Yamaha Aerox GDR155 Owner'S Manual Download

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Perio

ic maintenance an

justment

9-7

EAU18773

Removin

installin

pan-

els

The panels shown need to be removed
to perform some of the maintenance
jobs described in this chapter. Refer to
this section each time a panel needs to
be removed and installed.

EAU77170

Panel A

To remove the panel

1. Remove the screws and quick fas-

tener screw.

2. Extend the right passenger foot-

rest, and then pull the panel out-
ward.

To install the panel

1. Place the panel in the original po-

sition, and then install the screws
and quick fastener screw.

2. Retract the right passenger foot-

rest to its original position.

Panel B

To remove the panel

1. Remove panel A.
2. Remove the right floorboard mat

by pulling it up.

3. Remove the screws and bolts,

and then pull the panel outward.

1. Panel A
2. Panel B

1. Panel A
2. Screw
3. Quick fastener screw

UBF6EYE0.book Page 7 Friday, July 14, 2017 3:39 PM

Summary of Contents for Aerox GDR155

Page 1: ...DIC183 GDR155 GDR155 R GDR155 A OWNER S MANUAL Read this manual carefully before operating this vehicle BF6 F8199 EY English E ...

Page 2: ...EAU46093 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold UBF6EYE0 book Page 1 Friday July 14 2017 3 39 PM ...

Page 3: ...rom trouble and injury In addition the many tips given in this manual will help keep your scooter in the best possible condition If you have any further questions do not hesitate to contact your Yamaha dealer The Yamaha team wishes you many safe and pleasant rides So remember to put safety first Yamaha continually seeks advancements in product design and quality Therefore while this manual contain...

Page 4: ...ential personal injury 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 ...

Page 5: ...S MANUAL 2017 by Thai Yamaha Motor Co Ltd 1st edition July 2017 All rights reserved Any reprinting or unauthorized use without the written permission of Thai Yamaha Motor Co Ltd is expressly prohibited Printed in Thailand UBF6EYE0 book Page 2 Friday July 14 2017 3 39 PM ...

Page 6: ...Catalytic converter 6 14 Seat GDR155 GDR155 R 6 15 Helmet holders 6 15 Storage compartments 6 16 Sidestand 6 17 Ignition circuit cut off system 6 18 Auxiliary DC jack 6 20 For your safety pre operation checks 7 1 Operation and important riding points 8 1 Starting the engine 8 1 Starting off 8 2 Acceleration and deceleration 8 3 Braking 8 3 Tips for reducing fuel consumption 8 3 Engine break in 8 4...

Page 7: ...26 Battery 9 27 Replacing the fuses 9 28 Headlight 9 30 Replacing an auxiliary light bulb 9 30 Tail brake light 9 31 Replacing a front turn signal light bulb 9 31 Replacing a rear turn signal light bulb 9 32 Replacing the license plate light bulb 9 33 Troubleshooting 9 33 Troubleshooting charts 9 36 Emergency mode GDR155 A 9 38 Scooter care and storage 10 1 Matte color caution 10 1 Care 10 1 Stora...

Page 8: ... vehicle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label is available from your Yamaha dealer 1 2 UBF6EYE0 book Page 1 Friday July 14 2017 3 39 PM ...

Page 9: ...Location of important labels 1 2 1 100kPa 1bar kPa psi kPa psi 200 29 225 33 200 29 225 33 2BL F1668 00 1 2 UBF6EYE0 book Page 2 Friday July 14 2017 3 39 PM ...

Page 10: ...est you Safe Riding Perform the pre operation checks each time you use the vehicle to make sure it is in safe operating condition Failure to inspect or maintain the vehi cle properly increases the possibility of an accident or equipment damage See page 7 1 for a list of pre operation checks This scooter is designed to carry the operator and a passenger The failure of motorists to detect and recogn...

Page 11: ...o main tain control of the scooter The passenger should always hold onto the operator the seat strap or grab bar if equipped with both hands and keep both feet on the passenger footrests Never carry a passenger unless he or she can firmly place both feet on the passenger footrests Never ride under the influence of alcohol or other drugs This scooter is designed for on road use only It is not suita...

Page 12: ...o avoid the possibility of an accident use extreme caution when adding cargo or acces sories to your scooter Use extra care when riding a scooter that has added cargo or accessories Here along with the information about accessories be low are some general guidelines to fol low if loading cargo to your scooter The total weight of the operator pas senger accessories and cargo must not exceed the max...

Page 13: ...es in the vehicle Keep the following guidelines in mind as well as those provided under Load ing when mounting accessories Never install accessories or carry cargo that would impair the per formance of your scooter Careful ly inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance limit suspension travel steering travel or contr...

