Page 1 Manual Clutch and Automatic T135SE T135S T135 SERVICE MANUAL Sniper / Jupiter MX / Spark 135 / Exciter / 135LC 5YP-F8197-E0 http://www.motorcycle.in.th...
Page 2 http://www.motorcycle.in.th...
Page 3 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. http://www.motorcycle.in.th...
Page 4 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
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. 2nd title 2 :This title appears on the upper of each page on the left of the chapter symbol.
Page 6 http://www.motorcycle.in.th...
Page 7: 1 General Information
SYMBOLS The following symbols are not relevant to every vehicle. SPEC 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 6 Carburetor 7 Chassis CARB COOL 8 Electrical system...
Page 8 http://www.motorcycle.in.th...
Page 9: Table Of Contents
EAS00011 TABLE OF CONTENTS GENERALINFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS ENGINE COOLINGSYSTEM COOL CARBURETOR CARB CHASSIS CHAS ELECTRICALSYSTEM ELEC TROUBLESHOOTING TRBL SHTG http://www.motorcycle.in.th...
Page 10 http://www.motorcycle.in.th...
Page 11: Gen Info
INFO CHAPTER 1 GENERALINFORMATION VEHICLE IDENTIFICATION ...................1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 ENGINE SERIALNUMBER................1-1 IMPORTANT INFORMATION.................1-2 PREPARATION FOR REMOVALAND DISASSEMBLY........1-2 REPLACEMENTPARTS ..................1-2 GASKETS, OILSEALS AND O-RINGS ............1-2 LOCK WASHERS/PLATES AND COTTER PINS ..........1-3 BEARINGS AND OILSEALS ................1-3 CIRCLIPS ......................1-3 CHECKING THE CONNECTIONS.................1-4 SPECIALTOOLS ....................1-5 http://www.motorcycle.in.th...
Page 12 INFO http://www.motorcycle.in.th...
Page 13: Vehicleidentification
VEHICLE IDENTIFICATION INFO EAS00014 GENERALINFORMATION VEHICLEIDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The number 1 is stamped into the center of the frame. ENGINE SERIALNUMBER The engine serial number 1 is stamped into the crankcase. NOTE: Designs and specifications are subject to change without notice.
Page 14: Important Information
IMPORTANT INFORMATION INFO EAS00020 IMPORTANT INFORMATION PREPARATION FOR REMOVALAND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to the “SPECIALTOOLS”. 3. When disassembling, always keep mated parts together.
Page 15: Lock Washers/Plates And Cotter Pins
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. 300-000 EAS00024 BEARINGS AND OILSEALS...
Page 16: Checking The Connections
CHECKING THE CONNECTIONS INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: 9 lead 9 coupler 9 connector 2. Check: 9 lead 9 coupler 9 connector Moisture → Dry with compressed air. Rust/stains →...
Page 17: Specialtools
SPECIALTOOLS INFO EAS00027 SPECIALTOOLS 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. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
Page 18 SPECIALTOOLS 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 Radiator cap tester 90890-01325 Radiator cap tester adapter...
Page 19 SPECIALTOOLS 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 SPECIALTOOLS 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. Valve guide installer (4.5 mm) 90890-04117 This tool is needed to install the valve...
Page 21: Spec
SPEC CHAPTER 2 SPECIFICATIONS GENERALSPECIFICATIONS ................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 GENERALTIGHTENING TORQUE SPECIFICATIONS ........2-17 LUBRICATION POINTS AND LUBRICANT TYPES ..........2-18 ENGINE ......................2-18 CHASSIS......................2-20 COOLING SYSTEM DIAGRAMS ................2-21 CABLE ROUTING ....................2-22 http://www.motorcycle.in.th...
Page 22 SPEC http://www.motorcycle.in.th...
Page 23: Specifications
SPEC GENERALSPECIFICATIONS SPECIFICATIONS GENERALSPECIFICATIONS 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) Minimum ground clearance 140 mm (5.51 in)
Page 24 SPEC GENERALSPECIFICATIONS 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) Wet, multiple-disc and centrifugal automatic Clutch type Transmission Primary reduction system Spur gear Primary reduction ratio 69/24 (2.875)
Page 25 SPEC GENERALSPECIFICATIONS 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 Front shock absorber Coil spring/oil damper...
Page 26: Maintenance Specifications
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 (0.002 in) Camshaft Drive Method...
Page 27 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 HdDi Head Diameter Face Width Seat Width Margin Thickness “A”...
Page 28 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) Tilt limit “*”...
Page 29 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 0.20 mm ance (0.0079 in) Outer-rotor-to-oil-pump housing 0.06 – 0.11 mm 0.15 mm clearance (0.0024 – 0.0043 in) (0.0059 in) Oil-pump-housing-to-inner-rotor-and- 0.06 – 0.11 mm 0.15 mm outer-rotor clearance (0.0024 – 0.0043 in) (0.0059 in) Model T135SE/T135S Lubrication chart http://www.motorcycle.in.th...
Page 31: Tightening Torques
SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES ENGINE Tightening Thread torque Part to be tightened Part name Q’ty Remarks size Nmm·kgft·lb Cylinder head Bolt Cylinder head (timing chain side) Bolt Cylinder head (oil check) Screw Spark plug — 1.3 9.5 Cylinder head cover Bolt Reed valve assembly Bolt...
Page 32 SPEC MAINTENANCE SPECIFICATIONS Tightening Thread torque Part to be tightened Part name Q’ty Remarks size Nmm·kgft·lb Drive sprocket Bolt Main axle bearing retainer Screw Clutch release adjusting locknut Shift pedal Bolt Shift drum segment Bolt Shift drum stopper lever Bolt Shift lever stopper screw Screw Pickup coil...
Page 33: Chassis
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) 289.4 mm (11.39 in) Installed length...
Page 34 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 (0.02 in) Drive chain Type/manufacturer 428/DAIDO...
Page 35: Tightening Torques
SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES CHASSIS Tightening torque Part to be tightened Thread size Remarks Nmm·kg ft·lb Handlebar bracket and lower bracket Handlebar and handlebar bracket Brake hose and brake master cylinder Brake hose and brake caliper Brake master cylinder and holder Brake master cylinder and brake lever Rear view mirror (left and right) Front wheel axle nut...
Page 36 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Remarks Nmm·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
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 Pickup coil resistance/color ---- C.D.I.
Page 38 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Electric starting system (T135SE) Type Constant mesh ---- Starter motor Model/manufacturer 5YP/PTMORIC ---- Operation voltage 12 V ---- Power output 0.20 kW ---- 0.032 – 0.039 Ω at 20 ° C (68 ° F)
Page 39: Conversion Table
CONVERSIONTABLE/ SPEC GENERALTIGHTENING TORQUE SPECIFICATIONS EAS00028 EAS00029 CONVERSION TABLE GENERALTIGHTENING 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
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) Valve stem guide (IN, EX) Piston pin Piston outside and ring groove Piston ring...
Page 41 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 2-19 http://www.motorcycle.in.th...
Page 42: Chassis
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 Upper brake caliper retaining bolt Lower brake caliper retaining bolt Throttle grip tube guide inner surface Brake lever pivot bolt...
Page 43: Cooling System Diagrams
SPEC COOLINGSYSTEM 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. 3 Hose clamp ∫ Band the end of the cover, before install the pro- 4 Coolant reservoir hose jection of the reservoir tank.
Page 44: Cable Routing
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. 3 Left handlebar switch lead ∫ Connect the left handlebar Brake hose, throttle cable and 4 Speedometer cable switch lead coupler in front of...
Page 45 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 the right handlebar switch lead behind the handle- bar and connect the coupler with handlebar right side, and then set the turn signal light...
Page 46 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 u Coolant reservoir hose the acceleration pump cable 4 C.D.I.
Page 47 SPEC CABLE ROUTING ˙ Install the negative lead, µ Pass through the turn signal 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 left side of the engine and inside of the neutral switch lead.
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 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 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- 4 Plate Pass through the hone lead 5 Fan motor lead arate part.
Page 51 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 SPEC CABLE ROUTING 1 Speedometer cable å Route the acceleration pump 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. ç...
Page 53 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 FRONTCOWLING ...............3-3 INSTALLING THE FRONTCOWLING ..............3-3 REMOVING THE CENTER PANELS ..............3-4 INSTALLING THE CENTER PANELS ..............3-4 REMOVING THE REAR COWLINGS ...............3-4 INSTALLING THE REAR COWLINGS ..............3-5 REMOVING THE HEADLIGHTASSEMBLY.............3-6...
Page 54 CHECKING AND ADJUSTING THE STEERING HEAD ........3-35 CHECKING THE FRONTFORK ...............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 ..............3-41 LUBRICATING THE CENTERSTAND ..............3-41 ELECTRICALSYSTEM ..................3-42 CHECKING AND CHARGING THE BATTERY..........3-42 CHECKING THE FUSE ..................3-46...
Page 55: Periodic Checks And Adjustments
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. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
Page 56 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ODOMETER READING ( ⋅ 1000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK √√√ √√ 9 Check coolant level and vehicle for coolant leakage. Cooling system 9 Change the YAMAHA GENUINE COOLANT. Every 3 years √√√√...
Page 57: Covers
COVERS EASF0004 COVERS REMOVING THE SIDE COWLINGS 1. Remove: 9 screws 9 bolts 9 side cowlings (left and right) INSTALLING THE SIDE COWLINGS For installation, reverse the removal procedure. REMOVING THE FRONT COWLING 1. Remove: 9 screws 9 front cowling 2.
Page 58: Removing The Center Panels
COVERS REMOVING THE CENTER PANELS 1. Remove: 9 screws 9 center panel (lower) 1 9 main switch cover 2 9 screws 9 center panel (upper) 3 NOTE: Remove the main switch cover by turning it in the direction of the arrow shown. 2.
