Page 1 Manual Clutch and Automatic T135SE T135S T135 SERVICE MANUAL Sniper / Jupiter MX / Spark 135 / Exciter / 135LC YamahaT135.COM 03212007 5YP-F8197-E0...
Page 2 Yamaha T135 Service Manual YamahaT135.COM...
Page 3 Yamaha T135 Service Manual EAS00000 T135SE/T135S SERVICE 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. YamahaT135.COM...
Page 4: Specifications
EAS00002 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Page 5: How To Use This Manual
Yamaha T135 Service Manual EASF0001 HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1:This is a chapter with its symbol on the upper right of each page.
Page 6 Yamaha T135 Service Manual YamahaT135.COM...
Page 7: Periodic Checks And Adjustments
Yamaha T135 Service Manual SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system...
Page 8 Yamaha T135 Service Manual YamahaT135.COM...
Page 9: Table Of Contents
Yamaha T135 Service Manual TABLE OF CONTENTS EAS00011 GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS ENGINE COOLING SYSTEM COOL CARBURETOR CARB CHASSIS CHAS ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG YamahaT135.COM...
Page 10 Yamaha T135 Service Manual YamahaT135.COM...
Page 11: Gen Info
Yamaha T135 Service Manual INFO CHAPTER 1 GENERAL INFORMATION VEHICLE IDENTIFICATION ...................1-1 VEHICLE IDENTIFICATION NUMBER .............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...
Page 12 Yamaha T135 Service Manual INFO YamahaT135.COM...
Page 13: General Information
Yamaha T135 Service Manual VEHICLE IDENTIFICATION INFO EAS00014 GENERAL INFORMATION VEHICLE 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.
Page 14: Important Information
5. Keep all parts away from any source of fire. 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 inferior in quality.
Page 15: Lock Washers/Plates And Cotter Pins
Yamaha T135 Service Manual IMPORTANT INFORMATION INFO EAS00023 LOCK WASHERS/PLATES AND COT- TER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut.
Page 16: Checking The Connections
Yamaha T135 Service Manual CHECKING THE CONNECTIONS INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: 9lead 9coupler 9connector 2. Check: 9lead 9coupler 9connector Moisture → Dry with compressed air. Rust/stains → Connect and disconnect several times.
Page 17: Special Tools
Yamaha T135 Service Manual SPECIAL TOOLS INFO EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques.
Page 18 Yamaha T135 Service Manual SPECIAL TOOLS INFO Tool No. Tool name/Usage Illustration Adoptor (M12) 90890-01278 This tool is necessary for installing the crankshaft. Tappet adjusting tool 90890-01311 This tool is necessary for adjusting valve clearance. Radiator cap tester Radiator cap tester adapter...
Page 19 Yamaha T135 Service Manual SPECIAL TOOLS INFO Tool No. Tool name/Usage Illustration Compression gauge 90890-03081 These tools are used to measure the engine compression. Pocket tester 90890-03112 This instrument is necessary for checking the electrical system. Engine tachometer 90890-03113 This tool is needed for detecting engine rpm.
Page 20 Yamaha T135 Service Manual SPECIAL TOOLS INFO Tool No. Tool name/Usage Illustration Valve lapper 90890-04101 This tool is used for removeing and installing the lifter and for lapping the valve. Valve guide remover (4.5 mm) 90890-04116 This tool is needed to remove and installing the valve guide.
Page 21: Spec
Yamaha T135 Service Manual SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ................2-1 MAINTENANCE SPECIFICATIONS ..............2-4 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 ..........
Page 22 Yamaha T135 Service Manual SPEC YamahaT135.COM...
Page 23: Specifications
Yamaha T135 Service Manual SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model T135SE/T135S Model code 5YP1 (T135SE) 5YP2 (T135S) Dimensions Overall length 1,945 mm (76.6 in) Overall width 705 mm (27.8 in) Overall height 1,065mm (41.9 in) Seat height 770 mm (30.3 in) Wheelbase 1,245 mm (49.0 in)
Page 24 Yamaha T135 Service Manual SPEC GENERAL SPECIFICATIONS Model T135SE/T135S Carburetor Type/quantity VM22/1 Manufacturer MIKUNI Spark plug Type CPR8EA-9 Manufacturer Spark plug gap 0.8 – 0.9 mm (0.031 – 0.035 in) Clutch type Wet, multiple-disc and centrifugal automatic Transmission Primary reduction system...
Page 25 Yamaha T135 Service Manual SPEC GENERAL SPECIFICATIONS Model T135SE/T135S Brake Front brake type Single disc brake operation Right hand operation Rear brake type Drum brake operation Right foot operation Suspension Front suspension Telescopic fork Rear suspension Swingarm (monocross) Shock absorber...
Page 26: Maintenance Specifications
Yamaha T135 Service Manual SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head Max. warpage “*” ---- 0.03 mm (0.0012 in) Cylinder Bore 54.000 – 54.010 mm (2.1260 – 2.1264 in) 54.1 mm (2.1299 in) Out of round limit ---- 0.05 mm...
Page 27 Yamaha T135 Service Manual SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Valve, valve seat, valve guide Valve clearance (cold) 0.10 – 0.14 mm (0.0039 – 0.0055 in) ---- 0.16 – 0.20 mm (0.0063 – 0.0079 in) ---- Valve dimensions d Di...
Page 28 Yamaha T135 Service Manual SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Valve spring Free length IN/EX 47.33 mm (1.86 in) 44.96 mm (1.77 in) Installed length (valve closed) IN/EX 35.30 mm (1.39 in) ---- Compressed spring force IN/EX 135.6 – 156.0 N (13.8 – 15.8 kgf) ---- at 35.3 mm (1.39 in)
Page 29 Yamaha T135 Service Manual SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Crankshaft Crank width “A” 45.95 – 46.00 mm (1.81-1.81 in) ---- Max. runout limit “C” ---- 0.03 mm (0.0012 in) Big end side clearance “D” 0.11 – 0.41 mm (0.0403 – 0.016 in) ---- Big end radial clearance “E”...
Page 30 Yamaha T135 Service Manual SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Kickstarter Kickstarter type Ratchet type ---- Spring free length 15.5 mm (0.61 in) ---- Carburetor Type VM22 ---- I.D. mark 5YP1 00 ---- Main jet (M.J) #105 ---- Main air jet (M.A.J) ø1.2...
Page 31: Tightening Torques
Yamaha T135 Service Manual SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES ENGINE Tightening Thread torque Part to be tightened Part name Q’ty Remarks size Nm m·kg ft·lb Cylinder head Bolt Cylinder head (timing chain side) Bolt Cylinder head (oil check) Screw Spark plug —...
Page 32 Yamaha T135 Service Manual SPEC MAINTENANCE SPECIFICATIONS Tightening Thread torque Part to be tightened Part name Q’ty Remarks size Nm m·kg ft·lb Drive sprocket Bolt Main axle bearing retainer Screw Clutch release adjusting locknut Shift pedal Bolt Shift drum segment...
Page 33: Chassis
Yamaha T135 Service Manual SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system Steering bearing type Ball and race bearing ---- Lock-to-lock angle (left/right) 45° ---- Front suspension Front fork travel 100 mm (3.94 in) ---- Fork spring free length 295.3 mm (11.63 in)
Page 34 Yamaha T135 Service Manual SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Rear wheel Type Spoke wheel ---- 17 × 1.60 Rim size ---- Rim material Steel ---- Max. radial wheel runout ---- 1.0 mm (0.04 in) Max. lateral wheel runout ---- 0.5 mm...
Page 35: Tightening Torques
Yamaha T135 Service Manual SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES CHASSIS Tightening torque Part to be tightened Thread size Remarks Nm m·kg ft·lb Handlebar bracket and lower bracket Handlebar and handlebar bracket Brake hose and brake master cylinder Brake hose and brake caliper...
Page 36 Yamaha T135 Service Manual SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Remarks Nm m·kg ft·lb Fuel tank and frame Fuel cock and fuel tank Seat and seat bracket NOTE: 1. First tighten the lower ring nut 30 Nm (3.0 m • kg, 22 ft • lb) by using a torque wrench, then loosen the ring nut 1/4 turn.
Page 37: Electrical
Yamaha T135 Service Manual SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Item Standard Limit System voltage 12 V ---- Ignition system Ignition timing (B.T.D.C.) 10° at 1,400 r/min ---- Advanced type Digital ---- DC-C.D.I 248 – 372 Ω at 20 °C (68 °F)/R–W...
Page 38 Yamaha T135 Service Manual SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Electric starting system (T135SE) Type Constant mesh ---- Starter motor Model/manufacturer 5YP/PT MORIC ---- Operation voltage 12 V ---- Power output 0.20 kW ---- 0.032 – 0.039 Ω at 20 °C (68 °F)
Page 39: Conversion Table
Yamaha T135 Service Manual CONVERSION TABLE/ SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EAS00028 EAS00029 CONVERSION TABLE GENERAL TIGHTENING TORQUE All specification data in this manual are listed SPECIFICATIONS in SI and METRIC UNITS. This chart specifies tightening torques for stan- Use this table to convert METRIC unit data to dard fasteners with a standard ISO thread pitch.
Page 40: Lubrication Points And Lubricant Types
Yamaha T135 Service Manual SPEC LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Lubricant Oil seal lips Bearings O-rings Cylinder head tightening washer and bolt thread Rocker arm inner surfaces Rocker arm shaft Camshaft Valve stem (IN, EX)
Page 41 Yamaha T135 Service Manual SPEC LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Transmission side plate inner 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 YamahaT135.COM...
Page 42: Chassis
Yamaha T135 Service Manual SPEC LUBRICATION POINTS AND LUBRICANT TYPES CHASSIS Lubrication point Lubricant Front wheel oil seal lips Speedometer gear unit inner surface Rear wheel oil seal lips Rear brake camshaft Brake torque rod bolt Front wheel axle Rear wheel axle...
Page 43: Cooling System Diagrams
Yamaha T135 Service Manual SPEC COOLING SYSTEM DIAGRAMS COOLING SYSTEM DIAGRAMS 1 Radiator inlet hose å Align the white paint mark on the clamp with the 2 Radiator cap white paint mark on the radiator. ∫ Band the end of the cover, before install the pro-...
Page 44: Cable Routing
Yamaha T135 Service Manual SPEC CABLE ROUTING CABLE ROUTING 1 Turn signal light relay å Install the turn signal relay ƒ Pass through into the wire 2 Meter assembly onto the bracket. guide, follow the routing order. ∫ Connect the left handlebar...
Page 45 Yamaha T135 Service Manual SPEC CABLE ROUTING ˆ Pass the wireharness behind ˚ Take care not to bend the the turn signal relay and brake choke cable when installing. hose, and then connect the front brake switch. ∆ Route right...
Page 46 Yamaha T135 Service Manual SPEC CABLE ROUTING 1 Front turn signal light lead t Neutral switch lead lead in front of the stay. ∂ Check that the connection of 2 Fitting tape (red) y A.C. magneto lead 3 Throttle cable...
Page 47 Yamaha T135 Service Manual SPEC CABLE ROUTING ˙ Install µ Pass through the turn signal negative lead, should be stopped. light lead into the guide. ˆ Pass through the fuel hose and vacuum hose into the cable guide. ∆ Route the overflow pipe to the...
Page 48 3 Fuse box t Protector (T135SE) ´ Outside of the frame. 4 Starter motor lead (T135SE) 5 Rear brake switch lead å Pass through the fan relay ƒ Be sure does not over the out- 6 Battery breather pipe lead into the frame pipe and side of the frame.
Page 49 Yamaha T135 Service Manual SPEC CABLE ROUTING 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.
Page 50 Yamaha T135 Service Manual SPEC CABLE ROUTING 1 Throttle position sensor lead e Overflow pipe ∂ Pass through the wireharness 2 Radiator inlet hose r Wireharness into the main switch and cable 3 Grommet guide. å Turn the downward of the sep-...
Page 51 Yamaha T135 Service Manual SPEC CABLE ROUTING 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.
Page 52 Yamaha T135 Service Manual SPEC CABLE ROUTING å Route the acceleration pump 1 Speedometer cable 2 Acceleration pump cable cable into the right side of the 3 Throttle cable stay. ∫ Route the throttle cable into 4 Fuel sender lead 5 Choke cable the left side of the stay.
Page 53: Chk Adj
Yamaha T135 Service Manual CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ....................3-1 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ......3-1 COVERS ......................... 3-3 REMOVING THE SIDE COWLINGS ..............3-3 INSTALLING THE SIDE COWLINGS ............... 3-3 REMOVING THE FRONT COWLING ............... 3-3 INSTALLING THE FRONT COWLING ..............
