brake YAMAHA NEO115 2002 User Guide
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2002, Model line: NEO115, Model: YAMAHA NEO115 2002Pages: 72, PDF Size: 4.08 MB
Page 29 of 72
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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Page 30 of 72
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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Page 47 of 72
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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Page 48 of 72
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
6-22
6
EW000099*
WARNING
_ A soft or spongy feeling in the brake
lever can indicate the presence of
air in the hydraulic system. If there
is air in the hydraulic system, have a
Yamaha dealer bleed the system be-
fore operating the motorcycle. Air in
the hydraulic system will diminish
the braking performance, which
may result in loss of control and an
accident. _
EAU00704*
Adjusting the rear brake lever
free play The rear brake lever free play should
measure 10–20 mm as shown. Period-
ically check the rear brake lever free
play and, if necessary, adjust it as fol-
lows.To increase the rear brake lever free
play, turn the adjusting nut at the brake
shoe plate in direction a. To decrease
the rear brake lever free play, turn the
adjusting nut in direction b.
EW000101
WARNING
_ If proper adjustment cannot be ob-
tained as described, have a Yamaha
dealer make this adjustment. _
a. Rear brake lever free play
1. Rear brake lever free play adjusting nut
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Page 50 of 72
PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6
EAU00720
Checking the front brake pads
and rear brake shoes The front brake pads and the rear
brake shoes must be checked for wear
at the intervals specified in the periodic
maintenance and lubrication chart.
EAU03938
Front brake pads
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wear
indicator grooves have almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
EAU04502
Rear brake shoes
The rear brake is provided with a wear
indicator, which allows you to check the
brake shoe wear without having to dis-
assemble the brake. To check the
brake shoe wear, check the position of
the wear indicator while applying the
brake. If a brake shoe has worn to the
point that the wear indicator reaches
the wear limit line, have a Yamaha
dealer replace the brake shoes as a
set.
1. Brake pad wear indicator groove (× 3)Front
1. Brake shoe wear indicator
2. Brake shoe wear limit lineRear
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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
6-28
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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