Yamaha Y15ZR Owner'S Manual Download Page 62

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Periodic maintenance and adjustment

7-17

TIP

If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment.

EAU48434

Adjusting the throttle grip free
play

Measure the throttle grip free play as
shown.

Periodically check the throttle grip free
play and, if necessary, adjust it as fol-
lows.

TIP

The engine idling speed must be cor-
rectly adjusted before checking and
adjusting the throttle grip free play.

1. Slide the rubber cover back.
2. Loosen the locknut.
3. To increase the throttle grip free

play, turn the adjusting nut in di-
rection (a). To decrease the throt-
tle grip free play, turn the adjusting
nut in direction (b).

4. Tighten the locknut and then slide

the rubber cover to its original po-
sition.

Engine idling speed:

1300–1500 r/min

1. Rubber cover

2. Throttle grip free play adjusting nut

3. Locknut

4. Throttle grip free play

Throttle grip free play:

3.0–7.0 mm (0.12–0.28 in)

OFF

(a)

(b)

Summary of Contents for Y15ZR

Page 1: ...Read this manual carefully before operating this vehicle OWNER S MANUAL Y15ZR B17 F8199 31 OWNER S MANUAL Y15ZR B17 F8199 31 ...

Page 2: ...this vehicle This manual should stay with this vehicle if it is sold EAU46091 EAU46091 䘉 অ䖖ԕࡽˈ䈧 ݵ 䘉ሿ Ǆ䘉享Ԉо অ䖖а䎧Ǆ EAU46091 Baca buku panduan dengan teliti sebelum mengendalikan motosikal ini Buku panduan diberi bersama dengan pembelian motosikal ...

Page 3: ...rom trouble and injury In addition the many tips given in this manual will help keep your motorcycle 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 cont...

Page 4: ... used to alert you to potential 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 e...

Page 5: ...ion T150 OWNER S MANUAL 2019 by Yamaha Motor Co Ltd 1st edition March 2019 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Malaysia ...

Page 6: ... the emission control system 7 2 General maintenance and lubrication chart 7 4 Removing and installing the cowling and panels 7 8 Checking the spark plug 7 9 Engine oil and oil filter element 7 11 Why Yamalube 7 13 Coolant 7 14 Cleaning the air filter element 7 15 Adjusting the engine idling speed 7 16 Adjusting the throttle grip free play 7 17 Valve clearance 7 18 Tires 7 18 Cast wheels 7 20 Adju...

Page 7: ...ight bulb 7 34 Replacing a rear turn signal light bulb 7 35 Replacing the license plate light bulb 7 35 Front wheel 7 36 Rear wheel 7 37 Troubleshooting 7 38 Troubleshooting charts 7 39 Motorcycle care and storage 8 1 Matte color caution 8 1 Care 8 1 Storage 8 3 Specifications 9 1 Consumer information 10 1 Identification numbers 10 1 Index 11 1 ...

Page 8: ... of the labels on your 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 3 4 ...

Page 9: ...Location of important labels 1 2 1 1 100kPa 1bar kPa psi kPa psi 225 33 225 33 225 33 225 33 ...

Page 10: ...raining courses nearest 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 5 1 for a list of pre operation checks t This motorcycle is designed to carry the operator and a passen ger t The failure of mo...

Page 11: ... rests during operation to main tain control of the motorcycle t 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 z Never ride under the influence of alcohol or other drugs z This motorcycle is designed...

Page 12: ...the weight distribu tion of the motorcycle is changed To avoid the possibility of an accident use extreme caution when adding cargo or accessories to your motorcycle Use extra care when riding a motorcycle that has added cargo or accessories Here along with the information about accessories below are some general guidelines to follow if loading cargo to your motorcycle The total weight of the oper...

Page 13: ...le that change any of the vehicle s design or operation characteristics can put you and others at greater risk of serious injury or death You are responsible for injuries related to changes in the vehicle Keep the following guidelines in mind as well as those provided under Load ing when mounting accessories z Never install accessories or carry cargo that would impair the per formance of your moto...