Page 59: Installing The Rear Cowlings
COVERS 4. Remove: 9 screws 9 screw (with washer) 1 9 screws 9 rear cowlings (left and right) 2 INSTALLING THE REAR COWLINGS 1. Install: 9 rear cowlings (left and right) 1 9 screws 9 screw (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 Headlightassembly
COVERS REMOVING THE HEADLIGHT ASSEMBLY 1. Remove: 9 screws 9 headlight assembly 1 2. Disconnect: 9 headlight connectors 1 INSTALLING THE HEADLIGHT ASSEMBLY 1. Connect: 9 headlight connectors 1 2. Install: 9 headlight assembly 9 screws http://www.motorcycle.in.th...
Page 61: Engine
ADJUSTING THE VALVE CLEARANCE EAS00049 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: 9 Valve clearance adjustment should be made on a cold engine, at room temperature. 9 When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
Page 62 ADJUSTING THE VALVE CLEARANCE 5. Move: 9 radiator assembly To swing the radiator assembly toward the front side. 6. Remove: 9 water pump assembly 9 O-rings 7. Remove: 9 cylinder head cover 9 gasket 8. Remove: 9 timing check plug 1 (with O-ring) 9 center plug 2 (with O-ring)
Page 63: Adjusting The Valve Clearance
ADJUSTING THE VALVE CLEARANCE c on the generator c. Align the TDC mark d on the rotor with the stationary pointer crankcase cover. d. Measure the valve clearance with a thick- ness gauge 1 Out of specification → Adjust. 10. Adjust: 9 valve clearance a.
Page 64 ADJUSTING THE VALVE CLEARANCE 11. Install: 9 O-ring 9 timing check plug (with O-ring) 7 Nm (0.7 m•kg, 5.0 ft•lb) 9 center plug 7 Nm (0.7 m•kg, 5.0 ft•lb) (with O-ring) 12. Install: 9 gasket 1 9 cylinder head cover 10Nm (1.0 m•kg, 7.2 ft•lb) 13.
Page 65: Adjusting The Engine Idling Speed
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: 9 side cowlings (left and right) 9 front cowling 9 rear cowling (left) Refer to “REMOVING THESIDECOWL-...
Page 66: Adjusting The Throttle Cable Free Play
ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY 6. Adjust: 9 throttle 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) 7.
Page 67 ADJUSTING THE THROTTLE CABLE FREE PLAY 3. Adjust: 9 throttle cable free play 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: Chk Adj
CHECKING THE SPARK PLUG EAS00060 CHECKING THE SPARK PLUG 1. Remove: 9 side cowling (right) Refer to “REMOVING THE SIDE COWL- INGS”. 9 AIS resonator Be sure to remove the AIS hose, before removing the AIS resonator, otherwise to brake the AIS resonator mount. 2.
Page 69: Measuring The Compression Pressure
CHECKING THE SPARK PLUG/ MEASURING THE COMPRESSION PRESSURE 8. Install: 9 spark 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: 9 spark plug cap 10. Install: 9 AIS resonator 9 center panel (lower) Refer to “INSTALLING THE CENTER PAN-...
Page 70 MEASURING THE COMPRESSION PRESSURE 6. Install: 9 compression gauge 1 Compression gauge 90890-03081 7. Measure: 9 compression pressure → Refer to steps (c) Out of specification and (d). Compression pressure (at sea level) Minimum 490 kPa (4.9 kg/cm , 70 psi)/at 500 r/min Standard 560 kPa (5.6 kg/cm , 80 psi)/at 500 r/min...
Page 71: Checking The Engine Oillevel
MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OILLEVEL 8. Install: 9 spark plug 13 Nm (1.3 m•kg, 9.5 ft•lb) 9. Connect: 9 spark plug cap 10. Install: 9 side cowling (right) Refer to “INSTALLING THE SIDE COWL- INGS”. EAS00070 CHECKING THE ENGINE OILLEVEL 1.
Page 72: Changing The Engine Oil
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: 9 oil level plug 1 9 engine oil drain plug 2 (with O-ring) 9 spring...
Page 73: Checking The Oilfilter
CHANGING THE ENGINE OIL/ CHECKING THE EXHAUST SYSTEM CHECKING THE OILFILTER 1. Remove: 9 oil filter element cover 9 O-ring 9 oil filter element 2. Check: 9 oil filter element Dirt or clog → Replace. 3. Install: 9 oil filter element 9 O-ring 1 9 oil filter element cover 10 Nm (1.0 m•kg, 7.2 ft•lb)
Page 74: Cleaning The Air Filter Element
CLEANING THE AIR FILTER ELEMENT EAS00086 CLEANING THE AIR FILTER ELEMENT 1. Remove: 9 center panel (lower) Refer to “REMOVING THE CENTER PAN- ELS”. 2. Remove: 9 air filter case cover 1 9 air filter element 2 3. Clean: 9 air filter elements Apply compressed air to the outer surface of the air filter element.
Page 75: Adjusting The Clutch Release System
CLEANING THE AIR FILTER ELEMENT/ ADJUSTING THE CLUTCH RELEASE SYSTEM/ CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD 6. Install: 9 center panel (lower) Refer to “INSTALLING THE CENTERPAN- ELS”. EAS00086 ADJUSTING THE CLUTCH RELEASE SYSTEM 1. Adjust: 9 clutch release system a.
Page 76: Checking The Fueland Vacuum Hoses
CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD/ CHECKING THE FUELAND VACUUM HOSES 3. Install: 9 inner panel 9 rear cowlings (left and right) 9 front cowling 9 center panels (upper and lower) 9 side cowlings (left and right) Refer to “COVERS”. EAS00096 CHECKING THE FUELAND VACUUM HOSES...
Page 77: Checking The Crankcase Breather Pipe
CHECKING THE CRANKCASE BREATHER PIPE/ CHECKINGTHECOOLANTLEVEL EAS00098 CHECKING THE CRANKCASE BREATHER PIPE 1. Remove: 9 side cowlings (left and right) 9 center panels (upper and lower) 9 front cowling 9 rear cowlings (left and right) 9 inner panel Refer to “COVERS”. 2.
Page 78: Checkingthecoolingsystem
CHECKINGTHECOOLANTLEVEL/ CHECKINGTHECOOLINGSYSTEM 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. Use only distilled water. However, if dis- tilled water is not available, soft water may be used.
Page 79: Changingthecoolant
CHANGINGTHECOOLANT EAS00105 CHANGING THE COOLANT 1. Remove: 9 side cowlings (left and right) 9 front cowling Refer to “REMOVING THE SIDE COWL- INGS” and “REMOVING THE FRONT COWLING”. 2. Remove: 9 coolant reservoir tank cover 9 coolant reservoir cap 3. Disconnect: 9 coolant reservoir hose 1 4.
Page 80 CHANGINGTHECOOLANT 8. Install: 9 copper washer 9 coolant drain bolt 7 Nm (0.7 m•kg, 5.0 ft•lb) 9. Connect: 9 coolant reservoir hose 10. Fill: 9 cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze YAMAHAGENUINE COOLANT High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines...
Page 81 CHANGINGTHECOOLANT 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. Use only distilled water. However, if dis- tilled water is not available, soft water may be used.
Page 82: Chassis
ADJUSTING THE REAR BRAKE CHASSIS EAS00113 ADJUSTING THE REAR BRAKE 1. Check: 9 brake 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. Adjust: 9 brake pedal free play a.
Page 83: Checking The Frontbrake Pads
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. 2. Check: 9 front brake pad Wear indicator groove almost disap- peared →...
Page 84: Adjusting The Rear Brake Lightswitch
ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE FRONT BRAKE HOSE 2. Adjust: 9 rear brake light operation timing 1 of the rear brake a. Hold the main body light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time.
Page 85: Bleeding The Hydraulic Brake System
BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00133 BLEEDING THE HYDRAULIC BRAKE SYSTEM Bleed the hydraulic brake system whenever: the system is disassembled. a brake hose is loosened, disconnected or replaced. the brake fluid level is very low. brake operation is faulty. NOTE: 9 Be careful not to spill any brake fluid or allow the brake master cylinder reservoir to overflow.
Page 86: Adjusting The Drive Chain Slack
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. i.
Page 87 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. 2.
Page 88: Lubricating The Drive Chain
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
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 CHECKING AND ADJUSTING THE STEERING HEAD 4. Adjust: 9 steering head 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 . NOTE: Set the torque wrench at a right angle to the steering nut wrench.
Page 91: Checking The Frontfork
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: 9 inner tube Damage/scratches → Replace. 9 oil seal Oil leakage →...
Page 92: Checking The Tires
CHECKING THE TIRES EASF0015 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: 9 tire pressure Out of specification → Regulate. The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and...
Page 93 CHECKING THE TIRES 2. Check: 9 tire surfaces Damage/wear → Replace the tire. Minimum tire tread depth 0.8 mm (0.03 in) 1 Tire tread depth 2 Sidewall 3 Wear indicator Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation.
Page 94: Checking And Tightening The Spokes
CHECKING THE TIRES/ CHECKING AND TIGHTENING THE SPOKES 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. After a tire has been repaired or replaced, be sure to tighten the tire air valve stem locknut...
Page 95: Checking And Lubricating The Cables
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: Electricalsystem
CHECKING AND CHARGING THE BATTERY EAS00176 ELECTRICALSYSTEM 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 measures: Wear protective eye gear when handling or working near batteries.
Page 97 CHECKING AND CHARGING THE BATTERY 3. Disconnect: 9 battery leads (from the battery terminals) First, disconnect the negative battery lead 1 , and then the positive battery lead 2 . 4. Disconnect: 9 battery breather hose 5. Remove: 9 battery 6.
Page 98 CHECKING AND CHARGING THE BATTERY Loosen the battery sealing caps. Make sure the battery breather hose and battery vent are free of obstructions. To ensure maximum performance, always charge a new battery before using it. Do not use a high-rate battery charger. They force a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage.
Page 99 CHECKING AND CHARGING THE BATTERY 9 warpage or buckling of the battery plates or insulators is evident. 9. Check: 9 battery breather hose and battery vent Obstruction → Clean. Damage → Replace. 10. Install: 9 battery 11. Connect: 9 battery breather hose 1 When checking the battery, make sure the battery breather hose is properly installed and routed correctly.
Page 100: Checking The Fuse
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: 9 fuse holder 1 3. Check: 9 fuse a.
