User Manuals: Yamaha YZ 2015 Series Off-road Motorcycle

Manuals and User Guides for Yamaha YZ 2015 Series Off-road Motorcycle. We have 1 Yamaha YZ 2015 Series Off-road Motorcycle manual available for free PDF download: Owner's Service Manual

Yamaha YZ 2015 Series Owner's Service Manual

Yamaha YZ 2015 Series Owner's Service Manual (396 pages)

Brand: Yamaha | Category: Motorcycle | Size: 13.71 MB

Table of Contents

Table of Contents

9
- General Information
  11
- Location of Important Labels
  13
- Description
  14
- Identification
  15
- Vehicle Identification Number
  15
- Engine Serial Number
  15
- Features
  16
- Outline of the Fi System
  16
- Fi System
  17
- Fuel Hose Joint Cover
  18
- Coupler for Connecting Optional Part
  18
- Spark Plug Wrench
  18
- Handlebar Protector
  18
- Nipple Wrench
  18
- Included Parts
  18
- Important Information
  19
- Preparation for Removal and Disassembly
  19
- Replacement Parts
  19
- Gaskets, Oil Seals and O-Rings
  20
- Lock Washers/Plates and Cotter Pins
  20
- Bearings and Oil Seals
  20
- Circlips
  20
- Electrical System
  21
- Basic Service Information
  21
- Special Tools
  25
- Control Functions
  31
- Engine Stop Switch
  31
- Start Switch
  31
- Clutch Lever
  31
- Shift Pedal
  31
- Kickstarter Lever
  31
- Throttle Grip
  31
- Fuel Tank Cap
  32
- Starter Knob/Idle Adjusting Screw
  32
- Sidestand
  32
- Rear Brake Pedal
  32
- Front Brake Lever
  32
- Starting and Break-In
  34
- Fuel
  34
- Handling Note
  34
- Air Filter Maintenance
  34
- Starting a Cold Engine
  34
- Starting a Warm Engine
  35
- Break-In Procedures
  36
- Maintenance after Break-In
  37
- Major Maintenance
  37
- Torque-Check Points
  39
- Motorcycle Care and Storage
  40
- Care
  40
- Storage
  41
Specifications

43
- General Specifications
  44
- Engine Specifications
  45
- Chassis Specifications
  51
- Electrical Specifications
  54
- General Tightening Torque Specifications
  55
- Tightening Torques
  55
- Engine Tightening Torques
  56
- Chassis Tightening Torques
  59
- Engine
  62
- Lubrication Points and Lubricant Types
  62
- Chassis
  63
- Lubrication Diagrams
  66
- Lubrication System Chart and Diagrams
  66
- Cable Routing Diagram
  74
Periodic Checks and Adjustments

89
- Maintenance Intervals
  91
- General Inspection and Maintenance
  97
- Pre-Operation Inspection and Maintenance
  97
- Changing the Coolant
  98
- Checking the Coolant Level
  98
- Checking the Cooling System
  98
- Engine
  98
- Checking the Radiator Cap
  99
- Checking the Radiator Cap Opening Pressure
  99
- Adjusting the Clutch Lever Free Play
  100
- Checking the Coolant Circulatory System for Leaks
  100
- Adjusting the Throttle Grip Free Play
  101
- Lubricating the Throttle Cable
  101
- Cleaning the Air Filter Element
  102
- Checking the Breather Hoses
  103
- Checking the Exhaust System
  103
- Checking the Throttle Body Joint
  103
- Checking the Engine Oil Level
  104
- Checking the Fuel Line
  104
- Changing the Engine Oil
  105
- Adjusting the Engine Idling Speed
  106
- Adjusting the Valve Clearance
  107
- Bleeding the Brake System
  111
- Chassis
  111
- Adjusting the Front Brake
  112
- Checking the Brake Hose
  112
- Adjusting the Rear Brake
  113
- Checking the Front Brake Pads
  113
- Checking the Rear Brake Pads
  115
- Checking the Brake Fluid Level
  116
- Checking the Rear Brake Pad Insulator
  116
- Adjusting the Drive Chain Slack
  117
- Air Bleeding from Front Fork
  118
- Checking the Front Fork Legs
  118
- Checking the Front Fork Protector Guide
  118
- Cleaning the Front Fork Oil Seal and Dust Seal
  118
- Adjusting the Front Fork Legs
  119
- Adjusting the Rear Shock Absorber Assembly
  120
- Checking the Rear Suspension
  120
- Checking the Swingarm Operation
  120
- Checking and Tightening the Spokes
  122
- Checking the Tires
  122
- Checking and Adjusting the Steering Head
  123
- Checking the Wheel Bearings
  123
- Checking the Wheels
  123
- Checking and Lubricating the Cables
  124
- Lubricating the Levers
  124
- Lubricating the Pedal
  124
- Checking the Chassis Fasteners
  125
- Lubricating the Drive Chain
  125
- Lubricating the Sidestand
  125
- Checking the Ignition Timing
  126
- Checking the Spark Plug
  126
- Electrical System
  126
- Checking and Charging the Battery
  127
Chassis

