5AV-F8199-E1 hyosi 7/29/03 10:15 AM Page 1

OWNER'S
MANUAL

YAMAHA MOTOR CO., LTD.

5AV-F8199-E1
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EAA00100 EAA20301

T105E/SE
INTRODUCTION
Congratulations on your purchase of the
OWNERS MANUAL
Yamaha T105E/SE. This model is the result
2003 by Yamaha Motor Co, Ltd.
of Yamahas vast experience in the produc-
Manufacturing
tion of fine sporting, touring, and paceset-
1st edition, July 2003
ting racing machines. It represents the high
All rights reserved.
degree of craftsmanship and reliability that
Any reprinting or unauthorized use
have made Yamaha a leader in these fields.
without the written permission of
This manual will give you an understand-
Yamaha Motor Co, Ltd.
ing of the operation, inspection, and basic
is expressly prohibited.
maintenance of this motorcycle. If you
Printed in China
have any questions about the operation or
maintenance of your motorcycle, please
consult a Yamaha dealer.

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EAA10500 EUU13800*

Particularly important information is distin- NOTE:

guished in this manual by the following 9 Yamaha continually seeks advancements
notations: in product design and quality. Therefore,
Q while this manual contains the most cur-
The Safety Alert Symbol means ATTEN- rent product information available at the
TION! BECOME ALERT! YOUR SAFETY IS time of printing, there may be minor dis-
INVOLVED! crepancies between your machine and
this manual. If there is any question con-
w
cerning this manual, please consult your
Failure to follow WARNING instructions Yamaha dealer.
could result in severe injury or death to the 9 This manual should be considered a per-
motorcycle operator, a bystander or a per- manent part of this motorcycle and
son inspecting or repairing the motorcycle. should remain with it even if the motor-
cC cycle is subsequently sold.
A CAUTION indicates special precautions EUU60100

that must be taken to avoid damage to the w

motorcycle.
PLEASE READ THIS MANUAL CAREFULLY
NOTE: AND COMPLETELY BEFORE OPERATING
A NOTE provides key information to make THIS MOTORCYCLE.
procedures easier or clearer.

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EAA30001

CONTENTS
GIVE SAFETY THE RIGHT OF WAY...............5 Steering lock..............................................19
GENERAL NOTE..............................................6 Seat ............................................................20
DESCRIPTION..................................................8 Helmet holder ...........................................21
MOTORCYCLE IDENTIFICATION...................9 Side cover removal...................................21
Identification numbers record ...................9 PRE-OPERATION CHECKS ...........................22
Key identification number .......................10 Fuel.............................................................24
Frame serial number ................................10 Engine oil...................................................25
Engine serial number ...............................10 Tires............................................................26
CONTROL FUNCTIONS................................11 OPERATION AND IMPORTANT
Main switch ...............................................11 RIDING POINTS.............................................28
Indicator lights ..........................................12 Starting and warming up a
Instrument panel.......................................13 cold engine ................................................28
Handlebar switches ..................................14 Starting a warm engine ...........................30
Shift pedal .................................................16 Shifting.......................................................31
Front brake lever.......................................16 To start out and accelerate.......................31
Rear brake pedal .......................................17 To decelerate .............................................33
Fuel tank cap .............................................17 Engine break-in .........................................34
Starter lever 1..........................................18 Parking .......................................................36
Kick starter.................................................18

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PERIODIC MAINTENANCE AND Drive chain slack adjustment ..................57

MINOR REPAIR..............................................37 Drive chain lubrication .............................59
Tool kit........................................................38 Brake lever and pedal...............................60
Periodic maintenance/lubrication ...........39 Center and sidestand ...............................60
Engine oil...................................................41 Front fork inspection ................................61
Air filter ......................................................44 Battery........................................................62
Throttle cable adjustment........................46 Replenishing the battery fluid .................64
Carburetor adjustment.............................47 Fuse replacement .....................................65
Idle speed adjustment..............................47 Troubleshooting........................................66
Spark plug inspection ..............................48 CLEANING AND STORAGE .........................67
Front brake adjustment(T105E)...............50 Cleaning.....................................................67
Front brake adjustment (T105SE) ...........50 Storage ......................................................67
Checking the front brake pads SPECIFICAITIONS .........................................69
(T105SE) .................................................51
Checking the brake fluid level
(T105SE)..................................................51
Changing the brake fluid (T105SE) .........53
Rear brake adjustment .............................54
Brake light switch adjustment.................55
Checking the brake shoes ........................55
Drive chain slack check ............................56

