Yamaha Aerox GDR155 (2017)

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Yamaha Aerox GDR155 2017

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SERVICE MANUAL

GDR155/GDR155-A

2017

B63-F8197-EZ

Page 1

EAS20003
IMPORTANT
This manual was produced by the Yamaha Motor Vietnam Co.,Ltd. primarily for use by Yamaha dealers 
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles 
should have a basic understanding of mechanics and the techniques to repair these types of vehicles. 
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.
Yamaha Motor Vietnam Co.,Ltd. is continually striving to improve all of its models. Modifications and 
significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers 
and will appear in future editions of this manual where applicable.

TIP
Designs and specifications are subject to change without notice.

EAS30001
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations.

This is the safety alert symbol. It is used to alert you to potential personal inju-
ry hazards. Obey all safety messages that follow this symbol to avoid possible 
injury or death.

A WARNING indicates a hazardous situation which, if not avoided, could result 
in death or serious injury.

WARNING

A NOTICE indicates special precautions that must be taken to avoid damage to 
the vehicle or other property.

NOTICE

A TIP provides key information to make procedures easier or clearer.

TIP

EAS20002

NVX
SERVICE MANUAL
©2016 by Yamaha Motor Vietnam Co.,Ltd.
1st edition, December 2016
All rights reserved.
Any reproduction or unauthorized use 
without the written permission of 
Yamaha Motor Vietnam Co.,Ltd. 
is expressly prohibited.

Page 2

EAS20004
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive 
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid 
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title 
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each 
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of 
parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation 
and assembly procedure, reverse the steps.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.

1

3

4

5

6

2

7

Page 3

EAS20005
SYMBOLS
The following symbols are used in this manual for easier understanding.

TIP
The following symbols are not relevant to every vehicle.

SYMBOL
DEFINITION
SYMBOL
DEFINITION

Serviceable with engine mounted
Gear oil

Filling fluid
Molybdenum disulfide oil

Lubricant
Brake fluid

Special tool
Wheel bearing grease

Tightening torque
Lithium-soap-based grease

T R
.

.

Wear limit, clearance
Molybdenum disulfide grease

Engine speed
Silicone grease

Electrical data
Apply locking agent (LOCTITE®).

E
New

Engine oil
Replace the part with a new one.

Silicone fluid

S

G

M

BF

B

LS

M

S

LT

Page 4

EAS10003 TABLE OF CONTENTS

GENERAL INFORMATION
1

SPECIFICATIONS
2

PERIODIC CHECKS AND 
ADJUSTMENTS
3

CHASSIS
4

ENGINE
5

COOLING SYSTEM
6

FUEL SYSTEM
7

ELECTRICAL SYSTEM
8

9

Page 5

Page 6

GENERAL INFORMATION

IDENTIFICATION ............................................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
ENGINE SERIAL NUMBER ......................................................................1-1

IMPORTANT INFORMATION .........................................................................1-2
PREPARATION FOR REMOVAL AND DISASSEMBLY...........................1-2
REPLACEMENT PARTS...........................................................................1-2
GASKETS, OIL SEALS AND O-RINGS ....................................................1-2
LOCK WASHERS/PLATES AND COTTER PINS .....................................1-2
BEARINGS AND OIL SEALS....................................................................1-3
CIRCLIPS..................................................................................................1-3
RUBBER PARTS.......................................................................................1-3

BASIC SERVICE INFORMATION...................................................................1-4
QUICK FASTENERS.................................................................................1-4
ELECTRICAL SYSTEM.............................................................................1-5

SPECIAL TOOLS ..........................................................................................1-10

1

Page 7

EAS20007
IDENTIFICATION

EAS30002
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is stamped 
into the frame.

1

EAS30004
ENGINE SERIAL NUMBER
The engine serial number “1” is stamped into the 
crankcase.

1

1-1

IDENTIFICATION

Page 8

EAS20009
IMPORTANT INFORMATION

EAS30006
PREPARATION FOR REMOVAL AND 
DISASSEMBLY
1. Before removal and disassembly, remove all 
dirt, mud, dust and foreign material.

2. Use only the proper tools and cleaning equip-
ment.
Refer to “SPECIAL TOOLS” on page 1-10.
3. When disassembling, always keep mated 
parts together. This includes gears, cylinders, 
pistons and other parts that have been “mat-
ed” through normal wear. Mated parts must 
always be reused or replaced as an assem-
bly.

4. During disassembly, clean all of the parts and 
place them in trays in the order of disassem-
bly. This will speed up assembly and allow for 
the correct installation of all parts.
5. Keep all parts away from any source of fire.

EAS30007
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by 
Yamaha for all lubrication jobs. Other brands 
may be similar in function and appearance, but 
inferior in quality.

1-2

IMPORTANT INFORMATION

EAS30008
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all 
gaskets, seals and O-rings. All gasket surfac-
es, oil seal lips and O-rings must be cleaned.
2. During reassembly, properly oil all mating 
parts and bearings and lubricate the oil seal 
lips with grease.

1. Oil
2. Lip
3. Spring
4. Grease

EAS30009
LOCK WASHERS/PLATES AND COTTER 
PINS
After removal, replace all lock washers/plates 
“1” and cotter pins. After the bolt or nut has been 
tightened to specification, bend the lock tabs 
along a flat of the bolt or nut.

Page 9

EAS30010
BEARINGS AND OIL SEALS
Install bearings “1” and oil seals “2” so that the 
manufacturer’s marks or numbers are visible. 
When installing oil seals, lubricate the oil seal 
lips with a light coat of lithium-soap-based 
grease. Oil bearings liberally when installing, if 
appropriate.

ECA13300

NOTICE

Do not spin the bearing with compressed air 
because this will damage the bearing surfac-
es.

EAS30011
CIRCLIPS
Before reassembly, check all circlips carefully 
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use. 
When installing a circlip “1”, make sure the 
sharp-edged corner “2” is positioned opposite 
the thrust “3” that the circlip receives.

1-3

IMPORTANT INFORMATION

EAS30012
RUBBER PARTS
Check rubber parts for deterioration during in-
spection. Some of the rubber parts are sensitive 
to gasoline, flammable oil, grease, etc. Do not al-
low any items other than the specified one to 
contact the parts.

Page 10

EAS20010
BASIC SERVICE INFORMATION

EAS30013
QUICK FASTENERS

Rivet type
1. Remove:
• Quick fastener

TIP
To remove the quick fastener, push its pin with a 
screwdriver, then pull the fastener out.

2. Install:
• Quick fastener

TIP
To install the quick fastener, push its pin so that 
it protrudes from the fastener head, then insert 
the fastener into the part to be secured and push 
the pin in with a screwdriver. Make sure that the 
pin is flush with the fastener’s head.

1-4

BASIC SERVICE INFORMATION

Screw type
1. Remove:
• Quick fastener

TIP
To remove the quick fastener, loosen the screw 
with a screwdriver, then pull the fastener out.

2. Install:
• Quick fastener

TIP
To install the quick fastener, insert the fastener 
into the part to be secured and tighten the screw.

Page 11

EAS30014
ELECTRICAL SYSTEM

Electrical parts handling

ECA16600

NOTICE

Never disconnect a battery lead while the en-
gine is running; otherwise, the electrical 
components could be damaged.

ECA16751

NOTICE

When disconnecting the battery leads from 
the battery, be sure to disconnect the nega-
tive battery lead first, then the positive bat-
tery lead. If the positive battery lead is 
disconnected first and a tool or similar item 
contacts the vehicle, a spark could be gener-
ated, which is extremely dangerous.

TIP
If a battery lead is difficult to disconnect due to 
rust on the battery terminal, remove the rust us-
ing hot water.

1-5

BASIC SERVICE INFORMATION

ECA16760

NOTICE

Be sure to connect the battery leads to the 
correct battery terminals. Reversing the bat-
tery lead connections could damage the 
electrical components.

ECA16771

NOTICE

When connecting the battery leads to the 
battery, be sure to connect the positive bat-
tery lead first, then the negative battery lead. 
If the negative battery lead is connected first 
and a tool or similar item contacts the vehi-
cle while the positive battery lead is being 
connected, a spark could be generated, 
which is extremely dangerous.

ECA16610

NOTICE

Turn the main switch to “OFF” before dis-
connecting or connecting an electrical com-
ponent.

Page 12

ECA16620

NOTICE

Handle electrical components with special 
care, and do not subject them to strong 
shocks.

ECA16630

NOTICE

Electrical components are very sensitive to 
and can be damaged by static electricity. 
Therefore, never touch the terminals and be 
sure to keep the contacts clean.

TIP
When resetting the ECU by turning the main 
switch to “OFF”, be sure to wait approximately 5 
seconds before turning the main switch back to 
“ON”.

1-6

BASIC SERVICE INFORMATION

Checking the electrical system

TIP
Before checking the electrical system, make 
sure that the battery voltage is at least 12 V.

ECA14371

NOTICE

Never insert the tester probes into the cou-
pler terminal slots. Always insert the probes 
from the opposite end “a” of the coupler, tak-
ing care not to loosen or damage the leads.

a

ECA16640

NOTICE

For waterproof couplers, never insert the 
tester probes directly into the coupler. When 
performing any checks using a waterproof 
coupler, use the specified test harness or a 
suitable commercially available test har-
ness.

Page 13

Checking the connections
Check the leads, couplers, and connectors for 
stains, rust, moisture, etc.
1. Disconnect:
• Lead
• Coupler
• Connector

ECA16780

NOTICE

• When disconnecting a coupler, release the 
coupler lock, hold both sections of the cou-
pler securely, and then disconnect the cou-
pler.
• There are many types of coupler locks; 
therefore, be sure to check the type of cou-
pler lock before disconnecting the coupler.

ECA16790

NOTICE

When disconnecting a connector, do not pull 
the leads. Hold both sections of the connec-
tor securely, and then disconnect the con-
nector.

1-7

BASIC SERVICE INFORMATION

2. Check:
• Lead
• Coupler
• Connector
Moisture  Dry with an air blower.
Rust/stains  Connect and disconnect sev-
eral times.

3. Check:
• All connections
Loose connection  Connect properly.

TIP
• If the pin “1” on the terminal is flattened, bend 
it up.
• After disassembling and assembling a coupler, 
pull on the leads to make sure that they are in-
stalled securely.

1

Page 14

4. Connect:
• Lead
• Coupler
• Connector

TIP
• When connecting a coupler or connector, push 
both sections of the coupler or connector to-
gether until they are connected securely.
• Make sure all connections are tight.

5. Check:
• Continuity
(with the pocket tester)

Pocket tester
90890-03112
Analog pocket tester
YU-03112-C

 

TIP
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform 
steps (1) to (3).

1-8

BASIC SERVICE INFORMATION

• As a quick remedy, use a contact revitalizer 
available at most part stores.

6. Check:
• Resistance

Pocket tester
90890-03112
Analog pocket tester
YU-03112-C

 

TIP
The resistance values shown were obtained at 
the standard measuring temperature of 20 °C 
(68 °F). If the measuring temperature is not 20 
°C (68 °F), the specified measuring conditions 
will be shown.

Coolant temperature sensor re-
sistance
2512-2777  at 20 °C (2512-2777 
 at 68 °F)
Coolant temperature sensor re-
sistance
210–221  at 100 °C (210–221  
at 212 °F)

Page 15

Page 16

EAS20012
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only 
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools 
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.

TIP
• For U.S.A. and Canada, use part numbers starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part numbers starting with “90890-”.

Tool name/Tool No.
Illustration
Reference
pages

Pocket tester
90890-03112
Analog pocket tester
YU-03112-C

Tappet adjusting tool
90890-01311
Six piece tappet set
YM-A5970

YM-A5970

Yamaha diagnostic tool USB 
90890-03250
3-7, 3-8, 4-51, 
4-55, 7-14, 7-14, 
8-28, 8-69, 8-90

Yamaha diagnostic tool (A/I)
90890-03252
3-7, 3-8, 4-51, 
4-55, 7-14, 7-14, 
8-28, 8-69, 8-90

Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472

Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9

1-10

SPECIAL TOOLS

1-8, 1-8, 8-97, 
8-98, 8-98, 8-99, 
8-102, 8-103, 
8-103, 8-103, 
8-104, 8-104, 
8-105, 8-105, 
8-106, 8-107, 
8-108, 8-108

3-7

ø9
ø8
ø10

ø3
ø4

3-14, 3-15, 4-69

4-26

Page 17

# SPECIAL TOOLS

| Tool name/Tool No. | Illustration | Reference pages |
| :--------------------------------------- | :----------- | :-------------- |
| T-handle 90890-01326 T-handle 3/8" drive 60 cm long YM-01326 | | 4-63, 4-64 |
| Fork seal driver weight 90890-01367 Replacement hammer YM-A9409-7 | 90890-01367 YM-A9409-7/YM-A5142-4 | 4-64, 4-65 |
| Fork seal driver attachment (ø30) 90890-01400 | | 4-64, 4-65 |
| Compression gauge 90890-03081 Engine compression tester YU-33223 | 90890-03081 YU-33223 | 5-1 |
| Extension 90890-04136 | | 5-1 |
| Camshaft wrench 90890-04162 Camshaft wrench YM-04162 | | 5-13, 5-17 |
| Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) | | 5-16, 5-55 |

1-11

Page 18

# SPECIAL TOOLS

| Tool name/Tool No.                                   | Illustration | Reference pages |
| :--------------------------------------------------- | :----------- | :-------------- |
| Slide hammer bolt                                    |              | 5-19            |
| 90890-01085                                          |              |                 |
| Slide hammer bolt 8 mm                               |              |                 |
| YU-01083-2                                           |              |                 |
| Weight                                               |              | 5-19            |
| 90890-01084                                          |              |                 |
| Weight                                               |              |                 |
| YU-01083-3                                           |              |                 |
| Valve spring compressor                              |              | 5-23, 5-28      |
| 90890-04019                                          |              |                 |
| Valve spring compressor                              |              |                 |
| YM-04019                                             |              |                 |
| Valve spring compressor attachment                   |              | 5-23, 5-28      |
| 90890-04108                                          |              |                 |
| Valve spring compressor adapter 22 mm                |              |                 |
| YM-04108                                             |              |                 |
| Valve guide remover (ø5)                             |              | 5-24            |
| 90890-04097                                          |              |                 |
| Valve guide remover (5.0 mm)                         |              |                 |
| YM-04097                                             |              |                 |
| Valve guide installer (ø5)                           |              | 5-24            |
| 90890-04098                                          |              |                 |
| Valve guide installer (5.0 mm)                       |              |                 |
| YM-04098                                             |              |                 |
| Valve guide reamer (ø5)                              |              | 5-24            |
| 90890-04099                                          |              |                 |
| Valve guide reamer (5.0 mm)                          |              |                 |
| YM-04099                                             |              |                 |

