2002 YAMAHA NEO115 check engine

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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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
5-2
54. After starting the engine, move the
starter (choke) back about half-
way.
ECA00055
CAUTION:_ For maximum engine life, always
warm the engine up before starting
off. Never accelerate hard when the
engine is cold! _5. When the engine is warm, turn the
starter (choke) off.NOTE:_ For maximum engine life, always warm
up the engine before riding your motor-
cycle. Never accelerate hard with a
cold engine. _
EAU01258
Starting a warm engine Follow the same procedure as for start-
ing a cold engine with the exception
that the starter (choke) is not required
when the engine is warm.
EAU00433*
Starting off NOTE:_ Before starting off, allow the engine to
warm up. _1. While pulling the rear brake lever
with your left hand and holding the
grab bar with your right hand, push
the motorcycle off the centerstand.
2. Sit astride the seat, and then ad-
just the rear view mirrors.
3. Switch the turn signal on.
4. Check for oncoming traffic, and
then slowly turn the throttle grip
(on the right) in order to take off.
5. Switch the turn signal off.
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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
6-7
6
EAUT0004*
Checking the spark plug The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plug can re-
veal the condition of the engine.
To remove the spark plug
1. Remove panel A. (See page 6-4
for panel removal and installation
procedures.)
2. Remove the spark plug cap.3. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner’s tool kit.To check the spark plug
1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the motor-
cycle is ridden normally).
NOTE:_ If the spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle. _2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if
necessary.
1. Spark plug cap
1. Spark plug wrench
Specified spark plug:
CR7HSA (NGK)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
EAUT0016*
Engine oil and oil strainer The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil strainer
cleaned at the intervals specified in the
periodic maintenance and lubrication
chart.
To check the engine oil level
1. Place the motorcycle on the cen-
terstand.NOTE:_ Make sure that the motorcycle is posi-
tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading. _2. Start the engine, warm it up for
several minutes, and then turn it
off.3. Wait a few minutes until the oil set-
tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in), and then remove it
again to check the oil level.
NOTE:_ The engine oil should be between the
minimum and maximum level marks. _4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
1. Engine oil filler cap
1. Dipstick
2. Maximum level mark
3. Minimum level mark
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