Yamaha N MAX GPD150-A 2015 Manuals

Manuals and User Guides for Yamaha N MAX GPD150-A 2015. We have 1 Yamaha N MAX GPD150-A 2015 manual available for free PDF download: Service Manual

Yamaha N MAX GPD150-A 2015 Service Manual

Yamaha N MAX GPD150-A 2015 Service Manual (450 pages)

Brand: Yamaha | Category: Motorcycle | Size: 21.89 MB

Table of Contents

Table of Contents

7
- General Information
  9
- Identification
  10
- Vehicle Identification Number
  10
- Engine Serial Number
  10
- Features
  11
- Outline of the Fi System
  11
- Fi System
  12
- Outline of the Abs
  13
- Abs Component Functions
  17
- Abs Operation
  22
- Abs Warning Light and Operation
  25
- Instrument Functions
  27
- Important Information
  31
- Preparation for Removal and Disassembly
  31
- Replacement Parts
  31
- Gaskets, Oil Seals and O-Rings
  31
- Lock Washers/Plates and Cotter Pins
  31
- Bearings and Oil Seals
  32
- Circlips
  32
- Rubber Parts
  32
- Basic Service Information
  33
- Quick Fasteners
  33
- Electrical System
  34
- Special Tools
  42
Specifications

47
- General Specifications
  48
- Engine Specifications
  49
- Chassis Specifications
  54
- Electrical Specifications
  56
- General Tightening Torque Specifications
  58
- Tightening Torques
  58
- Engine Tightening Torques
  59
- Chassis Tightening Torques
  62
- Engine
  66
- Lubrication Points and Lubricant Types
  66
- Engine Oil Lubrication Chart
  68
- Lubrication System Chart and Diagrams
  68
- Lubrication Diagrams
  70
- Cooling System Diagrams
  74
- Cable Routing
  76
Periodic Checks and Adjustments

103
- General Maintenance and Lubrication Chart
  106
- Introduction
  106
- Periodic Maintenance
  106
- Periodic Maintenance Chart for the Emission Control System
  106
- Checking the Fuel Filter
  109
- Checking the Fuel Line
  109
- Checking the Spark Plug
  109
- Adjusting the Valve Clearance
  110
- Checking the Engine Idling Speed
  112
- Checking the Exhaust System
  112
- Adjusting the Exhaust Gas Volume
  113
- Checking the Breather Hoses
  113
- Replacing the Air Filter Element and Cleaning the Check Hose
  113
- Cleaning the V-Belt Case Air Filter Element and Cleaning the Check Hose
  114
- Checking and Charging the Battery
  115
- Checking the Brake Fluid Level
  115
- Checking the Brake Operation
  115
- Checking the Front Brake Pads
  115
- Checking the Rear Brake Pads
  115
- Checking the Front Brake Hoses
  116
- Checking the Rear Brake Hoses
  116
- Bleeding the Hydraulic Brake System
  117
- Checking the Tires
  118
- Checking the Wheels
  118
- Checking and Adjusting the Steering Head
  119
- Checking the Wheel Bearings
  119
- Checking the Centerstand
  121
- Checking the Chassis Fasteners
  121
- Checking the Front Fork
  121
- Checking the Sidestand
  121
- Checking the Sidestand Switch
  121
- Lubricating the Centerstand
  121
- Lubricating the Levers
  121
- Lubricating the Sidestand
  121
- Lubricating the Steering Head
  121
- Changing the Engine Oil
  122
- Checking the Engine Oil Level
  122
- Checking the Rear Shock Absorber Assemblies
  122
- Changing the Coolant
  124
- Checking the Coolant Level
  124
- Checking the Cooling System
  124
- Changing the Final Transmission Oil
  127
- Lubricating the Secondary Sheave
  127
- Replacing the V-Belt
  127
- Checking and Lubricating the Cables
  128
- Checking the Brake Light Switches
  128
- Checking the Throttle Grip Operation
  128
Chassis