1-12

Page 19

Tool name/Tool No.
Illustration
Reference
pages

Piston pin puller set
90890-01304
Piston pin puller
YU-01304

YU-01304

Rotor holding tool
90890-01235
Universal magneto and rotor holder
YU-01235

Rotor holding tool
90890-01701
5-37, 5-41

Socket wrench (39 mm)
90890-01493
5-37, 5-41

Sheave spring compressor
90890-04134
Sheave spring compressor
YM-04134

1-13

SPECIAL TOOLS

5-30

5-37, 5-42, 5-44, 
5-44

5-37, 5-40

Page 20

Tool name/Tool No.
Illustration
Reference
pages

Sheave fixed block
90890-04135
Sheave fixed bracket
YM-04135

Oil seal guide (37 mm)
90890-04177
5-40

Flywheel puller
90890-01189
Flywheel puller
YM-01189

Digital circuit tester
90890-03174
Model 88 Multimeter with tachometer
YU-A1927

Crankcase separating tool
90890-01135
Crankcase separator
YU-01135-B

1-14

SPECIAL TOOLS

5-37, 5-40

ø37

5-44

5-51, 8-106, 
8-109

5-53

Page 21

## SPECIAL TOOLS

| Tool name/Tool No. | Illustration | Reference pages |
| :--------------------------------------------------------- | :----------- | :-------------- |
| Crankshaft installer pot 90890-01274 Installing pot YU-90058 | | 5-54 |
| Crankshaft installer bolt 90890-01275 Bolt YU-90060 | | 5-54 |
| Adapter (M12) 90890-01278 Adapter #3 YU-90063 | | 5-54 |
| Spacer (crankshaft installer) 90890-04081 Pot spacer YM-91044 | | 5-54 |
| Radiator cap tester 90890-05375 | | 6-3, 6-3 |
| Mechanical seal installer 90890-04145 | | 6-8 |
| Middle driven shaft bearing driver 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058 | | 6-8 |

1-15

Page 22

# SPECIAL TOOLS

| Tool name/Tool No.                     | Illustration | Reference pages |
| :------------------------------------- | :----------- | :-------------- |
| Pressure gauge                         |              | 7-4             |
| 90890-03153                            |              |                 |
| Pressure gauge                         |              |                 |
| YU-03153                               |              |                 |
| Fuel pressure adapter 6.3mm            |              | 7-4             |
| 90890-03227                            |              |                 |
| Ignition checker                       |              | 8-105           |
| 90890-06754                            |              |                 |
| Oppama pet–4000 spark checker          |              |                 |
| YM-34487                               |              |                 |

1-16

Page 23

Page 24

SPECIFICATIONS

GENERAL SPECIFICATIONS ........................................................................2-1

ENGINE SPECIFICATIONS ............................................................................2-2

CHASSIS SPECIFICATIONS..........................................................................2-6

ELECTRICAL SPECIFICATIONS ...................................................................2-8

TIGHTENING TORQUES ..............................................................................2-10
GENERAL TIGHTENING TORQUE SPECIFICATIONS.........................2-10
ENGINE TIGHTENING TORQUES.........................................................2-11
CHASSIS TIGHTENING TORQUES.......................................................2-13

LUBRICATION POINTS AND LUBRICANT TYPES ....................................2-15
ENGINE...................................................................................................2-15

LUBRICATION SYSTEM CHART AND DIAGRAMS....................................2-16
ENGINE OIL LUBRICATION CHART .....................................................2-16
LUBRICATION DIAGRAMS ....................................................................2-17

COOLING SYSTEM DIAGRAMS..................................................................2-19

CABLE ROUTING .........................................................................................2-20

2

Page 25

Page 26

EAS20014
ENGINE SPECIFICATIONS

Engine
Engine type
Liquid cooled 4-stroke, SOHC
Displacement
155 cm³
Cylinder arrangement
Single cylinder
Bore  stroke
58.0  58.7 mm (2.28  2.31 in)
Compression ratio
10.5 : 1
Compression pressure
1374–1769 kPa/1393 r/min 
Starting system
Electric starter

Fuel
Recommended fuel
Regular unleaded gasoline (Gasohol [E10]
acceptable)
Fuel tank capacity
4.6 L (1.2 US gal, 1.1 lmp.gal)
Fuel reserve amount 
0.8 L

Engine oil
Lubrication system
Wet sump
Recommended brand
YAMALUBE
Type
SAE 10W-40
Recommended engine oil grade
API service SG type or higher, JASO standard 
MA or MB
Engine oil quantity
Quantity (disassembled)
1.00 L (1.06 US qt, 0.88 Imp.qt)
Periodic oil change
0.90 L (0.95 US qt, 0.79 Imp.qt)

Final transmission oil
Type
Motor oil SAE 10W-30 type SE or higher or Gear 
oil SAE 85W GL-3
Quantity (disassembled)
0.16 L (0.17 US qt, 0.14 Imp.qt)
Quantity
0.15 L (0.16 US qt, 0.13 Imp.qt)

Oil filter
Oil filter type
Centrifugal

Oil pump
Inner-rotor-to-outer-rotor-tip clearance
0.150 mm (0.0059 in)
Limit
0.23 mm (0.0091 in)
Outer-rotor-to-oil-pump-housing clearance
0.13–0.18 mm (0.0051–0.0071 in)
Limit
0.22 mm (0.0086 in)
Oil-pump-housing-to-inner-and-outer-rotor 
clearance
0.06–0.11 mm (0.0024–0.0043 in)
Limit
0.18 mm (0.0071 in)

Coolant quantity
Radiator (including all routes)
0.46 L (0.49 US qt, 0.40 Imp.qt)
Coolant reservoir (up to the maximum level mark)
0.13 L (0.13 US qt, 0.11 lmp.qt)

2-2

ENGINE SPECIFICATIONS

Page 27

# ENGINE SPECIFICATIONS

Radiator cap valve opening pressure
78.6–137.4 kPa (0.79–1.37 kgf/cm²,
11.4–19.9 psi)

**Thermostat**
Valve opening temperature
74.0–78.0 °C (165.20–172.40 °F)
Valve full open temperature
90.0 °C (194.00 °F)
Valve lift (full open)
7.0 mm (0.28 in)

**Water pump**
Water pump type
Single suction centrifugal pump

**Spark plug(s)**
Manufacturer/model
NGK/CPR8EA-9
DENSO/U24EPR-9
Spark plug gap
0.8–0.9 mm (0.031–0.035 in)

**Cylinder head**
Warpage limit
0.05 mm (0.0020 in)

**Camshaft**
Camshaft lobe dimensions
Lobe height (Intake)
32.211–32.311 mm (1.2681–1.2721 in)
Limit
32.111 mm (1.2642 in)
Lobe height (Intake high speed)
32.587–32.687 mm (1.2830–1.2869 in)
Limit (High speed)
32.487 mm (1.2790 in)
Lobe height (Exhaust)
29.420–29.520 mm (1.1583–1.1622 in)
Limit
29.320 mm (1.1543 in)
Camshaft runout limit
0.030 mm (0.0012 in)

**Rocker arm/rocker arm shaft**
Rocker arm inside diameter
9.985–10.000 mm (0.3931–0.3937 in)
Limit
10.015 mm (0.3943 in)
Rocker arm shaft outside diameter
9.966–9.976 mm (0.3924–0.3928 in)
Limit
9.935 mm (0.3911 in)

**Valve, valve seat, valve guide**
Valve clearance (cold)
Intake
0.10–0.14 mm (0.0039–0.0055 in)
Exhaust
0.21–0.25 mm (0.0083–0.0098 in)
Valve dimensions
Valve seat contact width (intake)
0.90–1.20 mm (0.0354–0.0472 in)
Limit
1.7 mm (0.068 in)
Valve seat contact width (exhaust)
0.90–1.20 mm (0.0354–0.0472 in)
Limit
1.7 mm (0.068 in)

**2-3**

Page 28

Valve stem diameter (intake)
4.975–4.990 mm (0.1959–0.1965 in)
Limit
4.945 mm (0.1946 in)
Valve stem diameter (exhaust)
4.960–4.975 mm (0.1953–0.1959 in)
Limit
4.930 mm (0.1940 in)
Valve guide inside diameter (intake)
5.000–5.012 mm (0.1969–0.1973 in)
Valve guide inside diameter (exhaust)
5.000–5.012 mm (0.1969–0.1973 in)
Valve-stem-to-valve-guide clearance (intake)
0.010–0.037 mm (0.0004–0.0015 in)
Limit
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance (exhaust)
0.025–0.052 mm (0.0010–0.0020 in)
Limit
0.100 mm (0.0039 in)
Valve stem runout
0.010 mm (0.0004 in)

Valve spring
Free length (intake)
33.81 mm (1.33 in)
Limit
32.11 mm (1.26 in)
Free length (exhaust)
33.81 mm (1.33 in)
Limit
32.11 mm (1.26 in)
Spring tilt (intake)
1.7 mm (0.068 in)
Spring tilt (exhaust)
1.7 mm (0.068 in)

Cylinder
Bore
58.000–58.010 mm (2.2835–2.2839 in)
Wear limit
58.060 mm (2.3224 in)

Piston
Diameter
57.962–57.985 mm (2.2820–2.2829 in)
Measuring point (from piston skirt bottom)
6.0 mm (0.24 in)
Piston pin bore inside diameter
14.002–14.013 mm (0.5513–0.5517 in)
Limit
14.043 mm (0.5529 in)
Piston pin outside diameter
13.995–14.000 mm (0.5510–0.5512 in)
Limit
13.975 mm (0.5502 in)
Piston-pin-to-piston-pin-bore clearance
0.002–0.018 mm (0.0001–0.0007 in)

Piston ring
Top ring
Ring type
Barrel
End gap (installed)
0.10–0.25 mm (0.0039–0.0098 in)
Limit
0.50 mm (0.0197 in)
Ring side clearance
0.030–0.065 mm (0.0012–0.0026 in)
Limit
0.115 mm (0.0045 in)
2nd ring
Ring type
Taper
End gap (installed)
0.35–0.50 mm (0.0138–0.0197 in)
Limit
0.85 mm (0.0335 in)
Ring side clearance
0.020–0.055 mm (0.0008–0.0022 in)
Limit
0.115 mm (0.0045 in)

Crankshaft
Crank assembly width
51.45–51.50 mm (2.026–2.028 in)
Runout limit
0.030 mm (0.0012 in)

2-4

ENGINE SPECIFICATIONS

Page 29

# ENGINE SPECIFICATIONS

## Clutch
*   Clutch type: Dry, centrifugal automatic

## Automatic centrifugal clutch
*   Clutch shoe thickness: 4.0 mm (0.16 in)
*   Limit: 2.5 mm (0.10 in)
*   Clutch shoe spring free length: 29.5 mm (1.16 in)
*   Clutch housing inside diameter: 125.0 mm (4.92 in)
*   Limit: 125.5 mm (4.94 in)
*   Compression spring free length: 116.4 mm (4.58 in)
*   Limit: 104.8 mm (4.12 in)
*   Weight outside diameter: 20.0 mm (0.79 in)
*   Limit: 19.5 mm (0.77 in)
*   Clutch-in revolution: 2200–2600 r/min
*   Clutch-stall revolution: 5000–5600 r/min

## V-belt
*   V-belt width: 24.1 mm (0.95 in)
*   Limit: 21.7 mm (0.85 in)

## Transmission
*   Transmission type: V-belt automatic
*   Primary reduction ratio: 1.000
*   Secondary reduction ratio: 10.769 (56/16 × 40/13)
*   Final drive: Gear
*   Gear ratio: 2.300–0.724 : 1

## Air filter
*   Air filter element: Oil-coated paper element

## Fuel injector
*   Resistance: 12.2 Ω

## Throttle body
*   ID mark: B631 00

## Fuel injection sensor
*   Intake air pressure sensor output voltage: 3.88–4.12 V at 101.3 kPa (3.88–4.12 V at
    1.01 kgf/cm², 3.88–4.12 V at 14.7 psi)
*   Intake air temperature sensor resistance: 5850.0–6150.0 Ω at 0 °C (5850.0–6150.0 Ω at
    32 °F)
*   Coolant temperature sensor resistance: 2512–2777 Ω at 20 °C (2512–2777 Ω at 68 °F)
*   Coolant temperature sensor resistance: 210–221 Ω at 100 °C (210–221 Ω at 212 °F)

## Idling condition
*   Fuel line pressure at idling: 220–300 kPa (2.2–3.0 kgf/cm², 31.9–43.5 psi)
*   Engine idling speed: 1500–1700 r/min
*   CO% (Muffler tail pipe): 0.0–1.0 %
*   Water temperature: 80 °C (175.2 °F)
*   Throttle grip free play: 3.0–5.0 mm (0.12–0.20 in)

2-5

Page 30

CHASSIS SPECIFICATIONS
EAS20015
# CHASSIS SPECIFICATIONS

## Chassis
*   Frame type: Underbone
*   Caster angle: 26.5°
*   Trail: 95 mm (3.7 in)

## Front wheel
*   Wheel type: Cast wheel
*   Rim size: 14M/C × MT2.50
*   Rim material: Aluminum
*   Radial wheel runout limit: 1.0 mm (0.04 in)
*   Lateral wheel runout limit: 1.0 mm (0.04 in)

## Rear wheel
*   Wheel type: Cast wheel
*   Rim size: 14M/C × MT3.50
*   Rim material: Aluminum
*   Radial wheel runout limit: 1.0 mm (0.04 in)
*   Lateral wheel runout limit: 1.0 mm (0.04 in)

## Front tire
*   Type: Tubeless
*   Size: 110/80-14M/C 53P
*   Manufacturer/model: IRC/SCT-005F
*   Wear limit (front): 1.0 mm (0.04 in)

## Rear tire
*   Type: Tubeless
*   Size: 140/70-14M/C 62P
*   Manufacturer/model: IRC/SCT-005R
*   Wear limit (rear): 1.0 mm (0.04 in)

## Tire air pressure (measured on cold tires)
*   Front (1 person): 200 kPa (2.00 kgf/cm², 29 psi)
*   Rear (1 person): 225 kPa (2.25 kgf/cm², 33 psi)
*   Front (2 persons): 200 kPa (2.00 kgf/cm², 29 psi)
*   Rear (2 persons): 225 kPa (2.25 kgf/cm², 33 psi)