Page 14: ...s or suitable straps that are attached to solid parts of the mo torcycle such as the frame or up per front fork triple clamp and not for example to rubber mounted handlebars or turn signals or parts that could break Choose the location for the straps carefully so the straps will not rub against painted surfaces during transport z The suspension should be com pressed somewhat by the tie downs if po...

Page 15: ...of an accident The majority 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 z The helmet must meet the safety standard SIRIM z The helmet size ...

Page 16: ...Safety information 2 7 2 z Full type use only for riding at low to mid range speeds z Full face type use for riding at mid range to high speeds ZAUU0004 ZAUU0005 ZAUU0006 ...

Page 17: ...ght page 7 34 2 Headlight page 7 33 3 Air filter element page 7 15 4 Battery page 7 31 5 Owner s tool kit page 7 1 6 Rear turn signal light page 7 35 7 Sidestand page 4 17 8 Centerstand page 7 29 9 Engine oil drain bolt page 7 11 10 Shift pedal page 4 12 11 Coolant reservoir page 7 14 ...

Page 18: ...ight view 3 2 1 4 5 6 7 1 Fuel tank cap page 4 13 2 Fuses page 7 32 3 Front brake fluid reservoir page 7 23 4 Engine oil filter element page 7 11 5 Brake pedal page 4 13 6 Dipstick page 7 11 7 Rear brake fluid reservoir page 7 23 ...

Page 19: ...nstruments 1 2 3 4 5 7 6 1 Clutch lever page 4 12 2 Left handlebar switches page 4 11 3 Multi function display page 4 6 4 Right handlebar switches page 4 11 5 Brake lever page 4 12 6 Throttle grip page 7 17 7 Main switch steering lock page 4 3 ...

Page 20: ...ight and auxiliary lights come on automatically when the key is turned to ON z The fuel pump can be heard when the key is turned to ON EAU45752 OFF All electrical systems are off The key can be removed WARNING EWA10073 Never turn the key to OFF while the vehicle is moving otherwise the electrical systems will be switched off which may result in loss of con trol or an accident EAUU1043 LOCK The ste...

Page 21: ...rol or an accident z 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 ...

Page 22: ...ing to the coolant temperature z If the engine overheats see page 7 40 for further instructions NOTICE ECA10022 Do not continue to operate the en gine if it is overheating EAU11507 Engine trouble warning light This warning light comes on or flashes if a problem is detected in the electrical circuit monitoring the engine If this oc curs have a Yamaha dealer check the self diagnosis system The elect...

Page 23: ...on 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 z a speedometer z a tachometer z a transmission gear display z a fuel meter z a multi function display TIP Be sure to turn the main switch on be fore using the RESET SELECT but ton Speedometer The speedometer shows the vehicle s tr...

Page 24: ...ccurs 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 1 Tachometer 1 Transmission gear display 1 1 1 4 5 The fuel meter indicates the amount of fuel in the fuel tank The display...

Page 25: ...m L or L 100 km o AVE_ _ _ km L or AVE_ _ _ L 100 km o AVE_ _ _ km h o ODO o TRIP 1 o TRIP 2 o TRIP F To reset a tripmeter select it by push ing the RESET SELECT button for one second If you do not reset the fuel reserve trip meter manually it resets itself auto matically and the display returns to the prior mode after refueling and traveling 5 km Odometer mode The odometer shows the total distanc...

Page 26: ...nstantaneous fuel consumption mode Shows the current fuel consumption when the vehicle is traveling at least 10 km h There are two display modes km L and L 100 km To switch the instantaneous fuel con sumption display between km L and L 100 km push the RESET SE LECT button for one second 1 Tripmeter 1 1 1 Instantaneous fuel consumption display 1 The clock uses a 12 hour time system To set the clock...

Page 27: ...et to the same as the instan taneous fuel consumption display mode z AVE_ _ _ km L The average dis tance that can be traveled on 1 0 L of fuel is shown z AVE_ _ _ L 100 km The average amount of fuel necessary to travel 100 km is shown To reset the average fuel consumption display press the RESET SELECT button for one second TIP After resetting the average fuel con sumption _ _ _ will be shown unti...

Page 28: ...AU12582 Light switch Set the light switch to to turn on the headlight taillight and meter light ing Set the switch to to turn off all the lights EAU12663 Engine stop switch Set this switch to run before starting the engine Set this switch to stop to stop the engine in case of an emergency such as in the event of an overturn or if the throttle is stuck EAU12713 Start switch Push this switch to cran...