Page 54 Yamaha T135 Service Manual CHECKING AND ADJUSTING THE STEERING HEAD ........3-35 CHECKING THE FRONT FORK ............... 3-37 CHECKING THE TIRES ................... 3-38 CHECKING AND TIGHTENING THE SPOKES ..........3-40 CHECKING AND LUBRICATING THE CABLES ..........3-41 LUBRICATING THE LEVER AND PEDALS ............3-41 LUBRICATING THE SIDESTAND ..............
Page 55: Periodic Checks And Adjustments
Yamaha T135 Service Manual INTRODUCTION/ PERIODIC MAINTENANCE AND LUBRICATION INTERVALS EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work.
Page 56 CHECK OR MAINTENANCE JOB CHECK √ √ √ √ √ 9 Check coolant level and vehicle for coolant leakage. 22 * Cooling system 9 Change the YAMAHA GENUINE COOLANT. Every 3 years √ √ √ √ √ √ Front and rear brake 9 Check operation.
Page 57: Covers
Yamaha T135 Service Manual COVERS 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 2. Disconnect:...
Page 58: Removing The Center Panels
Yamaha T135 Service Manual COVERS REMOVING THE CENTER PANELS 1. Remove: 9screws 9center panel (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.
Page 59: Installing The Rear Cowlings
Yamaha T135 Service Manual COVERS 4. Remove: 9screws 9screw (with washer) 1 9screws 9rear cowlings (left and right) 2 INSTALLING THE REAR COWLINGS 1. Install: 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.
Page 60: Removing The Headlight Assembly
Yamaha T135 Service Manual COVERS REMOVING THE HEADLIGHT ASSEMBLY 1. Remove: 9screws 9headlight assembly 1 2. Disconnect: 9headlight connectors 1 INSTALLING THE HEADLIGHT ASSEMBLY 1. Connect: 9headlight connectors 1 2. Install: 9headlight assembly 9screws YamahaT135.COM...
Page 61: Engine
Yamaha T135 Service Manual ADJUSTING THE VALVE CLEARANCE EAS00049 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: 9Valve clearance adjustment should be made on a cold engine, at room temperature. 9When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
Page 62 Yamaha T135 Service Manual ADJUSTING THE VALVE CLEARANCE 5. Move: 9radiator assembly To swing the radiator assembly toward the front side. 6. Remove: 9water pump assembly 9O-rings 7. Remove: 9cylinder head cover 9gasket 8. Remove: 9timing check plug 1 (with O-ring)
Page 63 Yamaha T135 Service Manual ADJUSTING THE VALVE CLEARANCE c. Align the TDC mark c on the generator rotor with the stationary pointer d on the crankcase cover. d. Measure the valve clearance with a thick- ness gauge 1 Out of specification → Adjust.
Page 64 Yamaha T135 Service Manual ADJUSTING THE VALVE CLEARANCE 11. Install: 9O-ring 9timing check plug (with O-ring) 7 Nm (0.7 m•kg, 5.0 ft•lb) 9center plug 7 Nm (0.7 m•kg, 5.0 ft•lb) (with O-ring) 12. Install: 9gasket 1 9cylinder head cover 10Nm (1.0 m•kg, 7.2 ft•lb) 13.
Page 65: Adjusting The Engine Idling Speed
Yamaha T135 Service Manual ADJUSTING THE ENGINE IDLING SPEED EAS00054 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the air filter element should be clean, and the engine should have adequate compression. 1. Remove: 9side cowlings (left and right)
Page 66: Adjusting The Throttle Cable Free Play
Yamaha T135 Service Manual ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY 6. Adjust: 9throttle cable free play Refer to “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)
Page 67 Yamaha T135 Service Manual ADJUSTING THE THROTTLE CABLE FREE PLAY 3. Adjust: 9throttle cable free play MMMMMMMMMMMMMMMMMMMMMMMM a. Pull back the adjusting nut cover. b. Loosen the locknut 1 c. Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained.
Page 68: Checking The Spark Plug
Yamaha T135 Service Manual CHECKING THE SPARK PLUG EAS00060 CHECKING THE SPARK PLUG 1. Remove: 9side cowling (right) Refer to “REMOVING THE SIDE COWL- INGS”. 9AIS resonator Be sure to remove the AIS hose, before removing the AIS resonator, otherwise to brake the AIS resonator mount.
Page 69: Measuring The Compression Pressure
Yamaha T135 Service Manual CHECKING THE SPARK PLUG/ MEASURING THE COMPRESSION PRESSURE 8. Install: 9spark plug 13 Nm (1.3 m•kg, 9.5 ft•lb) NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 9. Connect: 9spark plug cap 10.
Page 70 Yamaha T135 Service Manual MEASURING THE COMPRESSION PRESSURE 6. Install: 9compression gauge 1 Compression gauge 90890-03081 7. Measure: 9compression pressure Out of specification → Refer to steps (c) and (d). Compression pressure (at sea level) Minimum 490 kPa (4.9 kg/cm...
Page 71: Checking The Engine Oil Level
Yamaha T135 Service Manual MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL 8. Install: 9spark plug 13 Nm (1.3 m•kg, 9.5 ft•lb) 9. Connect: 9spark plug cap 10. Install: 9side cowling (right) Refer to “INSTALLING THE SIDE COWL- INGS”.
Page 72: Changing The Engine Oil
Yamaha T135 Service Manual CHANGING THE ENGINE OIL EAS00075 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove:...
Page 73: Checking The Oil Filter
Yamaha T135 Service Manual CHANGING THE ENGINE OIL/ CHECKING THE EXHAUST SYSTEM CHECKING THE OIL FILTER 1. Remove: 9oil filter element cover 9O-ring 9oil filter element 2. Check: 9oil filter element Dirt or clog → Replace. 3. Install: 9oil filter element...
Page 74: Cleaning The Air Filter Element
Yamaha T135 Service Manual CLEANING THE AIR FILTER ELEMENT EAS00086 CLEANING THE AIR FILTER ELEMENT 1. Remove: 9center panel (lower) Refer to “REMOVING THE CENTER PAN- ELS”. 2. Remove: 9air filter case cover 1 9air filter element 2 3. Clean:...
Page 75: Adjusting The Clutch Release System
Yamaha T135 Service Manual CLEANING THE AIR FILTER ELEMENT/ ADJUSTING THE CLUTCH RELEASE SYSTEM/ CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 6. Install: 9center panel (lower) Refer to “INSTALLING THE CENTER PAN- ELS”. EAS00086 ADJUSTING THE CLUTCH RELEASE SYSTEM 1. Adjust:...
Page 76: Checking The Fuel And Vacuum Hoses
Yamaha T135 Service Manual CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD/ CHECKING THE FUEL AND VACUUM HOSES 3. Install: 9inner panel 9rear cowlings (left and right) 9front cowling 9center panels (upper and lower) 9side cowlings (left and right) Refer to “COVERS”.
Page 77: Checking The Crankcase Breather Pipe
Yamaha T135 Service Manual CHECKING THE CRANKCASE BREATHER PIPE/ CHECKING THE COOLANT LEVEL EAS00098 CHECKING THE CRANKCASE BREATHER PIPE 1. Remove: 9side cowlings (left and right) 9center panels (upper and lower) 9front cowling 9rear cowlings (left and right) 9inner panel Refer to “COVERS”.
Page 78: Checking The Cooling System
Yamaha T135 Service Manual CHECKING THE COOLANT LEVEL/ CHECKING THE COOLING SYSTEM 9 9 Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if nec- essary, correct the antifreeze concentration of the coolant.
Page 79: Changing The Coolant
Yamaha T135 Service Manual CHANGING THE COOLANT EAS00105 CHANGING THE COOLANT 1. Remove: 9side cowlings (left and right) 9front cowling Refer to “REMOVING THE SIDE COWL- INGS” and “REMOVING THE FRONT COWLING”. 2. Remove: 9coolant reservoir tank cover 9coolant reservoir cap 3.
Page 80 Yamaha T135 Service Manual CHANGING THE COOLANT 8. Install: 9copper washer 9coolant drain bolt 7 Nm (0.7 m•kg, 5.0 ft•lb) 9. Connect: 9coolant reservoir hose 10. Fill: 9cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze...
Page 81 Yamaha T135 Service Manual CHANGING THE COOLANT 9 9 Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if nec- essary, correct the antifreeze concentration of the coolant.
Page 82: Chassis
Yamaha T135 Service Manual ADJUSTING THE REAR BRAKE CHASSIS EAS00113 ADJUSTING THE REAR BRAKE 1. Check: 9brake pedal free play a Out of specification → Adjust. Brake pedal free play (at the end of the brake pedal) 25–35 mm (0.98–1.38 in) 2.
Page 83: Checking The Front Brake Pads
Yamaha T135 Service Manual CHECKING THE FRONT BRAKE PADS/ CHECKING THE REAR BRAKE SHOES/ ADJUSTING THE REAR BRAKE LIGHT SWITCH EAS00120 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake.
Page 84: Adjusting The Rear Brake Light Switch
Yamaha T135 Service Manual ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE FRONT BRAKE HOSE 2. Adjust: 9rear brake light operation timing MMMMMMMMMMMMMMMMMMMMMMMM a. Hold the main body 1 of the rear brake light switch so that it does not rotate and...
Page 85: Bleeding The Hydraulic Brake System
Yamaha T135 Service Manual BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00133 BLEEDING THE HYDRAULIC BRAKE SYSTEM Bleed the hydraulic brake system whenever: 9 9 the system is disassembled. 9 9 a brake hose is loosened, disconnected or replaced. 9 9 the brake fluid level is very low.
Page 86: Adjusting The Drive Chain Slack
Yamaha T135 Service Manual BLEEDING THE HYDRAULIC BRAKE SYSTEM/ ADJUSTING THE DRIVE CHAIN SLACK NOTE: Loosening the bleed screw will release the pres- sure and cause the brake lever to contact the throttle grip. h. Tighten the bleed screw and then release the brake lever.
Page 87 Yamaha T135 Service Manual ADJUSTING THE DRIVE CHAIN SLACK 1. Stand the vehicle on a level surface. 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 rear wheel is elevated.
Page 88: Lubricating The Drive Chain
Yamaha T135 Service Manual LUBRICATING THE DRIVE CHAIN/ CHECKING THE BRAKE FLUID LEVEL EAS00143 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained prop- erly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the vehicle is used in dusty areas.
Page 89: Checking And Adjusting The Steering Head
Yamaha T135 Service Manual CHECKING THE BRAKE FLUID LEVEL/ CHECKING AND ADJUSTING THE STEERING HEAD Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. NOTE: In order to ensure a correct reading of the brake fluid level, make sure the top of the brake fluid reservoir is horizontal.
Page 90 Yamaha T135 Service Manual CHECKING AND ADJUSTING THE STEERING HEAD 4. Adjust: 9steering head MMMMMMMMMMMMMMMMMMMMMMMM a. Loosen the upper ring nut 1. b. Loosen the lower ring nut 2 and then tight- en it to specification with a steering nut wrench 3.
Page 91: Checking The Front Fork
Yamaha T135 Service Manual CHECKING THE FRONT FORK EAS00149 CHECKING THE FRONT FORK 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. 2. Check: 9inner tube Damage/scratches → Replace.
Page 92: Checking The Tires
Yamaha T135 Service Manual CHECKING THE TIRES EASF0015 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: 9tire pressure Out of specification → Regulate. 9 9 The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature.
Page 93 No guarantee concerning handling characteristics can be given if a tire combi- nation other than one approved by Yamaha is used on this vehicle. YamahaT135.COM 3-39...
Page 94: Checking And Tightening The Spokes
Yamaha T135 Service Manual CHECKING THE TIRES/ CHECKING AND TIGHTENING THE SPOKES 9 9 New 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.
Page 95: Checking And Lubricating The Cables
Yamaha T135 Service Manual CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE LEVER AND PEDALS/ LUBRICATING THE SIDESTAND/LUBRICATING THE CENTERSTAND EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables. Damaged outer cable may cause the cable to corrode and interfere with its movement.
Page 96: Electrical System
Yamaha T135 Service Manual CHECKING AND CHARGING THE BATTERY EAS00176 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY Batteries generate explosive hydrogen gas and contain electrolyte which is made of poi- sonous and highly caustic sulfuric acid. Therefore, always follow these preventive...
Page 97 Yamaha T135 Service Manual CHECKING AND CHARGING THE BATTERY 3. Disconnect: 9battery leads (from the battery terminals) First, disconnect the negative battery lead 1, and then the positive battery lead 2. 4. Disconnect: 9battery breather hose 5. Remove: 9battery 6. Check:...
Page 98 Yamaha T135 Service Manual CHECKING AND CHARGING THE BATTERY 9 9 Loosen the battery sealing caps. 9 9 Make sure the battery breather hose and battery vent are free of obstructions. 9 9 To ensure maximum performance, always charge a new battery before using it.
