engine YAMAHA NEO115 2002 Owners Manual

Engine start procedure
Engine oil replacement
V-belt inspection
Load limit Before pushing start button, make sure to
apply the Front or Rear Brake and that the
Sidestand is retracted.
Engine oil replacement : Every 2000 km.
Recommended oil : SAE20W - 50 type
SF Class Motor Oil
Convenience hook : 1 kg, Helmet box: 5 kg
5MX-F835Y-00
Periodic maintenance must be performed
by any authorized Yamaha Dealer (Refer to
the Owner's Manual for details.)

EAU00009
TABLE OF CONTENTS
GIVE SAFETY THE RIGHT OF WAY .................1-1
DESCRIPTION ...................................................2-1
Left view .............................................................2-1
Right view...........................................................2-2
Controls and instruments ...................................2-3
INSTRUMENT AND CONTROL FUNCTIONS ....3-1
Main switch/steering lock ..................................3-1
Indicator lights ...................................................3-2
Speedometer unit ..............................................3-2
Fuel gauge ........................................................3-2
Handlebar switches ...........................................3-3
Front brake lever ...............................................3-4
Rear brake lever ................................................3-4
Fuel tank cap .....................................................3-4
Fuel ...................................................................3-5
Starter (choke) lever ..........................................3-6
Kickstarter .........................................................3-6
Seat ...................................................................3-6
Helmet box ........................................................3-7
Convenience hook .............................................3-8
PRE-OPERATION CHECKS ...............................4-1
Pre-operation check list .....................................4-1OPERATION AND IMPORTANT RIDING
POINTS................................................................5-1
Starting and warming up a cold engine .............5-1
Starting a warm engine .....................................5-2
Starting off .........................................................5-2
Acceleration and deceleration ...........................5-3
Braking ..............................................................5-3
Engine break-in .................................................5-4
Parking ..............................................................5-5
General note ......................................................5-6
PERIODIC MAINTENANCE AND MINOR
REPAIR................................................................6-1
Owner’s tool kit ..................................................6-1
Periodic maintenance and lubrication chart ......6-2
Removing and installing the cowling and
panels ............................................................6-4
Checking the spark plug ....................................6-7
Engine oil and oil strainer ..................................6-9
Final transmission oil .......................................6-11
Cleaning the air filter element, V-belt case
air filter elements, and check hoses ............6-13
Adjusting the carburetor ..................................6-16
Adjusting the engine idling speed ...................6-17
Adjusting the throttle cable free play ...............6-17
Adjusting the valve clearance .........................6-18
1234
56
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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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2-1
2
EAU00026
2-DESCRIPTION Left view1. Convenience hook (page 3-8)
2. Throttle stop screw (page 6-17)
3. Helmet box, Owner’s tool kit (page 3-7, page 6-1)4. Kickstarter (page 3-6)
5. Engine oil drain bolt B (page 6-10)
6. Engine oil drain bolt A (page 6-10)
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DESCRIPTION
2-2
2
Right view7. Engine oil filler cap (page 6-9)
8. Air filter element (page 6-13)
9. Battery (page 6-29)
10. Fuses (page 6-31)
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3-1
3
EAU00027
3-INSTRUMENT AND CONTROL FUNCTIONS
EAU00029
Main switch/steering lock The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering. The various
positions are described below.
EAU00030*
ON
All electrical systems are supplied with
power, and the meter lighting comes
on, and the engine can be started. The
key cannot be removed.
EAU00038
OFF
All electrical systems are off. The key
can be removed.
EAU00040
LOCK
The steering is locked, and all electrical
systems are off. The key can be re-
moved.
To lock the steering1. Turn the handlebars all the way to
the left.
2. Push the key in from the “OFF” po-
sition, and then turn it to “LOCK”
while still pushing it.
3. Remove the key.To unlock the steering
Push the key in, and then turn it to
“OFF” while still pushing it.
EW000016
WARNING
_ Never turn the key to “OFF” or
“LOCK” while the motorcycle is
moving, otherwise the electrical
systems will be switched off, which
may result in loss of control or an
accident. Make sure that the motor-
cycle is stopped before turning the
key to “OFF” or “LOCK”. _1. Push.
2. Turn.
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INSTRUMENT AND CONTROL FUNCTIONS
3-3
3
EAU00118
Handlebar switches
EAU02948*
Light switch “/”
Set the light switch to “” to turn on
the headlight and the taillight. Set this
switch to “” to turn them off.
EAU03888
Dimmer switch “/”
Set this switch to “” for the high
beam and to “” for the low beam.
EAU03889
Turn signal switch “/”
To signal a right-hand turn, push this
switch to “”. To signal a left-hand
turn, push this switch to “”. When
released, the switch returns to the cen-
ter position. To cancel the turn signal
lights, push the switch in after it has re-
turned to the center position.
EAU00130
Horn switch “HORN”
Press this switch to sound the horn.
EAU00143
Start switch “START”
Push this switch to crank the engine
with the starter.
EC000005
CAUTION:_ See page 5-1 for starting instruc-
tions prior to starting the engine. _
1. Light switch “/”
2. Dimmer switch “/”
3. Turn signal switch “/”
4. Horn switch “HORN”
1. Start switch “START”
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INSTRUMENT AND CONTROL FUNCTIONS
3-5
3
To install the fuel tank cap
1. Insert the fuel tank cap into the
tank opening and turn it clockwise
until the alignment marks on the
cap and tank are aligned.
2. Close the seat.
EW000024
WARNING
_ Make sure that the fuel tank cap is
properly installed before riding. _
EAU03753
Fuel Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.
EW000130
WARNING
_

Do not overfill the fuel tank, oth-
erwise it may overflow when the
fuel warms up and expands.


Avoid spilling fuel on the hot
engine.
_
EAU00185
CAUTION:_ Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted surfac-
es or plastic parts. _
EAU00187*
1. Fuel tank filler tube
2. Fuel level
Recommended fuel:
Regular gasoline
Fuel tank capacity:
Total amount:
4.9 L
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INSTRUMENT AND CONTROL FUNCTIONS
3-6
3
EAU03839
Starter (choke) lever “” Starting a cold engine requires a richer
air-fuel mixture, which is supplied by
the starter (choke).
Move the lever in direction a to turn on
the starter (choke).
Move the lever in direction b to turn off
the starter (choke).
EAU00214
Kickstarter To start the engine, fold out the kick-
starter lever, move it down lightly with
your foot until the gears engage, and
then push it down smoothly but force-
fully.
EAU03802*
Seat To open the seat
1. Place the motorcycle on the cen-
terstand.
2. Insert the key into the main switch,
and then turn it counterclockwise.NOTE:_ Do not push inward when turning the
key. _3. Fold the seat up.
1. Starter (choke) lever “”
1. Kickstarter
1. Open.
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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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