2002 YAMAHA T105 maintenance

EAA00100*EAA20301
INTRODUCTION
Congratulations on your purchase of the
Yamaha T105S(E). This model is the result
of Yamaha’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 Yamaha a leader in these fields.
This manual will give you an understand-
ing of the operation, inspection, and basic
maintenance of this motorcycle. If you
have any questions about the operation or
maintenance of your motorcycle, please
consult a Yamaha dealer. T105S(E)
OWNER’S MANUAL
© 2001 by Yamaha Motor Co, Ltd.
1st edition, October 2001
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co, Ltd.
is expressly prohibited.
Printed in Vietnam
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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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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. 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 rid-
ers - more than car drivers - must always
be at their mental and physical best. Under
the influence of even small amounts of al-
cohol, there is a tendency to take danger-
ous 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 materi-
als with protectors), sturdy boots, motorcy-
cle gloves and a properly fitting helmet.
Optimum protective wear, however, should
not encourage carelessness. Though full-
coverage helmets and suits, in particular,
create an illusion of total safety and protec-
tion, motorcyclists will always be vulnera-
ble. 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!
5
EUU75901
GIVE SAFETY THE RIGHT OF WAY
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EAH00000
PERIODIC
MAINTENANCE AND
MINOR REPAIR
EAH00400Periodic 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 maintenance
and lubrication intervals.EUU63200wIf you are not familiar with motorcycle ser-
vice, this work should be done by a
Yamaha dealer.
35
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EAH10101*Tool 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.EUU67100wModifications to this motorcycle not ap-
proved by Yamaha may cause loss of per-
formance, and render it unsafe for use.
Consult a Yamaha dealer before attempt-
ing any changes.
36
q
1. Tool kit
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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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EAU03238Changing the brake fluid
Have a Yamaha dealer change the brake
fluid at the intervals specified in the period-
ic maintenance and lubrication chart. In ad-
dition, have the oil seals of the brake mas-
ter cylinder and caliper as well as the brake
hose replaced at the intervals listed below
or whenever they are damaged or leaking.
8Oil seals: Replace every two years.
8Brake hose: Replace every four years.
57
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