## Front brake
*   Type: Hydraulic single disc brake
*   Front disc brake
    *   Disc outside diameter × thickness: 230.0 × 4.0 mm (9.06 × 0.16 in)
    *   Brake disc thickness limit: 3.5 mm (0.14 in)
    *   Brake disc runout limit (as measured on wheel): 0.15 mm (0.0059 in)
    *   Brake pad lining thickness: 4.4 mm (0.17 in)
    *   Limit: 0.8 mm (0.03 in)

2-6

Page 31

Page 32

EAS20016
ELECTRICAL SPECIFICATIONS

Voltage
System voltage
12 V

Ignition system
Ignition system
TCI
Advancer type
Digital
Ignition timing (B.T.D.C.)
5.0°/1600 r/min

Ignition coil
Primary coil resistance
2.16–2.64 
Secondary coil resistance
8.64–12.96 k

Spark plug cap
Resistance
3.75–6.25 k

AC magneto
Standard output
14.0 V, 705 W at 5000 r/min
Stator coil resistance
0.048–0.072 

Battery
Model
GTZ7V
Voltage, capacity
12 V, 6.0 Ah (10HR)

Bulb voltage, wattage  quantity
Headlight
LED
Auxiliary light
12 V, 5.0 W  2
Tail/brake light
LED
Front turn signal light
12 V, 10.0 W  2
Rear turn signal light
12 V, 10.0 W  2
Meter lighting
LED
License plate light
12 V, 5.0 W  1

Indicator light
Turn signal indicator light
LED
High beam indicator light
LED
Coolant temperature warning light
LED
Engine trouble warning light
LED
ABS warning light
LED (GDR155-A)
Stop and Start System indicator light
LED (GDR155-A)
Smart key system indicator light
LED (GDR155-A)

Starter generator
Power output
0.29 kW

Fuel sender unit
Sender unit resistance (full)
10–14.0 
Sender unit resistance (empty)
267–273.0 

2-8

ELECTRICAL SPECIFICATIONS

Page 33

Page 34

EAS20017
TIGHTENING TORQUES

EAS30015
GENERAL TIGHTENING TORQUE 
SPECIFICATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread pitch. 
Tightening torque specifications for special com-
ponents or assemblies are provided for each 
chapter of this manual. To avoid warpage, tight-
en multi-fastener assemblies in a crisscross pat-
tern and progressive stages until the specified 
tightening torque is reached. Unless otherwise 
specified, tightening torque specifications re-
quire clean, dry threads. Components should be 
at room temperature.

A. Distance between flats
B. Outside thread diameter

A (nut)
B (bolt)
General tightening torques

N·m
kgf·m
lb·ft

10 mm
6 mm
6
0.6
4.3

12 mm
8 mm
15
1.5
11

14 mm
10 mm
30
3.0
22

17 mm
12 mm
55
5.5
40

19 mm
14 mm
85
8.5
61

22 mm
16 mm
130
13.0
94

2-10

TIGHTENING TORQUES

Page 35

## TIGHTENING TORQUES

EAS30016
### ENGINE TIGHTENING TORQUES

| Item                                    | Thread size | Q'ty | Tightening torque                          | Remarks |
| :-------------------------------------- | :---------- | :--- | :----------------------------------------- | :------ |
| Muffler nut                             | M8          | 2    | 20 N·m (2.0 kgf·m, 14 lb·ft)               |         |
| Muffler bolt                            | M10         | 3    | 57 N·m (5.7 kgf·m, 41 lb·ft)               |         |
| Muffler protector bolt                  | M6          | 2    | 8 N·m (0.8 kgf·m, 5.8 lb·ft)               |         |
| Cylinder head bolt                      | M6          | 2    | 10 N·m (1.0 kgf·m, 7.2 lb·ft)              |         |
| Cylinder head nut                       | M8          | 4    | 24 N·m (2.4 kgf·m, 17 lb·ft)               |         |
| VVA (variable valve actuator) sole-noid bolt | M6          | 2    | 10 N·m (1.0 kgf·m, 7.2 lb·ft)              |         |
| Cylinder head cover bolt                | M6          | 4    | 10 N·m (1.0 kgf·m, 7.2 lb·ft)              |         |
| Engine oil check bolt                   | M6          | 1    | 7 N·m (0.7 kgf·m, 5.1 lb·ft)               |         |
| Camshaft sprocket bolt                  | M8          | 1    | 30 N·m (3.0 kgf·m, 22 lb·ft)               |         |
| Spark plug                              | M10         | 1    | 13 N·m (1.3 kgf·m, 9.4 lb·ft)              |         |
| Valve clearance adjusting screw locknut | M5          | 4    | 7 N·m (0.7 kgf·m, 5.1 lb·ft)               |         |
| Coolant drain bolt (cylinder side)      | M6          | 1    | 10 N·m (1.0 kgf·m, 7.2 lb·ft)              |         |
| Radiator fan case bolt                  | M6          | 5    | 10 N·m (1.0 kgf·m, 7.2 lb·ft)              |         |
| Radiator fan bolt                       | M6          | 3    | 10 N·m (1.0 kgf·m, 7.2 lb·ft)              |         |
| Radiator bolt                           | M6          | 4    | 10 N·m (1.0 kgf·m, 7.2 lb·ft)              |         |
| Coolant drain bolt (radiator side)      | M12         | 1    | 1.0 N·m (0.10 kgf·m, 0.72 lb·ft)           |         |
| Radiator cover bolt                     | M6          | 3    | 10 N·m (1.0 kgf·m, 7.2 lb·ft)              |         |
| Fuel injector bolt                      | M6          | 1    | 10 N·m (1.0 kgf·m, 7.2 lb·ft)              |         |
| ISC (Idle Speed Control) unit holder screw | M6          | 1    | 5 N·m (0.5 kgf·m, 3.6 lb·ft)               |         |
| Air filter case bolt                    | M6          | 2    | 10 N·m (1.0 kgf·m, 7.2 lb·ft)              |         |
| AC magneto rotor nut                    | M12         | 1    | 70 N·m (7.0 kgf·m, 51 lb·ft)               |         |
| Transmission case cover bolt            | M8          | 6    | 20 N·m (2.0 kgf·m, 14 lb·ft)               |         |
| Final transmission oil drain bolt       | M8          | 1    | 20 N·m (2.0 kgf·m, 14 lb·ft)               |         |
| V-belt case bolt                        | M6          | 10   | 10 N·m (1.0 kgf·m, 7.2 lb·ft)              |         |
| Engine oil drain bolt                   | M12         | 1    | 20 N·m (2.0 kgf·m, 14 lb·ft)               |         |
| V-belt case air filter element cover bolt | M6          | 6    | 7 N·m (0.7 kgf·m, 5.1 lb·ft)               |         |
| Primary fixed sheave nut                | M12         | 1    | 49 N·m (4.9 kgf·m, 35 lb·ft)               |         |
| Clutch housing nut                      | M12         | 1    | 45 N·m (4.5 kgf·m, 33 lb·ft)               |         |
| Secondary sheave nut                    | M28         | 1    | 55 N·m (5.5 kgf·m, 40 lb·ft)               |         |

2-11

Page 36

Cylinder head tightening sequence:

3

1

6

2-12

TIGHTENING TORQUES

4

2

5

Page 37

# TIGHTENING TORQUES

EAS30017
## CHASSIS TIGHTENING TORQUES

| Item                                                    | Thread size | Q'ty | Tightening torque                           | Remarks             |
| :------------------------------------------------------ | :---------- | :--- | :------------------------------------------ | :------------------ |
| Engine bracket nut                                      | M10         | 1    | 54 N·m (5.4 kgf·m, 39 lb·ft)                |                     |
| Engine mounting nut (front side)                        | M10         | 2    | 50 N·m (5.0 kgf·m, 36 lb·ft)                |                     |
| Engine mounting nut (rear side)                         | M10         | 2    | 54 N·m (5.4 kgf·m, 39 lb·ft)                |                     |
| Grab bar bolt                                           | M8          | 4    | 11 N·m (1.1 kgf·m, 8.0 lb·ft)               |                     |
| Seat hinge nut                                          | M6          | 2    | 7 N·m (0.7 kgf·m, 5.1 lb·ft)                |                     |
| Storage box bolt                                        | M6          | 4    | 9 N·m (0.9 kgf·m, 6.5 lb·ft)                |                     |
| Front brake master cylinder holder bolt                 | M6          | 2    | 10 N·m (1.0 kgf·m, 7.2 lb·ft)               |                     |
| Brake master cylinder reservoir cap screw               | M4          | 2    | 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)             |                     |
| Front brake hose union bolt (master cylinder side)      | M10         | 1    | 29 N·m (2.9 kgf·m, 21 lb·ft)                |                     |
| Throttle cable holder bolt (handlebar switch side)      | M5          | 1    | 3.5 N·m (0.35 kgf·m, 2.5 lb·ft)             |                     |
| Lower ring nut                                          | M25         | 1    | See TIP.                                    |                     |
| Upper ring nut                                          | M25         | 1    | See TIP.                                    |                     |
| Horn bracket bolt                                       | M6          | 1    | 7 N·m (0.7 kgf·m, 5.1 lb·ft)                |                     |
| Horn bolt                                               | M6          | 1    | 7 N·m (0.7 kgf·m, 5.1 lb·ft)                |                     |
| Lower bracket pinch bolt                                | M10         | 4    | 53 N·m (5.3 kgf·m, 38 lb·ft)                |                     |
| Front fork damper rod bolt                              | M10         | 2    | 23 N·m (2.3 kgf·m, 17 lb·ft)                | [Note symbol]       |
| Front wheel sensor bolt                                 | M6          | 1    | 7 N·m (0.7 kgf·m, 5.1 lb·ft)                |                     |
| Front brake caliper bolt                                | M10         | 2    | 35 N·m (3.5 kgf·m, 25 lb·ft)                |                     |
| Front brake hose union bolt (brake caliper side)        | M10         | 1    | 29 N·m (2.9 kgf·m, 21 lb·ft)                |                     |
| Brake caliper bleed screw                               | M8          | 1    | 6 N·m (0.6 kgf·m, 4.3 lb·ft)                |                     |
| Front wheel axle nut                                    | M10         | 1    | 26 N·m (2.6 kgf·m, 19 lb·ft)                |                     |
| Front brake hose holder bolt                            | M6          | 1    | 7 N·m (0.7 kgf·m, 5.1 lb·ft)                |                     |
| Front brake disc bolt                                   | M8          | 3    | 23 N·m (2.3 kgf·m, 17 lb·ft)                | [Note symbol]       |
| Front wheel sensor rotor bolt                           | M5          | 3    | 8 N·m (0.8 kgf·m, 5.8 lb·ft)                | [Note symbol]       |
| Camshaft lever bolt                                     | M6          | 1    | 7 N·m (0.7 kgf·m, 5.1 lb·ft)                |                     |
| Rear wheel axle nut                                     | M16         | 1    | 95 N·m (9.5 kgf·m, 69 lb·ft)                |                     |
| Hydraulic unit assembly bolt                            | M6          | 2    | 7 N·m (0.7 kgf·m, 5.1 lb·ft)                |                     |
| Front brake hose union bolt (hydraulic unit assembly side) | M10         | 2    | 29 N·m (2.9 kgf·m, 21 lb·ft)                |                     |
| Starter generator control unit assembly bolt            | M6          | 2    | 7 N·m (0.7 kgf·m, 5.1 lb·ft)                |                     |
| Rear shock absorber assembly nut (upper)                | M8          | 2    | 23 N·m (2.3 kgf·m, 17 lb·ft)                |                     |
| Rear shock absorber assembly bolt (lower)               | M8          | 2    | 23 N·m (2.3 kgf·m, 17 lb·ft)                |                     |
| Swingarm mounting bolt                                  | M10         | 2    | 57 N·m (5.7 kgf·m, 41 lb·ft)                |                     |
| Fuel tank bolt                                          | M6          | 4    | 9 N·m (0.9 kgf·m, 6.5 lb·ft)                |                     |

2-13

Page 38

Item
Thread 
size
Q’ty
Tightening torque
Remarks

Throttle cable holder bolt (throttle 
body side)
M6
2
5 N·m (0.5 kgf·m, 3.6 lb·ft)

Sidestand switch bolt
M5
1
7 N·m (0.7 kgf·m, 5.1 lb·ft)

Centerstand spring hook bolt
M6
1
7 N·m (0.7 kgf·m, 5.1 lb·ft)

Sidestand nut
M8
1
32 N·m (3.2 kgf·m, 23 31 lb·ft)

TIP
Steering column ring nut
1. Tighten the lower ring nut 38 N·m (3.8 kgf·m, 27 lb·ft) with a torque wrench and the steering nut 
wrench, and then loosen the nut 1/4 turn.
2. Tighten the lower ring nut 16 N·m (1.6 kgf·m, 12 lb·ft) with a torque wrench and the steering nut 
wrench.
3. Install the rubber washer and the center ring nut.
4. Finger tighten the center ring nut, align the slots of both ring nuts, and then install the lock washer.
5. Hold the lower and center ring nuts, and then tighten the upper ring nut 75 N·m (7.5 kgf·m, 54 lb·ft) 

with a torque wrench and the steering nut wrench.

