2002 YAMAHA T105 engine

GIVE SAFETY THE RIGHT OF WAY ...............5
DESCRIPTION ..................................................6
MOTORCYCLE IDENTIFICATION ...................7
Identification numbers record ...................7
Key identification number .........................8
Frame serial number ..................................8
Engine serial number .................................8
CONTROL FUNCTIONS ..................................9
Main switch .................................................9
Indicator lights ..........................................10
Instrument panel.......................................11
Handlebar switches ..................................12
Shift pedal .................................................14
Front brake lever .......................................14
Rear brake pedal .......................................15
Fuel tank cap .............................................15
Starter lever 1..........................................16
Kick starter .................................................16Steering lock..............................................17
Seat ............................................................18
Helmet holder ...........................................19
PRE-OPERATION CHECKS ...........................20
Fuel .............................................................22
Engine oil ...................................................23
Tires ............................................................24
OPERATION AND IMPORTANT
RIDING POINTS.............................................26
Starting and warming up a
cold engine ................................................26
Starting a warm engine ...........................28
Shifting.......................................................29
To start out and accelerate.......................29
To decelerate .............................................31
Engine break-in .........................................32
Parking .......................................................34
3
EAA30001
CONTENTS
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4
PERIODIC MAINTENANCE AND
MINOR REPAIR..............................................35
Tool kit ........................................................36
Periodic maintenance/lubrication ...........37
Front cowlings and panels removal/
installation .................................................39
Side cover removal/installation ..............41
Engine oil ...................................................42
Air filter ......................................................45
Throttle cable adjustment ........................47
Carburetor adjustment .............................48
Idle speed adjustment ..............................48
Spark plug inspection ..............................49
Front brake adjustment ............................51
Rear brake adjustment .............................53
Brake light switch adjustment .................54
Checking the front brake pads ................54
Checking the rear brake shoes ................55
Checking the brake fluid level .................55
Changing the brake fluid..........................57
Drive chain slack check ............................58Drive chain slack adjustment ..................59
Drive chain lubrication .............................61
Brake lever and pedal ...............................62
Center and sidestand ...............................62
Front fork inspection ................................63
Battery ........................................................64
Replenishing the battery fluid .................66
Fuse replacement .....................................67
Troubleshooting ........................................68
CLEANING AND STORAGE .........................69
Cleaning .....................................................69
Storage ......................................................69
SPECIFICATIONS ..........................................71
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1. KEY IDENTIFICATION NUMBER:
2. FRAME SERIAL NUMBER:
3. ENGINE SERIAL NUMBER:
EAA61101Identification 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
Yamaha dealer for reference in case the ve-
hicle is stolen.
7
EAA60000
MOTORCYCLE IDENTIFICATION
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EAA61400Key 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.EAA60700Frame serial number
The frame serial number is stamped into
the the frame.EAA70001Engine serial number
The engine serial number is stamped into
the crankcase.
8
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Position Function Key removal
EAB00000
CONTROL FUNCTIONS
EAB00100Main switch
The main switch controls the ignition and lighting systems. Its operation is described
below.
9
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 is locked and all
electrical circuits are switched off. OFF
LOCK
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Horn switch
Lights switch
Start switch
13
e
3. Horn switch
r
4. Lights switch
t
5. Start switch
Position Function
*
(HORN)The horn sounds when push-
ing the switch.Position Function
STARTThe starter motor cranks the
engine when pushing the
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.
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EAC20100Starter 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.EAC60700Kick starter
Rotate the kick starter away from the en-
gine. Push the starter down lightly with
your foot until the gears engage, then kick
smoothly and forcefully to start the engine.
16
q
1. Starter lever
q
1. Kick starter
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20
PRE-OPERATION CHECKS
Before using this motorcycle, check the following points:
Item Routine Page
Fuel9Check fuel level/top up as required. 22Engine oil9Check oil level/add oil as required. 23, 42–44Front brake9Check operation and lever free play. Adjust if necessary.
9Check fluid level and fluid leakage Fill with DOT3 or 51–52, 54–57
DOT4 brake fluid if necessary.Rear brake9Check operation and pedal free play. Adjust if necessary. 53, 55Throttle grip/Housing9Check for smooth operation. Lubricate/Adjust if necessary. —Drive chain9Check chain slack and condition. Adjust if necessary. 58–61Wheels/Tires9Check tire pressure, wear, damage and spoke tightness. 24–25Control/Meter cable9Check for smooth operation. Lubricate if necessary. —Brake and shift pedal shafts9Check for smooth operation. Lubricate if necessary. 62Brake lever pivot9Check for smooth operation. Lubricate if necessary. 62Center and sidestand pivots9Check for smooth operation. Lubricate if necessary. 62Fittings/fasteners9Check all chassis fittings and fasteners.
—
9Tighten/Adjust, if necessary.Lights and signals9Check for proper operation. —Switches9Check for proper operation. —Battery9Check fluid level, fill with distilled water if necessary. 64–66
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