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EUU75901

GIVE SAFETY THE RIGHT OF WAY

Motorcycles are fascinating vehicles, which Protective clothing is as essential for the
can give you an unsurpassed feeling of motorcycle rider as seat belts are for car
power and freedom. However, they also drivers and passengers. Always wear a
impose certain limits, which you must ac- complete motorcycle suit (whether made
cept; even the best motorcycle does not ig- of leather or tear-resistant synthetic materi-
nore the laws of physics. als with protectors), sturdy boots, motorcy-
Regular care and maintenance are essen- cle gloves and a properly fitting helmet.
tial for preserving your motorcycles value Optimum protective wear, however, should
and operating condition. Moreover, what is not encourage carelessness. Though full-
true for the motorcycle is also true for the coverage helmets and suits, in particular,
rider: good performance depends on being create an illusion of total safety and protec-
in good shape. Riding under the influence tion, motorcyclists will always be vulnera-
of medication, drugs and alcohol is, of ble. Riders who lack critical self-control run
course, out of the question. Motorcycle rid- the risk of going too fast and are apt to
ers - more than car drivers - must always take chances. This is even more dangerous
be at their mental and physical best. Under in wet weather. The good motorcyclist
the influence of even small amounts of al- rides safely, predictably and defensively -
cohol, there is a tendency to take danger- avoiding all dangers, including those
ous risks. caused by others. Enjoy your ride!

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GENERAL NOTE
Much can be gained from the correct use and maintenance of a
motorcycle. A MOTORCYCLE CAN KEEP ITS PERFORMANCE
THE CUSTOMERS CAN USE THE FULLEST 2 CAPABILITY FOR A LONGER TIME
1 POTENTIAL OF YAMAHA MOTORCYCLES

Comparison of wear on engine parts

(piston, piston ring, cylinder, etc.)
100% With maintenance

Perfect operative
condition
Without
maintenance

Distance
covered (km) Engine overhaul, cylinder
boring, piston ring change, etc.

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GENERAL NOTE

FUEL COST AND REPAIR EXPENSES CAN BE A MOTORCYCLE CAN DEMAND A HIGH PRICE
3 KEPT TO A MINIMUM 4 WHEN IT IS TRADED IN AS A USED PRODUCT

Fuel consumption

With maintenance
100%

Without
maintenance
Distance covered (km)

Customers running cost

(fuel cost plus maintenance and repair expenses)
Without maintenance
S
Big repairs at higher expenses

With maintenance

Distance covered (km)

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EAA50000

DESCRIPTION

1. Tail/Brake light 11. Shift pedal

2. Rear flasher light 12. Handlebar switch
3. Side cover 13. Speedometer
4. Fuel tank cap 14. Fuel gauge
5. Front flasher light 15. Main switch/steering lock
6. Kick starter 16. Throttle grip
7. Rear brake pedal 17. Front brake lever
8. Head light 18. Indicator light
9. Fuel tank 19. Helmet holder
10. Seat lock 20. Starter lever

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EAA60000

MOTORCYCLE IDENTIFICATION
1. KEY IDENTIFICATION NUMBER: EAA61101

Identification numbers record

Record the key identification number,
frame serial number and engine serial
2. FRAME SERIAL NUMBER: 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.
3. ENGINE SERIAL NUMBER:

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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.

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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.
Cannot be removed.
The engine can be started.

OFF
All electrical circuits are switched off. Can be removed.

LOCK
The steering is locked and all
Can be removed.
electrical circuits are switched off.

