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Yamaha T135S, Service Manual

The Yamaha T135S Service Manual is a comprehensive guide for maintaining and repairing your T135S motorcycle. This manual provides step-by-step instructions, diagrams, and specifications to ensure your bike stays in top condition. Download this manual for free from our website to keep your Yamaha T135S running smoothly.

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CHAS

CHAPTER 7

CHASSIS

FRONT WHEEL AND BRAKE DISC .....................................................................

7-1

REMOVING THE FRONT WHEEL ....................................................................7-2
CHECKING THE FRONT WHEEL.....................................................................7-3
CHECKING THE BRAKE DISC .........................................................................7-5
CHECKING THE SPEEDOMETER GEAR UNIT...............................................7-6
INSTALLING THE FRONT WHEEL ...................................................................7-7

REAR WHEEL AND BRAKE .................................................................................

7-8

REMOVING THE REAR WHEEL ......................................................................7-9
DISASSEMBLING THE BRAKE SHOE PLATE .................................................7-11
CHECKING THE REAR WHEEL .......................................................................7-11
CHECKING THE REAR WHEEL DRIVE HUB...................................................7-12
CHECKING THE BRAKE...................................................................................7-13
ASSEMBLING THE BRAKE SHOE PLATE .......................................................7-14
INSTALLING THE REAR WHEEL .....................................................................7-14

FRONT BRAKE......................................................................................................

7-16

FRONT BRAKE CALIPER .................................................................................7-16
REPLACING THE FRONT BRAKE PADS .........................................................7-17
DISASSEMBLING THE FRONT BRAKE CALIPER ..........................................7-19
CHECKING THE FRONT BRAKE CALIPER .....................................................7-21
ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER ..................7-22
FRONT BRAKE MASTER CYLINDER ..............................................................7-24
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER........................7-25
CHECKING THE FRONT BRAKE MASTER CYLINDER ..................................7-26
ASSEMBLING AND INSTALLING 
THE FRONT BRAKE MASTER CYLINDER ......................................................7-27

FRONT FORK ........................................................................................................

7-30

REMOVING THE FRONT FORK LEGS ............................................................7-31
DISASSEMBLING THE FRONT FORK LEGS ..................................................7-32
CHECKING THE FRONT FORK LEGS .............................................................7-34
ASSEMBLING THE FRONT FORK LEGS ........................................................7-35
INSTALLING THE FRONT FORK LEGS ...........................................................7-37

HANDLEBAR .........................................................................................................

7-39

REMOVING THE HANDLEBAR ........................................................................7-40
CHECKING THE HANDLEBAR.........................................................................7-42
INSTALLING THE HANDLEBAR .......................................................................7-42

STEERING HEAD ..................................................................................................

7-45

REMOVING THE LOWER BRACKET ...............................................................7-46
CHECKING THE STEERING HEAD .................................................................7-46
INSTALLING THE STEERING HEAD................................................................7-48

5YP-F8197-E0_7_1  05.6.27 19:29  Page A

Yamaha T135 Service Manual

YamahaT135.COM

Summary of Contents for T135S

Page 1: ...Y a m a h a T 1 3 5 C O M T135 SERVICE MANUAL 5YP F8197 E0 T135SE T135S Sniper Jupiter MX Spark 135 Exciter 135LC YamahaT135 COM 03212007 Manual Clutch and Automatic ...

Page 2: ...Y a m a h a T 1 3 5 C O M Yamaha T135 Service Manual YamahaT135 COM ...

Page 3: ...E MANUAL 2005 by Yamaha Motor Co Ltd First edition April 2005 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited EAS00000 Yamaha T135 Service Manual YamahaT135 COM ...

Page 4: ...odels Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE Designs and specifications are subject to change without notice EAS00004 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following Q The Safety A...

Page 5: ... a easy to read handy reference that contains comprehensive explanations of all disassembly repair assembly and inspections A set of particularly important procedure 4 is placed between a line of mark or with each pro cedure preceded by 8 IMPORTANT FEATURES 8Data and a special tool are framed in a box preceded by a relevant symbol 5 8An encircled numeral 6 indicates a part name and an encircled al...

Page 6: ...Y a m a h a T 1 3 5 C O M Yamaha T135 Service Manual YamahaT135 COM ...

Page 7: ...bricant e Special tool r Tightening torque t Wear limit clearance y Engine speed u Electrical data Symbols i to d in the exploded diagrams indi cate the types of lubricants and lubrication points i Engine oil o Gear oil p Molybdenum disulfide oil a Wheel bearing grease s Lithium soap based grease d Molybdenum disulfide grease Symbols f to g in the exploded diagrams indi cate the following f Apply ...

Page 8: ...Y a m a h a T 1 3 5 C O M Yamaha T135 Service Manual YamahaT135 COM ...

Page 9: ...ING ELECTRICALSYSTEM CHASSIS ENGINE PERIODIC CHECKSAND ADJUSTMENTS GENERALINFORMATION GEN INFO TRBL SHTG ELEC CHAS ENG CHK ADJ SPEC TABLE OF CONTENTS 4 7 8 9 3 2 1 COOLING SYSTEM COOL 5 CARBURETOR CARB 6 EAS00011 Yamaha T135 Service Manual YamahaT135 COM ...

Page 10: ...Y a m a h a T 1 3 5 C O M Yamaha T135 Service Manual YamahaT135 COM ...

Page 11: ...1 1 ENGINE SERIAL NUMBER 1 1 IMPORTANT INFORMATION 1 2 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 2 REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 2 LOCK WASHERS PLATES AND COTTER PINS 1 3 BEARINGS AND OIL SEALS 1 3 CIRCLIPS 1 3 CHECKING THE CONNECTIONS 1 4 SPECIAL TOOLS 1 5 Yamaha T135 Service Manual YamahaT135 COM ...

Page 12: ...Y a m a h a T 1 3 5 C O M GEN INFO Yamaha T135 Service Manual YamahaT135 COM ...

Page 13: ... IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The number 1 is stamped into the center of the frame ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the crankcase NOTE Designs and specifications are subject to change without notice 1 1 Yamaha T135 Service Manual YamahaT135 COM ...

Page 14: ...e parts and place them in trays in the order of dis assembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire 1 2 EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but infer...

Page 15: ...025 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposite the thrust 3 that the circlip receives 4 Shaft GEN INFO IMPORTANT INFORMATION 1 300 000 300 003 1 300 002 1 300 001 3 4 1 2 EAS00023 LOCK WASHERS PLATES AND COT TER P...

Page 16: ...ct several times 3 Check 9all connections Loose connection Connect properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect 9lead 9coupler 9connector NOTE Make sure all connections are tight 5 Check 9continuity with the pocket tester NOTE 8If there is no continuity clean the terminals 8When checking the wire harness perform steps 1 to 3 8As a quick remedy use a contact revitali...

Page 17: ...case separating tool This tool is necessary for separating the crankcase 90890 01184 Fork seal driver weight This tool is used for to install the oil seal 90890 01186 Fork seal driver attachment This tool is used to install the oil seal 90890 01268 Ring nut wrencht This tool is used to loosen and tighten the steering ring nut Crankshaft instoller pot This tool is necessary for installing the crank...

Page 18: ...used to check the cooling syatem T handle This tool is used for holding the damper rod holder when removing or installing the damper rod holder 90890 01326 Flywheel puller This tool is used for removing the roter 90890 01362 90890 01403 Steering nut wrencht This tool is used to loosen and tighten the steering ring nut R20 90890 01701 Sheave holder This tool is used for holding the generator roter ...

Page 19: ...earing driver Mechanical seal installer These tools are used to install the water pump seal Valve spring compressor Attachment This tool is used when removing or installing the valve and valve spring 90890 04108 Ø22 Valve spring compressor This tool is used when removing or installing the valve and valve spring 90890 04019 fl31 M6xP1 0 90890 04081 Spacer This tool is necessary for insatlling the c...

Page 20: ...ool is needed to remove and installing the valve guide 90890 04117 Valve guide installer 4 5 mm This tool is needed to install the valve guide 90890 04118 Valve guide reamer 4 5 mm This tool is needed rebore the new valve guide 90890 06754 Ignition checker This instrument is necessary for check ing the ignition system components Tool No Tool name Usage Illustration Yamaha T135 Service Manual Yamah...

Page 21: ... ENGINE 2 4 TIGHTENING TORQUES 2 9 CHASSIS 2 11 TIGHTENING TORQUES 2 13 ELECTRICAL 2 15 CONVERSION TABLE 2 17 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 17 LUBRICATION POINTS AND LUBRICANT TYPES 2 18 ENGINE 2 18 CHASSIS 2 20 COOLING SYSTEM DIAGRAMS 2 21 CABLE ROUTING 2 22 Yamaha T135 Service Manual YamahaT135 COM ...

Page 22: ...Y a m a h a T 1 3 5 C O M SPEC Yamaha T135 Service Manual YamahaT135 COM ...

Page 23: ... 2 13 2 31 in Compression ratio 10 9 1 Compression pressure STD 560 kPa 80 psi 5 6 kgf cm2 at 500 r m with electric starter Starting system Kick and electric starter Lubrication system Wet sump Engine idling speed 1 300 1 500 r min Oil type or grade Engine oil SAE 20W40 type SF or higher grade motor oil Periodic oil change amount 0 8 L 0 70 Imp qt 0 85 US qt Total amount 1 15 L 1 01 Imp qt 1 22 US...

Page 24: ... Constant mesh 4 speed Operation Left foot operation Gear ratio 1st 34 12 2 833 2nd 30 16 1 875 3rd 23 17 1 353 4th 23 22 1 045 Chassis Frame type Diamond Caster angle 25 3 Trail 73 0 mm 2 87 in Tire Type With tube Size front 60 100 17M C 33P rear 80 90 17M C 44P Model manufacturer front IRC NF63B Vee Rubber V304 rear IRC NR78Y Vee Rubber V304 Min tire tread depth front 0 8 mm 0 03 in rear 0 8 mm ...

Page 25: ...travel 90 mm 3 54 in Electrical Ignition system DC C D I Generator system A C magneto Battery type manufacturer GM5Z 3B LOCAL MADE Battery capacity 12 V 5 AH Headlight type Krypton bulb Bulbs voltage wattage quantity Headlight 12 V 32 W 32 W 1 Auxiliary light 12 V 5 W 2 Tail brake light 12 V 5 W 21 W 1 Front turn signal light 12 V 10 W 2 Rear turn signal light 12 V 10 W 2 Meter light 12 V 1 7 W 1 ...

Page 26: ... in 29 912 mm 1 1776 in B 25 019 25 119 mm 0 9850 0 9889 in 24 989 mm 0 9838 in Camshaft runout limit 0 03 mm 0 0012 in Timing chain Timing chain type No of links SILENT CHAIN 96 Tensioning system Automatic Rocker arm rocker arm shaft Rocker arm inside diameter 9 985 10 000 mm 0 3931 0 3937 in 10 030 mm 0 0012 in Rocker arm shaft outside diameter 9 966 9 976 mm 0 3924 0 3928 in 9 950 mm 0 3917 in ...

Page 27: ...D margin thickness IN 0 5 0 9 mm 0 20 0 36 in EX 0 5 0 9 mm 0 20 0 36 in Valve stem outside diameter IN 4 475 4 490 mm 0 1762 0 1768 in 4 450 mm 0 1752 in EX 4 460 4 475 mm 0 1756 0 1762 in 4 435 mm 0 1746 in Guide inside diameter IN 3 950 4 050 mm 0 1555 0 1594 in 4 542 mm 0 1788 in EX 3 950 4 050 mm 0 1555 0 1594 in 4 542 mm 0 1788 in Valve stem to guide clearance IN 0 0010 0 037mm 0 0 0015 in 0...

Page 28: ...on pin bore inside diameter 14 002 14 013 mm 0 5513 0 5517 in 14 043 mm 0 5529 in Piston pin outside diameter 13 995 14 000 mm 0 5510 0 5512 in 13 975 mm 0 5502 in Piston rings Top ring Ring type Barrel Dimensions B T 0 80 1 90 mm 0 03 0 07 in End gap installed 0 10 0 25 mm 0 0098 in 0 00 0 01 in 0 40 mm 0 0157 in Ring side clearance installed 0 030 0 065 mm 0 0012 0 0026 in 0 10 mm 0 0039 in 2nd ...

Page 29: ...ess 1 59 1 68 mm 0 06 0 07 in Plate quantity 3 Max warpage 0 05 mm 0 0020 in Clutch springs Free length 40 5 mm 1 60 in 38 5 mm 1 52 in Spring quantity 4 Clutch release method Inner push cam push Clutch shoe thickness 2 0 mm 0 08 in Clutch shoe groove depth 1 0 mm 0 04 in 0 1 mm 0 0039 in Clutch housing inside diameter 116 mm 4 57 in 117 mm 4 6063 in Weight outside diameter 116 mm 4 57 in 115 mm 4...

Page 30: ...ilot air jet 1 55 Valve seat size ø2 Throttle valve size 2 0 Float height 9 2 mm 0 3622 in Oil pump Oil pump type Trochoid type Inner rotor to outer rotor tip clear 0 15 mm 0 0059 in 0 20 mm ance 0 0079 in Outer rotor to oil pump housing 0 06 0 11 mm 0 15 mm clearance 0 0024 0 0043 in 0 0059 in Oil pump housing to inner rotor and 0 06 0 11 mm 0 15 mm outer rotor clearance 0 0024 0 0043 in 0 0059 i...

Page 31: ... 0 7 5 0 Element cover Bolt M6 3 10 1 0 7 2 Engine oil drain bolt Bolt M35 1 32 3 2 23 Oil pump cover plate Bolt M6 2 10 1 0 7 2 Intake manifold engine side Bolt M6 2 10 1 0 7 2 Carburetor assembly Bolt M6 2 10 1 0 7 2 Resonator Bolt M6 1 10 1 0 7 2 Exhaust pipe Nut M8 2 15 1 5 11 Muffler and muffler bracket Bolt M8 1 17 1 7 13 Muffler and passenger footrest Bolt M10 1 38 3 8 28 Air filter assembl...

Page 32: ... 8 13 Shift drum segment Bolt M6 1 12 1 2 9 0 Shift drum stopper lever Bolt M6 1 10 1 0 7 2 Shift lever stopper screw Screw M8 1 10 1 0 7 2 Pickup coil Bolt M6 2 10 1 0 7 2 Stator coil Bolt M6 3 10 1 0 7 2 Neutral switch Screw M5 2 4 0 4 2 9 Starter motor Bolt M6 2 10 1 0 7 2 Part to be tightened Part name Thread size Q ty Tightening torque Remarks Nm m kg ft lb LT LT LT LT LT LT LT Yamaha T135 Se...

Page 33: ...l 104 5 mm 4 11 in Recommended oil Fork oil 10W or equivalent Inner tube outer diameter 26 mm 1 02 in Inner tube bend limit 0 2 mm 0 0079 in Rear suspension Shock absorber stroke 27 5 mm 1 0827 in Spring free length 115 4 mm 4 54 in 113 1 mm 4 4528 in Installed length 106 4 mm 4 19 in Spring rate K1 220 N mm 22 43 kgf mm 1256 2 lb in K2 316 N mm 32 22 kgf mm 1804 36 lb in Stroke K1 0 0 8 0 mm 0 00...

Page 34: ...in 0 8 mm 0 03 in Pad thickness outer 5 3 mm 0 21 in 0 8 mm 0 03 in Master cylinder inside diameter 11 mm 0 43 in Caliper cylinder inside diameter 33 3 mm 1 31 in Brake fluid type DOT 3 or 4 Rear brake Drum brake type Leading trailing Rear brake pedal free play pedal 25 35 mm 0 98 1 38 in end Drum inside diameter 130 mm 5 12 in 131 0 mm 5 16 in Lining thickness 4 mm 0 16 in 2 mm 0 08 in Shoe sprin...

Page 35: ...8 23 2 3 17 Brake camshaft and brake camshaft lever M6 7 0 7 5 0 Driven sprocket and rear wheel drive hub M8 30 3 0 22 Rear wheel axle nut M12 60 6 0 43 Rear shock absorber and frame M10 46 4 6 33 Rear shock absorber and swingarm M10 46 4 6 33 Swingarm pivot nut M12 66 6 6 48 Engine mounting nut M8 34 3 4 25 Engine mounting nut M10 72 7 2 52 Swingarm and drive chain case M6 7 0 7 5 0 Drive chain a...

Page 36: ...loosen the ring nut 1 4 turn 2 Then hold the lower ring nut and tighten the upper ring nut 75 Nm 7 5 m kg 54 ft lb by using a torque wrench Fuel tank and frame M6 7 0 7 5 0 Fuel cock and fuel tank M6 7 0 7 5 0 Seat and seat bracket M6 7 0 7 5 0 Part to be tightened Thread size Tightening torque Remarks Nm m kg ft lb Yamaha T135 Service Manual YamahaT135 COM ...

Page 37: ...68 F Secondary coil resistance 5 68 8 52 kΩ at 20 C 68 F Spark plug cap Material Resin Resistance 5 0 kΩ Charging system Type A C magneto Model manufacturer F5YP PT MORIC Nominal output 14 V 105 W at 5 000 r min Lighting coil resistance color 0 29 0 43 Ω at 20 C 68 F Y B Charging coil resistance color 0 38 0 58 Ω at 20 C 68 F W B Rectifier regulator Regulator type Semiconductor short circuit Model...

