Yamaha T105 (2002) manual

OWNER'S MANUAL 5A V -F8199-E0[...]

EAA00100 EAA20301 INTRODUCTION Congratulations on your purchase of the Y amaha T105E. This model is the result of Y amaha’ s vast experience in the produc- tion of fine sporting, touring, and paceset- ting racing machines. It represents the high degree of craftsmanship and reliability that have made Y amaha a leader in these fields. This manual w[...]

EAA10500 Particularly important information is distin- guished in this manual by the following notations: Q The Safety Alert Symbol means A TTEN- TION! BECOME ALER T! YOUR SAFETY IS INVOL VED! w Failure to follow W ARNING instructions could r esult in sever e injury or death to the motorcycle operator , a bystander or a per- son inspecting or repai[...]

GIVE SAFETY THE RIGHT OF W A Y ...............5 GENERAL NOTE ..............................................6 DESCRIPTION ..................................................8 MOTORCYCLE IDENTIFICA TION ...................9 Identification numbers record ...................9 Key identification number .......................10 Frame serial number ......[...]

4 PERIODIC MAINTENANCE AND MINOR REP AIR ..............................................37 T ool kit ........................................................38 Periodic maintenance/lubrication ...........39 Engine oil ................................................... 41 Air filter ......................................................44 Throttle c[...]

Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. However , they also impose certain limits, which you must ac- cept; even the best motorcycle does not ig- nore the laws of physics. Regular care and maintenance are essen- tial for preserving your motorcycle’ s value and operating condition. More[...]

6 Much can be gained from the correct use and maintenance of a motorcycle. 1 THE CUSTOMERS CAN USE THE FULLEST POTENTIAL OF YAMAHA MOTORCYCLES 2 A MOTORCYCLE CAN KEEP ITS PERFORMANCE CAPABILITY FOR A LONGER TIME Comparison of wear on engine parts With maintenance Without maintenance 100% Perfect operative Distance Engine overhaul, cylinder (piston,[...]

7 3 FUEL COST AND REPAIR EXPENSES CAN BE KEPT TO A MINIMUM 4 A MOTORCYCLE CAN DEMAND A HIGH PRICE WHEN IT IS TRADED IN AS A USED PRODUCT 100% With maintenance Without Distance covered (km) Fuel consumption maintenance Distance covered (km) Customer ’ s running cost S Without maintenance With maintenance Big repairs at higher expenses (fuel cost p[...]

EAA50000 DESCRIPTION 8 1. Tail/Brake light 2. Rear flasher light 3. Side cover 4. Fuel tank cap 5. Front flasher light 6. Kick starter 7. Rear brake pedal 8. Head light 9. Fuel tank 10. Seat lock 11. Shift pedal 12. Handlebar switch 13. Speedometer 14. Fuel gauge 15. Main switch/steering lock 16. Throttle grip 17. Front brake lever 18. Indicator li[...]

1. KEY IDENTIFICA TION NUMBER: 2. FRAME SERIAL NUMBER: 3. ENGINE SERIAL NUMBER: EAA61101 Identification numbers record Record the key identification number , frame serial number and engine serial number in the spaces provided for assis- tance when ordering spare parts from a Y amaha dealer for reference in case the ve- hicle is stolen. 9 EAA60000 M[...]

EAA61400 Key identification number The key identification number is stamped on the key . Record this number in the space provided and use it for reference when obtaining a new key . EAA60700 Frame serial number The frame serial number is stamped into the the frame. EAA70001 Engine serial number The engine serial number is stamped into the crankcase[...]

Position Function Key removal EAB00000 CONTROL FUNCTIONS EAB00100 Main switch The main switch controls the ignition and lighting systems. Its operation is described below . 11 ON Electrical circuits are switched on. The engine can be started. Cannot be removed. Can be removed. Can be removed. All electrical circuits are switched off. The steering i[...]

EAB10000 Indicator lights 12 1 Turn indicator light 2 Neutral indicator light 3 Top gear indicator light 4 High beam indicator light Description Function T urn indicator light “ 5 ” : Neutral indicator light “ N ” : T op gear indicator light “ TOP ” : High beam indica- tor light “ & ” : Flashes when the turn switch is “ ON ”[...]

