2021 Yamaha Aerox 155 Service Manual – Full Workshop PDF

Description

File Details

• Manual Type: Service Manual
• Brand: Yamaha
• Model: Aerox 155
• Model Year: 2021
• Language: English
• File Format: PDF
• Page Count: 462 pages
• Produced By: PT Yamaha Indonesia Motor Manufacturing

Chapters Covered

The 2021 Yamaha Aerox 155 Service Manual is organized into ten major sections, each addressing a specific area of the vehicle. Here is what you will find inside.

• General Information — Vehicle identification number location, engine serial number location, special tool references.
• Specifications — Engine specifications, chassis specifications, electrical specifications, tightening torques, cable routing diagrams.
• Periodic Maintenance — Emission control maintenance chart, general maintenance and lubrication chart, valve clearance adjustment, engine oil change, coolant change, final transmission oil change, V-belt replacement, brake system checks, tire and wheel inspection, steering head adjustment.
• Chassis — General chassis removal and installation (battery cover, side covers, cowlings, footrest boards, fuel tank cover, leg shield, grab bars, rear cowlings), front wheel, rear wheel, front brake, rear brake, ABS, handlebar, front fork, steering head, rear shock absorber assemblies, swingarm.
• Engine — Engine oil lubrication chart, engine inspection, compression pressure measurement, engine removal and installation, cylinder head, camshaft, valves and valve springs, cylinder and piston, V-belt automatic transmission, starter generator, oil pump, transmission, crankshaft, crankcase assembly.
• Cooling System — Cooling system diagrams, radiator removal and installation, thermostat assembly, water pump disassembly and assembly.
• Fuel System — Fuel tank removal and installation, fuel pump, fuel filter, fuel pressure check, fuel injector, air filter case, throttle body removal and installation, ISC unit cleaning.
• Electrical System — Ignition system, electric starting system, stop and start system, charging system, lighting system, signaling system, fuel pump system, electrical components, switch checks, fuse checks, battery service, relay checks, sensor checks.
• Self-Diagnostic Function and Diagnostic Code Table — MIL and warning light checks, Yamaha diagnostic tool usage, fuel injection system diagnostics, ABS troubleshooting, smart key system, DTC tables, diagnostic code tables, event code tables.
• Wiring Diagram — Complete color-coded wiring diagram for the 2021 Aerox 155.

Together, these chapters provide a complete path through the machine: from initial identification and specification lookup, through scheduled maintenance, into component-level repair and diagnosis, and finally to system-level troubleshooting using the self-diagnostic tables. The 2021 Yamaha Aerox 155 Service Manual is a vehicle-specific workshop document, not a generic scooter repair guide.

What the 2021 Yamaha Aerox 155 Service Manual Provides

This manual covers the systems, specifications, and procedures unique to the 2021 Aerox 155. Whether you are performing a routine oil change, replacing a V-belt, servicing the front fork, diagnosing an ABS fault code, or rebuilding the top end, the manual gives you the exact sequence, torque values, and service limits required.

The engine section alone covers compression pressure measurement, valve clearance adjustment, camshaft and rocker arm inspection, valve guide replacement, piston and ring measurement, crankshaft runout, and crankcase assembly. The V-belt automatic transmission chapter includes primary and secondary sheave disassembly, clutch shoe inspection, V-belt width measurement, and sheave reassembly torque values.

On the chassis side, you get exploded views and step-by-step procedures for front and rear wheel removal, brake disc inspection, brake pad replacement, brake caliper disassembly, brake master cylinder service, ABS hydraulic unit removal and installation, front fork disassembly and oil level setting, steering head bearing adjustment, and rear shock absorber and swingarm service.

The electrical and diagnostic sections are particularly detailed. The manual includes circuit diagrams for the ignition system, electric starting system, stop and start system, charging system, lighting system, signaling system, and fuel pump system. The self-diagnostic chapter provides DTC tables, diagnostic code tables, sensor operation tables, and actuator operation tables, along with troubleshooting procedures for each fault code.

Systems and Components Covered in Detail

Beyond the chapter list, the 2021 Yamaha Aerox 155 Service Manual includes specific data that owner’s manuals and generic guides simply do not provide. You will find engine oil capacities for both disassembled and oil-change conditions, final transmission oil quantities, coolant capacities for the radiator and reservoir, spark plug type and gap, valve clearance specifications, compression pressure ranges, and idle speed values.

Chassis specifications include tire sizes and recommended pressures, brake disc thickness limits, brake pad lining thickness limits, brake drum inside diameter limits, front fork spring free length, fork oil quantity and level, wheel runout limits, and wheel axle bending limits. Electrical specifications cover battery model and capacity, ignition coil resistance, spark plug cap resistance, charging system output, stator coil resistance, and regulator voltage.

Tightening torques are listed throughout the manual for engine, chassis, and brake components, making it possible to reassemble the vehicle to factory specifications. The cable routing diagrams show exactly how the wire harness, brake hoses, throttle cables, and control cables should be positioned, which is critical when reassembling bodywork or after a repair that involves removing the handlebar, front cowling, or engine.

Get the Complete 2021 Yamaha Aerox 155 Service Manual

The 2021 Yamaha Aerox 155 Service Manual is the right document for anyone who wants to maintain, repair, or diagnose this scooter correctly. It gives you the manufacturer’s procedures, specifications, and diagnostic tables in a single PDF that you can use on any device. The manual covers the full range of service work, from routine maintenance to engine overhaul, brake and ABS service, fuel injection diagnostics, and electrical troubleshooting.

Using the correct procedures and torque values matters. A scooter like the Aerox 155 has specific tolerances and service limits; guessing at them can lead to poor performance, premature wear, or unsafe conditions. This manual removes the guesswork by providing the exact numbers and step-by-step methods that Yamaha specifies.

Delivery is instant. After purchase, you receive the PDF file immediately — no shipping, no waiting for a physical book. You can view it on a computer, tablet, or smartphone, and print the pages you need for the workshop. Whether you are a professional technician or a dedicated owner performing your own maintenance, this manual gives you the information to do the job properly.

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