131
- General Chassis (1)
  135
- Installing the Battery Cover
  135
- INSTALLING the ECU (Engine Control Unit)
  135
- Removing the Battery Cover
  135
- REMOVING the ECU (Engine Control Unit)
  135
- General Chassis (2)
  136
- Installing the Front Side Cover
  138
- Installing the Tail/Brake Light Outer Cover
  138
- Removing the Front Side Cover
  138
- Removing the Tail/Brake Light Outer Cover
  138
- General Chassis (3)
  139
- Installing the Fuel Tank Cover
  141
- Removing the Fuel Tank Cover
  141
- General Chassis (4)
  142
- Installing the Rear Side Cover Assembly
  144
- Removing the Rear Side Cover Assembly
  144
- General Chassis (5)
  145
- Installing the Bottom Cover
  147
- Installing the Center Lower Cover
  147
- Installing the Footrest Board Assembly
  147
- Installing the Sidestand
  147
- General Chassis (6)
  148
- Assembling the Front Upper Cowling Assembly
  150
- Disassembling the Front Upper Cowling Assembly
  150
- Installing the Front Upper Cowling Assembly
  150
- Removing the Front Upper Cowling Assembly
  150
- General Chassis (7)
  151
- Installing the Front Cowling Assembly
  154
- Removing the Front Cowling Assembly
  154
- Removing the Front Side Cowling
  154
- Installing the Front Side Cowling
  155
- Installing the Front Turn Signal Light
  155
- General Chassis (8)
  156
- Installing the Key Shutter
  157
- Checking the Front Wheel
  160
- Disassembling the Front Wheel
  160
- Front Wheel
  160
- Removing the Front Wheel
  160
- Assembling the Front Wheel
  161
- Maintenance of the Front Wheel Sensor and Sensor Rotor
  161
- Adjusting the Front Wheel Static Balance
  162
- Installing the Front Wheel (Front Brake Disc)
  163
- Rear Wheel
  166
- Adjusting the Rear Wheel Static Balance
  167
- Checking the Rear Wheel
  167
- Installing the Rear Wheel (Rear Brake Disc)
  167
- Maintenance of the Rear Wheel Sensor Rotor
  167
- Removing the Rear Wheel (Disc)
  167
- Front Brake
  171
- Checking the Front Brake Disc
  175
- Introduction
  175
- Replacing the Front Brake Pads
  176
- Disassembling the Front Brake Caliper
  177
- Removing the Front Brake Caliper
  177
- Assembling the Front Brake Caliper
  178
- Checking the Front Brake Caliper
  178
- Installing the Front Brake Caliper
  178
- Removing the Front Brake Master Cylinder
  179
- Assembling the Front Brake Master Cylinder
  180
- Checking the Front Brake Master Cylinder
  180
- Installing the Front Brake Master Cylinder
  180
- Rear Brake
  184
- Checking the Rear Brake Disc
  188
- Introduction
  188
- Replacing the Rear Brake Pads
  188
- Removing the Rear Brake Caliper
  189
- Checking the Rear Brake Caliper
  190
- Disassembling the Rear Brake Caliper
  190
- Assembling the Rear Brake Caliper
  191
- Installing the Rear Brake Caliper
  191
- Assembling the Rear Brake Master Cylinder
  192
- Checking the Rear Brake Master Cylinder
  192
- Installing the Rear Brake Master Cylinder
  192
- Removing the Rear Brake Master Cylinder
  192
- Abs (Anti-Lock Brake System)
  194
- Checking the Hydraulic Unit Assembly
  196
- Installing the Hydraulic Unit Assembly
  196
- Removing the Hydraulic Unit Assembly
  196
- Hydraulic Unit Operation Tests
  198
- Checking the Abs Warning Light
  201
- Checking the Handlebar
  205
- Disassembling the Upper Handlebar Cover Assembly
  205
- Handlebar
  205
- Installing the Handlebar
  205
- Removing the Handlebar
  205
- Removing the Upper Handlebar Cover Assembly
  205
- Assembling the Upper Handlebar Cover Assembly
  208
- Installing the Upper Handlebar Cover Assembly
  208
- Front Fork
  209
- Disassembling the Front Fork Legs
  211
- Removing the Front Fork Legs
  211
- Assembling the Front Fork Legs
  212
- Checking the Front Fork Legs
  212
- Installing the Front Fork Legs
  215
- Steering Head
  216
- Checking the Steering Head
  218
- Installing the Steering Head
  218
- Removing the Lower Bracket
  218
- Rear Shock Absorber Assemblies and Swingarm
  221
- Checking the Rear Shock Absorber Assembly
  223
- Checking the Swingarm
  223
- Installing the Swingarm
  223
- Maintenance of the Rear Wheel Sensor
  223
- Removing the Swingarm
  223
Engine