129
- General Chassis
  131
- Removing the Left Side Cover
  132
- Removing the Number Plate
  132
- Removing the Seat
  132
- Front Wheel
  133
- Checking the Front Wheel
  134
- Removing the Front Wheel
  134
- Assembling the Front Wheel
  135
- Disassembling the Front Wheel
  135
- Installing the Front Wheel
  136
- Rear Wheel
  137
- Checking and Replacing the Rear Wheel Sprocket
  138
- Checking the Rear Wheel
  138
- Disassembling the Rear Wheel
  138
- Removing the Rear Wheel
  138
- Assembling the Rear Wheel
  139
- Installing the Rear Wheel
  140
- Front Brake
  142
- Checking the Front Brake Disc
  146
- Disassembling the Front Brake Caliper
  146
- Introduction
  146
- Removing the Front Brake Caliper
  146
- Assembling the Front Brake Caliper
  147
- Checking the Front Brake Caliper
  147
- Installing the Brake Caliper Piston
  147
- Installing the Front Brake Caliper
  148
- Assembling the Front Brake Master Cylinder
  149
- Checking the Front Brake Master Cylinder
  149
- Removing the Front Brake Master Cylinder
  149
- Installing the Front Brake Master Cylinder
  150
- Rear Brake
  152
- Checking the Rear Brake Disc
  156
- Introduction
  156
- Assembling the Rear Brake Caliper
  157
- Checking the Rear Brake Caliper
  157
- Disassembling the Rear Brake Caliper
  157
- Removing the Rear Brake Caliper
  157
- Installing the Brake Caliper Piston
  158
- Installing the Rear Brake Caliper
  158
- Checking the Rear Brake Master Cylinder
  159
- Removing the Rear Brake Master Cylinder
  159
- Assembling the Rear Brake Master Cylinder
  160
- Installing the Rear Brake Master Cylinder
  160
- Checking the Handlebar
  164
- Handlebar
  164
- Installing the Handlebar
  164
- Removing the Handlebar
  164
- Front Fork
  169
- Disassembling the Front Fork Legs
  171
- Removing the Front Fork Legs
  171
- Checking the Front Fork Legs
  172
- Assembling the Front Fork Legs
  173
- Installing the Front Fork Legs
  179
- Steering Head
  182
- Checking the Steering Head
  183
- Installing the Steering Head
  183
- Removing the Lower Bracket
  183
- Rear Shock Absorber Assembly
  186
- Disposing of a Rear Shock Absorber
  189
- Handling the Rear Shock Absorber
  189
- Removing the Bearing
  189
- Removing the Rear Shock Absorber Assembly
  189
- Checking the Connecting Arm and Relay Arm
  190
- Checking the Rear Shock Absorber Assembly
  190
- Installing the Relay Arm
  190
- Installing the Rear Shock Absorber Assembly
  191
- Swingarm
  193
- Checking the Swingarm
  194
- Removing the Bearing
  194
- Removing the Swingarm
  194
- Installing the Swingarm
  195
- Chain Drive
  196
- Checking the Drive Chain
  197
- Removing the Drive Chain
  197
- Checking the Drive Sprocket
  198
- Checking the Rear Wheel Sprocket
  198
- Installing the Drive Chain
  198
Engine

