EAA00100* EAA20301
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
Congratulations on your purchase of the
Yamaha T105S(E). This model is the result
of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting 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 understanding 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.
INTRODUCTION
EAA10500
Particularly important information is distinguished in this manual by the following
notations:
Q
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
w
Failure to follow WARNING instructions
could result in severe injury or death
to the
motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
cC
EUU13800*
NOTE:
9 Yamaha continually seeks advancements
in product design and quality. Therefore,
while this manual contains the most current product information available at the
time of printing, there may be minor discrepancies between your machine and
this manual. If there is any question concerning this manual, please consult your
Yamaha dealer.
9 This manual should be considered a per-
manent part of this motorcycle and
should remain with it even if the motorcycle is subsequently sold.
A CAUTION indicates special precautions
that must be taken to avoid damage to the
motorcycle.
NOTE:
A NOTE provides key information to make
procedures easier or clearer.
EUU60100
w
PLEASE READ THIS MANUAL CAREFULLY
AND COMPLETELY BEFORE OPERATING
THIS MOTORCYCLE.
2
EAA30001
CONTENTS
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.................................................16
Steering 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
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 ............................58
Drive 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
4
EUU75901
GIVE SAFETY THE RIGHT OF WAY
Motorcycles are fascinating vehicles, which
can give you an unsurpassed feeling of
power and freedom. However, they also
impose certain limits, which you must accept; even the best motorcycle does not ignore the laws of physics.
Regular care and maintenance are essential 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 riders - more than car drivers - must always
be at their mental and physical best. Under
the influence of even small amounts of alcohol, there is a tendency to take dangerous 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 materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet.
Optimum protective wear, however, should
not encourage carelessness. Though fullcoverage helmets and suits, in particular,
create an illusion of total safety and protection, motorcyclists will always be vulnerable. 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
EAA50000
qw e r t
yu
io !1
!2
!0
!3 !4 !5 !6
!7
!8
@0
!9
!3
DESCRIPTION
1. Tail/Brake light
2. Rear flasher light
3. Side cover
4. Fuel tank cap
5. Front flasher light
6. Rear brake pedal
7. Kick starter
8. Head light
9. Fuel tank
10. Helmet holder
11. Seat lock
6
12. Shift pedal
13. Handlebar switch
14. Speedometer
15. Fuel gauge
16. Front brake lever
17. Throttle grip
18. Main switch/steering lock
19. Indicator light
20. Starter lever
EAA60000
MOTORCYCLE IDENTIFICATION
1. KEY IDENTIFICATION 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 assistance when ordering spare parts from a
Yamaha dealer for reference in case the vehicle is stolen.
7
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.
8
EAB00000
CONTROL FUNCTIONS
EAB00100
Main switch
The main switch controls the ignition and lighting systems. Its operation is described
below.
Position Function Key removal
ON
Electrical circuits are switched on.
The engine can be started.
OFF
Cannot be removed.
LOCK
All electrical circuits are switched off.
The steering is locked and all
electrical circuits are switched off.
9
Can be removed.
Can be removed.
EAB10000
&
qw
e
r
Indicator lights
Description Function
1. High beam indicator light
2. Turn signal indicator light
3. Gear position indicator light
4. Neutral indicator light
High beam indicator light “&”:
Turn signal indicator light “ ”:
Gear position
indicator light
“1” “2” “3” “4”:
Neutral indicator
light “N”:
10
Lights when the
headlight high
beam is used.
Flashes when the
turn switch is
“ON”.
Light when the
transmission is in
1st,2nd,3rd,4th(top)
gear.
Lights when the
transmission is in
neutral.
Instrument panel
&
qw
e
Description Function
1. Speedometer 2. Odometer
3. Fuel gauge
Speedometer
Odometer
Fuel gauge
11
Shows riding speed.
Shows accumulated mileage.
Shows the fuel level
in the fuel tank.
Remaining fuel is
about 1.0 L at “E”
position.
q
1. Dimmer switch
w
2. Turn signal switch
Handlebar switches
Dimmer switch
Position Function
& (HI)
% (LO)
Turns on the headlight high
beam.
Turns on the headlight low
beam.
Turn signal switch
Position Function
4
OFF
Turns on the left flasher.
6
Turns on the right flasher.
Turns off the flasher.
∇
Push the switch in after it has
returned to center position.