Fuel gauge Instrument panel 13 1 Speedometer 2 Odometer 3 Fuel gauge Description Function Speedometer Odometer Shows riding speed. Shows accumlated mileage. Shows the fuel level in the fuel tank. T105(E) O/M-1 9/11/01 11:16 AM Page 13 (1,1)[...]

Position Function Handlebar switches Lights switch Dimmer switch T urn signal switch 14 1 Lights switch 2 Dimmer switch 3 Turn signal switch Position Function ON OFF Headlight, taillight and meter lights comes on when engine is running. Headlight, taillight and meter lights does not come on. Position Function & (HI) % (LO) T urns on the headlig[...]

Horn switch Start switch 15 4 Horn switch 5 Start switch Position Function * (HORN) The horn sounds when push- ing the switch. Position Function ST ART The starter motor cranks the engine when pushing the switch. T105(E) O/M-1 9/11/01 11:16 AM Page 15 (1,1)[...]

EAB80001 Shift pedal This motorcycle is equipped with a con- stant-mesh 4-speed transmission. The shift pedal is located on the left side of the en- gine. EAB90001 Front brake lever The front brake lever is located on the right handlebar . Pull it toward the handlebar to apply the front brake. 16 1 Shift pedal N. Neutral 1 Front brake lever T105(E)[...]

EAB90101 Rear brake pedal The rear brake pedal is on the right side of the motorcycle. Press down on the brake pedal to apply the rear brake. EAC01300* Fuel tank cap T o add fuel, open the seat. Then remove the fuel tank cap by turning it counterclock- wise. (See page 20 to open the seat.) 17 1 Rear brake pedal 1 Fuel tank cap T105(E) O/M-1 9/11/01[...]

EAC20100 Starter lever 1 The starter lever is located on the left han- dlebar . Starting a cold engine requires a richer fuel mixture. In such a case, turn the starter lever to the left. After the engine is warm, turn the lever to its original position. EAC60700 Kick starter Rotate the kick starter away from the en- gine. Push the starter down ligh[...]

EAC30401 Steering lock The steering is locked when the main switch is turned to “ LOCK ” . T o lock the steering, turn the handlebars all the way to the left. With the key at “ OFF ” , push it into the main switch and release it, turn it coun- terclockwise to “ LOCK ” , and remove it. T o release the lock, turn the key to “ OFF ” . [...]

EAC42301 Seat T o open the seat: 1. Insert the key in the lock and turn it as shown. 2. Lift the end of the seat up to open. T o lock the seat: 1. Replace the seat in the original posi- tion. 2. Slightly push the end of the seat down to lock. EUU01700 NOTE: Make sure that the seat is securely fitted. 20 T105(E) O/M-1 9/11/01 11:16 AM Page 20 (1,1)[...]

EAC50001 Helmet holder T o open the helmet holder , insert the key in the lock and turn it as shown. T o lock the helmet holder , replace the holder in its original position. EUU72900 w Never ride with a helmet in the helmet holder . The helmet may hit objects, caus- ing loss of control and possibly an acci- dent. Side cover removal Remove the scre[...]

22 PRE-OPERA TION CHECKS Before using this motorcycle, check the following points: Item Routine Page Fuel 9 Check fuel level/top up as required. 24 Engine oil 9 Check oil level/add oil as required. 25, 41~43 9 Check operation, condition and free play. Adjust if necessary. Brake Make sure the brankes are working properly by checking at 50~52 low spe[...]

23 NOTE: Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be thoroughly accomplished in a very short time; and the added safety it assures is more than worth the time involved. w If any item in the Pre-Operation Check is not working properly , have it inspected and re- paired before operating the motorcyc[...]

EAE80300 EAE80000 Fuel Make sure there is sufficient fuel in the tank. EUU61000 w Do not overfill the fuel tank. A void spilling fuel on the hot engine. Do not fill the fuel tank above the bottom of the filler tube as shown in the illustration or it may over- flow when the fuel heats up later and ex- pands. EUU39302 c C Always wipe off spilled fuel[...]

