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Yamaha CRYPTON T105E/SE Owner's Manual

Summary of CRYPTON T105E/SE

  • Page 1

    Owner's manual 5av-f8199-e1 yamaha motor co., ltd. 5av-f8199-e1 hyosi 7/29/03 10:15 am page 1.

  • Page 2: Introduction

    Eaa00100 eaa20301 introduction congratulations on your purchase of the yamaha t105e/se. This model is the result of yamaha’s vast experience in the produc- tion of fine sporting, touring, and paceset- ting racing machines. It represents the high degree of craftsmanship and reliability that have made...

  • Page 3

    Eaa10500 particularly important information is distin- guished in this manual by the following notations: q the safety alert symbol means atten- tion! Become alert! Your safety is involved! W failure to follow warning instructions could result in severe injury or death to the motorcycle operator, a ...

  • Page 4: Contents

    Give safety the right of way...............5 general note..............................................6 description..................................................8 motorcycle identification...................9 identification numbers record ...................9 key identification number ............

  • Page 5

    4 periodic maintenance and minor repair..............................................37 tool kit........................................................38 periodic maintenance/lubrication ...........39 engine oil...................................................41 air filter ..........................

  • Page 6: 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 ac- cept; even the best motorcycle does not ig- nore the laws of physics. Regular care and maintenance are essen- tial for preserving your mo...

  • Page 7: General Note

    6 much can be gained from the correct use and maintenance of a motorcycle. 1 the customers can use the fullest potential of yamaha motorcycles 2 a motorcycle can keep its performance capability for a longer time comparison of wear on engine parts with maintenance without maintenance 100% perfect ope...

  • Page 8: General Note

    7 3 fuel cost and repair expenses can be kept to a minimum 4 a motorcycle can demand a high price when it is traded in as a used product 100% with maintenance without distance covered (km) fuel consumption maintenance distance covered (km) customer’s running cost s without maintenance with maintenan...

  • Page 9: Description

    Eaa50000 description 8 1. Tail/brake light 2. Rear flasher light 3. Side cover 4. Fuel tank cap 5. Front flasher light 6. Kick starter 7. Rear brake pedal 8. Head light 9. Fuel tank 10. Seat lock 11. Shift pedal 12. Handlebar switch 13. Speedometer 14. Fuel gauge 15. Main switch/steering lock 16. Th...

  • Page 10: 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 assis- tance when ordering spare parts from a yamaha dealer for referenc...

  • Page 11

    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 en...

  • Page 12: Control Functions

    Position function key removal eab00000 control functions eab00100 main switch the main switch controls the ignition and lighting systems. Its operation is described below. 11 on electrical circuits are switched on. The engine can be started. Cannot be removed. Can be removed. Can be removed. All ele...

  • Page 13

    Eab10000 indicator lights 12 1 turn indicator light 2 neutral indicator light 3 top gear indicator light 4 high beam indicator light description function turn indicator light “ 5”: neutral indicator light “n”: top gear indicator light “top”: high beam indica- tor light “ &”: flashes when the turn sw...

  • Page 14

    Fuel gauge instrument panel 13 1 speedometer 2 odometer 3 fuel gauge description function speedometer odometer shows riding speed. Shows accumlated mileage. Shows the fuel level in the fuel tank. 5av-f8199-e1-1 7/29/03 3:32 pm page 13.

  • Page 15

    Position function handlebar switches lights switch dimmer switch turn signal switch 14 1 lights switch 2 dimmer switch 3 turn signal 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. Position...

  • Page 16

    Horn switch start switch 15 4 horn switch 5 start switch position function * (horn) the horn sounds when push- ing the switch. Position function start the starter motor cranks the engine when pushing the switch. 5av-f8199-e1-1 7/29/03 3:32 pm page 15.

  • Page 17

    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. Eab90001 front brake lever the front brake lever is located on the right handlebar. Pull it toward the handlebar to apply the front brake. 16 1 s...

  • Page 18

    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 counterclock- wise. (see page 20 to open the seat.) 17 1 rear ...

  • Page 19

    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. Eac60700 kick starter rotate the kick starter a...

  • Page 20

    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, tur...

  • Page 21

    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. ...

  • Page 22

    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 holder. The helmet may hit objects, caus- ing loss of control and possibly an a...

  • Page 23: Pre-Operation Checks

    22 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 le...

  • Page 24

    23 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 inspe...

  • Page 25

    Eae80300 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 over- flow when the fuel heats up later and ex-...

  • Page 26

    Eae40104* engine oil make sure the engine oil is at the specified level. Fill with oil as necessary (see page 41 for details). 25 1 oil level gauge 2 upper level 3 lower level recommended oil: yamalube 4 (20w40) or equivalent sae 20w40 type se motor oil oil quantity: total amount: 1.0 l periodic oil...