12
Horn switch
e
r
t
Position Function
3. Horn switch
4. Lights switch
5. Start switch
*
(HORN)
The horn sounds when pushing the switch.
Lights 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.
Start switch
Position Function
START
The starter motor cranks the
engine when pushing the
switch.
13
q
1. Shift pedal N. Neutral
q
1. Front brake lever
EAB80001
Shift pedal
This motorcycle is equipped with a constant-mesh 4-speed transmission. The shift
pedal is located on the left side of the engine.
EAB90001
Front brake lever
The front brake lever is located on the right
handlebar. Pull it toward the handlebar to
apply the front brake.
14
q
1. Rear brake pedal
q
1. Fuel tank cap
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
To add fuel, open the seat. Then remove
the fuel tank cap by turning it counterclockwise.
(See page 18 to open the seat.)
15
q
1. Starter lever
q
1. Kick starter
EAC20100
Starter lever 1
The starter lever is located on the left handlebar. 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 engine. Push the starter down lightly with
your foot until the gears engage, then kick
smoothly and forcefully to start the engine.
16
EAC30401
Steering lock
The steering is locked when the main
switch is turned to “LOCK”. To 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 counterclockwise to “LOCK”, and remove it. To
release the lock, turn the key to “OFF”.
1
1. Push 2. Release
3. Turn
2
3
17
EAC42301
Seat
To 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.
To lock the seat:
1. Replace the seat in the original position.
2. Slightly push the end of the seat down
to lock.
EUU01700
NOTE:
Make sure that the seat is securely fitted.
18
q
1. Helmet holder
EAU00262*
Helmet holder
The helmet holder is located under the
seat.
To secure a helmet :
1. Open the seat. (See page 18 for opening procedures.)
2. Attach the helmet to the helmet holder, and then securely close the seat.
EW000030
w
Never ride with a helmet attached to the
helmet holder, since the helmet may hit
objects, causing loss of control and possibly an accident.
To release the helmet;
Open the seat, remove the helmet from the
helmet holder, and then close the seat.
19
PRE-OPERATION CHECKS
Before using this motorcycle, check the following points:
Item Routine Page
Fuel 9 Check fuel level/top up as required. 22
Engine oil 9 Check oil level/add oil as required. 23, 42–44
Front brake 9 Check operation and lever free play. Adjust if necessary.
Rear brake 9 Check operation and pedal free play. Adjust if necessary. 53, 55
Throttle grip/Housing 9 Check for smooth operation. Lubricate/Adjust if necessary. —
Drive chain 9 Check chain slack and condition. Adjust if necessary. 58–61
Wheels/Tires 9 Check tire pressure, wear, damage and spoke tightness. 24–25
Control/Meter cable 9 Check for smooth operation. Lubricate if necessary. —
Brake and shift pedal shafts 9 Check for smooth operation. Lubricate if necessary. 62
Brake lever pivot 9 Check for smooth operation. Lubricate if necessary. 62
Center and sidestand pivots 9 Check for smooth operation. Lubricate if necessary. 62
Fittings/fasteners 9 Check all chassis fittings and fasteners.
Lights and signals 9 Check for proper operation. —
Switches 9 Check for proper operation. —
Battery 9 Check fluid level, fill with distilled water if necessary. 64–66
9 Check fluid level and fluid leakage Fill with DOT3 or 51–52, 54–57
DOT4 brake fluid if necessary.
9 Tighten/Adjust, if necessary.
—
20
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 repaired before operating the motorcycle.
21
2
1
1. Filler tube 2. Fuel level
EAE80300
Recommended fuel: Regular gasoline
Fuel tank capacity:
Total:
4.5 L
Reserve:
1.4 L
EAE80000
Fuel
Make sure there is sufficient fuel in the
tank.
EUU61000
w
Do not overfill the fuel tank. Avoid 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 overflow when the fuel heats up later and expands.
EUU39302
cC
Always wipe off spilled fuel immediately
with a dry and clean soft cloth. Fuel may
deteriorate painted surfaces or plastic
parts.
22
q
w
e
1. Oil level gauge 2. Upper level
3. Lower level
EAE40104*
Engine oil
Make sure the engine oil is at the specified
level. Fill with oil as necessary (see page 42
for details).
