YAMAHA T105 2002 Workshop Manual

EAU03851*Brake leverFront and rear brake leversThere should be no free play at the brake
lever end. If there is free play, have a
Yamaha dealer inspect the brake system.
51
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EW000099wA soft or spongy feeling in the brake lever
can indicate the presence of air in the hy-
draulic system. If there is air in the hy-
draulic system, have a Yamaha dealer
bleed the system before operating the mo-
torcycle. Air in the hydraulic system will
diminish the braking performance, which
may result in loss of control and an acci-
dent.
52
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Rear brake adjustment
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 coun-
terclockwise to increase free play.EUU69800w1. The rear brake pedal adjustment must
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.
53
A. Free play: 20–30 mm
q
1. Adjusting nut
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EAH83301Brake 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 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 grooves have
almost disappeared, have a Yamaha dealer
replace the brake pads as a set.
54
q
1. Brake light switch
q
q
1. Brake pad wear indicator groove (
×2)
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EAH81601Checking 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 re-
place the shoes.EAU00732Checking 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 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
sure to check the brake pads for wear and
the brake system for leakage.
55
1
2
1. Wear limit 2. Indicator
q
1. Minimum level mark
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Observe these precautions:
8When checking the fluid level, make
sure that the top of the master cylin-
der is level by turning the handlebars.
8Use only the recommended quality
brake fluid, otherwise the rubber seals
may deteriorate, causing leakage and
poor braking performance.NOTE:
If DOT 4 is not available, DOT 3 can be
used.8Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and lead to
poor braking performance.8Be careful that water does not enter
the master cylinder when refilling.
Water will significantly lower the boil-
ing point of the fluid and may result in
vapor lock.
8Brake fluid may deteriorate painted
surfaces or plastic parts. Always clean
up spilled fluid immediately.
8As 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
Recommended brake fluid: DOT 4
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EAU03238Changing the brake fluid
Have a Yamaha dealer change the brake
fluid at the intervals specified in the period-
ic maintenance and lubrication chart. In ad-
dition, have the oil seals of the brake mas-
ter cylinder and caliper as well as the brake
hose replaced at the intervals listed below
or whenever they are damaged or leaking.
8Oil seals: Replace every two years.
8Brake hose: Replace every four years.
57
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EAI40001Drive chain slack checkEUU04801NOTE:
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 shown in the illustration.
Normal slack is approximately 20–30 mm.
If the slack exceeds 30 mm, adjust it.
58
a
a. Drive chain slack: 20–30 mm
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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 ad-
justing 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.
59
q
w
1. Rear brake adjusting nut 2. Axle nut
qw
e
r
1. Rear wheel axle 2. Alignment marks
3. Adjusting nut 4. Locknut
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EC000096cCImproper 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 tight-
en the axle nut to the specified torque.
5. Adjust the brake pedal free play. (See
page 53 for adjustment procedure.)
EW000103wAfter adjusting the brake pedal free play,
check the operation of the brake light.
60
Tightening torque:
Axle nut:
60 Nm (6.0 m•kg)
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