2-14

TIGHTENING TORQUES

LT

Page 39

LUBRICATION POINTS AND LUBRICANT TYPES

EAS20018
LUBRICATION POINTS AND LUBRICANT TYPES

EAS30018
ENGINE

Lubrication point
Lubricant

Bearings

O-rings

O-rings (cam shaft)

Oil seals

Rocker arm stopper pin

Cylinder head nut contact face and stud bolt thread

Camshaft lobes

Decompression cam

Rocker arm shafts

Valve stems and valve guide (intake and exhaust)

Valve stem seals

Valve stem ends (intake and exhaust)

Rocker arm valve inner surface 

Camshaft sprocket

Connecting rod big end face

Piston pin outer surface

Piston, piston ring, and cylinder inner surface

Crank pin

Cam chain sprocket inner surface

Oil pump drive gear inner surface 

Oil pump shaft

O-ring (fuel injector)

Starter wheel and bearing

Starter clutch idle gear inner surface

Drive axle and bearings

Crankshaft threads and conical spring washer outer mating surface

Timing chain tensioner bolts
Yamaha bond 
No.1215®

Crankcase mating surfaces
Yamaha bond 
No.1215®

Crankcase bolt
Yamaha bond 
No.1215®

2-15

E

LS

M

LS

M

M

M

M

M

M

E

M

M

M

E

E

E

E

M

M

E

E

E

M

LS

LS

Page 40

LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS20019
LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS30020
ENGINE OIL LUBRICATION CHART

1.
Oil strainer
2.
Oil pump assembly
3.
Crankshaft
4.
Oil nozzle
5.
Camshaft

2-16

4

5

3

2

1

Page 41

LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS30021
LUBRICATION DIAGRAMS

1.
Oil strainer
2.
Oil pump assembly
3.
Camshaft

2-17

3

2

1

Page 42

LUBRICATION SYSTEM CHART AND DIAGRAMS

2

1

1.
Oil strainer
2.
Oil pump assembly
3.
Crankshaft
4.
Rocker arm/Valve stem end

2-18

4

3

Page 43

COOLING SYSTEM DIAGRAMS

EAS20020
COOLING SYSTEM DIAGRAMS

1. Radiator cap
2. Coolant reservoir hose
3. Radiator
4. Radiator inlet hose
5. Radiator outlet hose
6. Thermostat assembly
7. Water pump inlet hose
8. Water pump assembly

2-19

Page 44

EAS20021
CABLE ROUTING
Handlebar (front view)

(10)
F
(3)
(8)
(9)

(6)

(1)
(2)
(3)
A

(4)
B

(6)

(5)

(9)
(8)
E
C
D
(7)

(11)
I
(2)
(3)

G
(6)
(11)

H

2-20

Page 45

1.
Handlebar switch lead (right)
2.
Front brake light switch lead
3.
Front brake hose
4.
Rear brake light switch lead
5.
Handlebar switch lead (left)
6.
Rear brake cable
7.
Wire harness
8.
Throttle cable (decelerator cable)
9.
Throttle cable (accelerator cable)
10. Projection mark
11. Handlebar
A. Cover the meter coupler with the meter coupler 
cover.
B. Route the rear brake light switch lead above the 
left handlebar switch lead.
C. Route the wire harness to the rear of the front 
brake hose.
D. Secure the grommet by inserting the front brake 
hose grommet into the hose guide.
E. Secure the holder by inserting the projection on 
the holder into the hole in the steering pipe.
F.
73.5°
G. Route the left handlebar switch couplers to the rear 
of the rear brake cable.
H. Route the throttle cables through the hole of the 
handlebar cover.
I.
Route the right handlebar switch couplers to the 
rear of the front brake hose.

2-21

CABLE ROUTING

Page 46

Handlebar (left side view)

4

3

2

1

2-22

CABLE ROUTING

4

3

2

5

1

5

Page 47

CABLE ROUTING
1. Rear brake cable
2. Throttle cable
3. Front brake hose
4. Wire harness
5. Handlebar

2-23

Page 48

Headlight stay (right side view)

B

1

5

4

C

1

5

2-24

CABLE ROUTING

6
7

A

2

3

2

4

Page 49

# CABLE ROUTING

1.  Front brake hose
2.  Front wheel sensor lead
3.  Hydraulic unit
4.  Fuel lid cable
5.  Seat lock cable
6.  Front brake pipe (hydraulic unit to front brake caliper)
7.  Front brake pipe (front brake master cylinder to hydraulic unit)
    A. 30°
    B. GDR155-A
    C. GDR155

2-25

Page 50

Headlight stay (left side view)

1

3

2-26

CABLE ROUTING

3

A

1

2

3

4

1

5

B
1

3

3

1

5

Page 51

# CABLE ROUTING

---

1. Front wheel sensor lead
2. Front brake pipe (front brake master cylinder to hydraulic unit)
3. Front brake hose
4. Front brake pipe (hydraulic unit to front brake caliper)
5. Headlight stay

A. GDR155-A
B. GDR155

 

2-27

Page 52

CABLE ROUTING
2-28
Front fork (rear and right side view)
A
A
J
I
B
C
D
E
F
G
H
1
2
2
3
2
4
5
6
7
1
7
5
5
5
6
6
6
4
1
1
6
5
5
6

Page 53

1.
Horn lead
2.
Horn
3.
Front wheel sensor
4.
Front brake caliper
5.
Front brake hose
6.
Front wheel sensor lead
7.
Front brake hose holder
A. Position the holder within the range shown in the 
illustration.
B. Route the front brake hose through the guide.
C. Secure the clamp by hooking the horn lead clamp 
into the hole of the front brake hose holder.
D. Make sure the brake pipe touches the projection 
on the brake caliper.
E. Inward
F.
Outward
G. Forward
H. Rearward
I.
Align the holder with the white paint mark on the 
brake hose.
J.
Align the gap in the holder with the white paint 
mark on the brake hose.

2-29

CABLE ROUTING

Page 54

**CABLE ROUTING**

---

### Front frame (left side view)

*(Technical schematic diagram showing cable routing on the left side of the front frame)*

#### Key Labels (in boxes):
* **A**
* **B**
* **C**
* **D**
* **E**
* **F**
* **G**
* **H**
* **I**
* **J**

#### Numbered Callouts (in circles):
* **①**
* **②**
* **③**
* **④**
* **⑤**
* **⑥**
* **⑦**
* **⑧**

---

**2-30**

Page 55

1.
Rear brake cable
2.
Throttle cable (decelerator cable)
3.
Throttle cable (accelerator cable)
4.
Fuel hose
5.
Sidestand switch
6.
Wire harness
7.
Buzzer coupler (GDR155-A)
8.
O2 sensor lead

A. White tape
B. Secure the grommet by inserting the fuel hose 
grommet into the hose guide.
C. Route the sidestand switch lead through the cable 
guide.
D. Insert the projection on the brake cable holder 
completely into the hole in the frame.
E. Insert the projection on the wire harness holder 
completely into the hole in the headlight stay.
F.
Install the front wheel sensor coupler to the 
headlight stay.
G. Route the buzzer lead as shown in the illustration. 
(GDR155-A)
H. Fasten the rear brake cable and throttle cables 
with the holder.
I.
Route the O2 sensor lead between the cylinder 
head cover and the fuel hose bracket.
J.
Fasten the throttle cables with the holder.

2-31

CABLE ROUTING

Page 56

### CABLE ROUTING

#### Rear frame (left side view)

*   **Numbered Components:**
    *   ①
    *   ②
    *   ③
    *   ④
    *   ⑤
    *   ⑥ (with three detail views showing routing clips/guides)
    *   ⑦
    *   ⑧
    *   ⑨
    *   ⑩
    *   ⑪
    *   ⑫
    *   ⑬
    *   ⑭
    *   ⑮
    *   ⑯
    *   ⑰
    *   ⑱

*   **Lettered Reference Points/Instructions:**
    *   **[A]**
    *   **[B]**
    *   **[C]**
    *   **[D]**
    *   **[E]**
    *   **[F]**
    *   **[G]**
    *   **[H]**

***

**2-32**

Page 57

1.
Wire harness
2.
License light lead
3.
Rear turn signal light lead (left)
4.
Rear turn signal light lead (right)
5.
Tail/brake light lead
6.
Rear brake cable
7.
Yamaha diagnostic tool coupler
8.
ABS test coupler (GDR155-A)
9.
Starter generator lead
10. Ignition coil
11. Crankshaft position sensor lead
12. Engine ground
13. Ignition coil lead
14. Throttle body sensor assembly lead
15. ISC unit lead
16. Injector lead
17. O2 sensor lead

18. Fuel hose
A. Fit the slot in the ABS test coupler onto the battery 
case rib. (GDR155-A)
B. Route the VVA solenoid lead under the fuel hose.
C. Route the starter generator lead above the wire 
harness.
D. Secure the holder by inserting the wire harness 
holder into the hole of the bracket.
E. Fasten the spark plug lead with the band and then 
secure the holder to the coolant reservoir hose 
bracket.
F.
Cut off the excess end of the band to less than 5 
mm (0.20 in).
G. Cut off the excess end of the band.
H. Route the crankshaft position sensor lead above 
the starter generator lead.

2-33

CABLE ROUTING

Page 58

CABLE ROUTING

Front frame (left side view)

J
I

F ⑥
G

C

②

①

A

H

B
③

R

⑥K
⑦

⑥
L
④

C
⑤

⑧
⑨
M

E

D

C

⑪
P

G
C
⑪
⑥Q

⑩
O
N

2-34

Page 59

1. Main switch coupler
2. Hydraulic unit lead (GDR155-A)
3. Fuel lid cable
4. SGCU lead
5. Fuel pump lead
6. Seat lock cable
7. Frame
8. Fuel tank overflow hose
9. Inner fender
10.Frame ground lead
11.Sidestand switch lead
A. Route the wire harness to the inside of the 
cross tube.
B. Insert the projection on the fuel lid cable 
holder into the hole in the cover.
C. Insert the projection on the wire harness 
holder into the hole in the frame.
D. Route the coolant reservoir hose through the 
guide of the frame.
E. Route the wire harness above the engine 
bracket.
F. Route the seat lock cable to the outside of the 
holder.
G. Insert the projection on the wire harness 
holder into the hole in the footrest board.
H. Fasten the coolant reservoir hose at the white 
paint mark with the holder. Position the hose 
end facing forward.
I.
Route the seat lock cable through the bracket 
hole and route the cable between the wire 
harness and the frame.
J. Fit the slot in the turn signal relay onto the leg 
shield rib.
K. Route the seat lock cable between the wire 
harness holder and the frame.
L. Route the seat lock cable to the inside of the 
footrest board.
M. Insert the end of the fuel tank overflow hose 
into the inner fender. Make sure that the end 
of the hose protector on the fuel tank overflow 
hose contacts the edge of the hole in the 
inner fender.
N. Install the frame ground lead terminal as 
shown in the illustration.
O. Install the frame ground lead terminal so that 
the crimped section of the terminal that 
secures the lead is facing upward.
P. Route the coolant reservoir hose to the inside 
of the sidestand switch lead.
Q. Route the seat lock cable between the 
sidestand switch lead and the footrest board.
R. Do not route this SGCU lead above the other 
SGCU leads.

2-35

CABLE ROUTING

Page 60

Rear frame (right side view)

1

1

F

2-36

CABLE ROUTING

C

1

2

2

3

A

4

B

5

D

E

6

7

Page 61

1.
Seat lock cable
2.
Wire harness
3.
Coolant reservoir hose
4.
Coolant temperature sensor lead
5.
Spark plug lead
6.
VVA solenoid
7.
Radiator hose
A. Fasten the coolant reservoir hose at the white 
paint mark with the holder.
B. Insert the projection on the wire harness holder 
into the hole in the crankcase bracket.
C. Insert the projection on the wire harness holder 
into the hole in the rear side cover.
D. Route the spark plug lead between the VVA 
solenoid and the radiator hose.
E. Route the wire harness through the guide of the 
frame.
F.
Route the seat lock cable through the hole of the 
rear frame.

2-37

CABLE ROUTING

Page 62

# CABLE ROUTING

## Frame (top view)

![Cable Routing Diagram](https://github.com/user-attachments/assets/dd38f1ea-9c03-4f9e-a16f-df919df4345d)

### Details:
*   (1)
*   (2)
*   (3)
*   (4)
*   (5)
*   (6)
*   (7)
*   (8)
*   (9)
*   (10)
*   (11)
*   (12)
*   (13)
*   (14)
*   (15)
*   (16)

### Callouts:
*   A
*   B
*   C
*   D
*   E
*   F
*   G
*   H
*   I
*   J
*   K
*   L
*   M
*   N
*   O
*   P
*   Q
*   R
*   S
*   T
*   U
*   V

2-38

Page 63

1.
Auxiliary DC jack lead
2.
Buzzer (GDR155-A)
3.
Turn signal relay
4.
Main switch
5.
Wire harness
6.
Fuse box
7.
Main relay
8.
Starter charge relay
9.
Fuse box 2 (GDR155-A)
10. Rear turn signal light lead
11. License light lead
12. Tail/brake light lead
13. Smart key unit lead (GDR155-A)
14. Horn lead
15. Seat lock cable
16. Smart key unit (GDR155-A)
A. Fasten the sidestand switch lead with the band. 
Point the end of the band rearward.
B. Route the sidestand switch lead between the wire 
harness and the coolant reservoir hose.
C. Route the ABS test coupler lead above the relay. 
(GDR155-A)
D. 30–40 mm (1.18–1.57 in)
E. 10 mm (0.39 in)
F.
Fasten the license light lead, rear turn signal light 
lead, and tail/brake light lead with the plastic 
locking tie to the hole of the frame.
G. Route the seat lock cable outside of the wire 
harness.
H. Position the plastic locking tie to the rear of the rib 
on the grab bar.
I.
Be sure not to pinch the leads when installing the 
grab bar.
J.
Route the sidestand switch lead under the throttle 
cable and the fuel hose.
K. Route the sidestand switch lead over the frame.
L. Fasten the sidestand switch lead with the holder.
M. Insert the projection on the wire harness holder 
into the hole in the front brake hose holder.
N. Insert the projection on the wire harness holder 
into the hole in the main switch bracket.
O. Install the fuse to the fuse box as shown in the 
illustration.
P.
Fit the slot in the relay onto the rib on the battery 
box.
Q. 5 mm (0.20 in)
R. Insert the projection on the wire harness holder 
into the hole in the rear fender.
S. Fasten the license light lead, rear turn signal light 
lead, and tail/brake light lead with the plastic 
locking tie to the guide.
T.
Position the buckle of the plastic locking tie to the 
outside of the guide.
U. Insert the projection on the tail/brake light coupler 
into the hole in the rear fender.
V. Insert the projection on the wire harness holder 
into the hole in the frame.

2-39

CABLE ROUTING

Page 64

CABLE ROUTING
2-40
Headlight
A
B
C
D
E
F
G
H
I
J
K
1
2
3
2
3
2
1
3
6
5
4
2
1

Page 65

1. Headlight lead
2. Front turn signal light lead
3. Auxiliary light lead
4. Auxiliary DC jack lead
5. Front wheel sensor lead
6. Buzzer lead (GDR155-A)
A. Insert the front turn signal light lead into the 
groove in the headlight unit. Be sure to fasten 
the front turn signal light lead before the split 
in the lead.
B. Insert the coupler into the groove in the 
headlight unit.
C. Route the front turn signal light lead above 
the headlight lead and the auxiliary light lead.
D. Route the front turn signal light lead under the 
headlight lead and the auxiliary light lead.
E. Route the front turn signal light lead trough 
the hole of the front side panel.
F. Insert the auxiliary DC jack coupler into the 
slot in the leg shield.
G. Route the front wheel sensor lead above the 
auxiliary DC jack lead.
H. Fasten the front turn signal light lead and the 
auxiliary light lead with the clamp, making 
sure to align the clamp with the white tape on 
the front turn signal light lead. Point the ends 
of the clamp forward.
I.
Be sure not to pinch the front turn signal light 
lead when installing the front side panel.
J. Insert the headlight lead into the groove in the 
headlight unit.
K. Route the headlight lead through the hole of 
the headlight unit.

