YAMAHA NEO115 2002 Workshop Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
6
EAU00732
Checking the brake fluid level Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake flu-
id level may indicate worn brake pads
and/or brake system leakage. If the
brake level is low, be sure to check the
brake pads for wear and the brake sys-
tem for leakage.Observe these precautions:


When checking the fluid level,
make sure that the top of the mas-
ter cylinder is level by turning the
handlebars.


Use only the recommended quali-
ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.
NOTE:_ If DOT 4 is not available, DOT 3 can be
used. _

Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.


Be careful that water does not en-
ter the master cylinder when refill-
ing. Water will significantly lower
the boiling point of the fluid and
may result in vapor lock.


Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.


As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
1. Minimum level mark
Recommended brake fluid: DOT 4
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6
EAU03985
Changing the brake fluid Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addition,
have the oil seals of the brake master
cylinder and caliper as well as the
brake hose replaced at the intervals
listed below or whenever they are dam-
aged or leaking.

Oil seals: Replace every two
years.


Brake hose: Replace every four
years.
EAU00770*
Checking the V-belt The V-belt must be checked by a
Yamaha dealer at the intervals speci-
fied in the periodic maintenance and lu-
brication chart.NOTE:_ It is recommended to replace the V-belt
every 25,000 km. _
EAU02962
Checking and lubricating the
cables The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
EW000112
WARNING
_ Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions. _Recommended lubricant:
Engine oil
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
EAU04034
Checking and lubricating the
throttle grip and cable The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated or
replaced at the intervals specified in
the periodic maintenance chart.
EAU03118
Lubricating the front and rear
brake levers The pivoting points of the front and rear
brake levers must be lubricated at the
intervals specified in the periodic main-
tenance and lubrication chart.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
6
EAU03371
Checking and lubricating the
centerstand and sidestand The operation of the centerstand and
sidestand should be checked before
each ride, and the pivots and metal-to-
metal contact surfaces should be lubri-
cated if necessary.
EW000114
WARNING
_ If the centerstand or sidestand does
not move up and down smoothly,
have a Yamaha dealer check or re-
pair it. _
EAU02939
Checking the front fork The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
EW000115
WARNING
_ Securely support the motorcycle so
that there is no danger of it falling
over. _Check the inner tubes for scratches,
damage and excessive oil leakage.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6 To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
EC000098
CAUTION:_ If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it. _
EAU00794
Checking the steering Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
EW000115
WARNING
_ Securely support the motorcycle so
that there is no danger of it falling
over. _
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steer-
ing.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
6
EAU01144
Checking the wheel bearings The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.
EAU03806*
Battery A poorly maintained battery will cor-
rode and discharge quickly. The elec-
trolyte level, battery lead connections
and breather hose routing should be
checked before each ride and at the in-
tervals specified in the periodic mainte-
nance and lubrication chart.
To check the electrolyte level
1. Remove panel A. (See page 6-4
for panel removal and installation
procedures.)2. Unhook the battery band, and then
disconnect the negative battery
lead from the battery.
3. Pull the battery breather hose out
as shown.
4. Pull the battery out of the battery
compartment.
1. Negative battery lead
2. Battery band
3. Battery breather hose
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6 5. Place the battery on a level sur-
face, and then check the electro-
lyte level in the battery.
NOTE:_ The electrolyte should be between the
minimum and maximum level marks. _6. If the electrolyte is at or below the
minimum level mark, add distilled
water to raise the electrolyte to the
maximum level mark.
EW000116
WARNING
_

Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al-
ways shield your eyes when
working near batteries. In case
of contact, administer the fol-
lowing FIRST AID.
EXTERNAL: Flush with plenty
of water.
INTERNAL: Drink large quan-
tities of water or milk and im-
mediately call a physician.
EYES: Flush with water for
15 minutes and seek prompt
medical attention.


Batteries produce explosive hy-
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro-
vide sufficient ventilation when
charging it in an enclosed
space.


KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
_
EC000100
CAUTION:_ Use only distilled water, as tap water
contains minerals that are harmful
to the battery. _7. Check and, if necessary, tighten
the positive battery lead to the
positive battery terminal.
8. Place the battery in the battery
compartment.
9. Connect and tighten the negative
battery lead to the negative battery
terminal.
1. Maximum level mark
2. Minimum level markU5MXE0.book Page 30 Thursday, December 20, 2001 2:08 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
610. Place the breather hose into the
original position and make sure
that it is properly routed.
11. Hook the battery band onto the
holder.
12. Install the panel.
To store the battery
1. If the motorcycle will not be used
for more than one month, remove
the battery, fully charge it, and
then place it in a cool, dry place.2. If the battery will be stored for
more than two months, check the
specific gravity of the electrolyte at
least once a month and fully
charge the battery whenever nec-
essary.
3. Fully charge the battery before in-
stallation.
4. After installation, make sure that
the battery leads are properly con-
nected to the battery terminals and
that the breather hose is properly
routed, in good condition, and not
obstructed.
EC000099
CAUTION:_ If the breather hose is positioned in
such a way that the frame is ex-
posed to electrolyte or gas expelled
from the battery, the frame could
suffer structural and external dam-
ages. _
EAU01307*
Replacing the fuse The fuse is located behind panel A.
(See page 6-4 for panel removal and
installation procedures.)
If the fuse is blown, replace it as fol-
lows.
1. Turn the key to “OFF” and turn off
all electrical circuits.
2. Pull the battery out of the battery
compartment. (See page 6-29, “To
check the electrolyte level” for bat-
tery removal and installation pro-
cedures.)
1. Battery breather hoseU5MXE0.book Page 31 Thursday, December 20, 2001 2:08 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
6 3. Pull the starter relay out.
4. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
EC000103
CAUTION:_ Do not use a fuse of a higher amper-
age rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire. _
5. Place the starter relay into the
original position.
6. Place the battery in the battery
compartment.
7. Turn the key to “ON” and turn on
the electrical circuits to check if the
devices operate.
8. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
1. Starter relay
1. Fuse
2. Spare fuseSpecified fuse: 10 A
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
6
EAU04134*
Replacing a headlight bulb If a headlight bulb burns out, replace it
as follows.
EC000107
CAUTION:_ It is advisable to have a Yamaha
dealer perform this job. _1. Place the motorcycle on the cen-
terstand.
2. Remove cowling A. (See page 6-5
for cowling removal and installa-
tion procedures.)3. Remove the headlight bulb cover
by turning it counterclockwise.4. Remove the socket by pushing it
in and turning it counterclockwise.
5. Remove the defective bulb.
EW000119
WARNING
_ Headlight bulbs get very hot. There-
fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down. _6. Place a new headlight bulb into
position.
7. Install the socket by pushing it in
and turning it clockwise.
1. Headlight bulb cover (× 2)
1. Headlight bulb socket (× 2)
U5MXE0.book Page 33 Thursday, December 20, 2001 2:08 PM