Recommended oil:
Yamalube 4 (20W40) or equivalent
SAE 20W40 type SE or higher grade
motor oil
SAE 20W50 type SF/CC motor oil
Oil quantity:
Total amount:
1.0 L
Periodic oil change:
0.8 L
23
Cold tire pressure: Front Rear
Up to 90 kg load*
(Solo rider) (2.0 kgf/cm2) (2.25 kgf/cm2)
90 kg load ~
Maximum load*
(With passenger)
Maximum load* 110 kg
*Load is the total weight of cargo, rider, passenger, and
accessories.
200 kPa 225 kPa
200 kPa 225 kPa
(2.0 kgf/cm2) (2.25 kgf/cm2)
EAE96700
Tires
To ensure maximum performance, long
service, and safe operation, note the following:
1. Tire air pressure
Always check and adjust the tire pressure before operating the motorcycle.
EUU67500
w
Tire inflation pressure should be checked
and adjusted when the temperature of the
tire equals the ambient air temperature.
Tire inflation pressure must be adjusted
according to total weight of cargo, rider,
and passenger.
24
2. Tire inspection
1
2
Always check the tires before operating 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, contact a Yamaha dealer immediately and
have the tire replaced.
1. Tread depth 2. Side wall
FRONT:
Manufacturer Size
INOUE 2.50-17 38L
REAR:
Manufacturer Size
INOUE 2.75-17 41P
Minimum tire tread depth
(front and rear)
w
It is dangerous to ride with a worn-out
tire. When a tire tread begins to show
lines, have a Yamaha dealer replace the
tire immediately. Brakes, tires, and related
wheel parts replacement should be left to
a Yamaha Service Technician.
1.0 mm
25
N. Neutral
EAF00000
OPERATION AND
IMPORTANT RIDING
POINTS
EAF18800*
Starting and warming up a cold engine
1. Turn the main switch to “ON”.
2. Shift transmission into neutral.
EUU03000
NOTE:
When the transmission is in neutral, the
neutral indicator light “N” (green) should
be on. If the light does not come on, ask a
Yamaha dealer to inspect it.
26
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 not
crank the engine more than 10 seconds on
any one attempt. If the engine does not
start with the starter motor, kick the kick
starter to start the engine.
5. After starting the engine, move the
starter lever to warming up position
(about halfway).
27
EUU02600
NOTE:
For maximum engine life, always warm up
the engine before starting off. Never accelerate 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 normally to the throttle with the starter turned
off.
EAF10802*
Starting a warm engine
The starter lever “1” is not required when
the engine is warm.
cC
Make sure the starter is turned off before
starting a warm engine.
28
q
1. Shift pedal N. Neutral
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.
To start out and accelerate
1. Close the throttle completely.
cC
Always close the throttle while shifting
gears. Otherwise, damage to the engine
and drive train can result.
2. Shift into FIRST gear.
3. Open the throttle gradually.
29
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. Turning it
toward you increases the speed, and
turning it in the opposite direction decreases the speed.
Recommend shift point
Gear position Recommend speed
1 st 0–20 km/h
2 nd 20–40 km/h
3 rd 30 km/h–
4 th (Top) 40 km/h–
30
To 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 completely stopped, shift into neutral.
Recommend shift point:
Gear position Recommend speed
4th → 3rd 0–40 km/h
3rd → 2rd 0–30 km/h
2nd → 1st 0–15 km/h
31
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 motorcycle from time to time. Do not operate 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.
32
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 replace the engine oil.
4. 1,000 km and beyond:
Avoid prolonged full-throttle operation. Vary speed occasionally.
EUU32200
cC
If any engine trouble should occur during
the break-in period, consult a Yamaha
dealer immediately.
33
EAF40000
Parking
When parking the motorcycle, stop the engine 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 motorcycle on a slope or soft ground; the motorcycle may overturn.
34
EAH00000
PERIODIC
MAINTENANCE AND
MINOR REPAIR
EAH00400
Periodic inspection, adjustment and lubrication will keep your motorcycle in the
safest and most efficient condition possible. Safety is an obligation of the motorcycle owner. The maintenance and lubrication schedule chart should be considered
strictly as a guide to general maintenance
and lubrication intervals.
EUU63200
w
If you are not familiar with motorcycle service, this work should be done by a
Yamaha dealer.
35
EAH10101*
q
Tool kit
The tools provided in the owner’s tool kit
are to assist you in the performance of periodic maintenance. However, some other
tools such as a torque wrench are also necessary to perform the maintenance correctly.
