2002 YAMAHA NEO115 maintenance

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.)

EAU00000
INTRODUCTION
Congratulations on your purchase of the Yamaha AT115. This model is the result of
Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting
racing machines. It represents the high degree of craftsmanship and reliability that
have made Yamaha a leader in these fields.
This manual will give you an understanding of the operation, inspection, and basic
maintenance of this motorcycle. If you have any questions concerning the operation
or maintenance of your motorcycle, please consult a Yamaha dealer.
EAU04229*
AT115
OWNER’S MANUAL
©2001 by Yamaha Motor Co., Ltd.
1st edition, December 2001
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Indonesia.
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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
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1
2
3
4
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8
9
1-1
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1-
GIVE SAFETY THE RIGHT OF WAY
Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and
freedom. However, they also impose certain limits, which you must accept; even the best motorcycle
does not ignore the laws of physics.
Regular care and maintenance are essential for preserving value and operating condition of your
motorcycle. Moreover, what is true for the motorcycle is also true for the rider: good performance
depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of
course, out of the question. Motorcycle riders—more than car drivers—must always be at their mental
and physical best. Under the influence of even small amounts of alcohol, there is a tendency to take
dangerous risks.
Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and
passengers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant
synthetic materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet.
Optimum protective wear, however, should not encourage carelessness. Although full-coverage
helmets and suits, in particular, create an illusion of total safety and protection, motorcyclists will
always be vulnerable. Riders who lack critical self-control run the risk of going too fast and are apt to
take chances. This is even more dangerous in wet weather. The good motorcyclist rides safely,
predictably and defensively—avoiding all dangers, including those caused by others.
Enjoy your ride!
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6-1
6
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6-PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00464
Safety is an obligation of the owner.
Periodic inspection, adjustment and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.
EW000060
WARNING
_ If you are not familiar with motor-
cycle maintenance work, have a
Yamaha dealer do it for you. _
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Owner’s tool kit The owner’s tool kit is located on the
bottom of the seat. (See page 3-6 for
seat opening and closing procedures.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
NOTE:_ If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you. _
EW000063
WARNING
_ Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any chang-
es. _
1. Owner’s tool kit
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
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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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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.
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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
6-4
6
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Removing and installing the
cowling and panels The cowling and panels shown above
need to be removed to perform some
of the maintenance jobs described in
this chapter. Refer to this section each
time the cowling or a panel needs to be
removed and installed.
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Panel A
To remove the panelRemove the screws, and then pull the
panel off as shown.To install the panel
Place the panel in the original position,
and then install the screws.NOTE:_ Make sure that the projections fit into
the grommets and that the tabs fit into
the slots. _
1. Panel A
2. Panel B
3. Cowling B
4. Cowling A
1. Panel A
2. Screw (× 2)
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