Page 101: Replacing The Headlightbulbs
REPLACING THE HEADLIGHT BULBS EAS00183 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Remove: 9 headlight assembly Refer to “REMOVING THE HEADLIGHT ASSEMBLY”. 2. Remove: 9 headlight bulb holder 1 3. Remove: 9 headlight bulb Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.
Page 102: Adjusting The Headlightbeam
ADJUSTING THE HEADLIGHT BEAM EAS00186 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: 9 headlight beam (vertically) 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
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 SHIFTPEDAL....................4-2 SIDE COWLING BRACKET................4-3 WIRE, CABLE AND HOSE ................4-3 ENGINE ASSEMBLY..................4-4 INSTALLING THE ENGINE ...................4-5 ENGINE ASSEMBLY..................4-5 WIRE, CABLE AND HOSE ................4-6 SIDE COWLING BRACKET................4-6 SHIFTPEDAL....................4-6 BRAKE PEDAL....................4-6...
Page 104 CHECKING THE PISTON PIN ................4-35 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 OILPUMP......................4-44...
Page 105 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 ..............4-73 INSTALLING THE KICKSTARTER ..............4-74 TRANSMISSION ....................4-76 REMOVING THE TRANSMISSION ..............4-77 DISASSEMBLING THE TRANSMISSION ............4-77 CHECKING THE SHIFTFORKS ..............4-78 CHECKING THE SHIFTDRUM ASSEMBLY............4-79...
Page 106 http://www.motorcycle.in.th...
Page 107: Removing The Engine
REMOVING THE ENGINE EASF0018 ENGINE REMOVING THE ENGINE NOTE: It is not necessary to remove the engine in order to remove the following components. 9 Cylinder head 9 Cylinder 9 Piston 9 Clutch 9 Shift shaft 9 Oil pump 9 Generator 9 Starter clutch 1.
Page 108: Footrest
REMOVING THE ENGINE FOOTREST 1. Remove: 9 footrest bolts 1 9 footrest MUFFLER 1. Remove: 9 exhaust pipe nuts 1 9 exhaust pipe 2 2. Remove: 9 lower muffler bolt 1 9 washer 9 upper muffler bolt 2 9 washers 9 nut 9 muffler 3 BRAKE PEDAL...
Page 109: Side Cowling Bracket
9 neutral switch lead coupler 1 9 stator coil lead coupler 2 9 pick up coil lead coupler 3 9 crankcase breather pipe 2. Remove: 9 starter motor lead coupler (T135SE) 3. Remove: 9 spark plug cap 4. Remove: 9 fuel cock vacuum hose 1...
Page 110: Engine Assembly
REMOVING THE ENGINE 5. Remove: 9 crankcase breather pipe 1 ENGINE ASSEMBLY 1. Loosen: 9 rear lower mounting nut 1 9 plate nuts (front and rear) 2 9 front mounting nut 3 9 rear upper mounting nut 4 9 pivot shaft nut 5 2.
Page 111: Installing The Engine
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: 9 engine assembly 9 pivot shaft 1 9 washer 9 pivot shaft nut 9 rear upper mounting bolt 2 9 washer 9 rear upper mounting nut...
Page 112: Wire, Cable And Hose
INSTALLING THE ENGINE WIRE, CABLE AND HOSE 1. Connect: 9 starter motor lead coupler (T135SE) 9 neutral switch lead coupler 9 pickup coil lead coupler 9 stator coil lead coupler 2. Install: 9 crankcase breather pipe 9 fuel cock vacuum hose...
Page 113: Footrest
INSTALLING THE ENGINE FOOTREST 1. Install: 9 footrest 9 footrest bolts 1 23 Nm (2.3 m·kg, 17 ft•lb) CARBURETOR 1. Install: 9 carburetor assembly Refer to “CARBURETOR” in chapter 6. 2. Adjust: 9 throttle cable free play 9 rear brake light operation timing Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”...
Page 114: Cylinder Head
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 ) 10 Nm (1.0 m•kg, 7.2 ft•lb ) 10 Nm (1.0 m•kg, 7.2 ft•lb ) 10 Nm (1.0 m•kg, 7.2 ft•lb )
Page 115: Removing The Cylinder Head
CYLINDER HEAD EAS00222 REMOVING THE CYLINDER HEAD 1. Remove 9 side cowlings (left and right) 9 front cowling 9 center panels (upper and lower) 9 rear cowlings (left and right) Refer to “COVERS” in chapter 3. 9 carburetor assembly Refer to “CARBURETOR” in chapter 6. 9 muffler Refer to “REMOVING THE ENGINE”.
Page 116 CYLINDER HEAD 6. Align: 9 “I” mark a on the generator rotor (with the stationary pointer on the crankcase) a. Turn the crankshaft counterclockwise. b. When the piston is at TDC on the compres- c on the sion stroke, align the “I” mark camshaft sprocket with the stationary point- er d on the cylinder head.
Page 117: Checking The Cylinder Head
CYLINDER HEAD 10. Remove: 9 engine mount nut 9 washer 9 engine mount bolt 9 cylinder head bolts 9 cylinder head bolts 9 washers 9 cylinder head NOTE: 9 Loosen the nuts in the proper sequence as shown. 9 Loosen 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
CYLINDER HEAD 3. Measure: 9 cylinder head warpage Out of specification → Resurface the cylin- der head. Maximum cylinder head warpage 0.03 mm (0.0012 in) 1 and a thickness a. Place a straightedge gauge 2 across the cylinder head. b. Measure the warpage. c.
Page 119: Checking The Timing Chain Tensioner
CYLINDER HEAD EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1. Check: 9 timing chain tensioner Cracks/damage → Replace. a. While lightly pressing the timing chain ten- sioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1 . b.
Page 120 CYLINDER HEAD 3. Tighten: 9 cylinder head bolts 22 Nm (2.2 m·kg, 16 ft•lb) 9 cylinder head bolts 10 Nm (1.0 m•kg, 7.2 ft•lb) 9 engine mount nut 72 Nm (7.2 m•kg, 52 ft•lb) NOTE: 9 Lubricate the cylinder head bolts with engine oil.
Page 121 CYLINDER HEAD 5. Install: 9 timing chain tensioner a. While lightly pressing the timing chain ten- sioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1 . NOTE: Make sure that the tensioner rod has been fully set clockwise.
Page 122 CYLINDER HEAD 8. Check: 9 “I”mark a Align the “I” mark on the generator rotor with the stationary pointer 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
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 ) 4-17 http://www.motorcycle.in.th...
Page 124: Removing The Rocker Arms And Camshaft
CAMSHAFT EASF0022 REMOVING THE ROCKER ARMS AND CAMSHAFT NOTE: Prior to remove the rocker arms and camshaft, remove the cylinder head. 1. Loosen: 9 locknuts 1 9 adjusting screws 2 2. Remove: 9 camshaft retainer 1 3. Remove: 9 camshaft 1 NOTE: Screw an 8 mm bolt 2 into the threaded end of the camshaft and then pull out the camshaft.
Page 125: Checking The Camshaft
CAMSHAFT EAS00205 CHECKING THE CAMSHAFT 1. Check: 9 camshaft lobes Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: 9 camshaft lobe dimensions a and b → Out of specification Replace the camshaft. Camshaft lobe dimension limit Intake 29.613 mm (1.1659 in) 25.043 mm (0.9859 in) Exhaust 29.912 mm (1.1776 in)
Page 126 CAMSHAFT 2. Check: 9 rocker arm shaft Blue discoloration/excessive wear/pitting/ scratches → Replace or check the lubrica- tion system. 3. Measure: 9 rocker arm inside diameter Out of specification → Replace. Rocker arm inside diameter 9.985 – 10.000 mm (0.3931 – 0.3937 in) <Limit>: 9.950 mm (0.3917 in) 4.
Page 127: Checking The Camshaftsprocket
CAMSHAFT EAS00207 CHECKING THE CAMSHAFT SPROCKET 1. Check: 9 camshaft 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 2 Camshaft sprocket EAS00219 INSTALLING THE CAMSHAFT AND ROCKER ARMS...
Page 128: Valves And Valve Springs
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 4-22 http://www.motorcycle.in.th...
Page 129: Removing The Valves
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 seats), make sure the valves properly seal.
Page 130: Checking The Valves And Valve Guides
VALVES AND VALVE SPRINGS 2. Remove: 9 valve 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: 9 upper spring seat 1 9 valve spring 2 9 valve stem seal 3 9 lower spring seat 4...
Page 131 CYLINDER HEAD 5. Install: 9 timing chain tensioner a. While lightly pressing the timing chain ten- sioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1 . NOTE: Make sure that the tensioner rod has been fully set clockwise.
Page 132 CYLINDER HEAD 8. Check: 9 “I”mark a Align the “I” mark on the generator rotor with the stationary pointer 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 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 ) 4-17 http://www.motorcycle.in.th...
Page 134 CAMSHAFT EASF0022 REMOVING THE ROCKER ARMS AND CAMSHAFT NOTE: Prior to remove the rocker arms and camshaft, remove the cylinder head. 1. Loosen: 9 locknuts 1 9 adjusting screws 2 2. Remove: 9 camshaft retainer 1 3. Remove: 9 camshaft 1 NOTE: Screw an 8 mm bolt 2 into the threaded end of the camshaft and then pull out the camshaft.
Page 135 CAMSHAFT EAS00205 CHECKING THE CAMSHAFT 1. Check: 9 camshaft lobes Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: 9 camshaft lobe dimensions a and b → Out of specification Replace the camshaft. Camshaft lobe dimension limit Intake 29.613 mm (1.1659 in) 25.043 mm (0.9859 in) Exhaust 29.912 mm (1.1776 in)
Page 136 CAMSHAFT 2. Check: 9 rocker arm shaft Blue discoloration/excessive wear/pitting/ scratches → Replace or check the lubrica- tion system. 3. Measure: 9 rocker arm inside diameter Out of specification → Replace. Rocker arm inside diameter 9.985 – 10.000 mm (0.3931 – 0.3937 in) <Limit>: 9.950 mm (0.3917 in) 4.
Page 137 CAMSHAFT EAS00207 CHECKING THE CAMSHAFT SPROCKET 1. Check: 9 camshaft 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 2 Camshaft sprocket EAS00219 INSTALLING THE CAMSHAFT AND ROCKER ARMS...