Page 38: ... mm 0 05 in Starter relay T135SE Model manufacturer G4R THA OMRON Amperage rating 50 A Coil resistance 54 66 Ω at 20 C 68 F Horn Type Plane Quantity 1 Model manufacturer GF 12 THA NIKKO Max amperage 1 5 A Performance 95 105 db 2 m Coil resistance 4 30 4 80 Ω at 20 C 68 F Turn signal relay Relay type Condenser Model manufacturer FZ222SD THA DENSO Self canceling device built in No Flasher frequency ...

Page 39: ...0 mm 6 mm 6 0 6 12 mm 8 mm 15 1 5 14 mm 10 mm 30 3 0 17 mm 12 mm 55 5 5 19 mm 14 mm 85 8 5 22 mm 16 mm 130 13 0 A nut B bolt General tightening torques Nm m kg EAS00028 CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS Use this table to convert METRIC unit data to IMPERIAL unit data CONVERSION TABLE Ex METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 0...

Page 40: ...t wheel and ratchet wheel guide Kickstarter gear inner surface Kickstarter shaft Primary driven gear and primary drive gear 2 inner surface Clutch push rod 1 2 ball and main axle inside surface Clutch housing inside surface and crankshaft outer surface Clutch boss housing clutch plate and friction plate inside surface Clutch boss nut and lock washer contact surface Clutch shoe housing inner surfac...

Page 41: ...nner surface Transmission pinion gears inner surface Generator lead grommet Yamaha bond No 1215 Crankcase mating surface Yamaha bond No 1215 Timing chain tensioner bolts Yamaha bond No 1215 SPEC 2 19 LUBRICATION POINTS AND LUBRICANT TYPES Yamaha T135 Service Manual YamahaT135 COM ...

Page 42: ...t Brake torque rod bolt Front wheel axle Rear wheel axle Upper brake caliper retaining bolt Lower brake caliper retaining bolt Throttle grip tube guide inner surface Brake lever pivot bolt Steering head bearing inner race Steering head bearing outer race Steering head upper bearing Steering head lower bearing Sidestand pivot bolt Swingarm pivot shaft Centerstand pivot shaft Yamaha T135 Service Man...

Page 43: ...tor 7 Radiator outlet hose 8 Over flow hose 9 Coolant reservoir tank å Align the white paint mark on the clamp with the white paint mark on the radiator Band the end of the cover before install the pro jection of the reservoir tank ç Install the hook of the cover end into the slit of the bracket å å ç 1 2 3 1 2 3 4 4 5 6 7 8 9 A A B B A A B B Yamaha T135 Service Manual YamahaT135 COM ...

Page 44: ...d coupler in front of the handlebar left ç Pass through the choke cable into the wireharness Connect the couplers in front of the handlebar left side Do not pass the brake hose into the bracket ƒ Pass through into the wire guide follow the routing order Brake hose throttle cable and wireharness Hook the strap of the wirehar ness onto the bracket Pass through the brake hose into the wire guide on t...

Page 45: ...nect the front brake switch Route the right handlebar switch lead behind the handle bar and connect the coupler with handlebar right side and then set the turn signal light relay Take care not to bend the choke cable when installing å ç ƒ ˆ B B A A C C B B A A 1 2 3 4 5 6 7 4 5 6 7 8 D D Yamaha T135 Service Manual YamahaT135 COM ...

Page 46: ...r cable å Route inside of the choke cable Pass through the throttle cable choke cable and speedometer cable into the cable guide ç Pass through the C D I unit lead in front of the stay Check that the connection of the acceleration pump cable from case after adjusting and clamp the throttle cable and acceleration pump cable Clamp the breather pipe ƒ Cover the throttle cable adjust ing nut completel...

Page 47: ...uld be stopped ˆ Pass through the fuel hose and vacuum hose into the cable guide Route the overflow pipe to the left side of the engine and inside of the neutral switch lead Route the vacuum hose onto the fuel hose Route the fuel hose onto the cable guide µ Pass through the turn signal light lead into the guide Yamaha T135 Service Manual YamahaT135 COM ...

Page 48: ... Drain hose t Protector å Pass through the fan relay lead into the frame pipe and fuel tank Close the clamp end until stop contact to the fuel tank ç Pass through the positive lead into the starter relay and breather pipe T135SE Pass through the starter motor lead under the wireharness T135SE Outside of the frame ƒ Be sure does not over the out side of the frame Set in the connected point to the b...

Page 49: ... 5 6 6 7 8 9 0 q w e r t A A B B C A A B B C ˆ Route the overflow pipe in front of the cross pipe frame Pass through the drain hose and battery breather pipe into the guide Pass through the drain hose into the hole of the protector Yamaha T135 Service Manual YamahaT135 COM ...

Page 50: ...ireharness å Turn the downward of the sep arate part Route the brake hose through as shown ç Close the clamp certainly Wireharness and cable guide clearance is wit in 16 mm when straight the steering con dition Pass through the wireharness into the main switch and cable guide Pass through the hone lead and turn signal light lead under the wireharness Route the brake hose as shown ƒ Clamp the bend ...

Page 51: ... 9 0 q w e r C C ˆ To the A C magneto Cover the protector completely after the coupler connected Set the connected point below the pipe end Pass through the high tension cord fan motor lead and ther mo sensor lead into the cut part on the plate Yamaha T135 Service Manual YamahaT135 COM ...

Page 52: ...d 5 Choke cable å Route the acceleration pump cable into the right side of the stay Route the throttle cable into the left side of the stay ç Black plating joint Pass through the fuel sender lead in to the side hole of the fuel tank Clamp the fuel sender lead onto the hook of the box ƒ White plating joint Yamaha T135 Service Manual YamahaT135 COM ...

Page 53: ...URING THE COMPRESSION PRESSURE 3 15 CHECKING THE ENGINE OIL LEVEL 3 17 CHANGING THE ENGINE OIL 3 18 CHECKING THE OIL FILTER 3 19 CHECKING THE EXHAUST SYSTEM 3 19 CLEANING THE AIR FILTER ELEMENT 3 20 ADJUSTING THE CLUTCH RELEASE SYSTEM 3 21 CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 3 21 CHECKING THE FUEL AND VACUUM HOSES 3 22 CHECKING THE CRANKCASE BREATHER PIPE 3 23 CHECKING THE COOLANT LE...

Page 54: ...G THE SPOKES 3 40 CHECKING AND LUBRICATING THE CABLES 3 41 LUBRICATING THE LEVER AND PEDALS 3 41 LUBRICATING THE SIDESTAND 3 41 LUBRICATING THE CENTERSTAND 3 41 ELECTRICAL SYSTEM 3 42 CHECKING AND CHARGING THE BATTERY 3 42 CHECKING THE FUSE 3 46 REPLACING THE HEADLIGHT BULBS 3 47 ADJUSTING THE HEADLIGHT BEAM 3 48 Yamaha T135 Service Manual YamahaT135 COM ...

Page 55: ...he limit 7 Rear brake 9 Check operation and adjust brake pedal free play 9 Replace brake shoes Whenever worn to the limit 8 Brake hose 9 Check for cracks or damage 9 Replace Every 4 years 9 Wheels 9 Check runout spoke tightness and for damage 9 Tighten spokes if necessary 10 Tires 9 Check tread depth and for damage 9 Replace if necessary 9 Check air pressure 9 Correct if necessary 11 Wheel bearing...

Page 56: ...em 9 Check coolant level and vehicle for coolant leakage 9 Change the YAMAHA GENUINE COOLANT Every 3 years 23 Front and rear brake switches 9 Check operation 24 Moving parts and ca bles 9 Lubricate 25 Throttle grip housing and cable 9 Check operation and free play 9 Adjust the throttle cable free play if necessary 9 Lubricate the throttle grip housing and cable 26 Air induction system 9 Check the ...

Page 57: ...r installation reverse the removal procedure EASF0004 COVERS REMOVING THE SIDE COWLINGS 1 Remove 9screws 9bolts 9side cowlings left and right INSTALLING THE SIDE COWLINGS For installation reverse the removal procedure REMOVING THE FRONT COWLING 1 Remove 9screws 9front cowling Yamaha T135 Service Manual YamahaT135 COM ...

Page 58: ...anel lower 1 9main switch cover 2 9screws 9center panel upper 3 NOTE Remove the main switch cover by turning it in the direction of the arrow shown 2 Remove 9screw 9 inner panel 1 INSTALLING THE CENTER PANELS For installation reverse the removal procedure REMOVING THE REAR COWLINGS 1 Remove 9screws 9center panel lower 2 Remove 9screws 9storage compartment 1 Yamaha T135 Service Manual YamahaT135 CO...

Page 59: ...all 9rear cowlings left and right 1 9screws 9screw with washer 2 NOTE Before tightening the rear cowling screws make sure that all projections left and right are securely fitted 2 Install 9rear panel 1 9storage compartment 2 9screws NOTE Make sure that all projections are securely fit ted 1 3 Install 9center panel upper 1 9screw Yamaha T135 Service Manual YamahaT135 COM ...

Page 60: ...TALLING THE HEADLIGHT ASSEMBLY 1 Connect 9headlight connectors 1 2 Install 9headlight assembly 9screws 2 Disconnect 9headlight connectors 1 1 REMOVING THE HEADLIGHT ASSEMBLY 1 Remove 9screws 9headlight assembly 1 Yamaha T135 Service Manual YamahaT135 COM ...

Page 61: ...e 9side cowlings left and right 9front cowling Refer to REMOVING THE SIDE COWL INGS AND REMOVING THE FRONT COWLING CHK ADJ ADJUSTING THE VALVE CLEARANCE 3 7 2 Drain 9cooling system Refer to CHANGING THE COOLANT 3 Remove 9AIS resonator mount bolt 9AIS resonator 9spark plug 9bracket Refer to CHANGING THE COOLANT cC Be sure to remove the AIS hose before removing the AIS resonator otherwise to brake t...

Page 62: ...g check plug 1 with O ring 9center plug 2 with O ring 9 Measure 9valve clearance Out of specification Adjust a Turn the crankshaft counterclockwise b When the piston is at TDC on the compres sion stroke align the I mark a on the camshaft sprocket with the stationary point er b on the cylinder head Valve clearance cold Intake valve 0 10 0 14 mm 0 0039 0 0055 in Exhaust valve 0 16 0 20 mm 0 0063 0 0...

Page 63: ...e is obtained 9 Hold the adjusting screw to prevent it from moving and tighten the locknut to specifica tion d Measure the valve clearance again e If the valve clearance is still out of specifica tion repeat all of the valve clearance adjustment steps until the specified clear ance is obtained Direction a a Valve clearance is increased Direction b b Valve clearance is decreased Tappet adjusting to...

Page 64: ...hose 9radiator outlet cover 9radiator inlet hose 15 Install 9AIS resonator 9AIS resonator mount bolt 9spark plug 16 Fill 9cooling system Refer to CHANGING THE COOLANT 17 Install 9front cowling 9side cowlings left and right Refer to INSTALLING THE SIDE COWL INGS and INSTALLING THE FRONT COWLING 7 Nm 0 7 m kg 5 0 ft lb 7 Nm 0 7 m kg 5 0 ft lb 10Nm 1 0 m kg 7 2 ft lb 10Nm 1 0 m kg 7 2 ft lb 12 5Nm 1 ...

Page 65: ...he engine idling speed the air filter element should be clean and the engine should have adequate compression 1 Remove 9side cowlings left and right 9front cowling 9rear cowling left Refer to REMOVING THE SIDE COWL INGS REMOVING THE FRONT COWL ING and REMOVING THE REAR COWL INGS 2 Start the engine and let it warm up for sev eral minutes 3 Connect 9engine tachometer onto the spark plug lead 4 Check...

Page 66: ...NG SPEED ADJUSTING THE THROTTLE CABLE FREE PLAY Throttle cable free play at the flange of the throttle grip 3 7 mm 0 12 0 28 in a EAS00058 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE Prior to adjusting the throttle cable free play the engine idling speed should be adjusted 1 Check 9throttle cable free play a Out of specification Adjust 2 Remove 9center panel lower Refer to REMOVING THE CENTER PAN ...

Page 67: ...nal position w After adjusting the throttle cable free play start the engine and turn the handlebar to the right or left to ensure that this does not cause the engine idling speed to change 4 Adjust 9accelerator pump cable a Loosen the locknut 1 b Turn the adjusting nut 2 in direction a or b until align the projection c on the accel erator pump lever with projection d on the bracket e within 1mm c...

Page 68: ...9spark plug cC Before removing the spark plug blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder Spark plug type manufacturer CPR8EA 9 NGK 5 Check 9electrode 1 Damage wear Replace the spark plug 9insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 6 Clean 9spark plug with a spark plug cleaner or w...

Page 69: ... CLEAR ANCE 3 Start the engine warm it up for several min utes and then turn it off 4 Disconnect 9spark plug cap 5 Remove 9spark plug cC Before removing the spark plug use com pressed air to blow away any dirt accumulat ed in the spark plug well to prevent it from falling into the cylinder 8 Install 9spark plug NOTE Before installing the spark plug clean the spark plug and gasket surface 9 Connect...

Page 70: ...w the minimum specification pour a teaspoonful of engine oil into the spark plug bore and measure again Refer to the following table Compression pressure with oil applied into the cylinder Reading Diagnosis Piston ring s wear Higher than with or damage out oil Repair Piston valves cyl Same as without inder head gasket oil or piston possibly defective Repair 1 6 Install 9compression gauge 1 7 Measu...

Page 71: ...he engine oil level should be between the minimum level mark a and maximum level mark b Below the minimum level mark Add the recommended engine oil to the proper level cC Do not allow foreign materials to enter the crankcase NOTE 9Insert the oil level plug back into the oil filler hole without screwing it in and then remove it again to check the oil level 9Before checking the engine oil level wait...

Page 72: ...il 8 Install 9oil level plug 9 Start the engine warm it up for several min utes and then turn it off 10 Check 9engine for engine oil leaks 11 Check 9engine oil level Refer to CHECKING THE ENGINE OIL LEVEL CHANGING THE ENGINE OIL Quantity Total amount 1 15 L 1 22 US qt 1 01 Imp gt Periodic oil change amount 0 8 L 0 85 US qt 0 70 Imp gt 2 EAS00075 CHANGING THE ENGINE OIL 1 Start the engine warm it u...

Page 73: ...r clog Replace 3 Install 9oil filter element 9O ring 1 9oil filter element cover CHANGING THE ENGINE OIL CHECKING THE EXHAUST SYSTEM 10 Nm 1 0 m kg 7 2 ft lb 1 CHECKING THE EXHAUST SYSTEM 1 Check 9exhaust pipe nuts 1 Loose damage Tighten replace 9exhaust pipe gasket Exhaust gas leaks Tighten replace 15 Nm 1 5 m kg 11 ft lb Yamaha T135 Service Manual YamahaT135 COM ...

Page 74: ...lement Damage Replace 5 Install 9air filter element 9air filter case cover 9breather hose cC Never operate the engine without the air fil ter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect the carbure tor tuning leading to poor engine perfor mance NOTE When installing the air filt...

Page 75: ...w 2 in completely then turn the adjusting screw out the speci fied number of turns c Tighten the locknut NOTE Hold the adjusting screw and tighten the lock nut Adjusting screw 1 8 turns out 8 Nm 0 8 m kg 6 0 ft lb EAS00094 CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 1 Remove 9side cowlings left and right 9center panels upper and lower 9front cowling 9rear cowlings left and right 9inner panel...

Page 76: ...UM HOSES The following procedure applies to all of the fuel and vacuum hoses 1 Remove 9side cowlings left and right 9center panels upper and lower 9front cowling 9rear cowlings left and right 9inner panel Refer to COVERS 2 Check 9fuel cock vacuum hose 1 9fuel hose 2 Cracks damage Replace Loose connection Connect properly 3 Install 9inner panel 9rear cowlings left and right 9front cowling 9center p...

Page 77: ...ction Connect properly cC Make sure the crankcase breather pipe is routed correctly EAS00103 CHECKING THE COOLANT LEVEL 1 Stand the vehicle on a level surface NOTE Make sure the vehicle is upright 2 Check 9coolant level The coolant level should be between the minimum level mark a and maximum level mark b Below the minimum level mark Add the recommended coolant to the proper level 3 Install 9inner ...

Page 78: ...eral min utes and then turn it off 4 Check 9coolant level NOTE Before checking the coolant level wait a few minutes until it settles EAS00104 CHECKING THE COOLING SYSTEM 1 Remove 9side cowlings left and right 9front cowling Refer to REMOVING THE SIDE COWL INGS and REMOVING THE FRONT COWLING 2 Check 9radiator 1 9water pump inlet hose 2 9radiator outlet hose 3 9radiator inlet hose 4 9thermostat outl...

Page 79: ...re Therefore do not remove the radiator cap when the engine is hot Scalding hot fluid and steam may be blown out which could cause seri ous injury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter clockwise toward the detent to allow any residual pressure to escape When the hissing sound has stopp...

Page 80: ...are w 9 9If coolant splashes in your eyes thorough ly wash them with water and consult a doc tor 9 9If coolant splashes on your clothes quickly wash it away with water and then with soap and water 9 9If coolant is swallowed induce vomiting and get immediate medical attention Recommended antifreeze YAMAHA GENUINE COOLANT High quality ethylene glycol antifreeze containing corrosion inhibitors for al...

Page 81: ...nted surfaces immediately wash them with water 9 9Do not mix different types of antifreeze 11 Install 9radiator cap 9coolant reservoir cap 9coolant reservoir tank cover 12 Start the engine warm it up for several min utes and then stop it 13 Check 9coolant level Refer to CHECKING THE COOLANT LEVEL NOTE Before checking the coolant level wait a few minutes until the coolant has settled 14 Install 9fr...

