2002 YAMAHA NEO115 check engine

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6 To change the engine oil and clean
the oil strainer
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap
and drain bolts to drain the oil from
the crankcase.
NOTE:_ When only changing the engine oil, re-
move engine oil drain bolt A only. _
EC000070*
CAUTION:_ When removing the engine oil drain
bolt B, the O-ring, spring, and oil
strainer will fall out. Take care not to
lose these parts. _4. Clean the oil strainer with solvent,
and then check it for damage and
replace it if necessary.
5. Check the O-ring for damage and
replace it if necessary.
6. Install the oil strainer, spring, O-ring
and engine oil drain bolts, and then
tighten the drain bolts to the speci-
fied torque.
1. Engine oil drain bolt A
2. Engine oil drain bolt B
1. Strainer
2. Compression spring
3. O-ring
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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
6-15
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

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
6-25
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
6-28
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.
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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