227
- Engine Inspection
  230
- Measuring the Compression Pressure
  230
- Engine Removal
  232
- Installing the Engine
  236
- Connecting the Leads
  237
- Installing the Muffler
  237
- Cylinder Head
  238
- Checking the Cylinder Head
  242
- Removing the Cylinder Head
  242
- Checking the Camshaft Sprocket
  243
- Checking the Timing Chain Tensioner
  243
- Checking the Decompression System
  244
- Checking the Vva Solenoid
  244
- Installing the Cylinder Head
  244
- Camshaft
  247
- Checking the Camshaft
  248
- Removing the Camshaft
  248
- Checking the Rocker Arms and Rocker Arm Shafts
  249
- Installing the Camshaft and Rocker Arms
  249
- Valves and Valve Springs
  251
- Checking the Valves and Valve Guides
  252
- Removing the Valves
  252
- Checking the Valve Seats
  254
- Checking the Valve Springs
  255
- Installing the Valves
  256
- Cylinder and Piston
  258
- Checking the Cylinder and Piston
  259
- Removing the Piston
  259
- Checking the Piston Rings
  260
- Checking the Piston Pin
  261
- Checking the Timing Chain Guide (Exhaust Side)
  261
- Installing the Piston and Cylinder
  261
- V-Belt Automatic Transmission
  263
- Disassembling the Secondary Sheave
  267
- Removing the Primary Sheave
  267
- Removing the Secondary Sheave
  267
- Checking the Clutch Housing
  268
- Checking the Clutch Shoes
  268
- Checking the Primary Sheave
  268
- Checking the V-Belt
  268
- Assembling the Primary Sheave
  269
- Assembling the Secondary Sheave
  269
- Checking the Primary Sheave Sliders
  269
- Checking the Primary Sheave Weights
  269
- Checking the Secondary Sheave
  269
- Installing the Primary Sheave, V-Belt and Secondary Sheave
  270
- Starter Clutch
  273
- Checking the Starter Clutch
  275
- Checking the Starter Wheel
  275
- Checking the Timing Chain
  275
- Checking the Timing Chain Guide (Intake Side)
  275
- Installing the Starter Clutch
  275
- Ac Magneto
  276
- Installing the Ac Magneto
  278
- Removing the Ac Magneto
  278
- Electric Starter
  279
- Checking the Starter Motor
  281
- Assembling the Starter Motor
  282
- Installing the Starter Motor
  282
- Oil Pump
  283
- Assembling the Oil Pump
  285
- Checking the Oil Pump
  285
- Checking the Oil Strainer
  285
- Checking the Transmission
  288
- Installing the Transmission
  288
- Transmission
  288
- Checking the Crankshaft Assembly
  291
- Crankshaft
  291
- Disassembling the Crankcase
  291
- Removing the Crankshaft Assembly
  291
- Checking the Bearing
  292
- Checking the Crankcase
  292
- Checking the Oil Pump Drive Gear
  292
- Installing the Crankshaft
  292
- Assembling the Crankcase
  293
- Installing the Centerstand
  293
Cooling System

295
- Radiator
  296
- Checking the Radiator
  298
- Installing the Radiator
  298
- Checking the Thermostat Assembly
  301
- Installing the Thermostat Assembly
  301
- Thermostat
  301
- Water Pump
  302
- Assembling the Water Pump
  304
- Checking the Water Pump
  304
- Disassembling the Water Pump
  304
- Installing the Water Pump
  304
Fuel System