2-41

CABLE ROUTING

Page 66

PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE ............................................................................3-1
INTRODUCTION .......................................................................................3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION 
CONTROL SYSTEM ................................................................................3-1
GENERAL MAINTENANCE AND LUBRICATION CHART .......................3-1
CHECKING THE FUEL LINE ....................................................................3-4
CHECKING THE FUEL FILTER................................................................3-4
CHECKING THE SPARK PLUG ...............................................................3-4
ADJUSTING THE VALVE CLEARANCE ..................................................3-5
CHECKING THE ENGINE IDLING SPEED ..............................................3-7
CHECKING THE EXHAUST SYSTEM......................................................3-7
ADJUSTING THE EXHAUST GAS VOLUME ...........................................3-8
REPLACING THE AIR FILTER ELEMENT AND CLEANING 
THE CHECK HOSE..................................................................................3-8
CHECKING THE BREATHER HOSES .....................................................3-8
CLEANING THE V-BELT CASE AIR FILTER ELEMENT 
AND CLEANING THE CHECK HOSE......................................................3-9
CHECKING AND CHARGING THE BATTERY.......................................3-10
CHECKING THE BRAKE OPERATION ..................................................3-10
CHECKING THE FRONT BRAKE PADS ................................................3-10
CHECKING THE REAR BRAKE SHOES................................................3-10
CHECKING THE BRAKE FLUID LEVEL.................................................3-10
CHECKING THE FRONT BRAKE HOSES .............................................3-11
BLEEDING THE HYDRAULIC BRAKE SYSTEM ...................................3-11
CHECKING THE WHEELS .....................................................................3-12
CHECKING THE TIRES..........................................................................3-12
CHECKING THE WHEEL BEARINGS ....................................................3-14
CHECKING AND ADJUSTING THE STEERING HEAD .........................3-14
LUBRICATING THE STEERING HEAD..................................................3-15
CHECKING THE CHASSIS FASTENERS ..............................................3-15
LUBRICATING THE LEVERS .................................................................3-15
CHECKING THE SIDESTAND................................................................3-15
LUBRICATING THE SIDESTAND...........................................................3-15
CHECKING THE CENTERSTAND .........................................................3-15
LUBRICATING THE CENTERSTAND ....................................................3-16
CHECKING THE SIDESTAND SWITCH.................................................3-16
CHECKING THE FRONT FORK .............................................................3-16
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES................3-16
CHECKING THE ENGINE OIL LEVEL....................................................3-16
CHANGING THE ENGINE OIL ...............................................................3-17
CHECKING THE COOLANT LEVEL.......................................................3-18
CHECKING THE COOLING SYSTEM ....................................................3-19
CHANGING THE COOLANT...................................................................3-19
CHANGING THE FINAL TRANSMISSION OIL.......................................3-21
REPLACING THE V-BELT ......................................................................3-22

3

Page 67

LUBRICATING THE SECONDARY SHEAVE.........................................3-22
CHECKING THE BRAKE LIGHT SWITCHES.........................................3-22
CHECKING AND LUBRICATING THE CABLES ....................................3-22
CHECKING THE THROTTLE GRIP OPERATION .................................3-23
CHECKING THE SWITCHES, LIGHTS AND SIGNALS .........................3-24
ADJUSTING THE HEADLIGHT BEAM ...................................................3-24

Page 68

Page 69

EAS20022
PERIODIC MAINTENANCE

EAS30022
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If 
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a lon-
ger service life and reduce the need for costly overhaul work. This information applies to vehicles al-
ready in service as well as to new vehicles that are being prepared for sale. All service technicians 
should be familiar with this entire chapter.

EAU46932
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

TIP
• The annual checks must be performed every year, except if a kilometer-based maintenance is 
performed instead.
• From 16000 km, repeat the maintenance intervals starting from 4000 km.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, 
data and technical skills.

ODOMETER READING (whichever comes first)

NO.
ITEM
CHECK OR MAINTENANCE 
JOB

ANNUAL 
CHECK
1000 km 
or 
1 month

1
*
Fuel line
• Check fuel hoses for cracks or 
damage.






2
*
Fuel filter
• Check condition.
• Replace if necessary.
Every 12000 km (7500 mi)

3
Spark plug
• Check condition.
• Clean and regap.





• Replace.
Every 10000 km (6000 mi)

4
*
Valves
• Check valve clearance.
• Adjust if necessary.



5 *
Fuel injection
• Check engine idle speed.






• Check for leakage.
• Tighten if necessary.
• Replace gasket(s) if neces-
sary.






6
*
Exhaust system

EAUN0284
GENERAL MAINTENANCE AND LUBRICATION CHART

TIP
• The annual checks must be performed every year, except if a kilometer-based maintenance is 
performed instead.
• From 16000 km, repeat the maintenance intervals starting from 4000 km.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, 
data and technical skills.

ODOMETER READING (whichever comes first)
ANNUAL 
CHECK
1000 km 
or 
1 month

NO.
ITEM
CHECK OR MAINTENANCE 
JOB

• Perform dynamic inspection 
using Yamaha diagnostic tool.
• Check the error codes.







1
*
Diagnostic sys-
tem check

2
Air filter element
• Replace.
Every 16000 km (10000 mi)

3
Air filter check 
hose
• Clean.






3-1

PERIODIC MAINTENANCE

4000 km 
or 
4 months

7000 km 
or 
7 months

10000 km 
or 
10 months

13000 km 
or 
13 months

4000 km 
or 
4 months

7000 km 
or 
7 months

10000 km 
or 
10 months

13000 km 
or 
13 months

Page 70

ODOMETER READING (whichever comes first)
ANNUAL 
CHECK
1000 km 
or 
1 month

NO.
ITEM
CHECK OR MAINTENANCE 
JOB

4
*
V-belt case air fil-
ter element
• Clean.
• Replace if necessary.





5
*
Battery
• Check voltage.
• Charge if necessary.







6
*
Front brake
• Check operation, fluid level 
and vehicle for fluid leakage.







• Replace brake pads.
Whenever worn to the limit

7
*
Rear brake
• Check operation and adjust 
brake lever free play.







• Replace brake shoes.
Whenever worn to the limit

• Check for cracks or damage.
• Check for correct routing and 
clamping.






8
*
Brake hoses

• Replace.
Every 4 years

9
*
Brake fluid
• Change.
Every 2 years

10 *
Wheels
• Check runout and for dam-
age.





• Check tread depth and for 
damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.

11 *
Tires

12 *
Wheel bearings
• Check bearings for loose-
ness or damage.





• Check bearing play and steer-
ing for roughness.






13 *
Steering bearings

• Lubricate with lithium-soap-
based grease.
Every 12000 km (7500 mi)

14 *
Chassis fasteners
• Make sure that all nuts, bolts 
and screws are properly tight-
ened.






15
Front brake lever 
pivot shaft
• Lubricate with silicone 
grease.






16
Rear brake lever 
pivot shaft
• Lubricate with silicone 
grease.






• Check operation.
• Lubricate with lithium-soap-
based grease.






17
Sidestand, center-
stand

18 *
Sidestand switch
• Check operation.







19 *
Front fork
• Check operation and for oil 
leakage.





• Change the front fork oil.
Every 20000 km (12000 mi)

20 *
Shock absorber 
assemblies
• Check operation and shock 
absorbers for oil leakage.





21
Engine oil
• Change.
• Check oil level and vehicle for 
oil leakage.

Every 3000 km (1800 mi)

22 *
Engine oil strainer
• Clean.



• Check coolant level and vehi-
cle for coolant leakage.






23 *
Cooling system

• Change with Yamaha genuine 
coolant.
Every 3 years

24
Final transmis-
sion oil
• Check vehicle for oil leakage.






• Change.

Every 10000 km (6000 mi)

25 *
V-belt
• Check for damage and wear.





• Replace.
Every 25000 km (15500 mi)

26 *
V-belt secondary 
sheave
• Lubricate.
Every 12000 km (7500 mi)

27 *
Front and rear 
brake switches
• Check operation.







28
Moving parts and 
cables
• Lubricate.






3-2

PERIODIC MAINTENANCE

4000 km 
or 
4 months

7000 km 
or 
7 months

10000 km 
or 
10 months

13000 km 
or 
13 months







Page 71

ODOMETER READING (whichever comes first)
ANNUAL 
CHECK
1000 km 
or 
1 month

NO.
ITEM
CHECK OR MAINTENANCE 
JOB

• Check operation.
• Check throttle grip free play, 
and adjust if necessary.
• Lubricate cable and grip 
housing.

29 *
Throttle grip

30 *
Lights, signals 
and switches
• Check operation.
• Adjust headlight beam.







EAU62401
TIP

• Air filter
• This model’s air filter is equipped with a disposable oil-coated paper element, which must not be 
cleaned with compressed air to avoid damaging it.
• The air filter element needs to be replaced more frequently when riding in unusually wet or dusty 
areas.
• V-belt case air filter
• 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. After dissembling the brake master 
cylinders and calipers, always change the brake fluid.
• Every two years replace the internal components of the brake master cylinder and caliper, and 
change the brake fluid.
• Replace the brake hose every four years and if cracked or damaged.

3-3

PERIODIC MAINTENANCE

4000 km 
or 
4 months

7000 km 
or 
7 months

10000 km 
or 
10 months

13000 km 
or 
13 months







Page 72

EAS30619
CHECKING THE FUEL LINE
1. Remove:
• Front side cover assembly (left)
Refer to “GENERAL CHASSIS (2)” on page 
4-3.
• Footrest board (left)
Refer to “GENERAL CHASSIS (6)” on page 
4-16.
2. Check:
• Fuel hose “1”
Cracks/damage  Replace.
Loose connections  Connect properly.

1

3. Install:
• Footrest board (left)
Refer to “GENERAL CHASSIS (6)” on page 
4-16.
• Front side cover assembly (left)
Refer to “GENERAL CHASSIS (2)” on page 
4-3.

EAS31178
CHECKING THE FUEL FILTER
1. Remove:
• Front side cover assembly (left)
Refer to “GENERAL CHASSIS (2)” on page 
4-3.
• Footrest board (left)
Refer to “GENERAL CHASSIS (6)” on page 
4-16.
• Fuel filter
Refer to “FUEL TANK” on page 7-1.
2. Check:
• Fuel filter “1”
Damage/contaminants  Replace.

TIP
Replace the fuel filter every 12000 km (7500 mi) 
of operation.

3-4

PERIODIC MAINTENANCE

1

3. Install:
• Fuel filter
Refer to “FUEL TANK” on page 7-1.
• Footrest board (left)
Refer to “GENERAL CHASSIS (6)” on page 
4-16.
• Front side cover assembly (left)
Refer to “GENERAL CHASSIS (2)” on page 
4-3.

EAS30620
CHECKING THE SPARK PLUG
1. Remove:
• Front side cover assembly (right)
Refer to “GENERAL CHASSIS (2)” on page 
4-3.
• Footrest board  (right)
Refer to “GENERAL CHASSIS (6)” on page 
4-16.
2. Remove:
• Spark plug cap
• Spark plug

ECA13330

NOTICE

Before removing the spark plug, blow away 
any dirt accumulated in the spark plug well 
with compressed air to prevent it from falling 
into the cylinder.

3. Check:
• Spark plug type
Incorrect  Change.

Manufacturer/model
NGK/CPR8EA-9
DENSO/U24EPR-9

 

4. Check:
• Electrode “1”
Damage/wear  Replace the spark plug.
• Insulator “2”
Abnormal color  Replace the spark plug.
Normal color is medium-to-light tan.

Page 73

5. Clean:
• Spark plug
(with a spark plug cleaner or wire brush)
6. Measure:
• Spark plug gap “a”
(with a wire thickness gauge)
Out of specification  Regap.

Spark plug gap
0.8–0.9 mm (0.031–0.035 in)

 

7. Install:
• Spark plug “1”
• Spark plug cap

Spark plug
13 N·m (1.3 kg lbf·m, 9.4 lb·ft)

T R
.

.

 

TIP
• Before installing the spark plug, clean the 
spark plug and gasket surface.
• When tightening the spark plug, make sure 
that the inside “a” of the spark plug wrench “2” 
does not the contact the portion “b” of the spark 
plug.
• To route the spark plug lead, refer to “CON-
NECTING THE LEADS” on page 5-8.

3-5

PERIODIC MAINTENANCE

a
b
2

1

8. Install:
• Footrest board assembly (right)
Refer to “GENERAL CHASSIS (6)” on page 
4-16.
• Front side cover (right)
Refer to “GENERAL CHASSIS (2)” on page 
4-3.

EAS30622
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the 
valves.

TIP
• Valve clearance adjustment should be made 
on a cold engine, at room temperature.
• 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:
• Front side covers (left and right)
Refer to “GENERAL CHASSIS (2)” on page 
4-3.
• Footrest boards (left and right)
Refer to “GENERAL CHASSIS (6)” on page 
4-16.
• Radiator cover and radiator fan case
Refer to “RADIATOR” on page 6-1.
2. Move:
• Radiator “1”
• Radiator fan case “2”

TIP
Move the rear of the radiator outward.

Page 74

2
1

3. Move:
• Cylinder head cover “1”

1

4. Measure:
• Valve clearance
Out of specification  Adjust.

Valve clearance (cold)
Intake
0.10–0.14 mm (0.0039–0.0055 in)
Exhaust
0.21–0.25 mm (0.0083–0.0098 in)

 

a. Turn the crankshaft clockwise.
b. When the piston is at the Top Dead Center 
(TDC) on the compression stroke, align the 
“I” mark “a” on the camshaft sprocket with the 
match mark “b” on the camshaft stopper 
plate.
c. Align the “I” mark “c” on the A.C. magneto ro-
tor with the stationary pointer “d” on the 
crankcase.

d
c

3-6

PERIODIC MAINTENANCE

a
b

d. Measure the valve clearance with a thickness 
gauge “1”.
Out of specification  Adjust.

1

5. Adjust:
• Valve clearance
a. Loosen the locknut “1”.
b. Insert a thickness gauge “2” between the end 
of the adjusting screw and the valve tip.

2
1

c. Turn the adjusting screw “3” in direction “a” or 
“b” with the tappet adjusting tool “4” until the 
specified valve clearance is obtained.

Direction “a”
Valve clearance is increased.
Direction “b”
Valve clearance is decreased.