201
- Engine Removal
  204
- Removing the Drive Sprocket
  209
- Removing the Exhaust Pipe 2
  209
- Removing the Silencer
  209
- Changing the Silencer Fiber
  210
- Checking the Silencer and Exhaust Pipe
  210
- Removing the Engine
  210
- Installing the Engine
  211
- Installing the Brake Pedal
  212
- Installing the Drive Sprocket
  212
- Installing the Exhaust Pipe and Muffler
  213
- Camshaft
  215
- Removing the Camshaft
  217
- Checking the Camshaft
  218
- Checking the Timing Chain and Camshaft Sprocket
  219
- Checking the Timing Chain Tensioners
  219
- Checking the Decompression System
  220
- Installing the Camshafts
  220
- Cylinder Head
  223
- Checking the Cylinder Head
  225
- Checking the Timing Chain Guide (Intake Side)
  225
- Removing the Cylinder Head
  225
- Installing the Cylinder Head
  226
- Removing the Valves
  228
- Valves and Valve Springs
  228
- Checking the Valves and Valve Guides
  229
- Checking the Valve Seats
  230
- Checking the Valve Springs
  232
- Checking the Valve Lifters
  233
- Installing the Valves
  233
- Checking the Cylinder and Piston
  236
- Cylinder and Piston
  236
- Removing the Piston
  236
- Checking the Piston Rings
  237
- Checking the Piston Pin
  238
- Installing the Piston and Cylinder
  238
- Electric Starter
  240
- Checking the Starter Motor
  242
- Assembling the Starter Motor
  243
- Checking the Clutch Plates
  248
- Checking the Clutch Springs
  248
- Checking the Friction Plates
  248
- Clutch
  248
- Removing the Clutch
  248
- Checking the Clutch Boss
  249
- Checking the Clutch Housing
  249
- Checking the Clutch Push Rods
  249
- Checking the Pressure Plate
  249
- Checking the Primary Drive Gear
  249
- Checking the Push Lever Shaft
  249
- Checking the Primary Driven Gear
  250
- Installing the Clutch
  250
- Installing the Oil Seal
  250
- Installing the Right Crankcase Cover
  250
- Installing the Kickstarter Lever
  253
- Checking the Kick Gear, Kick Idle Gear and Ratchet Wheel
  255
- Checking the Kick Shaft and Ratchet Wheel
  255
- Installing the Kick Shaft Assembly
  255
- Kickstater
  255
- Removing the Kick Shaft Assembly
  255
- Installing the Kick Idle Gear
  256
- Shift Shaft
  257
- Checking the Shift Guide and Shift Lever Assembly
  258
- Checking the Shift Shaft
  258
- Checking the Stopper Lever
  258
- Removing the Segment
  258
- Removing the Shift Guide and Shift Lever Assembly
  258
- Installing the Segment
  259
- Installing the Shift Guide and Shift Lever Assembly
  259
- Installing the Stopper Lever
  259
- Installing the Shift Pedal
  260
- Installing the Shift Shaft
  260
- Oil Pump and Balancer Gear
  262
- Checking the Balancer
  263
- Checking the Oil Pump
  263
- Checking the Primary Drive Gear, Balancer Shaft Drive Gear, and Balancer Weight Gear
  263
- Removing the Balancer
  263
- Assembling the Oil Pump
  264
- Installing the Oil Pump and Balancer Gear
  264
- Checking the Starter Clutch
  269
- Generator and Starter Clutch
  269
- Removing the Generator
  269
- Installing the Generator
  270
- Installing the Starter Clutch
  270
- Crankcase
  274
- Checking the Crankcase
  276
- Checking the Timing Chain, Timing Chain Guide, Oil Strainer
  276
- Disassembling the Crankcase
  276
- Removing the Crankcase Bearing
  276
- Assembling the Crankcase
  277
- Installing the Oil Seal
  277
- Crankshaft Assembly and Balancer Shaft
  278
- Checking the Crankshaft Assembly
  279
- Removing the Crankshaft Assembly
  279
- Installing the Balancer Shaft
  280
- Installing the Crankshaft Assembly
  280
- Transmission
  281
- Checking the Shift Forks
  282
- Removing the Transmission
  282
- Checking the Shift Drum Assembly
  283
- Checking the Transmission
  283
- Installing the Transmission
  283
- Cooling System
  287
Fuel System