Page 82: ... 98 1 38 in 2 Adjust 9brake pedal free play a Turn the adjuster 1 in direction a or b until the specified brake pedal free play is obtained cC After adjusting the brake pedal free play make sure there is no brake drag 3 Adjust 9rear brake light switch Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH Direction a a Brake pedal free play is increased Direction b b Brake pedal free play is decreased Yam...

Page 83: ...PLACING THE FRONT BRAKE PADS in chapter 7 EAS00126 CHECKING THE REAR BRAKE SHOES 1 Operate the brake 2 Check 9wear indicator 1 Reaches the wear limit line 2 Replace the brake shoes as a set Refer to REAR WHEEL AND BRAKE in chapter 7 EAS00128 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE The rear brake light switch is operated by move ment of the brake pedal The rear brake light switch is properly adj...

Page 84: ...l the rear brake light comes on at the proper time Direction a a Brake light comes on sooner Direction b b Brake light comes on later EAS00129 CHECKING THE FRONT BRAKE HOSE 1 Check 9brake hose Cracks damage wear Replace 2 Check 9brake hose clamp Loose Connection Tighten the clamp bolt 3 Hold the vehicle upright and apply the front brake several times 4 Check 9brake hose Brake fluid leakage Replace...

Page 85: ...s pre caution could allow air to enter the hydraulic brake system considerably lengthening the bleeding procedure 9If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed 9hydraulic brake system a Fill the brake master cylinder reservoir to the proper level with the recommend...

Page 86: ... k Fill the brake master cylinder reservoir to the proper level with the recommended brake fluid Refer to CHECKING THE BRAKE FLUID LEVEL w After bleeding the hydraulic brake system check the brake operation Bleed screw 6 Nm 0 6 m kg 4 3 ft lb EAS00140 ADJUSTING THE DRIVE CHAIN SLACK NOTE The drive chain slack must be checked at the tightest point on the chain cC A drive chain that is too tight wil...

Page 87: ...ut of specification Adjust Drive chain slack 25 35 mm 0 93 1 38 in 4 Adjust 9drive chain slack a Loosen the wheel axle nut b Loosen both locknuts 1 c Turn both adjusting nuts 2 in direction a or b until the specified drive chain slack is obtained NOTE To maintain the proper wheel alignment adjust both sides evenly d Tighten both locknuts to specification e Tighten the wheel axle nut to specificati...

Page 88: ...ace NOTE Make sure the vehicle is upright 2 Check 9brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level w 9 9Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance 9 9Refill with the same type of brake fluid that is already in the system Mixing brake flu ids may resu...

Page 89: ... horizontal EASF0010 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the vehicle on a level surface w Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 2 Check 9steering head Grasp the bottom of the front fork legs and gently rock the front fork Binding looseness Adjust the steering head 3 Remo...

Page 90: ... upper ring nut 2 with a steering nut wrench w Do not overtighten the lower ring nut f Check the steering head for looseness or binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD in chapter 7 g Slide the rubber cover to its original posi tion 5 Install 9front cowlings left an...

Page 91: ...e is no danger of it falling over 2 Check 9inner tube Damage scratches Replace 9oil seal Oil leakage Replace 3 Hold the vehicle upright and apply the front brake 4 Check 9front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Rough movement Repair Refer to FRONT FORK in chapter 7 Yamaha T135 Service Manual YamahaT135 COM ...

Page 92: ...tal weight including cargo rider passenger and accessories and the anticipated riding speed 9 9Operation of an overloaded vehicle could cause tire damage an accident or an injury NEVER OVERLOAD THE VEHICLE Total weight of rider passenger cargo and accessories w It is dangerous to ride with a worn out tire When the tire tread reaches the wear limit replace the tire immediately Basic weight with oil...

Page 93: ...entered in the wheel groove 9 9Patching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality replacement 9 9After extensive tests the tires listed below have been approved by Yamaha Motor Co Ltd for this model The front and rear tires should always be by the same manufacturer and of the same design N...

Page 94: ...NG THE TIRES CHECKING AND TIGHTENING THE SPOKES w 9 9New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal speed before any high speed riding is done 9 9After a tire has been repaired or replaced be sure to tighten the tire air valve stem locknut 1 1 to specification NOTE For tires with a direction of...

Page 95: ... the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubricating device EAS00171 LUBRICATING THE LEVER AND PEDALS Lubricate the pivoting point and metal to metal moving parts of the lever and pedals EAS00172 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand EAS00173 LUBRICATING THE CENTERSTAND Lubric...

Page 96: ...e sparks or open flames e g welding equipment light ed cigarettes 9 9DO NOT SMOKE when charging or han dling batteries 9 9KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN 9 9Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL 9 9Skin Wash with water 9 9Eyes Flush with water for 15 minutes and get immediate m...

Page 97: ...evel The electrolyte level should be between the minimum level mark a and the maximum level mark b Below the minimum level mark Add dis tilled water to the proper level cC Add only distilled water Tap water contains minerals which are harmful to the battery 7 Check 9specific gravity Less than 1 280 Recharge the battery 8 Charge 9battery w Do not quick charge a battery Battery charging amperage and...

Page 98: ...e battery 9 9Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger 9 9Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted A corroded bat tery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks 9 9If the battery becomes hot to the ...

Page 99: ...stall 9battery band Recommended lubricant Dielectric grease 11 Connect 9battery breather hose 1 cC 9 9When checking the battery make sure the battery breather hose is properly installed and routed correctly If the battery breather hose is positioned so as to allow elec trolyte or hydrogen gas from the battery to contact the frame the vehicle and its fin ish may be damaged 9 9Make sure the battery ...

Page 100: ...nd check the continuity NOTE Set the pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse 4 Replace 9blown fuse w Never use a fuse with an amperage rating other than that specified Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electri cal system cause the lighting and ignition systems to malfunction and could possibly cause ...

Page 101: ...from the bulb until it has cooled down 4 Install 9headlight bulb Secure the new headlight bulb with the headlight bulb holder cC Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with a...

Page 102: ...st 9headlight beam vertically a Loosen the bolt 1 b Slide the bottom of the headlight unit for ward a or backward b c Tighten the bolt 1 ADJUSTING THE HEADLIGHT BEAM Slide forward Headlight beam is a raised Slide backward Headlight beam is b lowered Yamaha T135 Service Manual YamahaT135 COM ...

Page 103: ...OIL 4 7 CYLINDER HEAD 4 8 REMOVING THE CYLINDER HEAD 4 9 CHECKING THE CYLINDER HEAD 4 11 CHECKING TIMING CHAIN GUIDE 4 12 CHECKING THE TIMING CHAIN TENSIONER 4 13 INSTALLING THE CYLINDER HEAD 4 13 CAMSHAFT 4 17 REMOVING THE ROCKER ARMS AND CAMSHAFT 4 18 CHECKING THE CAMSHAFT 4 19 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS 4 19 CHECKING THE CAMSHAFT SPROCKET 4 21 INSTALLING THE CAMSHAFT AND ROC...

Page 104: ...E CLUTCH 4 50 CHECKING THE FRICTION PLATES 4 52 CHECKING THE CLUTCH PLATES 4 52 CHECKING THE CLUTCH SPRINGS 4 53 CHECKING THE CLUTCH HOUSING 4 53 CHECKING THE CLUTCH BOSS 4 53 CHECKING THE CLUTCH PRESSURE PLATE 4 54 CHECKING THE CLUTCH PUSH RODS 4 54 CHECKING THE PRIMARY DRIVEN GEAR 4 54 CHECKING THE CLUTCH SHOE HOUSING 4 55 CHECKING THE CLUTCH SHOE 4 55 CHECKING THE CAGE 4 55 CHECKING THE CLUTCH ...

Page 105: ...CASE 4 68 KICKSTARTER 4 70 REMOVING THE KICKSTARTER 4 71 CHECKING THE KICKSTARTER 4 73 INSTALLING THE KICKSTARTER 4 74 TRANSMISSION 4 76 REMOVING THE TRANSMISSION 4 77 DISASSEMBLING THE TRANSMISSION 4 77 CHECKING THE SHIFT FORKS 4 78 CHECKING THE SHIFT DRUM ASSEMBLY 4 79 CHECKING THE TRANSMISSION 4 79 INSTALLING THE TRANSMISSION 4 80 Yamaha T135 Service Manual YamahaT135 COM ...

Page 106: ...Y a m a h a T 1 3 5 C O M ENG Yamaha T135 Service Manual YamahaT135 COM ...

Page 107: ...wer 9rear cowlings left and right Refer to COVERS in chapter 3 9drive sprocket Refer to DRIVE CHAIN AND SPROCK ETS in chapter 7 COOLING SYSTEM 1 Drain 9coolant completely from the water jacket Refer to CHANGING THE COOLANT in chapter 3 2 Remove 9radiator assembly 9water pump assembly Refer to RADIATOR and WATER PUMP in chapter 5 ENGINE OIL 1 Drain 9engine oil completely from the crankcase Refer to...

Page 108: ...uffler bolt 1 9washer 9upper muffler bolt 2 9washers 9nut 9muffler 3 BRAKE PEDAL 1 Remove 9rear brake light switch spring 9brake pedal spring 9cotter pin 9brake pedal SHIFT PEDAL 1 Remove 9shift pedal bolt 1 9shift pedal 2 9sprocket cover 1 FOOTREST 1 Remove 9footrest bolts 1 9footrest 1 2 3 Yamaha T135 Service Manual YamahaT135 COM ...

Page 109: ...s 1 9side cowling bracket 2 WIRE CABLE AND HOSE 1 Disconnect 9neutral switch lead coupler 1 9stator coil lead coupler 2 9pick up coil lead coupler 3 9crankcase breather pipe 2 Remove 9starter motor lead coupler T135SE 3 Remove 9spark plug cap 4 3 4 Remove 9fuel cock vacuum hose 1 1 Yamaha T135 Service Manual YamahaT135 COM ...

Page 110: ...bolt 6 9plate nuts front and rear 2 9washers front and rear 9plate bolts front and rear 7 9front mounting nut 3 9washer 9front mounting bolt 8 9plate left and right 9 9rear upper mounting nut 4 9washer 9rear upper mounting bolt 0 9pivot shaft nut 3 9washer 9pivot shaft q 9engine assembly w Securely support the vehicle so there is no danger of it falling over 1 5 Remove 9crankcase breather pipe 1 A...

Page 111: ...late left and right 4 9plate bolts front and rear 5 9washers front and rear 9plate nuts front and rear 9rear lower mounting bolt 6 9washer 9rear lower mounting nut 2 Temporary tighten 9plate nuts front and rear 7 3 Tighten 9pivot shaft nut 8 9rear upper mounting nut 9 9front mounting nut 0 9plate nuts front and rear 7 9rear lower mounting nut q 34 Nm 3 4 m kg 25 ft lb 34 Nm 3 4 m kg 25 ft lb 72 Nm...

Page 112: ...r 9pickup coil lead coupler 9stator coil lead coupler 2 Install 9crankcase breather pipe 9fuel cock vacuum hose 9spark plug cap SIDE COWLING BRACKET 1 Install 9side cowling bracket 9side cowling bracket bolts SHIFT PEDAL 1 Install 9sprocket cover 9shift pedal 1 9shift pedal bolt 2 NOTE Align the punch mark a in the shift pedal with the punch mark b in the shift shaft 1 2 a b 7 Nm 0 7 m kg 5 0 ft l...

Page 113: ...AR BRAKE LIGHT SWITCH in chapter 3 FOOTREST 1 Install 9footrest 9footrest bolts 1 Throttle cable free play at the flange of the throttle grip 3 7 mm 0 12 0 28 mm 23 Nm 2 3 m kg 17 ft lb COOLING SYSTEM 1 Install 9water pump assembly 9radiator assembly Refer to RADIATOR and WATER PUMP in chapter 5 2 Fill 9coolant Refer to CHANGING THE COOLANT in chapter 3 ENGINE OIL 1 Fill 9engine oil Refer to CHANG...

Page 114: ... 7 2 ft lb 13 Nm 1 3 m kg 9 5 ft lb 22 Nm 2 2 m kg 16 ft lb 30 Nm 3 0 m kg 22 ft lb 10 Nm 1 0 m kg 7 2 ft lb LS E E EASF0023 CYLINDER HEAD 1 Water pump 2 Spark plug 3 Cylinder head cover 4 Dowel pin 5 Camshaft sprocket 6 Cylinder head 7 Timing chain guide exhaust side 8 Timing chain tensioner 9 Dowel pin 0 Gasket Yamaha T135 Service Manual YamahaT135 COM ...

Page 115: ...OVERS in chapter 3 9carburetor assembly Refer to CARBURETOR in chapter 6 9muffler Refer to REMOVING THE ENGINE 2 Drain 9cooling system Refer to CHANGING THE COOLANT in chapter 3 3 Remove 9water pump assembly bolts 9water pump assembly 9O rings 4 Remove 9spark plug cap 1 9spark plug 2 5 Remove 9cylinder head cover bolts 9cylinder head cover 9gasket 9dowel pin 9O ring Yamaha T135 Service Manual Yama...

Page 116: ...procket with the stationary point er d on the cylinder head 7 Loosen 9camshaft sprocket bolt 1 NOTE While holding the generator rotor with a wrench 2 loosen the camshaft sprocket bolt 8 Remove 9timing chain tensioner cap bolt 9timing chain tensioner bolts 9timing chain tensioner 1 9gasket 9 Remove 9camshaft sprocket bolt 1 9camshaft sprocket 2 9timing chain 3 NOTE To prevent the timing chain from ...

Page 117: ...h nut 1 2 of a turn at a time After all of the nuts are fully loosened remove them 11 Remove 9dowel pins 1 9gasket 2 9timing chain guide exhaust side 3 EAS00227 CHECKING THE CYLINDER HEAD 1 Eliminate 9combustion chamber carbon deposits with a rounded scraper NOTE Do not use a sharp instrument to avoid damag ing or scratching 9spark plug bore threads 9valve seats 2 Check 9cylinder head Damage scrat...

Page 118: ...he limit is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure eight sanding pattern NOTE To ensure an even surface rotate the cylinder head several times CHECKING TIMING CHAIN GUIDE 1 Check 9timing chain guide exhaust side Damage wear Replace Maximum cylinder head warpage 0 03 mm 0 0012 in Yamah...

Page 119: ...the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly If there is rough move ment replace the timing chain tensioner 2 Check 9cap bolt 9one way cam 9timing chain tensioner rod Damage wear Replace the defective part s EAS00232 INSTALLING THE CYLINDER HEAD 1 Install 9timing chain guide exhaust side 1 9dowel pins 2 9gasket 3 2 Install 9cylinder head 9washers 9cylinde...

Page 120: ...mshaft sprocket with the stationary pointer d on the cylinder head d Install the timing chain onto the camshaft sprocket and then install the camshaft sprocket onto the camshaft NOTE 9When installing the camshaft sprocket be sure to keep the timing chain as tight as possible on the exhaust side 9Align the projection c on the camshaft sprock et with the slot in the camshaft cC Do not turn the crank...

Page 121: ...sket NOTE Apply the YAMAHA bond 1215 onto the bolts c Turn the timing chain tensioner rod counter clockwise with a thin screwdriver 1 make sure it releases and then tighten the cap bolt to specification 6 Tighten 9camshaft sprocket bolt cC Be sure to tighten the camshaft sprocket bolt to the specified torque to avoid the pos sibility of the bolt coming loose and damag ing the engine 7 Turn 9cranks...

Page 122: ...linder head Out of alignment Correct Refer to the installation steps above 9 Measure 9valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE in chapter 3 10 Install 9O rings 9water pump assembly 9water pump assembly bolts 11 Install 9spark plug 12 Install 9intake manifold bolts 9intake manifold with carburetor 10 Nm 1 0 m kg 7 2 ft lb 13 Nm 1 3 m kg 9 5 ft lb 10 Nm 1 0...

Page 123: ...5 5 4 3 1 2 6 E E E 7 Nm 0 7 m kg 5 0 ft lb 7 Nm 0 7 m kg 5 0 ft lb LS E 4 17 CAMSHAFT EASf0020 CAMSHAFT 1 Locknut 2 Adjusting screw 3 Camshaft retainer 4 Camshaft 5 Rocker arm shaft 6 Rocker arm Yamaha T135 Service Manual YamahaT135 COM ...

Page 124: ...the rocker arms and camshaft remove the cylinder head 1 Loosen 9locknuts 1 9adjusting screws 2 2 Remove 9camshaft retainer 1 3 Remove 9camshaft 1 NOTE Screw an 8 mm bolt 2 into the threaded end of the camshaft and then pull out the camshaft 4 Remove 9rocker arm shafts 9rocker arms Yamaha T135 Service Manual YamahaT135 COM ...

Page 125: ...mshaft 3 Check 9camshaft oil passage Obstructions Blow out with compressed air EAS00206 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts 1 Check 9rocker arm Damage wear Replace Camshaft lobe dimension limit Intake a a 29 613 mm 1 1659 in b b 25 043 mm 0 9859 in Exhaust a a 29 912 mm 1 1776 in b b 24 989 mm 0 9838 in Yama...

Page 126: ...o rocker arm shaft clearance NOTE Calculate the clearance by subtracting the rock er arm shaft outside diameter from the rocker arm inside diameter Above 0 08 mm Replace the rocker arm and rocker arm shaft as a set Rocker arm inside diameter 9 985 10 000 mm 0 3931 0 3937 in Limit 9 950 mm 0 3917 in Rocker arm shaft outside diameter 9 966 9 976 mm 0 3924 0 3928 in Limit 9 950 mm 0 3917 in Rocker ar...

