2002 YAMAHA NEO115 battery
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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
U5MXE0.book Page 2 Thursday, December 20, 2001 2:08 PM
Page 9 of 72
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)
U5MXE0.book Page 2 Thursday, December 20, 2001 2:08 PM
Page 20 of 72
PRE-OPERATION CHECKS
4-2
4
NOTE:_ Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved. _
EWA00033
WARNING
_ If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the motorcycle. _Brake leversMake sure that operation is smooth.
Lubricate lever pivoting points if necessary.6-26
Centerstand, sidestandMake sure that operation is smooth.
Lubricate pivots if necessary.6-27
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.—
Instruments, lights, signals
and switchesCheck operation.
Correct if necessary.—
BatteryCheck fluid level.
Fill with distilled water if necessary.6-29–6-31 ITEM CHECKS PAGEU5MXE0.book Page 2 Thursday, December 20, 2001 2:08 PM
Page 21 of 72
5-1
5
EAU00372
5-OPERATION AND IMPORTANT RIDING POINTS
EAU00373*
WARNING
_
Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.
Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
For safety, always start the en-
gine with the centerstand.
Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
_
EAU00416*
Starting and warming up a
cold engine
EC000046
CAUTION:_ See page 5-4 for engine break-in in-
structions prior to operating the ve-
hicle for the first time. _1. Turn the key to “ON”.
2. Turn on the starter (choke) and
completely close the throttle grip.
(See page 3-6 for starter (choke)
operation.)3. Start the engine by pushing the
start switch, while applying the
front or rear brake or by pushing
the kickstarter lever down.
NOTE:_ If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 5 seconds on any one
attempt. If the engine does not start
with the starter motor, try using the
kickstarter with the motorcycle on the
centerstand. _
1. Starter (choke) lever “”
1. Start switch “START”
2. Kickstarter
U5MXE0.book Page 1 Thursday, December 20, 2001 2:08 PM
Page 29 of 72
PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU00473
Periodic maintenance and lubrication chart
CP-03ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (
×1,000 km)
0.5 2 4 8 12
1*Fuel line
Check fuel hoses and vacuum hose for cracks or damage.√√√√
2 Spark plugCheck condition.
Clean and regap.√√√√√
Replace if necessary.√√√
3*ValvesCheck valve clearance.
Adjust.√√√√√
4 Air filter element
Clean. Replace if necessary.√√√√
5V-belt case air filter
elementsClean. Replace if necessary.√√√√
6*BatteryCheck electrolyte level and specific gravity.
Make sure that the breather hose is properly routed.√√√√
7*Front brakeCheck operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-3.)
Replace brake pads if necessary.√√√√√
8*Rear brakeCheck operation and adjust brake lever free play.
Replace brake shoes if necessary.√√√√√
9*WheelsCheck runout, spoke tightness and for damage.
Tighten spokes if necessary.√√√√
10*Wheel bearings
Check bearing for looseness or damage.√√√√
11*SwingarmCheck operation and for excessive play.
Lubricate with lithium-soap based grease, every 24,000 km.√√√√
12*Steering bearingsCheck bearing play and steering for roughness.
Lubricate with lithium-soap-based grease, every 12,000 km.√√√√√
13*Chassis fasteners
Make sure that all nuts, bolts and screws are properly tightened.√√√√
14 Sidestand/centerstandCheck operation.
Lubricate.√√√√
15*Front fork
Check operation and for oil leakage.√√√√
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Page 56 of 72
PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
6
EAU01144
Checking the wheel bearings The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.
EAU03806*
Battery A poorly maintained battery will cor-
rode and discharge quickly. The elec-
trolyte level, battery lead connections
and breather hose routing should be
checked before each ride and at the in-
tervals specified in the periodic mainte-
nance and lubrication chart.
To check the electrolyte level
1. Remove panel A. (See page 6-4
for panel removal and installation
procedures.)2. Unhook the battery band, and then
disconnect the negative battery
lead from the battery.
3. Pull the battery breather hose out
as shown.
4. Pull the battery out of the battery
compartment.
1. Negative battery lead
2. Battery band
3. Battery breather hose
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Page 57 of 72
PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6 5. Place the battery on a level sur-
face, and then check the electro-
lyte level in the battery.
NOTE:_ The electrolyte should be between the
minimum and maximum level marks. _6. If the electrolyte is at or below the
minimum level mark, add distilled
water to raise the electrolyte to the
maximum level mark.
EW000116
WARNING
_
Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al-
ways shield your eyes when
working near batteries. In case
of contact, administer the fol-
lowing FIRST AID.
EXTERNAL: Flush with plenty
of water.
INTERNAL: Drink large quan-
tities of water or milk and im-
mediately call a physician.
EYES: Flush with water for
15 minutes and seek prompt
medical attention.
Batteries produce explosive hy-
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro-
vide sufficient ventilation when
charging it in an enclosed
space.
KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
_
EC000100
CAUTION:_ Use only distilled water, as tap water
contains minerals that are harmful
to the battery. _7. Check and, if necessary, tighten
the positive battery lead to the
positive battery terminal.
8. Place the battery in the battery
compartment.
9. Connect and tighten the negative
battery lead to the negative battery
terminal.
1. Maximum level mark
2. Minimum level markU5MXE0.book Page 30 Thursday, December 20, 2001 2:08 PM
Page 58 of 72
PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
610. Place the breather hose into the
original position and make sure
that it is properly routed.
11. Hook the battery band onto the
holder.
12. Install the panel.
To store the battery
1. If the motorcycle will not be used
for more than one month, remove
the battery, fully charge it, and
then place it in a cool, dry place.2. If the battery will be stored for
more than two months, check the
specific gravity of the electrolyte at
least once a month and fully
charge the battery whenever nec-
essary.
3. Fully charge the battery before in-
stallation.
4. After installation, make sure that
the battery leads are properly con-
nected to the battery terminals and
that the breather hose is properly
routed, in good condition, and not
obstructed.
EC000099
CAUTION:_ If the breather hose is positioned in
such a way that the frame is ex-
posed to electrolyte or gas expelled
from the battery, the frame could
suffer structural and external dam-
ages. _
EAU01307*
Replacing the fuse The fuse is located behind panel A.
(See page 6-4 for panel removal and
installation procedures.)
If the fuse is blown, replace it as fol-
lows.
1. Turn the key to “OFF” and turn off
all electrical circuits.
2. Pull the battery out of the battery
compartment. (See page 6-29, “To
check the electrolyte level” for bat-
tery removal and installation pro-
cedures.)
1. Battery breather hoseU5MXE0.book Page 31 Thursday, December 20, 2001 2:08 PM