EUU67100
1. Tool kit
w
Modifications to this motorcycle not approved by Yamaha may cause loss of performance, and render it unsafe for use.
Consult a Yamaha dealer before attempting any changes.
36
PERIODIC MAINTENANCE/LUBRICATION
INITIAL EVERY
ITEM REMARKS
* 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
*
Fuel line
Engine oil Replace (Warm engine before draining). 22EVERY 2,000 km
* Engine oil filter Check/clean/replace if necessary. 2222
* Front brake (See NOTE on page 38) 22
* Rear brake
* Rear arm pivot Correct if necessary. Moderately repack every 2
* Wheels
* Wheel bearings
Check idle speed/starter operation.
Adjust if necessary.
Check fuel hose and vacuum pipe for cracks or
damage. Replace if necessary.
Check operation, fluid level and fluid leakage.
Replace brake pads if necessary.
Check operation and adjust brake pedal free play.
Replace brake shoes if necessary.
Check rear arm assembly for looseness.
16,000 km.***
Check balance/damage/runout/spoke tightness.
Replace if necessary.
Check bearing assembly for looseness/damage.
Replace if damaged.
500 km 2,000 km 4,000 km 8,000 km
2222
22
22
22
22 2
37
ITEM REMARKS
INITIAL EVERY
500 km 2,000 km 4,000 km 8,000 km
* Steering bearing Correct if necessary. Moderately repack every 22
* Front forks Check operation/oil leakage. Repair if necessary. 22
* Rear shock absorber Check operation/oil leakage. Repair if necessary. 22
Drive chain
* Fittings/Fasteners
* Centerstand and
sidestand
* Battery
*: 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)
Check bearing assembly for looseness.
8,000 km. **
Check chain slack/alignment. Adjust if necessary.
Clean and lube.
Check all chassis fitting and fasteners.
Correct if necessary.
Check operation. Repair if necessary. 2222
Check specific gravity. Check that the breather
pipe is working properly. Correct if necessary.
2222
EVERY 500 km
22
NOTE:
8 The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
8 Hydraulic brake service
9 Regularly check and, if necessary, correct the brake fluid level.
9 Every two years replace the internal components of the brake master cylinder and
caliper, and change the brake fluid.
9 Replace the brake hoses every four years and if cracked or damaged.
38
w
q
1. Front panels 2. Front cowlings
w
q
w
e
r
Front cowlings and panels removal/installation
T
o remove the front cowlings and panels.
1. Remove the screws of the front cowlings and panels.
2. Remove the main switch cover by
slightly turning it counterclockwise.
3. Take the panels off, and take the cowlings off.
1. Screw (×2) 2. Screw (×8)
3. Screw (×2) 4. Main switch cover
39
q
q
w
1. Front cowlings 2. Screw (×2)
w
q
1. Front panels 2. Front cowlings
To install the cowlings and panels.
1. Place the cowlings in the original position, and then install the screws.
2. Place the panels in the original position, and then install the screws.
3. Install the main switch cover and
slightly turn it clockwise.
40
q
1. Screw
EAU00488*
Side cover removal/installation
T
o remove the panel
Remove the screw, and then pull the panel
off as shown.
T
o install the panel
Place the panel in the original position, and
then install the screw.
41
q
w
e
1. Oil level gauge 2. Upper level
3. Lower level
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.
42
q
1. Drain plug
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.
Tightening torque
Drain plug 20 Nm (2.0 m•kg)
d. Reinstall the drain plug (make sure it
is tight.)
43
Recommended oil:
See page 23
Oil quantity:
Total amount:
1.0 L
Periodic oil change:
0.8 L
e. Fill engine with oil through the oil
level gauge hole.
EUU47700
cC
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 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
q
w
1. Air filter case cover 2. Screw (×4)
q
1. Air filter element
Air filter
1. Remove the front panel and the cowls
by removing the screws.
See page 39 for removing and installing the front panel and cowls.
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 solvent by squeezing the element.
45
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.
Recommended oil:
Yamalube 2 (2 stroke engine oil) or
Yamalube 4 (20W40)
5. Install the element in its case.
cC
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 without
the air filter element installed; excessive
piston and/or cylinder wear may result.
