Yamaha YZF155D-A 2022 Manuals

Manuals and User Guides for Yamaha YZF155D-A 2022. We have 1 Yamaha YZF155D-A 2022 manual available for free PDF download: Service Manual

Yamaha YZF155D-A 2022 Service Manual

Yamaha YZF155D-A 2022 Service Manual (497 pages)

Brand: Yamaha | Category: Motorcycle | Size: 64.81 MB

Table of Contents

Table of Contents

5
- General Information
  7
- Identification
  8
- Vehicle Identification Number
  8
- Engine Serial Number
  8
- Features
  9
- OUTLINE of the TCS (Traction Control System)
  9
- Outline of the Fi System
  13
- Features
  14
- Outline of the Abs
  15
- Abs Component Functions
  19
- Abs Operation
  25
- Abs Warning Light and Operation
  28
- CCU (Communication Control Unit)
  29
- Handlebar Switches
  30
- Indicator Lights and Warning Lights
  31
- Display
  32
- Menu Mode
  38
- Important Information
  41
- Preparation for Removal and Disassembly
  41
- Replacement Parts
  41
- Gaskets, Oil Seals and O-Rings
  41
- Lock Washers/Plates and Cotter Pins
  41
- Rubber Parts
  42
- Circlips
  42
- Bearings and Oil Seals
  42
- Basic Service Information
  43
- Quick Fasteners
  43
- Electrical System
  44
- Special Tools
  55
Specifications

57
- General Specifications
  58
- Maintenance Specification (Engine)
  59
- Maintenance Specification (Chassis)
  63
- Maintenance Specification (Electrical)
  65
- General Tightening Torque Specifications
  67
- Tightening Torques
  67
- Engine Tightening Torques
  68
- Chassis Tightening Torques
  72
- Engine
  77
- Lubrication Points and Lubricant Types
  77
- Chassis
  79
- Lubrication System Chart and Diagrams
  81
- Cooling System Diagrams
  84
- Cable Routing
  88
Periodic Checks and Adjustments

111
- General Maintenance and Lubrication Chart
  113
- Introduction
  113
- Periodic Maintenance
  113
- Periodic Maintenance Chart for the Emission Control System
  113
- Adjusting the Valve Clearance
  116
- Checking the Vehicle Using the Yamaha Diagnostic Tool
  116
- Engine
  116
- Adjusting the Engine Idling Speed
  118
- Adjusting the Throttle Grip Free Play
  119
- Checking the Throttle Grip
  119
- Checking the Spark Plug
  120
- Measuring the Compression Pressure
  120
- Checking the Engine Oil Level
  121
- Changing the Engine Oil
  122
- Adjusting the Clutch Lever Free Play
  123
- Replacing the Air Filter Element
  124
- Checking the Canister
  126
- Checking the Cylinder Head Breather Hose
  126
- Checking the Fuel Line
  126
- Checking the Throttle Body Joint and Air Filter Case Joint
  126
- Checking the Coolant Level
  127
- Checking the Cooling System
  127
- Checking the Exhaust System
  127
- Changing the Coolant
  128
- Chassis
  130
- Checking the Brake Fluid Level
  130
- Checking the Brake Lever Free Play
  130
- Checking the Brake Operation
  130
- Checking the Front Brake Hose
  131
- Checking the Front Brake Pads
  131
- Checking the Rear Brake Hose
  131
- Checking the Rear Brake Pads
  131
- Adjusting the Rear Brake Light Switch
  132
- Bleeding the Hydraulic Brake System (Abs)
  132
- Adjusting the Drive Chain Slack
  133
- Lubricating the Drive Chain
  134
- Checking and Adjusting the Steering Head
  135
- Checking the Front Fork
  136
- Checking the Tires
  136
- Checking and Lubricating the Cables End
  138
- Checking the Chassis Fasteners
  138
- Checking the Swingarm Operation
  138
- Checking the Wheel Bearings
  138
- Checking the Wheels
  138
- Lubricating the Brake Lever
  138
- Lubricating the Clutch Lever
  138
- Lubricating the Steering Head
  138
- Lubricating the Swingarm Pivot
  138
- Checking the Sidestand
  139
- Lubricating Shift Pedal Rod Joint
  139
- Lubricating the Pedals
  139
- Lubricating the Rear Suspension
  139
- Lubricating the Sidestand
  139
- Adjusting the Headlight Beams
  140
- Checking and Charging the Battery
  140
- Checking the Fuses
  140
- Electrical System
  140
- Replacing License Plate Light Bulb
  140
- Replacing Turn Signal Indicator Light Bulb
  140
Chassis