Page 14: ...reak Choose the lo cation for the straps carefully so the straps will not rub against painted surfaces during transport The suspension should be com pressed somewhat by the tie downs if possible so that the scooter will not bounce exces sively during transport EAU57600 Further safe riding points Be sure to signal clearly when making turns Braking can be extremely difficult on a wet road Avoid hard...

Page 15: ...ty of fatalities from motorcycle or scooter accidents are the result of head injuries The use of a safety hel met is the single most critical factor in the prevention or reduction of head in juries Always select an approved motorcy cle helmet Pay attention to the following when choosing a motorcycle helmet The helmet must meet the safety standard TIS The helmet size must match the size of the ride...

Page 16: ...information 2 7 2 Full type use only for riding at low to mid range speeds Full face type use for riding at mid range to high speeds ZAUU0004 ZAUU0005 ZAUU0006 UBF6EYE0 book Page 7 Friday July 14 2017 3 39 PM ...

Page 17: ...2 4 Owner s tool kit page 9 1 5 Rear storage compartment page 6 16 6 Air filter element page 9 15 7 Final transmission oil filler cap page 9 12 8 Final transmission oil drain bolt page 9 12 9 V belt case air filter element page 9 15 10 Engine oil drain bolt A page 9 10 11 Engine oil drain bolt B page 9 10 UBF6EYE0 book Page 1 Friday July 14 2017 3 39 PM ...

Page 18: ...2 2 Tail brake light page 9 31 3 Battery page 9 27 4 Fuse box page 9 28 5 Headlight page 9 30 6 Auxiliary light page 9 30 7 Front turn signal light page 9 31 8 Coolant reservoir page 9 13 9 Spark plug page 9 8 10 Engine oil filler cap page 9 10 UBF6EYE0 book Page 2 Friday July 14 2017 3 39 PM ...

Page 19: ... 6 1 Rear brake lever page 6 11 2 Left handlebar switches page 6 10 3 Multi function meter unit page 6 5 4 Right handlebar switch page 6 10 5 Front brake lever page 6 11 6 Throttle grip page 9 17 7 Main switch steering lock page 6 1 UBF6EYE0 book Page 3 Friday July 14 2017 3 39 PM ...

Page 20: ...page 6 11 2 Left handlebar switches page 6 10 3 Multi function meter unit page 6 5 4 Right handlebar switches page 6 10 5 Front brake lever page 6 11 6 Throttle grip page 9 17 7 Main switch steering lock page 6 1 UBF6EYE0 book Page 4 Friday July 14 2017 3 39 PM ...

Page 21: ...ffect the opera tion of such devices when close by If you have an electric medical device consult a doctor or the device manufacturer before us ing this vehicle NOTICE ECA15763 The smart key system uses weak ra dio waves The smart key system may not work in the following situa tions The smart key is placed in a lo cation exposed to strong radio waves or other electromagnetic noise There are facili...

Page 22: ... on EAU78941 Operating range of the smart key system The operating range of the smart key system is about 80 cm 31 5 in from the main switch TIP As the smart key system uses weak radio waves the operating range may be affected by the sur rounding environment When the battery of the smart key is discharged the smart key may not work or its operating range may become very small If the smart key is t...

Page 23: ...d with the vehicle is one smart key two mechanical keys and one identification number card The identi fication number can also be found on the inside of the smart key itself Keep one mechanical key and the identifica tion number card in a safe place sepa rate from the vehicle If the vehicle battery is discharged the mechanical key can be used to open the seat to charge or replace the bat tery Ther...

Page 24: ...ctric medical equipment Do not allow oils polishing agents fuel or any strong chemicals to come in contact with the smart key The smart key body may become discol ored or cracked TIP The smart key battery life is ap proximately two years but this may vary according to operating conditions Replace the smart key battery when the smart key system indi cator light flashes for 20 seconds when the vehic...

Page 25: ...f Remote answer back function Push the smart key button to operate the answer back function remotely The beeper will sound twice and all of the turn signal lights will flash twice This feature is convenient for locating your vehicle in a parking lot and other areas To turn the answer back beeper on or off The beeper which sounds when the answer back function is operated can be turned on or off acc...

Page 26: ...nlight or other heat sources NOTICE ECA15784 Use a cloth when opening the smart key case with a screw driver Direct contact with hard objects may damage or scratch the smart key Take precautions to prevent the waterproof seal from being damaged or contaminated by dirt Do not touch the internal cir cuits and terminals This may cause malfunctions Do not apply excessive force to the smart key when re...

Page 27: ... smart key case closed EAU76490 Main switch The main switch is used to turn the ve hicle power on and off lock and unlock the steering and open the seat or fuel tank cap lid After pushing the main switch knob and confirmation with the 1 Battery Specified battery CR2032 1 1 Battery 1 1 Main switch knob 1 Smart key system indicator light 1 1 UBF6EYE0 book Page 7 Friday July 14 2017 3 39 PM ...