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EAB10000

Indicator lights
Description Function

Flashes when the

Turn indicator light
turn switch is
5:
ON.

Lights when the

Neutral indicator
transmission is in
light N:
1 Turn indicator light neutral.
2 Neutral indicator light
3 Top gear indicator light
4 High beam indicator light Light when the
Top gear indicator
transmission is in
light TOP:
top (4th) gear.

Lights when the

High beam indica-
headlight high
tor light &:
beam is used.

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Instrument panel
Description Function

Speedometer Shows riding speed.

Shows accumlated
Odometer
mileage.
1 Speedometer 2 Odometer
3 Fuel gauge

Shows the fuel level

Fuel gauge
in the fuel tank.

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Handlebar switches
Lights switch
Position Function
Headlight, taillight and meter lights
ON
comes on when engine is running.
Headlight, taillight and meter lights
OFF
1 Lights switch does not come on.
Dimmer switch
Position Function
Turns on the headlight high
& (HI)
beam.
Turns on the headlight low
% (LO)
beam.
2 Dimmer switch
Turn signal switch
Position Function
4 Turns on the left flasher.
6 Turns on the right flasher.
Turns off the flasher.
Push the switch in after it has
OFF
returned to center position.
3 Turn signal switch

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Horn switch
Position Function

* The horn sounds when push-

(HORN) ing the switch.

4 Horn switch
Start switch
Position Function

The starter motor cranks the

START
engine when pushing the
switch.

5 Start switch

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EAB80001

Shift pedal
This motorcycle is equipped with a con-
stant-mesh 4-speed transmission. The shift
pedal is located on the left side of the en-
gine.

1 Shift pedal N. Neutral

EAB90001

Front brake lever

The front brake lever is located on the right
handlebar. Pull it toward the handlebar to
apply the front brake.

1 Front brake lever

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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.

1 Rear brake pedal

EAC01300*

Fuel tank cap

To add fuel, open the seat. Then remove
the fuel tank cap by turning it counterclock-
wise.
(See page 20 to open the seat.)

1 Fuel tank cap

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EAC20100

Starter 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.

1 Starter lever

EAC60700

Kick 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.

1 Kick starter

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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 coun-
terclockwise to LOCK, and remove it. To
release the lock, turn the key to OFF.

1 Push 2 Release 3 Turn

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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 posi-
tion.
2. Slightly push the end of the seat down
to lock.
EUU01700

NOTE:
Make sure that the seat is securely fitted.

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EAC50001

Helmet holder
To open the helmet holder, insert the key in
the lock and turn it as shown. To lock the
helmet holder, replace the holder in its
original position.
EUU72900

w
Never ride with a helmet in the helmet
1 Helmet holder
holder. The helmet may hit objects, caus-
ing loss of control and possibly an acci-
dent.

Side cover removal

Remove the screw. Then remove the side
cover by pulling outward as shown.

1 Screw

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PRE-OPERATION CHECKS
Before using this motorcycle, check the following points:

Item Routine Page

Fuel 9 Check fuel level/top up as required. 24
Engine oil 9 Check oil level/add oil as required. 25, 41~43
9 Check operation, condition and free play. Adjust if necessary.
Front brake 9 Check fluid level and fluid leakage. Fill with DOT3 or DOT4 50~53
brake fluid if necessary. (T105SE)
Rear brake 9 Check operation and pedal free play. Adjust if necessary. 54
Throttle grip/Housing 9 Check for smooth operation. Lubricate/Adjust if necessary.
Drive chain 9 Check chain slack and condition. Adjust if necessary. 56~59
Wheels/Tires 9 Check tire pressure, wear, damage and spoke tightness. 26~27
Control/Meter cable 9 Check for smooth operation. Lubricate if necessary.
Brake and shift pedal shafts 9 Check for smooth operation. Lubricate if necessary. 60
Brake lever pivots 9 Check for smooth operation. Lubricate if necessary. 60
Center and sidestand pivots 9 Check for smooth operation. Lubricate if necessary. 60
Fittings/fasteners 9 Check all chassis fittings and fasteners.

