Target Audience:
Yamaha AL115 owners, independent repair shops, and automotive technicians working on scooters of this era.
Manual Value:
Provides critical technical data often unavailable in owner's manuals, enabling comprehensive maintenance and repair, thus reducing reliance on expensive dealership services.
Completeness:
The 'COMPLETE official full factory service repair manual' designation signifies comprehensive coverage across all aspects of the vehicle.
Usability:
Downloadable PDF format allows for selective printing of pages, offering practical convenience for workshop use.
Engine Service:
Full engine overhaul, disassembly, assembly, inspection, and adjustment procedures.
Fuel System:
Carburetor servicing, fuel pump, fuel filter, fuel lines, and tank inspection.
Cooling System:
Radiator, fan, thermostat, water pump, and coolant flow diagnostics.
Transmission Service:
Automatic transmission disassembly, inspection, clutch operation, and torque converter.
Brakes:
Front and rear brake system servicing, including hydraulic components, pads, rotors, and bleeding procedures.
Electrical System:
Wiring diagrams, battery, starter motor, charging system (alternator/stator), ignition system, lighting, and fuses.
Suspension:
Front fork servicing, rear shock absorber inspection and replacement, and linkage system.
Steering:
Handlebar assembly, steering stem bearings, and related components.
Chassis And Bodywork:
Frame inspection, body panel removal and installation, seat, and storage compartment.
Wheels And Tires:
Tire inspection, replacement, wheel bearing maintenance, and pressure specifications.
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, chain adjustment (if applicable), and general lubrication.
Troubleshooting:
Diagnostic charts for common problems, symptom-based troubleshooting, and fault finding.
Repair Procedures:
Step-by-step instructions for component removal, repair, and reassembly.
Overhaul Instructions:
Detailed procedures for complete engine, transmission, and suspension overhauls.
Electrical Diagnostics:
Testing electrical components, circuits, and using multimeters.
Specification Settings:
Torque specifications, valve clearances, ignition timing, and carburetor adjustments.
Depth:
Comprehensive factory-level detail suitable for professional technicians and advanced DIY mechanics.
Diagnostic Level:
In-depth diagnostic procedures for all major systems, including electrical and mechanical fault finding.
Rebuild Capability:
Enables complete engine, transmission, and component rebuilds with detailed instructions and specifications.
Engine Type:
Likely a 4-stroke, air-cooled, single-cylinder engine (typical for this class of scooter).
Displacement:
Specific displacement not provided but expected to be around 115cc or similar, based on model nomenclature. Consult manual for exact figure.
Horsepower:
Refer to manual for specific horsepower and torque figures for the 2003-2005 AL115 models.
Torque:
Refer to manual for specific horsepower and torque figures for the 2003-2005 AL115 models.
Carburetor Type:
Likely a Keihin or similar brand carburetor. Manual will detail model and settings.
Fuel Type:
Unleaded gasoline (refer to manual for octane rating recommendation).
Ignition Type:
CDI (Capacitor Discharge Ignition) is typical for this era.
Oil Type:
Yamaha recommends specific motorcycle engine oil grades (e.g., Yamalube) - manual will specify.
Oil Capacity:
Manual will provide exact oil capacity for engine oil changes.
Length:
Refer to manual for exact dimensions.
Width:
Refer to manual for exact dimensions.
Height:
Refer to manual for exact dimensions.
Dry Weight:
Refer to manual for exact dry weight.
Curb Weight:
Refer to manual for exact curb weight.
Front Tire Size:
Manual will specify exact tire size and pressure (e.g., 100/90-10).
Rear Tire Size:
Manual will specify exact tire size and pressure (e.g., 110/90-10).
Wheel Type:
Likely cast alloy or steel wheels.
Bolt Pattern:
Refer to manual for wheel bolt pattern (if applicable, many scooters have hub-centric mounting).
Instrument Cluster:
Analog or digital speedometer, odometer, fuel gauge, and indicator lights (turn signals, oil, high beam).
ABS:
Anti-lock Braking System (ABS) was generally not a standard feature on scooters of this displacement and era, but manual should clarify.
Features:
No advanced connectivity features like Bluetooth or smartphone integration are expected for this model year.
Oil Change Interval:
Manual will specify mileage or time interval for engine oil and filter changes (e.g., every 3,000-5,000 km).
Spark Plug Replacement:
Manual will detail recommended intervals for spark plug inspection and replacement.
Air Filter Maintenance:
Manual will provide schedule for air filter cleaning or replacement.
Engine Oil Grade:
Specific Yamalube or equivalent API SG/SH/SJ (or higher) SAE 10W-40 or 20W-50 recommended, per manual.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid, as specified in the manual.
Common Wear Items:
Brake pads, tires, drive belt (CVT), and battery are common wear items. Manual provides inspection guidelines.
Carburetor Cleaning:
Carburetors may require periodic cleaning and adjustment, especially if the scooter has been stored for extended periods.
Manufacturer:
Yamaha Motor Corporation, a Japanese manufacturer renowned for motorcycles, marine products, and musical instruments.
Al Series:
The AL series likely represents a line of practical, commuter-oriented scooters from Yamaha, focusing on reliability and ease of use.
Manufacturing Location:
Likely manufactured in Yamaha's overseas production facilities, common for scooters of this class.