Page 28: ... light stops flashing and then operate the main switch The main switch positions are de scribed below EAU76500 ON on All electrical circuits are supplied with the power and the engine can be start ed To turn the vehicle power on 1 Turn the smart key on and bring it within operating range 2 Push the main switch knob and the smart key indicator light will come on for approximately 4 sec onds 3 While...

Page 29: ...e vehicle power will turn off automatically To turn the vehicle power off im mediately push the main switch knob four times within 2 seconds EAU76520 lock The steering is locked and all electrical systems are off To lock the steering 1 Turn the handlebar all the way to the left 2 With the smart key turned on and within operating range turn and push the main switch to TIP If the steering will not l...

Page 30: ...When the main switch is in the OPEN position and the smart key is moved out of operating range the beeper will sound The beeper will also sound if the main switch is left in the OPEN position for 3 minutes To stop the beeper move the smart key back to within operating range or turn the main switch to OFF To close the fuel tank cap lid Push the fuel tank cap lid until it is closed TIP Make sure tha...

Page 31: ...e OPEN position and the smart key is moved out of operating range the beeper will sound The beeper will also sound if the main switch is left in the OPEN position for 3 minutes To stop the beeper move the smart key back to within operating range or turn the main switch to OFF To open the seat with the mechanical key 1 Open the keyhole cover 2 Insert the mechanical key into the seat lock and then t...

Page 32: ...he keyhole cover is installed when the mechanical key is not being used To close the seat Close the seat and push down on the rear to lock it in position TIP Make sure that the seat is properly se cured before riding UBF6EYE0 book Page 12 Friday July 14 2017 3 39 PM ...

Page 33: ...it may not be possible to restart the engine due to insuffi cient battery voltage TIP Although the engine normally stops at the same time the vehicle is stopped it may take a while un til the engine stops when operat ing the vehicle under 10km h such as in heavy traffic If you think the battery voltage has decreased because the engine cannot be started using the starter switch or for some other re...

Page 34: ...stem may not activate EAU76831 Stop the engine After the indicator light on the multi function meter comes on the en gine stops automatically when the en gine is left idling when the vehicle is stopped and the throttle grip is in the fully closed position At this time the indicator light on the multi function meter starts flashing to indicate that the engine is currently stopped by the Stop and St...

Page 35: ...improper operation carefully read and observe the following precautions WARNING EWA18741 When walking while pushing the ve hicle be sure to turn the main switch off If the vehicle is pushed while the Stop and Start System is left turned on the engine could start and the vehicle could start moving if the throttle grip is turned accidentally WARNING EWA18751 When placing the vehicle on the centersta...

Page 36: ...e the en gine could start and the vehicle could start moving if the throttle grip is turned accidentally WARNING EWA18781 Before performing maintenance be sure to turn the main switch off If maintenance is performed while the Stop and Start System is turned on the engine could start and the vehi cle could start moving if the throttle grip is turned OFF OFF OFF UBF6EYE0 book Page 4 Friday July 14 2...

Page 37: ...ighting taillight license plate light and auxiliary light come on automatically when the key is turned to ON The fuel pump can be heard when the key is turned to ON EAUU1131 OFF All electrical systems are off The key can be removed EAUU1043 LOCK The steering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left 2 Pus...

Page 38: ...ccident If the vehicle turns over and af ter placing it upright ensure that there is no fuel leakage If fuel is leaking have a Yamaha dealer check the vehicle EAUU0822 Keyhole cover To open the keyhole cover Insert the key head into the keyhole cover receptacle as shown and then turn the key to the right to open the cover To close the keyhole cover Press the PUSH SHUT button to close the keyhole c...

Page 39: ... light should come on for a few seconds and then go off If the warning light does not come on initially when main switch is turned on or if the warning light remains on have a Yamaha dealer check the electrical circuit NOTICE ECA10022 Do not continue to operate the en gine if it is overheating 1 Left turn signal indicator light 2 Right turn signal indicator light 3 Coolant temperature warning ligh...

Page 40: ...high er The ABS may not work correctly If any of the above occurs have a Yamaha dealer check the system as soon as possible See page 6 11 for an expla nation of the ABS WARNING EWA16041 If the ABS warning light does not go off after traveling at a speed of 10 km h 6 mi h or higher or if the warning light comes on or flashes while riding the brake system re verts to conventional braking If ei ther ...

Page 41: ...e page 5 1 EAU77153 Multi function meter unit WARNING EWA12423 Be sure to stop the vehicle before making any setting changes to the multi function meter unit Changing settings while riding can distract the operator and increase the risk of an accident The multi function meter unit is equipped with the following a speedometer a tachometer a VVA indicator a clock a fuel meter a multi function displa...