Page 99 Yamaha T135 Service Manual CHECKING AND CHARGING THE BATTERY 9warpage or buckling of the battery plates or insulators is evident. 9. Check: 9battery breather hose and battery vent Obstruction → Clean. Damage → Replace. 10. Install: 9battery 11. Connect: 9battery breather hose 1...
Page 100: Checking The Fuse
Yamaha T135 Service Manual CHECKING THE FUSE EASF0017 CHECKING THE FUSE To avoid a short circuit, always set the main switch to “OFF” when checking or replacing a fuse. 1. Open the seat and battery cover. 2. Remove: 9fuse holder 1 3.
Page 101: Replacing The Headlight Bulbs
Yamaha T135 Service Manual REPLACING THE HEADLIGHT BULBS EAS00183 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Remove: 9headlight assembly Refer to “REMOVING THE HEADLIGHT ASSEMBLY”. 2. Remove: 9headlight bulb holder 1 3. Remove:...
Page 102: Adjusting The Headlight Beam
Yamaha T135 Service Manual ADJUSTING THE HEADLIGHT BEAM EAS00186 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: 9headlight beam (vertically) MMMMMMMMMMMMMMMMMMMMMMMM a. Loosen the bolt 1. b. Slide the bottom of the headlight unit for- ward a or backward b. Slide forward Headlight beam is raised.
Page 103: Eng
Yamaha T135 Service Manual CHAPTER 4 ENGINE REMOVING THE ENGINE ..................4-1 COOLING SYSTEM ..................4-1 ENGINE OIL ...................... 4-1 CARBURETOR ....................4-1 FOOTREST ...................... 4-2 MUFFLER ......................4-2 BRAKE PEDAL ....................4-2 SHIFT PEDAL ....................4-2 SIDE COWLING BRACKET ................4-3 WIRE, CABLE AND HOSE ................
Page 104 INSTALLING THE PISTON AND CYLINDER ........... 4-36 GENERATOR AND STARTER CLUTCH ............... 4-38 REMOVING THE GENERATOR ............... 4-39 REMOVING THE STARTER CLUTCH (T135SE) ..........4-40 CHECKING THE STARTER CLUTCH (T135SE) ..........4-41 INSTALLING THE STARTER CLUTCH (T135SE) ..........4-42 INSTALLING THE GENERATOR ..............4-42 OIL PUMP ......................
Page 105 Yamaha T135 Service Manual CHECKING THE BEARINGS ................4-67 CHECKING THE TIMING CHAIN GUIDE ............4-67 CHECKING THE TIMING CHAIN ..............4-67 INSTALLING THE CRANKSHAFT ..............4-68 ASSEMBLING THE CRANKCASE ..............4-68 KICKSTARTER ...................... 4-70 REMOVING THE KICKSTARTER ..............4-71 CHECKING THE KICKSTARTER ..............
Page 106 Yamaha T135 Service Manual YamahaT135.COM...
Page 107: Removing The Engine
Yamaha T135 Service Manual REMOVING THE ENGINE EASF0018 ENGINE REMOVING THE ENGINE NOTE: It is not necessary to remove the engine in order to remove the following components. 9Cylinder head 9Cylinder 9Piston 9Clutch 9Shift shaft 9Oil pump 9Generator 9Starter clutch 1.
Page 108: Footrest
Yamaha T135 Service Manual REMOVING THE ENGINE FOOTREST 1. Remove: 9footrest bolts 1 9footrest MUFFLER 1. Remove: 9exhaust pipe nuts 1 9exhaust pipe 2 2. Remove: 9lower muffler bolt 1 9washer 9upper muffler bolt 2 9washers 9nut 9muffler 3 BRAKE PEDAL 1.
Page 109: Side Cowling Bracket
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. Remove: 9fuel cock vacuum hose 1 YamahaT135.COM...
Page 110: Engine Assembly
Yamaha T135 Service Manual REMOVING THE ENGINE 5. Remove: 9crankcase breather pipe 1 ENGINE ASSEMBLY 1. Loosen: 9rear lower mounting nut 1 9plate nuts (front and rear) 2 9front mounting nut 3 9rear upper mounting nut 4 9pivot shaft nut 5 2.
Page 111: Installing The Engine
Yamaha T135 Service Manual INSTALLING THE ENGINE EASF0019 INSTALLING THE ENGINE ENGINE ASSEMBLY Securely support the vehicle so there is no danger of it falling over when installing engine. 1. Install: 9engine assembly 9pivot shaft 1 9washer 9pivot shaft nut...
Page 112: Wire, Cable And Hose
Yamaha T135 Service Manual INSTALLING THE ENGINE WIRE, CABLE AND HOSE 1. Connect: 9starter motor lead coupler (T135SE) 9neutral switch lead coupler 9pickup coil lead coupler 9stator coil lead coupler 2. Install: 9crankcase breather pipe 9fuel cock vacuum hose 9spark plug cap SIDE COWLING BRACKET 1.
Page 113: Footrest
Yamaha T135 Service Manual INSTALLING THE ENGINE FOOTREST 1. Install: 9footrest 9footrest bolts 1 23 Nm (2.3 m·kg, 17 ft•lb) CARBURETOR 1. Install: 9carburetor assembly Refer to “CARBURETOR” in chapter 6. 2. Adjust: 9throttle cable free play 9rear brake light operation timing Refer to “ADJUSTING THE THROTTLE...
Page 114: Cylinder Head
Yamaha T135 Service Manual CYLINDER HEAD EASF0023 CYLINDER HEAD 1 Water pump 8 Timing chain tensioner 2 Spark plug 9 Dowel pin 3 Cylinder head cover 0 Gasket 4 Dowel pin 5 Camshaft sprocket 6 Cylinder head 7 Timing chain guide (exhaust side) 10 Nm (1.0 m•kg, 7.2 ft•lb )
Page 115: Removing The Cylinder Head
Yamaha T135 Service Manual CYLINDER HEAD EAS00222 REMOVING THE CYLINDER HEAD 1. Remove 9side cowlings (left and right) 9front cowling 9center panels (upper and lower) 9rear cowlings (left and right) Refer to “COVERS” in chapter 3. 9carburetor assembly Refer to “CARBURETOR” in chapter 6.
Page 116 Yamaha T135 Service Manual CYLINDER HEAD 6. Align: 9“I” mark a on the generator rotor (with the stationary pointer b on the crankcase) MMMMMMMMMMMMMMMMMMMMMMMM a. Turn the crankshaft counterclockwise. b. When the piston is at TDC on the compres- sion stroke, align the “I” mark c on the camshaft sprocket with the stationary point- er d on the cylinder head.
Page 117: Checking The Cylinder Head
Yamaha T135 Service Manual CYLINDER HEAD 10. Remove: 9engine mount nut 9washer 9engine mount bolt 9cylinder head bolts 9cylinder head bolts 9washers 9cylinder head NOTE: 9Loosen the nuts in the proper sequence as shown. 9Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.
Page 118: Checking Timing Chain Guide
Yamaha T135 Service Manual CYLINDER HEAD 3. Measure: 9cylinder head warpage Out of specification → Resurface the cylin- der head. Maximum cylinder head warpage 0.03 mm (0.0012 in) MMMMMMMMMMMMMMMMMMMMMMMM a. Place a straightedge 1 and a thickness gauge 2 across the cylinder head.
Page 119: Checking The Timing Chain Tensioner
Yamaha T135 Service Manual CYLINDER HEAD EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1. Check: 9timing chain tensioner Cracks/damage → Replace. MMMMMMMMMMMMMMMMMMMMMMMM a. While lightly pressing the timing chain ten- sioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1.
Page 120 Yamaha T135 Service Manual CYLINDER HEAD 3. Tighten: 9cylinder head bolts 22 Nm (2.2 m·kg, 16 ft•lb) 9cylinder head bolts 10 Nm (1.0 m•kg, 7.2 ft•lb) 9engine mount nut 72 Nm (7.2 m•kg, 52 ft•lb) NOTE: 9Lubricate the cylinder head bolts with engine oil.
Page 121 Install the gasket and the timing chain ten- sioner 2 onto the cylinder. Always use a new gasket. NOTE: Apply the YAMAHA bond 1215 onto the bolts. Yamaha bond No. 1215 90890-85505 Timing chain tensioner bolt 10 Nm (1.0 m·kg, 7.2 ft•lb) c.
Page 122 Yamaha T135 Service Manual CYLINDER HEAD 8. Check: 9“I”mark a Align the “I” mark on the generator rotor with the stationary pointer b on the crankcase. 9“I”mark c Align the “I”mark on the camshaft sprocket with the stationary pointer d on the cylinder head.
Page 123: Camshaft
Yamaha T135 Service Manual CAMSHAFT EASf0020 CAMSHAFT 1 Locknut 2 Adjusting screw 3 Camshaft retainer 4 Camshaft 5 Rocker arm shaft 6 Rocker arm 7 Nm (0.7 m•kg, 5.0 ft•lb ) 7 Nm (0.7 m•kg, 5.0 ft•lb ) YamahaT135.COM 4-17...
Page 124: Removing The Rocker Arms And Camshaft
Yamaha T135 Service Manual CAMSHAFT EASF0022 REMOVING THE ROCKER ARMS AND CAMSHAFT NOTE: Prior to remove 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...
Page 125: Checking The Camshaft
Yamaha T135 Service Manual CAMSHAFT EAS00205 CHECKING THE CAMSHAFT 1. Check: 9camshaft lobes Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: 9camshaft lobe dimensions a and b → specification Replace camshaft. Camshaft lobe dimension limit Intake a a 29.613 mm (1.1659 in) b b 25.043 mm (0.9859 in)
Page 126 Yamaha T135 Service Manual CAMSHAFT 2. Check: 9rocker arm shaft Blue discoloration/excessive wear/pitting/ scratches → Replace or check the lubrica- tion system. 3. Measure: 9rocker arm inside diameter Out of specification → Replace. Rocker arm inside diameter 9.985 – 10.000 mm (0.3931 –...
Page 127: Checking The Camshaft Sprocket
Yamaha T135 Service Manual CAMSHAFT EAS00207 CHECKING THE CAMSHAFT SPROCKET 1. Check: 9camshaft sprocket Worn more than 1/4 tooth a → Replace the camshaft sprocket and the timing chain as a set. a 1/4 tooth b Correct 1 Timing chain...
Page 128: Valves And Valve Springs
Yamaha T135 Service Manual VALVES AND VALVE SPRINGS 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 YamahaT135.COM 4-22...
Page 129: Removing The Valves
Yamaha T135 Service Manual VALVES AND VALVE SPRINGS EASF0025 REMOVING THE VALVES NOTE: Prior to remove the valves, remove the cylinder head, camshaft and rocker arms. The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve...
Page 130: Checking The Valves And Valve Guides
Yamaha T135 Service Manual VALVES AND VALVE SPRINGS 2. Remove: 9valve cotters 1 NOTE: Remove the valve cotters by compressing the valve spring with the valve spring compressor Valve spring compressor 90890-04019 Valve spring compressor attachment 90890-04108 3. Remove: 9upper spring seat 1...
Page 131 Install the gasket and the timing chain ten- sioner 2 onto the cylinder. Always use a new gasket. NOTE: Apply the YAMAHA bond 1215 onto the bolts. Yamaha bond No. 1215 90890-85505 Timing chain tensioner bolt 10 Nm (1.0 m·kg, 7.2 ft•lb) c.
Page 132 Yamaha T135 Service Manual CYLINDER HEAD 8. Check: 9“I”mark a Align the “I” mark on the generator rotor with the stationary pointer b on the crankcase. 9“I”mark c Align the “I”mark on the camshaft sprocket with the stationary pointer d on the cylinder head.
Page 133 Yamaha T135 Service Manual CAMSHAFT EASf0020 CAMSHAFT 1 Locknut 2 Adjusting screw 3 Camshaft retainer 4 Camshaft 5 Rocker arm shaft 6 Rocker arm 7 Nm (0.7 m•kg, 5.0 ft•lb ) 7 Nm (0.7 m•kg, 5.0 ft•lb ) YamahaT135.COM 4-17...
Page 134 Yamaha T135 Service Manual CAMSHAFT EASF0022 REMOVING THE ROCKER ARMS AND CAMSHAFT NOTE: Prior to remove 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...
Page 135 Yamaha T135 Service Manual CAMSHAFT EAS00205 CHECKING THE CAMSHAFT 1. Check: 9camshaft lobes Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: 9camshaft lobe dimensions a and b → specification Replace camshaft. Camshaft lobe dimension limit Intake a a 29.613 mm (1.1659 in) b b 25.043 mm (0.9859 in)
Page 136 Yamaha T135 Service Manual CAMSHAFT 2. Check: 9rocker arm shaft Blue discoloration/excessive wear/pitting/ scratches → Replace or check the lubrica- tion system. 3. Measure: 9rocker arm inside diameter Out of specification → Replace. Rocker arm inside diameter 9.985 – 10.000 mm (0.3931 –...
