac-
tion control cannot prevent loss of traction due to excessive speed when entering turns, when
accelerating hard at a sharp lean angle, or while braking, and cannot prevent front wheel slip-
ping. As with any vehicle, approach surfaces that may be slippery with caution and avoid espe-
cially slippery surfaces.
Setting the traction control system
When the key is turned to “ON”, traction control is turned on automatically.
The “ ” indicator light flashes when traction control has engaged. You may notice slight changes in
engine and exhaust sounds when the system has engaged.
When the traction control system has been set to “OFF”, the “ ” indicator light will come on.
TCS “OFF”
TCS “OFF” turns the traction control system off.
TCS “ON”
TCS “ON” turns the traction control system on.
NOTICE
ECA19650
Use only the specified tires. Using different sized tires will prevent the traction control system
from controlling tire rotation accurately.
TIP
• The current TCS setting is shown in the TCS display.
• Traction control can be turned on or off only when the vehicle is stopped.
• When the key is turned to “ON”, traction control is turned on.
• Turn the traction control system off to help free the rear wheel if the vehicle gets stuck in mud, sand,
or other soft surfaces.
• When the vehicle is on the centerstand, do not rev the engine for an extended period of time. Other-
wise, the traction control system will automatically disable and need to be reset.
• In normal operation, “ ” indicator light flashes when traction control has engaged.
• When the traction control system has been turned off, “ ” indication light will come on.
• Ifthe tractioncontrol system becomes disabled while riding, “ ”indicator lightand the engine trouble
warning light will come on.
1. Trip / information switch (To “ON” or “OFF”
TCS mode)
2. TCS display
3. “TCS” indicator light
EE
FF
2
3
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1-5
GEN
INFO
FEATURES
Resetting the traction control system
The traction control system will automatically disable when:
• the front wheel or rear wheel comes off the ground while riding.
• excessive rear wheel spin is detected while riding.
• either wheel is rotated with the key turned to “ON” (such as when performing maintenance).
• When a sensor fault is detected, or when only one wheel is allowed to rotate for more than a few sec-
onds. Should this happen, the “ ” indicator light will come on.
If the tractioncontrolsystem isdisabled,both the“ ” indicator light and the “ ” warning lightwillcome
on.
Should this occur, try resetting the system as follows.
1. Stop the vehicle and turn the key to “OFF”.
2. Wait a few seconds and then turn key back to “ON”.
3. The “ ” indicator light should turn off and the system be enabled.
4. Check the vehicle and turn off the “ ” warning light.
TIP
If the “ ” indicator light or the “ ” warning light remains on after resetting, the vehicle may still be
ridden. Check the fuel injection system (Refer to “FUEL INJECTION SYSTEM” on page 8-28).
Quick shift system
The quick shift system (QS) allows for full-throttle, clutch lever-less, electronically-assisted upshifts.
When the quick shift switch detects motion in the shift pedal, engine power and drive torque are mo-
mentarily adjusted to allow the upshift to occur.
TIP
• The quick shift system operates when traveling at least 20 km/h (12 mi/h) with an engine speed of
2000 r/min or higher, and only when accelerating.
• It does not operate when the clutch lever is pulled.
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1-6
FEATURES
GEN
INFO
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 con-
ditions, 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 air-
fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the en-
gine.
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 accom-
modate this need,this modelhas 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. Ignition coil
3. Spark plug
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
12.O2sensor
13.Radiator fan motor
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1-7
GEN
INFO
FEATURES
FEATURES
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, 36.3 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. There-
fore, the longer the length of time the fuel injector is energized (injection duration), the greater the vol-
ume 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, coolant temperature sensor and O2sensor enable the ECU to determine
the injection duration. The injection timing is determined through the signals from the crankshaft posi-
tion 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.
13
15
11
10
1
2
34
6
5
8
9
12
14
7
1. Fuel pump
2. Fuel injector
3. Ignition coil
4. Coolant temperature sensor
5. ECU (engine control unit)
6. Lean angle sensor
7. O2sensor
8. Crankshaft position sensor
9. FID (fast idle solenoid)
10.Air filter case
11.Throttle body
12.Throttle body sensor assembly
13.Intake air temperature sensor
14.Throttle position sensor
15.Intake air pressure sensor
A. Fuel system
B. Air system
C. Control system
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1-8
FEATURES
GEN
INFO
EAS30683
OUTLINE OF THE ABS
1. The Yamaha ABS (anti-lock brake system) features an electronic control system, which acts on the
front and rear brakes independently.