Page 42: ...n switch to ON 3 Release the RESET SELECT af ter one second 4 Push the RESET SELECT but ton to turn the indicator off or on TIP Turning the VVA indicator off does not turn off the variable valve actuation system Clock The clock uses a 12 hour time system To set the clock 1 With the display in the odometer mode push the RESET SELECT button for four seconds 2 When the hour digits start flash ing use...

Page 43: ...ircuit all the display segments will flash repeatedly If this occurs have a Yamaha dealer check the vehicle NOTICE ECAV0041 When the fuel indicator has dropped to only one block refuel as soon as possible as the movement of fuel when going up or downhill or when turning may lead to the engine not getting any fuel resulting in engine stop Multi function display The multi function display is equippe...

Page 44: ...onsumption mode The instantaneous fuel consumption display can be set to either km L or L 100 km km L The distance that can be traveled on 1 0 L of fuel under the current riding conditions is shown L 100 km The amount of fuel necessary to travel 100 km under the current riding conditions is shown To switch between the instantaneous fuel consumption display settings push the RESET SELECT button for...

Page 45: ...ehicle has traveled 0 1 km 0 06 mi The battery voltage indicator This indicator shows the current charge state of the battery Over 12 8 V Full charge Under 12 7 V Charging is required TIP If the battery voltage is less than 9 0 V _ _ _ will be displayed Self diagnosis mode This model is equipped with a self di agnosis device for various electrical circuits If a problem is detected in any of those ...

Page 46: ...e turned to the center position EAU12501 Horn switch Press this switch to sound the horn EAU12722 Start switch With the sidestand up push this switch while applying the front or rear brake to crank the engine with the starter See page 8 1 for starting instructions prior to starting the engine EAU76391 Stop and Start System switch GDR155 A To turn on the Stop and Start System set the switch to To t...

Page 47: ...If the ABS is activated a pulsating sensation may be felt at the front brake lever In this situation continue to ap ply the brakes and let the ABS work do not release and re apply the brakes i e pump the brakes as this will re duce braking effectiveness WARNING EWA16051 Always keep a sufficient distance from the vehicle ahead to match the riding speed even with ABS The ABS performs best with long ...

Page 48: ...ce of the ABS will result EAUV0681 Fuel tank cap To remove the fuel tank cap 1 Turn the main switch to OPEN position 2 Push the FUEL button to open the fuel tank cap lid 3 Turn the fuel tank cap counter clockwise and pull it off To install the fuel tank cap 1 Insert the fuel tank cap into the tank opening and turn it clockwise until the marks on the cap and tank are aligned 2 Push the fuel tank ca...

Page 49: ...ater heaters and clothes dryers 2 Do not overfill the fuel tank Stop filling when the fuel reaches the bottom of the filler tube Because fuel expands when it heats up heat from the engine or the sun can cause fuel to spill out of the fuel tank 3 Wipe up any spilled fuel immedi ately NOTICE Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfaces or ...

Page 50: ...t blocked and clean it if necessary EAU13434 Catalytic converter This model is equipped with a catalytic converter in the exhaust system WARNING EWA10863 The exhaust system is hot after op eration To prevent a fire hazard or burns Do not park the vehicle near possible fire hazards such as grass or other materials that easily burn Park the vehicle in a place where pedestrians or children are not li...

Page 51: ...r of the seat down to lock it in place TIP Make sure that the seat is properly se cured before riding EAU37482 Helmet holders The helmet holders are located under the seat To secure a helmet to a helmet hold er 1 Open the seat See page 6 15 2 Attach a helmet to a helmet hold er and then securely close the seat WARNING Never ride with a helmet attached to the helmet holder since the helmet may hit ...

Page 52: ...nt under the seat See page 4 11 for seat opening and closing information To store a helmet in the rear storage compartment place the helmet upside down with the front fac ing to the left side TIP Some helmets cannot be stored in the rear storage compartment be cause of their size or shape Do not leave your scooter unat tended with the seat open The interior of the rear storage compartment lies out...

Page 53: ...light do not store anything susceptible to heat such as food or flamma ble items inside the compart ment WARNING EWA15861 Do not exceed the following loading limits Front storage compartment 0 2 kg 0 4 lb Rear storage compartment 3 kg 6 6 lb Maximum load for the vehicle 153 kg 337 lb GDR155 A GDR155 R 154 kg 340 lb GDR155 EAU76780 Sidestand The sidestand is located on the left side of the frame Ra...

Page 54: ...ting off Therefore check this system regularly and have a Yamaha dealer repair it if it does not function properly EAUT1097 Ignition circuit cut off system Check the operation of the sidestand switch according to the following pro cedure UBF6EYE0 book Page 18 Friday July 14 2017 3 39 PM ...

Page 55: ...ither of the brake levers The engine will start Put the sidestand down If the engine stalls The sidestand switch is OK The vehicle must be placed on the center stand during this inspection If a malfunction is noted have a Yamaha dealer check the system before riding WARNING UBF6EYE0 book Page 19 Friday July 14 2017 3 39 PM ...