Page 137 Yamaha T135 Service Manual CAMSHAFT EAS00207 CHECKING THE CAMSHAFT SPROCKET 1. Check: 9camshaft sprocket Worn more than 1/4 tooth a → Replace the camshaft sprocket and the timing chain as a set. a 1/4 tooth b Correct 1 Timing chain...
Page 138 Yamaha T135 Service Manual VALVES AND VALVE SPRINGS 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 YamahaT135.COM 4-22...
Page 139 Yamaha T135 Service Manual VALVES AND VALVE SPRINGS EASF0025 REMOVING THE VALVES NOTE: Prior to remove the valves, remove the cylinder head, camshaft and rocker arms. The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve...
Page 140 Yamaha T135 Service Manual VALVES AND VALVE SPRINGS 2. Remove: 9valve cotters 1 NOTE: Remove the valve cotters by compressing the valve spring with the valve spring compressor Valve spring compressor 90890-04019 Valve spring compressor attachment 90890-04108 3. Remove: 9upper spring seat 1...
Page 141 Yamaha T135 Service Manual VALVES AND VALVE SPRINGS 2. Replace: 9valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °C in an oven. MMMMMMMMMMMMMMMMMMMMMMMM a. Remove the valve guide with the valve guide remover 1.
Page 142: Checking The Valve Seats
Yamaha T135 Service Manual VALVES AND VALVE SPRINGS 6. Measure: 9valve stem runout Out of specification → Replace the valve. NOTE: 9When installing a new valve, always replace the valve guide. 9If the valve is removed or replaced, always replace the valve stem seal.
Page 143 Yamaha T135 Service Manual VALVES AND VALVE SPRINGS NOTE: Where the valve seat and valve face contacted one another, the blueing will have been removed. LLLLLLLLLLLLLLLLLLLLLLLL 4. Lap: 9valve face 9valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped.
Page 144: Checking The Valve Springs
Yamaha T135 Service Manual VALVES AND VALVE SPRINGS j. Measure the valve seat width c again. If the valve seat width is out of specification, reface and lap the valve seat. LLLLLLLLLLLLLLLLLLLLLLLL EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs.
Page 145 Yamaha T135 Service Manual VALVES AND VALVE SPRINGS EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: 9valve stem end (with an oil stone) 2. Lubricate: 9valve stem 1 9valve stem seal 2...
Page 146 Yamaha T135 Service Manual VALVES AND VALVE SPRINGS 4. Install: 9valve cotters 1 NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor Valve spring compressor 90890-04019 Valve spring compressor attachment 90890-04108 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer.
Page 147: Cylinder And Piston
Yamaha T135 Service Manual CYLINDER AND PISTON EASF0027 CYLINDER AND PISTON 1 Cylinder 8 Piston pin 2 Cylinder gasket 9 Piston 3 Dowel pin 4 Top ring 5 2nd ring 6 Oil ring 7 Piston pin clip YamahaT135.COM 4-31...
Page 148: Removing The Cylinder And Piston
Yamaha T135 Service Manual CYLINDER AND PISTON EASF0028 REMOVING THE CYLINDER AND PISTON NOTE: Prior to removing the cylinder and piston, remove the cylinder head. 1. Remove: 9cylinder 1 2. Remove: 9dowel pins 1 9gasket 2 3. Remove: 9piston pin clip 1...
Page 149: Checking The Cylinder And Piston
Yamaha T135 Service Manual CYLINDER AND PISTON EAS00255 CHECKING THE CYLINDER AND PISTON 1. Check: 9piston surface 9cylinder wall Vertical scratches → Replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: 9piston-to-cylinder clearance MMMMMMMMMMMMMMMMMMMMMMMM a.
Page 150: Checking The Piston Rings
Yamaha T135 Service Manual CYLINDER AND PISTON Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance 0.0015 – 0.048 mm (0.0006 – 0.0019 in) <Limit>: 0.15 mm (0.0059) f. If out of specification, replace the cylinder, and replace the piston and piston rings as a set.
Page 151: Checking The Piston Pin
Yamaha T135 Service Manual CYLINDER AND PISTON 3. Measure: 9piston ring end gap Out of specification → Replace the piston ring. NOTE: The end gap of the oil ring expander cannot be measured. If the end gaps of the oil ring rails are excessive, replace all three piston rings.
Page 152: Installing The Piston And Cylinder
Yamaha T135 Service Manual CYLINDER AND PISTON 4. Calculate: 9piston-pin-to-piston-pin-bore clearance Out of specification → Replace the piston pin and piston as a set. Piston-pin-to-piston-pin-bore clearance = Piston pin bore diameter b b – Piston pin outside diameter a a...
Page 153 Yamaha T135 Service Manual CYLINDER AND PISTON 3. Install: 9gasket 1 9dowel pins 2 4. Lubricate: 9piston 9piston rings 9cylinder (with the recommended lubricant) NOTE: Be sure to apply enough engine oil onto them. Recommended lubricant Engine oil 5. Offset:...
Page 154: Generator And Starter Clutch
Yamaha T135 Service Manual GENERATOR AND STARTER CLUTCH EASF0034 GENERATOR AND STARTER CLUTCH 1 Starter clutch gear 8 Starter clutch idle gear shaft 2 Starter clutch roller 9 Starter clutch idle gear 3 Starter clutch spring cap 0 Pickup coil...
Page 155: Removing The Generator
Yamaha T135 Service Manual GENERATOR AND STARTER CLUTCH EAS00346 REMOVING THE GENERATOR 1. Drain: 9engine oil (completely from the crankcase) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 2. Remove: 9side cowling (left) Refer to “REMOVING THE SIDE COWL- INGS”...
Page 156 Yamaha T135 Service Manual GENERATOR AND STARTER CLUTCH 6. Remove: 9generator rotor 1 (with the flywheel puller 2) 9woodruff key Flywheel puller 90890-01362 EAS00344 REMOVING THE STARTER CLUTCH (T135SE) 1. Remove: 9starter clutch idle gear shaft 1 9starter clutch idle gear 2...
Page 157: Checking The Starter Clutch (T135Se)
Yamaha T135 Service Manual GENERATOR AND STARTER CLUTCH EAS00351 CHECKING THE STARTER CLUTCH (T135SE) 1. Check: 9starter clutch rollers 1 Damage/wear → Replace. 2. Check: 9starter clutch idle gear 1 9starter clutch gear 2 Burrs/chips/roughness/wear → Replace the defective part(s).
Page 158: Installing The Starter Clutch (T135Se)
Yamaha T135 Service Manual GENERATOR AND STARTER CLUTCH EAS00355 INSTALLING THE STARTER CLUTCH (T135SE) 1. Install: 9starter clutch 1 14 Nm (1.4 m•kg, 10 ft•lb) NOTE: 9While holding the generator rotor 2 with the sheave holder, tighten the starter clutch bolt.
Page 159 Yamaha T135 Service Manual GENERATOR AND STARTER CLUTCH 3. Apply: 9sealant (on to the generator lead grommet) Yamaha bond No. 1215 90890-85505 4. Apply: 9sealant NOTE: Be sure to apply the sealant onto the crankcase cover bolt thread as shown one.
Page 160: Oil Pump
Yamaha T135 Service Manual OIL PUMP EASF0035 OIL PUMP 1 Oil drain bolt 8 Gear cover 2 O-ring 9 Oil pump assembly 3 Spring 0 Gasket 4 Oil strainer 5 Oil filter cover 6 O-ring 7 Oil filter 10 Nm (1.0 m•kg, 7.2 ft•lb ) 7 Nm (0.7 m•kg, 5.0 ft•lb )
Page 161: Removing The Oil Pump
Yamaha T135 Service Manual OIL PUMP REMOVING THE OIL PUMP 1. Drain: 9engine oil (completely from the crankcase) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 2. Remove: 9generator Refer to “GENERATOR AND STARTER CLUTCH”. 3. Remove: 9clutch release shift arm 4.
Page 162: Checking The Oil Pump
Yamaha T135 Service Manual OIL PUMP EAS00364 CHECKING THE OIL PUMP 1. Check: 9oil pump driven gear 1 9oil pump housing 2 9outer rotor 9inner rotor Cracks/damage/wear → Replace the defec- tive part(s). 2. Measure: 9inner-rotor-to-outer-rotor-tip clearance a 9outer-rotor-to-oil-pump-housing clearance...
Page 163: Assembling The Oil Pump
Yamaha T135 Service Manual OIL PUMP EAS00375 ASSEMBLING THE OIL PUMP 1. Lubricate: 9inner rotor 9outer rotor 9oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: 9oil pump shaft (to the oil pump housing) 9inner rotor 1...
Page 164: Installing The Oil Pump
Yamaha T135 Service Manual OIL PUMP EAS00376 INSTALLING THE OIL PUMP 1. Install: 9gasket 1 9oil pump assembly 7 Nm (0.7 m•kg, 5.0 ft•lb) NOTE: Install the gasket with section a in the position as shown in the illustration. After tightening the bolts, make sure the oil pump turns smoothly.
Page 165: Clutch
Yamaha T135 Service Manual CLUTCH EASF0029 CLUTCH 1 Clutch pressure plate bolt 9 Clutch push rod #1 y Clutch shoe housing nut 2 Clutch spring 0 Clutch boss nut u Primary drive gear 3 Clutch pressure plate q Clutch boss...
Page 166: Removing The Clutch
Yamaha T135 Service Manual CLUTCH EAS00277 REMOVING THE CLUTCH 1. Drain: 9engine oil (completely from the crankcase) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 2. Remove: 9side cowlings (left and right) Refer to “REMOVING THE SIDE COWL- INGS” in chapter 3.
Page 167 Yamaha T135 Service Manual CLUTCH 7. Straighten the lock washer tab. 8. Loosen: 9clutch boss nut 1 NOTE: While holding the clutch boss 2 with the univer- sal clutch holder 3, loosen the clutch boss nut. Universal clutch holder 90890-04086 9.
Page 168: Checking The Friction Plates
Yamaha T135 Service Manual CLUTCH 11. Remove: 9collar 1 9clutch shoe housing 2 9washer 3 9rollers 4 9cage springs 5 9cage 6 9clutch shoe housing boss 7 9clutch shoe 8 EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric- tion plates.
Page 169: Checking The Clutch Springs
Yamaha T135 Service Manual CLUTCH EAS00282 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1. Check: 9clutch spring Damage → Replace the clutch springs as a set. 2. Measure: 9clutch spring free length a Out of specification →...
Page 170: Checking The Clutch Pressure Plate
Yamaha T135 Service Manual CLUTCH EAS00286 CHECKING THE CLUTCH PRESSURE PLATE 1. Check: 9clutch pressure plate Cracks/damage → Replace. EAS00288 CHECKING THE CLUTCH PUSH RODS 1. Check: 9clutch push rod #1 Cracks/damage/wear → Replace the clutch push rod #1. 9clutch push rod #2 Cracks/damage/wear →...
Page 171: Checking The Clutch Shoe Housing
Yamaha T135 Service Manual CLUTCH CHECKING THE CLUTCH SHOE HOUSING 1. Check: 9clutch shoe housing Damage/wear → Replace. 2. Measure: 9clutch shoe housing inside diameter a Out of specification → Replace. Clutch shoe housing inside diame- 116 mm (4.57 in) <Limit>: 117 mm (4.61 in)
Page 172: Checking The Clutch Release Shift Arm
Yamaha T135 Service Manual CLUTCH CHECKING THE CLUTCH RELEASE SHIFT ARM 1. Check: 9clutch release shift arm 1 Damage/wear → Replace. 9clutch release adjusting screw 2 Damage/wear → Replace. EAS00293 INSTALLING THE CLUTCH 1. Install: 9washer 9cage 1 9cage springs 2...
Page 173 Yamaha T135 Service Manual CLUTCH 4. Tighten: 9clutch boss nut 1 70 Nm (7.0 m•kg, 50 ft•lb) NOTE: While holding the clutch boss 2 with the univer- sal clutch holder 3, tighten the clutch boss nut. Universal clutch holder 90890-04086 5.
Page 174: Shift Shaft
Yamaha T135 Service Manual SHIFT SHAFT EASF0032 SHIFT SHAFT 1 Shift pedal 8 Washer t Collar 2 Washer 9 Thrust bearing y Plate 3 Spring 0 Dowel pin u Shift drum segment 4 Shift fork guide bar q Shift shaft...
Page 175: Removing The Shift Shaft
Yamaha T135 Service Manual SHIFT SHAFT REMOVING THE SHIFT SHAFT 1. Drain: 9engine oil (completely from the crankcase) Refer 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.
Page 176 Yamaha T135 Service Manual SHIFT SHAFT 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:...