9 Tighten/Adjust, if necessary.
Lights and signals 9 Check for proper operation.
Switches 9 Check for proper operation.
Battery 9 Check fluid level, top-up with distilled water if necessary. 62~64

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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 re-
paired before operating the motorcycle.

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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
1. Filler tube 2. Fuel level shown in the illustration or it may over-
flow when the fuel heats up later and ex-
EAE80300
pands.
Recommended fuel:
Regular gasoline EUU39302

Fuel tank capacity:

cC
4.3 L
Always wipe off spilled fuel immediately
with a dry and clean soft cloth. Fuel may
deteriorate painted surfaces or plastic
parts.

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EAE40104*

Engine oil
Make sure the engine oil is at the specified
level. Fill with oil as necessary (see page 41
for details).

Recommended oil:
Yamalube 4 (20W40) or equivalent
SAE 20W40 type SE motor oil
Oil quantity:
1 Oil level gauge 2 Upper level 3 Lower level Total amount:
1.0 L
Periodic oil change:
0.8 L

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EAE96700

Cold tire pressure: Front Rear Tires

175 kPa 200 kPa To ensure maximum performance, long
Solo rider
(1.75 kgf/cm2) (2.0 kgf/cm2)
200 kPa 225 kPa service, and safe operation, note the fol-
With passenger
(2.0 kgf/cm2) (2.25 kgf/cm2) lowing:
1. Tire air pressure
Always check and adjust the tire pres-
sure 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.

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2. Tire inspection
Always check the tires before operat-
ing 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, con-
tact a Yamaha dealer immediately and
have the tire replaced.

1. Tread depth 2. Side wall 3. Wear indicator

w
It is dangerous to ride with a worn-out
Size tire. When a tire tread begins to show
FRONT
2.25-17 33L lines, have a Yamaha dealer replace the
tire immediately. Brakes, tires, and related
Size wheel parts replacement should be left to
REAR
2.50-17 38L
a Yamaha Service Technician.

Minimum tire tread depth

1.0 mm
(front and rear)

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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 (green) should be
on. If the light does not come on, ask a
Yamaha dealer to inspect it.

N. Neutral

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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 warmming up position
(about halfway).

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EUU02600

NOTE:
For maximum engine life, always warm up
the engine before starting off. Never accel-
erate 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 nor-
mally 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.
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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 completery.
1 Shift pedal N. Neutral
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.

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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 de-
creases 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~

32
4 th (Top) 40 km/h~
5AV-F8199-E1-2 8/1/03 1:47 PM Page 33

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 com-
pletely stopped, shift into nutral.

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

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EAF30000*

Engine break-in
0~150Km 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
1/3 must be avoided during this period.
EAF30800

1. 0~150 km:
Avoid prolonged operation above 1/3
throttle. Vary the speed of the motor-
0~500Km 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
1/2 the gears, but do not use full throttle
at any time.

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3. 500~1,000 km:
500~1000Km Avoid cruising speeds in excess of 3/4
throttle.
EUU40400

cC
After 1,000 km of operation, be sure to re-
3/4 place the engine oil.

4. 1,000 km and beyond:

Avoid prolonged full-throttle opera-
tion. Vary speed occasionally.
1000Km~ EUU32200

cC
If any engine trouble should occur during
the break-in period, consult a Yamaha
dealer immediately.

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EAF40000

Parking
When parking the motorcycle, stop the en-
gine 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 mo-
torcycle on a slope or soft ground; the mo-
torcycle may overturn.

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EAH00000

PERIODIC
MAINTENANCE AND
MINOR REPAIR
EAH00400

Periodic 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.
EUU63200

w
If you are not familiar with motorcycle ser-
vice, this work should be done by a
Yamaha dealer.

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EAH10101*

Tool kit
The tools provided in the owners 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.
EUU67100

w
1 Tool kit
Modifications 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.