EAE40104* Engine oil Make sure the engine oil is at the specified level. Fill with oil as necessary (see page 41 for details). 25 1 Oil level gauge 2 Upper level 3 Lower level Recommended oil: Y amalube 4 (20W40) or equivalent SAE 20W40 type SE motor oil Oil quantity: T otal amount: 1.0 L Periodic oil change: 0.8 L T105(E) O/M-2 9/11/01 11:17 AM Pa[...]

EAE96700 T ires T o ensure maximum performance, long service, and safe operation, note the fol- lowing: 1. T ire air pressure Always check and adjust the tire pres- sure before operating the motorcycle. EUU67500 w T ire inflation pressure should be checked and adjusted when the temperature of the tire equals the ambient air temperature. T ire infla[...]

2. T ire inspection Always check the tires before operat- ing the motorcycle. If center tread depth reaches the limit as shown, if the tire has a nail or glass fragments in it, or if the side wall is cracked, con- tact a Y amaha dealer immediately and have the tire replaced. w It is dangerous to ride with a worn-out tire. When a tire tread begins t[...]

EAF00000 OPERA TION AND IMPORT ANT RIDING POINTS EAF18800* Starting and warming up a cold engine 1. T urn the main switch to ON”. 2. Shift transmission into neutral. EUU03000 NOTE: When the transmission is in neutral, the neutral indicator light (green) should be on. If the light does not come on, ask a Y amaha dealer to inspect it. 28 N. Neutral[...]

3. Fully open the starter lever “ 1 ”, and completely close the throttle grip. 4. Start the engine by pushing the starter switch or by kicking the kick starter . EUU03401 NOTE: If the engine fails to start, release the starter switch, wait a few seconds, then try again. Each attempt should be as short as possible to preserve the battery . Do no[...]

EUU02600 NOTE: For maximum engine life, always warm up the engine before starting off. Never accel- erate hard with a cold engine! 6. After warming up the engine, turn off the starter completely . EUU02700 NOTE: The engine is warm when it responds nor- mally to the throttle with the starter turned off. EAF10802* Starting a warm engine The starter l[...]

Shifting The transmission lets you control the amount of power you have available at a given speed for starting, accelerating, climbing hills, etc. The use of the shift pedal is shown in the illustration. T o start out and accelerate 1. Close the throttle completery . c C Always close the throttle while shifting gears. Otherwise, damage to the engi[...]

4. Once the motorcycle has reached a high enough speed to change gears, close the throttle. 5. Shift into SECOND gear . 6. Open the throttle gradually . 7. Follow the same procedure when shifting to the next higher gear . 8. The speed can be adjusted by opening and closing the throttle grip. T urning it toward you increases the speed, and turning i[...]

T o decelerate 1. Close the throttle and apply both the front and the rear brakes at the same time to slow the motorcycle. 2. Downshift through the gears and when the motorcycle is almost com- pletely stopped, shift into nutral. Recommend shift point: 33 Gear position Recommend speed 4th → 3rd 0~40 km/h 3rd → 2rd 0~30 km/h 2nd → 1st 0~15 km/h[...]

EAF30000* Engine break-in There is never a more important period in the life of your motorcycle than the period between zero and 1,000 km. Because the engine is brand new , prolonged full throttle operation, or any condition which might result in excessive heating of the engine must be avoided during this period. EAF30800 1. 0~150 km: A void prolon[...]

3. 500~1,000 km: A void cruising speeds in excess of 3/4 throttle. EUU40400 c C After 1,000 km of operation, be sure to re- place the engine oil. 4. 1,000 km and beyond: A void prolonged full-throttle opera- tion. V ary speed occasionally . EUU32200 c C If any engine trouble should occur during the break-in period, consult a Y amaha dealer immediat[...]

