Yamaha YZF-R15, Service Manual

Page: 71 / 338

ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
NOTE:
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Valve clearance adjustment should be made
on a cold engine, at room temperature.
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When the valve clearance is to be measured or
adjusted, the piston must be at top dead center
(TDC) on the compression stroke.
1. Remove:
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Front panels
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Seat
Refer to “GENERAL CHASSIS” on page 4-1.
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Fuel tank
Refer to “FUEL TANK ” on page 7-1.
2. Disconnect:
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Spark plug cap
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Air induction system vacuum hose
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Air induction system hose (3-way joint to air
cut-off valve)
Refer to “AIR INDUCTION SYSTEM” on
page 7-9.
3. Remove:
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Air cut-off valve
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Reed valve
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Reed valve plate
Refer to “AIR INDUCTION SYSTEM” on
page 7-9.
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Cylinder head cover
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Cylinder head cover gasket
Refer to “CYLINDER HEAD” on page 5-6.
4. Remove:
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Timing mark accessing screw “1”
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Crankshaft end accessing screw “2”
5. Measure:
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Valve clearance
Out of specification
→ Adjust.
a. Turn the crankshaft counterclockwise.
ssssssssssssssssssssssss
b. Align the TDC mark “a” on the magnero rotor
with the stationary pointer “b” on the magneto
cover.
c. Check that the cam lobes are positioned as
shown in the illustration.
d. Measure the valve clearance with a thickness
gauge “1”.
Out of specification
→ Adjust.
6. Adjust:
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Valve clearance
a. Loosen the locknut “1”.
b. Insert a thickness gauge “2” between the end
of the adjusting screw and the valve tip.
1
2
Valve clearance (cold)
Intake
0.10–0.14 mm
Exhaust
0.20–0.24 mm
b
a
1
3-2 3-3
ENGINE PERIODIC MAINTENANCE
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15 * Steering
16 * Chassis
17 Sidestand
18 * Front fork
19 *
20 * Injector
21 *
22
23 Cooling system
24.
Engine oil
Shock absorber
assembly
Engine oil filter
element
Front and rear
brake switches
bearings
fasteners
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NO. ITEM CHECK OR MAINTENANCE JOB
ODOMETER READING (x 1000 km)
1 3 6 9 12 15
• Check bearing play and steering for
roughness.
• Lubricate with lithium-soap-based
grease.
• Make sure that all nuts, bolts and screws
are properly tightened.
• Check operation.
• Lubricate.
• Check operation and for oil leakage
• Check operation and shock absorber for
oil leakage.
• Check operation.
• Change.
• Check oil level and vehicle for oil leakage.
• Replace.
• Check coolant level and vehicle for
coolant leakage.
• Adjust engine idling speed.
• Change coolant
• Check operation
Every 12000 km
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Every 10000 km (on odometer)
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Every 2 Years
25 *
26
27
28 *
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• Lubricate.
• Check the air cut-off valve, reed valve,
and hose for damage.
• Check operation.
• Check operation and free play.
• Adjust the throttle cable free play if
necessary.
• Lubricate the throttle grip housing and
cable.
• Replace any damaged parts if
necessary.
• Adjust headlight beam (if necessary).
Air induction
system
Lights, signals and
switches
NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinder and caliper, and change the
brake fluid.
Replace the brake hoses every four years and if cracked or damaged.
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Moving parts and
cables
Throttle grip housing
and cable
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