Yamaha YZF-R15 2008 Manuals

Manuals and User Guides for Yamaha YZF-R15 2008. We have 1 Yamaha YZF-R15 2008 manual available for free PDF download: Service Manual

Yamaha YZF-R15 2008 Service Manual

Yamaha YZF-R15 2008 Service Manual (338 pages)

Brand: Yamaha | Category: Motorcycle | Size: 22.19 MB

Table of Contents

Table of Contents

6
- Symbols
  5
- 1 General Information
  7
  - Identification
    8
    
    Vehicle Identification Number
    8
    
    Engine Serial Number
    8
  - Features
    9
    
    Outline of the Fi System
    9
    
    Fi System
    10
    
    Multi-Function Display
    11
  - Important Information
    12
    
    Preparation for Removaland Disassembly
    12
    
    Replacement Parts
    12
    
    Gaskets, Oil Seals and O-Rings
    12
    
    Lock Washers/Plates and Cotter Pins
    12
    
    Bearings and Oil Seals
    13
    
    Circlips
    13
  - Checking the Connections
    14
  - Special Tools
    15
Specifications

19
- General Specifications
  20
- Engine Specifications
  21
- Chassis Specifications
  28
- Electrical Specifications
  31
- Tightening Torques
  34
- Lubrication Points and Lubricant Types
  41
  - Engine
    41
  - Chassis
    43
- Lubrication System Chart and Diagrams
  44
  - Engine Oil Lubrication Chart
    44
  - Lubrication Diagrams
    46
- Cooling System Diagrams
  50
- Cable Routing
  52
Periodic Checks and Adjustments

67
Chassis

96
- General Chassis
  100
  - Installing the Air Filter Case
    100
- Front Wheel
  101
  - Removing the Front Wheel
    103
  - Disassembling the Front Wheel
    103
  - Checking the Front Wheel
    103
  - Assembling the Front Wheel
    104
  - Adjusting the Front Wheel Static Balance
    104
  - Installing the Front Wheel (Disc)
    105
- Rear Wheel
  107
- Front Brake
  112
- Rear Brake
  122
- Handlebar
  135
  - Removing the Handlebars
    135
  - Checking the Handlebar
    135
  - Installing the Handlebar
    135
- Front Fork
  138
  - Removing the Front Fork Legs
    141
  - Disassembling the Front Fork Legs
    141
  - Checking the Front Fork Legs
    142
  - Assembling the Front Fork Legs
    142
  - Installing the Front Fork Legs
    145
- Steering Head
  146
  - Removing the Lower Bracket
    148
  - Checking the Steering Head
    148
  - Installing the Steering Head
    148
- Rear Shock Absorber Assembly
  151
- Swingarm
  153
  - Removing the Swingarm
    155
  - Checking the Swingarm
    155
  - Installing the Swingarm
    155
- Chain Drive
  157
  - Checking the Drive Chain
    158
  - Installing the Drive Chain
    159
Engine

160
- Engine Removal
  163
  - Installing the Engine
    167
- Cylinder Head
  168
- Camshaft
  175
- Valves and Valve Springs
  178
  - Removing the Valves
    179
  - Checking the Valves and Valve Guides
    179
  - Checking the Valve Seats
    180
  - Checking the Valve Springs
    181
  - Installing the Valves
    182
  - Cylinder and Piston
    184
  - Removing the Piston
    185
  - Checking the Cylinder and Piston
    185
  - Checking the Piston Rings
    186
  - Checking the Piston Pin
    187
  - Installing the Piston and Cylinder
    187
- Magneto and Starter Clutch
  189
  - Removing the Starter Clutch
    191
  - Checking the Starter Clutch
    191
  - Installing the Starter Clutch
    192
  - Installing the Magneto
    192
- Electric Starter
  194
  - Disassembling the Starter Motor
    196
  - Checking the Starter Motor
    196
  - Assembling the Starter Motor
    197
- Clutch
  198
  - Removing the Clutch
    202
  - Checking the Friction Plates
    202
  - Checking the Clutch Plates
    202
  - Checking the Clutch Springs
    203
  - Checking the Clutch Housing
    203
  - Checking the Clutch Boss
    203
  - Checking the Pressure Plate
    203
  - Checking the Clutch Push Lever and Short Clutch Push Rod
    203
  - Checking the Primary Drive Gear
    203
  - Checking the Primary Driven Gear
    204
  - Installing the Clutch
    204
- Oil Pump
  207
  - Checking the Oil Pump
    209
  - Assembling the Oil Pump
    209
  - Installing the Oil Pump
    210
- Shift Shaft
  211
  - Checking the Shift Shaft
    212
  - Checking the Stopper Lever
    212
  - Installing the Shift Shaft
    212
- Balancer Gear
  213
- Crankcase
  217
  - Separating the Crankcase
    220
  - Checking the Crankcase
    220
  - Checking the Timing Chain and Timing Chain Guide
    220
  - Checking the Oil Strainer
    220
  - Checking the Bearings and Oil Seal
    220
  - Installing the Bearing Retainer
    221
  - Assembling the Crankcase
    221
- Crankshaft
  222
  - Removing the Crankshaft
    223
  - Checking the Crankshaft
    223
  - Installing the Crankshaft
    223
- Transmission
  225
Cooling System