Page 138 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 4-22 http://www.motorcycle.in.th...
Page 139 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 seats), make sure the valves properly seal.
Page 140 VALVES AND VALVE SPRINGS 2. Remove: 9 valve 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: 9 upper spring seat 1 9 valve spring 2 9 valve stem seal 3 9 lower spring seat 4...
Page 141 VALVES AND VALVE SPRINGS 2. Replace: 9 valve 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. a. Remove the valve guide with the valve guide remover 1 .
Page 142: Checking The Valve Seats
VALVES AND VALVE SPRINGS 6. Measure: 9 valve stem runout Out of specification → Replace the valve. NOTE: 9 When installing a new valve, always replace the valve guide. 9 If the valve is removed or replaced, always replace the valve stem seal. Valve stem runout limit 0.01 mm (0.0004 in) EAS00240...
Page 143 VALVES AND VALVE SPRINGS NOTE: Where the valve seat and valve face contacted one another, the blueing will have been removed. 4. Lap: 9 valve face 9 valve 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
VALVES AND VALVE SPRINGS c again. If j. Measure the valve seat width the valve seat width is out of specification, reface and lap the valve seat. EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs.
Page 145: Installing The Valves
VALVES AND VALVE SPRINGS EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: 9 valve stem end (with an oil stone) 2. Lubricate: 9 valve stem 1 9 valve stem seal 2 (with the recommended lubricant) Recommended lubricant Molybudemium oil...
Page 146 VALVES AND VALVE SPRINGS 4. Install: 9 valve 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
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 4-31 http://www.motorcycle.in.th...
Page 148: Removing The Cylinder And Piston
CYLINDER AND PISTON EASF0028 REMOVING THE CYLINDER AND PISTON NOTE: Prior to removing the cylinder and piston, remove the cylinder head. 1. Remove: 9 cylinder 1 2. Remove: 9 dowel pins 1 9 gasket 2 3. Remove: 9 piston pin clip 1 9 piston pin 2 9 piston 3 Do not use a hammer to drive the piston pin...
Page 149: Checking The Cylinder And Piston
CYLINDER AND PISTON EAS00255 CHECKING THE CYLINDER AND PISTON 1. Check: 9 piston surface 9 cylinder wall Vertical scratches → Replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: 9 piston-to-cylinder clearance a. Measure cylinder bore “C” with the cylinder bore gauge.
Page 150: Checking The Piston Rings
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
CYLINDER AND PISTON 3. Measure: 9 piston 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. Piston ring end gap Top ring 0.10 –...
Page 152: Installing The Piston And Cylinder
CYLINDER AND PISTON 4. Calculate: 9 piston-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 – Piston pin outside diameter Piston-pin-to-piston-pin-bore clear- ance 0.002 – 0.018 mm (0.0001 –...
Page 153 CYLINDER AND PISTON 3. Install: 9 gasket 1 9 dowel pins 2 4. Lubricate: 9 piston 9 piston rings 9 cylinder (with the recommended lubricant) NOTE: Be sure to apply enough engine oil onto them. Recommended lubricant Engine oil 5. Offset: 9 piston ring end gaps a Top ring b Lower oil ring rail...
Page 154: Generator And Starter Clutch
6 Woodruff key e Dowel pin 7 Generator rotor r Crankcase cover (left) T135SE 14 Nm (1.4 m•kg, 20 ft•lb ) 14 Nm (1.4 m•kg, 20 ft•lb ) 70 Nm (7.0 m•kg, 50 ft•lb ) 10 Nm (1.0 m•kg, 7.2 ft•lb )
Page 155: Removing The Generator
GENERATOR AND STARTER CLUTCH EAS00346 REMOVING THE GENERATOR 1. Drain: 9 engine oil (completely from the crankcase) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 2. Remove: 9 side cowling (left) Refer to “REMOVING THE SIDE COWL- INGS” in chapter 3. 9 shift pedal 9 drive sprocket cover Refer to “REMOVING THE DRIVE CHAIN...
Page 156: Removing The Starter Clutch (T135Se)
(with the flywheel puller 2 ) 9 woodruff key Flywheel puller 90890-01362 EAS00344 REMOVING THE STARTER CLUTCH (T135SE) 1. Remove: 9 starter clutch idle gear shaft 1 9 starter clutch idle gear 2 9 starter clutch gear 3 9 washer 2.
Page 157: Checking The Starter Clutch (T135Se)
GENERATOR AND STARTER CLUTCH EAS00351 CHECKING THE STARTER CLUTCH (T135SE) 1. Check: 9 starter clutch rollers 1 Damage/wear → Replace. 2. Check: 9 starter clutch idle gear 1 9 starter clutch gear 2 Burrs/chips/roughness/wear → Replace the defective part(s). 3. Check: 9 starter clutch gear contacting surfaces a Damage/pitting/wear →...
Page 158: Installing The Starter Clutch (T135Se)
GENERATOR AND STARTER CLUTCH EAS00355 INSTALLING THE STARTER CLUTCH (T135SE) 1. Install: 9 starter clutch 1 14 Nm (1.4 m•kg, 10 ft•lb) NOTE: 9 While holding the generator rotor 2 with the sheave holder, tighten the starter clutch bolt. 9 Do not allow the sheave holder to touch the projection on the generator rotor.
Page 159 GENERATOR AND STARTER CLUTCH 3. Apply: 9 sealant (on to the generator lead grommet) Yamaha bond No. 1215 90890-85505 4. Apply: 9 sealant NOTE: Be sure to apply the sealant onto the crankcase cover bolt thread as shown one. Yamaha bond No. 1215 90890-85505 5.
Page 160: Oilpump
OILPUMP EASF0035 OILPUMP 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 ) 10 Nm (1.0 m•kg, 7.2 ft•lb ) 32 Nm (3.2 m•kg, 23 ft•lb ) 4-44...
Page 161: Removing The Oilpump
OILPUMP REMOVING THE OILPUMP 1. Drain: 9 engine oil (completely from the crankcase) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 2. Remove: 9 generator Refer to “GENERATOR AND STARTER CLUTCH”. 3. Remove: 9 clutch release shift arm 4. Remove: 9 gear cover 5.
Page 162: Checking The Oilpump
OILPUMP EAS00364 CHECKING THE OILPUMP 1. Check: 9 oil pump driven gear 1 9 oil pump housing 2 9 outer rotor 9 inner rotor Cracks/damage/wear → Replace the defec- tive part(s). 2. Measure: 9 inner-rotor-to-outer-rotor-tip clearance a 9 outer-rotor-to-oil-pump-housing clearance 9 oil-pump-housing-to-inner-rotor-and-outer- rotor clearance c →...
Page 163: Assembling The Oilpump
OILPUMP EAS00375 ASSEMBLING THE OILPUMP 1. Lubricate: 9 inner rotor 9 outer rotor 9 oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: 9 oil pump shaft (to the oil pump housing) 9 inner rotor 1 9 outer rotor 9 pin 2 9 oil pump housing cover 3...
Page 164: Installing The Oilpump
OILPUMP EAS00376 INSTALLING THE OILPUMP 1. Install: 9 gasket 1 9 oil 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
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 Clutch shoe housing 4 Friction plate #1 w Clutch housing o Cage 5 Clutch plate...
Page 166: Removing The Clutch
CLUTCH EAS00277 REMOVING THE CLUTCH 1. Drain: 9 engine oil (completely from the crankcase) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 2. Remove: 9 side cowlings (left and right) Refer to “REMOVING THE SIDE COWL- INGS” in chapter 3. 9 muffler 9 footrest 9 brake pedal...
Page 167 CLUTCH 7. Straighten the lock washer tab. 8. Loosen: 9 clutch 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. Remove: 9 clutch boss nut 1 9 lock washer 2 9 clutch boss 3...
Page 168: Checking The Friction Plates
CLUTCH 11. Remove: 9 collar 1 9 clutch shoe housing 2 9 washer 3 9 rollers 4 9 cage springs 5 9 cage 6 9 clutch shoe housing boss 7 9 clutch shoe 8 EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric- tion plates.
Page 169: Checking The Clutch Springs
CLUTCH EAS00282 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1. Check: 9 clutch spring Damage → Replace the clutch springs as a set. 2. Measure: 9 clutch spring free length a Out of specification → Replace the clutch springs as a set.
Page 170: Checking The Clutch Pressure Plate
CLUTCH EAS00286 CHECKING THE CLUTCH PRESSURE PLATE 1. Check: 9 clutch pressure plate Cracks/damage → Replace. EAS00288 CHECKING THE CLUTCH PUSH RODS 1. Check: 9 clutch push rod #1 Cracks/damage/wear → Replace the clutch push rod #1. 9 clutch push rod #2 Cracks/damage/wear →...
Page 171: Checking The Clutch Shoe Housing
CLUTCH CHECKING THE CLUTCH SHOE HOUSING 1. Check: 9 clutch shoe housing Damage/wear → Replace. 2. Measure: 9 clutch 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) CHECKING THE CLUTCH SHOE 1.
Page 172: Checking The Clutch Release Shiftarm
CLUTCH CHECKING THE CLUTCH RELEASE SHIFT ARM 1. Check: 9 clutch release shift arm 1 Damage/wear → Replace. 9 clutch release adjusting screw 2 Damage/wear → Replace. EAS00293 INSTALLING THE CLUTCH 1. Install: 9 washer 9 cage 1 9 cage springs 2 9 rollers 3 9 clutch shoe housing boss 4 NOTE:...
Page 173 CLUTCH 4. Tighten: 9 clutch 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. Bend the lock washer tab along a flat side of the nut.
Page 174: Shift Shaft
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 5 Shift guide w Shift lever assembly 6 Pawl holder e Stopper lever spring 7 Guide...
Page 175: Removing The Shiftshaft
SHIFT SHAFT REMOVING THE SHIFT SHAFT 1. Drain: 9 engine oil (completely from the crankcase) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 2. Remove: 9 clutch Refer to “CLUTCH”. 3. Remove: 9 shift pedal 9 crankcase cover bolts 9 crankcase cover (left) 4.