Page 56: ...icle is equipped with an auxil iary DC jack in the front storage com partment A 12 V accessory connected to the auxiliary jack can be used when the main switch is on and should only be used when the engine is running To use the auxiliary DC jack 1 Open the front storage compart ment lid See page 6 16 2 Turn the main switch off 3 Remove the auxiliary DC jack cap 4 Turn the accessory off 5 Insert th...

Page 57: ...AGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage Check fuel tank overflow hose for obstructions cracks or damage and check hose connection 6 13 6 14 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 9 10 Final transmission oil Check vehicle for oil leakage 9 12 Coolant Check coolant level in ...

Page 58: ...k tire condition and tread depth Check air pressure Correct if necessary 9 18 9 19 Brake levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 9 24 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 9 25 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signa...

Page 59: ...y may be deeper than expected EAU77800 Starting the engine NOTICE ECA10251 See page 8 4 for engine break in in structions prior to operating the ve hicle for the first time In order for the ignition circuit cut off system to enable starting the side stand must be up See page 6 18 1 Turn the main switch on The following warning lights and indicator lights should come on for a few seconds then go of...

Page 60: ... start release the start switch after 5 seconds Before pressing the start switch again wait 10 seconds to allow battery voltage to re store NOTICE ECA11043 For maximum engine life never ac celerate hard when the engine is cold EAU45093 Starting off 1 While pulling the rear brake lever with your left hand and holding the grab bar with your right hand push the scooter off the center stand 2 Sit astr...

Page 61: ...n when approaching such areas and cross them with cau tion Keep in mind that braking on a wet road is much more difficult Ride slowly down a hill as brak ing downhill can be very diffi cult 1 Close the throttle completely 2 Apply both front and rear brakes simultaneously while gradually in creasing the pressure EAU16821 Tips for reducing fuel con sumption Fuel consumption depends largely on your r...

Page 62: ...00 km 1000 mi and beyond The vehicle can now be operated nor mally NOTICE ECA10271 If any engine trouble should occur during the engine break in period immediately have a Yamaha dealer check the vehicle EAU77860 Parking When parking turn off the Stop and Start System and then stop the engine After turning off the main switch be sure to remove the key and take it with you For smart key models be su...

Page 63: ...cation partitioned by a fence or the glass window of a shop if the smart key is within operating range other people will be able to start the engine and operate the vehicle Please turn the smart key off when leaving the ve hicle See page 4 8 UBF6EYE0 book Page 5 Friday July 14 2017 3 39 PM ...

Page 64: ...e engine when performing maintenance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine while ser vicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 3 for more in formation about carbon monox ide WARNING EWA15461 Brake dis...

Page 65: ...system NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING whichever comes first ANNUAL CHECK 1000 km or 2 months 4000 km or 6 months 8000 km or 10 months 12000 km or 14 months 16000 km or 18 months 1 Fuel line Check fuel hoses for cracks or damage 2 Fuel filter Check condition Replace if necessary Every 12000 km 7500 mi 3 Spark plug Check condition Clean and regap Replace Every 8000 km 5000 mi 4 Va...

Page 66: ... 16000 km 10000 mi 3 Air filter check hose Clean 4 V belt case air filter element Clean Replace if necessary 5 Battery Check voltage Charge if necessary 6 Front brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 7 Rear brake Check operation and adjust brake lever free play Replace brake shoes Whenever worn to the limit 8 Brake hose Check f...

Page 67: ...ed 15 Front brake lever pivot shaft Lubricate with silicone grease 16 Rear brake lever pivot shaft Lubricate with silicone grease 17 Sidestand center stand Check operation Lubricate with lithium soap based grease 18 Sidestand switch Check operation 19 Front fork Check operation and for oil leak age 20 Shock absorber as sembly Check operation and shock ab sorber for oil leakage NO ITEM CHECK OR MAI...

Page 68: ...place Every 25000 km 15500 mi 26 V belt secondary sheave Lubricate Every 12000 km 7500 mi 27 Front and rear brake switches Check operation 28 Moving parts and cables Lubricate 29 Throttle grip Check operation Check throttle grip free play and adjust if necessary Lubricate cable and grip housing 30 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHECK OR MAINTENANCE JOB OD...

Page 69: ...not wear or damage Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged Fuel system service Use only unleaded gasoline The use of leaded gasoline will cause severe damage to interna...

Page 70: ...rew 2 Extend the right passenger foot rest and then pull the panel out ward To install the panel 1 Place the panel in the original po sition and then install the screws and quick fastener screw 2 Retract the right passenger foot rest to its original position Panel B To remove the panel 1 Remove panel A 2 Remove the right floorboard mat by pulling it up 3 Remove the screws and bolts and then pull t...

