warning YAMAHA NEO115 2002 User Guide

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
U5MXE0.book Page 12 Thursday, December 20, 2001 2:08 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6
EAU03790*
Tires To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
EW000091
WARNING
_ The tire air pressure must be
checked and adjusted on cold tires
(i.e., when the temperature of the
tires equals the ambient tempera-
ture). _
CE-24E
CE-07EEW000087
WARNING
_ Because loading has an enormous
impact on the handling, braking, per-
formance and safety characteristics
of your motorcycle, you should keep
the following precautions in mind.

NEVER OVERLOAD THE
MOTORCYCLE! Operation of an
overloaded motorcycle may re-
sult in tire damage, loss of con-
trol, or severe injury. Make sure
that the total weight of rider, pas-
senger, cargo, and accessories
does not exceed the specified
maximum load for the vehicle.


Do not carry along loosely
packed items, which can shift
during a ride.


Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.


Adjust the tire air pressure with
regard to the load.


Check the tire condition and air
pressure before each ride.
_
Tire air pressure
(measured on cold tires)
Front Rear
200 kPa
(2.00 kgf/cm2)225 kPa
(2.25 kgf/cm
2)
Maximum load* 116 kg
* Total weight of rider, passenger, cargo and
accessories
U5MXE0.book Page 19 Thursday, December 20, 2001 2:08 PM

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
U5MXE0.book Page 20 Thursday, December 20, 2001 2:08 PM

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
U5MXE0.book Page 21 Thursday, December 20, 2001 2:08 PM

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
U5MXE0.book Page 22 Thursday, December 20, 2001 2:08 PM

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
6-27
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)
U5MXE0.book Page 27 Thursday, December 20, 2001 2:08 PM

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.
U5MXE0.book Page 28 Thursday, December 20, 2001 2:08 PM

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
6-33
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