YAMAHA YZF R15

TDF100001

A25, Krishna Towers, 50 Sardar Patel Road, Chennai 600113

Ph : (91) (44) 22352673, 6450665, Fax : (91) (44) 22351684
email : fmsci @vsnl.com, web : www.fmsci.in

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 FMSCI TDF No. :TDF10001
YAMAHA YZF R15 Valid From :
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Article Description

1. General
101 Manufacturer's Name India Yamaha Motor Pvt. Ltd.
A-3, Industrial Area, Noida-Dadri Road, Surajpur -
102 Manufacturer's address
201306, Distt. Gautam Budh Nagar (UP) India.
103 Brand name Yamaha

Model

(a) Model Year 2008

104 (b) Model Identification Name YZF R15

(c) Beginning Serial No.

(d) End Serial No.

105 Type Motorcycle Scooter Moped

Minimum weight
106 ** 106 kgs
( Refer Manual )

Right Side view of the vehicle Left Side view of the vehicle

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2. Engine
201 Type of Engine Four Stroke Two Stroke

202 Number of Cylinders One

a) Bore ** 57.00 mm

b) Stroke ** 58.70 mm

203 ** c) Conrod length ** mm

d) Supercharging Yes No

e) Type and number of compressors NA

204 Cubic capacity (Refer Manual) 149.80 cc

(a) Minimum Volume of Cylinder Head
10.1 cc
205 ** (Refer Manual)
(b) No. of spark plugs per Cylinder One

206 Compression Ratio (Refer Manual) 10.4 : 1

Piston

a) Material Aluminium

b) Minimum Weight (Refer Manual) ** 106.70

207 ** c) No. of Rings per Piston THREE

d) Piston pin offset (Refer Manual) ** 0.25 mm

e) Piston pin material Steel

f) Piston pin weight 30 gms

Material

a) Crankcase Aluminium Alloy

b) Cylinder barrel Aluminium Alloy

c) Cylinder head Aluminium Alloy

d) Generator cover Aluminium Alloy

208 e) Primary case cover Aluminium Alloy

f) Clutch cover Aluminium Alloy

g) Crankshaft cover Aluminium Alloy

h) Gear Box cover Aluminium Alloy

i) Ignition cover Aluminium Alloy

k) Cylinder head cover (valve) Aluminium Alloy

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Material Weight

l) Crank shaft Assembly** STEEL 2770 gms **

208 m) Conrod ** (with cap, bolts and shell included in the above
STEEL
bearings) (Refer Manual) gms **
209 Thickness of tightened cylinder head gasket 0.30 mm +/- 0.1 mm
Position of Cylinder & head relative
210 degree
to the Crank Case
a) Method of cooling Air Liquid Air & Liquid
211
b) Type of liquid Coolant with water
Does the cylinder have a sleeve or liner
212 Yes Material : , No
If yes, material
Chrome Nickel Electrofusion
213 Cylinder barrel – coating
Others : DIASIL Coating with shine

214 Reed Valve Rotary Valve

Method of Induction
Piston Port Poppet Valve

View of Engine / Crankcase Assembly – Left Side View of Engine / Crankcase Assembly– Right Side

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View of Engine/Crankcase Assembly– Front Side View of Engine / Crankcase Assembly– Rear View

View of Engine/ Crankcase Assembly – Top View View of Engine / Crankcase Assembly– Bottom Side

A) Fuel feed by Carburettor

a) Make NA

b) Type / Model NA
215
c) Venturi diameter NA mm +/- 0.25 mm

d)Maximum diameter of Carburettor exit port NA mm

e) Length of adaptor NA mm

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Carburettor showing exit port

NA

B) Fuel feed by Injection

a) Make MIKUNI

b) Model AC28/1

c) Kind of fuel measurement Mechanical Electronic Hydraulic

215 d) Dimensions of intake pipe at the

31.30 mm
throttle or slide location

e) Number of effective fuel outlets Six

f) Position of injectors PHOTO

f1) Manifold / Cylinderhead Manifold Cylinderhead

g) Sensors of injection system SEVEN

h) Actuators of injection system TWO

Injection System

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Location of Sensors & Actuators

1. Throttle body sensor assembly (consisting of Throttle Position Sensor(s1),

Intake Air Pressure Sensor (s2), Intake Air Temperature Sensor (s3))
2. Lean Angle Sensor (s4)
3. Crankshaft Position Sensor (s5)
4. Coolant Temperature Sensor (s6)

