2002 YAMAHA NEO115 brake

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
U5MXE0.book Page 1 Thursday, December 20, 2001 2:08 PM

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

DESCRIPTION
2-3
2
Controls and instruments1. Rear brake lever (page 3-4)
2. Starter choke lever (page 3-6)
3. Left handlebar switches (page 3-3)
4. Speedometer unit (page 3-2)5. Fuel gauge (page 3-2)
6. Start switch (page 3-3)
7. Throttle grip (page 6-17)
8. Front brake lever (page 3-4)
U5MXE0.book Page 3 Thursday, December 20, 2001 2:08 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-4
3
EAU03882
Front brake lever The front brake lever is located on the
right handlebar grip. To apply the front
brake, pull this lever toward the handle-
bar grip.
EAU00163
Rear brake lever The rear brake lever is located on the
left handlebar grip. To apply the rear
brake, pull this lever toward the handle-
bar grip.
EAU03468*
Fuel tank cap To remove the fuel tank cap
1. Open the seat. (See page 3-6 for
seat opening and closing proce-
dures.)
2. Turn the fuel tank cap counter-
clockwise and pull it off.
1. Front brake lever
1. Rear brake lever
1. Fuel tank cap
a. Open.
b. Close.
U5MXE0.book Page 4 Thursday, December 20, 2001 2:08 PM

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
U5MXE0.book Page 1 Thursday, December 20, 2001 2:08 PM

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

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