Page 177: Checking The Shift Shaft
Yamaha T135 Service Manual SHIFT SHAFT EAS00328 CHECKING THE SHIFT SHAFT 1. Check: 9shift shaft 1 9shift lever 2 Bends/damage/wear → Replace. 9springs Damage/wear → Replace. EAS00330 CHECKING THE STOPPER LEVER 1. Check: 9stopper lever 1 Bends/damage → Replace. Roller turns roughly → Replace.
Page 178: Installing The Shift Shaft
Yamaha T135 Service Manual SHIFT SHAFT EAS00331 INSTALLING THE SHIFT SHAFT 1. Install: 9shift drum segment 1 9plate 12 Nm (1.2 m•kg, 9.0 ft•lb) NOTE: Apply locking agent (LOCTITE ) to the threads of shift drum segment screw. 2. Install:...
Page 179: Crankcase And Crankshaft
Yamaha T135 Service Manual 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 4 Nm (0.4 m•kg, 3.0 ft•lb ) 14 Nm (1.4 m•kg, 20 ft•lb )
Page 180: Disassembling The Crankcase
DISASSEMBLING THE CRANKCASE 1. Remove: 9engine Refer to “REMOVING THE ENGINE”. 2. Remove: 9starter motor lead (T135SE) 9starter motor (T135SE) Refer to “STARTER MOTOR (T135SE)” in chapter 8. 3. Remove: 9cylinder head Refer to “CYLINDER HEAD”. 9cylinder 9piston Refer to “CYLINDER AND PISTON”.
Page 181: Checking The Crankshaft And Connecting Rod
Yamaha T135 Service Manual CRANKCASE AND CRANKSHAFT 5. Remove: 9crankcase bolts 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:...
Page 182 Yamaha T135 Service Manual CRANKCASE AND CRANKSHAFT 2. Measure: 9big end side clearance Out of specification → Replace the crank- shaft. Big end side clearance 0.11 – 0.41 mm (0.0043 – 0.0161 in) 3. Measure: 9crankshaft width Out of specification → Replace the crank- shaft.
Page 183: Checking The Crankcase
Yamaha T135 Service Manual CRANKCASE AND CRANKSHAFT EAS00399 CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: 9crankcase Cracks/damage → Replace. 9oil delivery passages Obstructions →...
Page 184: Installing The Crankshaft
Yamaha T135 Service Manual CRANKCASE AND CRANKSHAFT EAS00408 INSTALLING THE CRANKSHAFT 1. Install: 9crankshaft assembly 1 NOTE: Use the crankshaft installing tool (spacer 2, installer pot 3, installer bolt 4, adaptor 5) to install the crankcase (left). To avoid scratching the crankshaft and to...
Page 185 Yamaha T135 Service Manual CRANKCASE AND CRANKSHAFT 4. Install: 9neutral switch 4 Nm (0.4 m•kg, 3.0 ft•lb) 9crankcase bolts 10 Nm (1.0 m•kg, 7.2 ft•lb) 5. Apply: 9engine oil (onto the crankshaft bearings and oil deliv- ery holes) 6. Check: 9crankshaft and transmission operation Rough movement →...
Page 186: Kickstarter
Yamaha T135 Service Manual KICKSTARTER EASF0033 KICKSTARTER 1 Oil level plug 8 Collar 2 Kickstarter lever 9 Kickstarter spring 3 Crankcase cover (right) 0 Washer 4 Gasket q Spring 5 Washer w Kickstarter ratchet gear 6 Kickstarter gear e Kickstarter shaft 7 Guide stopper 50 Nm (5.0 m•kg, 36 ft•lb )
Page 187: Removing The Kickstarter
Yamaha T135 Service Manual KICKSTARTER REMOVING THE KICKSTARTER 1. Drain: 9engine oil (completely from the crankcase) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 9coolant (completely from the water jacket) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Remove:...
Page 188 Yamaha T135 Service Manual KICKSTARTER 6. Remove: 9clutch Refer to “CLUTCH”. 9shift shaft Refer to “SHIFT SHAFT”. 9oil pump assembly 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.
Page 189: Checking The Kickstarter
Yamaha T135 Service Manual KICKSTARTER 11. Remove: 9washer 1 9kickstarter gear 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 →...
Page 190: Installing The Kickstarter
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”.
Page 191 Yamaha T135 Service Manual KICKSTARTER 9. Install: 9piston 9cylinder Refer to “CYLINDER AND PISTON”. 9cylinder head Refer to “CYLINDER HEAD”. 9radiator assembly Refer to “RADIATOR” in chapter 5. 9cylinder head Refer to “CYLINDER HEAD”. 10. Install: 9muffler 9footrest 9brake pedal Refer to “REMOVING THE ENGINE”.
Page 192: Transmission
Yamaha T135 Service Manual TRANSMISSION EASF0041 TRANSMISSION 1 Shift fork guide bar 9 1st wheel gear 2 Shift fork “R” 0 4th wheel gear 3 Shift fork “L” q 3rd wheel gear 4 Shift drum w 2nd wheel gear 5 2nd pinion gear...
Page 193: Removing The Transmission
Yamaha T135 Service Manual TRANSMISSION EASF0042 REMOVING THE TRANSMISSION NOTE: Prior to removing the transmission, separate the crankcase. 1. Remove: 9shift fork guide bar 1 9shift fork guide bar springs 9shift fork “R” 2 9shift fork “L” 3 9shift drum 4 NOTE: Note the position of each part.
Page 194: Checking The Shift Forks
Yamaha T135 Service Manual TRANSMISSION 2. Remove: 9circlips 1 9washers 2 91st wheel gear 3 94th wheel gear 4 93rd wheel gear 5 9side plate 6 9side plate spring 7 92nd wheel gear 8 9drive axle 9 EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to both of the shift forks.
Page 195: Checking The Shift Drum Assembly
Yamaha T135 Service Manual TRANSMISSION EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: 9shift drum grooves 1 Damage/scratches/wear → Replace the shift drum assembly. 9shift drum bearing Damage/pitting → Replace the shift drum assembly. EAS00424 CHECKING THE TRANSMISSION 1. Measure:...
Page 196: Installing The Transmission
Yamaha T135 Service Manual TRANSMISSION 4. Check: 9transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect → Reassemble the transmission axle assemblies. NOTE: 21.1~21.3 mm When reassembling the drive axle, press the 2nd wheel gear 1 onto the drive axle 2 as shown.
Page 197 Yamaha T135 Service Manual TRANSMISSION 2. Check: 9transmission 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.
Page 198 Yamaha T135 Service Manual YamahaT135.COM...
Page 199: Cool
Yamaha T135 Service Manual COOL CHAPTER 5 COOLING SYSTEM RADIATOR ......................5-1 WATER PUMP ....................... 5-2 REMOVING 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 ..............
Page 200 Yamaha T135 Service Manual COOL YamahaT135.COM...
Page 201: Cooling System
Yamaha T135 Service Manual COOL COOLING SYSTEM EAS00454 COOLING SYSTEM RADIATOR 1 Radiator cap 9 Radiator assembly 2 Bracket 0 Fan motor assembly 3 Water pump inlet hose 4 Radiator outlet hose 5 Radiator inlet hose 6 Bracket 7 Thermostat housing cover 8 Thermostat 10 Nm (1.0 m•kg, 7.2 ft•lb )
Page 202: Water Pump
Yamaha T135 Service Manual COOL COOLING SYSTEM EAS00468 WATER PUMP 1 O-ring 9 Bearing 2 O-ring 0 Water pump seal 3 Water pump cover q Water pump housing 4 Gasket 5 Plate 6 Impeller 7 Plate 8 Housing cover gasket 10 Nm (1.0 m•kg, 7.2 ft•lb )
Page 203: Removing The Radiator
Yamaha T135 Service Manual COOL COOLING SYSTEM REMOVING THE RADIATOR A hot radiator is under pressure. Therefore,do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury. When the...
Page 204: Checking The Radiator
Yamaha T135 Service Manual COOL COOLING SYSTEM 5. Remove: 9bracket 9thermostat cover 1 9thermostat 2 6. Remove: 9fan motor EAS00455 CHECKING THE RADIATOR 1. Check: 9radiator fins Obstruction → Clean. Apply compressed air to the rear of the radi- ator.
Page 205 Yamaha T135 Service Manual COOL COOLING SYSTEM 3. Measure: 9radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Radiator cap opening pressure 93.2 – 122.6 kPa (0.93 – 1.23 kg/cm , 13.5 – 17.8 psi) MMMMMMMMMMMMMMMMMMMMMMMM a.
Page 206: Checking The Thermostat
Yamaha T135 Service Manual COOL COOLING SYSTEM EAS00462 CHECKING THE THERMOSTAT 1. Check: 9thermostat 1 Does not open at 80.5 – 83.5°C (176.9 – 182.3°F) → Replace. MMMMMMMMMMMMMMMMMMMMMMMM a. Suspend the thermostat in a container filled with water. b. Slowly heat the water.
Page 207: Checking The Water Pump
Yamaha T135 Service Manual COOL COOLING SYSTEM 2. Remove: 9plate NOTE: Slide the plate as shown, and then remove the plate from the water pump housing. 3. Remove: 9impeller 1 9bearing 2 NOTE: Remove the bearing from the outside of the water pump housing.
Page 208: Assembling The Water Pump
Yamaha T135 Service Manual COOL COOLING SYSTEM EAS00475 ASSEMBLING THE WATER PUMP 1. Install: 9water pump seal 1 NOTE: Install the water pump seal with the special tools. Mechanical seal installer 90890-04145 2 2 Middle driven shaft bearing driver 90890-04058 3 3 å...
Page 209: Installing The Water Pump
Yamaha T135 Service Manual COOL COOLING SYSTEM EAS00478 INSTALLING THE WATER PUMP 1. Install: 9O-rings 9water pump housing 1 10 Nm (1.0 m•kg, 7.2 ft•lb) Always use a new O-ring. NOTE: 9Align the projection a on the impeller shaft with the slit b on the camshaft.
Page 210 Yamaha T135 Service Manual COOL COOLING SYSTEM 4. Check: 9cooling system Leaks → Repair or replace any faulty part. MMMMMMMMMMMMMMMMMMMMMMMM a. Attach the radiator cap tester 1 to the radi- ator. Radiator cap tester 90890-01325 Radiator cap tester adapter 90890-01352 b.
Page 211: Carb
Yamaha T135 Service Manual CARB CHAPTER 6 CARBURETOR CARBURETOR ......................6-1 REMOVING THE CARBURETOR ..............6-2 DISASSEMBLING THE CARBURETOR ............6-5 CHECKING THE CARBURETOR..............6-6 ASSEMBLING THE CARBURETOR ..............6-9 INSTALLING 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...
Page 212 Yamaha T135 Service Manual CARB YamahaT135.COM...
Page 213: Carburetor
Yamaha T135 Service Manual CARB CARBURETOR EASF0043 CARBURETOR CARBURETOR 1 Coasting enricher assembly w Float chamber rubber gasket 2 Carburetor top cover e Float pivot pin 3 Throttle valve spring r Float chamber 4 Needle set t Fuel drain screw...
Page 214: Removing The Carburetor
Gasoline is highly flammable. Avoid spilling 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) 4. Remove: 9negative lead (from the frame) 5.
Page 215 Yamaha T135 Service Manual CARB CARBURETOR 6. Loosen: 9fuel drain screw 1 7. Drain: 9fuel (from float chamber) 8. Loosen: 9clamp screw 9air filter assembly bolt 9. Remove: 9carburetor top cover 1 9o-ring 9choke cable 2 9accelerator pump cable 3 10.
Page 216 Yamaha T135 Service Manual CARB CARBURETOR 12. Remove: 9carburetor assembly NOTE: Use the ball point hexagon wrench to loosen the bolts. 13. Disconnect: 9fuel hose 1 9carburetor overflow hose 2 9vacuum sensing hose 3 9air vent hose 4 9vacuum sensing hose 5 14.
Page 217: Disassembling The Carburetor
Yamaha T135 Service Manual CARB CARBURETOR DISASSEMBLING THE CARBURETOR NOTE: The following parts can be cleaned and inspect- ed without disassembly. 9Coasting enricher 9Throttle stop screw 9Pilot air screw 1. Remove: 9coasting enricher assembly 9o-ring 2. Remove: 9pilot air screw set 1 3.
Page 218: Checking The Carburetor
Yamaha T135 Service Manual CARB CARBURETOR 5. Remove: 9main jet 1 9needle jet 2 9pilot jet 3 6. Remove: 9float pivot pin 1 9float 2 9needle valve 3 EAS00485 CHECKING THE CARBURETOR 1. Check: 9carburetor body 9float chamber Cracks/damage → Replace.
Page 219 Yamaha T135 Service Manual CARB CARBURETOR 5. Check: 9float Damage → Replace. 6. Check: 9needle valve Damage/wear → Replace. 7. Check: 9coasting enricher assembly 1 Cracks/damage → Replace. 8. Check: 9jet needle 1 9needle jet 2 9main jet 3 9pilot jet 4...
