YAMAHA NEO115 2002 Service Manual
Manufacturer: YAMAHA, Model Year: 2002, Model line: NEO115, Model: YAMAHA NEO115 2002Pages: 72, PDF Size: 4.08 MB
Page 41 of 72
PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
6 5. Lightly tap the air filter element to
remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air.
6. Check the air filter element for
damage and replace it if neces-
sary.
7. Insert the air filter element into the
air filter case.
8. Install the air filter case cover by
installing the screws.
9. Install the panel.Cleaning the V-belt case air filter
elements
1. Remove V-belt case air filter cover
A by removing the bolts.2. Remove V-belt case air filter cover
B by removing the bolts.
1. V-belt case air filter cover A
2. Bolt (× 2)
1. V-belt case air filter cover B
2. Bolt (× 3)
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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
Page 43 of 72
PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6 To clean the air filter check hoses
1. Check each hose at the bottom of
the air filter case and the V-belt
case for accumulated dirt or water.2. If dirt or water is visible, remove
the hose, clean it, and then install
it.
EAU00629
Adjusting the carburetor The carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, most car-
buretor adjustments should be left to a
Yamaha dealer, who has the neces-
sary professional knowledge and expe-
rience. The adjustment described in
the following section, however, may be
serviced by the owner as part of routine
maintenance.
EC000094
CAUTION:_ The carburetor has been set and ex-
tensively tested at the Yamaha fac-
tory. Changing these settings
without sufficient technical knowl-
edge may result in poor perfor-
mance of or damage to the engine. _
1. Check hose (× 2)
1. Check hose
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
6
EAU01168
Adjusting the engine idling
speed The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.NOTE:_ A diagnostic tachometer is needed to
make this adjustment. _1. Attach the tachometer to the spark
plug lead.
2. Start the engine and warm it up
for several minutes at 1,000–
2,000 r/min while occasionally
revving it to 4,000–5,000 r/min.NOTE:_ The engine is warm when it quickly re-
sponds to the throttle. _
3. Check the engine idling speed
and, if necessary, adjust it to spec-
ification by turning the throttle stop
screw. To increase the engine
idling speed, turn the screw in di-
rection a. To decrease the engine
idling speed, turn the screw in di-
rection b.NOTE:_ If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment. _
EAU00634*
Adjusting the throttle cable
free play The throttle cable free play should
measure 3–7 mm at the throttle grip.
Periodically check the throttle cable
free play and, if necessary, adjust it as
follows.NOTE:_ The engine idling speed must be cor-
rectly adjusted before checking and ad-
justing the throttle cable free play. _
1. Throttle stop screwEngine idling speed:
1,500–1,700 r/min
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
6 1. Loosen the locknut.
2. To increase the throttle cable free
play, turn the adjusting nut in di-
rection a. To decrease the throttle
cable free play, turn the adjusting
nut in direction b.
3. Tighten the locknut.
NOTE:_After adjusting the throttle free play, be
sure to place the cable cover in the
original position._
EAU00637
Adjusting the valve clearance The valve clearance changes with use,
resulting in improper air-fuel mixture
and/or engine noise. To prevent this
from occurring, the valve clearance
must be adjusted by a Yamaha dealer
at the intervals specified in the periodic
maintenance and lubrication chart.
1. Throttle cable free play adjusting nut
2. Locknut
3. Cable cover
c. Throttle cable free playU5MXE0.book Page 18 Thursday, December 20, 2001 2:08 PM
Page 46 of 72
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
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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
6-22
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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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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