Page 127: ...2 Camshaft sprocket a 1 EAS00219 INSTALLING THE CAMSHAFT AND ROCKER ARMS 1 Lubricate 9camshaft journals 2 Lubricate 9rocker arm inside surface 9camshaft oil passage 3 Install 9camshaft retainer 1 9camshaft retainer bolt NOTE Install the camshaft retainer with the bent ends facing inward Recommended lubricant Engine oil Recommended lubricant Molybdenum disulfide grease 7 Nm 0 7 m kg 5 0 ft lb Yamah...

Page 128: ...E SPRINGS 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 6 6 7 7 EASF0024 VALVES AND VALVE SPRINGS 1 Valve cotter 2 Upper spring seat 3 Valve spring 4 Valve stem seal 5 Lower spring seat 6 Intake valve 7 Exhaust valve Yamaha T135 Service Manual YamahaT135 COM ...

Page 129: ...efore removing the internal parts of the cylin der head e g valves valve springs valve seats make sure the valves properly seal 1 Check 9valve sealing Leakage at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal NOTE There should be no leakage at the ...

Page 130: ...e EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides 1 Measure 9valve stem to valve guide clearance Out of specification Replace the valve guide Valve spring compressor 90890 04019 Valve spring compressor attachment 90890 04108 Valve stem to valve guide clearance Valve guide inside diameter a a Valve stem diameter b b Valve stem to v...

Page 131: ...sket NOTE Apply the YAMAHA bond 1215 onto the bolts c Turn the timing chain tensioner rod counter clockwise with a thin screwdriver 1 make sure it releases and then tighten the cap bolt to specification 6 Tighten 9camshaft sprocket bolt cC Be sure to tighten the camshaft sprocket bolt to the specified torque to avoid the pos sibility of the bolt coming loose and damag ing the engine 7 Turn 9cranks...

Page 132: ...linder head Out of alignment Correct Refer to the installation steps above 9 Measure 9valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE in chapter 3 10 Install 9O rings 9water pump assembly 9water pump assembly bolts 11 Install 9spark plug 12 Install 9intake manifold bolts 9intake manifold with carburetor 10 Nm 1 0 m kg 7 2 ft lb 13 Nm 1 3 m kg 9 5 ft lb 10 Nm 1 0...

Page 133: ...5 5 4 3 1 2 6 E E E 7 Nm 0 7 m kg 5 0 ft lb 7 Nm 0 7 m kg 5 0 ft lb LS E 4 17 CAMSHAFT EASf0020 CAMSHAFT 1 Locknut 2 Adjusting screw 3 Camshaft retainer 4 Camshaft 5 Rocker arm shaft 6 Rocker arm Yamaha T135 Service Manual YamahaT135 COM ...

Page 134: ...the rocker arms and camshaft remove the cylinder head 1 Loosen 9locknuts 1 9adjusting screws 2 2 Remove 9camshaft retainer 1 3 Remove 9camshaft 1 NOTE Screw an 8 mm bolt 2 into the threaded end of the camshaft and then pull out the camshaft 4 Remove 9rocker arm shafts 9rocker arms Yamaha T135 Service Manual YamahaT135 COM ...

Page 135: ...mshaft 3 Check 9camshaft oil passage Obstructions Blow out with compressed air EAS00206 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to all of the rocker arms and rocker arm shafts 1 Check 9rocker arm Damage wear Replace Camshaft lobe dimension limit Intake a a 29 613 mm 1 1659 in b b 25 043 mm 0 9859 in Exhaust a a 29 912 mm 1 1776 in b b 24 989 mm 0 9838 in Yama...

Page 136: ...o rocker arm shaft clearance NOTE Calculate the clearance by subtracting the rock er arm shaft outside diameter from the rocker arm inside diameter Above 0 08 mm Replace the rocker arm and rocker arm shaft as a set Rocker arm inside diameter 9 985 10 000 mm 0 3931 0 3937 in Limit 9 950 mm 0 3917 in Rocker arm shaft outside diameter 9 966 9 976 mm 0 3924 0 3928 in Limit 9 950 mm 0 3917 in Rocker ar...

Page 137: ...2 Camshaft sprocket a 1 EAS00219 INSTALLING THE CAMSHAFT AND ROCKER ARMS 1 Lubricate 9camshaft journals 2 Lubricate 9rocker arm inside surface 9camshaft oil passage 3 Install 9camshaft retainer 1 9camshaft retainer bolt NOTE Install the camshaft retainer with the bent ends facing inward Recommended lubricant Engine oil Recommended lubricant Molybdenum disulfide grease 7 Nm 0 7 m kg 5 0 ft lb Yamah...

Page 138: ...E SPRINGS 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 6 6 7 7 EASF0024 VALVES AND VALVE SPRINGS 1 Valve cotter 2 Upper spring seat 3 Valve spring 4 Valve stem seal 5 Lower spring seat 6 Intake valve 7 Exhaust valve Yamaha T135 Service Manual YamahaT135 COM ...

Page 139: ...efore removing the internal parts of the cylin der head e g valves valve springs valve seats make sure the valves properly seal 1 Check 9valve sealing Leakage at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal NOTE There should be no leakage at the ...

Page 140: ...e EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides 1 Measure 9valve stem to valve guide clearance Out of specification Replace the valve guide Valve spring compressor 90890 04019 Valve spring compressor attachment 90890 04108 Valve stem to valve guide clearance Valve guide inside diameter a a Valve stem diameter b b Valve stem to v...

Page 141: ...he proper valve stem to valve guide clearance NOTE After replacing the valve guide reface the valve seat 3 Eliminate 9carbon deposits from the valve face and valve seat 4 Check 9valve face Pitting wear Grind the valve face 9valve stem end Mushroom shape or diameter larger than the body of the valve stem Replace the valve 5 Measure 9valve margin thickness a Out of specification Replace the valve Va...

Page 142: ...eposits from the valve face and valve seat 2 Check 9valve seat Pitting wear Replace the cylinder head 3 Measure 9valve seat width a Out of specification Replace the cylinder head a Apply Mechanic s blueing dye Dykem b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat ...

Page 143: ... Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then clean off all of the lapping compound NOTE For the best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to cl...

Page 144: ...n Replace the valve spring 2 Measure 9compressed valve spring force a Out of specification Replace the valve spring b Installed length 3 Measure 9valve spring tilt a Out of specification Replace the valve spring Valve spring free length Intake and exhaust valve springs 47 33 mm 1 86 in Limit 44 96 mm 1 77 in Compressed valve spring force installed Intake and exhaust valve springs 135 6 156 0 N 13 ...

Page 145: ...e stem end with an oil stone 2 Lubricate 9valve stem 1 9valve stem seal 2 with the recommended lubricant 3 Install 9valve 1 9lower spring seat 2 9valve stem seal 3 9valve spring 4 9upper spring seat 5 into the cylinder head NOTE Install the valve spring with the larger pitch a facing up b Smaller pitch Recommended lubricant Molybudemium oil Yamaha T135 Service Manual YamahaT135 COM ...

Page 146: ... valve spring with the valve spring compressor 2 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer cC Hitting the valve tip with excessive force could damage the valve Valve spring compressor 90890 04019 Valve spring compressor attachment 90890 04108 Yamaha T135 Service Manual YamahaT135 COM ...

Page 147: ...INDER AND PISTON E 4 5 6 7 9 8 3 3 2 1 E 7 E EASF0027 CYLINDER AND PISTON 1 Cylinder 2 Cylinder gasket 3 Dowel pin 4 Top ring 5 2nd ring 6 Oil ring 7 Piston pin clip 8 Piston pin 9 Piston 4 31 Yamaha T135 Service Manual YamahaT135 COM ...

Page 148: ...g the piston pin clip cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase 9Before removing the piston pin deburr the pis ton pin clip groove and the piston pin bore area of the piston If both areas are deburred and the piston pin is still difficult to remove remove it with a piston pin puller set 4 Remove 9top ring 92nd ring 9oil ring NOTE Wh...

Page 149: ... of specification replace the cylinder and replace the piston and piston rings as a set c Measure piston skirt diameter P with a micrometer a 5 mm from the bottom edge of the piston d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with the following formula Cylinder bore C 54 000 54 010 mm 2 1260 2 1264 in Limit 54 100 mm 2 1299 in...

Page 150: ...ce eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install 9piston ring into the cylinder NOTE Level the piston ring into the cylinder with the piston crown a 40 mm Piston to cylinder clearance 0 0015 0 048 mm 0 0006 0 0019 in Limit 0 15 mm 0 0059 Piston to cylinder clearance Cylinder bore C Piston skirt diameter P Piston ring side clearance Top ring 0 030 0 065 mm 0 ...

Page 151: ...cation system 2 Measure 9piston pin outside diameter a Out of specification Replace the piston pin 3 Measure 9piston pin bore diameter of the piston b Out of specification Replace the piston Piston ring end gap Top ring 0 10 0 25 mm 0 0039 0 0098 in Limit 0 4 mm 0 0157 in 2nd ring 0 10 0 25 mm 0 0039 0 0098 in Limit 0 4 mm 0 0157 in Oil ring rails 0 20 0 70 mm 0 01 0 03 in Piston pin outside diame...

Page 152: ...he manufacturer s marks or numbers face up 2 Install 9piston 1 9piston pin 2 9piston pin clip 3 NOTE 9Apply engine oil to the piston pin 9Make sure the mark a on the piston points towards the exhaust side of the cylinder 9Before installing the piston pin clip cover the crankcase opening with a clean rag to prevent the clip from falling into the crankcase Piston pin to piston pin bore clearance Pis...

Page 153: ...e oil onto them 5 Offset 9piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring å forward 6 Install 9cylinder 1 NOTE 9While compressing the piston rings with one hand install the cylinder with the other hand 9Pass the timing chain and timing chain guide intake side through the timing chain cavity Recommended lubricant Engine oil Yamaha T135 Service Manual YamahaT13...

Page 154: ...m kg 20 ft lb E T135SE EASF0034 GENERATOR AND STARTER CLUTCH 1 Starter clutch gear 2 Starter clutch roller 3 Starter clutch spring cap 4 Starter clutch spring 5 Starter clutch 6 Woodruff key 7 Generator rotor 8 Starter clutch idle gear shaft 9 Starter clutch idle gear 0 Pickup coil q Stator coil w Gasket e Dowel pin r Crankcase cover left Yamaha T135 Service Manual YamahaT135 COM ...

Page 155: ...ft pedal 9drive sprocket cover Refer to REMOVING THE DRIVE CHAIN AND SPROCKETS in chapter 6 3 Disconnect 9stator coil coupler 1 9pickup coil coupler 2 5 Remove 9generator rotor nut 1 9washer NOTE 9While holding the generator rotor 2 with the sheave holder 3 loosen the generator rotor nut 9Do not allow the sheave holder to touch the projection on the generator rotor Sheave holder 90890 01701 4 Remo...

Page 156: ...idle gear 2 9starter clutch gear 3 9washer 2 Remove 9starter clutch rollers 1 9starter clutch spring caps 9starter clutch springs 3 Remove 9starter clutch bolt 9starter clutch 1 NOTE 9While holding the generator rotor 2 with the sheave holder remove the starter clutch bolt 9Do not allow the sheave holder to touch the projection on the generator rotor Flywheel puller 90890 01362 Sheave holder 90890...

Page 157: ...s a Damage pitting wear Replace the starter clutch gear 4 Check 9starter clutch operation a Install the starter clutch gear 1 onto the starter clutch and hold the starter clutch b When turning the starter clutch gear clock wise å the starter clutch and the starter clutch gear should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter clutch gear coun tercl...

Page 158: ... THE GENERATOR 1 Install 9woodruff key 9generator rotor 9generator rotor nut NOTE 9Clean the tapered portion of the crankshaft and the generator rotor hub 9When installing the generator rotor make sure the woodruff key is properly sealed in the key way of the crankshaft 2 Tighten 9generator rotor nut 1 NOTE 9While holding the generator rotor 2 with the sheave holder 3 tighten the generator rotor n...

Page 159: ...nkcase cover bolt thread as shown one 5 Install 9gasket 9crankcase cover 4 43 ENG GENERATOR AND STARTER CLUTCH 3 Apply 9sealant on to the generator lead grommet Yamaha bond No 1215 90890 85505 Yamaha bond No 1215 90890 85505 10 Nm 1 0 m kg 7 2 ft lb Yamaha T135 Service Manual YamahaT135 COM ...

Page 160: ...0 Nm 1 0 m kg 7 2 ft lb 32 Nm 3 2 m kg 23 ft lb 7 Nm 0 7 m kg 5 0 ft lb 4 44 OIL PUMP 1 Oil drain bolt 2 O ring 3 Spring 4 Oil strainer 5 Oil filter cover 6 O ring 7 Oil filter 8 Gear cover 9 Oil pump assembly 0 Gasket EASF0035 OIL PUMP Yamaha T135 Service Manual YamahaT135 COM ...

Page 161: ...NGINE OIL in chapter 3 2 Remove 9generator Refer to GENERATOR AND STARTER CLUTCH 3 Remove 9clutch release shift arm 4 Remove 9gear cover 5 Remove 9oil pump assembly 1 9gasket DISASSEMBLING THE OIL PUMP 1 Remove 9screw 9pump cover 1 9pin 2 9inner rotor 3 9outer rotor 4 9oil pump housing 5 9oil pump driven cover 6 Yamaha T135 Service Manual YamahaT135 COM ...

Page 162: ...nd outer rotor clearance c Out of specification Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump housing 3 Check 9oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s Inner rotor to outer rotor tip clearance 0 15 mm 0 0059 in Limit 0 20 mm 0 0079 in Outer rotor to oil pump housing clearance 0 06 0 11 mm 0 0024 0 0043 in Limit 0 15 mm 0 0059 in Oil pump ...

Page 163: ...ll 9oil pump shaft to the oil pump housing 9inner rotor 1 9outer rotor 9pin 2 9oil pump housing cover 3 9screw 4 NOTE When installing the inner rotor align the pin in the oil pump shaft with the groove a in the inner rotor 3 Check 9oil pump operation Refer to CHECKING THE OIL PUMP Recommended lubricant Engine oil 1 Nm 0 1 m kg 0 7 ft lb Yamaha T135 Service Manual YamahaT135 COM ...

Page 164: ...THE OIL PUMP 1 Install 9gasket 1 9oil pump assembly NOTE Install the gasket with section a in the position as shown in the illustration cC After tightening the bolts make sure the oil pump turns smoothly 7 Nm 0 7 m kg 5 0 ft lb Yamaha T135 Service Manual YamahaT135 COM ...

Page 165: ...olt 2 Clutch spring 3 Clutch pressure plate 4 Friction plate 1 5 Clutch plate 6 Friction plate 2 7 Cushion ring 8 Seat plate 9 Clutch push rod 1 0 Clutch boss nut q Clutch boss w Clutch housing e Clutch push rod 2 r Clutch release shift arm t Clutch release adjusting screw y Clutch shoe housing nut u Primary drive gear i Clutch shoe housing o Cage p Clutch shoe housing boss a Clutch shoe Yamaha T1...

Page 166: ...kstarter lever Refer to KICKSTARTER 9crankcase cover left Refer to GENERATOR AND STARTER CLUTCH 5 Remove 9clutch pressure plate bolts 1 9clutch springs 9clutch pressure plate 2 NOTE Loosen each bolt 1 4 of a turn at a time in stages and in a crisscross pattern After all of the bolts are fully loosened remove them 6 Remove 9clutch push rod 1 1 9friction plates 1 2 9friction plates 2 3 9clutch plate...

Page 167: ... 9clutch boss nut 1 9lock washer 2 9clutch boss 3 9washer 4 9clutch housing 5 9spacer 6 9clutch push rod 2 7 10 Remove 9clutch shoe housing nut 1 9washer NOTE 9Loosen the clutch shoe housing nut while hold ing the generator rotor 2 with the sheave holder 3 9Do not allow the sheave holder to touch the projection on the generator rotor Universal clutch holder 90890 04086 Sheave holder 90890 01701 Ya...

Page 168: ...iction plate thickness Out of specification Replace the friction plates as a set NOTE Measure the friction plate at four places EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates 1 Check 9clutch plate Damage Replace the clutch plates as a set 2 Measure 9clutch plate warpage with a surface plate and thickness gauge 1 Out of specification Replace the clut...

Page 169: ...0284 CHECKING THE CLUTCH HOUSING 1 Check 9clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing NOTE Pitting on the clutch housing dogs will cause erratic clutch operation EAS00285 CHECKING THE CLUTCH BOSS 1 Check 9clutch boss splines Damage pitting wear Replace the clutch boss NOTE Pitting on the clutch boss splines will cause erratic clutch operatio...

Page 170: ... clutch push rod 2 2 Measure 9clutch push rods bending limit Out of specification Replace the clutch push rod EAS00292 CHECKING THE PRIMARY DRIVEN GEAR 1 Check 9primary drive gear on the clutch shoe housing 9primary driven gear on the clutch housing Damage wear Replace the clutch shoe housing and clutch housing as a set Excessive noise during operation Replace the clutch shoe housing and clutch ho...

Page 171: ...Check 9clutch shoe Scratches Smooth using coarse sandpa per Damage wear Replace 2 Measure 9clutch shoe groove depth a Groove is worn away Replace CHECKING THE CAGE 1 Check 9cage 1 Damage wear cracks Replace 9rollers 2 Wear bend Replace 9cage springs 3 Wear Replace Clutch shoe housing inside diame ter 116 mm 4 57 in Limit 117 mm 4 61 in Clutch shoe groove depth 1 0 mm 0 04 in Limit 0 1 mm 0 004 in ...