Page 75

Tappet adjusting tool
90890-0131m, 1
Six piece tappet set
YM-A5970

 

3

(b)

4
(a)

d. Hold the adjusting screw to prevent it from 
moving and tighten the locknut to specifica-
tion.

Valve clearance adjusting screw 
locknut
7 N·m (0.7 kgf·m, 5.1 lb·ft)

T R
.

.

 

e. Measure the valve clearance again.
f. If the valve clearance is still out of specifica-
tion, repeat all of the valve clearance adjust-
ment steps until the specified clearance is 
obtained.

6. Install:
• All removed parts

TIP
For installation, reverse the removal procedure.

EAS31017
CHECKING THE ENGINE IDLING SPEED

TIP
Prior to checking the engine idling speed, the air 
filter element should be clean, and the engine 
should have adequate compression.

1. Start the engine and let it warm up for several 
minutes.
2. Check:
• Engine idling speed
Out of specification  Go to next step.

Engine idling speed
1500–1700 r/min

 

3. Check:
• ISC (idle speed control) learning value
“00” or “01”  Check the intake system.

3-7

PERIODIC MAINTENANCE

“02”  Clean the ISC (idle speed control) unit 
and throttle body.
Refer to “CLEANING THE ISC (IDLE SPEED 
CONTROL) UNIT AND THROTTLE BODY” 
on page 7-12.
a. Connect the Yamaha diagnostic tool. 
Use the diagnostic code number “67”.
Refer to “ FUNCTION 
AND DIAGNOSTIC CODE TABLE” on page 
9-5.

Yamaha diagnostic tool USB
90890-03250
Yamaha diagnostic tool (A/I)
90890-03252

 

EAS30625
CHECKING THE EXHAUST SYSTEM
1. Check:
• Muffler “1”
Cracks/damage  Replace.
• Gasket “2”
Exhaust gas leaks  Replace.
2. Check:
Tightening torque
• Muffler nuts “3”
• Muffler bolts “4”

Muffler nut
20 N·m (2.0 kgf·m, 14 lb·ft)
Muffler bolt
57 N·m (5.7 kgf·m, 41 lb·ft)

T R
.

.

 

1
4

2

4

3

Page 76

EAS30799
ADJUSTING THE EXHAUST GAS VOLUME

TIP
• Be sure to set the CO density level to standard, 
and then adjust the exhaust gas volume.
• To adjust the exhaust gas volume, use the CO 
adjustment mode of the Yamaha diagnostic 
tool. For more information, refer to the opera-
tion manual of the Yamaha diagnostic tool.

1. Connect the Yamaha diagnostic tool to the 
connector. For information about connecting 
the Yamaha diagnostic tool, refer to “YAMA-
HA DIAGNOSTIC TOOL” on page 8-46.

Yamaha diagnostic tool USB
90890-03250
Yamaha diagnostic tool (A/I)
90890-03252

 

EAS31130
REPLACING THE AIR FILTER ELEMENT 
AND CLEANING THE CHECK HOSE

TIP
Check the air filter check hose “1” that is located 
on the rear side of the air filter case. If dust or 
water or both collects in the hose, clean the hose 
and replace the air filter element.

1

1. Remove:
• Air filter case cover “1”
• Air filter element “2”

1

3-8

PERIODIC MAINTENANCE

2

2. Check:
• Air filter element
Damage  Replace.

TIP
• Replace the air filter element every 16000 km 
(1000 mi) of operation.
• The air filter needs more frequent service if you 
are riding in unusually wet or dusty areas.

3. Install:
• Air filter element
• Air filter case cover

Air filter case cover screw
1.2 N·m (0.12 kgf·m, 0.87 lb·ft)

T R
.

.

 

ECA20480

NOTICE

Never operate the engine without the air filter 
element installed. Unfiltered air will cause 
rapid wear of engine parts and may damage 
the engine. Operating the engine without the 
air filter element will also affect throttle body 
tuning, leading to poor engine performance 
and possible overheating.

TIP
When installing the air filter element into the air 
filter case, make sure that the sealing surfaces 
are aligned to prevent any air leaks.

EAS31179
CHECKING THE BREATHER HOSES
1. Remove:
• Front side cover assembly (left)
Refer to “GENERAL CHASSIS (2)” on page 
4-3.
2. Check:
• Cylinder head breather hose “1”
• Transmission case breather hose “2”
Cracks/damage  Replace.
Loose connections  Connect properly.

Page 77

ECA21600

NOTICE

Make sure the cylinder head breather hose 
and transmission case breather hose are 
routed correctly.

1

1

3. Install:
• Front side cover assembly (left)
Refer to “GENERAL CHASSIS (2)” on page 
4-3.

EAS31704
CLEANING THE V-BELT CASE AIR FILTER 
ELEMENT AND CLEANING THE CHECK 
HOSE

TIP
Check the V-belt case air filter check hose “1” 
that is located on the rear side of the V-belt case. 
If dust or water or both collects in the hose, clean 
the hose and replace the V-belt case air filter el-
ement.

1

3-9

PERIODIC MAINTENANCE

1. Remove:
• V-belt case air filter element cover “1”
• V-belt case air filter element “2”

1

2

2. Clean:
• V-belt case air filter element
(with solvent)

EWA17971

WARNING

Never use low flash point solvents, such as 
gasoline, to clean the V-belt case air filter el-
ement. Such solvents may cause a fire or an 
explosion.

TIP
• The air filter needs more frequent service if you 
are riding in unusually wet or dusty areas.
• After cleaning, gently squeeze the V-belt case 
air filter element to remove the excess solvent.

ECA21590

NOTICE

Do not twist the V-belt case air filter element 
when squeezing it.

Page 78

3. Check:
• V-belt case air filter element
Damage  Replace.
4. Apply the recommended oil to the entire sur-
face of the V-belt case air filter element and 
squeeze out the excess oil. The V-belt case 
air filter element should be wet but not drip-
ping.

Recommended oil
Engine oil

 

5. Install:
• V-belt case air filter element
• V-belt case air filter element cover

V-belt case air filter element cov-
er bolt
7 N·m (0.7 kgf·m, 5.1 lb·ft)

T R
.

.

 

EAS30816
CHECKING AND CHARGING THE BATTERY
Refer to “CHECKING AND CHARGING THE 
BATTERY” on page 8-124.

EAS30801
CHECKING THE BRAKE OPERATION
1. Check:
• Brake operation
Brake not working properly  Check the 
brake system.
Refer to “FRONT BRAKE” on page 4-30 and 
“REAR BRAKE” on page 4-43.

TIP
Drive on the road, operate the front and rear 
brakes separately and check to see if the brakes 
are operating properly.

EAS30633
CHECKING THE FRONT BRAKE PADS
The following procedure applies to all of the 
brake pads.
1. Operate the brake.
2. Check:
• Front brake pad
Wear indicator grooves “a” almost disap-
peared  Replace the brake pads as a set.
Refer to “FRONT BRAKE” on page 4-30.

3-10

PERIODIC MAINTENANCE

a
a

EAS00126
CHECKING THE REAR BRAKE SHOES
1. Operate the brake.
2. Check:
• Wear indicator “1”
Reaches the wear limit line “2”  Replace the 
brake shoes as a set.
Refer to “REAR WHEEL AND BRAKE” in 
chapter 4.

2
1

EAS30632
CHECKING THE BRAKE FLUID LEVEL
1. Stand the vehicle on a level surface.

TIP
• Place the vehicle on the centerstand.
• Make sure the vehicle is upright.
• In order to ensure a correct reading of the 
brake fluid level, make sure the top of the brake 
fluid reservoir is horizontal.

2. Check:
• Brake fluid level
Below the minimum level mark “1”  Add the 
specified brake fluid to the proper level.

Specified brake fluid
YAMAHA GENUINE BRAKE FLUID 
(DOT 3 or DOT 4)-GDR155
YAMAHA GENUINE BRAKE 
FLUID (DOT 4-plus)-GDR155-A

Page 79

1

EWA13540

WARNING

• Use only the designated brake fluid. Other 
brake fluids may cause the rubber seals to 
deteriorate, causing leakage and poor 
brake performance.
• Refill with the same type of brake fluid that 
is already in the system. Mixing brake fluids 
may result in a harmful chemical reaction, 
leading to poor brake performance.
• When refilling, be careful that water does 
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause 
vapor lock.

ECA13540

NOTICE

Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean up 
any spilt brake fluid immediately.

EAS30635
CHECKING THE FRONT BRAKE HOSES
1. Check:
• Brake hoses “1”
Cracks/damage  Replace.

1

2. Check:
• Brake hose holder
• Brake hose guide
Loose  Tighten the holder and guide bolt.

3-11

PERIODIC MAINTENANCE

3. Hold the vehicle upright and apply the front 
brake several times.
4. Check:
• Brake hoses
Brake fluid leakage  Replace the damaged 
hose.
Refer to “FRONT BRAKE” on page 4-30 and 
“ABS (ANTI-LOCK BRAKE SYSTEM) 
(GDR155-A)” on page 4-47.

EAS30893
BLEEDING THE HYDRAULIC BRAKE 
SYSTEM

EWA14000

WARNING

Always bleed the brake system when the 
brake related parts are removed.

ECA22780

NOTICE

• Bleed the brake system in the following or-
der.
• Front brake caliper

EWA16530

WARNING

Bleed the ABS whenever:
• the system is disassembled.
• a brake hose is loosened, disconnected or 
replaced.
• the brake fluid level is very low.
• brake operation is faulty.

TIP
• Be careful not to spill any brake fluid or allow 
the brake master cylinder reservoir to overflow.
• When bleeding the ABS, make sure that there 
is always enough brake fluid before applying 
the brake. Ignoring this precaution could allow 
air to enter the ABS, considerably lengthening 
the bleeding procedure.
• If bleeding is difficult, it may be necessary to let 
the brake fluid settle for a few hours.
• Repeat the bleeding procedure when the tiny 
bubbles in the hose have disappeared.

1. Bleed:
• ABS

▼▼▼
▼
▼
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▼
▼
▼▼▼
▼
▼
▼▼▼
▼
▼
▼▼▼
▼
▼
▼▼▼
▼
▼▼▼
a. Fill the brake master cylinder reservoir to the 
proper level with the specified brake fluid.
b. Install the brake master cylinder diaphragm.
c. Connect a clear plastic hose “1” tightly to the 
bleed screw “2”.

Page 80

1

2

d. Place the other end of the hose into a con-
tainer.
e. Slowly apply the brake several times.
f. Fully squeeze the brake lever and hold it in 
position.
g. Loosen the bleed screw.

TIP
Loosening the bleed screw will release the pres-
sure and cause the brake lever to contact the 
throttle grip or handlebar grip.

h. Tighten the bleed screw and then release the 
brake lever.
i. Repeat steps (e) to (h) until all of the air bub-
bles have disappeared from the brake fluid in 
the plastic hose.
j. Check the operation of the hydraulic unit.
Refer to “HYDRAULIC UNIT OPERATION 
TESTS” on page 4-51.

ECA18060

NOTICE

Make sure that the main switch is turned to 
“OFF” before checking the operation of the 
hydraulic unit.

k. After operating the ABS, repeat steps (e) to 
(i), and then fill the brake master cylinder res-
ervoir to the proper level with the specified 
brake fluid.
l. Tighten the bleed screw to specification.

Brake caliper bleed screw
6 N·m (0.6 kgf·m, 4.3 lb·ft)

T R
.

.

 

m. Fill the brake master cylinder reservoir to the 
proper level with the specified brake fluid.
Refer to “CHECKING THE BRAKE FLUID 
LEVEL” on page 3-10.

EWA13110

WARNING

After bleeding the hydraulic brake system, 
check the brake operation.

▲▲▲
▲
▲
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▲
▲
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▲
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3-12

PERIODIC MAINTENANCE

EAS30638
CHECKING THE WHEELS
The following procedure applies to all of the 
wheels.
1. Check:
• Wheel
Damage/out-of-round  Replace.

EWA13260

WARNING

Never attempt to make any repairs to the 
wheel.

TIP
After a tire or wheel has been changed or re-
placed, always balance the wheel.

2. Measure:
• Radial wheel runout
• Lateral wheel runout
Refer to “CHECKING THE FRONT WHEEL” 
on page 4-22 and “CHECKING THE REAR 
WHEEL” on page 4-29.

EAS30640
CHECKING THE TIRES
The following procedure applies to all of the 
tires.
1. Check:
• Tire pressure
Out of specification  Regulate.

EWA13181

WARNING

• The tire pressure should only be checked 
and regulated when the tire temperature 
equals the ambient air temperature.
• The tire pressure and the suspension must 
be adjusted according to the total weight 
(including cargo, rider, passenger and ac-
cessories) and the anticipated riding 
speed.
• Operation of an overloaded vehicle could 
cause tire damage, an accident or an injury.
NEVER OVERLOAD THE VEHICLE.

Page 81

Tire air pressure (measured on 
cold tires)
Front (1 person)
200 kPa (2.00 kgf/cm², 29 psi)
Rear (1 person)
225 kPa (2.25 kgf/cm², 33 psi)
Front (2 persons)
200 kPa (2.00 kgf/cm², 29 psi)
Rear (2 persons)
225 kPa (2.25 kgf/cm², 33 psi)
Maximum load
154 kg (339 lb) (GDR155)
153 kg (336 lb) (GDR155-A)
* Total weight of rider, passenger, cargo 
and accessories

 

EWA13190

WARNING

It is dangerous to ride with a worn-out tire. 
When the tire tread reaches the wear limit, re-
place the tire immediately.

2. Check:
• Tire surfaces
Damage/wear  Replace the tire.

1. Tire tread depth
2. Side wall
3. Wear indicator

Wear limit (front)
1.0 mm (0.04 in)
Wear limit (rear)
1.0 mm (0.04 in)

 

EWA14080

WARNING

• Do not use a tubeless tire on a wheel de-
signed only for tube tires to avoid tire fail-
ure and personal injury from sudden 
deflation.
• When using a tube tire, be sure to install the 
correct tube.
• Always replace a new tube tire and a new 
tube as a set.

3-13

PERIODIC MAINTENANCE

• To avoid pinching the tube, make sure the 
wheel rim band and tube are centered in the 
wheel groove.
• Patching a punctured tube is not recom-
mended. If it is absolutely necessary to do 
so, use great care and replace the tube as 
soon as possible with a good quality re-
placement.