Page 29: ...d with a clutch switch which is part of the start ing circuit cut off system See page 4 18 EAU12875 Shift pedal The shift pedal is located on the left side of the motorcycle To shift the transmission to a higher gear move the shift pedal up To shift to the trans mission to a lower gear move the shift pedal down See page 6 2 EAU12892 Brake lever The brake lever is located on the right side of the h...

Page 30: ...ank cap 1 Open the seat See page 4 16 2 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 Close the seat WARNING EWA11092 Make sure that the fuel tank cap is properly closed after filling fuel Leaking fuel is a fire hazard 1 Brake pedal 1 1 Fu...

Page 31: ...curely close the fuel tank cap WARNING EWA15152 Gasoline is poisonous and can cause injury or death Handle gaso line with care Never siphon gasoline by mouth If you should swallow some gasoline or inhale a lot of gas oline vapor or get some gasoline in your eyes see your doctor immedi ately If gasoline spills on your skin wash with soap and water If gaso line spills on your clothing change your cl...

Page 32: ... burns z Do not park the vehicle near possible fire hazards such as grass or other materials that easily burn z Park the vehicle in a place where pedestrians or children are not likely to touch the hot exhaust system z Make sure that the exhaust sys tem has cooled down before doing any maintenance work z Do not allow the engine to idle more than a few minutes Long idling can cause a build up of he...

Page 33: ...move the key from the main switch if the motorcycle will be left unattended 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 4 16 2 Attach a helmet to a helmet hold er and then securely close the seat WARNING Never ride with a helmet attached to the he...

Page 34: ...astic bag so that they will not get wet When washing the vehicle be careful not to let any water enter the storage compartment EAU37491 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright WARNING EWA14191 The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved ...

Page 35: ...f system This system prevents in gear engine starts unless the clutch lever is pulled Periodically check the system via the following procedure TIP z This check is most reliable if per formed with a warmed up engine z See pages 4 3 and 4 11 for switch operation information ...

Page 36: ...t be working correctly The vehicle should not be ridden 5 Stop the engine 6 Set engine stop switch to run position 7 Shift transmission into gear 8 Pull the clutch lever 9 Push the start switch Does the engine start The clutch switch may not be working correctly The vehicle should not be ridden NO YES The system is OK The motorcycle can be ridden YES NO If a malfunction is noted have the vehicle i...

Page 37: ... inspected by a Yamaha dealer Before using this vehicle check the following points E G A P S K C E H C M E T I Fuel t Refuel if necessary t Check fuel line for leakage 4 14 Engine oil t Check oil level in engine t If necessary add recommended oil to specified level t Check vehicle for oil leakage 7 11 Coolant t Check coolant level in reservoir t If necessary add recommended coolant to specified le...

Page 38: ... Yamaha dealer adjust throttle grip free play and lubricate ca ble and grip housing 7 17 7 27 Control cables t Make sure that operation is smooth t Lubricate if necessary 7 27 Drive chain t Check chain slack t Adjust if necessary t Check chain condition t Lubricate if necessary 7 25 7 27 Wheels and tires t Check for damage t Check tire condition and tread depth t Check air pressure t Correct if ne...

Page 39: ... that operation is smooth t Lubricate pivots if necessary 7 29 Chassis fasteners t Make sure that all nuts bolts and screws are properly tightened t Tighten if necessary Instruments lights signals and switches t Check operation t Correct if necessary E G A P S K C E H C M E T I ...

Page 40: ...which could cause an accident or injury EAU45311 TIP This model is equipped with a lean an gle sensor to stop the engine in case of a turnover To start the engine after a turnover be sure to turn the main switch to OFF and then to ON Fail ing to do so will prevent the engine from starting even though the engine will crank when pushing the start switch EAUN0073 NOTICE ECAN0072 Do not ride through d...

Page 41: ...ator light should come on If not ask a Yamaha dealer to check the electrical circuit 3 Start the engine by pushing the start switch If the engine fails to start release the start switch wait a few sec onds and then try again Each starting attempt should be as short as possible to preserve the battery Do not crank the engine more than 10 seconds on any one attempt NOTICE ECA11043 For maximum engine...