46
A. Free play: 3–7 mm
EAH92200
Throttle cable adjustment
EUU06400
NOTE:
Before adjusting the throttle cable free
play, the engine idling speed should be adjusted.
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.
Free play:
3–7 mm
47
q
1. Tachometer
q
1. Throttle stop screw
EAH92300
Carburetor adjustment
The carburetor is a vital part of the engine
and requires very sophisticated adjustment. Most adjustments should be left to a
Yamaha dealer who has the professional
knowledge and experience to do so.
Standard idle speed:
1,400–1,600 r/min
EAH92000
Idle speed adjustment
1. Attach the tachometer.
2. Set the idle to the specified engine
speed by adjusting the throttle stop
screw; turn the screw in to increase
engine speed, and out to decrease engine speed.
48
Standard spark plug:
C7HSA/NGK or U22FS-U/DENSO
1
1. Spark plug gap
EAH20304
Spark plug inspection
The spark plug is an important engine
component and is easy to inspect. The condition of the spark plug can indicate the
condition of the engine. The ideal color on
the white insulator around the center electrode is a medium-to-light tan color for a
motorcycle that is being ridden normally.
Do not attempt to diagnose any problems
yourself. Instead, take the motorcycle to a
Yamaha dealer. You should periodically remove and inspect the spark plug because
heat and deposits will cause the spark plug
to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you
should replace the spark plug with the
specified plug.
49
Spark plug gap:
0.6–0.7 mm
Spark plug torque:
12.5 Nm (1.25 m•kg)
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 available when
you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn
past finger tight. Have the spark plug
torqued to the correct value as soon as
possible with a torque wrench.
50
EAU03851*
Brake lever
Front and rear brake levers
There should be no free play at the brake
lever end. If there is free play, have a
Yamaha dealer inspect the brake system.
51
EW000099
w
A soft or spongy feeling in the brake lever
can indicate the presence of air in the hydraulic system. If there is air in the hydraulic system, have a Yamaha dealer
bleed the system before operating the motorcycle. Air in the hydraulic system will
diminish the braking performance, which
may result in loss of control and an accident.
52
Rear brake adjustment
q
The rear brake pedal free play should be
adjusted to 20–30 mm at the brake pedal
end. Turn the adjusting nut on the brake
rod clockwise to reduce free play or counterclockwise to increase free play.
EUU69800
w
A. Free play: 20–30 mm
1. Adjusting nut
1. The rear brake pedal adjustment must
be checked whenever the chain is adjusted or the rear wheel is removed
and then reinstalled.
2. Check the operation of the brake light
after adjusting the rear brake.
53
q
1. Brake light switch
q
q
1. Brake pad wear indicator groove (×2)
EAH83301
Brake light switch adjustment
The brake light switch is operated by
movement of the brake pedal. To 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.
EAU01119*
Checking the front brake pads
Front brake pad is provided with wear indicator grooves. This indicator allow you to
check the brake pad wear without disassembling the brake. To check the brake pad
wear, check the wear indicator grooves. If
the brake pad wear indicator grooves have
almost disappeared, have a Yamaha dealer
replace the brake pads as a set.
54
1
2
1. Wear limit 2. Indicator
q
1. Minimum level mark
EAH81601
Checking the rear brake shoes
A wear indicator is provided on rear brake.
This indicator allows checking of shoe
wear without disassembling the brake.
Apply the brake and check the position of
the indicator. If the indicator reaches to the
wear limit line, ask a Yamaha dealer to replace the shoes.
EAU00732
Checking the brake fluid level
Insufficient brake fluid may allow air to
enter the brake system, possibly causing it
to become ineffective.
Before riding, check that the brake fluid is
above the minimum level mark and replenish if necessary. A low brake fluid level
may indicate worn brake pads and/or brake
system leakage. If the brake level is low, be
sure to check the brake pads for wear and
the brake system for leakage.
55
Observe these precautions:
8 When checking the fluid level, make
sure that the top of the master cylinder is level by turning the handlebars.
8 Use only the recommended quality
brake fluid, otherwise the rubber seals
may deteriorate, causing leakage and
poor braking performance.
Recommended brake fluid: DOT 4
NOTE:
If DOT 4 is not available, DOT 3 can be
used.
8 Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and lead to
poor braking performance.
8 Be careful that water does not enter
the master cylinder when refilling.
Water will significantly lower the boiling point of the fluid and may result in
vapor lock.