Page 220 Yamaha T135 Service Manual CARB CARBURETOR 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. YamahaT135.COM...
Page 221: Assembling The Carburetor
Yamaha T135 Service Manual CARB CARBURETOR EAS00487 ASSEMBLING THE CARBURETOR 9 9 Before assembling the carburetor, wash all of the parts in a petroleum-based solvent. 9 9 Always use a new gasket and new O-rings. 1. Measure: 9float height a Out of specification →...
Page 222: Installing The Carburetor
Yamaha T135 Service Manual CARB CARBURETOR EAS00492 INSTALLING THE CARBURETOR 1. Install: 9needle set 2. Install: 9joint 1 9intake manifold 2 10 Nm (1.0 m·kg, 7.2 ft·lb) 3. Connect: 9fuel hose 1 9carburetor overflow hose 2 9vacuum sensing hose 3...
Page 223: Checking And Adjusting The Throttle Position Sensor
Yamaha T135 Service Manual CARB CARBURETOR 7. Adjust: 9engine idling speed Engine idling speed 1,300–1,500 r/min Refer to “ADJUSTING THE ENGINE IDLING SPEED” in chapter 3. 8. Adjust: 9throttle cable free play Throttle cable free play (at the flange of the throttle grip) 3–7 mm (0.12–0.18 in)
Page 224 Yamaha T135 Service Manual CARB CARBURETOR c. Connect the pocket tester (DC20V) to the terminals of the throttle position sensor. Positive (+) pocket tester probe → → B/L L Y yellow terminal 3 3 Negative (-) pocket tester probe → →...
Page 225: Checking The Fuel Cock Operation
Yamaha T135 Service Manual CARB CARBURETOR EAS00506 CHECKING THE FUEL COCK OPERA- TION 1. Remove: 9rear cowling (left) Refer to “REMOVING THE REAR COWL- INGS” in chapter 3. 2. Place a container under the end of the fuel hose 1.
Page 226: Air Induction System
Yamaha T135 Service Manual CARB AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned exhaust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port.
Page 227: Air Induction System Diagrams
Yamaha T135 Service Manual CARB AIR INDUCTION SYSTEM 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 YamahaT135.COM 6-15...
Page 228: Removing The Air Induction System
Yamaha T135 Service Manual CARB AIR INDUCTION SYSTEM REMOVING THE AIR INDUCTION SYS- 1. Disconnect: 9vacuum sensing hose 9bend hose 2. Remove: 9air cut cut-off valve assembly 1 9reed valve assembly 2 CHECKING THE AIR INDUCTION SYS- 1. Check: 9hoses Loose connections →...
Page 229: Chas
Yamaha T135 Service Manual 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...
Page 230 Yamaha T135 Service Manual CHAS REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM........7-49 REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM ....................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...
Page 231: Front Wheel And Brake Disc
Yamaha T135 Service Manual CHAS FRONT WHEEL AND BRAKE DISC EASF0044 CHASSIS FRONT WHEEL AND BRAKE DISC 1 Front wheel axle 2 Brake disc 3 Spacer 4 Oil seal 5 Bearing 6 Spacer 7 Speedometer gear unit 23 Nm (2.3 m•kg, 17 ft•lb ) 40 Nm (4.0 m•kg, 29 ft•lb )
Page 232: Removing The Front Wheel
Yamaha T135 Service Manual CHAS FRONT WHEEL AND BRAKE DISC EAS00519 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. 2. Remove: 9speedometer cable 1...
Page 233: Checking The Front Wheel
Yamaha T135 Service Manual CHAS FRONT WHEEL AND BRAKE DISC EAS00526 CHECKING THE FRONT WHEEL 1. Check: 9wheel axle Roll the wheel axle on a flat surface. Bends → Replace. Do not attempt to straighten a bent wheel axle. 2. Check: 9tire Damage/wear →...
Page 234 Yamaha T135 Service Manual CHAS FRONT WHEEL AND BRAKE DISC 5. Check: 9spacers Damage/wear → Replace. 9 9 After mounting a new tire, ride conserva- tively for a while to become accustomed to the “feel” of the new tire and to allow the tire to seat itself properly in the rim.
Page 235: Checking The Brake Disc
Yamaha T135 Service Manual CHAS FRONT WHEEL AND BRAKE DISC d. Install the new wheel bearings and oil seals in the reverse order of disassembly. Do not contact the wheel bearing inner race 4 4 or balls 5 5 . Contact should be made only with the outer race 6 6 .
Page 236: Checking The Speedometer Gear Unit
Yamaha T135 Service Manual CHAS FRONT WHEEL AND BRAKE DISC 3. Measure: 9brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification → Replace. Brake disc thickness limit (mini- mum) 3.0 mm (0.12 in) 4.
Page 237: Installing The Front Wheel
Yamaha T135 Service Manual CHAS FRONT WHEEL AND BRAKE DISC EAS00542 INSTALLING THE FRONT WHEEL 1. Lubricate: 9wheel axle 9wheel bearings 9oil seal lips 9speedometer gear unit Recommended lubricant Lithium-soap-based grease 2. Install: 9brake disc 9front wheel Refer to “CHECKING THE BRAKE DISC”.
Page 238: Rear Wheel And Brake
Yamaha T135 Service Manual CHAS REAR WHEEL AND BRAKE EASF0049 REAR WHEEL AND BRAKE 1 Collar 0 Cotter pin 2 Brake camshaft lever q Brake torque rod 3 Pin w Rear wheel drive hub damper 4 Drive chain puller (right)
Page 239: Removing The Rear Wheel
Yamaha T135 Service Manual CHAS REAR WHEEL AND BRAKE EAS00563 REMOVING THE REAR WHEEL 1. Stand the vehicle on a level surface. 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 rear wheel is elevated.
Page 240 Yamaha T135 Service Manual CHAS REAR WHEEL AND BRAKE 5. Remove: 9rear wheel axle nut 1 9washer 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.
Page 241: Disassembling The Brake Shoe Plate
Yamaha T135 Service Manual CHAS REAR WHEEL AND BRAKE 10. Remove: 9O-ring 9rear wheel drive hub dampers 1 DISASSEMBLING THE BRAKE SHOE PLATE 1. Remove: 9brake shoes 1 9brake shoe springs 2 (48 mm, 1.89 in) 9brake shoe springs 3 (52 mm, 2.01 in) 2.
Page 242: Checking The Rear Wheel Drive Hub
Yamaha T135 Service Manual CHAS REAR WHEEL AND BRAKE 2. Check: 9tire Damage/wear → Replace. Refer to “CHECKING 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 1.
Page 243: Checking The Brake
Yamaha T135 Service Manual CHAS REAR WHEEL AND BRAKE EAS00539 CHECKING THE BRAKE The following procedure applies to all of the brake shoes. 1. Check: 9brake shoe lining Glazed areas → Repair. Sand the glazed areas with course sandpa- per.
Page 244: Assembling The Brake Shoe Plate
Yamaha T135 Service Manual CHAS REAR WHEEL AND BRAKE EAS00570 ASSEMBLING THE BRAKE SHOE PLATE 1. Install: 9brake camshaft 1 9brake shoe wear indicator 2 9brake camshaft lever 7 Nm (0.7 m·kg, 5.0 ft·lb) MMMMMMMMMMMMMMMMMMMMMMMM a. Install the brake camshaft so its punch mark a is positioned as shown.
Page 245 Yamaha T135 Service Manual CHAS REAR WHEEL AND BRAKE 4. Adjust: 9drive chain slack Drive chain slack 25–35 mm (0.98–1.38 in) Refer to “ADJUSTING THE DRIVE CHAIN SLACK” in chapter 3. 5. Tighten: 9wheel axle nut 60 Nm (6.0 m·kg, 43 ft·lb) Do not loosen the wheel axle nut after tight- ening it to the specified torque.
Page 246: Front Brake
Yamaha T135 Service Manual CHAS FRONT BRAKE FRONT BRAKE EASF0052 FRONT BRAKE CALIPER 1 Brake pad retaining pin 8 Brake caliper piston seal 2 Air bleed screw 9 Brake pad 3 Brake caliper 0 Brake pad spring 4 Brake caliper bracket...
Page 247: Replacing The Front Brake Pads
Yamaha T135 Service Manual CHAS FRONT BRAKE EAS00579 Disc brake components rarely require disas- sembly. Therefore, always follow these preventive measures: 9 9 Never disassemble brake components unless absolutely necessary. 9 9 If any connection on the hydraulic brake system is disconnected, the entire brake...
Page 248 Yamaha T135 Service Manual CHAS FRONT BRAKE 2. Remove: 9clips 9brake pad retaining pin 9brake pads 1 9brake pad spring 3. Measure: 9brake pad wear limit a Out of specification → Replace the brake pads as a set. Brake pad wear limit 0.8 mm (0.03 in)
Page 249: Disassembling The Front Brake Caliper
Yamaha T135 Service Manual CHAS FRONT BRAKE 5. Lubricate: 9brake pad retaining pin Recommended lubricant Lithium-soap-based grease 9Do not allow grease to contact the brake pads. 9Remove any excess grease. 6. Install: 9brake caliper bolts 35 Nm (3.5 m·kg, 25 ft·lb) 7.
Page 250 Yamaha T135 Service Manual CHAS FRONT BRAKE 1. Remove: 9union bolt 1 9copper washers 2 9brake hose NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 2. Remove: 9brake caliper 1...
Page 251: Checking The Front Brake Caliper
Yamaha T135 Service Manual CHAS FRONT BRAKE EAS00631 CHECKING THE FRONT BRAKE CALIPER Recommended brake component replacement schedule Brake pads If necessary Piston seal Every two years Brake hose Every four years Every two years and Brake fluid whenever the brake is disassembled 1.
Page 252: Assembling And Installing The Front Brake Caliper
Yamaha T135 Service Manual CHAS FRONT BRAKE EAS00634 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER 9 9 Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. 9 9 Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.
Page 253 Yamaha T135 Service Manual CHAS FRONT BRAKE 5. Fill: 9brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 3 or 4 9 9 Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
Page 254: Front Brake Master Cylinder
Yamaha T135 Service Manual CHAS FRONT BRAKE EASF0050 FRONT BRAKE MASTER CYLINDER 1 Brake master cylinder kit 8 Front brake light switch 2 Brake master cylinder reser- voir cap 3 Brake master cylinder reser- voir diaphragm 4 Brake master cylinder...
Page 255: Disassembling The Front Brake Master Cylinder
Yamaha T135 Service Manual CHAS FRONT BRAKE EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: 9side cowlings (left and right) 9front cowling Refer to “REMOVING THE SIDE COWL-...
Page 256: Checking The Front Brake Master Cylinder
Yamaha T135 Service Manual CHAS FRONT BRAKE 5. Remove: 9brake master cylinder kit 1 6. Remove: 9brake master cylinder reservoir cap 1 9brake master cylinder reservoir diaphragm holder 2 9brake master cylinder reservoir diaphragm 3 7. Remove: 9brake hose 1...
Page 257: Assembling And Installing The Front Brake Master Cylinder
Yamaha T135 Service Manual CHAS FRONT BRAKE 3. Check: 9brake master cylinder reservoir 1 Cracks/damage → Replace. 9brake master cylinder reservoir diaphragm 2 Damage/wear → Replace. 4. Check: 9brake hose 1 Cracks/damage/wear → Replace. EAS00598 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER...
Page 258 Yamaha T135 Service Manual CHAS FRONT BRAKE 2. Install: 9copper washers 1 9brake hose 2 9union bolt 26 Nm (2.6 m·kg, 19 ft·lb) Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE ROUTING”. NOTE: Turn the handlebar to the left and right to make sure the brake hose does not touch other parts (e.g., wire harness, cables, leads).
Page 259 Yamaha T135 Service Manual CHAS FRONT BRAKE 4. Bleed: 9brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 5. Check: 9brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level.
Page 260: Front Fork
Yamaha T135 Service Manual CHAS FRONT FORK EASF0054 FRONT FORK 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 43 Nm (4.3 m•kg, 31 ft•lb )
Page 261: Removing The Front Fork Legs
Yamaha T135 Service Manual CHAS FRONT FORK EAS00649 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over.
Page 262: Disassembling The Front Fork Legs
Yamaha T135 Service Manual CHAS FRONT FORK 5. Remove: 9front fork cap bolt 1 (with a 10-mm hexagonal wrench) 6. Loosen: 9lower bracket pinch bolt 2 Before loosening the lower bracket pinch bolt, support the front fork leg. 7. Remove:...
Page 263 Yamaha T135 Service Manual CHAS FRONT FORK 4. Remove: 9damper rod assembly bolt 9copper washer NOTE: While holding the damper rod assembly with a 10 mm hexagon nut/socket wrench 1 and the T- handle 2, loosen the damper rod assembly bolt...