Page 176 SHIFT SHAFT 7. Remove: 9 shift shaft assembly 1 9 shift lever assembly 2 8. Remove: 9 stopper lever assembly 3 9 stopper lever spring 4 9 collar 9. Remove: 9 stopper lever spring 1 9 stopper lever 2 9 collar 3 10.
Page 177: Checking The Shiftshaft
SHIFT SHAFT EAS00328 CHECKING THE SHIFT SHAFT 1. Check: 9 shift shaft 1 9 shift lever 2 Bends/damage/wear → Replace. 9 springs Damage/wear → Replace. EAS00330 CHECKING THE STOPPER LEVER 1. Check: 9 stopper lever 1 Bends/damage → Replace. Roller turns roughly → Replace. 9 stopper lever spring Damage/wear →...
Page 178: Installing The Shiftshaft
SHIFT SHAFT EAS00331 INSTALLING THE SHIFT SHAFT 1. Install: 9 shift drum segment 1 9 plate 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: 9 collar 9 stopper lever 1 9 stopper lever spring 2 NOTE:...
Page 179: Crankcase And Crankshaft
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 ) 10 Nm (1.0 m•kg, 7.2 ft•lb ) 4-63 http://www.motorcycle.in.th...
Page 180: Disassembling The Crankcase
1. Remove: 9 engine Refer to “REMOVING THE ENGINE”. 2. Remove: 9 starter motor lead (T135SE) 9 starter motor (T135SE) Refer to “STARTER MOTOR (T135SE)” in chapter 8. 3. Remove: 9 cylinder head Refer to “CYLINDER HEAD”. 9 cylinder 9 piston Refer to “CYLINDER AND PISTON”.
Page 181: Checking The Crankshaftand Connecting Rod
CRANKCASE AND CRANKSHAFT 5. Remove: 9 crankcase 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: 9 right crankcase 9 dowel pins Tap on one side of the crankcase with a soft- face hammer.
Page 182 CRANKCASE AND CRANKSHAFT 2. Measure: 9 big 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: 9 crankshaft width Out of specification → Replace the crank- shaft.
Page 183: Checking The Crankcase
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: 9 crankcase Cracks/damage → Replace. 9 oil delivery passages Obstructions → Blow out with compressed air.
Page 184: Installing The Crankshaft
CRANKCASE AND CRANKSHAFT EAS00408 INSTALLING THE CRANKSHAFT 1. Install: 9 crankshaft assembly 1 NOTE: Use the crankshaft installing tool (spacer installer pot 3 , installer bolt 4 , adaptor 5 ) to install the crankcase (left). To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease and each bearing with engine oil.
Page 185 CRANKCASE AND CRANKSHAFT 4. Install: 9 neutral switch 4 Nm (0.4 m•kg, 3.0 ft•lb) 9 crankcase bolts 10 Nm (1.0 m•kg, 7.2 ft•lb) 5. Apply: 9 engine oil (onto the crankshaft bearings and oil deliv- ery holes) 6. Check: 9 crankshaft and transmission operation Rough movement →...
Page 186: Kickstarter
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 ) 12 Nm (1.2 m•kg, 9.0 ft•lb ) 4-70...
Page 187: Removing The Kickstarter
KICKSTARTER REMOVING THE KICKSTARTER 1. Drain: 9 engine oil (completely from the crankcase) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 9 coolant (completely from the water jacket) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Remove: 9 side cowlings (left and right) 9 front cowling 9 center panels (upper and lower) 9 rear cowlings (left and right)
Page 188 Refer to “SOILPUMP”. 9 generator 9 starter clutch Refer to “GENERATOR AND STARTER CLUTCH. 7. Remove: 9 starter motor (T135SE) Refer to “STARTER MOTOR” in chapter 8. 8. Remove: 9 engine Refer to “REMOVING THE ENGINE”. 9. Separate: 9 crankcase Refer to “CRANKCASE”.
Page 189: Checking The Kickstarter
KICKSTARTER 11. Remove: 9 washer 1 9 kickstarter gear 2 9 kickstarter spring 3 9 collar 4 9 washer 5 9 spring 6 9 kickstarter ratchet gear 7 9 kickstarter shaft EAS00339 CHECKING THE KICKSTARTER 1. Check: 9 kickstarter ratchet gear 1 9 kickstarter gear 2 Damage/wear →...
Page 190: Installing The Kickstarter
Refer to “CRANKCASE”. 4. Install: 9 engine Refer to “REMOVING THE ENGINE”. 5. Install: 9 starter motor (T135SE) Refer to “STARTER MOTOR (T135SE)” in chapter 8. 6. Install: 9 oil pump assembly Refer to “OILPUMP”. 9 generator Refer to “GENERATOR AND STARTER CLUTCH”.
Page 191 KICKSTARTER 9. Install: 9 piston 9 cylinder Refer to “CYLINDER AND PISTON”. 9 cylinder head Refer to “CYLINDER HEAD”. 9 radiator assembly Refer to “RADIATOR” in chapter 5. 9 cylinder head Refer to “CYLINDER HEAD”. 10. Install: 9 muffler 9 footrest 9 brake pedal Refer to “REMOVING THE ENGINE”.
Page 192: Transmission
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 e Side plate spring 6 3rd pinion gear r Side plate 7 4th pinion gear...
Page 193: Removing The Transmission
TRANSMISSION EASF0042 REMOVING THE TRANSMISSION NOTE: Prior to removing the transmission, separate the crankcase. 1. Remove: 9 shift fork guide bar 1 9 shift fork guide bar springs 9 shift fork “R” 2 9 shift fork “L” 3 9 shift drum 4 NOTE: Note the position of each part.
Page 194: Checking The Shiftforks
TRANSMISSION 2. Remove: 9 circlips 1 9 washers 2 9 1st wheel gear 3 9 4th wheel gear 4 9 3rd wheel gear 5 9 side plate 6 9 side plate spring 7 9 2nd wheel gear 8 9 drive axle 9 EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to both of the...
Page 195: Checking The Shiftdrum Assembly
TRANSMISSION EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: 9 shift drum grooves 1 Damage/scratches/wear → Replace the shift drum assembly. 9 shift drum bearing Damage/pitting → Replace the shift drum assembly. EAS00424 CHECKING THE TRANSMISSION 1. Measure: 9 main axle runout (with a centring device and dial gauge 1 ) →...
Page 196: Installing The Transmission
TRANSMISSION 4. Check: 9 transmission 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 1 onto the drive axle 2 as 2nd wheel gear shown.
Page 197 TRANSMISSION 2. Check: 9 transmission 9 shift drum 9 shift forks Rough movement → Repair. NOTE: 9 Oil each gear, shaft, and bearing thoroughly. 9 Before assembling the crankcase, be sure that the transmission is in neutral and that the gears turn freely.
Page 198 http://www.motorcycle.in.th...
Page 199: Cool
COOL CHAPTER 5 COOLINGSYSTEM 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..............5-8 INSTALLING THE THERMOSTAT..............5-8 INSTALLING THE WATER PUMP..............5-9 INSTALLING THE RADIATOR ................5-9 http://www.motorcycle.in.th...
Page 200 COOL http://www.motorcycle.in.th...
Page 201: Radiator
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 ) 10 Nm (1.0 m•kg, 7.2 ft•lb ) 10 Nm (1.0 m•kg, 7.2 ft•lb )
Page 202: Water Pump
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 ) 10 Nm (1.0 m•kg, 7.2 ft•lb ) http://www.motorcycle.in.th...
Page 203: Removing The Radiator
COOL COOLING SYSTEM REMOVING THE RADIATOR Ahot 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 engine has cooled, open the radiator cap as fol- lows: Place a thick rag or a towel over the radi- ator cap and slowly turn the radiator cap coun- terclockwise toward the detent to allow any...
Page 204: Checking The Radiator
COOL COOLINGSYSTEM 5. Remove: 9 bracket 9 thermostat cover 1 9 thermostat 2 6. Remove: 9 fan motor EAS00455 CHECKING THE RADIATOR 1. Check: 9 radiator fins Obstruction → Clean. Apply compressed air to the rear of the radi- ator. Damage →...
Page 205 COOL COOLING SYSTEM 3. Measure: 9 radiator 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) a. Install the radiator cap tester 1 and radiator cap tester adapter 2 to the radiator cap 3 .
Page 206: Checking The Thermostat
COOL COOLINGSYSTEM EAS00462 CHECKING THE THERMOSTAT 1. Check: 9 thermostat 1 Does not open at 80.5 – 83.5° C (176.9 – 182.3° F) → Replace. a. Suspend the thermostat in a container filled with water. b. Slowly heat the water. c.
Page 207: Checking The Water Pump
COOL COOLING SYSTEM 2. Remove: 9 plate NOTE: Slide the plate as shown, and then remove the plate from the water pump housing. 3. Remove: 9 impeller 1 9 bearing 2 NOTE: Remove the bearing from the outside of the water pump housing.
Page 208: Assembling The Water Pump
COOL COOLINGSYSTEM EAS00475 ASSEMBLING THE WATER PUMP 1. Install: 9 water pump seal 1 NOTE: Install the water pump seal with the special tools. Mechanical seal installer 90890-04145 Middle driven shaft bearing driver 90890-04058 å Push down. 2. Lubricate: 9 water pump seal 1 Recommended lubricant Lithium soap base grease 3.
Page 209: Installing The Water Pump
COOL COOLING SYSTEM EAS00478 INSTALLING THE WATER PUMP 1. Install: 9 O-rings 9 water pump housing 1 10 Nm (1.0 m•kg, 7.2 ft•lb) Always use a new O-ring. NOTE: 9 Align the projection a on the impeller shaft with the slit b on the camshaft. 9 Lubricate the O-ring with a thin coat of lithium- soap-based grease.
Page 210 COOL COOLINGSYSTEM 4. Check: 9 cooling system Leaks → Repair or replace any faulty part. a. Attach the radiator cap tester 1 to the radi- ator. Radiator cap tester 90890-01325 Radiator cap tester adapter 90890-01352 b. Apply 100 kPa (1.0 kg/cm , 14.22 psi) of pressure.
