2005 YAMAHA T105 engine

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:
Avoid prolonged operation above 1/3
throttle. Vary the speed of the motor-
cycle from time to time. Do not oper-
ate it at one set throttle position.
2. 150~500 km:
Avoid prolonged operation above 1/2
throttle. Rev the engine freely through
the gears, but do not use full throttle
at any time.
34
0~500Km
1/2
1/3
0~150Km
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3. 500~1,000 km:
Avoid cruising speeds in excess of 3/4
throttle.
EUU40400
cC
After 1,000 km of operation, be sure to re-
place the engine oil.
4. 1,000 km and beyond:
Avoid prolonged full-throttle opera-
tion. Vary speed occasionally.
EUU32200
cC
If any engine trouble should occur during
the break-in period, consult a Yamaha
dealer immediately.
35
500~1000Km
3/4
1000Km~
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39
* Valve(s)Check valve clearance. Adjust if necessary.2222
Spark plug Check condition. Clean or replace if necessary.2222
Air filterClean. Replace if necessary.22
* CarburetorCheck idle speed/stater operation.
2222
Adjust if necessary.
*
Fuel lineCheck fuel hose and vacuum pipe for cracks or
22
damage. Replace if necessary.
Engine oilReplace (Warm engine before draining).22EVERY 2,000 km
* Engine oil filterCheck/clean/replace if necessary2222
*Front brakeCheck operation, fluid level and fluid leakage.
22
(T105SE)Replace brake pads if necessary.
*Front brakeCheck operation and adjust brake lever free play.
22
(T105E)Replace brake shoes if necessary.
* Rear brakeCheck operation and adjust brake pedal free play.
22
Replace brake shoes if necessary.
Check rear arm assembly for looseness.
* Rear arm pivotCorrect if necessary. Moderately repack every.2
16,000 km***
* WheelsCheck balance/damage/runout/spoke tightness.
22
Replace 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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EAH48201*
Engine oil
1. Oil level measurement
a. Place the motorcycle on the center-
stand. Warm 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 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.
41
1Oil level gauge2Upper level3Lower level
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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. Warm 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. Reinstall the drain plug (make sure it
is tight.)
42
q
1Drain plug
Tightening torque
Drain plug20 Nm (2.0 m•kg)
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e. Fill engine with oil through the oil
level gauge hole.
EUU47700
cC
9Do 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.
43
Recommended oil:
See page 25
Oil quantity:
Total amount:
1.0 L
Periodic oil change:
0.8 L
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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.
cC
9If oil is not applied to the element, the
engine damage may occur.
9Make sure the element is properly seat-
ed in the filter case.
9The engine should never be run without
the air filter element installed; excessive
piston and/or cylinder wear may result.
45
Recommended oil:
Yamalube 2 (2 stroke engine oil) or
Yamalube 4 (20W40)
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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
Yamaha dealer to make adjustment.
46
A. Free play: 3~7 mm
Free play:
3~7 mm
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