307
- Fuel Tank
  308
- Checking the Fuel Filter
  309
- Checking the Fuel Pump Body
  309
- Installing the Fuel Filter
  309
- Removing the Fuel Filter
  309
- Removing the Fuel Pump
  309
- Removing the Fuel Tank
  309
- Checking the Fuel Pressure
  310
- Installing the Fuel Pump
  310
- Installing the Fuel Tank
  310
- Fuel Injector
  312
- Checking the Fuel Injector
  313
- Installing the Fuel Hose
  313
- Installing the Fuel Injector
  313
- Removing the Fuel Hose
  313
- Air Filter Case
  314
- Installing the Air Filter Case
  316
- Throttle Body
  317
- Checking the Throttle Body
  319
- Cleaning the Isc (Idle Speed Control) Unit and Throttle Body
  319
- Removing the Throttle Body
  319
- Installing the Throttle Body
  321
- Replacing the Throttle Body
  321
Electrical System

323
- Circuit Diagram
  326
- Ignition System
  326
- Troubleshooting
  328
- Circuit Diagram
  330
- Electric Starting System
  330
- Starting Circuit Cut-Off System Operation
  332
- Troubleshooting
  333
- Charging System
  336
- Circuit Diagram
  336
- Troubleshooting
  338
- Circuit Diagram
  340
- Lighting System
  340
- Troubleshooting
  342
- Circuit Diagram
  344
- Signaling System
  344
- Troubleshooting
  346
- Circuit Diagram
  350
- Fuel Injection System
  350
- Ecu Self-Diagnostic Function
  352
- Troubleshooting Method
  352
- Yamaha Diagnostic Tool
  353
- Troubleshooting Details
  356
- Circuit Diagram
  382
- Fuel Pump System
  382
- Troubleshooting
  384
- Abs (Anti-Lock Brake System)
  386
- Circuit Diagram
  386
- Abs Coupler Location Chart
  388
- Abs Troubleshooting Outline
  390
- Maintenance of the Abs Ecu
  390
- Basic Instructions for Troubleshooting
  391
- Basic Process for Troubleshooting
  392
- [A-1] Only the Abs Warning Light Fails to Come on
  393
- [A-2] All Indicator Lights Fail to Come on
  393
- [A-3] the Abs Warning Light Comes on
  393
- [A] Checking the Abs Warning Light
  393
- [A-4] ONLY the ABS ECU FAILS to COMMUNICATE (the Select Unit Screen Does Not Appear.)
  394
- [A-5] ABS ECU and FI ECU FAIL to COMMUNICATE (Cannot Connect Due to a Tool Error.)
  394
- [B-1] Malfunction Are Currently Detected
  394
- [B-2] Diagnosis Using the Fault Codes
  394
- [B-3] Deleting the Fault Codes
  415
- [C-1] Final Check
  416
- Electrical Components
  418
- Checking the Switches
  420
- Checking the Bulbs and Bulb Sockets
  423
- Checking and Charging the Battery
  424
- Checking the Fuses
  424
- REPLACING the ECU (Engine Control Unit)
  424
- Checking the Relays
  427
- Checking the Diode
  428
- Checking the Turn Signal Relay
  428
- Checking the Ignition Coil
  429
- Checking the Spark Plug Cap
  429
- Checking the Crankshaft Position Sensor
  430
- Checking the Ignition Spark Gap
  430
- Checking the Rectifier/Regulator
  431
- Checking the Starter Motor Operation
  431
- Checking the Stator Coil
  431
- Checking the Fuel Meter/Fuel Level Warning Indicator
  432
- Checking the Fuel Sender
  432
- Checking the Coolant Temperature Sensor
  433
- Checking the Fuel Injector
  433
- Checking the Vva Solenoid
  434
Troubleshooting

435
- General Information
  436
- Incorrect Engine Idling Speed
  436
- Starting Failure/Hard Starting
  436
- Troubleshooting
  436
- Faulty Clutch
  437
- Overheating
  437
- Poor Medium-And-High-Speed Performance
  437
- Faulty Front Fork Legs
  438
- Faulty Lighting or Signaling System
  438
- Overcooling
  438
- Poor Braking Performance
  438
- Unstable Handling
  438
- Communication Error with the Yamaha Diagnostic Tool
  440
- Self-Diagnostic Function and Diagnostic Code Table
  440
- Self-Diagnostic Function Table
  440
- Diagnostic Code: Sensor Operation Table
  441
- Diagnostic Code: Actuator Operation Table
  442
- Event Code Table
  444

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