Page 211: Carb
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 FUELCOCK OPERATION............6-13 AIR INDUCTION SYSTEM..................6-14 AIR INJECTION....................6-14 AIR CUT-OFF VALVE..................6-14 AIR INDUCTION SYSTEM DIAGRAMS............6-15 REMOVING THE AIR INDUCTION SYSTEM............6-16 CHECKING THE AIR INDUCTION SYSTEM............6-16 INSTALLING THE AIR INDUCTION SYSTEM..........6-16...
Page 212 CARB http://www.motorcycle.in.th...
Page 213: Carburetor
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 5 Throttle valve y Carburetor overflow hose 6 Throttle stop screw set u Throttle position sensor 7 Pilot air screw set...
Page 214: Removing The Carburetor
Gasoline is highly flammable. Avoid spilling fuel on the hot engine. 1. Remove: 9 battery 9 seat assembly with battery box 2. Remove: 9 starter relay 1 (T135SE) 3. Remove: 9 positive lead 1 (from the battery box) 4. Remove: 9 negative lead (from the frame) 5.
Page 215 CARB CARBURETOR 6. Loosen: 9 fuel drain screw 1 7. Drain: 9 fuel (from float chamber) 8. Loosen: 9 clamp screw 9 air filter assembly bolt 9. Remove: 9 carburetor top cover 1 9 o-ring 9 choke cable 2 9 accelerator pump cable 3 10.
Page 216 CARB CARBURETOR 12. Remove: 9 carburetor assembly NOTE: Use the ball point hexagon wrench to loosen the bolts. 13. Disconnect: 9 fuel hose 1 9 carburetor overflow hose 2 9 vacuum sensing hose 3 9 air vent hose 4 9 vacuum sensing hose 5 14.
Page 217: Disassembling The Carburetor
CARB CARBURETOR DISASSEMBLING THE CARBURETOR NOTE: The following parts can be cleaned and inspect- ed without disassembly. 9 Coasting enricher 9 Throttle stop screw 9 Pilot air screw 1. Remove: 9 coasting enricher assembly 9 o-ring 2. Remove: 9 pilot air screw set 1 3.
Page 218: Checking The Carburetor
CARB CARBURETOR 5. Remove: 9 main jet 1 9 needle jet 2 9 pilot jet 3 6. Remove: 9 float pivot pin 1 9 float 2 9 needle valve 3 EAS00485 CHECKING THE CARBURETOR 1. Check: 9 carburetor body 9 float chamber Cracks/damage →...
Page 219 CARB CARBURETOR 5. Check: 9 float Damage → Replace. 6. Check: 9 needle valve Damage/wear → Replace. 7. Check: 9 coasting enricher assembly 1 Cracks/damage → Replace. 8. Check: 9 jet needle 1 9 needle jet 2 9 main jet 3 9 pilot jet 4 9 pilot air screw 5 9 throttle stop screw 6...
Page 220 CARB CARBURETOR 10. Check: 9 accelerator pump → Replace stuck or unsmooth operation the float chamber. 11. Check: 9 air vent hose 9 fuel hoses Cracks/damage/wear → Replace. Obstructions → Clean. Blow out the hoses with compressed air. http://www.motorcycle.in.th...
Page 221: Assembling The Carburetor
CARB CARBURETOR EAS00487 ASSEMBLING THE CARBURETOR Before assembling the carburetor, wash all of the parts in a petroleum-based solvent. Always use a new gasket and new O-rings. 1. Measure: 9 float height a Out of specification → Adjust. Float height 9.2 mm (0.36 in) a.
Page 222: Installing The Carburetor
CARB CARBURETOR EAS00492 INSTALLING THE CARBURETOR 1. Install: 9 needle set 2. Install: 9 joint 1 9 intake manifold 2 10 Nm (1.0 m·kg, 7.2 ft·lb) 3. Connect: 9 fuel hose 1 9 carburetor overflow hose 2 9 vacuum sensing hose 3 9 air vent hose 4 9 vacuum sensing hose 5 4.
Page 223: Checking And Adjusting The Throttle Position Sensor
CARB CARBURETOR 7. Adjust: 9 engine idling speed Engine idling speed 1,300–1,500 r/min Refer to “ADJUSTING THE ENGINE IDLING SPEED” in chapter 3. 8. Adjust: 9 throttle cable free play Throttle cable free play (at the flange of the throttle grip) 3–7 mm (0.12–0.18 in) Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”...
Page 224 CARB CARBURETOR c. Connect the pocket tester (DC20V) to the terminals of the throttle position sensor. →→ Positive (+) pocket tester probe B/LLY yellow terminal →→ Negative (-) pocket tester probe black/blue terminal Throttle position sensor input volt- 5V at 20 ° C (yellow-black/blue) 2.
Page 225: Checking The Fuelcock Operation
CARB CARBURETOR EAS00506 CHECKING THE FUELCOCK OPERA- TION 1. Remove: 9 rear cowling (left) Refer to “REMOVING THE REAR COWL- INGS” in chapter 3. 2. Place a container under the end of the fuel hose 1 . 3. Check: 9 fuel cock operation a.
Page 226: Air Induction System
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
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 6-15 http://www.motorcycle.in.th...
Page 228: Removing The Air Induction System
CARB AIR INDUCTION SYSTEM REMOVING THE AIR INDUCTION SYS- 1. Disconnect: 9 vacuum sensing hose 9 bend hose 2. Remove: 9 air cut cut-off valve assembly 1 9 reed valve assembly 2 CHECKING THE AIR INDUCTION SYS- 1. Check: 9 hoses Loose connections →...
Page 229: Chas
CHAS CHAPTER 7 CHASSIS FRONT WHEELAND BRAKE DISC..............7-1 REMOVING THE FRONTWHEEL..............7-2 CHECKING THE FRONTWHEEL..............7-3 CHECKING THE BRAKE DISC.................7-5 CHECKING THE SPEEDOMETER GEAR UNIT..........7-6 INSTALLING THE FRONTWHEEL..............7-7 REAR WHEELAND BRAKE.................7-8 REMOVING THE REAR WHEEL..............7-9 DISASSEMBLING THE BRAKE SHOE PLATE..........7-11 CHECKING THE REAR WHEEL...............7-11 CHECKING THE REAR WHEELDRIVE HUB...........7-12 CHECKING THE BRAKE...................7-13 ASSEMBLING THE BRAKE SHOE PLATE............7-14...
Page 230 CHAS REAR SHOCK ABSORBER ASSEMBLYAND 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 CHECKING THE DRIVE CHAIN................7-57 INSTALLING THE DRIVE CHAIN AND SPROCKETS........7-58 http://www.motorcycle.in.th...
Page 231: Front Wheeland Brake Disc
CHAS FRONT WHEELAND BRAKE DISC EASF0044 CHASSIS FRONT WHEELAND 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 ) http://www.motorcycle.in.th...
Page 232: Removing The Frontwheel
CHAS FRONT WHEELAND 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: 9 speedometer cable 1 9 axle nut 2 9 washer 3 3.
Page 233: Checking The Frontwheel
CHAS FRONT WHEELAND BRAKE DISC EAS00526 CHECKING THE FRONT WHEEL 1. Check: 9 wheel axle Roll the wheel axle on a flat surface. Bends → Replace. Do not attempt to straighten a bent wheel axle. 2. Check: 9 tire Damage/wear → Replace. Refer to “CHECKING THE TIRES”...
Page 234 CHAS FRONT WHEELAND BRAKE DISC 5. Check: 9 spacers Damage/wear → Replace. 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. Failure to do so could lead to an accident with possible injury to the rider or damage to the vehicle.
Page 235: Checking The Brake Disc
CHAS FRONT WHEELAND 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 or balls . Contact should be made only with the outer race NOTE: Use a socket 7 that matches the diameter of the wheel bearing outer race and oil seal.
Page 236: Checking The Speedometer Gear Unit
CHAS FRONT WHEELAND BRAKE DISC 3. Measure: 9 brake 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. Adjust: 9 brake disc deflection a.
Page 237: Installing The Frontwheel
CHAS FRONT WHEELAND BRAKE DISC EAS00542 INSTALLING THE FRONT WHEEL 1. Lubricate: 9 wheel axle 9 wheel bearings 9 oil seal lips 9 speedometer gear unit Recommended lubricant Lithium-soap-based grease 2. Install: 9 brake disc 9 front wheel Refer to “CHECKING THE BRAKE DISC”. NOTE: Make sure the projection a on the speedometer gear unit fits between the projections on the...
Page 238: Rear Wheeland Brake
CHAS REAR WHEELAND BRAKE EASF0049 REAR WHEELAND 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) e Rear wheel drive hub 5 Brake shoe wear indicator r Drive chain puller (left) 6 Brake shoe plate t Rear wheel axle...
Page 239: Removing The Rear Wheel
CHAS REAR WHEELAND 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 CHAS REAR WHEELAND BRAKE 5. Remove: 9 rear wheel axle nut 1 9 washer 9 rear wheel axle 2 9 washer 9 collar 6. Remove: 9 rear wheel assembly 1 NOTE: Push the rear wheel forward and remove the drive chain from the driven sprocket. 7.
Page 241: Disassembling The Brake Shoe Plate
CHAS REAR WHEELAND BRAKE 10. Remove: 9 O-ring 9 rear wheel drive hub dampers 1 DISASSEMBLING THE BRAKE SHOE PLATE 1. Remove: 9 brake shoes 1 9 brake shoe springs 2 (48 mm, 1.89 in) 9 brake shoe springs 3 (52 mm, 2.01 in) 2.
Page 242: Checking The Rear Wheeldrive Hub
CHAS REAR WHEELAND BRAKE 2. Check: 9 tire Damage/wear → Replace. Refer to “CHECKING THE TIRES” in chap- ter 3. 3. Measure: 9 radial wheel runout 9 lateral wheel runout Refer to “FRONTWHEELAND BRAKE DISC”. EAS00567 CHECKING THE REAR WHEELDRIVE 1.
Page 243: Checking The Brake
CHAS REAR WHEELAND BRAKE EAS00539 CHECKING THE BRAKE The following procedure applies to all of the brake shoes. 1. Check: 9 brake shoe lining Glazed areas → Repair. Sand the glazed areas with course sandpa- per. NOTE: After sanding the glazed areas, clean the brake shoe with a cloth.