  • Page 27

    Eae96700 tires to ensure maximum performance, long service, and safe operation, note the fol- 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 e...

  • Page 28

    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. W it is dangerous to ride ...

  • Page 29: Operation and

    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 ...

  • Page 30

    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...

  • Page 31

    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 of...

  • Page 32

    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. C c always close the throttle whi...

  • Page 33

    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...

  • Page 34

    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: 33 gear position recommend speed 4th → 3rd 0~40 k...

  • Page 35

    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...

  • Page 36

    3. 500~1,000 km: avoid cruising speeds in excess of 3/4 throttle. Euu40400 c c 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 c c if any engine trouble should occur during the brea...

  • Page 37

    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; t...

  • Page 38: Periodic

    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 con...

  • Page 39

    Eah10101* tool kit the tools provided in the owner’s tool kit are to assist you in the performance of pe- riodic maintenance. However, some other tools such as a torque wrench are also nec- essary to perform the maintenance correct- ly. Euu67100 w modifications to this motorcycle not ap- proved by y...

  • Page 40

    39 * 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 * carburetor check idle speed/stater operation. 2 2 2 2 adjust if necessary. * fuel line check fuel hose and vacuum pipe fo...

  • Page 41

    *: 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) 40 check bearing assembly for looseness. * steering bearing correct if necessary. Moderately repack every 2 2 8,000 km. ** * front f...

  • Page 42

    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 eng...

  • Page 43

    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. Re...

  • Page 44

    E. Fill engine with oil through the oil level gauge hole. Euu47700 c c 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 co...

  • Page 45

    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. 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. 4...

  • Page 46

    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. C c 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 fi...

  • Page 47

    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 ...

  • Page 48

    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. Eah92000 idle speed adjustment 1. Attach the tachometer. 2. Set the...

  • Page 49

    Eah20304 spark plug inspection the spark plug is an important engine component and is easy to inspect. The con- 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...

  • Page 50

    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 torqu...

  • Page 51

    Eah85201 front brake adjustment (t105e) the front brake lever free play should be adjusted to 8~12 mm at the brake lever end. Adjustment is accomplished at the front brake hub. To adjust, turn the adjuster clockwise to reduce play or counterclock- wise to increase play. Front brake adjustment (t105s...

  • Page 52

    51 eau01119* checking the front brake pads (t105se) front brake pad is provided with wear indi- 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 groove...

  • Page 53

    52 observe these precautions: 8 when checking the fluid level, make sure that the top of the master cylin- der 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. Note: if dot 4 ...

  • Page 54

    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 l...

  • Page 55

    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 be checked whenever the chain is ad- just...

  • Page 56

    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 eff...

  • Page 57

    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 tight- est position. Inspect the drive chain when the motorcy- cle is on the centerstand. Check the slack at the position s...

  • Page 58

    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- j...

  • Page 59

    5. After adjusting, be sure to tighten the loosened parts. Tighten the axle nut at specified torque. 6. Adjust the free play in the brake pedal. 58 tightening torque: axle nut: 60 nm (6.0 m•kg) sprocket shaft nut: 80 nm (8.0 m•kg) 5av-f8199-e1-3 8/1/03 1:48 pm page 58.

  • Page 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 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 man...

  • Page 61

    Eai30601 brake lever and pedal lubricate the pivoting parts. Eai30801 center and sidestand lubricate the pivoting parts. Check to see that the center and sidestand move up and down smoothly. 60 recommended lubricant: yamalube 4 or sae 20w40 motor oil recommended lubricant: yamalube 4 or sae 20w40 mo...

  • Page 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. E...

  • Page 63

    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 c c when inspecting the battery, be sure the breather pipe is routed...

  • Page 64

    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 vegeta...

  • Page 65

    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 c c normal tap water conta...

  • Page 66

    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 immedia...

  • Page 67

    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 ...

  • Page 68: Cleaning and

    Eak00000 cleaning and storage eak01302* a. Cleaning frequent, thorough cleaning of your mo- torcycle will not only enhance its appear- ance but will improve its general perfor- mance and extend the useful life of many components. 1. Rinse the dirt and degreaser off with a garden hose. Euu34602 c c e...

  • Page 69

    3. Remove the drive chain. Thoroughly clean the chain with solvent and lubri- cate it. Reinstall the chain or store it in 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...

  • Page 70: Specifications

    69 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 coole...

  • Page 71

    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 5av-f8199-e1-3 ...

  • Page 72

    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) tr...

  • Page 73

    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 ope...

  • Page 74

    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 ligh...

  • Page 75

    5av-f8199-e1-3 8/1/03 1:48 pm page 74.

  • Page 76: Owner'S

    Owner's manual 5av-f8199-e1 yamaha motor co., ltd. 5av-f8199-e1 hyosi 7/29/03 10:15 am page 1.