2. The ABS features a compact and lightweight design to help maintain the basic maneuverability of
the vehicle.
ABS layout
1. Yamaha diagnostic tool coupler/ ABS test
coupler
2. ABS control unit fuse
3. ABS solenoid fuse
4. ABS motor fuse
5. ABS warning light
6. Front wheel sensor rotor
7. Front wheel sensor
8. Hydraulic unit assembly
9. Rear wheel sensor rotor
10.Rear wheel sensor
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1-9
GEN
INFO
FEATURES
ABS
The operation of the Yamaha ABS brakes is the same as conventional brakes on other vehicles, with
a brake lever for operating the front brake and a brake pedal for operating the rear brake.
When wheel lock is detected during braking, hydraulic control is performed by the hydraulic system on
the front and rear brakes independently.
Useful terms
• Wheel speed:
The rotation speed of the front and rear wheels.
• Chassis speed:
The speed of the chassis.
When the brakes are applied, wheel speed and chassis speed are reduced. However, the chassis
travels forward by its inertia even though the wheel speed is reduced.
• Brake force:
The force applied by braking to reduce the wheel speed.
• Wheel lock:
A condition that occurs when the rotation of one or both of the wheels has stopped, but the vehicle
continues to travel.
• Side force:
The force on the tires which supports the vehicle when cornering.
• Slip ratio:
When the brakes are applied, slipping occurs between the tires and the road surface. This causes a
difference between the wheel speed and the chassis speed.
Slip ratio is the value that shows the rate of wheel slippage and is defined by the following formula.
Slip ratio = (Chassis speed – Wheel speed)/Chassis speed ×100 (%)
0%: There is no slipping between the wheel and the road surface. The chassis speed is equal to the
wheel speed.
100%: The wheel speed is “0”, but the chassis is moving (i.e., wheel lock).
Brake force and vehicle stability
When the brake pressure is increased, wheel speed is reduced. Slipping occurs between the tire and
the roadsurface and brake force is generated. The limit of this brake force is determined by the friction
force between the tire and the road surface and is closely related to wheel slippage. Wheel slippage is
represented by the slip ratio.
Side force is also closely related to wheel slippage. See figure “A”. If the brakes are applied while keep-
ing the proper slipratio,it is possible to obtain themaximum brake force without losing much side force.
ABS allows full use of the tires’ capabilities even on slippery road surfaces or less slippery road surfac-
es. See figure “B”.
b
c
a
A
d
(%)
a
e
f
g
B
d
(%)
a. Friction force between the tire and road
surface
b. Brake force
c. Side force
d. Slip ratio
e. Less slippery road surface
f. Controlling zone
g. Slippery road surface
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1-10
FEATURES
GEN
INFO
Wheel slip and hydraulic control
The ABS ECU calculates the wheel speed of each wheel according to the rotation signal received from
the front and rear wheel sensors. In addition, the ABS ECU calculates the vehicle chassis speed and
the rate of speed reduction based on the wheel speed values.
The difference between the chassis speed and the wheel speed calculated in the slip ratio formula is
equal to the wheel slip. When the wheel speed is suddenly reduced, the wheel has a tendency to lock.
When the wheel slip and the wheel speed reduction rate exceed the preset values, the ABS ECU de-
termines that the wheel has a tendency to lock.
If the slip is large and the wheel has a tendency to lock (point “A” in the following figure), the ABS ECU
reduces the hydraulic pressure in the brake caliper. Once the ABS ECU determines that the tendency
of the wheel to lock has diminished after the hydraulic pressure is reduced, it increases the hydraulic
pressure (point “B”inthe following figure).The hydraulic pressure is initially increased quickly,and then
it is increased gradually.
ABS operation and vehicle control
If the ABS starts operating, there is a tendency of the wheel to lock, and the vehicle is approaching the
limit of control. To make the rider aware of this condition, the ABS has been designed to generate a
reaction-force pulsating action in the brake lever and brake pedal independently.
TIP
When the ABS is activated, a pulsating action may be felt at the brake lever or brake pedal, but this
does not indicate a malfunction.