A
B

A. Tire
B. Wheel

Tube wheel
Tube tire only

Tubeless wheel
Tube or tubeless tire

EWA14090

WARNING

After extensive tests, the tires listed below 
have been approved by Yamaha Motor Co., 
Ltd. for this model. The front and rear tires 
should always be by the same manufacturer 
and of the same design. No guarantee con-
cerning handling characteristics can be giv-
en if a tire combination other than one 
approved by Yamaha is used on this vehicle.

Front tire
Size
110/80–14M/C 53P
Manufacturer/model
IRC/SCT-005F

 

Rear tire
Size
140/70–14M/C 62P
Manufacturer/model
IRC/SCT-005R

Page 82

EWA13210

WARNING

New tires have a relatively low grip on the 
road surface until they have been slightly 
worn. Therefore, approximately 100 km 
should be traveled at normal speed before 
any high-speed riding is done.

TIP
For tires with a direction of rotation mark “1”:
• Install the tire with the mark pointing in the di-
rection of wheel rotation.
• Align the mark “2” with the valve installation 
point.

1
2

EAS30641
CHECKING THE WHEEL BEARINGS
The following procedure applies to all of the 
wheel bearings.
1. Check:
• Wheel bearings
Refer to “CHECKING THE FRONT WHEEL” 
on page 4-22.

EAS30645
CHECKING AND ADJUSTING THE 
STEERING HEAD
1. Stand the vehicle on a level surface.

EWA13120

WARNING

Securely support the vehicle so that there is 
no danger of it falling over.

TIP
Place the vehicle on a suitable stand so that the 
front wheel elevated.

2. Check:
• Steering head
Grasp the handlebar and gently rock the han-
dlebar.
Binding/looseness  Adjust the steering 
head.

3-14

PERIODIC MAINTENANCE

3. Remove:
• Front cover assembly
• Front cowling assembly
Refer to “GENERAL CHASSIS (4)” on page 
4-9.
• Handlebar
Refer to “HANDLEBAR” on page 4-55.
4. Adjust:
• Steering head

▼▼▼
▼
▼
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▼
▼
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▼
▼
▼▼▼
▼
▼
▼▼▼
▼
▼
▼▼▼
▼
▼▼▼
a. Remove the upper ring nut “1”, lock washer 
“2”, center ring nut “3” and rubber washer “4”.

1

3

4

2

b. Loosen the lower ring nut “5” and then tighten 
it to specification with a steering nut wrench 
“6”.

TIP
Set the torque wrench at a right angle to the 
steering nut wrench.

Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472

 

Lower ring nut (initial tightening 
torque)
38 N·m (3.8 kgf·m, 27 lb·ft)

T R
.

.

 

6

5

c. Loosen the lower ring nut 1/4 of a turn, and 
then tighten it to specification with a steering 
nut wrench.

Page 83

EWA13140

WARNING

Do not overtighten the lower ring nut.

Lower ring nut (final tightening 
torque)
16 N·m (1.6 kgf·m, 12 lb·ft)

T R
.

.

 

d. Check the steering head for looseness or 
binding by turning the front fork all the way in 
both directions. If any binding is felt, remove 
the lower bracket and check the upper and 
lower bearings.
Refer to “STEERING HEAD” on page 4-67.
e. Install the rubber washer.
f. Install the center ring nut.
g. Finger tighten the center ring nut, then align 
the slots of both ring nuts. If necessary, hold 
the lower ring nut and tighten the center ring 
nut until their slots are aligned.
h. Install the lock washer “2”.

TIP
Make sure the lock washer tabs “a” sit correctly 
in the ring nut slots “b”.

2

a

b

i. Hold the lower and center ring nuts with a 
steering nut wrench and tighten the upper 
ring nut with a another steering nut wrench.

Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472

 

Upper ring nut
75 N·m (7.5 kgf·m, 54 lb·ft)

T R
.

.

 

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3-15

PERIODIC MAINTENANCE

5. Install:
• Handlebar
Refer to “HANDLEBAR” on page 4-55.
• Front cowling assembly
• Front cover assembly
Refer to “GENERAL CHASSIS (4)” on page 
4-9.

EAS30646
LUBRICATING THE STEERING HEAD
1. Lubricate:
• Upper bearing
• Lower bearing
• Lower bearing dust seal

Recommended lubricant
Lithium-soap-based grease

 

EAS31186
CHECKING THE CHASSIS FASTENERS
Make sure that all nuts, bolts, and screws are 
properly tightened.
Refer to “CHASSIS TIGHTENING TORQUES” 
on page 2-13.

EAS30648
LUBRICATING THE LEVERS
Lubricate the pivoting point and metal-to-metal 
moving parts of the levers.

Recommended lubricant
Silicone grease

 

EAS30650
CHECKING THE SIDESTAND
1. Check:
• Sidestand operation
Check that the sidestand moves smoothly.
Rough movement  Repair or replace.

EAS30651
LUBRICATING THE SIDESTAND
Lubricate the pivoting point, metal-to-metal mov-
ing parts, and spring contact point of the side-
stand.

Recommended lubricant
Lithium-soap-based grease

 

EAS30856
CHECKING THE CENTERSTAND
1. Check:
• Centerstand operation
Check that the centerstand moves smoothly.
Rough movement  Repair or replace.

Page 84

EAS30857
LUBRICATING THE CENTERSTAND
Lubricate the pivoting point, metal-to-metal mov-
ing parts, and spring contact points of the center-
stand.

Recommended lubricant
Lithium-soap-based grease

 

EAS30652
CHECKING THE SIDESTAND SWITCH
Refer to “CHECKING THE SWITCHES” on 
page 8-120.

EAS30653
CHECKING THE FRONT FORK
1. Stand the vehicle on a level surface.

EWA13120

WARNING

Securely support the vehicle so that there is 
no danger of it falling over.

2. Check:
• Inner tube
Damage/scratches  Replace.
• Oil seal
Oil leakage  Replace.
3. Hold the vehicle upright and apply the front 
brake.
4. Check:
• Front fork operation
Push down hard on the handlebar several 
times and check if the front fork rebounds 
smoothly.
Rough movement  Repair.
Refer to “FRONT FORK” on page 4-60.

EAS30808
CHECKING THE REAR SHOCK ABSORBER 
ASSEMBLIES
The following procedure applies to both of the 
rear shock absorber assemblies.
1. Stand the vehicle on a level surface.

EWA13120

WARNING

Securely support the vehicle so that there is 
no danger of it falling over.

3-16

PERIODIC MAINTENANCE

2. Check:
• Rear shock absorber assembly
Oil leaks  Replace the rear shock absorber 
assembly.
Refer to “CHECKING THE REAR SHOCK 
ABSORBER ASSEMBLY” on page 4-81.
3. Check:
• Rear shock absorber assembly operation
Push down seat on the vehicle several times 
and check if the rear shock absorber assem-
bly rebounds smoothly.
Rough movement  Replace.
Refer to “REAR SHOCK ABSORBER AS-
SEMBLIES AND SWINGARM” on page 
4-79.

EAS30656
CHECKING THE ENGINE OIL LEVEL
1. Stand the vehicle on a level surface.

TIP
• Place the vehicle on the centerstand.
• Make sure the vehicle is upright.

2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Remove:
• Dipstick “1”
4. Check:
• Engine oil level
The engine oil level should be between the 
minimum level mark “a” and maximum level 
mark “b”.
Below the minimum level mark  Add the 
recommended engine oil to the proper level.

TIP
• Before checking the engine oil level, wait a few 
minutes until the oil has settled.
• Do not screw the dipstick in when inspecting 
the oil level.

Page 85

1
b
a
1

Recommended brand
YAMALUBE
Type
SAE 10W-40
Recommended engine oil grade
API service SG type or higher, 
JASO standard MA or MB

 

–20 –10
0
10

ECA13370

NOTICE

Do not allow foreign materials to enter the 
crankcase.

5. Start the engine, warm it up for several min-
utes, and then turn it off.
6. Check the engine oil level again.

TIP
Before checking the engine oil level, wait a few 
minutes until the oil has settled.

EAS30657
CHANGING THE ENGINE OIL
1. Start the engine, warm it up for several min-
utes, and then turn it off.
2. Place a container under the engine oil drain 
bolt.
3. Remove:
• Dipstick “1”
• Engine oil drain bolt “2”
(along with the gasket “3”)

3-17

PERIODIC MAINTENANCE

1

3

2

4. Drain:
• Engine oil
(completely from the crankcase)
5. If the oil strainer is also to be cleaned, per-
form the following procedure.

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a. Remove the oil strainer cover “1”, spring “2”, 
and oil strainer “3”.
b. Install a new O-ring “4”.

TIP
Lubricate the O-ring with lithium-soap-based 
grease.

3

2

1
4 New

c. Clean the engine oil strainer with solvent, and 
then check it for damage and replace it if nec-
essary.
d. Install the oil strainer, spring, and oil strainer 
cover.

Oil strainer cover
32 N·m (3.2 kgf·m, 23 lb·ft)

T R
.

.

 

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Page 86

6. Install:
• Engine oil drain bolt

New

(along with the gasket 
)

Engine oil drain bolt
20 N·m (2.0 kgf·m, 14 lb·ft)

T R
.

.

 

7. Fill:
• Crankcase
(with the specified amount of the recom-
mended engine oil)

Engine oil quantity
Quantity (disassembled)
1.00 L (1.06 US qt, 0.88 Imp.qt)
Periodic oil change
0.90 L (0.95 US qt, 0.79 Imp.qt)

 

8. Install:
• Dipstick
9. Start the engine, warm it up for several min-
utes, and then turn it off.
10.Check:
• Engine
(for engine oil leaks)
11.Check:
• Engine oil level
Refer to “CHECKING THE ENGINE OIL 
LEVEL” on page 3-16.
12.Remove:
• Front side cover assembly (right)
Refer to “GENERAL CHASSIS (2)” on page 
4-3.
13.Check:
• Engine oil pressure

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a. Slightly loosen the oil check bolt “1”.

1

b. Start the engine and keep it idling until engine 
oil starts to seep from the oil check bolt. If no 
engine oil comes out after one minute, turn 
the engine off so that it will not seize.
c. Check the engine oil passages and the oil 
pump for damage or leakage. Refer to “OIL 
PUMP” on page 5-45.

3-18

PERIODIC MAINTENANCE

d. Start the engine after solving the problem(s) 
and check the engine oil pressure again.
e. Tighten the oil check bolt to specification.

Engine oil check bolt
7 N·m (0.7 kgf·m, 5.1 lb·ft)

T R
.

.

 

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EAS30811
CHECKING THE COOLANT LEVEL
1. Stand the vehicle on a level surface.

TIP
• Place the vehicle on the centerstand.
• Make sure the vehicle is upright.

2. Check:
• Coolant level
The coolant level should be between the min-
imum level mark “a” and maximum level mark 
“b”.
Below the minimum level mark  Add the 
recommended coolant to the proper level.

b
a

ECA13470

NOTICE

• Adding water instead of coolant lowers the 
antifreeze content of the coolant. If water is 
used instead of coolant check, and if nec-
essary, correct the antifreeze concentra-
tion of the coolant.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may 
be used.

3. Start the engine, warm it up for several min-
utes, and then turn it off.
4. Check:
• Coolant level

TIP
Before checking the coolant level, wait a few 
minutes until the coolant has settled.

Page 87

EAS30812
CHECKING THE COOLING SYSTEM
1. Remove:
• Radiator cover
Refer to “RADIATOR” on page 6-1.
2. Check:
• Radiator “1”
• Coolant reservoir hose “2”
• Radiator inlet hose “3”
• Radiator outlet hose “4”
• Thermostat assembly “5”
• Water pump inlet hose “6”
Cracks/tears  Replace.
Refer to “RADIATOR” on page 6-1 and 
“THERMOSTAT” on page 6-4.

3

2

5

1

6
4

3. Install:
• Radiator cover
Refer to “RADIATOR” on page 6-1.

EAS30813
CHANGING THE COOLANT
1. Remove:
• Front side cover assembly (right)
Refer to “GENERAL CHASSIS (2)” on page 
4-3.
• Footrest board (right)
Refer to “GENERAL CHASSIS (6)” on page 
4-16.
2. Remove:
• Coolant reservoir cap “1”

1

3-19

PERIODIC MAINTENANCE

3. Disconnect:
• Coolant reservoir hose “1”

1

4. Drain:
• Coolant
(from the coolant reservoir)
5. Remove:
• Radiator cover “1”

1

6. Remove:
• Radiator cap “1”

1

EWA13030

WARNING

A hot radiator is under pressure. Therefore, 
do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may 
be blown out, which could cause serious in-
jury. When the engine has cooled, open the 
radiator cap as follows:
Place a thick rag or a towel over the radiator 
cap and slowly turn the radiator cap counter-
clockwise toward the detent to allow any re-
sidual pressure to escape. When the hissing

Page 88

sound has stopped, press down on the radi-
ator cap and turn it counterclockwise to re-
move.

7. Remove:
• Coolant drain bolt (radiator side) “1”
(along with the O-ring)
• Coolant drain bolt (cylinder side) “2”
(along with the copper washer)

1

2

8. Drain:
• Coolant
(from the engine and radiator)
9. Install:
• Coolant drain bolt (cylinder side)

(along with the copper washer 
)
• Coolant drain bolt (radiator side)

New

(along with the O-ring 
)

New

Coolant drain bolt (cylinder side)
10 N·m (1.0 kgf·m, 7.2 lb·ft)
Coolant drain bolt (radiator side)
1.0 N·m (0.10 kgf·m, 0.72 lb·ft)

T R
.

.

 

10.Connect:
• Coolant reservoir hose
11.Fill:
• Cooling system
(with the specified amount of the recom-
mended coolant)

3-20

PERIODIC MAINTENANCE

Recommended antifreeze
YAMAHA GENUINE COOLANT
Mixing ratio
1:1 (antifreeze: water)
Radiator (including all routes)
0.46 L (0.49 US qt, 0.40 Imp.qt)
Coolant reservoir (up to the 
maximum level mark)
0.13 L (0.13 US qt, 0.11 Imp.qt)

 

Handling notes for coolant
Coolant is potentially harmful and should be 
handled with special care.

EWA13040

WARNING

• If coolant splashes in your eyes, thoroughly 
wash them with water and consult a doctor.
• If coolant splashes on your clothes, quickly 
wash it away with water and then with soap 
and water.
• If coolant is swallowed, induce vomiting 
and get immediate medical attention.

ECA13481

NOTICE

• Adding water instead of coolant lowers the 
antifreeze content of the coolant. If water is 
used instead of coolant, check, and if nec-
essary, correct the antifreeze concentra-
tion of the coolant.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may 
be used.
• If coolant comes into contact with painted 
surfaces, immediately wash them with wa-
ter.
• Do not mix different types of antifreeze.