Page 244: Assembling The Brake Shoe Plate
CHAS REAR WHEELAND BRAKE EAS00570 ASSEMBLING THE BRAKE SHOE PLATE 1. Install: 9 brake camshaft 1 9 brake shoe wear indicator 2 9 brake camshaft lever 7 Nm (0.7 m·kg, 5.0 ft·lb) a. Install the brake camshaft so its punch mark a is positioned as shown.
Page 245 CHAS REAR WHEELAND BRAKE 4. Adjust: 9 drive 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: 9 wheel 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
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 5 Lower brake caliper retaining bolt 6 Brake caliper piston 7 Brake caliper dust seal...
Page 247: Replacing The Frontbrake Pads
CHAS FRONT BRAKE EAS00579 Disc brake components rarely require disas- sembly. Therefore, always follow these preventive measures: Never disassemble brake components unless absolutely necessary. If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly.
Page 248 CHAS FRONT BRAKE 2. Remove: 9 clips 9 brake pad retaining pin 9 brake pads 1 9 brake pad spring 3. Measure: 9 brake pad wear limit a → Replace the brake Out of specification pads as a set. Brake pad wear limit 0.8 mm (0.03 in) 4.
Page 249: Disassembling The Frontbrake Caliper
CHAS FRONT BRAKE 5. Lubricate: 9 brake pad retaining pin Recommended lubricant Lithium-soap-based grease 9 Do not allow grease to contact the brake pads. 9 Remove any excess grease. 6. Install: 9 brake caliper bolts 35 Nm (3.5 m·kg, 25 ft·lb) 7.
Page 250 CHAS FRONT BRAKE 1. Remove: 9 union bolt 1 9 copper washers 2 9 brake hose NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 2. Remove: 9 brake caliper 1 9 pin 9 brake pad retaining pin 9 brake pads...
Page 251: Checking The Frontbrake Caliper
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. Check: 9 brake caliper piston 1 Rust/scratches/wear →...
Page 252: Assembling And Installing The Frontbrake Caliper
CHAS FRONT BRAKE EAS00634 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.
Page 253 CHAS FRONT BRAKE 5. Fill: 9 brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 3 or 4 Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
Page 254: Frontbrake Master Cylinder
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 5 Brake master cylinder holder 6 Brake hose 7 Brake lever 26 Nm (2.6 m•kg, 19 ft•lb )
Page 255: Disassembling The Frontbrake Master Cylinder
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: 9 side cowlings (left and right) 9 front cowling Refer to “REMOVING THE SIDE COWL- INGS”...
Page 256 CHAS FRONT BRAKE 5. Remove: 9 brake master cylinder kit 1 6. Remove: 9 brake master cylinder reservoir cap 1 9 brake master cylinder reservoir diaphragm holder 2 9 brake master cylinder reservoir diaphragm 3 7. Remove: 9 brake hose 1 9 brake hose clamp 2 9 brake hose holder 3 EAS00590...
Page 257: Assembling And Installing The Frontbrake Master Cylinder
CHAS FRONT BRAKE 3. Check: 9 brake master cylinder reservoir 1 Cracks/damage → Replace. 9 brake master cylinder reservoir diaphragm 2 Damage/wear → Replace. 4. Check: 9 brake hose 1 Cracks/damage/wear → Replace. EAS00598 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid.
Page 258 CHAS FRONT BRAKE 2. Install: 9 copper washers 1 9 brake hose 2 9 union 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 CHAS FRONT BRAKE 4. Bleed: 9 brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 5. Check: 9 brake fluid level a → Add Below the minimum level mark the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”...
Page 260: Front Fork
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 ) 23 Nm (2.3 m•kg, 17 ft•lb ) 7-30 http://www.motorcycle.in.th...
Page 261: Removing The Frontfork Legs
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. NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated.
Page 262: Disassembling The Frontfork Legs
CHAS FRONT FORK 5. Remove: 9 front fork cap bolt 1 (with a 10-mm hexagonal wrench) 6. Loosen: 9 lower bracket pinch bolt 2 Before loosening the lower bracket pinch bolt, support the front fork leg. 7. Remove: 9 front fork leg EAS00655 DISASSEMBLING THE FRONT FORK LEGS...
Page 263 CHAS FRONT FORK 4. Remove: 9 damper rod assembly bolt 9 copper 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 T-handle 90890-01326 5.
Page 264: Checking The Frontfork Legs
CHAS FRONT FORK EAS00657 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: 9 inner tube 1 9 outer 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 Frontfork Legs
CHAS FRONT FORK EAS00659 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. Make sure the oil levels in both front fork legs are equal. Uneven oil levels can result in poor han- dling and a loss of stability.
Page 266 CHAS FRONT FORK NOTE: 1 while Tighten the damper rod assembly bolt holding the damper rod with the T-handle 2 and a 10 mm hexagon nut/socket wrench 3 . T-handle 90890-01326 4. Install: 9 oil seal 1 (with the fork seal driver weight 2 and fork seal driver attachment 3 ) Fork seal driver weight 90890-01184...
Page 267: Installing The Frontfork Legs
CHAS FRONT FORK 6. Fill: 9 front 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 Front fork leg oil level (from the top of the inner tube, with the inner tube fully compressed and without...
Page 268 CHAS FRONT FORK 3. Install: 9 front fender 10 Nm (1.0 m·kg, 7.2 ft·lb) 4. Install: 9 front wheel Refer to “FRONTWHEELAND BRAKE DISC”. 9 brake hose clamp 9 brake caliper assembly Refer to “FRONTBRAKE”. 7-38 http://www.motorcycle.in.th...
Page 269 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 ) 53 Nm (5.3 m•kg, 39 ft•lb ) 7-39 http://www.motorcycle.in.th...
Page 270 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: 9 side cowlings (left and right) 9 front cowling 9 center panels Refer to “REMOVING THE FRONTCOWL- INGS”...
Page 271 CHAS HANDLEBAR 7. Remove: 9 lever holder 1 8. Remove: 9 throttle cable 1 9 throttle grip 2 9. Remove: 9 grip end 1 10. Remove: 9 handlebar grip 1 NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar.
Page 272: Handlebar
CHAS HANDLEBAR 11. Remove: 9 relay 9 wire harness strap 1 12. Remove: 9 handlebar 1 9 washers 9 bushings 9 handlebar bracket 2 EAS00668 CHECKING THE HANDLEBAR 1. Check: 9 handlebar 1 Bends/cracks/damage → Replace. Do not attempt to straighten a bent handle- bar as this may dangerously weaken it.
Page 273 CHAS HANDLEBAR 3. Install: 9 bushings 9 washers 9 handlebar 23 Nm (2.3 m·kg, 17 ft·lb) 9 wire harness strap Refer to “CABLE ROUTING” in chapter 2. 4. Install: 9 handlebar grip a. Apply a thin coat of rubber adhesive onto the left end of the handlebar.
Page 274 CHAS HANDLEBAR 7. Install: 9 brake master cylinder 11 Nm (1.1 m·kg, 8.0 ft·lb) Refer to “FRONTBRAKE”. 8. Install: 9 plastic locking ties Refer to “CABLE ROUTING” in chapter 2. 9. Adjust: 9 throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”...
Page 275: Steering Head
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 ) 43 Nm (4.3 m•kg, 31 ft•lb ) 7-45...
Page 276: Removing The Lower Bracket
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: 9 side cowlings (left and right) 9 center panels 9 inner panel Refer to “REMOVING THE FRONTCOWL- INGS”...
Page 277 CHAS STEERING HEAD 2. Check: 9 bearings 1 9 bearing races 2 Damage/pitting → Replace. 3. Replace: 9 bearings 9 bearing races a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer.
Page 278: Installing The Steering Head
CHAS STEERING HEAD EAS00683 INSTALLING THE STEERING HEAD 1. Lubricate: 9 upper bearing 9 lower bearing 9 bearing races Recommended lubricant Lithium-soap-based grease 2. Install: 9 lower ring nut 9 upper ring nut Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” in chapter 3. 3.
Page 279: Rear Shock Absorber Assemblyand Swingarm
CHAS REAR SHOCK ABSORBER ASSEMBLYAND SWINGARM REAR SHOCK ABSORBER ASSEMBLYAND 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 ) 66 Nm (6.6 m•kg, 48 ft•lb ) 7-49 http://www.motorcycle.in.th...
Page 280: Removing The Rear Shock Absorber Assemblies And Swingarm
CHAS REAR SHOCK ABSORBER ASSEMBLYAND 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. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.
Page 281 CHAS REAR SHOCK ABSORBER ASSEMBLYAND SWINGARM 5. Remove: 9 rear shock absorber bolt (upper and lower) 9 washer 9 rear shock absorber nut (upper and lower) 9 washers 9 rear shock absorber assembly 3 6. Measure: 9 swingarm side play 9 swingarm vertical movement ∫...
Page 282: Checking The Rear Shock Absorber Assemblies
CHAS REAR SHOCK ABSORBER ASSEMBLYAND SWINGARM 7. Remove: 9 swingarm pivot shaft nut 1 9 washer 2 9 swingarm pivot shaft 3 9 swingarm 4 EAS00695 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES The following procedure applies to both rear shock absorber assemblies. 1.
Page 283: Checking The Swingarm
CHAS REAR SHOCK ABSORBER ASSEMBLYAND SWINGARM EAS00707 CHECKING THE SWINGARM 1. Check: 9 swingarm Bends/cracks/damage → Replace. 2. Check: 9 swingarm pivot shaft Roll the pivot shaft on a flat surface. Bends → Replace. Do not attempt to straighten a bent pivot shaft.
Page 284 CHAS REAR SHOCK ABSORBER ASSEMBLYAND SWINGARM 2. Install: 9 swingarm 9 swingarm pivot shaft 9 collar 9 swingarm pivot shaft nut 66 Nm (6.6 m·kg, 48 ft·lb) 3. Install: 9 rear shock absorber assemblies 9 rear shock absorber nuts 9 rear shock absorber bolts 46 Nm (4.6 m·kg, 33 ft·lb) 4.