EAF40000 Parking When parking the motorcycle, stop the en- gine and remove the ignition key . EUU63000 w The muffler and exhaust pipe are hot. Park the motorcycle in a place where pedestrians or children are not likely to touch the motorcycle. Do not park the mo- torcycle on a slope or soft ground; the mo- torcycle may overturn. 36 T105(E) O/M-2 9/[...]

EAH00000 PERIODIC MAINTENANCE AND MINOR REP AIR EAH00400 Periodic inspection, adjustment and lubri- cation will keep your motorcycle in the safest and most efficient condition possi- ble. Safety is an obligation of the motorcy- cle owner . The maintenance and lubrica- tion schedule chart should be considered strictly as a guide to general maintenan[...]

EAH10101* T ool kit The tools provided in the owner’ s tool kit are to assist you in the performance of pe- riodic maintenance. However , some other tools such as a torque wrench are also nec- essary to perform the maintenance correct- ly . EUU67100 w Modifications to this motorcycle not ap- proved by Y amaha may cause loss of per- formance, and [...]

39 * Valve(s) Check valve clearance. Adjust if necessary. 2222 Spark plug Check condition. Clean or replace if necessary. 2222 Air filter Clean. Replace if necessary. 22 * Carburetor Check idle speed/stater operation. 2222 Adjust if necessary. * Fuel line Check fuel hose and vacuum pipe for cracks or 22 damage. Replace if necessary. Engine oil Repl[...]

*: It is recommended that these items be serviced by a Yamaha dealer. **: Medium weight wheel bearing grease. (bearing type) ***: Lithium soap base grease. (bush type) 40 Check bearing assembly for looseness. * Steering bearing Correct if necessary. Moderately repack every 22 8,000 km. ** * Front forks Check operation/oil leakage. Repair if necessa[...]

EAH48201* Engine oil 1. Oil level measurement a. Place the motorcycle on the center- stand. W arm up the engine for several minutes. EUU03901 NOTE: Be sure the motorcycle is positioned straight up when checking the oil level. A slight tilt toward the side can result in false readings. b. With the engine stopped, wait a few minutes and then remove t[...]

d. The oil level should be between the maximum and minimum marks. If the level is low , add sufficient oil to raise it to the proper level. 2. Engine oil replacement a. W arm up the engine for a few min- utes. b. Stop the engine. Place an oil pan under the engine, and remove the oil level gauge. c. Remove the drain plug and drain the oil. d. Reinst[...]

e. Fill engine with oil through the oil level gauge hole. EUU47700 c C 9 Do not put in any chemical additives or use oils with a grade of “CD (for Diesel engine)” or higher . Also, be sure not to use oils labeled “ENERGY CONSERVING II ” or higher . Engine oil also lubricates the clutch and additives could cause clutch slippage. 9 Be sure no[...]

Air filter 1. Remove the front panel and the legshield by removing the screws. 2. Remove the air filter case fitting screws and the filter case cover . 3. Remove the air filter element from its case, and clean it with solvent. After cleaning, remove the remaining sol- vent by squeezing the element. 44 1 Air filter case cover 2 Screw (4 pcs) 1 Air f[...]

4. Apply recommended oil to the entire surface of the filter and squeeze out the excess oil. The element should be wet but not dripping. 5. Install the element in its case. c C 9 If oil is not applied to the element, the engine damage may occur . 9 Make sure the element is properly seat- ed in the filter case. 9 The engine should never be run witho[...]

EAH92200 Throttle cable adjustment EUU06400 NOTE: Before adjusting the throttle cable free play , the engine idling speed should be ad- justed. The throttle cable should have a specified free play in the turning direction at the grip flange. If the free play is incorrect, ask a Y amaha dealer to make adjustment. 46 A. Free play: 3~7 mm Free play: 3[...]

EAH92300 Carburetor adjustment The carburetor is a vital part of the engine and requires very sophisticated adjust- ment. Most adjustments should be left to a Y amaha dealer who has the professional knowledge and experience to do so. EAH92000 Idle speed adjustment 1. Attach the tachometer . 2. Set the idle to the specified engine speed by adjusting[...]