Page 42: ...own and avoid high engine speeds with no load on the en gine z Turn the engine off instead of let ting it idle for an extended length of time e g in traffic jams at traf fic lights or at railroad crossings EAU16842 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read the fol lowing material c...

Page 43: ...a dealer check the vehi cle EAU17214 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10312 z Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them and be burned z Do not park on a slope or on soft ground otherwise the vehicle may overturn increasing the risk of a fuel leak and...

Page 44: ...STOMERS CAN USE THE FULLEST POTENTIAL OF YAMAHA MOTORCYCLES 2 A MOTORCYCLE CAN KEEP ITS PERFORMANCE CAPABILITY FOR A LONGER TIME Comparison of wear on engine parts piston piston ring cylinder etc 100 Perfect operative condition Without maintenance Distance covered km Engine overhaul cylinder boring piston ring change etc With maintenance ZAUV0284 ...

Page 45: ...CLE CAN DEMAND A HIGH PRICE WHEN IT IS TRADED IN AS A USED PRODUCT Fuel consumption 100 Without maintenance Distance covered km With maintenance Customer s running cost fuel cost plus maintenance and repair expenses Without maintenance With maintenance Big repairs at higher expenses Distance covered km S ZAUV0285 ...

Page 46: ...ARNING EWA15123 Turn off the engine when performing maintenance unless otherwise specified z A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires z 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...

Page 47: ...emission control system NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING whichever comes first ANNUAL CHECK 1000 km or 2 months 4000 km or 6 months 7000 km or 10 months 10000 km or 14 months 13000 km or 18 months 1 Fuel line t Check fuel hose for cracks or damage 2 Fuel filter t Check condition t Replace if necessary Every 12000 km 7500 mi 3 Spark plug t Check condition t Clean and regap i m 0 0 ...

Page 48: ...Check for leakage t Tighten if necessary t Replace gasket s if necessary NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING whichever comes first ANNUAL CHECK 1000 km or 2 months 4000 km or 6 months 7000 km or 10 months 10000 km or 14 months 13000 km or 18 months ...

Page 49: ...ltage t Charge if necessary 4 Clutch t Check operation t Adjust 5 Front brake t Check operation fluid level and vehicle for fluid leakage t i m i l e h t o t n r o w r e v e n e h W s d a p e k a r b e c a l p e R t 6 Rear brake t Check operation fluid level and vehicle for fluid leakage t i m i l e h t o t n r o w r e v e n e h W s d a p e k a r b e c a l p e R t 7 Brake hose t Check for cracks o...

Page 50: ...chain lubricant thoroughly Every 1000 km 600 mi and after washing the motorcycle riding in the rain or riding in wet areas 14 Steering bearings t Check bearing play and steering for roughness t Lubricate with lithium soap based grease Every 10000 km 6250 mi 15 Chassis fasteners t Make sure that all nuts bolts and screws are properly tightened 16 Brake lever pivot shaft t Lubricate with silicone gr...

Page 51: ...hock ab sorber for oil leakage 22 Engine oil t Change t Check oil level and vehicle for oil leakage Every 3000 km 1800 mi 23 Engine oil filter ele ment i m 0 0 0 6 m k 0 0 0 0 1 y r e v E e c a l p e R t 24 Cooling system t Check coolant level and vehicle for coolant leakage t Change with Yamaha genuine coolant Every 3 years 25 Front and rear brake switches t Check operation 26 Moving parts and ca...

Page 52: ...brake master cylinder and caliper and change the brake fluid t Replace the brake hoses every four years and if cracked or damaged 27 Throttle grip t Check operation t Check throttle grip free play and adjust if necessary t Lubricate cable and grip housing 28 Lights signals and switches t Check operation t Adjust headlight beam NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING km ANNUAL CHECK 1000 ...

Page 53: ...ach time the cowling or a panel needs to be re moved and installed EAU18792 Cowling A To remove the cowling Remove the screws and then take the cowling off To install the cowling Place the cowling in the original posi tion and then install the screws EAUV0521 Panels A and B To remove a panel Remove the screws and then pull the panel off as shown 1 Panel A 1 1 Panel C 2 Cowling A 3 Panel B 1 2 3 2 ...