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PERIODIC MAINTENANCE/LUBRICATION

INITIAL EVERY
ITEM REMARKS
500 km 2,000 km 4,000 km 8,000 km

* Valve(s) Check valve clearance. Adjust if necessary. 2 2 2 2

Spark plug Check condition. Clean or replace if necessary. 2 2 2 2
Air filter Clean. Replace if necessary. 2 2
Check idle speed/stater operation.
* Carburetor 2 2 2 2
Adjust if necessary.
Check fuel hose and vacuum pipe for cracks or
* Fuel line 2 2
damage. Replace if necessary.
Engine oil Replace (Warm engine before draining). 2 2 EVERY 2,000 km
* Engine oil filter Check/clean/replace if necessary 2 2 2 2
Front brake Check operation, fluid level and fluid leakage.
* 2 2
(T105SE) Replace brake pads if necessary.
Front brake Check operation and adjust brake lever free play.
* 2 2
(T105E) Replace brake shoes if necessary.
Check operation and adjust brake pedal free play.
* Rear brake 2 2
Replace brake shoes if necessary.
Check rear arm assembly for looseness.
* Rear arm pivot Correct if necessary. Moderately repack every. 2
16,000 km***
Check balance/damage/runout/spoke tightness.
* Wheels 2 2
Replace if necessary.
Check bearing assembly for looseness/damage.
* Wheel bearings 2 2 2
Replace if damaged.

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INITIAL EVERY
ITEM REMARKS
500 km 2,000 km 4,000 km 8,000 km

Check bearing assembly for looseness.

* Steering bearing Correct if necessary. Moderately repack every 2 2
8,000 km. **
* Front forks Check operation/oil leakage. Repair if necessary. 2 2
* Rear shock absorber Check operation/oil leakage. Repair if necessary. 2 2
Check chain slack/alignment. Adjust if necessary.
Drive chain EVERY 500 km
Clean and lube.
Check all chassis fitting and fasterners.
* Fittings/Fasteners 2 2 2 2
Correct if necessary.
* Centerstand and
Check operation. Repair if necessary. 2 2 2 2
sidestand
Check specific gravity. Check that the breather
* Battery 2 2
pipe is working properly. Correct if necessary

*: 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)

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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
1 Oil level gauge 2 Upper level 3 Lower level 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
5AV-F8199-E1-2 8/1/03 1:47 PM Page 42

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.
q Tightening torque
1 Drain plug
Drain plug 20 Nm (2.0 mkg)

d. Reinstall the drain plug (make sure it

is tight.)

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5AV-F8199-E1-2 8/1/03 1:47 PM Page 43

e. Fill engine with oil through the oil

Recommended oil: level gauge hole.
See page 25 EUU47700
Oil quantity:
cC
Total amount:
1.0 L 9 Do not put in any chemical additives or
Periodic oil change: use oils with a grade of CD (for Diesel
0.8 L 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.

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5AV-F8199-E1-2 8/1/03 1:47 PM Page 44

Air filter
1. Remove the front panel and the
legshield by removing the screws.
2. Remove the air filter case fitting
screws and the filter case cover.

1 Air filter case cover 2 Screw (4 pcs)

3. Remove the air filter element from its
case, and clean it with solvent. After
cleaning, remove the remaining sol-
vent by squeezing the element.

1 Air filter element

44
5AV-F8199-E1-2 8/1/03 1:47 PM Page 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.

45
5AV-F8199-E1-3 8/1/03 1:48 PM Page 46

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

A. Free play: 3~7 mm 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

46
5AV-F8199-E1-3 8/1/03 1:48 PM Page 47

EAH92300

Carburetor adjustment
The carburetor is a vital part of the engine
and requires very sophisticated adjust-
ment. 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
1 Tachometer

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 en-
gine speed.

