2002 YAMAHA NEO115 transmission
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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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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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OPERATION AND IMPORTANT RIDING POINTS
5-4
5
EAU00436
Engine break-in There is never a more important period
in the life of your engine than the period
between 0 and 1,000 km. For this rea-
son, you should read the following ma-
terial carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1,000 km. The various parts in the en-
gine wear and polish themselves to the
correct operating clearances. During
this period, prolonged full-throttle oper-
ation or any condition that might result
in engine overheating must be avoided.
EAU00447*
0–150 km
Avoid prolonged operation above
1/3 throttle.
After every hour of operation, stop
the engine, and then let it cool for
five to ten minutes.
Vary the engine speed from time
to time. Do not operate the engine
at one set throttle position.
150–500 km
Avoid prolonged operation above
1/2 throttle.
Rev the engine freely through the
gears, but do not use full throttle at
any time.
EC000058*
CAUTION:_ After 500 km of operation, the en-
gine oil and the final transmission
oil must be changed and the engine
oil strainer cleaned. _
500–1,000 km
Avoid prolonged operation above
3/4 throttle.
1,000 km and beyond
Avoid prolonged full-throttle operation.
Vary the speed occasionally.
EC000049
CAUTION:_ If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle. _
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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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PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
6
NOTE:_ Make sure that the O-ring is properly
seated. _7. Add the specified amount of the
recommended engine oil, and
then install and tighten the engine
oil filler cap.
ECA00105
CAUTION:_
In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives with
the oil or use oils of grade “CD”
or higher. In addition, do not
use oils labeled “ENERGY CON-
SERVING II” or higher.
Make sure that no foreign mate-
rial enters the crankcase.
_8. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.
9. Turn the engine off, and then
check the oil level and correct it if
necessary.
EAU04228*
Final transmission oil The final transmission case must be
checked for oil leakage before each
ride. If any leakage is found, have a
Yamaha dealer check and repair the
motorcycle. In addition, the final trans-
mission oil must be changed as follows
at the intervals specified in the periodic
maintenance and lubrication chart.
1. Start the engine, warm it up by
riding the motorcycle for several
minutes, and then stop the engine.
2. Place the motorcycle on the cen-
terstand.
3. Place an oil pan under the final
transmission case to collect the
used oil. Tightening torques:
Engine oil drain bolt A:
20 Nm (2.0 m·kgf)
Engine oil drain bolt B:
20 Nm (2.0 m·kgf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Periodic oil change:
0.8 L
Total amount (dry engine):
0.9 L1. Oil filler cap
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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
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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
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