2002 YAMAHA NEO115 tires

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

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

PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6
EAU03790*
Tires To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
EW000091
WARNING
_ The tire air pressure must be
checked and adjusted on cold tires
(i.e., when the temperature of the
tires equals the ambient tempera-
ture). _
CE-24E
CE-07EEW000087
WARNING
_ Because loading has an enormous
impact on the handling, braking, per-
formance and safety characteristics
of your motorcycle, you should keep
the following precautions in mind.

NEVER OVERLOAD THE
MOTORCYCLE! Operation of an
overloaded motorcycle may re-
sult in tire damage, loss of con-
trol, or severe injury. Make sure
that the total weight of rider, pas-
senger, cargo, and accessories
does not exceed the specified
maximum load for the vehicle.


Do not carry along loosely
packed items, which can shift
during a ride.


Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.


Adjust the tire air pressure with
regard to the load.


Check the tire condition and air
pressure before each ride.
_
Tire air pressure
(measured on cold tires)
Front Rear
200 kPa
(2.00 kgf/cm2)225 kPa
(2.25 kgf/cm
2)
Maximum load* 116 kg
* Total weight of rider, passenger, cargo and
accessories
U5MXE0.book Page 19 Thursday, December 20, 2001 2:08 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6 Tire inspection
The tires must be checked before each
ride. If the tire shows crosswise lines
(minimum tread depth), if the tire has a
nail or glass fragments in it, or if the
sidewall is cracked, have a Yamaha
dealer replace the tire immediately.
CE-23ENOTE:_ The tire tread depth limits may differ
from country to country. Always comply
with the local regulations. _
EW000079
WARNING
_

Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding sta-
bility and can lead to loss of
control.


The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.
_
Tire information
This motorcycle is equipped with tube
tires.
EW000078
WARNING
_

The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the motor-
cycle cannot be guaranteed.


After extensive tests, only the
tires listed below have been ap-
proved for this model by
Yamaha Motor Co., Ltd.
_CE-10E
1. Sidewall
2. Tire wear indicator
a. Tire tread depthMinimum tire tread depth
(front and rear)1.0 mm
FRONT
Manufacturer Size Model
Dunlop 70/90-16 36P D110
REAR
Manufacturer Size Model
Dunlop 80/90-16 43P D110
U5MXE0.book Page 20 Thursday, December 20, 2001 2:08 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6
EAU00680
WARNING
_

It is dangerous to ride with a
worn-out tire. When a tire tread
begins to show crosswise lines,
have a Yamaha dealer replace
the tire immediately.


The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.


It is not recommended to patch
a punctured tube. If unavoid-
able, however, patch the tube
very carefully and replace it as
soon as possible with a high-
quality product.
_
EAU00685
Spoke wheels To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified wheels.

The wheel rims should be checked
for cracks, bends or warpage, and
the spokes for looseness or dam-
age before each ride. If any dam-
age is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.


The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.


Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
EAU03851*
Checking the front brake lever
free playSince this model is equipped with a hy-
draulic front brake, adjusting the brake
lever free play is not needed.
However, it is necessary to check the
brake fluid level and check the hydrau-
lic system for leakage.1. Front brake lever
U5MXE0.book Page 21 Thursday, December 20, 2001 2:08 PM

SPECIFICATIONS
8-2
8
Transmission
Primary reduction system Helical gear
Primary reduction ratio 3.133
Secondary reduction system Spur gear
Secondary reduction ratio 3.583
Number of drive chain
sprocket teeth (rear/front) 43/12
Transmission type V-belt automatic
Operation Centrifugal automatic type
Chassis
Frame type Steel tube underbone
Caster angle 25°
Trail 112 mm
Tires
Fro nt
Ty p e Tu b e t i r e
Size 70/90-16 36P
Manufacturer/
model Dunlop/D110
Rear
Ty p e Tu b e t i r e
Size 80/90-16 43P
Manufacturer/
model Dunlop/D110Tire air pressure
(measured on cold tires)
Front 200 kPa (2.00 kgf/cm
2)
Rear 225 kPa (2.25 kgf/cm2)
Wheels
Fr on t
Type Spoke wheel
Size 16 × 1.40
Rear
Type Spoke wheel
Size 16 × 1.60
Brakes
Fr on t
Type Single disc brake
Operation Right hand
Fluid DOT 3 or 4
Rear
Ty p e
Drum brake
Operation Left hand
Suspension
Fr on t
Ty p e
Telescopic fork
Rear
Ty p e
Unit swing
U5MXE0.book Page 2 Thursday, December 20, 2001 2:08 PM