Page 71: ...check Since heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checked in accordance with the periodic main tenance and lubrication chart In addi tion the condition of the spark plug can reveal the condition of the engine To remove the spark plug 1 Remove panel A See page 9 7 2 Remove the spark plug cap 3 Remove the spark plug as shown with a spark plu...

Page 72: ...ness gauge and if nec essary adjust the gap to specifi cation To install the spark plug 1 Clean the surface of the spark plug gasket and its mating sur face and then wipe off any grime from the spark plug threads 2 Install the spark plug with the spark plug wrench and then tight en it to the specified torque TIP If a torque wrench is not available when installing a spark plug a good estimate of th...

Page 73: ...nsert it back into the oil filler hole without screwing it in and then remove it again to check the oil level WARNING EWAU0031 The muffler and muffler protector become very hot during use To avoid possible burns let the muffler and protector cool before removing the oil filler cap TIP The engine oil should be between the tip of the dipstick and maximum level mark 4 If the engine oil is at or below...

Page 74: ...with solvent and then check it for damage and replace it if neces sary 5 Install the engine oil strainer com pression spring engine oil drain bolt with new O ring and then tighten the drain bolt to the speci fied torque TIP Make sure that the O ring is properly seated 6 Refill with the specified amount of the recommended engine oil and then install and tighten the oil filler cap TIP Be sure to wip...

Page 75: ... If any leakage is found have a Yamaha dealer check and repair your motorcycle In addition the final trans mission oil must be changed as follows at the intervals specified in the periodic maintenance and lubrication chart 1 Start the engine and warm up the final transmission oil by riding the motorcycle for several minutes 2 Stop the engine and then place the motorcycle on the center stand 3 Plac...

Page 76: ... the periodic maintenance and lubrication chart EAU67000 To check the coolant level 1 Place the vehicle on the center stand TIP The coolant level must be checked on a cold engine since the level varies with engine tem perature Make sure that the vehicle is posi tioned straight up when checking the coolant level A slight tilt to the side can result in a false reading 2 Check the coolant level throu...

Page 77: ...rosion If water has been added to the coolant have a Yamaha dealer check the anti freeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced ECA10473 6 Install the coolant reservoir cover 7 Place the right floorboard mat in the original position and push it downward to secure it EAU33032 Changing the coolant The coolant must be changed at the in te...

Page 78: ... install it TIP If dirt or water was found in the check hose be sure to check the air filter ele ment for excessive dirt or damage and replace it if necessary Replacing the air filter element 1 Place the vehicle on the center stand 2 Remove the air filter case cover by removing the screws 3 Pull the air filter element out 4 Insert a new air filter element into the air filter case NOTICE Make sure ...

Page 79: ...mage and clean or replace it if nec essary Cleaning the V belt case air filter el ement 1 Place the vehicle on the center stand 2 Remove the screws and then pull the V belt case air filter element cover outward and away from the V belt case 3 Pull the V belt case air filter ele ment out and then clean it with solvent After cleaning remove the remaining solvent by squeez ing the element WARNING Use...

Page 80: ...ip free play Measure the throttle grip free play as shown Periodically check the throttle grip free play and if necessary have a Yamaha dealer adjust it EAU21402 Valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the perio...

Page 81: ...rdance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model WARNING EWA10512 Never overload your vehicle Opera tion of an overloaded vehicle could cause an accident Tire inspection The tires must be checked before each ride If a tire tread shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the...

Page 82: ...or further use WARNING EWA10462 The front and rear tires should be of the same make and design other wise the handling characteristics of the vehicle may be different which could lead to an accident After extensive tests only the tires list ed below have been approved for this model by Yamaha EAU21963 Cast wheels To maximize the performance durabil ity and safe operation of your vehicle note the f...

Page 83: ...r in the hydraulic system will diminish the braking performance which may re sult in loss of control and an acci dent EAU22172 Adjusting the rear brake lever free play Measure the rear brake lever free play as shown Periodically check the brake lever free play and if necessary adjust it as fol lows To increase the brake lever free play turn the adjusting nut at the brake shoe plate in direction a ...

Page 84: ...k the wear indicator grooves If a brake pad has worn to the point that the wear indicator grooves have almost disap peared have a Yamaha dealer replace the brake pads as a set EAU22541 Rear brake shoes The rear brake is provided with a wear indicator which allows you to check the brake shoe wear without having to disassemble the brake To check the brake shoe wear check the position of the wear ind...

Page 85: ...oir and filler cap before removing Use only fresh brake fluid from a sealed con tainer Use only the specified brake flu id Use of a different brake fluid may result in a harmful chemical reaction may cause the rubber seals to deteriorate or cause in ternal rusting of the brake sys tem NOTICE ECA17641 Brake fluid may damage painted surfaces or plastic parts Always clean up spilled fluid immediately...

