engine YAMAHA NEO115 2002 User Guide

5-1
5
EAU00372
5-OPERATION AND IMPORTANT RIDING POINTS
EAU00373*
WARNING
_

Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.


Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.


For safety, always start the en-
gine with the centerstand.


Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
_
EAU00416*
Starting and warming up a
cold engine
EC000046
CAUTION:_ See page 5-4 for engine break-in in-
structions prior to operating the ve-
hicle for the first time. _1. Turn the key to “ON”.
2. Turn on the starter (choke) and
completely close the throttle grip.
(See page 3-6 for starter (choke)
operation.)3. Start the engine by pushing the
start switch, while applying the
front or rear brake or by pushing
the kickstarter lever down.
NOTE:_ If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 5 seconds on any one
attempt. If the engine does not start
with the starter motor, try using the
kickstarter with the motorcycle on the
centerstand. _
1. Starter (choke) lever “”
1. Start switch “START”
2. Kickstarter
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OPERATION AND IMPORTANT RIDING POINTS
5-2
54. After starting the engine, move the
starter (choke) back about half-
way.
ECA00055
CAUTION:_ For maximum engine life, always
warm the engine up before starting
off. Never accelerate hard when the
engine is cold! _5. When the engine is warm, turn the
starter (choke) off.NOTE:_ For maximum engine life, always warm
up the engine before riding your motor-
cycle. Never accelerate hard with a
cold engine. _
EAU01258
Starting a warm engine Follow the same procedure as for start-
ing a cold engine with the exception
that the starter (choke) is not required
when the engine is warm.
EAU00433*
Starting off NOTE:_ Before starting off, allow the engine to
warm up. _1. While pulling the rear brake lever
with your left hand and holding the
grab bar with your right hand, push
the motorcycle off the centerstand.
2. Sit astride the seat, and then ad-
just the rear view mirrors.
3. Switch the turn signal on.
4. Check for oncoming traffic, and
then slowly turn the throttle grip
(on the right) in order to take off.
5. Switch the turn signal off.
U5MXE0.book Page 2 Thursday, December 20, 2001 2:08 PM

OPERATION AND IMPORTANT RIDING POINTS
5-4
5
EAU00436
Engine break-in There is never a more important period
in the life of your engine than the period
between 0 and 1,000 km. For this rea-
son, you should read the following ma-
terial carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1,000 km. The various parts in the en-
gine wear and polish themselves to the
correct operating clearances. During
this period, prolonged full-throttle oper-
ation or any condition that might result
in engine overheating must be avoided.
EAU00447*
0–150 km

Avoid prolonged operation above
1/3 throttle.


After every hour of operation, stop
the engine, and then let it cool for
five to ten minutes.


Vary the engine speed from time
to time. Do not operate the engine
at one set throttle position.
150–500 km


Avoid prolonged operation above
1/2 throttle.


Rev the engine freely through the
gears, but do not use full throttle at
any time.
EC000058*
CAUTION:_ After 500 km of operation, the en-
gine oil and the final transmission
oil must be changed and the engine
oil strainer cleaned. _
500–1,000 km
Avoid prolonged operation above
3/4 throttle.
1,000 km and beyond
Avoid prolonged full-throttle operation.
Vary the speed occasionally.
EC000049
CAUTION:_ If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle. _
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OPERATION AND IMPORTANT RIDING POINTS
5-5
5
EAU00460
Parking When parking, stop the engine, and
then remove the key from the main
switch.
EW000058
WARNING
_

Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.


Do not park on a slope or on
soft ground, otherwise the
motorcycle may overturn.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
EAU03057*
NOTE:_

From 16,000 km, repeat the maintenance intervals starting from 4,000 km.


Depending on riding conditions, the V-belt replacement interval may vary.


The air filter needs more frequent service if you are riding in unusually wet or dusty areas.


