Re: Yamaha YZF-R15 version 2.0

I think of it this way: too much play is not good for the rider and too little play is bad for the bike.

Certainly i would like to keep as little play as possible in the throttle, because that gives a better feel during throttle off-on transition during cornering. Though personally i don't mind some extra free play in the clutch.
U do need a certain minimum amount of free play in the throttle so that when you move the bars they don't pull on the throttle cable and in case of the clutch cable to ensure that you are not riding with a slightly disengaged clutch.

Re: Yamaha YZF-R15 version 2.0

Adjusting free play is not a complex task, especially the clutch. You can adjust the clutch free play at the handle bar side. If you couldn't achieve desired play from adjusting in handlebar side, you could adjust it from the engine side. Same goes for throttle play, you can adjust it at the handlebar side and if you don't get the desired play, you can adjust it further at the throttle body side. Also prior adjusting the throttle play, you may have to adjust the idling speed as well. I have personally not adjusted the throttle play in my bike as I feel the stock is good enough. But I have increased the clutch play from stock though.

Clutch play adjustment



Throttle play adjustment

Re: Yamaha YZF-R15 version 2.0

I faced some issues, listed below, with my bike and had been struggling to address them for the last 1.5 months. I had a lot of sleepless nights thinking about how to resolve those issues, as I simply can't withstand even a small unwanted noise coming from my bike.

Thanks to Mr. Nitin Tiple from Yamaha Factory Shop, Pune who did all the analysis and fixed those issues. Today I can say that all the issues have been addressed well.

Also thanks to Pinaki sir, abhimanyu31 and Ron Syl for their valuable guidance to help me identify the possible problem areas.

So I thought of sharing my experience with you all so that it may help you or at least guide you if you have such issues.

I have a 16 months old R15 V2. Current ODO is at 21900 kms. All the service has been done as per service book timeframe and from ASCs. The idle RPM was set at 1.5k. I never had to worry about any cold start. Recently I had my engine's tappet fixed. After the fix I found out some problems:

1. The engine was not getting started at idle RPM. It simply could not sustain at the idle RPM when the engine is cold. It was going till 1.0 k and then turning off. But when I was running the engine for around 15-20 kms or mins, the engine is behaving normally and getting started at idle RPM of 1.25k - 1.35k. But when I am trying to start the cold engine, say after a gap of 4 hours or more, the idle RPM issue is coming back. Also, after a long gap, of 4 hrs and more, when I was trying to start the engine with a little throttle, only then the engine was staying at idle RPM. I was facing this start issue only when the engine is cold.

2. I was hearing a strange tick-tick sound. It seems to be coming from somewhere below the fuel tank on the left side. The sound was coming even when the engine is turned off but the bike is in motion, mostly downhill. Also when I was suddenly applying throttle or the bike was going through undulated roads or sudden jerks, happening mostly when the throttle is released suddenly, the sound was clear, sometimes twice consecutively.

3. The engine was not giving good response below 4k RPM but above that it was running normally and holding speed without any issue.
I have asked many experts and they have given me the following possible causes:

1^st & 3^rd issue:

1. Low Compression.
2. Valve clearance not correct.
3. Battery not charged correctly.
4. Fuel system not adjusted correctly.

2^nd issue:

1. Valve clearance not correct.
2. Front brake faults.
3. Cone set.
4. Fork issues.

I had to go to ASC, in this case Yamaha Factory Shop at Pune, for more than twice to get almost all the matters solved out.

The checks that I asked the ASC guys to perform, after taking help from different experts to concentrate on the areas which can be responsible:

1. Compression check for low compression.
2. Diagnostic check of ECU to find out detailed error.
3. Tappet check/all valves check.
4. Fuel system check/clean.
5. Leaks check (cam sector/valves).
6. Battery check/recharge.
7. Catalytic converter check.
8. ECU check.
9. Idle RPM to be set to 1.4k-1.5k.

So they checked all of the above checks one by one to fix those issues. Below are the causes of those issues:

1^st & 3^rd issue:

Valve clearance was not correct. In R15 the valve need to have a minimum of 0.20 mm gap for the AFR to work correctly and to make the engine produce correct power and function normally. In my case the valve clearance had gone below 0.15 mm. As a result required amount of air was not coming through to make the correct combustion. Hence there was inadequate power and engine was thriving at very low RPM or even shutting down when cold with no idle RPM in play.

ECU diagnostic check also showed 2 errors:

1. Speedometer malfunctioning – which I never noticed but the error was there.
2. The other one I forgot and I will update about it next.

They have also fixed both the errors.