Page 172: ... position to turn the lateral direction And then take care comes off to install them onto the crankshaft 2 Tighten 9clutch shoe housing nut 1 NOTE 9While holding the generator rotor 2 with the sheave holder 3 tighten the clutch shoe housing nut 9Do not allow the sheave holder to touch the projection on the generator rotor 3 Install 9clutch push rod 2 1 9spacer 2 9clutch housing 3 9washer 4 9clutch...

Page 173: ...to face the cushion ring 2 toward as shown illustration and then install it onto the clutch boss 9First install the seat plate cushion ring and then alternate between a clutch plate and a friction plate 8 Install 9clutch springs 9clutch pressure plate 1 9clutch pressure plate bolts 2 NOTE 9Align the punch mark a on the pressure plate with clutch housing mark b 9Tighten the clutch pressure plate bo...

Page 174: ... lb E E E E LS SHIFT SHAFT EASF0032 SHIFT SHAFT 1 Shift pedal 2 Washer 3 Spring 4 Shift fork guide bar 5 Shift guide 6 Pawl holder 7 Guide 8 Washer 9 Thrust bearing 0 Dowel pin q Shift shaft w Shift lever assembly e Stopper lever spring r Stopper lever assembly t Collar y Plate u Shift drum segment Yamaha T135 Service Manual YamahaT135 COM ...

Page 175: ... to CHANGING THE ENGINE OIL in chapter 3 2 Remove 9clutch Refer to CLUTCH 3 Remove 9shift pedal 9crankcase cover bolts 9crankcase cover left 4 Remove 9shift fork guide bar 1 9washer 2 9shift guide spring 5 Remove 9shift guide 1 9pawl holder 2 9guide 3 9dowel pin 4 6 Remove 9washers 1 9thrust bearing 2 Yamaha T135 Service Manual YamahaT135 COM ...

Page 176: ...7 Remove 9shift shaft assembly 1 9shift lever assembly 2 8 Remove 9stopper lever assembly 3 9stopper lever spring 4 9collar 9 Remove 9stopper lever spring 1 9stopper lever 2 9collar 3 10 Remove 9plate 9shift drum segment 1 Yamaha T135 Service Manual YamahaT135 COM ...

Page 177: ...EAS00330 CHECKING THE STOPPER LEVER 1 Check 9stopper lever 1 Bends damage Replace Roller turns roughly Replace 9stopper lever spring Damage wear Replace CHECKING THE SHIFT GUIDE 1 Check 9shift guide 1 9pawl holder 2 9guide 3 Bends damage Replace 9shift guide spring 4 Damage wear Replace CHECKING THE OIL SEAL 1 Check 9oil seal Damage wear Replace Yamaha T135 Service Manual YamahaT135 COM ...

Page 178: ...crew 2 Install 9collar 9stopper lever 1 9stopper lever spring 2 NOTE 9Apply locking agent LOCTITER to the stopper lever bolt 9Hook the ends 3 of the stopper lever spring onto the stopper lever and the crankcase boss 9Mesh the stopper lever with the shift drum seg ment assembly 3 Install 9shift lever assembly 1 9shift shaft assembly 2 LT 12 Nm 1 2 m kg 9 0 ft lb Yamaha T135 Service Manual YamahaT13...

Page 179: ... m kg 7 2 ft lb E 4 Nm 0 4 m kg 3 0 ft lb 4 63 CRANKCASE AND CRANKSHAFT EASF0037 CRANKCASE AND CRANKSHAFT 1 Neutral switch 2 Right crankcase 3 Dowel pin 4 Timing chain 5 Timing chain guide intake side 6 Crankshaft assembly 7 Left crankcase Yamaha T135 Service Manual YamahaT135 COM ...

Page 180: ... T135SE in chapter 8 3 Remove 9cylinder head Refer to CYLINDER HEAD 9cylinder 9piston Refer to CYLINDER AND PISTON 9clutch Refer to CLUTCH 9shift shaft Refer to SHIFT SHAFT 9generator 9starter clutch Refer to GENERATOR AND STARTER CLUTCH 9oil pump assembly Refer to OIL PUMP 4 Remove 9neutral switch 1 9timing chain guide intake side bolts 9timing chain guide intake side 2 9timing chain 3 Yamaha T13...

Page 181: ...crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure the crankcase halves sepa rate evenly 7 Remove 9crankshaft assembly NOTE Use the crankcase separating tool w Never use the hammer to tapping and removing the crankshaft directory EAS00394 CHECKING THE CRANKSHAFT AND CONNECTING ROD 1 Measure 9crankshaft runout Out of specification Replace the crank shaft bearing ...

Page 182: ...t of specification Replace the crank shaft 4 Check 9crankshaft sprocket 1 Damage wear Replace the crankshaft 9bearing 2 Cracks damage wear Replace the crank shaft 5 Check 9crankshaft journal Scratches wear Replace the crankshaft Big end side clearance 0 11 0 41 mm 0 0043 0 0161 in Crankshaft width 45 95 46 00 mm 1 809 1 811 in Yamaha T135 Service Manual YamahaT135 COM ...

Page 183: ...il delivery passages Obstructions Blow out with compressed air EAS00401 CHECKING THE BEARINGS 1 Check 9bearings Clean and lubricate the bearings then rotate the inner race with your finger Rough movement Replace CHECKING THE TIMING CHAIN GUIDE 1 Check 9timing chain guide intake side Damage wear Replace CHECKING THE TIMING CHAIN 1 Check 9timing chain Damage stiffness Replace the timing chain and ca...

Page 184: ...center with one hand while turning the nut of the installing tool with the other 9 9Operate the installing tool until the crank shaft bottoms against the bearing EAS00416 ASSEMBLING THE CRANKCASE 1 Apply 9 9sealant onto the crankcase mating surfaces NOTE Do not allow any sealant to come into contact with the oil gallery 1 2 Install 9dowel pins 2 3 Install 9right crankcase onto the left crankcase N...

Page 185: ...oles 6 Check 9crankshaft and transmission operation Rough movement Repair 7 Install 9timing chain 9timing chain guide intake side 9timing chain guide intake side bolts NOTE Apply locking agent LOCTITER to the threads of timing chain guide intake side bolts 10 Nm 1 0 m kg 7 2 ft lb 4 Nm 0 4 m kg 3 0 ft lb 10 Nm 1 0 m kg 7 2 ft lb Yamaha T135 Service Manual YamahaT135 COM ...

Page 186: ...6 ft lb 4 70 1 Oil level plug 2 Kickstarter lever 3 Crankcase cover right 4 Gasket 5 Washer 6 Kickstarter gear 7 Guide stopper 8 Collar 9 Kickstarter spring 0 Washer q Spring w Kickstarter ratchet gear e Kickstarter shaft ENG KICKSTARTER EASF0033 KICKSTARTER Yamaha T135 Service Manual YamahaT135 COM ...

Page 187: ... lower 9rear cowlings left and right Refer to COVERS in chapter 3 9carburetor assembly Refer to CARBURETOR in chapter 6 9muffler 9footrest 9Brake pedal Refer to REMOVING THE ENGINE 3 Remove 9cylinder head Refer to CYLINDER HEAD 9cylinder 9piston Refer to CYLINDER AND PISTON 4 Remove 9kickstarter nut 1 9kickstarter lever 2 5 Remove 9oil level plug 9crankcase cover bolts 9crankcase cover right 3 9ga...

Page 188: ... Refer to SOIL PUMP 9generator 9starter clutch Refer to GENERATOR AND STARTER CLUTCH 7 Remove 9starter motor T135SE Refer to STARTER MOTOR in chapter 8 8 Remove 9engine Refer to REMOVING THE ENGINE 9 Separate 9crankcase Refer to CRANKCASE 10 Remove 9guide stopper 9kickstarter shaft assembly Yamaha T135 Service Manual YamahaT135 COM ...

Page 189: ...2 9kickstarter spring 3 9collar 4 9washer 5 9spring 6 9kickstarter ratchet gear 7 9kickstarter shaft EAS00339 CHECKING THE KICKSTARTER 1 Check 9kickstarter ratchet gear 1 9kickstarter gear 2 Damage wear Replace 2 Check 9kickstarter spring Damage wear Replace Yamaha T135 Service Manual YamahaT135 COM ...

Page 190: ...er clockwise to 3 4 turns b 2 Install 9guide stopper 3 9guide stopper bolts 9kickstarter gear 4 3 Install 9crankcase Refer to CRANKCASE 4 Install 9engine Refer to REMOVING THE ENGINE 5 Install 9starter motor T135SE Refer to STARTER MOTOR T135SE in chapter 8 6 Install 9oil pump assembly Refer to OIL PUMP 9generator Refer to GENERATOR AND STARTER CLUTCH 9shift shaft Refer to SHIFT SHAFT 9clutch Refe...

Page 191: ...NDER HEAD 10 Install 9muffler 9footrest 9brake pedal Refer to REMOVING THE ENGINE 9inner panel 9center panels left and right 9front cowling 9side cowlings left and right Refer to COVERS in chapter 3 11 Fill 9coolant completely from the water jacket Refer to CHANGING THE COOLANT in chapter 3 9engine oil completely from the crankcase Refer to CHANGING THE ENGINE OIL in chapter 3 Yamaha T135 Service ...

Page 192: ...ION 1 Shift fork guide bar 2 Shift fork R 3 Shift fork L 4 Shift drum 5 2nd pinion gear 6 3rd pinion gear 7 4th pinion gear 8 Main axle 1st pinion gear 9 1st wheel gear 0 4th wheel gear q 3rd wheel gear w 2nd wheel gear e Side plate spring r Side plate t Washer y Drive axle Yamaha T135 Service Manual YamahaT135 COM ...

Page 193: ... guide bar springs 9shift fork R 2 9shift fork L 3 9shift drum 4 NOTE Note the position of each part Pay particular attention to location and direction of shift forks 2 Remove 9main axle assembly 1 9drive axle assembly 2 DISASSEMBLING THE TRANSMISSION 1 Remove 9washer 1 92nd pinion gear 2 93rd pinion gear 3 9circlip 4 9washer 5 94th pinion gear 6 9main axle 1st pinion gear 7 Yamaha T135 Service Ma...

Page 194: ...procedure applies to both of the shift forks 1 Check 9shift fork cam follower 1 9shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check 9shift fork guide bar Roll the shift fork guide bar on a flat sur face Bends Replace w Do not attempt to straighten a bent shift fork guide bar 3 Check 9shift fork movement along the shift fork guide bar Rough movement Replace the shift forks a...

Page 195: ...e runout with a centring device and dial gauge 1 Out of specification Replace the main axle 2 Measure 9drive axle runout with a centring device and dial gauge 1 Out of specification Replace the drive axle 3 Check 9transmission gears Blue discoloration pitting wear Replace the defective gear s 9transmission gear dogs Cracks damage rounded edges Replace the defective gear s Main axle runout limit 0 ...

Page 196: ...le 2 as shown 5 Check 9transmission gear movement Rough movement Replace the defective part s 6 Check 9circlips Bends damage looseness Replace EAS00426 INSTALLING THE TRANSMISSION 1 Install 9shift fork guide bar 1 9shift fork R 2 9shift fork L 3 9shift drum 4 NOTE 9The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence R L 9Be sure i...

Page 197: ...transmission 9shift drum 9shift forks Rough movement Repair NOTE 9Oil each gear shaft and bearing thoroughly 9Before assembling the crankcase be sure that the transmission is in neutral and that the gears turn freely Yamaha T135 Service Manual YamahaT135 COM ...

Page 198: ...Y a m a h a T 1 3 5 C O M ENG Yamaha T135 Service Manual YamahaT135 COM ...

Page 199: ...G THE RADIATOR 5 3 CHECKING THE RADIATOR 5 4 CHECKING THE THERMOSTAT 5 6 DISASSEMBLING THE WATER PUMP 5 6 CHECKING THE WATER PUMP 5 7 ASSEMBLING THE WATER PUMP 5 8 INSTALLING THE THERMOSTAT 5 8 INSTALLING THE WATER PUMP 5 9 INSTALLING THE RADIATOR 5 9 Yamaha T135 Service Manual YamahaT135 COM ...

Page 200: ...Y a m a h a T 1 3 5 C O M COOL Yamaha T135 Service Manual YamahaT135 COM ...

Page 201: ...4 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 1 Radiator cap 2 Bracket 3 Water pump inlet hose 4 Radiator outlet hose 5 Radiator inlet hose 6 Bracket 7 Thermostat housing cover 8 Thermostat 9 Radiator assembly 0 Fan motor assembly Yamaha T135 Service Manual YamahaT135 COM ...

Page 202: ...P 5 7 8 6 0 q 1 9 2 4 3 LS LS LS 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 1 O ring 2 O ring 3 Water pump cover 4 Gasket 5 Plate 6 Impeller 7 Plate 8 Housing cover gasket 9 Bearing 0 Water pump seal q Water pump housing Yamaha T135 Service Manual YamahaT135 COM ...

Page 203: ...kwise toward the detent to allow any residual pressure to escape When the hissing sound has stopped press down on the radiator cap and turn it counter clockwise to remove 1 Remove 9side cowlings left and right 9front cowling 9center panels 9seat assembly with battery box 9inner panel Refer to REMOVING THE FRONT COWL INGS in chapter 3 2 Drain 9cooling water Refer to CHANGING THE COOLANT in chapter ...

Page 204: ...tor EAS00455 CHECKING THE RADIATOR 1 Check 9radiator fins Obstruction Clean Apply compressed air to the rear of the radi ator Damage Repair or replace NOTE Straighten any flattened fins with a thin flat head screwdriver 2 Check 9radiator hoses 9radiator pipes Cracks damage Replace Yamaha T135 Service Manual YamahaT135 COM ...

Page 205: ...o the radiator cap 3 b Apply the specified pressure for ten seconds and make sure there is no drop in pressure 4 Check 9radiator fan motor Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM in chapter 8 Radiator cap opening pressure 93 2 122 6 kPa 0 93 1 23 kg cm2 13 5 17 8 psi Radiator cap tester 1 1 90890 01325 Radiator cap tester adapter 2 2 90890 01352 Yamaha T135 Service Manu...

Page 206: ...tirring the water observe the thermo stat and thermometer s indicated tempera ture 1 Thermometer 2 Water 3 Thermostat 4 Container å Fully closed Fully open NOTE If the accuracy of the thermostat is in doubt replace it A faulty thermostat could cause seri ous overheating or overcooling 2 Check 9thermostat housing cover 9thermostat housing Cracks damage Replace EAS00470 DISASSEMBLING THE WATER PUMP ...

Page 207: ...r pump housing cover 9water pump housing 9impeller 9rubber damper 9rubber damper holder 9water pump seal 9oil seal Cracks damage wear Replace 4 Remove 9water pump seal 4 NOTE Remove the water pump seal from the inside of the water pump housing 2 Check 9bearing Rough movement Replace 2 Remove 9plate NOTE Slide the plate as shown and then remove the plate from the water pump housing Yamaha T135 Serv...

Page 208: ...mp seal 1 NOTE Install the water pump seal with the special tools å Push down 2 Lubricate 9water pump seal 1 Mechanical seal installer 90890 04145 2 2 Middle driven shaft bearing driver 90890 04058 3 3 Recommended lubricant Lithium soap base grease 3 Install 9impeller 9plate NOTE 9Align the slit in the impeller shaft with the slot of the plate 9After installation check that the impeller shaft rota...

Page 209: ...ter 3 5 9 COOL COOLING SYSTEM 1 2 a b LS LS EAS00478 INSTALLING THE WATER PUMP 1 Install 9O rings 9water pump housing 1 w Always use a new O ring NOTE 9Align the projection a on the impeller shaft with the slit b on the camshaft 9Lubricate the O ring with a thin coat of lithium soap based grease 2 Install 9water pump housing cover 2 9water pump inlet hose 9water pump outlet hose 10 Nm 1 0 m kg 7 2...

Page 210: ...cated pressure with the gauge 5 Measure 9radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR 6 Install 9inner panel 9seat assembly with battery box 9center panels 9front cowling 9side cowlings left and right Refer to REMOVING THE FRONT COWL INGS in chapter 3 Radiator cap tester 90890 01325 Radiator cap tester adapter 90890 01352 Yamaha...

Page 211: ...NSTALLING THE CARBURETOR 6 10 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 6 11 CHECKING THE FUEL COCK OPERATION 6 13 AIR INDUCTION SYSTEM 6 14 AIR INJECTION 6 14 AIR CUT OFF VALVE 6 14 AIR INDUCTION SYSTEM DIAGRAMS 6 15 REMOVING THE AIR INDUCTION SYSTEM 6 16 CHECKING THE AIR INDUCTION SYSTEM 6 16 INSTALLING THE AIR INDUCTION SYSTEM 6 16 Yamaha T135 Service Manual YamahaT135 COM ...

Page 212: ...Y a m a h a T 1 3 5 C O M CARB Yamaha T135 Service Manual YamahaT135 COM ...

Page 213: ...tor top cover 3 Throttle valve spring 4 Needle set 5 Throttle valve 6 Throttle stop screw set 7 Pilot air screw set 8 Needle jet 9 Main jet 0 Needle valve assembly q Float w Float chamber rubber gasket e Float pivot pin r Float chamber t Fuel drain screw y Carburetor overflow hose u Throttle position sensor Yamaha T135 Service Manual YamahaT135 COM ...

Page 214: ... fuel on the hot engine 1 Remove 9battery 9seat assembly with battery box 2 Remove 9starter relay 1 T135SE 3 Remove 9positive lead 1 from the battery box 1 1 4 Remove 9negative lead from the frame 5 Loosen 9rear cowling left Refer to REMOVING THE REAR COWL INGS in chapter 3 Yamaha T135 Service Manual YamahaT135 COM ...