For Two Strokes Only

a) Number of Ports

Total

Intake
216
Transfer

Boost

Exhaust

216 b) Height of Ports

Intake mm

Transfer mm

Boost mm

Exhaust mm

c) Width of Ports

Intake mm

Transfer mm

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Boost mm

Exhaust mm

For Four Strokes only

Inlet valves

a) Number Two

b) Diameter ** 19.40 mm

c) Stem dia ** 4.40 mm

d) Overall length ** 85.10 mm

e) Weight ** 14 gms

217 ** f) Number of springs per valve One

g) Type of valve springs Coil Spring

h) Maximum length of the spring under a load of N

i) External diameter of springs +/- 0.2 mm

j) Diameter of spring wire 2.90

k) Number of spring coils Nine

l) Maximum free length of springs 41.40 mm

Exhaust valves

a) Number Two

b) Diameter ** 17.00 mm

c) Stem dia ** 4.40 mm

d) Overall length ** 84.80 mm

e) Weight ** 14 gms

f) Number of springs per valve One

218 **
g) Type of valve springs Coil

h) Maximum length of the spring under a load of N

i) External diameter of springs +/- 0.2 mm

j) Diameter of spring wire 2.90 mm

k) Number of spring coils Nine

l) Maximum free length of springs 41.40 mm

m) Diameter of pipe between manifold and
mm +/- 5%
first silencer
219 Maximum valve lift

a) Intake 5 mm

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b) Exhaust 5 mm

Tappet Rockerarm Oscillating Lever

220 Type of valve operation
Direct Hydraulic

Ratio

a) Rocker Arm 1.38 /

221
b) Oscillating lever NA

c) Rocker Arm weight INLET : 86 gms EXHAUST : 92 gms

222 Overhead valve Yes No

223 Overhead CAM Yes No

224 Pushrod Yes No

225 Method of Cam shaft drive Chain

CAM Timing

a) Inlet opens Degree BTDC

226 b) Inlet closes Degree ABDC

c) Exhaust opens Degree BBDC

d) Exhaust closes Degree BTDC

CAM dimensions
a) Inlet ** A=25.02 +/-0.1 mm

B=30.02 +/-0.1 mm

b) Exhaust ** A=25.02 +/-0.1 mm

B=30.02 +/-0.1 mm
227 **
c) Weight of the Cam ** 228 gms

d) Number One

e) Location SOHC

f) Number of bearings per shaft One

g) Inside diameter of bearings +/- 0.1 mm

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Cam lift in mm (dismounted camshaft)

Intake Exhaust
Rotation Rotation Rotation Rotation
Lift in Lift in Lift in Lift in
Angle in Angle in angle in angle in
Mm mm Mm mm
Degrees Degrees Degrees Degrees
0 5.263 5.263 0 5.227 5.227
-5 5.139 +5 5.279 -5 5.063 +5 5.289
-10 4.897 +10 5.184 -10 4.791 +10 5.244
-15 4.540 +15 4.977 -15 4.406 +15 5.085
-30 2.722 +30 3.717 -30 2.477 +30 3.943
-45 0.953 +45 1.808 -45 0.808 +45 2.047
-60 0.279 +60 1.532 -60 0.217 +60 0.669
-75 0.172 +75 0.162 -75 0.095 +75 0.257
-90 0.080 +90 0.048 -90 0.004 +90 0.182
-105 0.022 +105 0.000 -105 -0.003 +105 0.101
-120 0.020 +120 -0.008 -120 -0.006 +120 0.031
-135 0.018 +135 -0.005 -135 -0.011 +135 -0.017
-150 0.015 +150 -0.002 -150 -0.014 +150 -0.018
A shift of +/- 2 degrees of the whole measurement is accepted

Applicable to both 2 & 4 Stroke Engines

228 Type of Ignition TCI

229 Starting Devices Kick Self Both

a) Clutch wet dry

230 b) Method of operation Cable Hydraulic

c) Weight of Clutch Basket (Refer Manual) ** 2.190 kg

231 ** Transmission

Primary Drive

a) Method of primary drive Gear Belt Chain

b) If gear drive Helical Straight Cut

Primary Drive Ratio 3.042 : 1

If gears / Chain Drive Driven

a) No. of teeth ** 73 24

b) Thickness ** 11.60 mm 14.25 mm

if belt

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a) Diameter of pulleys NA mm

Gear Box

a) Shell Material Aluminium Alloy

232 **
b) No. of speeds Six

c) Material of gears Steel

Gear Ratio No. of teeth Thickness **

Drive Driven Drive Driven

First 2.833 34 12 10.8 13.2

Second 1.875 30 16 10.3 10.70

Third 1.364 30 22 9.8 10.86

Fourth 1.143 24 21 10.80 10.73

Fifth 0.957 22 23 12.53 12.60

Sixth 0.840 21 25 12.30 12.50

Secondary Drive
a) Method of Secondary Drive Chain Shaft Belt
233 ** b) Secondary Drive Ratio 3.00:1
c) If chain, No. of teeth ** Drive 42 Driven 14
d) If belt, diameter of pulleys NA

3 Chassis and Suspension

a) Main frame type Tubular
301
b) Material (Gussets / Tubes) Steel, Sheet Metal / Box