2^nd issue:

Swingarm bearings and bush were rusted and eroded. The swingarm is attached to the bike through a bush and bearings. Those bearings were rusted which was stopping the free play of the swingarm. In turn when the bike was on move, the swingarm was trying to move up & down as required but getting stopped and creating that tick tick noise.

Hope this post help all the people like us who love our R15 like nothing else.

Re: Yamaha YZF-R15 version 2.0

Hey guys. I have an R15 v2 9 months old and approx 10500km on the odo. Recebtly had been to a ride where there was a rough patch full of pot holes. The patch was around 15km. Covered this patch at the speed of 45 to 55. The problem is that next day I felt that my bikes fork was not proper.

Issues are that when I lean to the left I feel that the handle is turning towards left
When I leave the handle at good speed the bikes moves towards the right

Having a pain in left arm after driving certain km

And when I brake or when I use the front brake while taking reverse or when I turn there are some tick tick noise coming from the fork

I find the handle little stiff

Please help on the above issues

Sent from my GT-I9300 using xBhp Connect mobile app

Re: Yamaha YZF-R15 version 2.0

Check if the handle bars are correctly aligned. Turn the handle to extreme left and measure the distance from the fuel tank. Do the same for right side. Also the handle bar should be ending nearby the Yamaha logo in the fuel tank. If the measurements are not similar, then it is time to realign/change the handle bar/s from the ASCs.

If the bike is moving towards right at high speed while you leave the handles, try to adjust your balance accordingly and check it then. I face this problem sometimes but then after adjusting myself the bike goes straight. If you still have this issue after every possible adjustments then check both the rims. If the rims are bent by less than 5 degrees then it is ok else have them checked by the ASCs. I had done the round trip of Pune-Hyderabad and trust me after Solapur, I had to go through a patch of 100/120 kms with very rough and dangerous potholes and I couldn't go above 40 kmph. The rims got bent a little but not that much and they are still running.

That tick tick sound and stiffness are related as far as I can understand from the explanation. Its time to check the coneset and if required get it replaced.

Re: Yamaha YZF-R15 version 2.0

Hello All,
I am facing a difficult time with my bike. I am completing 20K soon on my r15 2.0. I was a proud owner till I have clocked 15K. Afterwards there is a drastic pickup drop and hardly I can touch 90. I took the bike to service center. They said bore has scratch. The bore has to be replaced and the head assembly has to be repaired. It was ok for 300 km after the service. After that the situation became worse. Mileage dropped and pickup is worsened. I have completed 800 km after the service. Can you guys point me what could have gone wrong with the bike? I love my bike so much that I am unable to see it suffer like this.

Re: Yamaha YZF-R15 version 2.0

How was this fixed then? Were the bushes/bearings repalced?

BTW, +1 for the post. I like reading these problem/fixes post when its presented clearly and succinctly.

Re: Yamaha YZF-R15 version 2.0

Thanks. I tried to be as clear as I can and in the flow things happened.

Yes, the bush and both the bearings were replaced.

Re: Yamaha YZF-R15 version 2.0

You said after completing 15k kms your bike started facing this problem and now you're completing almost 20k kms. You've mentioned only about 800 kms between now and the beginning of your problem. Please let us know the following information:

1. Was there any engine work done after 15k? If yes, then what work in details?
2. What engine oil you're using?
3. How you ride your bike normally?
4. How have you ridden your bike in between 15k and 20k kms?
5. How is the engine sound? Is it like the engine is suffering?
6. Are you having engine start problem?

Give us as much information you can, if I missed any part include that also, and in as much detailed way. It will help us in guessing the problem and suggest you the correct way out.

Re: Yamaha YZF-R15 version 2.0

Can anyone tell me the cost of the R15's footpegs? (front). The local dealer here is renovating the workshop, so i couldn't get the prices.

Re: Yamaha YZF-R15 version 2.0

Pillion footpeg is around 80rs as I heard from the ASC spare section last month. But front one should cost you around 120 may be [MENTION=35455]Ivin[/MENTION] would help you with updated cost of it
Cheers:thumbup:

Re: Yamaha YZF-R15 version 2.0

Yes, the foot-peg costs around 120 for front and around 80 for rear.

By the by, I found out some time at last and changed the tyres.
The high speed wobbling issue is history now. The bike is dead stable all around 140's.

Re: Yamaha YZF-R15 version 2.0

Thanks guys! That was very helpful btw [MENTION=35455]Ivin[/MENTION] the new 140section looks great! ride safe

Re: Yamaha YZF-R15 version 2.0

Thats the stock 130. I was saying about 140kmph

Re: Yamaha YZF-R15 version 2.0

Ivin: Just a small question. What was the lifespan of both the previous tyres?