295
- Fuel Tank
  296
- Checking the Fuel Pump Body
  297
- Installing the Fuel Pump
  297
- Removing the Fuel Pump
  297
- Removing the Fuel Tank
  297
- Checking the Fuel Pressure
  298
- Installing the Fuel Tank
  298
- Checking and Replacing the Protector
  299
- Checking the Damper
  299
- Throttle Body
  300
- Checking the Injector
  303
- Checking the Throttle Body
  303
- Checking the Throttle Body Joint
  303
- Adjusting the Throttle Position Sensor
  304
Electrical System

305
- Circuit Diagram
  308
- Ignition System
  308
- Troubleshooting
  310
- Circuit Diagram
  312
- Electric Starting System
  312
- Starting Circuit Cut-Off System Operation
  314
- Troubleshooting
  316
- Charging System
  318
- Circuit Diagram
  318
- Troubleshooting
  320
- Circuit Diagram
  322
- COOLING SYSTEM (for JPN)
  322
- Troubleshooting
  324
- Circuit Diagram
  326
- Fuel Injection System
  326
- Yamaha Diagnostic Tool
  328
- Troubleshooting Details
  331
- Circuit Diagram
  352
- Fuel Pump System
  352
- Troubleshooting
  354
- Electrical Components
  356
- Checking the Switches
  360
- Checking and Charging the Battery
  363
- Checking the Fuses
  363
- Checking the Relays
  366
- Checking the Diode
  367
- Checking the Ignition Coil
  368
- Checking the Ignition Spark Gap
  368
- Checking the Spark Plug Cap
  368
- Checking the Crankshaft Position Sensor
  369
- Checking the Lean Angle Sensor
  369
- Checking the Starter Motor Operation
  370
- Checking the Stator Coil
  370
- Checking the Coolant Temperature Sensor
  371
- CHECKING the RADIATOR FAN MOTOR (for JPN)
  371
- Checking the Rectifier/Regulator
  371
- Checking the Throttle Position Sensor
  372
- Checking the Intake Air Pressure Sensor
  373
- Checking the Throttle Position Sensor Input Voltage
  373
Troubleshooting

375
- General Information
  376
- Incorrect Engine Idling Speed
  376
- Starting Failures
  376
- Troubleshooting
  376
- Clutch Drags
  377
- Clutch Slips
  377
- Jumps out of Gear
  377
- Overheating
  377
- Poor Medium-And-High-Speed Performance
  377
- Shift Pedal Does Not Move
  377
- Shifting Is Difficult
  377
- Faulty Front Fork Legs
  378
- Front Fork Oil Leaking
  378
- Overcooling
  378
- Poor Braking Performance
  378
- Unstable Handling
  378
- List of Self-Diagnostic and Fail-Safe Actions
  380
Tuning

383
- Chassis
  384
- Drive and Rear Wheel Sprockets Setting Parts
  384
- Selection of the Secondary Reduction Ratio (Sprocket)
  384
- Tire Pressure
  384
- Change in Amount and Characteristics of Fork Oil
  385
- Front Fork Setting
  385
- Setting of Spring after Replacement
  385
- Choosing Set Length
  386
- Front Fork Setting Parts
  386
- Rear Suspension Setting
  386
- Setting of Spring after Replacement
  387
- Suspension Setting (Front Fork)
  389
- Suspension Setting (Rear Shock Absorber)
  390

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