Page 86: ...maha dealer at the inter vals specified in the periodic maintenance and lubrication chart EAU23098 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and the ca bles and cable ends should be lubri cated if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or re place it WARNIN...

Page 87: ...e intervals specified in the periodic maintenance chart EAU43643 Lubricating the front and rear brake levers The pivoting points of the front and rear brake levers must be lubricated at the intervals specified in the periodic main tenance and lubrication chart Front brake lever Rear brake lever Recommended lubricants Front brake lever Silicone grease Rear brake lever Lithium soap based grease UBF6...

Page 88: ...3 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart To check the condition Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an upright posi tion WARNING To avoid injury securely ...

Page 89: ... center stand WARNING To avoid inju ry securely support the vehicle so there is no danger of it falling over EWA10752 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steer ing EAU23292 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified ...

Page 90: ...ed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To charge the battery Have a Yamaha dealer charge the bat tery as soon as possible if it seems to have discharged Keep in mind that the battery tends to discharge more quick ly if the vehicle is equipped with op tional electrical accessories NOTICE ECA16522 To charge a VRLA Valve Regulated Lead Acid battery a special con stant volt...

Page 91: ...ed battery can cause permanent battery damage EAU66795 Replacing the fuses The fuse boxes which contain the fus es for the individual circuits are locat ed under the seat See page 6 15 GDR155 GDR155 R GDR155 A GDR155 GDR155 R 1 Fuse box 1 Fuse box 1 1 1 Main fuse 2 Spare fuse 3 Fuel injection system fuse 4 Backup fuse 5 Ignition fuse 6 Headlight fuse 7 Signaling system fuse 8 Terminal fuse 1 for a...

Page 92: ...e electrical circuit in question to check if the device op erates 1 Main fuse 2 Spare fuse 3 Fuel injection system fuse 4 Backup fuse 5 Ignition fuse 6 Headlight fuse 7 Signaling system fuse 8 ABS solenoid fuse 9 ABS motor fuse 10 ABS control unit fuse 11 Smart key system fuse 12 Terminal fuse 1 for auxiliary DC jack 7 2 3 4 5 6 8 10 11 12 1 9 1 Battery cover 2 Screw 1 2 2 Specified fuses Main fus...

Page 93: ...its electrical circuit NOTICE ECA16581 Do not affix any type of tinted film or stickers to the headlight lens EAUV0700 Replacing an auxiliary light bulb This model is equipped with two auxil iary lights If an auxiliary light bulb burns out replace it as follows 1 Place the vehicle on the center stand 2 Remove the auxiliary light bulb socket together with the bulb by turning the socket counterclock...

Page 94: ...ake light If the tail brake light does not come on have a Yamaha dealer check it EAU43054 Replacing a front turn signal light bulb 1 Place the vehicle on the center stand 2 Remove the turn signal light bulb socket together with the bulb by turning it counterclockwise 3 Remove the burnt out bulb by pulling it out 1 Auxiliary light bulb 1 1 Turn signal light bulb socket 1 UBF6EYE0 book Page 31 Frida...

Page 95: ...ve the burnt out bulb by pulling it out 3 Insert a new bulb into the socket by pushing it in NOTICE ECAU0081 If a turn signal light bulb of different wattage than recommended is used the turn signal light flashing may be affected 4 Install the lens by installing the screw NOTICE Do not over tighten the screw otherwise the lens may break ECA11192 1 Turn signal light bulb 1 1 Screw 1 Turn signal lig...

Page 96: ...el compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your vehicle re quire any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the vehicle prop erly Use only gen...

Page 97: ...w ing before taking the vehicle to a Yamaha dealer The Stop and Start System indicator light does not come on 1 Is the main switch turned on 2 Is the Stop and Start System switch set to 3 Was the engine warmed up suffi ciently after starting 4 After the engine was warmed up was the engine left idling for a cer tain period of time 5 Did the vehicle travel at a speed of 10 km h or higher Even if the...

Page 98: ...p and Start System switch is set to while the Stop and Start System is activated the Stop and Start System will be turned off 2 Was the sidestand operated When the sidestand is lowered the Stop and Start System is de activated 3 Was the engine left stopped by the Stop and Start System for a long period of time If the engine is left stopped by the Stop and Start System for a long period of time the...

Page 99: ...the vehicle Have a Yamaha dealer check the vehicle Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the vehicle The engine does not start Check the compression Operate the electric starter 2 Battery The engine turns over quickly The engine turns over slowly The battery is good Dry...

Page 100: ...ped press down on the cap while turning it counterclockwise and then remove the cap TIP If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended cool ant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the cooling system for l...