1 Throttle stop screw

47
5AV-F8199-E1-3 8/1/03 1:48 PM Page 48

EAH20304

Spark plug inspection

Standard spark plug:
The spark plug is an important engine
C7HSA/NGK
component and is easy to inspect. The con-
U22FS-U/DENSO
dition of the spark plug can indicate the
condition of the engine. The ideal color on
the white insulator around the center elec-
trode 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 re-
move and inspect the spark plug because
heat and deposits will cause the spark plug
to slowly break down and erode. If elec-
trode erosion becomes excessive, or if car-
bon and other deposits are excessive, you
should replace the spark plug with the
specified plug.

1 Spark plug gap

48
5AV-F8199-E1-3 8/1/03 1:48 PM Page 49

Before installing the spark plug, measure

Spark plug gap:
the electrode gap with a wire thickness
0.6 ~ 0.7 mm
gauge; adjust the gap to specification as
necessary.
Spark plug torque: When installing the plug, always clean the
12.5 Nm (1.25 mkg) 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 esti-
mate 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.

49
5AV-F8199-E1-3 8/1/03 1:48 PM Page 50

EAH85201

Front brake adjustment (T105E)

The front brake lever free play should be
a
adjusted to 8~12 mm at the brake lever
end. Adjustment is accomplished at the
1
front brake hub. To adjust, turn the adjuster
clockwise to reduce play or counterclock-
wise to increase play.

A. Free play: 8~12 mm 1 Adjuster

Front brake adjustment (T105SE)

qw a The free play at the end of the front brake
lever should be 5~8 mm.
To adjust, turn the adjuster 2 until the free
play (a) is within the specified limits.
After adjusting, tighten the lock nut.

1 Lock nut a. 5~8 mm

2 Adjuster

50
5AV-F8199-E1-3 8/1/03 1:48 PM Page 51

EAU01119*

Checking the front brake pads (T105SE)

Front brake pad is provided with wear indi-
1 1 cator grooves. This indicator allow you to
check the brake pad wear without disas-
sembling 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
1. Brake pad wear indicator groove (3) replace the brake pads as a set.
EAU00732

Checking the brake fluid level (T105SE)

Insufficient brake fluid may allow air to
enter the brake system, possibly causing it
q to become ineffective.
Before riding, check that the brake fluid is
above the minimum level mark and replen-
ish if necessary. A low brake fluid level
may indicate worn brake pads and/or brake
system leakage. If the brake level is low, be
1. Minimum level mark sure to check the brake pads for wear and
the brake system for leakage.
51
5AV-F8199-E1-3 8/1/03 1:48 PM Page 52

Observe these precautions: 8 Be careful that water does not enter

8 When checking the fluid level, make the master cylinder when refilling.
sure that the top of the master cylin- Water will significantly lower the boil-
der is level by turning the handlebars. ing point of the fluid and may result in
8 Use only the recommended quality vapor lock.
brake fluid, otherwise the rubber seals 8 Brake fluid may deteriorate painted
may deteriorate, causing leakage and surfaces or plastic parts. Always clean
poor braking performance. up spilled fluid immediately.
8 As the brake pads wear, it is normal
Recommended brake fluid: DOT 4 for the brake fluid level to gradually
go down. However, if the brake fluid
NOTE: level goes down suddenly, have a
If DOT 4 is not available, DOT 3 can be Yamaha dealer check the cause.
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.

52
5AV-F8199-E1-3 8/1/03 1:48 PM Page 53

EAU03238

Changing the brake fluid (T105SE)

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.
8 Oil seals: Replace every two years.
8 Brake hose: Replace every four years.

53
5AV-F8199-E1-3 8/1/03 1:48 PM Page 54

Rear brake adjustment

The rear brake pedal free play should be
adjusted to 20~30 mm at the brake pedal
end. Turn the adjuster on the brake rod
clockwise to reduce play or counterclock-
wise to increase play.
EUU69800

w
1. The rear brake pedal adjustment must
A. Free play: 20~30 mm
be checked whenever the chain is ad-
justed or the rear wheel is removed
and then reinstalled.
2. Check the operation of the brake light
after adjusting the rear brake.

1 Adjuster

54
5AV-F8199-E1-3 8/1/03 1:48 PM Page 55

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.