Page 264: Checking The Front Fork Legs
Yamaha T135 Service Manual CHAS FRONT FORK EAS00657 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: 9inner tube 1 9outer tube 2 Bends/damage/scratches → Replace. Do not attempt to straighten a bent inner tube as this may dangerously weaken it.
Page 265: Assembling The Front Fork Legs
Yamaha T135 Service Manual CHAS FRONT FORK EAS00659 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 9 9 Make sure the oil levels in both front fork legs are equal. 9 9 Uneven oil levels can result in poor han- dling and a loss of stability.
Page 266 Yamaha T135 Service Manual CHAS FRONT FORK NOTE: Tighten the damper rod assembly bolt 1 while holding the damper rod with the T-handle 2 and a 10 mm hexagon nut/socket wrench 3. T-handle 90890-01326 4. Install: 9oil seal 1 (with the fork seal driver weight 2 and fork...
Page 267: Installing The Front Fork Legs
Yamaha T135 Service Manual CHAS FRONT FORK 6. Fill: 9front fork leg (with the specified amount of the recom- mended fork oil) Quantity (each front fork leg) 0.064 L (2.26 Imp.oz, 2.16 US oz) Recommended oil Fork oil 10W or equivalent...
Page 268 Yamaha T135 Service Manual CHAS FRONT FORK 3. Install: 9front fender 10 Nm (1.0 m·kg, 7.2 ft·lb) 4. Install: 9front wheel Refer to “FRONT WHEEL AND BRAKE DISC”. 9brake hose clamp 9brake caliper assembly Refer to “FRONT BRAKE”. YamahaT135.COM 7-38...
Page 269: Handlebar
Yamaha T135 Service Manual CHAS HANDLEBAR EASF0055 HANDLEBAR 1 Rear view mirror (left and 9 Throttle cable 0 Handlebar bracket right) 2 Throttle grip 3 Throttle housing 4 Master cylinder 5 Handlebar 6 Left handlebar switch 7 Handlebar grip 8 Starter cable 23 Nm (2.3 m•kg, 17 ft•lb )
Page 270: Removing The Handlebar
Yamaha T135 Service Manual CHAS HANDLEBAR EAS00666 REMOVING THE HANDLEBAR 1.Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. 2. Remove: 9side cowlings (left and right) 9front cowling 9center panels Refer to “REMOVING THE FRONT COWL-...
Page 271 Yamaha T135 Service Manual CHAS HANDLEBAR 7. Remove: 9lever 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.
Page 272: Checking The Handlebar
Yamaha T135 Service Manual CHAS HANDLEBAR 11. Remove: 9relay 9wire harness strap 1 12. Remove: 9handlebar 1 9washers 9bushings 9handlebar bracket 2 EAS00668 CHECKING THE HANDLEBAR 1. Check: 9handlebar 1 Bends/cracks/damage → Replace. Do not attempt to straighten a bent handle- bar as this may dangerously weaken it.
Page 273 Yamaha T135 Service Manual CHAS HANDLEBAR 3. Install: 9bushings 9washers 9handlebar 23 Nm (2.3 m·kg, 17 ft·lb) 9wire harness strap Refer to “CABLE ROUTING” in chapter 2. 4. Install: 9handlebar grip MMMMMMMMMMMMMMMMMMMMMMMM a. Apply a thin coat of rubber adhesive onto the left end of the handlebar.
Page 274 Yamaha T135 Service Manual CHAS HANDLEBAR 7. Install: 9brake master cylinder 11 Nm (1.1 m·kg, 8.0 ft·lb) Refer to “FRONT BRAKE”. 8. Install: 9plastic locking ties Refer to “CABLE ROUTING” in chapter 2. 9. Adjust: 9throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”...
Page 275: Steering Head
Yamaha T135 Service Manual CHAS STEERING HEAD EASF0057 STEERING HEAD 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 1st: 30 Nm (3.0 m•kg, 22 ft•lb ) 2nd: 75 Nm (7.5 m•kg, 54 ft•lb )
Page 276: Removing The Lower Bracket
Yamaha T135 Service Manual CHAS STEERING HEAD EAS00679 REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over. 2. Remove: 9side cowlings (left and right)
Page 277 Yamaha T135 Service Manual CHAS STEERING HEAD 2. Check: 9bearings 1 9bearing races 2 Damage/pitting → Replace. 3. Replace: 9bearings 9bearing races MMMMMMMMMMMMMMMMMMMMMMMM a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer.
Page 278: Installing The Steering Head
Yamaha T135 Service Manual CHAS STEERING HEAD EAS00683 INSTALLING THE STEERING HEAD 1. Lubricate: 9upper bearing 9lower bearing 9bearing races Recommended lubricant Lithium-soap-based grease 2. Install: 9lower ring nut 9upper ring nut Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” in chapter 3.
Page 279: Rear Shock Absorber Assembly And Swingarm
Yamaha T135 Service Manual CHAS REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM 1 Rear shock absorber 2 Brake torque rod 3 Swingarm 4 Bushing 5 Swingarm pivot shaft 6 Drive chain case 46 Nm (4.6 m•kg, 33 ft•lb ) 46 Nm (4.6 m•kg, 33 ft•lb )
Page 280: Removing The Rear Shock Absorber Assemblies And Swingarm
Yamaha T135 Service Manual CHAS REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM EAS00691/EAS00702 REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 1. Stand the vehicle on a level surface. Securely support the vehicle so that there is no danger of it falling over.
Page 281 Yamaha T135 Service Manual CHAS REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM 5. Remove: 9rear shock absorber bolt (upper and lower) 9washer 9rear shock absorber nut (upper and lower) 9washers 9rear shock absorber assembly 3 6. Measure: 9swingarm side play 9swingarm vertical movement MMMMMMMMMMMMMMMMMMMMMMMM ∫...
Page 282: Checking The Rear Shock Absorber Assemblies
Yamaha T135 Service Manual CHAS REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM 7. Remove: 9swingarm pivot shaft nut 1 9washer 2 9swingarm pivot shaft 3 9swingarm 4 EAS00695 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES The following procedure applies to both rear shock absorber assemblies.
Page 283: Checking The Swingarm
Yamaha T135 Service Manual CHAS REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM EAS00707 CHECKING THE SWINGARM 1. Check: 9swingarm Bends/cracks/damage → Replace. 2. Check: 9swingarm pivot shaft Roll the pivot shaft on a flat surface. Bends → Replace. Do not attempt to straighten a bent pivot shaft.
Page 284 Yamaha T135 Service Manual CHAS REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM 2. Install: 9swingarm 9swingarm pivot shaft 9collar 9swingarm pivot shaft nut 66 Nm (6.6 m·kg, 48 ft·lb) 3. Install: 9rear shock absorber assemblies 9rear shock absorber nuts 9rear shock absorber bolts 46 Nm (4.6 m·kg, 33 ft·lb)
Page 285: Drive Chain And Sprockets
Yamaha T135 Service Manual CHAS DRIVE CHAIN AND SPROCKETS DRIVE CHAIN AND SPROCKETS 1 Rear wheel drive hub 0 Circlip 2 Driven sprocket q Drive sprocket cover 3 Lock washer 4 Collar 5 Oil seal 6 Bearing 7 Master link...
Page 286: Removing The Drive Chain And Sprockets
Yamaha T135 Service Manual CHAS DRIVE CHAIN AND SPROCKETS EAS00706 REMOVING THE DRIVE CHAIN AND SPROCKETS 1.Stand the vehicle on a level surface. 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 rear wheel is elevated.
Page 287: Checking The Drive Chain
Yamaha T135 Service Manual CHAS DRIVE CHAIN AND SPROCKETS 7. Straighten the lock washer tabs. 8. Remove: 9driven sprocket nuts 9driven sprocket bolts 9lock washers 1 9driven sprocket 2 EAS00710 CHECKING THE DRIVE CHAIN 1. Measure: 1 2 3 4 5 6 7 8 9 0 q w e r t...
Page 288: Installing The Drive Chain And Sprockets
Yamaha T135 Service Manual CHAS DRIVE CHAIN AND SPROCKETS 4. Check: 9drive chain rollers 1 Damage/wear → Replace the drive chain. 9drive chain side plates 2 Cracks/damage/wear → Replace the drive chain. 5. Lubricate: 9drive chain Recommended lubricant Engine oil or chain lubricant suitable for non-O-ring chains 6.
Page 289 Yamaha T135 Service Manual CHAS DRIVE CHAIN AND SPROCKETS 3. Install: 9drive sprocket 1 9sprocket holder 2 9Sprocket holder bolt 4. Lubricate: 9drive chain 9master link Recommended lubricant Engine oil or chain lubricant suitable for non-O-ring chains 5. Install: 9master link body 9master link plate 6.
Page 290 Yamaha T135 Service Manual CHAS YamahaT135.COM...
Page 291: Elec
CHECKING THE CONDITION OF THE BULB SOCKETS ....... 8-9 IGNITION SYSTEM ....................8-10 CIRCUIT DIAGRAM ..................8-10 TROUBLESHOOTING ..................8-11 ELECTRIC STARTING SYSTEM (T135SE) ............8-15 CIRCUIT DIAGRAM ..................8-15 TROUBLESHOOTING ..................8-16 STARTER MOTOR (T135SE) ................8-18 REMOVING THE STARTER MOTOR .............. 8-19 DISASSEMBLING THE STARTER MOTOR .............
Page 292 Yamaha T135 Service Manual ELEC YamahaT135.COM...
Page 293: Electrical System
ELECTRICAL COMPONENTS EAS00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 1 Ignition coil 7 Positive battery lead (T135S) 2 Main switch 8 Fuse 3 Rear brake light switch 9 Wire harness 4 Negative battery lead 5 Battery 6 Positive battery lead (T135SE) YamahaT135.COM...
Page 294 Yamaha T135 Service Manual ELEC ELECTRICAL COMPONENTS 1 Horn 8 Thermo sensor 2 Turn signal relay 9 C.D.I. unit 3 Starter relay (T135SE) 4 Fuel gauge 5 Rectifier/regulator 6 Fan motor relay 7 Neutral switch YamahaT135.COM...
Page 295: Checking Switch Continuity
Yamaha T135 Service Manual ELEC CHECKING SWITCH CONTINUITY EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Never insert the tester probes into the cou- pler terminal slots 1 1 .
Page 296 Yamaha T135 Service Manual ELEC CHECKING SWITCH CONTINUITY YamahaT135.COM...
Page 297: Checking The Switches
Yamaha T135 Service Manual ELEC 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.
Page 298 Yamaha T135 Service Manual ELEC 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 YamahaT135.COM...
Page 299: Checking The Bulbs And Bulb Sockets
Yamaha T135 Service Manual ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00732 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continu- ity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both.
Page 300: Checking The Condition Of The Bulbs
Yamaha T135 Service Manual ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: 9bulb Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.
Page 301: Checking The Condition Of The Bulb Sockets
Yamaha T135 Service Manual ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: 9bulb socket (for continuity) (with the pocket tester) No continuity → Replace.
Page 302: Ignition System
Yamaha T135 Service Manual ELEC IGNITION SYSTEM EAS00734 IGNITION SYSTEM CIRCUIT DIAGRAM YamahaT135.COM 8-10...
Page 303: Troubleshooting
Yamaha T135 Service Manual ELEC IGNITION SYSTEM EAS00736 EAS00739 TROUBLESHOOTING 2. Battery The ignition system fails to operate (no 9Check the condition of the battery. spark or intermittent spark). Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1.
Page 304 Yamaha T135 Service Manual ELEC IGNITION SYSTEM EAS00742 EAS00744 4. Ignition spark gap 5. Spark plug cap resistance 9Disconnect the spark plug cap from the 9Remove the spark plug cap from the spark spark plug. plug lead. 9Connect the pocket tester (“Ω × 1k” range) to 9Connect the ignition checker 1 as shown.
Page 305 Yamaha T135 Service Manual ELEC IGNITION SYSTEM EAS00746 EAS00748 6. Ignition coil resistance 7. Pickup coil resistance 9Disconnect the ignition coil connector from 9Disconnect the pickup coil coupler from the the ignition coil terminal. wire harness. 9Connect the pocket tester (Ω × 1) to the igni- 9Connect the pocket tester (Ω...
Page 306 Yamaha T135 Service Manual ELEC IGNITION SYSTEM EAS00754 9. Wiring 9Check the entire ignition system wiring. Refer to “CIRCUIT DIAGRAM”. 9Is the ignition system wiring properly con- nected and without defects? Properly connect or Replace the C.D.I. repair the ignition unit.
Page 307: Electric Starting System (T135Se)
Yamaha T135 Service Manual ELEC ELECTRIC STARTING SYSTEM (T135SE) EAS00755 ELECTRIC STARTING SYSTEM (T135SE) CIRCUIT DIAGRAM YamahaT135.COM 8-15...