The higher the side force on a tire, the less traction there is available for braking. This is true whether
the vehicle is equipped with ABS or not. Therefore, sudden braking while cornering is not recommend-
ed. Excessive side force, which ABS cannot prevent, could cause the tire to slip sideways.
ddede
A
A
B
BA
A
B
B
A
A
B
B
b
c
a
e
a. Chassis speed
b. Wheel speed
c. Brake force
d. Depressurizing phase
e. Pressurizing phase
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1-11
GEN
INFO
FEATURES
WARNING
EWA16510
The braking of the vehicle, even in the worst case, is principally executed when the vehicle is
advancing straight ahead. During a turn, sudden braking is liable to cause a loss of traction of
the tires. Even in vehicles equipped with ABS, overturning of the vehicle cannot be prevented
if it is braked suddenly.
The ABS functions to prevent the tendency of the wheel to lock by controlling the hydraulic pressure.
However, if there is a tendency of the wheel to lock on a slippery road surface, due to engine braking,
the ABS may not be able to prevent the wheel from locking.
WARNING
EWA13870
The ABS controls only the tendency of the wheel to lock caused by applying the brakes. The
ABS cannot prevent wheel lock on slippery surfaces, such as ice, when it is caused by engine
braking, even if the ABS is operating.
Electronic ABS features
The Yamaha ABS (anti-lock brake system) has been developed with the most advanced electronic
technology.
The ABS control is processed with good response under various vehicle travel conditions.
The ABS also includes a highly developed self-diagnosis function. The ABS detects any problem con-
dition and allows normal braking even if the ABS is not operating properly.
When this occurs, the ABS warning light on the meter assembly comes on.
The ABS stores the fault codes in the memory of the ABS ECU for easy problem identification and trou-
bleshooting.
(%)
a. Friction force between the tire and road
surface
b. Brake force
c. Side force
d. Slip ratio
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1-12
FEATURES
GEN
INFO
ABS block diagram
EAS30684
ABS COMPONENT FUNCTIONS
Wheel sensors and wheel sensor rotors
Wheel sensors “1” detect the wheel speed and transmit the rotation signal to the ABS ECU.
Each wheel sensor is composed of a permanent magnet and ahall IC.The sensor rotors“2” rotate with
the wheels. The sensor rotors “2” have 40 slots and are installed close to the wheel sensors. As the
sensor rotor rotates, the hallelement in the hallIC installed in the wheel sensor generates pulses. The
pulse frequency, which is proportional tothe wheelspeed, isconverted into awave inthe hallIC so that
it can be output.
The ABS ECU calculates the wheel rotation speed by detecting the pulse frequency.
1
2
3
44
77
566
8
99
10
11
12
13
14
1. Rear brake master cylinder
2. Hydraulic unit assembly
3. Front brake master cylinder
4. Inlet solenoid valve
5. ABS motor
6. Hydraulic pump
7. Outlet solenoid valve
8. ABS ECU
9. Buffer chamber
10.Rear brake caliper
11.Rear wheel sensor
12.ABS warning light
13.Front brake caliper
14.Front wheel sensor
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1-13
GEN
INFO
FEATURES
ABS warning light
The ABS warning light “1” comes on to warn the rider if a malfunction in the ABS occurs.
When the main switch is turned to “ON”, the ABS warning light comes on to check the electrical circuit
and the system function (ABS self-diagnosis), and goes off when the vehicle is operated (the function
check is properly completed at a speed of about 10 km/h (6.3 mi/h)).
TIP
After all checksand servicingarecompleted, theABS warning light willgooff whenthevehicle isridden
or pushed at a speed of 10 km/h (6.3 mi/h) or faster.
NOTICE
ECA20950
If the rear wheel is raced with the vehicle on a suitable stand, the ABS warning light may flash
or come on. If this occurs, turn the main switch to “OFF”, then back to “ON”. The ABS operation
is normal if the ABS warning light goes off after the vehicle starts off. If the fault codes are not
deleted, the ABS warning light goes off after the vehicle is ridden at a speed of about 30 km/h
(19 mi/h).
7374
5
88
6
3. At low speed
4. At high speed
5. Wheel sensor
6. Wheel sensor rotor
7. Voltage
8. Time
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