Frame

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Front Suspension
a) Method of suspension
302
b) Front tube O.D. mm
c) Lower Slider O.D. mm
Rear Suspension
a) Method of suspension Mono Shock Twin Shock
303
b) Swinging Arm Type Tubular Rectangular Box Section
c) Material of Swinging Arm Steel Box
Wheels
304 a) Front wheel rim diameter (OD) 17 Inches
b) Width 1.6 Inches
a) Rear wheel rim diameter (OD) 17 Inches
305
b) Width 2.15 Inches
306 Oil Tank Capacity liters
Fuel Tank
307 a) Capacity 12 Litres
b) Material Sheet Metal

308 Has the fuel system an electrical pump Yes

4 Exhaust System

401 Detachable baffles Yes

Weight of the silencer system with bolts for
402 ** 5.20 kgs
fixing the same **
403 Inner diameter of the bend of the silencer mm

404 Anti Pollution System : Description Catalytic Converter

501 5. Brakes Front Rear

a) Number of pistons per caliper 2 1
b) OD of piston in caliper 25.10 mm 31.88 mm
c) Drum Brakes Yes No Yes No

c1) Internal diameter +/-1.5 mm +/-1.5 mm

c2) Number of linings per wheel
c3) Developed length of lining +/-1.5 mm +/-1.5 mm
c4) Width of lining +/- 1mm +/- 1mm

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d) Disc Brakes Yes No Yes No

d1) Number of pads per wheel 2 2

d2) Number of calipers per wheel 1 1
d3) Caliper Material Cast Aluminium Cast Aluminium
d4) Thickness of new disc 4.00+/- 1 mm 4.50+/- 1 mm
d5) External diameter of disc 267 +/-1.5 mm 203 +/-1.5 mm
d6) External diameter of pads rubbing
265 +/-1.5 mm 202 +/-1.5 mm
surface
d7) Internal diameter of pads rubbing
210 +/-1.5 mm 138 +/-1.5 mm
surface
d8) Overall friction length of pads 61.5 +/-1.5 mm 59.2 +/-1.5 mm
d9) Ventilated discs Yes No Yes No

6 Radiator
Radiator Core Dimensions

a) Height 128
601
b) Width 197.90

c) Depth 24.00

7 Airbox
a) Air Box Yes No

b) Material PVC
701
c) RAM Air intake opening in fairing Yes No

d) Dimension

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YAMAHA YZF R15 Valid From :
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VARIANT FOR YAMAHA YZF R15

DAGREX RACING KIT

Manufactured by : DAYTONA, Japan
Marketed by : India Yamaha Motor Pvt. Ltd.

CAM dimensions
a) Inlet ** A=25.5 +/-0.1 mm

B= 30.0 +/-0.1 mm

b) Exhaust ** A= 25.5 +/-0.1 mm

B= 30.0 +/-0.1 mm
227 **
c) Weight of the Cam ** 230 gms

d) Number One

e) Location SOHC

f) Number of bearings per shaft One

g) Inside diameter of bearings +/- 0.1 mm

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 FMSCI TDF No. :TDF10001
YAMAHA YZF R15 Valid From :
Valid till :

VARIANT FOR YAMAHA YZF R15

DAGREX RACING KIT
Manufactured by : DAYTONA, Japan Marketed by : India Yamaha Motor Pvt. Ltd.

Cam lift in mm (dismounted camshaft)

Intake Exhaust
Rotation Rotation Rotation Rotation
Lift in Lift in Lift in Lift in
Angle in Angle in angle in angle in
Mm mm Mm mm
Degrees Degrees Degrees Degrees
0 5.400 5.400 0 5.265 5.265
-5 5.275 +5 5.431 -5 5.076 +5 5.347
-10 5.041 +10 5.361 -10 4.783 +10 5.326
-15 4.714 +15 5.152 -15 4.388 +15 5.204
-30 3.154 +30 4.133 -30 2.651 +30 4.272
-45 1.298 +45 2.484 -45 0.974 +45 2.708
-60 0.397 +60 0.972 -60 0.269 +60 1.157
-75 0.214 +75 0.257 -75 0.098 +75 0.389
-90 0.126 +90 0.099 -90 0.002 +90 0.138
-105 -0.204 +105 -0.001 -105 -0.002 +105 0.138
-120 0.008 +120 0.001 -120 -0.002 +120 0.043
-135 0.007 +135 0.003 -135 -0.002 +135 0.018
-150 0.007 +150 0.006 -150 0.000 +150 0.009
A shift of +/- 2 degrees of the whole measurement is accepted

Secondary Drive
a) Method of Secondary Drive Chain Shaft Belt
233 ** b) Secondary Drive Ratio 3.08 : 1
c) If chain, No. of teeth ** Drive 40 Driven 13
d) If belt, diameter of pulleys NA

4 Exhaust System

401 Detachable baffles Yes

Weight of the silencer system with bolts for
402 ** 2.10 kgs
fixing the same **
403 Inner diameter of the bend of the silencer mm

404 Anti Pollution System : Description NIL

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