Page 215: ...air filter assembly bolt 9 Remove 9carburetor top cover 1 9o ring 9choke cable 2 9accelerator pump cable 3 10 Remove 9throttle valve assembly 1 9throttle valve spring 2 11 Remove 9throttle valve 1 9jet needle set 2 9holder 3 cC Do not make a burr when remove the holder 3 3 from throttle valve 1 1 1 2 3 Yamaha T135 Service Manual YamahaT135 COM ...

Page 216: ...h to loosen the bolts 2 3 1 5 4 14 Remove 9carburetor assembly 13 Disconnect 9fuel hose 1 9carburetor overflow hose 2 9vacuum sensing hose 3 9air vent hose 4 9vacuum sensing hose 5 1 2 15 Remove 9intake manifold bolt 9intake manifold 1 9joint 2 16 Move 9air filter assembly Yamaha T135 Service Manual YamahaT135 COM ...

Page 217: ... air screw set 1 3 Remove 9throttle stop screw set 1 DISASSEMBLING THE CARBURETOR NOTE The following parts can be cleaned and inspect ed without disassembly 9Coasting enricher 9Throttle stop screw 9Pilot air screw 1 4 Remove 9float chamber 1 9float chamber rubber gasket Yamaha T135 Service Manual YamahaT135 COM ...

Page 218: ...3 3 1 2 6 Remove 9float pivot pin 1 9float 2 9needle valve 3 EAS00485 CHECKING THE CARBURETOR 1 Check 9carburetor body 9float chamber Cracks damage Replace 2 Check 9fuel passages Obstructions Clean a Wash the carburetor in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of the passages and jets with compressed air Yamaha T135 Service Manual YamahaT135 C...

Page 219: ...ly 1 Cracks damage Replace 8 Check 9jet needle 1 9needle jet 2 9main jet 3 9pilot jet 4 9pilot air screw 5 9throttle stop screw 6 Bends damage wear Replace Obstruction Clean Blow out the jets with compressed air 5 Check 9float Damage Replace 9 Check 9throttle valve Damage scratches wear Replace Yamaha T135 Service Manual YamahaT135 COM ...

Page 220: ...8 10 Check 9accelerator pump stuck or unsmooth operation Replace the float chamber 11 Check 9air vent hose 9fuel hoses Cracks damage wear Replace Obstructions Clean Blow out the hoses with compressed air Yamaha T135 Service Manual YamahaT135 COM ...

Page 221: ...t chamber with the gasket removed to the top of the float NOTE The float arm should rest on the needle valve without depressing it c If the float height is not within specification check the needle valve seat and needle valve d If either the needle valve seat or needle valve is worn replace them both e If both the needle valve seat and needle valve are fine adjust the float height by bending the f...

Page 222: ...hose 5 4 Install 9carburetor assembly 9intake manifold bolts 9clamp screw 5 Install 9throttle valve assembly NOTE 9Align the slit a of the throttle valve with the tab b of the carburetor body 9Be careful to fall off the O ring on the carbure tor top cover when installing the throttle valve assembly 6 Install 9accelerator pump cable 1 9choke cable 2 9o ring 9carburetor top cover 3 10 Nm 1 0 m kg 7 ...

Page 223: ...ttle position sensor resis tance Out of specification Replace the throttle position sensor B L L Y 2 1 Maximum throttle position sensor resistance 3 7 kΩ at 20 C blue black blue Positive pocket tester probe blue terminal 1 1 Negative pocket tester probe black blue terminal 2 2 8 Adjust 9throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 Throttle cable free play a...

Page 224: ...thin the specified range d After adjusting the throttle position sensor angle tighten the throttle position sensor screws B L L Y 2 3 1 B L L Y 4 3 Throttle position sensor voltage 0 5 V blue yellow Digital circuit tester 90890 03174 Positive digital circuit tester probe blue terminal 4 4 Negative digital circuit tester probe yellow terminal 3 3 Throttle position sensor input volt age 5V at 20 C y...

Page 225: ... REAR COWL INGS in chapter 3 2 Place a container under the end of the fuel hose 1 1 3 Check 9fuel cock operation a Suck on the end of the vacuum hose 1 4 Install 9rear cowling left Refer to INSTALLING THE REAR COWL INGS in chapter 3 Fuel flows Fuel cock is OK Fuel does not flow Replace the fuel cock Yamaha T135 Service Manual YamahaT135 COM ...

Page 226: ...y 600 to 700 C AIR CUT OFF VALVE The air cutoff valve is operated by the intake gas pressure through the piston valve diaphragm Normally the air cut off valve is open to allow fresh air to flow into the exhaust port å to During sudden deceleration the throttle valve suddenly closes negative pressure ç is gen erated and the air cutoff valve is closed in order to prevent after burning Additionally a...

Page 227: ... O M CARB AIR INDUCTION SYSTEM 6 15 AIR INDUCTION SYSTEM DIAGRAMS 1 Bend hose air filter case to air cut off valve 2 Air cut off valve 3 AIS resonator 4 Vacuum sensing hose 1 2 3 4 Yamaha T135 Service Manual YamahaT135 COM ...

Page 228: ...Cracks damage Replace the reed valve 3 Check 9air cut off valve Cracks damage Replace 2 1 1 2 REMOVING THE AIR INDUCTION SYS TEM 1 Disconnect 9vacuum sensing hose 9bend hose 2 Remove 9air cut cut off valve assembly 1 9reed valve assembly 2 INSTALLING THE AIR INDUCTION SYS TEM 1 Install 9reed valve assembly 1 9air cut cut off valve assembly 2 2 Connect 9vacuum sensing hose 9bend hose 10 Nm 1 0 m kg...

Page 229: ...MBLING THE FRONT BRAKE CALIPER 7 19 CHECKING THE FRONT BRAKE CALIPER 7 21 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER 7 22 FRONT BRAKE MASTER CYLINDER 7 24 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER 7 25 CHECKING THE FRONT BRAKE MASTER CYLINDER 7 26 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER 7 27 FRONT FORK 7 30 REMOVING THE FRONT FORK LEGS 7 31 DISASSEMBLING THE FRONT FORK...

Page 230: ...7 50 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES 7 52 CHECKING THE SWINGARM 7 53 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 7 53 DRIVE CHAIN AND SPROCKETS 7 55 REMOVING THE DRIVE CHAIN AND SPROCKETS 7 56 CHECKING THE DRIVE CHAIN 7 57 INSTALLING THE DRIVE CHAIN AND SPROCKETS 7 58 Yamaha T135 Service Manual YamahaT135 COM ...

Page 231: ...E DISC EASF0044 CHASSIS FRONT WHEEL AND BRAKE DISC 1 23 Nm 2 3 m kg 17 ft lb LS LS 40 Nm 4 0 m kg 29 ft lb 2 3 4 5 6 5 7 1 Front wheel axle 2 Brake disc 3 Spacer 4 Oil seal 5 Bearing 6 Spacer 7 Speedometer gear unit Yamaha T135 Service Manual YamahaT135 COM ...

Page 232: ...upport the vehicle so that there is no danger of it falling over 2 Remove 9speedometer cable 1 9axle nut 2 9washer 3 3 Elevate 9front wheel NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 4 Remove 9front wheel axle 1 9spacer 2 9speedometer gear unit 3 9front wheel 5 Remove 9brake disc 1 Yamaha T135 Service Manual YamahaT135 COM ...

Page 233: ...e wear Replace Refer to CHECKING THE TIRES in chap ter 3 3 Check 9spokes Bends damage Replace Loose Tighten Tap the spokes with a screwdriver Refer to CHECKING AND TIGHTENING THE SPOKES in chapter 3 4 Measure 9front wheel radial runout a 9front wheel lateral runout b Over the specified limits Replace Front wheel radial runout limit 1 0 mm 0 04 in Front wheel lateral runout limit 0 5 mm 0 02 in Yam...

Page 234: ...e vehicle 9 9After a tire has been repaired or replaced be sure to tighten the tire air valve stem locknut 1 1 properly 6 Check 9wheel bearings Front wheel turns roughly or is loose Replace the wheel bearings 9oil seals Damage wear Replace 7 Replace 9wheel bearings 9oil seals a Clean the outside of the front wheel hub b Remove the oil seals 1 with a flat head screwdriver NOTE To prevent damaging t...

Page 235: ...amage galling Replace 2 Measure 9brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc deflection turn the handlebar to the left or right to ensure that the front wheel is sta tionary c Remove the brake caliper d Hold the dial gauge at...

Page 236: ...ke disc bolts in stages and in a crisscross pattern d Measure the brake disc deflection e If out of specification repeat the adjustment steps until the brake disc deflection is within specification f If the brake disc deflection cannot be brought within specification replace the brake disc EAS00535 CHECKING THE SPEEDOMETER GEAR UNIT 1 Check 9speedometer clutch Bends damage wear Replace Brake disc ...

Page 237: ...its between the projections on the outer tube 3 Tighten 9wheel axle nut 4 Connect 9speedometer cable 1 NOTE Be sure that slit a on the speedometer cable meshes with the projection b on the speedome ter gear unit 2 w Make sure the brake cable is routed properly cC Before tightening the wheel axle nut push down hard on the handlebar several times and check if the front fork rebounds smooth ly Recomm...

Page 238: ...ft lb 30 Nm 3 0 m kg 22 ft lb 0 0 8 LS 4 7 y 9 1 3 2 5 6 q LS w e r LS 1 Collar 2 Brake camshaft lever 3 Pin 4 Drive chain puller right 5 Brake shoe wear indicator 6 Brake shoe plate 7 Brake camshaft 8 Brake shoe 9 Rear wheel 0 Cotter pin q Brake torque rod w Rear wheel drive hub damper e Rear wheel drive hub r Drive chain puller left t Rear wheel axle y Brake rod Yamaha T135 Service Manual Yamaha...

Page 239: ...on a suitable stand so that the rear wheel is elevated 2 Remove 9brake rod adjusting nut 1 9brake rod 2 9compression spring 3 9washer 9pin 4 NOTE Press down on the brake pedal to remove the pin from the brake rod 3 Remove 9cotter pin 9brake torque rod nut 1 9washer 9brake torque rod bolt 9brake torque rod 2 4 Loosen 9chain puller locknuts left and right 1 9chain puller adjusting nuts left and righ...

Page 240: ...sher 9rear wheel axle 2 9washer 9collar 6 Remove 9rear wheel assembly 1 NOTE Push the rear wheel forward and remove the drive chain from the driven sprocket 7 Remove 9brake shoe plate assembly 1 8 Remove 9collar 1 9rear wheel drive hub assembly 2 9 Remove 9spacer 1 Yamaha T135 Service Manual YamahaT135 COM ...

Page 241: ... 2 Remove 9brake camshaft lever nut 9brake camshaft lever bolt 9brake camshaft lever 1 9brake shoe wear indicator 9brake camshaft NOTE When removing the brake camshaft lever mark the position on the brake camshaft lever where it is aligned with the punch mark in the brake camshaft EAS00566 CHECKING THE REAR WHEEL 1 Check 9wheel axle 9rear wheel 9wheel bearings 9oil seals Refer to FRONT WHEEL AND B...

Page 242: ...CKING THE TIRES in chap ter 3 3 Measure 9radial wheel runout 9lateral wheel runout Refer to FRONT WHEEL AND BRAKE DISC EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1 Check 9rear wheel drive hub Cracks damage Replace 9rear wheel drive hub dampers Damage wear Replace Yamaha T135 Service Manual YamahaT135 COM ...

Page 243: ...low oil or grease to contact the brake shoes NOTE Replace the brake shoes as a set if either is worn to the wear limit 3 Measure 9brake drum inside diameter a Out of specification Replace the wheel 4 Check 9brake drum inner surface Oil deposits Clean Remove the oil with a rag soaked in lacquer thinner or solvent Scratches Repair Lightly and evenly polish the scratches with an emery cloth 5 Check 9...

Page 244: ... with the mark on the brake camshaft lever d Check that the brake shoes are properly positioned EAS00571 INSTALLING THE REAR WHEEL 1 Lubricate 9spacer 9collar 9wheel axle 1 9wheel bearings 9rear brake camshaft 9brake torque rod bolt 9oil seal lips 2 Install 9brake torque rod to brake shoe plate 9washer 9cotter pin 3 Install 9pin 9washer 9compression spring 9brake rod 9brake rod adjusting nut NOTE ...

Page 245: ...ain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 5 Tighten 9wheel axle nut cC Do not loosen the wheel axle nut after tight ening it to the specified torque Drive chain slack 25 35 mm 0 98 1 38 in 60 Nm 6 0 m kg 43 ft lb Yamaha T135 Service Manual YamahaT135 COM ...

Page 246: ... LS 4 1 5 LS 6 Nm 0 6 m kg 4 6 ft lb 6 7 8 9 0 1 Brake pad retaining pin 2 Air bleed screw 3 Brake caliper 4 Brake caliper bracket 5 Lower brake caliper retaining bolt 6 Brake caliper piston 7 Brake caliper dust seal 8 Brake caliper piston seal 9 Brake pad 0 Brake pad spring Yamaha T135 Service Manual YamahaT135 COM ...

Page 247: ...onents 9 9Use only clean or new brake fluid for clean ing brake components 9 9Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 9 9Avoid brake fluid coming into contact with the eyes as it can cause serious injury FIRST AID FOR BRAKE FLUID ENTERING THE EYES 9 9Flush with water for 15 minutes and get immediate medical attention EAS...

Page 248: ... brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Install new brake pads and a new brake pad spring NOTE Make sure the brake pad spring is installed cor rectly as shown Brake pad w...

Page 249: ...rake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 8 Check 9brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 EAS00619 DISASSEMBLING THE FRONT BRAKE CALIPER NOTE Before disassembling the brake caliper drain the brake fluid from the entire brake system Recommended lubricant Lithium soap base...

Page 250: ...brake caliper bracket 1 4 Remove 9brake caliper piston 1 9brake caliper piston seal 2 9brake caliper dust seal 3 a Blow compressed air into the brake hose joint opening to force out the piston from the brake caliper w 9 9Cover the brake caliper piston with a rag Be careful not to get injured when the pis ton are expelled from the brake caliper 9 9Never try to pry out the brake caliper piston b Rem...

Page 251: ...ed 1 Check 9brake caliper piston 1 Rust scratches wear Replace the brake caliper pistons 9brake caliper cylinder 2 Scratches wear Replace the brake caliper assembly 9brake caliper body 3 Cracks damage Replace the brake caliper assembly 9brake fluid delivery passages brake caliper body Obstructions Blow out with compressed air w Whenever a brake caliper is disassembled replace the piston seals 2 Ch...

Page 252: ...iper 1 temporarily 9copper washers 9brake hose 2 9union bolt 3 w Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING cC When installing the brake hose onto the brake caliper 1 1 make sure the brake pipe a a touches the projection b b on the brake caliper 2 Remove 9brake caliper 3 Install 9brake pad springs 9brake pads 9brake pad retaining pin 9brake calip...

Page 253: ... Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock cC Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 6 Bleed 9brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 7 Check 9brake fluid level Below the minimum level mark a Add the recommended brake fluid to the prope...

Page 254: ...6 m kg 19 ft lb 1 2 3 5 4 6 8 7 1 Brake master cylinder kit 2 Brake master cylinder reser voir cap 3 Brake master cylinder reser voir diaphragm 4 Brake master cylinder 5 Brake master cylinder holder 6 Brake hose 7 Brake lever 8 Front brake light switch Yamaha T135 Service Manual YamahaT135 COM ...

Page 255: ...ont cowling Refer to REMOVING THE SIDE COWL INGS and REMOVING THE FRONT COWLING in chapter 3 9headlight assembly Refer to REMOVING THE HEADLIGHT ASSEMBLY in chapter 3 2 Remove 9union bolt 1 9copper washers 2 9brake hose NOTE To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose 3 Remove 9brake master cylinder assembly 1 4 Remove 9brake light...

Page 256: ... cylinder reservoir diaphragm 3 7 Remove 9brake hose 1 9brake hose clamp 2 9brake hose holder 3 EAS00590 CHECKING THE FRONT BRAKE MAS TER CYLINDER 1 Check 9brake master cylinder 1 Damage scratches wear Replace 9brake fluid delivery passages 2 brake master cylinder body Obstructions Blow out with compressed air 2 Check 9brake master cylinder kit Damage scratches wear Replace Yamaha T135 Service Man...

Page 257: ...R CYLINDER w 9 9Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid 9 9Never use solvents on internal brake com ponents 1 Install 9brake master cylinder 1 NOTE 9Install the brake master cylinder holder with the mark facing up 9Adjust the brake master cylinder to the proper angle 9First tighten the upper bolt then the lower bolt Recommen...

Page 258: ...fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance 9 9Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance 9 9When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly low...

Page 259: ...eck 9brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 6 Check 9brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 Yamaha T135 Service Manual YamahaT135 COM ...

Page 260: ...054 FRONT FORK 23 Nm 2 3 m kg 17 ft lb 1 43 Nm 4 3 m kg 31 ft lb 5 6 9 8 4 3 2 7 1 Front fork cap bolt 2 Dust seal 3 Oil seal clip 4 Oil seal 5 Fork spring 6 Damper rod 7 Inner tube 8 Outer tube 9 Damper rod bolt Yamaha T135 Service Manual YamahaT135 COM ...

Page 261: ...danger of it falling over NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 2 Remove 9side cowlings left and right 9front cowling 9center panels 9inner panel Refer to COVERS in chapter 3 3 Remove 9brake caliper assembly 9brake hose clamp Refer to FRONT BRAKE 9front wheel Refer to FRONT WHEEL AND BRAKE DISC 4 Remove 9front fender bolts 9washers 9collars 9front fender 1 ...