8 Brake fluid may deteriorate painted
surfaces or plastic parts. Always clean
up spilled fluid immediately.
8 As 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
EAU03238
Changing the brake fluid
Have a Yamaha dealer change the brake
fluid at the intervals specified in the periodic maintenance and lubrication chart. In addition, have the oil seals of the brake master cylinder and caliper as well as the brake
hose replaced at the intervals listed below
or whenever they are damaged or leaking.
8 Oil seals: Replace every two years.
8 Brake hose: Replace every four years.
57
a
a. Drive chain slack: 20–30 mm
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 tightest position.
Inspect the drive chain when the motorcycle is on the centerstand. Check the slack at
the position shown in the illustration.
Normal slack is approximately 20–30 mm.
If the slack exceeds 30 mm, adjust it.
58
q
w
1. Rear brake adjusting nut 2. Axle nut
q
w
e
r
EAU03780*
Drive chain slack adjustment
1. Loosen the rear brake adjusting nut
and axle nut.
2. Loosen the locknut at each end of the
swingarm.
3. To tighten the drive chain, turn the ad-
justing nut clockwise.
To loosen the drive chain, turn the adjusting nut counterclockwise and then
push the rear wheel forward.
NOTE:
There are the alignment marks on each
side of the swingarm, use these marks to
align the rear wheel.
1. Rear wheel axle 2. Alignment marks
3. Adjusting nut 4. Locknut
59
EC000096
EW000103
cC
Improper drive chain slack will overload
the engine and other vital parts and can
lead to chain slippage or breakage. Keep
the drive chain slack within the specified
limits.
4. Tighten both locknuts, and then tighten the axle nut to the specified torque.
Tightening torque:
Axle nut:
60 Nm (6.0 m•kg)
5. Adjust the brake pedal free play. (See
page 53 for adjustment procedure.)
w
After adjusting the brake pedal free play,
check the operation of the brake light.
60
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 quickly. Therefore, the chain must be serviced
regularly. This service is especially necessary when riding in dusty areas.
1. Use any of the many brands of chain
lubricant. First, remove all dirt and
mud from the chain with a brush or
cloth, then apply lubricant between
both rows of side plates and on all
center rollers. The chain should be lubricated every 500 km.
2. If the chain is too dirty or rusty, take
the motorcycle for repair.
61
EAI30601
Brake lever and pedal
Lubricate the pivoting parts.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
EAI30801
Center and sidestand
Lubricate the pivoting parts. Check to see
that the center and sidestand move up and
down smoothly.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
62
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
cC
If any damage or unsmooth movement is
found with the front fork, consult a
Yamaha dealer.
63
q
w
1. Upper level 2. Lower level
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
cC
When inspecting the battery, be sure the
breather pipe is routed correctly.
64
q
EUU65800
w
Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid 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 physician immediately.
Eyes: Flush with water for 15 minutes and
get prompt medical attention. Batteries
produce explosive gases. Keep sparks,
flame, cigarettes etc., away. Ventilate
when charging or using in an enclosed
space. Always shield your eyes when
working near batteries.
KEEP OUT OF REACH OF CHILDREN.
1. Battery breather pipe
65
Replenishing the battery fluid
1
2
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
1. Maximum level “UPPER LEVEL”
2. Minimum level “LOWER LEVEL”
cC
Normal tap water contains minerals which
are harmful to a battery; therefore, refill
only with distilled water.
EUU65901
w
Take care not to spill battery fluid on the
chain. Battery fluid may weaken the chain
causing shorter chain life and possibly result in an accident.
66
q
1. Fuse case
Specified fuse: 10 A
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. Turn on the switches and
see if the electrical device operates. If
the fuse immediately blows again,
consult a Yamaha dealer.
EUU34400
cC
Do not use fuses of higher amperage rating
than those recommended. Substitution of a
fuse of improper rating can cause extensive
electrical system damage and possibly a
fire.
67
EAJ50002
Troubleshooting
Although Yamaha motorcycles receive a
rigid inspection before shipment from the
factory, trouble may occur during operation. If your motorcycle requires any repair,
bring it to a Yamaha dealer. The skilled
technicians at a Yamaha dealership have
the tools, experience, and know-how to
properly service your motorcycle. Use only
genuine Yamaha parts on your motorcycle.
Imitation parts may look like Yamaha parts,
but they are often inferior. Consequently,
they have a shorter service life and can
lead to expensive repair bills.