12.Install:
• Radiator cap
13.Fill:
• Coolant reservoir
(with the recommended coolant to the maxi-
mum level mark “a”)

a

Page 89

14.Install:
• Coolant reservoir cap “1”

TIP
Point the tab “a” on the coolant reservoir cap for-
ward.

FWD
FWD

1
a

15.Start the engine, warm it up for several min-
utes, and then turn it off.
16.Check:
• Coolant level
Refer to “CHECKING THE COOLANT LEV-
EL” on page 3-18.

TIP
Before checking the coolant level, wait a few 
minutes until the coolant has settled.

17.Install:
• Radiator cover

Radiator cover bolt
10 N·m (1.0 kgf·m, 7.2 lb·ft)

T R
.

.

 

18.Install:
• Footrest board (right)
Refer to “GENERAL CHASSIS (6)” on page 
4-16.
• Front side cover assembly (right)
Refer to “GENERAL CHASSIS (2)” on page 
4-3.

EAS31187
CHANGING THE FINAL TRANSMISSION OIL
1. Stand the vehicle on a level surface.

TIP
• Place the vehicle on the centerstand.
• Make sure the vehicle is upright.

2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Place a container under the final transmis-
sion.
4. Remove:
• Final transmission oil filler cap “1”
(along with the O-ring “2”)

3-21

PERIODIC MAINTENANCE

• Final transmission oil drain bolt “3”
(along with the copper washer “4”)
Completely drain the final transmission oil.

1

2

3
4

5. Install:
• Final transmission oil drain bolt
(along with the copper washer 
)

New

Final transmission oil drain bolt
20 N·m (2.0 kgf·m, 14 lb·ft)

T R
.

.

 

6. Fill:
• Final transmission oil
(with the specified amount of the recom-
mended final transmission oil)

Final transmission oil
Type
Motor oil SAE 10W-30 type SE 
or higher or Gear oil SAE 85W 
GL-3
Quantity
0.15 L (0.16 US qt, 0.13 Imp.qt)

 

7. Install:
• Final transmission oil filler cap
(along with the O-ring 
)

New

TIP
Lubricate the O-ring with lithium-soap-based 
grease.

8. Start the engine, warm it up for several min-
utes, and then turn it off.
9. Check:
• Final transmission oil leakage

Page 90

EAS31188
REPLACING THE V-BELT
1. Remove:
• Air filter case
Refer to “AIR FILTER CASE” on page 7-7.
• V-belt case
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-34.
2. Check:
• V-belt
Damage/wear  Replace.
Grease/oil  Clean the primary and second-
ary pulleys.
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-34.
TIP
Replace the V-belt every 25000 km (15500 mi) 
of operation.

3. Install:
• V-belt case
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-34.
• Air filter case
Refer to “AIR FILTER CASE” on page 7-7.

EAS31705
LUBRICATING THE SECONDARY SHEAVE
1. Remove:
• Air filter case
Refer to “AIR FILTER CASE” on page 7-7.
• Secondary sheave assembly
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-34.
2. Disassemble:
• Secondary sheave assembly
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-34.
3. Lubricate:
• Spring seat“1”
• O-rings “2”
• Oil seals “3”
• Secondary sliding sheave“4”
• Secondary fixed sheave“5”

Recommended lubricant
Shell dolium grease R®

 

3-22

PERIODIC MAINTENANCE

1

5

4

3

3

2

4. Assemble:
• Secondary sheave assembly
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-34.
5. Install:
• Secondary sheave assembly
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-34.
• Air filter case
Refer to “AIR FILTER CASE” on page 7-7.

EAS30658
CHECKING THE BRAKE LIGHT SWITCHES
1. Check:
• Front brake light switch operation
• Rear brake light switch operation
When operating the brake levers, confirm 
that the brake light comes on.
Faulty  Refer to “CHECKING THE 
SWITCHES” on page 8-120.

EAS30660
CHECKING AND LUBRICATING THE 
CABLES
The following procedure applies to all of the in-
ner and outer cables.

EWA13270

WARNING

Damaged outer cable may cause the cable to 
corrode and interfere with its movement. Re-
place damaged outer cable and inner cables 
as soon as possible.

Page 91

1. Check:
• Outer cable
Damage  Replace.
2. Check:
• Cable operation
Rough movement  Lubricate.

Recommended lubricant
Engine oil or a suitable cable lu-
bricant

 

TIP
Hold the cable end upright and pour a few drops 
of lubricant into the cable sheath or use a suit-
able lubricating device.

EAS30861
CHECKING THE THROTTLE GRIP 
OPERATION
1. Check:
• Throttle cables
Damage/deterioration  Replace.
• Throttle cable installation
Incorrect  Reinstall the throttle cables.
Refer to “HANDLEBAR” on page 4-55.
2. Check:
• Throttle grip movement
Rough movement  Lubricate or replace the 
defective part(s).

Recommended lubricant
Suitable cable lubricant

 

TIP
With the engine stopped, turn the throttle grip 
slowly and release it. Make sure that the throttle 
grip turns smoothly and returns properly when 
released. 
Repeat this check with the handlebar turned all 
the way to the left and right.

3. Check:
• Throttle grip free play “a”
Out of specification  Adjust.

Throttle grip free play
3.0–5.0 mm (0.12–0.20 in)

 

3-23

PERIODIC MAINTENANCE

a

A

A

4. Adjust:
• Throttle grip free play

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a. Slide back the rubber cover “1”.
b. Loosen the locknut “3”.
c. Turn the adjusting nut “2” in direction “a” or “b” 
until the specified throttle grip free play is ob-
tained.

Direction “a”
Throttle grip free play is increased.
Direction “b”
Throttle grip free play is decreased.

b

a
1
2
3

d. Tighten the locknut.

Throttle cable adjusting locknut
3.8 N·m (0.38 kgf·m, 2.8 lb·ft)

T R
.

.

 

e. Slide the rubber cover its original position.

TIP
Make sure that the adjusting nut is covered com-
pletely by the rubber cover.

EWA17990

WARNING

After adjusting the throttle grip free play, 
start the engine and turn the handlebars to 
the right and to the left to ensure that this 
does not cause the engine idling speed to 
change.

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Page 92

EAS30663
CHECKING THE SWITCHES, LIGHTS AND 
SIGNALS
1. Check that all switches operate and that all 
lights come on.
Refer to “INSTRUMENT AND CONTROL 
FUNCTIONS” in Owner’s manual.
Faulty  Refer to “CHECKING THE 
SWITCHES” on page 8-120 and “CHECK-
ING THE BULBS AND BULB SOCKETS” on 
page 8-123.

EAS30664
ADJUSTING THE HEADLIGHT BEAM
1. Adjust:
• Headlight beam (vertically)

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a. Turn the adjusting bolt “1” in direction “a” or 
“b”.

Direction “a”
Headlight beam is raised.
Direction “b”
Headlight beam is lowered.

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3-24

PERIODIC MAINTENANCE

Page 93

Page 94

CHASSIS

GENERAL CHASSIS (1) .................................................................................4-1
REMOVING THE BATTERY COVER .......................................................4-2
INSTALLING THE BATTERY COVER ......................................................4-2

GENERAL CHASSIS (2) .................................................................................4-3
REMOVING THE TAIL/BRAKE LIGHT OUTER COVER ..........................4-4
INSTALLING THE TAIL/BRAKE LIGHT OUTER COVER.........................4-4
REMOVING THE FRONT SIDE COVER ASSEMBLY..............................4-4
INSTALLING THE FRONT SIDE COVER ASSEMBLY ............................4-5
REMOVING THE MOLE SIDE COVER ....................................................4-5
INSTALLING THE MOLE SIDE COVER ...................................................4-5

GENERAL CHASSIS (3) .................................................................................4-6
REMOVING THE REAR SIDE COVER ASSEMBLY ................................4-8
INSTALLING THE REAR SIDE COVER ASSEMBLY...............................4-8

GENERAL CHASSIS (4) .................................................................................4-9
REMOVING THE FRONT UPPER COWLING ASSEMBLY ...................4-10
INSTALLING THE FRONT UPPER COWLING ASSEMBLY ..................4-10
DISASSEMBLING THE FRONT UPPER COWLING ASSEMBLY..........4-10
ASSEMBLING THE FRONT UPPER COWLING ASSEMBLY................4-10

GENERAL CHASSIS (5) ...............................................................................4-12
REMOVING THE FRONT COWLING ASSEMBLY.................................4-13
INSTALLING THE FRONT COWLING ASSEMBLY ...............................4-13
REMOVING THE FRONT SIDE COWLING............................................4-13
INSTALLING THE FRONT SIDE COWLING ..........................................4-14
REMOVING THE FRONT BODY COWLING ..........................................4-14
INSTALLING THE FRONT BODY COWLING.........................................4-14
INSTALLING THE FRONT TURN SIGNAL LIGHT .................................4-15

GENERAL CHASSIS (6) ...............................................................................4-16
INSTALLING THE FOOTREST BOARD .................................................4-17
INSTALLING THE LOWER MOLE COVER ............................................4-17

GENERAL CHASSIS (7) ...............................................................................4-18
INSTALLING THE CENTER LOWER COVER........................................4-19

FRONT WHEEL.............................................................................................4-20
REMOVING THE FRONT WHEEL..........................................................4-22
DISASSEMBLING THE FRONT WHEEL................................................4-22
CHECKING THE FRONT WHEEL ..........................................................4-22

4

Page 95

MAINTENANCE OF THE FRONT WHEEL SENSOR 
AND SENSOR ROTOR..........................................................................4-23
ASSEMBLING THE FRONT WHEEL......................................................4-23
ADJUSTING THE FRONT WHEEL STATIC BALANCE .........................4-24
INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC)..................4-25

REAR WHEEL...............................................................................................4-28
CHECKING THE REAR WHEEL.............................................................4-29
ADJUSTING THE REAR WHEEL STATIC BALANCE............................4-29

FRONT BRAKE.............................................................................................4-30
INTRODUCTION .....................................................................................4-36
CHECKING THE FRONT BRAKE DISC .................................................4-36
REPLACING THE FRONT BRAKE PADS ..............................................4-37
REMOVING THE FRONT BRAKE CALIPER..........................................4-38
DISASSEMBLING THE FRONT BRAKE CALIPER ................................4-38
CHECKING THE FRONT BRAKE CALIPER ..........................................4-39
ASSEMBLING THE FRONT BRAKE CALIPER ......................................4-39
INSTALLING THE FRONT BRAKE CALIPER ........................................4-39
REMOVING THE FRONT BRAKE MASTER CYLINDER .......................4-40
CHECKING THE FRONT BRAKE MASTER CYLINDER........................4-41
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ...................4-41
INSTALLING THE FRONT BRAKE MASTER CYLINDER......................4-41

REAR BRAKE ...............................................................................................4-43
REMOVING THE REAR BRAKE.............................................................4-44
CHECKING THE REAR BRAKE SHOES................................................4-44
ASSEMBLING THE REAR BRAKE SHOE PLATE .................................4-45
CHECKING THE REAR BRAKE DRUM WEAR LIMIT ...........................4-46

ABS (ANTI-LOCK BRAKE SYSTEM) (GDR155-A)......................................4-47
REMOVING THE HYDRAULIC UNIT ASSEMBLY .................................4-49
CHECKING THE HYDRAULIC UNIT ASSEMBLY..................................4-49
INSTALLING THE HYDRAULIC UNIT ASSEMBLY................................4-49
HYDRAULIC UNIT OPERATION TESTS................................................4-51
CHECKING THE ABS WARNING LIGHT ...............................................4-54

HANDLEBAR ................................................................................................4-55
REMOVING THE FRONT HANDLEBAR COVER ASSEMBLY ..............4-57
DISASSEMBLING THE FRONT HANDLEBAR COVER ASSEMBLY ....4-57
REMOVING THE HANDLEBAR..............................................................4-57
CHECKING THE HANDLEBAR ..............................................................4-57
INSTALLING THE HANDLEBAR ............................................................4-57
ASSEMBLING THE FRONT HANDLEBAR COVER ASSEMBLY ..........4-59
INSTALLING THE FRONT HANDLEBAR COVER ASSEMBLY.............4-59

Page 96

FRONT FORK................................................................................................4-60
REMOVING THE FRONT FORK LEGS..................................................4-62
DISASSEMBLING THE FRONT FORK LEGS ........................................4-62
CHECKING THE FRONT FORK LEGS ..................................................4-63
ASSEMBLING THE FRONT FORK LEGS ..............................................4-63
INSTALLING THE FRONT FORK LEGS ................................................4-66

STEERING HEAD..........................................................................................4-67
REMOVING THE LOWER BRACKET.....................................................4-69
CHECKING THE STEERING HEAD.......................................................4-69
INSTALLING THE STEERING HEAD.....................................................4-69

REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM...................4-71
REMOVING THE SWINGARM................................................................4-73
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ...................4-73
CHECKING THE SWINGARM ................................................................4-73
INSTALLING THE SWINGARM ..............................................................4-73

Page 97

EAS20026
GENERAL CHASSIS (1)

Removing the battery and battery cover

4

2

Order
Job/Parts to remove
Q’ty
Remarks

Seat
Open.

1
Battery cover
1

2
Negative battery lead
1
Disconnect.

3
Positive battery lead
1
Disconnect.

4
Battery
1

4-1

GENERAL CHASSIS (1)

1

3

Page 98

EAS31677
REMOVING THE BATTERY COVER
1. Remove:
• Battery cover “1”

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a. Open the seat.
b. Remove the battery cover screws.
c. Slide the battery cover rearward to remove 
the projections “a” on the battery cover from 
the holes “b” in the storage box.

1

a

b

a

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EAS31678
INSTALLING THE BATTERY COVER
1. Install:
• Battery cover “1”

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a. Fit the projections “a” on the battery cover 
into the holes “b” in the storage box, and then 
slide the cover forward.

4-2

GENERAL CHASSIS (1)

1

a

b

a

b. Install the battery cover screws, and then 
tighten the screws to specification.

Battery cover screw
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

T R
.

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Page 99

EAS20155
GENERAL CHASSIS (2)

Removing the front side cover assembly and tail/brake light outer cover

2

3

Order
Job/Parts to remove
Q’ty
Remarks

1
Tail/brake light outer cover
1

2
Front side cover (right)
1

3
Mole side cover (right)
1

4
Front side cover (left)
1

5
Mole side cover (left)
1

4-3

GENERAL CHASSIS (2)

1

5

4

Owner's Manual Yamaha Aerox GDR155

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