Page 262: ...rt the front fork leg 7 Remove 9front fork leg EAS00655 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove 9fork spring 2 Drain 9fork oil NOTE Stroke the inner tube 1 several times while draining the fork oil 3 Remove 9dust seal 1 9oil seal clip 2 with a flat head screwdriver cC Do not scratch the inner tube Yamaha T135 Service Manual YamahaT1...

Page 263: ...g the damper rod assembly with a 10 mm hexagon nut socket wrench 1 and the T handle 2 loosen the damper rod assembly bolt 3 5 Remove 9inner tube 9rebound spring 9damper rod NOTE Pull out the inner tube and damper rod together 6 Remove 9oil seal 1 2 Rag T handle 90890 01326 Yamaha T135 Service Manual YamahaT135 COM ...

Page 264: ... length a Out of specifications Replace 3 Check 9damper rod 1 Damage wear Replace Obstructions Blow out all of the oil pas sages with compressed air cC 9 9The front fork leg has a built in damper adjusting rod and a very sophisticated inter nal construction which are particularly sen sitive to foreign material 9 9When disassembling and assembling the front fork leg do not allow any foreign materia...

Page 265: ...rk leg be sure to replace the oil seal 9Before assembling the front fork leg make sure all of the components are clean 1 Install 9damper rod 1 9rebound spring 9inner tube 2 cC Allow the damper rod to slide slowly down the inner tube 2 2 until it protrudes from the bottom of the inner tube Be careful not to damage the inner tube 2 Lubricate 9inner tube outer surface 3 Tighten 9damper rod assembly b...

Page 266: ... up NOTE 9Before installing the oil seal lubricate its lips with lithium soap based grease 9Lubricate the outer surface of the inner tube with fork oil 9Before installing the oil seal cover the top of the front fork leg with a plastic bag 4 to protect the oil seal during installation 5 Install 9oil seal clip 1 NOTE Adjust the oil seal clip so that it fits into the outer tube s groove T handle 9089...

Page 267: ...pplies to both of the front fork legs 1 Install 9front fork leg 1 9front fork cap bolt 2 Temporarily tighten the lower bracket pinch bolt NOTE Pull up the inner tube until it is stopped then install the front fork cap bolt 2 2 Tighten 9lower bracket pinch bolt 1 9front fork cap bolt 2 Quantity each front fork leg 0 064 L 2 26 Imp oz 2 16 US oz Recommended oil Fork oil 10W or equivalent Front fork ...

Page 268: ...S FRONT FORK 7 38 3 Install 9front fender 4 Install 9front wheel Refer to FRONT WHEEL AND BRAKE DISC 9brake hose clamp 9brake caliper assembly Refer to FRONT BRAKE 10 Nm 1 0 m kg 7 2 ft lb Yamaha T135 Service Manual YamahaT135 COM ...

Page 269: ... lb 23 Nm 2 3 m kg 17 ft lb 1 2 3 4 5 6 7 8 8 9 0 9 1 Rear view mirror left and right 2 Throttle grip 3 Throttle housing 4 Master cylinder 5 Handlebar 6 Left handlebar switch 7 Handlebar grip 8 Starter cable 9 Throttle cable 0 Handlebar bracket Yamaha T135 Service Manual YamahaT135 COM ...

Page 270: ... Refer to REMOVING THE FRONT COWL INGS in chapter 3 9headlight assembly Refer to REPLACING THE HEADLIGHT BULBS in chapter 3 3 Disconnect 9meter assembly couplers 1 9right handlebar switch coupler 2 9left handlebar switch coupler 3 9front brake light switch connectors 4 4 Disconnect 9speedometer cable 1 9choke cable 2 5 Remove 9speedometer assembly 3 6 Remove 9rear view mirrors left and right 9brak...

Page 271: ...lever holder 1 8 Remove 9throttle cable 1 9throttle grip 2 9 Remove 9grip end 1 10 Remove 9handlebar grip 1 NOTE Blow compressed air between the handlebar and the handlebar grip and gradually push the grip off the handlebar Yamaha T135 Service Manual YamahaT135 COM ...

Page 272: ...mage Replace w Do not attempt to straighten a bent handle bar as this may dangerously weaken it EAS00670 INSTALLING THE HANDLEBAR 1 Stand the vehicle on a level surface w Securely support the vehicle so that there is no danger of it falling over 2 Install 9handlebar bracket 1 NOTE Align the projection a in the handlebar bracket with the slit b in the steering shaft 53 Nm 5 3 m kg 38 ft lb Yamaha T...

Page 273: ...ss rubber adhesive with a clean rag w Do not touch the handlebar grip until the rub ber adhesive has fully dried 5 Install 9throttle grip 1 9throttle cable 2 9throttle housing NOTE Lubricate the inside of the throttle grip with a thin coat of lithium soap based grease and install it onto the handlebar 6 Install 9lever holder 1 NOTE Align the projection a on the right handlebar switch with the hole...

Page 274: ...stall 9plastic locking ties Refer to CABLE ROUTING in chapter 2 9 Adjust 9throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 Throttle cable free play at the flange of the throttle grip 3 7 mm 0 12 0 28 in 11 Nm 1 1 m kg 8 0 ft lb Yamaha T135 Service Manual YamahaT135 COM ...

Page 275: ...Nm 3 0 m kg 22 ft lb 2nd 75 Nm 7 5 m kg 54 ft lb LS 1 43 Nm 4 3 m kg 31 ft lb LS 2 3 4 5 6 6 7 4 8 1 Upper ring nut 2 Lower ring nut 3 Ball race cover 4 Bearing inner race 5 Upper bearing 6 Bearing outer race 7 Lower bearing 8 Lower bracket Yamaha T135 Service Manual YamahaT135 COM ...

Page 276: ...apter 3 9front fork Refer to FRONT FORK 9handlebar Refer to HANDLEBAR 3 Remove 9upper ring nut 1 9lower ring nut 2 NOTE Hold the lower ring nut with the steering nut wrench and then remove the upper ring nut with the ring nut wrench w Securely support the lower bracket so that there is no danger of it falling EAS00681 CHECKING THE STEERING HEAD 1 Wash 9bearings 9bearing races Steering nut wrench 9...

Page 277: ...ng race from the lower bracket with a floor chisel 2 and hammer c Install a new rubber seal and new bearing races cC If the bearing race is not installed properly the steering head pipe could be damaged NOTE 9Always replace the bearings and bearing races as a set 9Whenever the steering head is disassembled replace the rubber seal 4 Check 9lower bracket 1 along with the steering stem Bends cracks d...

Page 278: ...bricate 9upper bearing 9lower bearing 9bearing races 2 Install 9lower ring nut 9upper ring nut Refer to CHECKING AND ADJUSTING THE STEERING HEAD in chapter 3 3 Install 9front fork legs Refer to FRONT FORK Recommended lubricant Lithium soap based grease Yamaha T135 Service Manual YamahaT135 COM ...

Page 279: ...9 REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM 46 Nm 4 6 m kg 33 ft lb LS 46 Nm 4 6 m kg 33 ft lb 66 Nm 6 6 m kg 48 ft lb 1 2 3 4 4 5 6 1 Rear shock absorber 2 Brake torque rod 3 Swingarm 4 Bushing 5 Swingarm pivot shaft 6 Drive chain case Yamaha T135 Service Manual YamahaT135 COM ...

Page 280: ...anger of it falling over NOTE Place the vehicle on a suitable stand so that the rear wheel is elevated 2 Remove 9center panel 9rear cowlings left and right Refer to REMOVING THE REAR COWL INGS in chapter 3 9muffler Refer to REMOVING THE ENGINE in chapter 4 9rear wheel Refer to REAR WHEEL AND BRAKE 1 3 Remove 9drive chain case bolts 9drive chain case 1 1 4 Remove 9cotter pin 9washer 9brake torque r...

Page 281: ...g torque of the swingarm pivot shaft nut b Measure the swingarm side play å by mov ing the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers and bearings d Check the swingarm vertical movement by moving the swingarm up and down If swingarm vertical movement is not smooth or if there is binding check the washer and bushings Swingarm side play at the e...

Page 282: ...ER ASSEMBLIES The following procedure applies to both rear shock absorber assemblies 1 Check 9rear shock absorber rod Bends damage Replace the rear shock absorber assembly 9rear shock absorber Oil leaks Replace the rear shock absorber assembly 9spring Damage wear Replace the rear shock absorber assembly 9bushings Damage wear Replace 9bolts Bends damage wear Replace Yamaha T135 Service Manual Yamah...

Page 283: ...face Bends Replace w Do not attempt to straighten a bent pivot shaft 3 Wash 9swingarm pivot shaft 9washer 9bushings 4 Check 9washer Damage wear Replace 9bushings Damage wear Replace EAS00711 EAS00699 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 1 Lubricate 9swingarm pivot shaft Recommended cleaning solvent Kerosene Recommended lubricant Lithium soap based grease Yamaha T135 Service M...

Page 284: ...ts 9rear shock absorber bolts 4 Install 9brake torque rod to swingarm 5 Install 9drive chain case 6 Install 9rear wheel Refer to REAR WHEEL AND BRAKE 9muffler Refer to REMOVING THE ENGINE in chapter 4 9rear cowlings left and right Refer to INSTALLING THE REAR COWL INGS in chapter 3 66 Nm 6 6 m kg 48 ft lb 46 Nm 4 6 m kg 33 ft lb 16 Nm 1 6 m kg 12 ft lb 10 Nm 1 0 m kg 7 2 ft lb Yamaha T135 Service ...

Page 285: ...CKETS 7 Nm 0 7 m kg 5 0 ft lb 30 Nm 3 0 m kg 20 ft lb LS 7 1 2 3 4 6 5 8 q 9 0 1 Rear wheel drive hub 2 Driven sprocket 3 Lock washer 4 Collar 5 Oil seal 6 Bearing 7 Master link 8 Drive chain 9 Drive sprocket 0 Circlip q Drive sprocket cover Yamaha T135 Service Manual YamahaT135 COM ...

Page 286: ...e on a suitable stand so that the rear wheel is elevated 2 Remove 9rear wheel 9rear wheel drive hub assembly Refer to REAR WHEEL AND BRAKE 2 1 3 Remove 9shift pedal bolt 9shift pedal 1 9drive sprocket cover bolts 9drive sprocket cover 2 4 Remove 9master link clip 1 9master link plate 2 9master link body 3 5 Remove 9drive chain 1 2 6 Remove 9sprocket holder bolt 9drive sprocket holder 1 9drive spro...

Page 287: ...mension a outer dimension b 2 915 Link section c of the drive chain Out of specification Replace the drive chain drive sprocket and rear wheel sprock et as a set NOTE 9While measuring the 15 link section push down on the drive chain to increase its tension 9Perform this measurement at two or three dif ferent places 2 Check 9drive chain Stiffness Clean and lubricate or replace 3 Clean 9drive chain ...

Page 288: ...nt teeth Replace the drive chain and sprockets as a set b Correct 1 Drive chain roller 2 Drive chain sprocket New 1 2 1 EAS00714 INSTALLING THE DRIVE CHAIN AND SPROCKETS 1 Install 9driven sprocket 2 9lock washers 1 9driven sprocket bolts 9driven sprocket nuts NOTE Tighten the bolts in a crisscross pattern 2 Bend 9lock washer tab 1 NOTE Bend the lock washer tabs along a flat side of each bolt Recom...

Page 289: ...drive chain onto worn drive chain sprockets this will dramatically shorten the drive chains life 7 Adjust 9drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 cC A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swingarm or cause an accident Therefore keep the drive chain slack within the speci fied ...

Page 290: ...Y a m a h a T 1 3 5 C O M CHAS Yamaha T135 Service Manual YamahaT135 COM ...

Page 291: ...BLESHOOTING 8 16 STARTER MOTOR T135SE 8 18 REMOVING THE STARTER MOTOR 8 19 DISASSEMBLING THE STARTER MOTOR 8 19 CHECKING THE STARTER MOTOR 8 19 ASSEMBLING THE STARTER MOTOR 8 21 INSTALLING THE STARTER MOTOR 8 21 CHARGING SYSTEM 8 22 CIRCUIT DIAGRAM 8 22 TROUBLESHOOTING 8 23 LIGHTING SYSTEM 8 25 CIRCUIT DIAGRAM 8 25 TROUBLESHOOTING 8 26 CHECKING THE LIGHTING SYSTEM 8 27 SIGNALING SYSTEM 8 30 CIRCUI...

Page 292: ...Y a m a h a T 1 3 5 C O M ELEC Yamaha T135 Service Manual YamahaT135 COM ...

Page 293: ...ONENTS 1 Ignition coil 2 Main switch 3 Rear brake light switch 4 Negative battery lead 5 Battery 6 Positive battery lead T135SE 7 Positive battery lead T135S 8 Fuse 9 Wire harness 1 2 3 4 5 6 7 8 9 ELEC ELECTRICAL COMPONENTS 8 1 Yamaha T135 Service Manual YamahaT135 COM ...

Page 294: ...LECTRICAL COMPONENTS 8 2 1 Horn 2 Turn signal relay 3 Starter relay T135SE 4 Fuel gauge 5 Rectifier regulator 6 Fan motor relay 7 Neutral switch 8 Thermo sensor 9 C D I unit 2 1 3 4 5 6 7 8 9 Yamaha T135 Service Manual YamahaT135 COM ...

Page 295: ...t tester to 0 and to the Ω 1 range 9When checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustration similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration NO...

Page 296: ...Y a m a h a T 1 3 5 C O M ELEC CHECKING SWITCH CONTINUITY 8 4 Yamaha T135 Service Manual YamahaT135 COM ...

Page 297: ... 4 5 6 7 8 9 CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear proper connections and also for continuity between the termi nals Refer to CHECKING SWITCH CONTINUITY Damage wear Repair or replace Improperly connected Properly connect Incorrect continuity reading Replace the switch ELEC 8 5 Yamaha T135 Service Manual YamahaT135 COM ...

Page 298: ...LEC 8 6 CHECKING THE SWITCHES 1 Horn switch 2 Dimmer switch 3 Turn signal switch 4 Neutral switch 5 Rear brake light switch 6 Fuse 7 Start switch 8 Front brake light switch 9 Main switch Yamaha T135 Service Manual YamahaT135 COM ...

Page 299: ...ed on this vehicle are shown in the illustration on the left 9Bulbs A and B are used for the headlights and usually use a bulb holder that must be detached before removing the bulb The major ity of these types of bulbs can be removed from their respective socket by turning them counterclockwise 9Bulb C is used for turn signal and tail brake lights and can be removed from the socket by pushing and ...

Page 300: ...sparency of the glass the life of the bulb and the luminous flux will be adverse ly affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check 9bulb for continuity with the pocket tester No continuity Replace NOTE Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the positive tester probe to t...

Page 301: ...ontinuity Replace NOTE Check each bulb socket for continuity in the same manner as described in the bulb section however note the following a Install a good bulb into the bulb socket b Connect the pocket tester probes to the respective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity replace the bulb socket Pocket tester 90890 03112 Yama...

Page 302: ...L W L W B L G R G R G W B Br G Y G Y G Y Br Br W Br W Br W Br Y R L N R Ch Dg L G Y P B Y G G Y Y P HI LO OFF PUSH Br W Ch B Dg L B W Y Y P B Y R Br W P Ch Dg RED RED Br B B B Ch Dg Ch Dg B L L B B L L B L Y Ch Dg G Y Dg B L Ch R W W R B L B L L Y G B L P W Br B O Y R Y R Y R W W R R W Br R B L B L B B R W R L Y Y L L P L Br B L B L B L Br G W Y W Y W G R G R G W B B Ch Dg Ch Dg L L Br Br 1 2 3 4 ...

Page 303: ...intermittent spark EAS00738 1 Fuse 9Check the fuse for continuity Refer to CHECKING THE FUSE in chapter 3 9Is the fuse OK YES NO Replace the fuse EAS00739 2 Battery 9Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 9Is the battery OK YES NO 9Clean the battery terminals 9Recharge or replace the battery Minimum open circuit voltage 12 8 V or more at 20 C EAS...

Page 304: ... cap resistance 5 kΩ at 20 C 68 F EAS00742 4 Ignition spark gap 9Disconnect the spark plug cap from the spark plug 9Connect the ignition checker 1 as shown 2 Spark plug cap 9Set the main switch to ON 9Crank the engine by pushing the start switch and gradually increase the spark gap until a misfire occurs 9Measure the ignition spark gap a 9Is there a spark and is the spark gap within specification ...

Page 305: ...own Negative tester probe terminal 1 1 Positive tester probe spark plug lead 2 2 9Measure the secondary coil resistance 9Is the ignition coil OK 1 2 1 2 Primary coil resistance 0 32 0 48 Ω at 20 C 68 F EAS00748 7 Pickup coil resistance 9Disconnect the pickup coil coupler from the wire harness 9Connect the pocket tester Ω 100 to the pickup coil terminal as shown Positive tester probe white 1 1 Nega...

Page 306: ...ring 9Check the entire ignition system wiring Refer to CIRCUIT DIAGRAM 9Is the ignition system wiring properly con nected and without defects YES NO Properly connect or repair the ignition system wiring Replace the C D I unit Yamaha T135 Service Manual YamahaT135 COM ...

Page 307: ...W B Br G Y G Y G Y Br Br W Br W Br W Br Y R L N R Ch Dg L G Y P B Y G G Y Y P HI LO OFF PUSH Br W Ch B Dg L B W Y Y P B Y R Br W P Ch Dg RED RED Br B B B Ch Dg Ch Dg B L L B B L L B L Y Ch Dg G Y Dg B L Ch R W W R B L B L L Y G B L P W Br B O Y R Y R Y R W W R R W Br R B L B L B B R W R L Y Y L L P L Br B L B L B L Br G W Y W Y W G R G R G W B B Ch Dg Ch Dg L L Br Br L W R Br R W L W R Br R W 1 2 ...