143
- General Chassis (1)
  152
- Installing the Rear View Mirror Assembly
  152
- Removing the Rear View Mirror Assembly
  152
- Installing the Air Filter Case
  154
- General Chassis (7)
  155
- General Chassis (8)
  155
- Front Wheel
  158
- Checking the Front Wheel
  160
- Disassembling the Front Wheel
  160
- Removing the Front Wheel
  160
- Assembling the Front Wheel
  161
- Maintenance of the Wheel Sensor and Sensor Rotor
  161
- Installing the Front Wheel
  163
- Rear Wheel
  165
- Checking the Rear Brake Caliper Bracket
  167
- Checking the Rear Wheel
  167
- Checking the Rear Wheel Drive Hub
  167
- Disassembling the Rear Wheel
  167
- Removing the Rear Wheel
  167
- Assembling the Rear Wheel
  168
- Checking and Replacing the Rear Wheel Sprocket
  168
- Installing the Rear Wheel
  168
- Maintenance of the Rear Wheel Sensor and Sensor Rotor
  168
- Front Brake
  171
- Checking the Front Brake Disc
  176
- Replacing the Front Brake Pads
  177
- Disassembling the Front Brake Caliper
  178
- Removing the Front Brake Caliper
  178
- Assembling the Front Brake Caliper
  179
- Checking the Front Brake Caliper
  179
- Installing the Front Brake Caliper
  179
- Checking the Front Brake Master Cylinder
  180
- Removing the Front Brake Master Cylinder
  180
- Assembling the Front Brake Master Cylinder
  181
- Installing the Front Brake Master Cylinder
  181
- Rear Brake
  183
- 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
- Checking the Rear Brake Caliper Bracket
  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
- Rear Brake Hose Installation
  193
- Abs (Anti-Lock Brake System)
  194
- Checking the Hydraulic Unit Assembly
  196
- Removing the Hydraulic Unit Assembly
  196
- Installing the Hydraulic Unit Assembly
  197
- Hydraulic Unit Operation Tests
  198
- Checking the Abs Warning Light
  201
- Checking the Handlebars
  204
- Handlebars
  204
- Installing the Handlebars
  204
- Removing the Handlebars
  204
- Front Fork
  207
- Disassembling the Front Fork Leg (Left)
  210
- Removing the Front Fork Legs
  210
- Checking the Front Fork Legs
  211
- Assembling the Front Fork Leg (Left)
  212
- Installing the Front Fork Legs
  215
- Assembling the Front Fork Leg (Right)
  216
- Steering Head
  220
- Checking the Steering Head
  222
- Installing the Steering Head
  222
- Removing the Lower Bracket
  222
- Checking the Connecting Arms and Relay Arm
  225
- Checking the Rear Shock Absorber Assembly
  225
- Installing the Rear Shock Absorber Assembly
  225
- Installing the Relay Arm
  225
- Rear Shock Absorber Assembly
  225
- Removing the Rear Shock Absorber Assembly
  225
- Swingarm
  226
- Checking the Swingarm
  228
- Installing the Swingarm
  228
- Removing the Swingarm
  228
- Chain Drive
  230
- Checking the Drive Chain
  231
- Removing the Drive Chain by Using Chain Cutter
  231
- Checking the Drive Sprocket
  232
- Checking the Rear Wheel Drive Hub
  232
- Checking the Rear Wheel Sprocket
  232
- Installing the Drive Chain by Using Chain Riveting Tool
  232
- Cleaning and Lubricating the Drive Chain
  234
Engine