Page 308: Troubleshooting
Yamaha T135 Service Manual ELEC ELECTRIC STARTING SYSTEM (T135SE) EAS00757 EAS00739 TROUBLESHOOTING 2. Battery The starter motor fails to turn. 9Check the condition of the battery. Refer to “CHECKING AND CHARGING THE Check: BATTERY” in chapter 3. 1. fuse Minimum open-circuit voltage 2.
Page 309 Yamaha T135 Service Manual ELEC ELECTRIC STARTING SYSTEM (T135SE) EAS00761 EAS00764 4. Starter relay 6. Start switch 9Remove the starter relay from the starter 9Check the start switch for continuity. relay coupler on the wire harness. Refer to “CHECKING THE SWITCHES”.
Page 310: Starter Motor (T135Se)
Yamaha T135 Service Manual ELEC STARTER MOTOR (T135SE) EASF0061 STARTER MOTOR (T135SE) 1 Starter motor yoke 2 Armature 3 Brush set 4 Starter motor lead 5 Starter motor front cover YamahaT135.COM 8-18...
Page 311: Removing The Starter Motor
Yamaha T135 Service Manual ELEC STARTER MOTOR (T135SE) REMOVING THE STARTER MOTOR 1. Remove: 9breather pipe 1 2. Remove: 9starter motor 1 3. Remove: 9starter motor lead 1 DISASSEMBLING THE STARTER MOTOR 1. Remove: 9starter motor front cover bolts (with washers)
Page 312 Yamaha T135 Service Manual ELEC STARTER MOTOR (T135SE) 2. Measure: 9commutator diameter a Out of specification → Replace the starter motor. Commutator wear limit 16.6 mm (0.65 in) 3. Measure: 9mica undercut a Out of specification → Scrape the mica to...
Page 313: Assembling The Starter Motor
Yamaha T135 Service Manual ELEC STARTER MOTOR (T135SE) 5. Measure: 9brush length a Out of specification → Replace the brush- es as a set. Brush length wear limit 3.5 mm (0.14 in) 6. Measure: 9brush spring force Out of specification → Replace the brush springs as a set.
Page 314: Charging System
Yamaha T135 Service Manual ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM YamahaT135.COM 8-22...
Page 315: Troubleshooting
Yamaha T135 Service Manual ELEC CHARGING SYSTEM EAS00774 EAS00739 TROUBLESHOOTING 2. Battery The battery cannot be charged. 9Check the condition of the battery. Refer to “CHECKING AND CHARGING THE Check: BATTERY” in chapter 3. 1. fuse Minimum open-circuit voltage 2. battery 12.8 V or more at 20 °C...
Page 316 Yamaha T135 Service Manual ELEC CHARGING SYSTEM EAS00775 EAS00776 3. Charging voltage 4. Charging coil resistance 9Connect the engine tachometer to the spark 9Disconnect the stator coil coupler from the plug lead. wire harness. 9Connect the pocket tester (Ω × 1) to the 9Connect the pocket tester (DC 20 V) to the battery as shown.
Page 317: Lighting System
Yamaha T135 Service Manual ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM YamahaT135.COM 8-25...
Page 318: Troubleshooting
Yamaha T135 Service Manual ELEC LIGHTING SYSTEM EAS00781 EAS00776 TROUBLESHOOTING 1. Lighting coil resistance Any of the following fail to light: head- 9Disconnect the stator coil coupler from the light, high beam indicator light, taillight, wire harness. auxiliary light, or meter light.
Page 319: Checking The Lighting System
Yamaha T135 Service Manual ELEC LIGHTING SYSTEM EAS00788 3. Voltage CHECKING THE LIGHTING SYSTEM 9Connect the pocket tester (AC 20 V) to the 1. The headlight and the high beam indicator headlight and high beam indicator light con- light fail to come on.
Page 320 Yamaha T135 Service Manual ELEC LIGHTING SYSTEM EAS00789 EAS00790 2. The meter light fails to come on. 3. The tail/brake light fails to come on. 1. Meter light bulb and socket 1. Tail/brake light bulb and socket 9Check the meter light bulb and socket for 9Check the tail/brake light bulb and socket for continuity.
Page 321 Yamaha T135 Service Manual ELEC LIGHTING SYSTEM 4. The auxiliary light fails to come on. 1. Meter light bulb and socket 9Check the meter light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. 9Are the meter light bulb and socket OK?
Page 322: Signaling System
Yamaha T135 Service Manual ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM YamahaT135.COM 8-30...
Page 323 Yamaha T135 Service Manual ELEC SIGNALING SYSTEM 1 Main switch 3 Fuse 4 Battery u Front brake light switch i Rear brake light switch o Turn signal relay p Horn s Horn switch f Turn signal switch g Tail/brake light...
Page 324: Troubleshooting
Yamaha T135 Service Manual ELEC SIGNALING SYSTEM EAS00794 EAS00739 TROUBLESHOOTING 2. Battery 9 9 Any of the following fail to light: turn sig- 9Check the condition of the battery. nal light, brake light or an indicator light. Refer to “CHECKING AND CHARGING THE 9 9 The horn fails to sound.
Page 325: Checking The Signaling System
Yamaha T135 Service Manual ELEC SIGNALING SYSTEM EAS00796 3. Horn CHECKING THE SIGNALING SYSTEM 9Disconnect the pink connector at the horn 1. The horn fails to sound. terminal. 1. Horn switch 9Connect a jumper lead 1 to the horn termi- nal and ground the jumper lead.
Page 326 Yamaha T135 Service Manual ELEC SIGNALING SYSTEM EAS00797 3. Voltage 2. The tail/brake light fails to come on. 9Connect the pocket tester (DC 20 V) to the 1. Tail/brake light bulb and socket tail/brake light coupler (wire harness side) as shown.
Page 327 Yamaha T135 Service Manual ELEC SIGNALING SYSTEM EAS00799 3. Voltage 3. The turn signal light, turn signal indicator 9Connect the pocket tester (DC 20 V) to the light or both fail to blink. turn signal relay coupler as shown. 1. Turn signal indicator light bulb and socket Positive tester probe →...
Page 328 Yamaha T135 Service Manual ELEC SIGNALING SYSTEM 5. Voltage 4. Voltage 9Connect the pocket tester (DC 20 V) to the 9Connect the pocket tester (DC 20 V) to the turn signal light coupler (wire harness side) turn signal relay coupler as shown.
Page 329 Yamaha T135 Service Manual ELEC SIGNALING SYSTEM EAS00801 9Set the main switch to “ON”. 4. The gear position indicator lights fail to 9Set the turn signal switch to “4” or “6”. come on. 9Measure the voltage (DC 12 V) of the chocolate 1 or dark green lead terminal 2 1.
Page 330 Yamaha T135 Service Manual ELEC SIGNALING SYSTEM EAS00804 3. Voltage 5. The fuel level gauge fails to operate. 9Connect the pocket tester (DC 20 V) to the 1. Fuel sender meter assembly coupler (wire harness side) as shown. 9Remove the fuel sender from the fuel tank.
Page 331 Yamaha T135 Service Manual ELEC SIGNALING SYSTEM 2. Voltage 3. Fuel level gauge 9Connect the pocket tester (DC 20 V) to the 9Set the main switch to “ON”. 9Move the float up 1 or down 2. meter assembly coupler (wire harness side) 9Check that the fuel level gauge needle as shown.
Page 332: Cooling System
Yamaha T135 Service Manual ELEC COOLING SYSTEM COOLING SYSTEM CIRCUIT DIAGRAM YamahaT135.COM 8-40...
Page 333: Troubleshooting
Yamaha T135 Service Manual ELEC COOLING SYSTEM TROUBLESHOOTING EAS00739 2. Battery 9The radiator fan motor fails to turn. 9Check the condition of the battery. Refer to “CHECKING AND CHARGING THE Check: BATTERY” in chapter 3. 1. fuse Minimum open-circuit voltage 2.
Page 334 Yamaha T135 Service Manual ELEC COOLING SYSTEM 4. Radiator fan motor 5. Radiator fan motor relay 9Disconnect the radiator fan motor coupler 9Disconnect the radiator fan motor relay cou- from the wireharness. pler. 9Connect the battery (12 V) as shown.
Page 335 Yamaha T135 Service Manual ELEC COOLING SYSTEM 6. Thermo sensor 9Remove the thermo sensor from the cylinder. 9Connect the digital circuit tester (Ω × 100) to the thermo switch 1 as shown. 9Immerse the thermo sensor in a container filled with coolant 2.
Page 336: Self-Diagnosis
Yamaha T135 Service Manual ELEC SELF-DIAGNOSIS SELF-DIAGNOSIS The T135SE/S features a self-diagnosing system for following circuit (-s). 1. Throttle position sensor (TPS) 2. Thermo sensor 1. ENGINE TROUBLE INDICATOR LIGHT When the main switch is turned to “ON”, the following items are monitored and the condition codes are displayed on the coolant temperature warning indicator light (irrespective of whether the engine is run- ning or not).
Page 337 Yamaha T135 Service Manual ELEC SELF-DIAGNOSIS Display order on the coolant temperature warning indicator light When one item being monitored Fault Condition code å ∫ Repetition å ∫ Repetition å ∫ Repetition 1 3 seconds å Light on ∫ Light off 2 1 second 3 1.5 seconds...
Page 338 Yamaha T135 Service Manual ELEC SELF-DIAGNOSIS TROUBLESHOOTING 1. Wire harness The coolant temperature warning indicator 9Check the wire harness for continuity. light starts to display the self-diagnosis Refer to “CIRCUIT DIAGRAM”. sequence. 9Is the wire harness OK? Check: 1. throttle position sensor 2.
Page 339 Yamaha T135 Service Manual ELEC SELF-DIAGNOSIS 2. Thermo sensor 2. Thermo sensor CIRCUIT DIAGRAM 9Check the thermo sensor. Refer to “COOLING SYSTEM”. 9Is the thermo sensor OK? B /L W/Y Y (BLACK) (BLACK) Replace the C.D.I. Replace the thermo unit.
Page 340 Yamaha T135 Service Manual ELEC YamahaT135.COM...
Page 341: Trbl Shtg
Yamaha T135 Service Manual TRBL SHTG CHAPTER 9 TROUBLESHOOTING TROUBLESHOOTING ...................9-1 ELECTRICAL SYSTEM ..................9-1 COMPRESSION SYSTEM ................9-2 INTAKE AND EXHAUST SYSTEM ..............9-3 YamahaT135.COM...
Page 342 Yamaha T135 Service Manual TRBL SHTG YamahaT135.COM...
Page 343: Troubleshooting
Yamaha T135 Service Manual TRBL TROUBLESHOOTING SHTG EASF0062 TROUBLESHOOTING TROUBLESHOOTING ELECTRICAL SYSTEM *CHECK ALL WIRES CONNECTIONS IGNITION COIL (see page 8-13) MAIN SWITCH (see page 8-5) 8 Primary or secondary windings 8 Main switch is shorted are broken or faulty...
Page 344: Compression System
Yamaha T135 Service Manual TRBL TROUBLESHOOTING SHTG COMPRESSION SYSTEM WEAR/SCRATCHES INSUFFICIENT TIGHTENING TORQUE DAMAGE INSUFFICIENT TIGHTENING TORQUE DAMAGE WEAR/SCRATCH/DAMAGE WEAR/STUCK/BROKEN DAMAGE WEAR/CARBON DEPOSITS INSUFFICIENT TIGHTENING TORQUE YamahaT135.COM...
Page 345: Intake And Exhaust System
Yamaha T135 Service Manual TRBL TROUBLESHOOTING SHTG INTAKE AND EXHAUST SYSTEM FUEL COCK 8 Clogged FUEL TANK CAP DRY TYPE 8 Clogged AIR FILTER ELEMENT FUEL HOSE 8 Dirty or clogged 8 Clogged, damaged or kinked SILENCER EXHAUST PIPE 8 Clogged...
Page 346 Yamaha T135 Service Manual TRBL SHTG YamahaT135.COM...
Page 347 Yamaha T135 Service Manual YamahaT135.COM...
Page 348 Yamaha T135 Service Manual YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN YamahaT135.COM...
Page 349 Yamaha T135 Service Manual T135SE/ T135S WIRING DIAGRAM 1 Main switch 2 Rectifier/regurator 3 Fuse B /L 4 Battery W/Y Y 5 Starter motor (BLACK) (BLACK) 6 Starter relay Br R 7 Right handlber switch 8 Start switch åT135SE 9 A.C. magneto L /W 0 C.D.I.

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T135s

Yamaha T135SE Service Manual

Table of Contents

Spec Chapter 2 Specifications

Chapter 3 Periodic Checks and Adjustments

Chapter 4 Engine

Cool Chapter 5 Cooling System

Carb Chapter 6 Carburetor

Chapter 7 Chassis

Chapter 8 Electrical System

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Yamaha T135SE