Page 308: ...in switch 6 start switch 7 wiring connections of the entire starting system NOTE 9Before troubleshooting remove the following part s 1 side cowlings left and right 2 front cowling 3 center panels upper and lower 4 rear cowlings left and right 5 inner panel 9Troubleshoot with the following special tool s EAS00739 2 Battery 9Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTE...

Page 309: ...YES NO Replace the starter relay R R W 3 4 2 1 L W R Br R W L W R Br R W Properly connect or repair the starting system wiring The starting sys tem circuit is OK EAS00766 7 Wiring 9Check the entire starting system wiring Refer to CIRCUIT DIAGRAM 9Is the starting system wiring properly con nected and without defects YES NO EAS00749 5 Main switch 9Check the main switch for continuity Refer to CHECKI...

Page 310: ... 3 5 C O M ELEC STARTER MOTOR T135SE 8 18 EASF0061 STARTER MOTOR T135SE 1 Starter motor yoke 2 Armature 3 Brush set 4 Starter motor lead 5 Starter motor front cover 1 2 3 5 4 Yamaha T135 Service Manual YamahaT135 COM ...

Page 311: ...move 9starter motor 1 3 Remove 9starter motor lead 1 DISASSEMBLING THE STARTER MOTOR 1 Remove 9starter motor front cover bolts with washers 9starter motor front cover 1 9O ring 2 9armature 3 EAS00769 CHECKING THE STARTER MOTOR 1 Check 9commutator Dirt Clean with 600 grit sandpaper 1 Yamaha T135 Service Manual YamahaT135 COM ...

Page 312: ...nsure proper operation of the commutator 4 Measure 9armature assembly resistances commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resis tances with the pocket tester b If any resistance is out of specification replace the starter motor Commutator wear limit 16 6 mm 0 65 in Mica undercut 1 35 mm 0 05 in Pocket tester 90890 03112 Armature coi...

Page 313: ...e EAS00772 ASSEMBLING THE STARTER MOTOR 1 Install 9O ring 9armature in start motor front cover 1 9O ring 9starter motor yoke 9starter motor front cover bolts with washers 9O ring NOTE Align the mark a on the starter motor yoke with the mark b on the starter motor front cover INSTALLING THE STARTER MOTOR For installation reverse the removal procedure Brush length wear limit 3 5 mm 0 14 in Brush spr...

Page 314: ...r L W Br L W B B L W L W B L G R G R G W B Br G Y G Y G Y Br Br W Br W Br W Br Y R L N R Ch Dg L G Y P B Y G G Y Y P HI LO OFF PUSH Br W Ch B Dg L B W Y Y P B Y R Br W P Ch Dg RED RED Br B B B Ch Dg Ch Dg B L L B B L L B L Y Ch Dg G Y Dg B L Ch R W W R B L B L L Y G B L P W Br B O Y R Y R Y R W W R R W Br R B L B L B B R W R L Y Y L L P L Br B L B L B L Br G W Y W Y W G R G R G W B B Ch Dg Ch Dg L...

Page 315: ... inner panel 9Troubleshoot with the following special tool s EAS00739 2 Battery 9Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 9Is the battery OK YES NO 9Clean the battery terminals 9Recharge or replace the bat tery Engine tachometer 90890 03113 Pocket tester 90890 03112 Minimum open circuit voltage 12 8 V or more at 20 C EAS00738 1 Fuse 9Check the fuse...

Page 316: ...t is OK NO YES EAS00776 4 Charging coil resistance 9Disconnect the stator coil coupler from the wire harness 9Connect the pocket tester Ω 1 to the charging coil terminals as shown Positive tester probe white 1 1 Negative tester probe black 2 2 9Measure the charging coil resistances 9Is the charging coil OK YES NO W B Y R W 1 2 EAS00779 5 Wiring 9Check the wiring connections of the entire charging ...

Page 317: ... G Y G Y G Y Br Br W Br W Br W Br Y R L N R Ch Dg L G Y P B Y G G Y Y P HI LO OFF PUSH Br W Ch B Dg L B W Y Y P B Y R Br W P Ch Dg RED RED Br B B B Ch Dg Ch Dg B L L B B L L B L Y Ch Dg G Y Dg B L Ch R W W R B L B L L Y G B L P W Br B O Y R Y R Y R W W R R W Br R B L B L B B R W R L Y Y L L P L Br B L B L B L Br G W Y W Y W G R G R G W B B Ch Dg Ch Dg L L Br Br 1 2 3 4 5 6 7 8 9 0 q w e r y t u i ...

Page 318: ...ing coil resistance 9Disconnect the stator coil coupler from the wire harness 9Connect the pocket tester Ω 1 to the lighting coil terminals as shown Positive tester probe yellow 1 1 Negative tester probe black 2 2 9Measure the lighting coil resistances 9Is the lighting coil OK YES NO W B Y R W 1 2 EAS00787 2 Wiring 9Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM 9Is the lighting ...

Page 319: ...b socket or both 3 Voltage 9Connect the pocket tester AC 20 V to the headlight and high beam indicator light con nectors as shown åWhen the dimmer switch is set to When the dimmer switch is set to Headlight Positive tester probe green 1 1 or yellow 2 2 Negative tester probe black 3 3 High beam indicator light Positive tester probe yellow 4 4 Negative tester probe black 5 5 9Set the main switch to ...

Page 320: ...er light coupler wire harness side as shown Positive tester probe blue 1 1 Negative tester probe black 2 2 9Set the main switch to ON 9Start the engine 9Measure the voltage AC 12 V of blue lead terminal 1 on the meter light coupler wire harness side 9Is the voltage within specification Br G Ch L B Dg L B Br Dg G Ch 1 2 YES NO Replace the rectifi er regulator This circuit is OK 2 Voltage 9Connect t...

Page 321: ... socket or both 2 Voltage 9Connect the pocket tester AC 20 V to the auxiliary light coupler wire harness side as shown Positive tester probe blue 1 1 Negative tester probe black 2 2 9Set the main switch to ON 9Start the engine 9Measure the voltage AC 12 V of blue lead terminal 1 on the auxiliary light coupler wire harness side 9Is the voltage within specification B Dg Dg B L L Ch Ch B B L L 1 1 L ...

Page 322: ... B B R R O O W Y R B Y B W Br L W Br L W B B L W L W B L G R G R G W B Br G Y G Y G Y Br Br W Br W Br W Br Y R L N R Ch Dg L G Y P B Y G G Y Y P HI LO OFF PUSH Br W Ch B Dg L B W Y Y P B Y R Br W P Ch Dg RED RED Br B B B Ch Dg Ch Dg B L L B B L L B L Y Ch Dg G Y Dg B L Ch R W W R B L B L L Y G B L P W Br B O Y R Y R Y R W W R R W Br R B L B L B B R W R L Y Y L L P L Br B L B L B L Br G W Y W Y W G...

Page 323: ...witch f Turn signal switch g Tail brake light h Rear turn signal light j Front turn signal light z Fuel gauge x Fuel sender c Neutral switch n Turn signal indicator light m Neutral indicator light 1st gear position indicator light 2nd gear position indicator light 3rd gear position indicator light 4th gear position indicator light Yamaha T135 Service Manual YamahaT135 COM ...

Page 324: ...ter 3 9Is the battery OK YES NO 9Clean the battery terminals 9Recharge or replace the bat tery Pocket tester 90890 03112 Minimum open circuit voltage 12 8 V or more at 20 C 68 F 9 9Any of the following fail to light turn sig nal light brake light or an indicator light 9 9The horn fails to sound Replace the main switch EAS00783 3 Main switch 9Check the main switch for continuity Refer to CHECKING T...

Page 325: ...CKING THE SWITCHES 9Is the horn switch OK YES NO Replace the left han dlebar switch 2 Voltage 9Connect the pocket tester DC 20 V to the horn connector at the horn terminal as shown Positive tester probe brown 1 1 Negative tester probe ground 9Set the main switch to ON 9Measure the voltage DC 12 V of brown lead terminal at the horn terminal 9Is the voltage within specification YES NO The wiring cir...

Page 326: ...2 9Set the main switch to ON 9Pull in the brake lever or push down on the brake pedal 9Measure the voltage DC 12 V of green yel low lead terminal 1 on the tail brake light coupler wire harness side 9Is the voltage within specification 2 Brake light switches 9Check the brake light switches for continuity Refer to CHECKING THE SWITCHES 9Is the brake light switch OK YES NO Replace the tail brake ligh...

Page 327: ...ECKING THE SWITCHES 9Is the turn signal switch OK YES NO Replace the turn sig nal light bulb socket or both YES NO Replace the left han dlebar switch 3 Voltage 9Connect the pocket tester DC 20 V to the turn signal relay coupler as shown Positive tester probe brown 1 1 Negative tester probe ground 9Set the main switch to ON 9Measure the voltage DC 12 V on brown lead terminal 1 at the turn signal re...

Page 328: ...ter probe ground Positive tester probe dark green 4 4 Negative tester probe ground B Ch L Dg Y L Dg B G Y Ch 2 1 4 Voltage 9Connect the pocket tester DC 20 V to the turn signal relay coupler as shown Positive tester probe brown white 1 1 Negative tester probe ground 9Set the main switch to ON 9Measure the voltage DC 12 V on brown white lead terminal 1 at the turn sig nal relay coupler 9Is the volt...

Page 329: ...k the neutral switch for continuity Refer to CHECKING THE SWITCHES 9Is the neutral switch OK YES NO Replace the neutral switch YES NO This circuit is OK The wiring circuit from the turn signal switch to the turn signal light coupler is faulty and must be repaired 9Set the main switch to ON 9Set the turn signal switch to 4 or 6 9Measure the voltage DC 12 V of the chocolate 1 or dark green lead term...

Page 330: ...o ON 9Shift the transmission into each gear 9Measure the voltage DC 12 V of the sky blue 1 white 2 pink 3 yellow white 4 or blue white 5 lead terminal at the meter assembly coupler wire harness side 9Is the voltage within specification ELEC 8 38 SIGNALING SYSTEM YES NO This circuit is OK The wiring circuit from the main switch to the meter assembly coupler is faulty and must be repaired EAS00804 5...

Page 331: ...L Dg G B Ch Dg B Br Ch L G 1 ELEC 8 39 SIGNALING SYSTEM YES NO Check the wiring connections of the entire signaling sys tem YES NO Replace the fuel level gauge 3 Fuel level gauge 9Set the main switch to ON 9Move the float up 1 or down 2 9Check that the fuel level gauge needle moves to F or E NOTE Before reading the fuel level gauge leave the float in one position either up or down for at least thr...

Page 332: ... G Y G Y G Y Br Br W Br W Br W Br Y R L N R Ch Dg L G Y P B Y G G Y Y P HI LO OFF PUSH Br W Ch B Dg L B W Y Y P B Y R Br W P Ch Dg RED RED Br B B B Ch Dg Ch Dg B L L B B L L B L Y Ch Dg G Y Dg B L Ch R W W R B L B L Y G B L P W Br B O Y R Y R Y R W W R R W Br R B L B L B B R W R L Y Y L L P L Br B L L B B L Br G W Y W Y W G R G R G W B B Ch Dg Ch Dg L L Br Br 1 2 3 4 5 6 7 8 9 0 q w e r y t u i p ...

Page 333: ...ntinuity Refer to CHECKING THE FUSE in chapter 3 9Is the fuse OK YES NO Replace the fuse EAS00739 2 Battery 9Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 9Is the battery OK YES NO 9Clean the battery terminals 9Recharge or replace the bat tery Pocket tester 90890 03112 Digital circuit tester 90890 03174 Minimum open circuit voltage 12 8 V or more at 20 ...

Page 334: ...replaced B L 2 1 5 Radiator fan motor relay 9Disconnect the radiator fan motor relay cou pler 9Connect the pocket tester to the radiator fan motor relay coupler relay side as shown Battery positive lead brown 1 1 Battery negative lead white yellow 2 2 Positive tester probe brown 3 3 Negative tester probe blue 4 4 9Check the radiator fan motor relay blue and brown for continuity 9Does the coupler i...

Page 335: ...rmo sensor with special care 9 9Never subject the thermo sensor to strong shocks If the thermo sensor is dropped replace it 9Does the thermo sensor operate properly as described above 1 3 2 YES NO Replace the thermo sensor Tighten the thermo sensor to specified torque EAS00795 7 Wiring 9Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM 9Is the signaling system wiring properly con n...

Page 336: ...ine is run ning or not Item Condition Response Display condition code 9Enables the vehicle to run so that the ignition timing is fixed when the throttle is fully opened 9Displays the condition code on the coolant temperature warning indicator light 9Enables the vehicle to run so that the ignition timing is fixed 9Displays the condition code on the coolant temperature warning indicator light Thrott...

Page 337: ...1 2 3 2 å Repetition 1 3 4 1 3 seconds 2 1 second 3 1 5 seconds 4 0 5 seconds 5 0 5 seconds å Light on Light off When more than one item is being monitored 2 3 4 5 1 å Repetition 2 3 4 5 2 Light on seconds 1 scond 3 Light off seconds 1 5 sconds 4 Light on seconds 0 5 sconds 5 Light off seconds 0 5 sconds 6 1 cycle Fault code 1 7 1 cycle Fault code 2 1 1 Light off seconds 3 sconds 7 6 Fault code Ya...

Page 338: ...03112 The coolant temperature warning indicator light starts to display the self diagnosis sequence 1 Throttle position sensor CIRCUIT DIAGRAM 0 C D I unit e Throttle position sensor BLACK BLACK BLACK Br Br L Y W B B B O O B L G R G R G W B W Y Y B L B L L Y L P W Br B O W W B L B L R L Y Y L L P L Br B L B L B L Br G W Y W Y W G R G R Br Br 9 0 w e r y t 2 Throttle position sensor 9Check the thro...

Page 339: ... L B L R L Y Y L L P L Br B L B L B L Br G W Y W Y W G R G R Br Br 9 0 e r y t 1 Wireharness 9Check the wireharness for continuity Refer to CIRCUIT DIAGRAM 9Is the wireharness OK YES NO Repair or replace the wireharness 2 Thermo sensor 9Check the thermo sensor Refer to COOLING SYSTEM 9Is the thermo sensor OK YES NO Replace the thermo sensor Replace the C D I unit Yamaha T135 Service Manual YamahaT...

Page 340: ...Y a m a h a T 1 3 5 C O M ELEC Yamaha T135 Service Manual YamahaT135 COM ...

Page 341: ...Y a m a h a T 1 3 5 C O M TRBL SHTG CHAPTER 9 TROUBLESHOOTING TROUBLESHOOTING 9 1 ELECTRICAL SYSTEM 9 1 COMPRESSION SYSTEM 9 2 INTAKE AND EXHAUST SYSTEM 9 3 Yamaha T135 Service Manual YamahaT135 COM ...

Page 342: ...Y a m a h a T 1 3 5 C O M TRBL SHTG Yamaha T135 Service Manual YamahaT135 COM ...

Page 343: ...is faulty 8 Spark plug cap is faulty C D I unit 8 C D I unit is broken CHARGING COIL see page 8 24 PICKUP COIL see page 8 13 8 Windings are broken SPARK PLUG 8 Wet carbon deposits 8 Electrodes 8 Improper gap 8 Broken EASF0062 TROUBLESHOOTING TROUBLESHOOTING ELECTRICAL SYSTEM STARTER MOTOR see page 8 18 8 Starter motor is broken or faulty 8 Starter relay is broken 8 Starter switch is broken Yamaha ...

Page 344: ... 9 2 COMPRESSION SYSTEM WEAR SCRATCH DAMAGE WEAR STUCK BROKEN DAMAGE DAMAGE WEAR SCRATCHES INSUFFICIENT TIGHTENING TORQUE INSUFFICIENT TIGHTENING TORQUE WEAR CARBON DEPOSITS DAMAGE INSUFFICIENT TIGHTENING TORQUE Yamaha T135 Service Manual YamahaT135 COM ...

Page 345: ...djusted idling and starting NEEDLE VALVE ASSEMBLY 8 Wear PILOT JET 8 Clogged low speed FLOAT CHAMBER 8 Accumulated dust and or water FLOAT 8 Incorrect fuel level adjustment 8 Puncture MAIN JET 8 Incorrect size 8 Clogged high speed PILOT AIR SCREW 8 Improperly adjusted idling and starting EXHAUST PIPE 8 Cracked or broken 8 Carbon deposits SILENCER 8 Clogged NEEDLE SET 8 Improperly adjusted medium s...

Page 346: ...Y a m a h a T 1 3 5 C O M TRBL SHTG Yamaha T135 Service Manual YamahaT135 COM ...

Page 347: ...Y a m a h a T 1 3 5 C O M Yamaha T135 Service Manual YamahaT135 COM ...

Page 348: ...Y a m a h a T 1 3 5 C O M YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN Yamaha T135 Service Manual YamahaT135 COM ...

Page 349: ... White Y Yellow B L Black Blue Br W Brown White G R Green Red G W Green White G Y Green Yellow L B Blue Black L W Blue White R W Red White W Y White Yellow Y R Yellow Red Y W Yellow White COLOR CORD R Br W W OFF ON Br R R OFF START B L W L W B B Sb W P Y W L W Sb W P Y W L W G G L Dg Ch Br B G R Br Br R Br L W L W R W R W R W Y Sb Y W P L W W L W G W G W Sb W Y W P Br L Dg G B Ch Dg B Br Ch L G BL...

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