wheel YAMAHA NEO115 2002 Owners Manual

TABLE OF CONTENTS
Tires ................................................................ 6-19
Spoke wheels .................................................. 6-21
Checking the front brake lever free play .......... 6-21
Adjusting the rear brake lever free play .......... 6-22
Checking the front brake pads and rear
brake shoes ................................................. 6-23
Checking the brake fluid level ......................... 6-24
Changing the brake fluid ................................. 6-25
Checking the V-belt ......................................... 6-25
Checking and lubricating the cables ............... 6-25
Checking and lubricating the throttle grip
and cable ..................................................... 6-26
Lubricating the front and rear brake levers ..... 6-26
Checking and lubricating the centerstand
and sidestand .............................................. 6-27
Checking the front fork .................................... 6-27
Checking the steering ..................................... 6-28
Checking the wheel bearings .......................... 6-29
Battery ............................................................. 6-29
Replacing the fuse .......................................... 6-31
Replacing a headlight bulb .............................. 6-33
Replacing a front turn signal light bulb ............ 6-34
Replacing the tail/brake light bulb or a rear
turn signal light bulb .................................... 6-35
Troubleshooting .............................................. 6-37
Troubleshooting chart ..................................... 6-38MOTORCYCLE CLEANING AND STORAGE ..... 7-1
A. CLEANING .................................................... 7-1
B. STORAGE ..................................................... 7-1
SPECIFICATIONS ............................................... 8-1
Specifications .................................................... 8-1
CONSUMER INFORMATION.............................. 9-1
Identification numbers ....................................... 9-1
Frame serial number ......................................... 9-1
Engine serial number ........................................ 9-1
789
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4-1
4
EAU01114
4-PRE-OPERATION CHECKS
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-
tion, to check the following points before each ride.
EAU03439
Pre-operation check list
CO-01E
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-5
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-9
Final transmission oil
Check vehicle for oil leakage. 6-11–6-12
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-21–6-24
Rear brakeCheck operation.
Check lever free play.
Adjust if necessary.6-22–6-23
Throttle gripMake sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.6-17–6-18, 6-26
Control cablesMake sure that operation is smooth.
Lubricate if necessary.6-25
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-19–6-21
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU00473
Periodic maintenance and lubrication chart
CP-03ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×1,000 km)
0.5 2 4 8 12
1*Fuel line
Check fuel hoses and vacuum hose for cracks or damage.√√√√
2 Spark plugCheck condition.
Clean and regap.√√√√√
Replace if necessary.√√√
3*ValvesCheck valve clearance.
Adjust.√√√√√
4 Air filter element
Clean. Replace if necessary.√√√√
5V-belt case air filter
elementsClean. Replace if necessary.√√√√
6*BatteryCheck electrolyte level and specific gravity.
Make sure that the breather hose is properly routed.√√√√
7*Front brakeCheck operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-3.)
Replace brake pads if necessary.√√√√√
8*Rear brakeCheck operation and adjust brake lever free play.
Replace brake shoes if necessary.√√√√√
9*WheelsCheck runout, spoke tightness and for damage.
Tighten spokes if necessary.√√√√
10*Wheel bearings
Check bearing for looseness or damage.√√√√
11*SwingarmCheck operation and for excessive play.
Lubricate with lithium-soap based grease, every 24,000 km.√√√√
12*Steering bearingsCheck bearing play and steering for roughness.
Lubricate with lithium-soap-based grease, every 12,000 km.√√√√√
13*Chassis fasteners
Make sure that all nuts, bolts and screws are properly tightened.√√√√
14 Sidestand/centerstandCheck operation.
Lubricate.√√√√
15*Front fork
Check operation and for oil leakage.√√√√
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6 4. Remove the oil filler cap and drain
bolt to drain the oil from the final
transmission case.
5. Install the final transmission oil
drain bolt, and then tighten it to the
specified torque.
6. Add the specified amount of the
recommended final transmission
oil, and then install and tighten the
oil filler cap.
EWA00062
WARNING
_

Make sure that no foreign mate-
rial enters the final transmis-
sion case.


Make sure that no oil gets on
the tire or wheel.
_7. Check the final transmission case
for oil leakage. If oil is leaking,
check for the cause.
1. Final transmission oil drain boltTightening torque:
Final transmission oil drain bolt:
22 Nm (2.2 m·kgf)
Recommended final transmission
oil:
See page 8-1.
Oil quantity:
0.1 L
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6 Tire inspection
The tires must be checked before each
ride. If the tire shows crosswise lines
(minimum tread depth), if the tire has a
nail or glass fragments in it, or if the
sidewall is cracked, have a Yamaha
dealer replace the tire immediately.
CE-23ENOTE:_ The tire tread depth limits may differ
from country to country. Always comply
with the local regulations. _
EW000079
WARNING
_

Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding sta-
bility and can lead to loss of
control.


