SERVICE MANUAL

DR155/GDR155-A

B63-F8197-EZ

d unfit for use.

or Vietnam Co.,Ltd. is continually striving to improve all of its models. Modifications and

anges in specifications or procedures will be forwarded to all authorized Yamaha dealers

ar in future editions of this manual where applicable.

specifications are subject to change without notice.

MANUAL INFORMATION

mportant 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.

A NOTICE indicates special precautions that must be taken to avoid damage to

the vehicle or other property.

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

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.

G

titles “2” appear in smaller print than the section title.

tify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each

disassembly section.

” are given in the order of the jobs in the exploded diagram. A number indicates a disas-

.

indicate parts to be lubricated or replaced.

YMBOLS”.

ction chart “6” accompanies the exploded diagram, providing the order of jobs, names of

in jobs, etc. This step explains removal and disassembly procedure only. For installation

ly procedure, reverse the steps.

uiring more information (such as special tools and technical data) are described sequen-

1

7

2

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

Wear limit, clearance

Molybdenum disulfide grease

Engine speed

Silicone grease

Electrical data

Apply locking agent (LOCTITE®).

Engine oil

Replace the part with a new one.

Silicone fluid

G

M

BF

B

LS

M

S

LT

New

NERAL INFORMATION

1

ECIFICATIONS

2

RIODIC CHECKS AND

DJUSTMENTS

3

ASSIS

4

GINE

5

OOLING SYSTEM

6

EL SYSTEM

7

ECTRICAL SYSTEM

8

OUBLESHOOTING

9

1

ORTANT 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

SIC SERVICE INFORMATION...................................................................1-4

QUICK FASTENERS.................................................................................1-4

ELECTRICAL SYSTEM.............................................................................1-5

ECIAL TOOLS ..........................................................................................1-10

1-1

RIAL NUMBER

erial number “1” is stamped into the

1

1

1-2

he proper tools and cleaning equip-

PECIAL TOOLS” on page 1-10.

ssembling, always keep mated

her. This includes gears, cylinders,

d other parts that have been “mat-

h normal wear. Mated parts must

reused or replaced as an assem-

assembly, clean all of the parts and

m in trays in the order of disassem-

ll speed up assembly and allow for

installation of all parts.

arts away from any source of fire.

ENT PARTS

uine Yamaha parts for all replace-

l and grease recommended by

ll lubrication jobs. Other brands

r in function and appearance, but

lity.

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.

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.

1. Oil

2. Lip

3. Spring

4. Grease

1-3

he bearing with compressed air

will damage the bearing surfac-

embly, check all circlips carefully

amaged or distorted circlips. Al-

piston pin clips after one use.

ng a circlip “1”, make sure the

corner “2” is positioned opposite

that the circlip receives.

1-4

ener

e quick fastener, push its pin with a

hen pull the fastener out.

ener

quick fastener, push its pin so that

om the fastener head, then insert

to the part to be secured and push

a screwdriver. Make sure that the

th the fastener’s head.

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.

1-5

L SYSTEM

rts handling

nnect a battery lead while the en-

ng; otherwise, the electrical

could be damaged.

nnecting the battery leads from

be sure to disconnect the nega-

ead first, then the positive bat-

he positive battery lead is

d first and a tool or similar item

vehicle, a spark could be gener-

s extremely dangerous.

ad is difficult to disconnect due to

ttery terminal, remove the rust us-

NOTICE

ECA16760

Be sure to connect the battery leads to the

correct battery terminals. Reversing the bat-

tery lead connections could damage the

electrical components.

NOTICE

ECA16771

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.

NOTICE

ECA16610

Turn the main switch to “OFF” before dis-

connecting or connecting an electrical com-

ponent.

1-6

rical components with special

not subject them to strong

mponents are very sensitive to

amaged by static electricity.

ever touch the terminals and be

the contacts clean.

g the ECU by turning the main

F”, be sure to wait approximately 5

re turning the main switch back to

Checking the electrical system

TIP

Before checking the electrical system, make

sure that the battery voltage is at least 12 V.

NOTICE

ECA14371

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.

NOTICE

ECA16640

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.

a

1-7

e connections

ds, couplers, and connectors for

moisture, etc.

t:

onnecting a coupler, release the

k, hold both sections of the cou-

ly, and then disconnect the cou-

many types of coupler locks;

e sure to check the type of cou-

efore disconnecting the coupler.

necting a connector, do not pull

old both sections of the connec-

and then disconnect the con-

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

1-8

ecting a coupler or connector, push

s of the coupler or connector to-

they are connected securely.

all connections are tight.

ocket tester)

continuity, clean the terminals.

king the wire harness, perform

(3).

6. Check:

• Resistance

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.

cket tester

0890-03112

alog pocket tester

U-03112-C

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

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)