YAMAHA NEO115 2002 Repair Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
6 8. Install the headlight bulb cover by
turning it clockwise.
9. Install the cowling.
10. Have a Yamaha dealer adjust the
headlight beam if necessary.
EAUT0022*
Replacing a front turn signal
light bulb
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 socket (together with
the bulb) by turning it counter-
clockwise.
4. Remove the defective bulb.
5. Insert a new bulb into position.
6. Install the socket (together with
the bulb) by turning it clockwise.
7. Install the cowling.
1. Turn signal light bulb socket (× 2)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-35
6
EAUS0013*
Replacing the tail/brake light
bulb or a rear turn signal light
bulb
EC000107
CAUTION:_ It is advisable to have a Yamaha
dealer perform this job. _Place the motorcycle on the center-
stand.
Tail/brake light bulb
1. Remove panel B. (See page 6-5
for panel removal and installation
procedures.)2. Remove the screws, unhook the
tab from the slot, and then pull the
tail/brake light lens outward.3. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
4. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
5. Place the tail/brake light lens into
the original position, and then in-
stall the screws.
EC000108
CAUTION:_ Do not overtighten the screws, oth-
erwise the lens may break. _6. Install the panel.
1. Screw (× 2)
1. Tab
2. Slot
1. Tail/brake light bulb
U5MXE0.book Page 35 Thursday, December 20, 2001 2:08 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-36
6 Turn signal light bulb
1. Remove the tail/brake light lens.
(See “Tail/brake light bulb” for lens
removal and installation proce-
dures.)
2. Pull the turn signal light lens off. 3. Remove the defective bulb.
4. Insert a new bulb into position.
5. Place the turn signal light lens into
the original position.
6. Install the tail/brake light lens.
1. Turn signal light bulb (× 2)
U5MXE0.book Page 36 Thursday, December 20, 2001 2:08 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-37
6
EAU01008
Troubleshooting Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.
U5MXE0.book Page 37 Thursday, December 20, 2001 2:08 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-38
6
EAU03473
Troubleshooting chart
EW000125
WARNING
_ Keep away open flames and do not smoke while checking or working on the fuel system. _
CT-1FE
Check the fuel level in
the fuel tank.1. Fuel
There is
enough fuel.
There is
no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the
electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plug
and check electrodes.3. Ignition
Wet
Dry
Wipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Have a Yamaha dealer check the vehicle.
The engine does not start. Have a
Yamaha dealer check the vehicle.The engine does not start.
Check the battery.Open the throttle halfway and
operate the electric starter.
Operate the
electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.
The battery is good.Check fluid, recharge,
check connections.
U5MXE0.book Page 38 Thursday, December 20, 2001 2:08 PM

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

SPECIFICATIONS
8-2
8
Transmission
Primary reduction system Helical gear
Primary reduction ratio 3.133
Secondary reduction system Spur gear
Secondary reduction ratio 3.583
Number of drive chain
sprocket teeth (rear/front) 43/12
Transmission type V-belt automatic
Operation Centrifugal automatic type
Chassis
Frame type Steel tube underbone
Caster angle 25°
Trail 112 mm
Tires
Fro nt
Ty p e Tu b e t i r e
Size 70/90-16 36P
Manufacturer/
model Dunlop/D110
Rear
Ty p e Tu b e t i r e
Size 80/90-16 43P
Manufacturer/
model Dunlop/D110Tire air pressure
(measured on cold tires)
Front 200 kPa (2.00 kgf/cm
2)
Rear 225 kPa (2.25 kgf/cm2)
Wheels
Fr on t
Type Spoke wheel
Size 16 × 1.40
Rear
Type Spoke wheel
Size 16 × 1.60
Brakes
Fr on t
Type Single disc brake
Operation Right hand
Fluid DOT 3 or 4
Rear
Ty p e
Drum brake
Operation Left hand
Suspension
Fr on t
Ty p e
Telescopic fork
Rear
Ty p e
Unit swing
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SPECIFICATIONS
8-3
8
Spring/shock absorbers
Front Coil spring / oil damper
Rear Coil spring / oil damper
Wheel travel
Front 80 mm
Rear 55 mm
Electrical
Ignition system DC. C.D.I.
Charging system
Type A.C. magneto
Standard output 14 V, 105 W@ 5,000 r/min
Battery
Model Local made
Voltage, capacity 12 V, 7 Ah
Headlight bulb type
Incandesce bulb
Bulb voltage, wattage
× quantity
Headlight 12 V, 25/25 W × 2
Tail/brake light 12 V, 5/21 W × 1
Turn signal light 12 V, 10 W × 4
Meter lighting 12 V, 1.7 W × 1
12 V, 3.4 W × 1
High beam indicator light 12 V, 1.7 W × 1
Turn signal indicator light 12 V, 3.4 W × 2
Fuse
10 A
U5MXE0.book Page 3 Thursday, December 20, 2001 2:08 PM

9-1
9
EAU01039
9-CONSUMER INFORMATION
EAU02945*
Identification numbers Record the key identification number
and engine serial number in the spaces
provided below for assistance when or-
dering spare parts from a Yamaha
dealer or for reference in case the vehi-
cle is stolen.
1. FRAME SERIAL NUMBER:CA-02E2. ENGINE SERIAL NUMBER: CA-02EEAU01046
Frame serial number The frame serial number is stamped
into the frame.NOTE:_ The frame serial number is used to
identify your motorcycle and may be
used to register your motorcycle with
the licensing authority in your area. _
EAU01048*
Engine serial number The engine serial number is stamped
into the final transmission case.
1. Frame serial number
1. Engine serial number
U5MXE0.book Page 1 Thursday, December 20, 2001 2:08 PM