1 Brake light switch

EAH81601

Checking the brake shoes

A wear indicator is provided on each 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 re-
place the shoes.
1 Wear limit 2 Indicator

55
5AV-F8199-E1-3 8/1/03 1:48 PM Page 56

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 its in this tight-
est position.

a. Drive chain slack: 20~30 mm

Inspect the drive chain when the motorcy-
cle 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.

56
5AV-F8199-E1-3 8/1/03 1:48 PM Page 57

Drive chain slack adjustment

1. Loosen the rear brake adjuster.
2. Loosen the axle nut.
3. Loosen the sprocket shaft nut and the
axle nut.
4. To tighten the chain, turn the chain ad-
juster clockwise. To loosen the chain,
turn the adjuster counterclockwise and
push the wheel forward. Turn each ad-
1 Rear brake adjuster 2 Axle nut juster exactly the same amount to main-
tain correct axle alignment. There are
marks on each side of the swingarm and
a match mark on each chain puller. Use
these marks to align the rear wheel.
EUU33301

cC
Too little chain slack will overload the en-
gine and other vital parts. Keep the slack
within the specified limits.
1 Axle nut 2 Sprocket shaft nut
3 Chain puller 4 Chain adjuster

57
5AV-F8199-E1-3 8/1/03 1:48 PM Page 58

5. After adjusting, be sure to tighten the

Tightening torque: loosened parts.
Axle nut: Tighten the axle nut at specified
60 Nm (6.0 mkg) torque.
Sprocket shaft nut: 6. Adjust the free play in the brake pedal.
80 Nm (8.0 mkg)

58
5AV-F8199-E1-3 8/1/03 1:48 PM Page 59

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 quick-
ly. Therefore, the chain must be serviced
regularly. This service is especially neces-
sary 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 lu-
bricated every 500 km.
2. If the chain is too dirty or rusty, take
the motorcycle for repair.

59
5AV-F8199-E1-3 8/1/03 1:48 PM Page 60

EAI30601

Brake lever and pedal

Lubricate the pivoting parts.
Recommended lubricant:
Yamalube 4 or SAE 20W40 motor oil

EAI30801

Center and sidestand

Lubricate the pivoting parts. Check to see
that the center and sidestand move up and
down smoothly.

Recommended lubricant:
Yamalube 4 or SAE 20W40 motor oil

60
5AV-F8199-E1-3 8/1/03 1:48 PM Page 61

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.

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5AV-F8199-E1-3 8/1/03 1:48 PM Page 62

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.
1 Upper level 2 Lower level

EUU33601

cC
When inspecting the battery, be sure the
breather pipe is routed correctly.

62
5AV-F8199-E1-3 8/1/03 1:48 PM Page 63

EUU65800

w
Battery electrolyte is poisonous and dan-
gerous, causing severe burns, etc. It con-
tains 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 physi-
cian 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

63
5AV-F8199-E1-3 8/1/03 1:48 PM Page 64

Replenishing the battery fluid

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

cC
1. Maximum level UPPER LEVEL
2. Minimum level LOWER LEVEL 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 re-
sult in an accident.

64
5AV-F8199-E1-3 8/1/03 1:48 PM Page 65

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,
1 Fuse case consult a Yamaha dealer.
EUU34400
Specified fuse: 7A
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.

65
5AV-F8199-E1-3 8/1/03 1:48 PM Page 66

EAJ50002

Troubleshooting
Although Yamaha motorcycles receive a
rigid inspection before shipment from the
factory, trouble may occur during opera-
tion. 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.