EAH20304 Spark plug inspection The spark plug is an important engine component and is easy to inspect. The con- dition of the spark plug can indicate the condition of the engine. The ideal color on the white insulator around the center elec- trode is a medium-to-light tan color for a motorcycle that is being ridden normally . Do not attempt to diag[...]

Before installing the spark plug, measure the electrode gap with a wire thickness gauge; adjust the gap to specification as necessary . When installing the plug, always clean the gasket surface and use a new gasket. Wipe off any grime from the threads and tighten the spark plug to the specified torque. EUU03801 NOTE: If a torque wrench is not avail[...]

EAH85201 Front brake adjustment The front brake lever free play should be adjusted to 8~12 mm at the brake lever end. Adjustment is accomplished at the front brake hub. T o adjust, turn the adjuster clockwise to reduce play or counterclock- wise to increase play . 50 a A. Free play: 8~12 mm 1 Adjuster T105(E) O/M-3 9/11/01 11:17 AM Page 50 (1,1)[...]

Rear brake adjustment The rear brake pedal free play should be adjusted to 20~30 mm at the brake pedal end. T urn the adjuster on the brake rod clockwise to reduce play or counterclock- wise to increase play . EUU69800 w 1. The rear brake pedal adjustment must be checked whenever the chain is ad- justed or the rear wheel is removed and then reinsta[...]

EAH83301 Brake light switch adjustment The brake light switch is operated by movement of the brake pedal. T o adjust, hold the main body of the switch so it does not rotate and turn the adjusting nut. Proper adjustment is achieved when the brake light comes on just before the brake begins to take effect. EAH81601 Checking the brake shoes A wear ind[...]

EAI40001 Drive chain slack check EUU04801 NOTE: Spin the wheel several times and find the tightest position of the chain. Check and/or adjust the chain slack while it’ s in this tight- est position. Inspect the drive chain when the motorcy- cle is on the centerstand. Check the slack at the position shown in the illustration. Normal slack is appro[...]

Drive chain slack adjustment 1. Loosen the rear brake adjuster . 2. Loosen the axle nut. 3. Loosen the sprocket shaft nut and the axle nut. 4. T o tighten the chain, turn the chain ad- juster clockwise. T o loosen the chain, turn the adjuster counterclockwise and push the wheel forward. T urn each ad- juster exactly the same amount to main- tain co[...]

5. After adjusting, be sure to tighten the loosened parts. T ighten the axle nut at specified torque. 6. Adjust the free play in the brake pedal. 55 T ightening torque: Axle nut: 60 Nm (6.0 m • kg) Sprocket shaft nut: 80 Nm (8.0 m • kg) T105(E) O/M-3 9/11/01 11:17 AM Page 55 (1,1)[...]

EAI40601 Drive chain lubrication The chain consists of many parts which work with each other . If the chain is not maintained properly , it will wear out quick- ly . Therefore, the chain must be serviced regularly . This service is especially neces- sary when riding in dusty areas. 1. Use any of the many brands of chain lubricant. First, remove all[...]

EAI30601 Brake lever and pedal Lubricate the pivoting parts. EAI30801 Center and sidestand Lubricate the pivoting parts. Check to see that the center and sidestand move up and down smoothly . 57 Recommended lubricant: Y amalube 4 or SAE 20W40 motor oil Recommended lubricant: Y amalube 4 or SAE 20W40 motor oil T105(E) O/M-3 9/11/01 11:17 AM Page 57 [...]

EAH20501 Front fork inspection EUU65700 w Securely support the motorcycle so there is no danger of it falling over . Operation check Place the motorcycle on a level place. a. Hold the motorcycle in an upright po- sition and apply the front brake. b. Stroke the front forks up and down several times. EUU42500 c C If any damage or unsmooth movement is[...]

EAI70001* Battery Check the level of the battery electrolyte and make sure that the terminals are tight. Add distilled water if the electrolyte level is low . NOTE: The battery fluid should be checked at least once a month. EUU33601 c C When inspecting the battery , be sure the breather pipe is routed correctly . 59 1 Upper level 2 Lower level T105[...]