Page 54: ...t EAUT1838 Checking the spark plug The spark plug is an important engine component which is easy to 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 Place...

Page 55: ... 3 Measure the spark plug gap with a wire thickness 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 whe...

Page 56: ...ne oil should be between the tip of the dipstick and the maximum level mark 4 If the engine oil is at or below the minimum level mark add suffi cient oil of the recommended type to raise it to the correct level 5 Insert the dipstick into the oil filler hole and then tighten the oil filler cap To change the engine oil with or without oil filter element replace ment 1 Start the engine warm it up for...

Page 57: ...TIP Make sure that the O ring is properly seated 8 Install the engine oil strainer com pression spring new O ring and engine oil drain bolt and then tighten the drain bolt to the speci fied torque NOTICE Before in stalling the engine oil drain bolt do not forget to install the O ring compression spring and oil strainer in position ECA10422 1 Engine oil drain bolt 2 O ring 3 Compression spring 4 St...

Page 58: ... 11 Turn the engine off and then check the oil level and correct it if necessary EAU85450 Why Yamalube YAMALUBE oil is a Genuine YAMAHA Part born of the engineers passion and belief that engine oil is an impor tant liquid engine component We form teams of specialists in the fields of me chanical engineering chemistry elec tronics and track testing and have them develop the engine together with the...

Page 59: ...olant reser voir See page 7 8 4 Remove the coolant reservoir cap add coolant to the maximum level mark and then install the reservoir cap WARNING Remove only the coolant reservoir cap Never attempt to remove the radiator cap when the engine is hot EWA15162 NOTICE If coolant is not available use distilled water or soft tap water instead Do not use hard water or salt water since it is harmful to the...

Page 60: ...ecified in the periodic maintenance and lubrication chart Clean the air filter element more fre quently if you are riding in unusually wet or dusty areas 1 Remove panel C See page 7 8 2 Remove the seat by pulling the seat pin out as shown 3 Remove the air filter case cover by removing the screws and bolts and then pull the air filter element out 4 Lightly tap the air filter element to remove the m...

Page 61: ...remove the clamp and then remove the plug to drain the hose 7 Install the seat by installing the seat pin 8 Install the panel EAU34302 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart The engine should be warm before making this adjustment Check the engine idli...

Page 62: ...st be cor rectly adjusted before checking and adjusting the throttle grip free play 1 Slide the rubber cover back 2 Loosen the locknut 3 To increase the throttle grip free play turn the adjusting nut in di rection a To decrease the throt tle grip free play turn the adjusting nut in direction b 4 Tighten the locknut and then slide the rubber cover to its original po sition Engine idling speed 1300 ...

Page 63: ...aintain the tires in good condition at all times and replace them at the appropriate time with the speci fied tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10504 Operation of this vehicle with im proper tire pressure may cause se vere injury or death from loss of control t The tire air pressure must be checked and adjusted on ...

Page 64: ...n for it to develop its optimal characteristics Tire information This model is equipped with tubeless tires and tire air valves Tires age even if they have not been used or have only been used occasion ally Cracking of the tread and sidewall rubber sometimes accompanied by carcass deformation is an evidence of ageing Old and aged tires shall be checked by tire specialists to ascertain their suitab...

Page 65: ... lever free play should mea sure 8 0 12 0 mm 0 31 0 47 in as shown Periodically check the clutch lever free play and if necessary adjust it as follows 1 Remove cowling A See page 7 8 2 Loosen the locknut 3 To increase the clutch lever free play turn the clutch lever free play adjusting bolt in direction a To decrease the clutch lever free play turn the adjusting bolt in di rection b TIP If the spe...

Page 66: ... end If there is free play have a Yamaha dealer inspect the brake system WARNING EWA14212 A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hydraulic system have a Yamaha dealer bleed the system be fore operating the vehicle Air in the hydraulic system will diminish the braking performance which may re sult in loss of contro...