Page 101: ...ght will come on for three seconds to indicate the transition to emergency mode 3 After the smart key system indica tor light goes off input the identifi cation number as follows 4 Inputting the identification number is done by counting the number of flashes of the smart key system in dicator light For example if the identification number is 123456 Push and hold the knob The smart key system indic...

Page 102: ... will flash quickly for 3 seconds In this case start over again from step 2 When there are no knob opera tions for 10 seconds during the identification number input pro cess When the smart key system indi cator light is allowed to flash nine or more times The identification number is not entered correctly 5 While the smart key system indi cator light is on push the knob once more to complete emerg...

Page 103: ... muffler outlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and cov ers as well as all electrical cou plers and connectors including the spark plug cap are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets and wheel axles Always rinse the dirt ...

Page 104: ...n rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain or near the sea Since sea salt is extremely corrosive carry out the following steps after each ride in the rain or near the sea 1 Clean the scooter with cold...

Page 105: ... Consult a Yamaha dealer for ad vice on what products to use Washing rainy weather or humid climates can cause the headlight lens to fog Turning the headlight on for a short period of time will help remove the moisture from the lens EAU36564 Storage Short term Always store your scooter in a cool dry place and if necessary protect it against dust with a porous cover Be sure the engine and the exhau...

Page 106: ... To prevent damage or injury from sparking make sure to ground the spark plug elec trodes while turning the en gine over EWA10952 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 5 Check and if necessary correct the tire air pressure and then lift the scooter so that both of its wheels are off the ground Alterna tively turn th...

Page 107: ...hange 0 90 L 0 95 US qt 0 79 Imp qt Final transmission oil Type Motor oil SAE 10W 30 type SE or higher or Gear oil SAE 85W GL 3 Quantity 0 15 L 0 16 US qt 0 13 Imp qt Coolant quantity Coolant reservoir up to the maximum level mark 0 13 L 0 14 US qt 0 11 Imp qt Radiator including all routes 0 46 L 0 49 US qt 0 40 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommended fuel Re...

Page 108: ...pe Cast wheel Rim size 14M C x MT3 50 Front brake Type Hydraulic single disc brake Specified brake fluid YAMAHA GENUINE BRAKE FLUID DOT 4 Rear brake Type Mechanical leading trailing drum brake Front suspension Type Telescopic fork Spring Coil spring Shock absorber Hydraulic damper Wheel travel 100 mm 3 9 in Rear suspension Type Unit swing Spring Coil spring Shock absorber Hydraulic damper Wheel tr...

Page 109: ...light LED GDR155 A Fuse s Main fuse 30 0 A Terminal fuse 1 2 0 A Headlight fuse 7 5 A Signaling system fuse 7 5 A Ignition fuse 7 5 A Fuel injection system fuse 7 5 A ABS control unit fuse 2 0 A GDR155 A ABS motor fuse 10 0 A GDR155 A ABS solenoid fuse 7 5 A GDR155 A Backup fuse 7 5 A Smart key system fuse 2 0 A GDR155 A UBF6EYE0 book Page 3 Friday July 14 2017 3 39 PM ...

Page 110: ...ON NUMBER ENGINE SERIAL NUMBER EAU62971 Vehicle identification number The vehicle identification number is stamped into the frame under the pas senger seat TIP The vehicle identification number is used to identify your vehicle and may be used to register it with the licensing authority in your area EAU26442 Engine serial number The engine serial number is stamped into the crankcase 1 Vehicle ident...

Page 111: ...cks or service procedures are performed Although the sensors and recorded data will vary by model the main data points are Vehicle status and engine perfor mance data Fuel injection and emission relat ed data Yamaha will not disclose this data to a third party except With the consent of the vehicle owner Where obligated by law For use by Yamaha in litigation For general Yamaha conducted research p...

Page 112: ...6 14 Fuses replacing 9 28 H Handlebar switches 6 10 Headlight 9 30 Helmet holders 6 15 Helmets 2 6 High beam indicator light 6 3 Horn switch 6 10 I Identification numbers 12 1 Ignition circuit cut off system 6 18 Indicator lights and warning lights 6 3 K Key handling of smart and mechanical keys 4 3 Keyhole cover 6 2 L Labels location 1 1 License plate light bulb replacing 9 33 M Main switch 4 7 M...

Page 113: ...hrottle grip and cable checking and lubricating 9 24 Throttle grip free play checking 9 17 Tires 9 18 Tool kit 9 1 Troubleshooting 9 33 Troubleshooting charts 9 36 Turn signal indicator lights 6 3 Turn signal light bulb front replacing 9 31 Turn signal switch 6 10 V Valve clearance 9 17 V belt checking 9 23 Vehicle identification number 12 1 W Wheel bearings checking 9 26 Wheels 9 19 UBF6EYE0 book...

Page 114: ...DIC183 PRINTED IN THAILAND 2017 07 E ...

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Yamaha Aerox GDR155, Owner'S Manual

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