68
EAK00000
CLEANING AND
STORAGE
EAK01302*
A. CLEANING
Frequent, thorough cleaning of your motorcycle will not only enhance its appearance but will improve its general performance and extend the useful life of many
components.
1. Rinse the dirt and degreaser off with a
garden hose.
EUU34602
cC
Excessive hose pressure may cause water
seepage and deterioration of wheel bearings, front fork, brakes, transmission seals
and electrical parts.
2. After cleaning the motorcycle, dry all
surfaces with a chamois, clean towel,
or soft absorbent cloth.
3. Dry the chain and lubricate it to prevent rust.
4. Automotive-type wax may be applied
to all painted and chrome-plated surfaces. When finished, start the engine
and let it idle for several minutes.
EAK00700
B. STORAGE
Long term storage (60 days or more) of
your motorcycle will require some preventive procedures to guard against deterioration. After thoroughly cleaning the motorcycle, prepare for storage as follows:
1. Drain the fuel tank, fuel lines, and carburetor float bowl(s).
2. Remove the empty fuel tank, pour a
cup of SAE 10W30 or 20W40 motor oil
in the tank, shake the tank to coat the
inner surfaces thoroughly and drain
off the excess oil. Reinstall the tank.
69
3. Remove the drive chain. Thoroughly
clean the chain with solvent and lubricate it. Reinstall the chain or store it in
a plastic bag (tied to frame for safekeeping).
4. Lubricate all control cables.
5. Block up the frame to raise both
wheels off the ground.
6. Tie a plastic bag over the exhaust pipe
outlet to prevent moisture from entering.
7. If storing in a humid or salt-air atmosphere, coat all exposed metal surfaces
with a light film of oil. Do not apply oil
to any rubber parts or the seat cover.
8. Remove the battery and charge it.
Store it in a dry place and recharge it
once a month. Do not store the battery in an excessively warm or cold
place (less than 0°C (32°F) or more
than 30°C (86°F)).
EUU05800
NOTE:
Make any necessary repairs before storing
the motorcycle.
70
SPECIFICATIONS
Model
Dimensions:
Overall length 1,890 mm
Overall width 670 mm
Overall height 1,055 mm
Seat height 770 mm
Wheelbase 1,210 mm
Minimum ground clearance 145 mm
Basic weight:
With oil and full fuel tank 99 kg
Minimum turning radius: 1,800 mm
Engine:
Type Air cooled 4 stroke, SOHC
Cylinder arrangement Forward inclined single cylinder
Displacement 101.8 cm
Bore ×stroke 49.0 ×54.0 mm
Compression ratio 9.0 : 1
Starting system Electric and kick starter
Lubrication system: Wet sump
3
71
Model
Engine oil (4-cycle):
Type Yamalube 4 (20W40) or equivalent
SAE 20W40 type SE or higher grade
motor oil
SAE 20W50 type SF/CC 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 4.5 L
Carburetor:
Type/manufacturer VM16SH/MIKUNI
72
Model
Spark plug:
Type/manufacturer C7HSA/NGK, U22FS-U/DENSO
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 38/15 (2.533)
Transmission type Constant mesh 4 speed
Operation Left foot operation
Gear ratio:
1st 38/12 (3.167)
2nd 33/17 (1.941)
3rd 29/21 (1.381)
4th 23/21 (1.095)
73
Model
Chassis:
Frame type Steel Tube underbone
Caster angle 26.5°
Trail 79 mm
Tire:
Type With tube
Size – Front 2.50-17 38L
Rear 2.75-17 41P
Brake:
Front brake type Single disc 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 spring/oil damper
Rear Coil spring/oil damper
74
Model
Wheel travel:
Front 90 mm
Rear 66 mm
Electrical:
Ignition system DC. CDI
Generator system A.C. magneto
Battery type/capacity 12V5AH
Headlight type: Bulb type
Bulb wattage/quantity:
Headlight 12V25W/25W × 2
Tail/brake light 12V/5W/21W × 1
Flasher light 12V10W × 4
Meter light 14V3W × 1
Indicator light wattage/quantity:
High beam indicator light 12V1.7W × 1
Turn signal indicator light 12V1.7W × 1
Neutral indicator light 12V1.7W × 1
Gear position indicator light 12V1.7W × 4
75
Loading...