235
- Engine Removal
  238
- Installing the Engine
  242
- Installing the Exhaust Assembly
  242
- Installing the Shift Arm
  242
- Cylinder Head
  244
- Removing the Cylinder Head
  247
- Checking the Camshaft Sprocket and Timing Chain Guide
  248
- Checking the Cylinder Head
  248
- Checking the Decompression System
  249
- Checking the Timing Chain Tensioner
  249
- Installing the Cylinder Head
  249
- Camshaft
  253
- Checking the Camshaft
  254
- Removing the Camshaft
  254
- Checking the Rocker Arms and Rocker Arm Shafts
  255
- Removing and Installing the Camshaft Bearing
  255
- Installing the Camshaft and Rocker Arms
  256
- Checking the Valves and Valve Guides
  259
- Removing the Valves
  259
- Valves and Valve Springs
  259
- Checking the Valve Seats
  260
- Checking the Valve Springs
  262
- Installing the Valves
  262
- Cylinder and Piston
  264
- Checking the Cylinder and Piston
  265
- Removing the Piston
  265
- Checking the Piston Pin
  266
- Checking the Piston Rings
  266
- Installing the Piston and Cylinder
  267
- Magneto and Starter Clutch
  269
- Checking the Starter Clutch
  271
- Removing the Magneto
  271
- Removing the Starter Clutch
  271
- Installing the Magneto
  272
- Installing the Starter Clutch
  272
- Electric Starter
  274
- Checking the Starter Motor
  276
- Assembling the Starter Motor
  277
- Clutch
  278
- Checking the Clutch Plates
  282
- Checking the Friction Plates
  282
- Removing the Clutch
  282
- Checking the Clutch Boss
  283
- Checking the Clutch Housing
  283
- Checking the Clutch Push Lever and Short Clutch Push Rod
  283
- Checking the Clutch Springs
  283
- Checking the Pressure Plate
  283
- Checking the Clutch Push Rods
  284
- Checking the Primary Drive Gear
  284
- Checking the Primary Driven Gear
  284
- Installing the Clutch
  284
- Oil Pump
  287
- Checking the Oil Pump
  288
- Installing the Oil Pump
  288
- Shift Shaft
  289
- Checking the Shift Shaft
  290
- Checking the Stopper Lever
  290
- Installing the Shift Shaft
  290
- Balancer Gear
  291
- Assembling the Balancer Driven Gear
  292
- Checking the Balancer Gears and Primary Drive Gear
  292
- Installing the Primary Drive Gear and Balancer Gears
  292
- Removing the Primary Drive Gear and Balancer Gears
  292
- Crankcase
  294
- Removing the Crankcase Bearing
  297
- Separating the Crankcase
  297
- Assembling the Crankcase
  298
- Checking the Bearings and Oil Seal
  298
- Checking the Crankcase
  298
- Checking the Oil Strainer
  298
- Checking the Timing Chain and Timing Chain Guide
  298
- Installing the Bearing Retainer
  298
- Crankshaft
  300
- Checking the Crankshaft
  301
- Installing the Crankshaft
  301
- Removing the Crankshaft
  301
- Transmission
  303
- Checking the Shift Drum Assembly
  305
- Checking the Shift Forks
  305
- Checking the Transmission
  305
- Assembling the Drive Axle
  306
- Installing the Shift Forks and Shift Drum Assembly
  306
Cooling System

309
- Radiator
  310
- Checking the Radiator
  312
- Installing the Radiator
  312
- Checking the Thermostat Assembly
  314
- Installing the Thermostat Assembly
  314
- Thermostat
  314
- Water Pump
  315
- Assembling the Water Pump
  317
- Checking the Water Pump
  317
- Disassembling the Water Pump
  317
- Installing the Water Pump
  317
Fuel System

319
- Fuel Tank
  320
- Checking the Fuel Pump Body
  323
- Installing the Fuel Pump Assembly
  323
- Removing the Fuel Pump
  323
- Removing the Fuel Tank
  323
- Checking the Fuel Pressure
  324
- Installing the Fuel Tank
  324
- Throttle Body
  326
- Checking the Fuel Injector
  328
- Checking the Throttle Body
  328
- Installing the Fuel Injector
  328
- Installing the Throttle Body
  328
- Removing the Throttle Body
  328
Electrical System

331
- Circuit Diagram
  334
- Ignition System
  334
- Engine Stopping Due to Sidestand Operation
  335
- Troubleshooting
  336
- Circuit Diagram
  338
- Electric Starting System
  338
- Starting Circuit Cut-Off System Operation
  339
- Troubleshooting
  340
- Charging System
  342
- Circuit Diagram
  342
- Troubleshooting
  343
- Circuit Diagram
  345
- Lighting System
  345
- Troubleshooting
  347
- Circuit Diagram
  349
- Signaling System
  349
- Troubleshooting
  351
- Circuit Diagram
  357
- Cooling System
  357
- Troubleshooting
  358
- Circuit Diagram
  361
- Fuel Injection System
  361
- Self-Diagnostic Function and Diagnostic Code Table
  370
- Diagnostic Code: Sensor Operation Table
  377
- Diagnostic Code: Actuator Operation Table
  379
- Fault Code Table
  380
- Fuel Injection System Troubleshooting
  380
Troubleshooting

489
- General Information
  490
- Incorrect Engine Idling Speed
  490
- Starting Failures
  490
- Troubleshooting
  490
- Faulty Clutch
  491
- Faulty Gear Shifting
  491
- Jumps out of Gear
  491
- Poor Medium-And-High-Speed Performance
  491
- Shift Pedal Does Not Move
  491
- Faulty Front Fork Legs
  492
- Overcooling
  492
- Overheating
  492
- Poor Braking Performance
  492
- Faulty Lighting or Signaling System
  493
- Troubleshooting at the Abs Warning Light
  493

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