Page 67: ... Check that the brake light comes on just before braking takes ef fect If necessary adjust the rear brake light switch as follows Turn the rear brake light switch adjust ing nut while holding the rear brake light switch in place To make the brake light come on earlier turn the ad justing nut in direction a To make the brake light come on later turn the ad justing nut in direction b TIP The front b...

Page 68: ...d 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 EAU22501 Rear brake pads Check each rear brake pad for damage and measure the lining thickness If a brake pad is damaged or if the lining thickness is less than 1 5 mm 0 06 in have a Yamaha dealer replace the brake pads as a set EAUV0530 Checking the brake fluid lev...

Page 69: ...4 may result in a harmful chemical re action t Be careful that water does not enter the brake fluid reservoir when refilling Water will signifi cantly lower the boiling point of the fluid and may result in vapor lock NOTICE ECA17641 Brake fluid may damage painted surfaces or plastic parts Always clean up spilled fluid immediately As the brake pads wear it is normal for the brake fluid level to gra...

Page 70: ... shown 4 If the drive chain slack is incorrect adjust it as follows NOTICE Im proper drive chain slack will overload the engine as well as other vital parts of the motorcy cle and can lead to chain slip page or breakage To prevent this from occurring keep the drive chain slack within the specified limits ECA10572 EAU66611 To adjust the drive chain slack Consult a Yamaha dealer before ad justing th...

Page 71: ...t the brake cal iper bracket bolt and then tighten the locknuts to the specified torques 4 Make sure that the drive chain pullers are in the same position the drive chain slack is correct and the drive chain moves smoothly 1 Locknut 2 Drive chain slack adjusting nut 3 Axle nut 3 2 2 1 1 1 Brake caliper bracket 2 Brake caliper bracket bolt 1 Washer 2 Alignment marks 3 Drive chain slack adjusting nu...

Page 72: ...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 WARNING Damage to the outer housing of cables may result in internal rusting and cause inter ference with cable movement Re place damaged cables as soon as possible to prevent unsafe condi tions EWA10712 EAU23...

Page 73: ...d the lever pivots should be lu bricated if necessary Brake lever Clutch lever EAU23185 Checking and lubricating the brake pedal The operation of the brake pedal should be checked before each ride and the pedal pivot should be lubricat ed if necessary Recommended lubricants Brake lever Silicone grease Clutch lever Lithium soap based grease Recommended lubricant Lithium soap based grease ...

Page 74: ...nterstand or sidestand does not move up and down smoothly have a Yamaha dealer check or re pair it Otherwise the centerstand or sidestand could contact the ground and distract the operator resulting in a possible loss of control EAUM1653 Lubricating the swingarm piv ots The swingarm pivots must be lubricat ed by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication...

Page 75: ...wn hard on the handle bars several times to check if the front fork compresses and re bounds smoothly NOTICE ECA10591 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU45512 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified...

Page 76: ...re burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID t EXTERNAL Flush with plenty of water t INTERNAL Drink large quan tities of water or milk and im mediately call a physician t EYES Flush with water for 15 minutes and seek prompt medical attention t Batteries produce explosive hy drog...

Page 77: ...ry will be stored for more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation NOTICE When install ing the battery be sure to turn the main switch off then con nect the positive lead before connecting the negative lead ECA16842 4 After installation make sure that the battery leads are properly con nected to the battery ter...

Page 78: ...his model is equipped with an LED type headlight If a headlight does not come on have a Yamaha dealer check its electrical circuit NOTICE ECA16581 Do not affix any type of tinted film or stickers to the headlight lens EAU44941 Auxiliary light This model is equipped with an LED type auxiliary light If the auxiliary light does not come on have a Yamaha dealer check it Specified fuses Main fuse 15 0 ...

Page 79: ...lb NOTICE ECA10671 It is advisable to have a Yamaha dealer perform this job 1 Place the vehicle on the center stand 2 Remove panel A and B See page 7 8 3 Remove the turn signal light bulb socket together with the bulb by turning it counterclockwise 4 Remove the burnt out bulb by pulling it out 5 Insert a new bulb into the socket 6 Install the socket together with the bulb by turning it clockwise 7...

Page 80: ...rn 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 EAU24314 Replacing the license plate light bulb 1 Remove the license plate light unit by removing the screws 2 Remove the license plate light bulb socket together with ...