The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.
_
Tire information
This motorcycle is equipped with tube
tires.
EW000078
WARNING
_

The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the motor-
cycle cannot be guaranteed.


After extensive tests, only the
tires listed below have been ap-
proved for this model by
Yamaha Motor Co., Ltd.
_CE-10E
1. Sidewall
2. Tire wear indicator
a. Tire tread depthMinimum tire tread depth
(front and rear)1.0 mm
FRONT
Manufacturer Size Model
Dunlop 70/90-16 36P D110
REAR
Manufacturer Size Model
Dunlop 80/90-16 43P D110
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6
EAU00680
WARNING
_

It is dangerous to ride with a
worn-out tire. When a tire tread
begins to show crosswise lines,
have a Yamaha dealer replace
the tire immediately.


The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.


It is not recommended to patch
a punctured tube. If unavoid-
able, however, patch the tube
very carefully and replace it as
soon as possible with a high-
quality product.
_
EAU00685
Spoke wheels To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified wheels.

The wheel rims should be checked
for cracks, bends or warpage, and
the spokes for looseness or dam-
age before each ride. If any dam-
age is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.


The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.


Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
EAU03851*
Checking the front brake lever
free playSince this model is equipped with a hy-
draulic front brake, adjusting the brake
lever free play is not needed.
However, it is necessary to check the
brake fluid level and check the hydrau-
lic system for leakage.1. Front brake lever
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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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7-1
7
EAK00000
7-MOTORCYCLE CLEANING AND STORAGE
EAK01302*
A. CLEANINGFrequent, thorough cleaning of your
motorcycle will not only enhance its ap-
pearance but will improve its general
performance and extend the useful life
of many components.
1. Rinse the dirt and degreaser off
with a garden hose.
EUU34602
CAUTION:_Excessive hose pressure may cause
water seepage and deterioration of
wheel bearings, front fork, brakes,
transmission seals and electrical
parts.2. After cleaning the motorcycle, dry
all surfaces with a chamois, clean
towel, or soft absorbent cloth.
3. Automotive-type wax may be ap-
plied to all painted and chrome-
plated surfaces. When finished,
start the engine and let it idle for
several minutes.
EAK00700*
B. STORAGELong term storage (60 days or more) of
your motorcycle will require some pre-
ventive procedures to guard against
deterioration. After thoroughly cleaning
the motorcycle, prepare for storage as
follows:
1. Drain the fuel tank, fuel lines, and
carburetor float bowl(s).
2. Lubricate all control cables.
3. Block up the frame to raise both
wheels off the ground.
4. Tie a plastic bag over the exhaust
pipe outlet to prevent moisture
from entering.
5. If storing in a humid or salt-air at-
mosphere, coat all exposed metal
surfaces with a light film of oil. Do
not apply oil to any rubber parts or
the seat cover.6. Remove the battery and charge it.
Store it in a dry place and re-
charge it once a month. Do not
store the battery in an excessively
warm or cold place (less than 0°C
or more than 30°C).
EUU05800
NOTE:_Make any necessary repairs before
storing the motorcycle.
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8-1
8
EAU01038
8-SPECIFICATIONS
Specifications CS-01E
Model AT115
Dimensions
Overall length 1,935 mm
Overall width 675 mm
Overall height 1,070 mm
Seat height 755 mm
Wheelbase 1,280 mm
Ground clearance 135 mm
Minimum turning radius 1,900 mm
Basic weight (with oil and full
fuel tank)
103 kg
Maximum load*
116 kg
* Total weight of rider, passenger, cargo and accessories
Engine
Engine type Forced air-cooled 4-stroke,
SOHC
Cylinder arrangement Forward inclined single cylinder
Displacement 113.7 cm
3
Bore × stroke 50.0 × 57.9 mm
Compression ratio 8.8:1
Starting system Electric and kickstarter
Lubrication system Wet sumpEngine oil
Ty p eSAE 20W-50 API Service “SF”
type motor oil
Capacity
Periodic oil change 0.8 L
Total amount (dry engine) 0.9 L
Final transmission oil
Type SAE 10W-40 API Service “SE”
type motor oil
Quantity 0.1 L
Air filter
Dry element
Fuel
Type REGULAR GASOLINE
Fuel tank capacity 4.9 L
Carburetor
Manufacturer MIKUNI
Model × quantity BS25 × 1
Spark plug
Manufacturer/Type NGK / CR7HSA
Gap 0.6–0.7 mm
Clutch type
V-belt automatic
U5MXE0.book Page 1 Thursday, December 20, 2001 2:08 PM