231
- Radiator
  232
  - Checking the Radiator
    234
  - Installing the Radiator
    234
- Thermostat
  235
  - Checking the Thermostat
    236
  - Installing the Thermostat
    236
- Water Pump
  237
  - Disassembling the Water Pump
    239
  - Checking the Water Pump
    239
  - Assembling the Water Pump
    239
  - Installing the Water Pump
    240
Fuel System

241
- Fuel Tank
  242
  - Removing the Fuel Tank
    243
  - Removing the Fuel Pump
    243
  - Checking the Fuel Pump Body
    243
  - Installing the Fuel Pump
    243
  - Installing the Fuel Tank
    243
- Throttle Body
  247
  - Removing the Throttle Body
    247
  - Checking the Fuel Injector
    247
  - Checking the Throttle Body
    247
  - Checking the Fuel Pressure
    247
  - Installing the Throttle Body
    247
- Air Induction System
  250
  - Checking the Air Induction System
    253
Electrical System

255
- Ignition System
  258
  - Circuit Diagram
    258
  - Troubleshooting
    260
- Electric Starting System
  262
  - Circuit Diagram
    262
  - Starting Circuit Cut-Off System Operation
    264
  - Troubleshooting
    266
- Charging System
  268
  - Circuit Diagram
    268
  - Troubleshooting
    270
- Lighting System
  272
  - Circuit Diagram
    272
  - Troubleshooting
    274
- Signaling System
  276
  - Circuit Diagram
    276
  - Troubleshooting
    278
- Cooling System
  282
  - Circuit Diagram
    282
  - Troubleshooting
    284
- Fuel Injection System
  286
  - Circuit Diagram
    286
  - Ecu Self-Diagnostic Function
    288
  - Self-Diagnostic Function Table
    289
  - Troubleshooting Method
    291
  - Diagnostic Mode
    292
  - Troubleshooting Details
    298
- Fuel Pump System
  308
  - Circuit Diagram
    308
  - Troubleshooting
    310
- Electrical Components
  312
- Checking the Switches
  314
- Checking the Bulbs and Bulb Sockets
  317
- Checking and Charging the Battery
  318
- Checking the Fuse
  318
- Checking the Relays
  321
- Checking the Turn Signal Relay
  322
- Checking the Diode
  323
- Checking the Spark Plug Cap
  323
- Checking the Ignition Coil
  324
- Checking the Ignition Spark Gap
  324
- Checking the Crankshaft Position Sensor
  325
- Checking the Lean Angle Sensor
  325
- Checking the Rectifier/Regulator
  326
- Checking the Starter Motor Operation
  326
- Checking the Stator Coil
  326
- Checking the Fuel Sender
  327
- Checking the Horn
  327
- Checking the Coolant Temperature Sensor
  328
- Checking the Radiator Fan Motor
  328
- Checking the Throttle Body Sensor Assembly
  329
- Specifications
  329
  - Checking the Speed Sensor
    331
Troubleshooting

332
- General Information
  332
- Incorrect Engine Idling Speed
  333
- Starting Failures
  333
- Faulty Clutch
  334
- Faulty Gear Shifting
  334
- Jumps out of Gear
  334
- Overheating
  334
- Poor Medium-And-High-Speed Performance
  334
- Shift Pedal Does Not Move
  334
- Faulty Front Fork Legs
  335
- Overcooling
  335
- Poor Braking Performance
  335
- Unstable Handling
  335
- Faulty Lighting or Signaling System
  336
- Wiring Diagram
  337

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