66
5AV-F8199-E1-3 8/1/03 1:48 PM Page 67

EAK00000

CLEANING AND 3. Dry the chain and lubricate it to pre-

STORAGE vent rust.
EAK01302* 4. Automotive-type wax may be applied
A. CLEANING to all painted and chrome-plated sur-
Frequent, thorough cleaning of your mo- faces. When finished, start the engine
torcycle will not only enhance its appear- and let it idle for several minutes.
ance but will improve its general perfor- EAK00700

mance and extend the useful life of many B. STORAGE

components. Long term storage (60 days or more) of
1. Rinse the dirt and degreaser off with a your motorcycle will require some preven-
garden hose. tive procedures to guard against deteriora-
EUU34602 tion. After thoroughly cleaning the motor-
cC cycle, prepare for storage as follows:
1. Drain the fuel tank, fuel lines, and car-
Excessive hose pressure may cause water
buretor float bowl(s).
seepage and deterioration of wheel bear-
2. Remove the empty fuel tank, pour a
ings, front fork, brakes, transmission seals
cup of SAE 10W30 or 20W40 motor oil
and electrical parts.
in the tank, shake the tank to coat the
inner surfaces thoroughly and drain
2. After cleaning the motorcycle, dry all off the excess oil. Reinstall the tank.
surfaces with a chamois, clean towel,
or soft absorbent cloth.
67
5AV-F8199-E1-3 8/1/03 1:48 PM Page 68

EUU05800

3. Remove the drive chain. Thoroughly NOTE:

clean the chain with solvent and lubri- Make any necessary repairs before storing
cate it. Reinstall the chain or store it in the motorcycle.
a plastic bag (tied to frame for safe-
keeping).
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 enter-
ing.
7. If storing in a humid or salt-air atmos-
phere, 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 bat-
tery in an excessively warm or cold
place (less than 0C (32F) or more
than 30C (86)).

68
5AV-F8199-E1-3 8/1/03 1:48 PM Page 69

SPECIFICATIONS

Model T105E/T105SE
Dimensions:
Overall length 1,870 mm
Overall width 655 mm
Overall height 1,050 mm
Seat height 755 mm
Wheelbase 1,190 mm
Minimum ground clearance 130 mm
Basic weight:
With oil and full fuel tank 96 kg (T105E)
101 kg (T105SE)
Minimum turning radius: 1,800 mm
Engine:
Type Air cooled 4 stroke, SOHC
Cylinder arrangement Forward inclined single cylinder
Displacement 101.8 cm3
Bore stroke 49.0 54.0 mm
Compression ratio 9.0 : 1
Starting system Electric and kick starter
Lubrication system: Wet sump

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5AV-F8199-E1-3 8/1/03 1:48 PM Page 70

Model T105E/T105SE
Engine oil (4-cycle):
Type Yamalibe 4 (20W40) or equivalent
SAE 20W40 type SE 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 4.3 L
Carburetor:
Type/manufacturer VM16SH/MIKUNI

70
5AV-F8199-E1-3 8/1/03 1:48 PM Page 71

Model T105E/T105SE
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 37/15 (2.467)
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)

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5AV-F8199-E1-3 8/1/03 1:48 PM Page 72

Model T105E/T105SE
Chassis:
Frmae type Steel Tube underbone
Caster angle 27
Trail 78 mm
Tire:
Type With tube
Size Front 2.25-17 33L
Rear 2.50-17 38L
Brake:
Front brake type Drum brake (T105E)
Disk brake (T105SE)
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

72
5AV-F8199-E1-3 8/1/03 1:48 PM Page 73

Model T105E/T105SE
Wheel travel:
Front 90 mm
Rear 65 mm
Electrical:
Ignition system C.D.I
Generator system Flywheel magneto
Battery type/capacity 12V5AH
Headlight type: Krypton bulb
Bulb wattage/quantity:
Headlight 12V30W/30W 1
Tail/brake light 12V/5W/21W 1
Flasher light 12V10W 4
Meter light 12V1.7W 1
Indicator light wattage/quantity:
NEUTRAL 12V3.4W 1
HIGH BEAM 12V3.4W 1
TURN 12V3.4W 1
TOP 12V3.4W 1

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5AV-F8199-E1 hyosi 7/29/03 10:15 AM Page 1

OWNER'S
MANUAL

YAMAHA MOTOR CO., LTD.

5AV-F8199-E1