EUU65800 w Battery electrolyte is poisonous and dan- gerous, causing severe burns, etc. It con- tains sulfuric acid. A void contact with skin, eyes or clothing. Antidote: EXTERNAL: Flush with water . INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call a physi- cian immediately . Eyes: [...]

Replenishing the battery fluid A poorly maintained battery will corrode and discharge quickly . The battery fluid should be checked at least once a month. The level should be between the minimum and maximum marks. Use only distilled water if refilling is necessary . EUU33800 c C Normal tap water contains minerals which are harmful to a battery; the[...]

EAI91001* Fuse replacement 1. The fuse case is located inside the right sidecover . 2. If a fuse is blown, turn off the ignition switch and the switch of the circuit in question. Install a new fuse of proper amperage. T urn on the switches and see if the electrical device operates. If the fuse immediately blows again, consult a Y amaha dealer . EUU[...]

EAJ50002 T roubleshooting Although Y amaha motorcycles receive a rigid inspection before shipment from the factory , trouble may occur during opera- tion. If your motorcycle requires any repair , bring it to a Y amaha dealer . The skilled technicians at a Y amaha dealership have the tools, experience, and know-how to properly service your motorcycl[...]

EAK00000 CLEANING AND STORAGE EAK01302* A. CLEANING Frequent, thorough cleaning of your mo- torcycle will not only enhance its appear- ance but will improve its general perfor- mance and extend the useful life of many components. 1. Rinse the dirt and degreaser off with a garden hose. EUU34602 c C Excessive hose pressure may cause water seepage and[...]

3. Remove the drive chain. Thoroughly clean the chain with solvent and lubri- cate it. Reinstall the chain or store it in a plastic bag (tied to frame for safe- keeping). 4. Lubricate all control cables. 5. Block up the frame to raise both wheels off the ground. 6. T ie a plastic bag over the exhaust pipe outlet to prevent moisture from enter- ing.[...]

66 Model Dimensions: Overall length 1,870 mm Overall width 655 mm Overall height 1,050 mm Seat height 755 mm Wheelbase 1,190 mm Minimum ground clearance 130 mm Basic weight: With oil and full fuel tank 96 kg Minimum turning radius: 1,800 mm Engine: Type Air cooled 4 stroke, SOHC Cylinder arrangement Forward inclined single cylinder Displacement 101[...]

67 Model Engine oil (4-cycle): Type Yamalibe 4 (20W40) or equivalent SAE 20W40 type SE motor oil Capacity Periodic oil change 0.8 L Total amount 1.0 L Air filter: Wet type element Fuel: Type Regular gasoline Tank capacity 4.3 L Reserve amount Carburetor: Type/manufacturer VM16SH/MIKUNI T105(E) O/M-3 9/11/01 11:17 AM Page 67 (1,1)[...]

68 Model Spark plug: Type/manufacturer CR7HSA/NGK Gap 0.6~0.7 mm Clutch type: Wet, centrifugal, automatic Transmission: Primary reduction system Spur gear Primary reduction ratio 67/18 (3.722) Secondary reduction system Chain drive Secondary reduction ratio 37/15 (2.467) Transmission type Constant mesh 4 speed Operation Left foot operation Gear rat[...]

69 Model Chassis: Frmae type Steel Tube underbone Caster angle 27° Trail 78 mm Tire: Type With tube Size – Front 2.25-17-4PR Rear 2.50-17-4PR Brake: Front brake type Drum brake Operation Right hand operation Rear brake type Drum brake Operation Right foot operation Suspension: Front Telescopic fork Rear Swing arm Shock absorber: Front Coil sprin[...]

70 Model Wheel travel: Front 80 mm Rear 65 mm Electrical: Ignition system C.D.I Generator system Flywheel magneto Battery type/capacity 12V5AH Headlight type: Krypton bulb Bulb wattage/quantity: Headlight 12V30W/30W Tail/brake light 12V/5W/21W Flasher light 12V10W × 4 Meter light 12V1.7W × 1 Indicator light wattage/quantity: “NEUTRAL” 12V3.4W[...]

Y AMAHA MOTOR CO. , L TD.[...]