Hydraulic brake system
After disassembling the brake master cylinder, and caliper cylinder, always change the fluid. Regularly check the
brake fluid level and fill reservoir as required.
Replace the oil seals on the inner parts of the brake master cylinder and caliper cylinder every two years.
Replace the brake hose every four years or if cracked or damaged.
_16
*Shock absorber
assembliesCheck operation and shock absorbers for oil leakage.√√√√
17*CarburetorCheck starter (choke) operation.
Adjust engine idling speed.√√√√√
18 Engine oilChange.
Check oil level and vehicle for oil leakage.√√Every 2,000 km
19*Engine oil strainer
Clean.√√
20 Final transmission oilCheck vehicle for oil leakage.√√√√√
Change.√Every 10,000 km
21*V-beltCheck the damage and wear.√√√
Replace. Every 25,000 km (See NOTE.)
22*Front and rear brake
switchesCheck operation.√√√√√
23 Moving parts and cables
Lubricate.√√√√
24*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×1,000 km)
0.5 2 4 8 12
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6
EAUT0004*
Checking the spark plug The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plug can re-
veal the condition of the engine.
To remove the spark plug
1. Remove panel A. (See page 6-4
for panel removal and installation
procedures.)
2. Remove the spark plug cap.3. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner’s tool kit.To check the spark plug
1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the motor-
cycle is ridden normally).
NOTE:_ If the spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle. _2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if
necessary.
1. Spark plug cap
1. Spark plug wrench
Specified spark plug:
CR7HSA (NGK)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
EAUT0016*
Engine oil and oil strainer The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil strainer
cleaned at the intervals specified in the
periodic maintenance and lubrication
chart.
To check the engine oil level
1. Place the motorcycle on the cen-
terstand.NOTE:_ Make sure that the motorcycle is posi-
tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading. _2. Start the engine, warm it up for
several minutes, and then turn it
off.3. Wait a few minutes until the oil set-
tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in), and then remove it
again to check the oil level.
NOTE:_ The engine oil should be between the
minimum and maximum level marks. _4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
1. Engine oil filler cap
1. Dipstick
2. Maximum level mark
3. Minimum level mark
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6 To change the engine oil and clean
the oil strainer
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap
and drain bolts to drain the oil from
the crankcase.
NOTE:_ When only changing the engine oil, re-
move engine oil drain bolt A only. _
EC000070*
CAUTION:_ When removing the engine oil drain
bolt B, the O-ring, spring, and oil
strainer will fall out. Take care not to
lose these parts. _4. Clean the oil strainer with solvent,
and then check it for damage and
replace it if necessary.
5. Check the O-ring for damage and
replace it if necessary.
6. Install the oil strainer, spring, O-ring
and engine oil drain bolts, and then
tighten the drain bolts to the speci-
fied torque.
1. Engine oil drain bolt A
2. Engine oil drain bolt B
1. Strainer
2. Compression spring
3. O-ring
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
6
NOTE:_ Make sure that the O-ring is properly
seated. _7. Add the specified amount of the
recommended engine oil, and
then install and tighten the engine
oil filler cap.
ECA00105
CAUTION:_

In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives with
the oil or use oils of grade “CD”
or higher. In addition, do not
use oils labeled “ENERGY CON-
SERVING II” or higher.


Make sure that no foreign mate-
rial enters the crankcase.
_8. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.
9. Turn the engine off, and then
check the oil level and correct it if
necessary.
EAU04228*
Final transmission oil The final transmission case must be
checked for oil leakage before each
ride. If any leakage is found, have a
Yamaha dealer check and repair the
motorcycle. In addition, the final trans-
mission oil must be changed as follows
at the intervals specified in the periodic
maintenance and lubrication chart.
1. Start the engine, warm it up by
riding the motorcycle for several
minutes, and then stop the engine.
2. Place the motorcycle on the cen-
terstand.
3. Place an oil pan under the final
transmission case to collect the
used oil. Tightening torques:
Engine oil drain bolt A:
20 Nm (2.0 m·kgf)
Engine oil drain bolt B:
20 Nm (2.0 m·kgf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Periodic oil change:
0.8 L
Total amount (dry engine):
0.9 L1. Oil filler cap
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
63. Remove the air filter elements,
and then blow out the dirt with
compressed air as shown.4. Check each air filter element for
damage and replace them if nec-
essary.
5. Install the air filter elements.
6. Install V-belt case air filter cover B
by installing the bolts.7. Install V-belt case air filter cover A
by installing the bolts.
EC000092*
CAUTION:_

Make sure that each filter ele-
ment is properly seated in its
case.


The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston and/or cylinder may be-
come excessively worn.
_
1. Air filter element (× 2)U5MXE0.book Page 15 Thursday, December 20, 2001 2:08 PM