Page 81: ...wheel NOTICE Do not apply the brake after the wheel and brake disc have been removed otherwise the brake pads will be forced shut ECA11073 To install the front wheel 1 Lift the wheel up between the fork legs 2 Insert the wheel axle and then in stall the axle nut 3 Take the motorcycle off the cen terstand so that the front wheel is on the ground 4 Tighten the axle nut to the speci fied torque TIP W...

Page 82: ...fting the wheel pull the wheel axle out TIP A rubber mallet may be useful to tap the wheel axle out 7 Remove the wheel NOTICE Do not apply the brake after the wheel and brake disc have been removed otherwise the brake pads will be forced shut ECA11073 To install the rear wheel 1 Install the wheel and the brake cal iper bracket by inserting the wheel axle from the right hand side TIP t Make sure th...

Page 83: ...king these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bil...

Page 84: ...ve a Yamaha dealer check 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 slowl...

Page 85: ...pressure to escape When the hiss ing sound has stopped 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 ...

Page 86: ...ng 1 Cover the 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 sprock ets the drive cha...

Page 87: ...lean sponge and then 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 th...

Page 88: ...s as they will wear away the paint TIP t Consult a Yamaha dealer for ad vice on what products to use t 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 EAU43204 Storage Short term Always store your motorcycle in a cool dry place and if necessary protect it against dust with a ...

Page 89: ...ectrodes while turning the engine over EWA10952 e Remove the spark plug cap from the spark plug and then install the spark plug and the spark plug cap 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 motorcycle so that both of its wheels are off the groun...

Page 90: ...ed engine oil grade API service SG type or higher JASO standard MA Engine oil quantity Oil change 0 95 L 1 00 US qt 0 84 Imp qt With oil filter removal 1 00 L 1 06 US qt 0 88 Imp qt Coolant quantity Coolant reservoir up to the maximum level mark 0 28 L 0 30 US qt 0 25 Imp qt Radiator including all routes 0 48 L 0 51 US qt 0 42 Imp qt Air filter Air filter element Dry element Fuel Recommended fuel ...

Page 91: ...essure measured on cold tires 1 person Front Rear 2 persons Front Rear Front wheel Wheel type Cast wheel Rim size 17M C x MT1 85 Rear wheel Wheel type Cast wheel Rim size 17MC x MT3 50 Front brake Type Hydraulic single disc brake Specified brake fluid DOT 3 or 4 Rear brake Type Hydraulic single disc brake Specified brake fluid DOT 3 or 4 Front suspension Type Telescopic fork Spring Coil spring Sho...

Page 92: ...t 10 0 W Rear turn signal light 10 0 W Auxiliary light LED License plate light 5 0 W Meter lighting LED Neutral indicator light LED High beam indicator light LED Turn signal indicator light LED Coolant temperature warning light LED Engine trouble warning light LED Fuse s Main fuse 15 0 A Sub fuse 7 5 A Answer back fuse 10 0 A ...

Page 93: ...DENTIFICATION NUMBER ENGINE SERIAL NUMBER EAUV0540 Vehicle identification number The vehicle identification number is stamped into the frame under the seat See page 4 16 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 EAUU1221 Engine serial number The engine serial number is stamped on the bottom left s...

Page 94: ...ng 7 23 Front fork checking 7 30 Fuel 4 14 Fuel consumption tips for reducing 6 3 Fuel tank cap 4 13 Fuses replacing 7 32 G General note 6 5 H Handlebar switches 4 11 Headlight 7 33 Helmet holders 4 16 Helmets 2 6 High beam indicator light 4 5 Horn switch 4 11 I Identification numbers 10 1 Indicator lights and warning lights 4 5 K Keyhole cover 4 4 L Labels location 1 1 License plate light bulb re...

Page 95: ...hooting charts 7 39 Turn signal indicator light 4 5 Turn signal light bulb front replacing 7 34 Turn signal switch 4 11 V Valve clearance 7 18 Vehicle identification number 10 1 W Wheel bearings checking 7 31 Wheel front 7 36 Wheel rear 7 37 Wheels 7 20 Y Yamalube 7 13 ...

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Yamaha Y15ZR, Owner'S Manual

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