2002 YAMAHA T105 check oil

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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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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37
* Valve(s)Check valve clearance. Adjust if necessary.2222Spark plug Check condition. Clean or replace if necessary.2222Air filterClean. Replace if necessary.22
* CarburetorCheck idle speed/starter operation.
2222
Adjust if necessary.
*
Fuel lineCheck fuel hose and vacuum pipe for cracks or
22damage. Replace if necessary.
Engine oilReplace (Warm engine before draining).22EVERY 2,000 km* Engine oil filterCheck/clean/replace if necessary.2222
Check operation, fluid level and fluid leakage.
* Front brake(See NOTE on page 38)22
Replace brake pads if necessary.
* Rear brakeCheck operation and adjust brake pedal free play.
22Replace brake shoes if necessary.
Check rear arm assembly for looseness.
* Rear arm pivotCorrect if necessary. Moderately repack every216,000 km.***
* WheelsCheck balance/damage/runout/spoke tightness.
22Replace if necessary.
* Wheel bearingsCheck bearing assembly for looseness/damage.
22 2
Replace if damaged.
INITIAL EVERY
ITEM REMARKS
500 km 2,000 km 4,000 km 8,000 km
PERIODIC MAINTENANCE/LUBRICATION
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*: 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)NOTE:
8The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8Hydraulic brake service
9Regularly check and, if necessary, correct the brake fluid level.
9Every two years replace the internal components of the brake master cylinder and
caliper, and change the brake fluid.
9Replace the brake hoses every four years and if cracked or damaged.
38
Check bearing assembly for looseness.
* Steering bearingCorrect if necessary. Moderately repack every228,000 km. **
* Front forksCheck operation/oil leakage. Repair if necessary.22* Rear shock absorberCheck operation/oil leakage. Repair if necessary.22
Drive chainCheck chain slack/alignment. Adjust if necessary.
EVERY 500 km
Clean and lube.
* Fittings/FastenersCheck all chassis fitting and fasteners.
2222Correct if necessary.
* Centerstand and
Check operation. Repair if necessary.2222
sidestand
* BatteryCheck specific gravity. Check that the breather
22
pipe is working properly. Correct if necessary.
INITIAL EVERY
ITEM REMARKS
500 km 2,000 km 4,000 km 8,000 km
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EAH48201*Engine oil
1. Oil level measurement
a. Place the motorcycle on the center-
stand. Warm up the engine for several
minutes.EUU03901NOTE:
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 the oil level
gauge.
c. Wipe the oil level gauge off with a
clean rag and insert it in the filler hole
without screwing it in.
42
q
w
e
1. Oil level gauge 2. Upper level
3. Lower level
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e. Fill engine with oil through the oil
level gauge hole.EUU47700cC9Do 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.
9Be sure no foreign material enters the
crankcase.f. Start the engine and warm up for a
few minutes. While warming up check
for oil leakage. If oil leakage is found,
stop the engine immediately, and ask
a Yamaha dealer to check the cause.
44
Recommended oil:
See page 23
Oil quantity:
Total amount:
1.0 L
Periodic oil change:
0.8 L
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Observe these precautions:
8When checking the fluid level, make
sure that the top of the master cylin-
der is level by turning the handlebars.
8Use only the recommended quality
brake fluid, otherwise the rubber seals
may deteriorate, causing leakage and
poor braking performance.NOTE:
If DOT 4 is not available, DOT 3 can be
used.8Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and lead to
poor braking performance.8Be careful that water does not enter
the master cylinder when refilling.
Water will significantly lower the boil-
ing point of the fluid and may result in
vapor lock.
8Brake fluid may deteriorate painted
surfaces or plastic parts. Always clean
up spilled fluid immediately.
8As the brake pads wear, it is normal
for the brake fluid level to gradually
go down. However, if the brake fluid
level goes down suddenly, have a
Yamaha dealer check the cause.
56
Recommended brake fluid: DOT 4
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