Page 285: Drive Chain And Sprockets
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 8 Drive chain 9 Drive sprocket 30 Nm (3.0 m•kg, 20 ft•lb ) 7 Nm (0.7 m•kg, 5.0 ft•lb ) 7-55...
Page 286: Removing The Drive Chain And Sprockets
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
CHAS DRIVE CHAIN AND SPROCKETS 7. Straighten the lock washer tabs. 8. Remove: 9 driven sprocket nuts 9 driven sprocket bolts 9 lock washers 1 9 driven sprocket 2 EAS00710 CHECKING THE DRIVE CHAIN 1. Measure: 1 23 4 5 67 8 90 9 Measure the length of 15 links on the inner side a and outer side b of the pin and cal-...
Page 288: Installing The Drive Chain And Sprockets
CHAS DRIVE CHAIN AND SPROCKETS 4. Check: 9 drive chain rollers 1 Damage/wear → Replace the drive chain. 9 drive chain side plates 2 Cracks/damage/wear → Replace the drive chain. 5. Lubricate: 9 drive chain Recommended lubricant Engine oil or chain lubricant suitable for non-O-ring chains 6.
Page 289 CHAS DRIVE CHAIN AND SPROCKETS 3. Install: 9 drive sprocket 1 9 sprocket holder 2 9 Sprocket holder bolt 4. Lubricate: 9 drive chain 9 master link Recommended lubricant Engine oil or chain lubricant suitable for non-O-ring chains 5. Install: 9 master link body 9 master link plate 6.
Page 290 CHAS http://www.motorcycle.in.th...
Page 291: Elec
CHECKING THE CONDITION OF THE BULBS ..........8-8 CHECKING THE CONDITION OF THE BULB SOCKETS .......8-9 IGNITION SYSTEM ....................8-10 CIRCUITDIAGRAM ..................8-10 TROUBLESHOOTING ..................8-11 ELECTRIC STARTING SYSTEM (T135SE)............8-15 CIRCUITDIAGRAM ..................8-15 TROUBLESHOOTING ..................8-16 STARTER MOTOR (T135SE) ................8-18 REMOVING THE STARTER MOTOR ..............8-19 DISASSEMBLING THE STARTER MOTOR .............8-19 CHECKING THE STARTER MOTOR ...............8-19...
Page 292 ELEC http://www.motorcycle.in.th...
Page 293: Electricalcomponents
ELEC ELECTRICALCOMPONENTS EAS00729 ELECTRICALSYSTEM ELECTRICALCOMPONENTS 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) http://www.motorcycle.in.th...
Page 294 ELEC ELECTRICALCOMPONENTS 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 http://www.motorcycle.in.th...
Page 295: Checking Switch Continuity
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 .
Page 296 ELEC CHECKING SWITCH CONTINUITY http://www.motorcycle.in.th...
Page 297: Checking The Switches
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. Incorrect continuity reading →...
Page 298 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 http://www.motorcycle.in.th...
Page 299: Checking The Bulbs And Bulb Sockets
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
ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: 9 bulb Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. Be sure to hold the socket firmly when removing the bulb.
Page 301: Checking The Condition Of The Bulb Sockets
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: 9 bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester 90890-03112 NOTE: Check each bulb socket for continuity in the...
Page 302: Ignition System
ELEC IGNITION SYSTEM EAS00734 IGNITION SYSTEM CIRCUIT DIAGRAM 8-10 http://www.motorcycle.in.th...
Page 303: Troubleshooting
ELEC IGNITION SYSTEM EAS00736 EAS00739 TROUBLESHOOTING 2. Battery 9 Check the condition of the battery. The ignition system fails to operate (no spark or intermittent spark). Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. fuse Minimum open-circuit voltage 2.
Page 304 ELEC IGNITION SYSTEM EAS00742 EAS00744 4. Ignition spark gap 5. Spark plug cap resistance 9 Disconnect the spark plug cap from the 9 Remove the spark plug cap from the spark spark plug. plug lead. 9 Connect the ignition checker 1 as shown. 9 Connect the pocket tester (“...
Page 305 ELEC IGNITION SYSTEM EAS00746 EAS00748 6. Ignition coil resistance 7. Pickup coil resistance 9 Disconnect the ignition coil connector from 9 Disconnect the pickup coil coupler from the the ignition coil terminal. wire harness. 9 Connect the pocket tester ( Ω⋅ 1) to the igni- 9 Connect the pocket tester ( Ω⋅...
Page 306 ELEC IGNITION SYSTEM EAS00754 9. Wiring 9 Check the entire ignition system wiring. Refer to “CIRCUITDIAGRAM”. 9 Is the ignition system wiring properly con- nected and without defects? Properly connect or Replace the C.D.I. repair the ignition unit. system wiring. 8-14 http://www.motorcycle.in.th...
Page 307: Electric Starting System (T135Se)
ELEC ELECTRIC STARTING SYSTEM (T135SE) EAS00755 ELECTRIC STARTING SYSTEM (T135SE) CIRCUIT DIAGRAM 8-15 http://www.motorcycle.in.th...
Page 308: Troubleshooting
ELEC ELECTRIC STARTING SYSTEM (T135SE) EAS00757 EAS00739 TROUBLESHOOTING 2. Battery 9 Check the condition of the battery. The starter motor fails to turn. 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 °...
Page 309 ELEC ELECTRIC STARTING SYSTEM (T135SE) EAS00761 EAS00764 4. Starter relay 6. Start switch 9 Remove the starter relay from the starter 9 Check the start switch for continuity. relay coupler on the wire harness. Refer to “CHECKING THE SWITCHES”. 9 Connect the pocket tester ( Ω⋅...
Page 310: Starter Motor (T135Se)
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 8-18 http://www.motorcycle.in.th...
Page 311: Removing The Starter Motor
ELEC STARTER MOTOR (T135SE) REMOVING THE STARTER MOTOR 1. Remove: 9 breather pipe 1 2. Remove: 9 starter motor 1 3. Remove: 9 starter motor lead 1 DISASSEMBLING THE STARTER MOTOR 1. Remove: 9 starter motor front cover bolts (with washers)
Page 312 ELEC STARTER MOTOR (T135SE) 2. Measure: 9 commutator diameter a Out of specification → Replace the starter motor. Commutator wear limit 16.6 mm (0.65 in) 3. Measure: 9 mica undercut a Out of specification → Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator.
Page 313: Assembling The Starter Motor
ELEC STARTER MOTOR (T135SE) 5. Measure: 9 brush length a Out of specification → Replace the brush- es as a set. Brush length wear limit 3.5 mm (0.14 in) 6. Measure: 9 brush spring force Out of specification → Replace the brush springs as a set.
Page 314: Charging System
ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM 8-22 http://www.motorcycle.in.th...
Page 315: Troubleshooting
ELEC CHARGING SYSTEM EAS00774 EAS00739 TROUBLESHOOTING 2. Battery 9 Check the condition of the battery. The battery cannot be charged. 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 3.
Page 316 ELEC CHARGING SYSTEM EAS00775 EAS00776 3. Charging voltage 4. Charging coil resistance 9 Connect the engine tachometer to the spark 9 Disconnect the stator coil coupler from the plug lead. wire harness. 9 Connect the pocket tester (DC 20 V) to the 9 Connect the pocket tester ( Ω⋅...
Page 317: Lighting System
ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM 8-25 http://www.motorcycle.in.th...
Page 318: Troubleshooting
ELEC LIGHTING SYSTEM EAS00781 EAS00776 TROUBLESHOOTING 1. Lighting coil resistance 9 Disconnect the stator coil coupler from the Any of the following fail to light: head- light, high beam indicator light, taillight, wire harness. 9 Connect the pocket tester ( Ω⋅...
Page 319: Checking The Lighting System
ELEC LIGHTING SYSTEM EAS00788 3. Voltage CHECKING THE LIGHTING SYSTEM 9 Connect 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. nectors as shown.
Page 320 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 9 Check the meter light bulb and socket for 9 Check the tail/brake light bulb and socket for continuity.
Page 321 ELEC LIGHTING SYSTEM 4. The auxiliary light fails to come on. 1. Meter light bulb and socket 9 Check the meter light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. 9 Are the meter light bulb and socket OK? Replace the auxil- iary light bulb, socket or both.
Page 322: Signaling System
ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM 8-30 http://www.motorcycle.in.th...
Page 323 ELEC SIGNALING SYSTEM 1 Main switch 3 Fuse 4 Battery u Front brake light switch Rear brake light switch o Turn signal relay p Horn Horn switch Turn signal switch g Tail/brake light h Rear turn signal light Front turn signal light Fuel gauge x Fuel sender Neutral switch...
Page 324: Troubleshooting
ELEC SIGNALING SYSTEM EAS00794 EAS00739 TROUBLESHOOTING 2. Battery 9 Check the condition of the battery. Any of the following fail to light: turn sig- nal light, brake light or an indicator light. Refer to “CHECKING AND CHARGING THE The horn fails to sound. BATTERY”...
Page 325: Checking The Signaling System
ELEC SIGNALING SYSTEM EAS00796 3. Horn CHECKING THE SIGNALING SYSTEM 9 Disconnect the pink connector at the horn 1. The horn fails to sound. terminal. 9 Connect a jumper lead 1 to the horn termi- 1. Horn switch 9 Check the horn switch for continuity. nal and ground the jumper lead.
Page 326 ELEC SIGNALING SYSTEM EAS00797 3. Voltage 2. The tail/brake light fails to come on. 9 Connect the pocket tester (DC 20 V) to the 1. Tail/brake light bulb and socket tail/brake light coupler (wire harness side) as 9 Check the tail/brake light bulb and socket for shown.
Page 327 ELEC SIGNALING SYSTEM EAS00799 3. Voltage 3. The turn signal light, turn signal indicator 9 Connect 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 →→...
Page 328 ELEC SIGNALING SYSTEM 5. Voltage 4. Voltage 9 Connect the pocket tester (DC 20 V) to the 9 Connect the pocket tester (DC 20 V) to the turn signal light coupler (wire harness side) turn signal relay coupler as shown. →→...
Page 329 ELEC SIGNALING SYSTEM EAS00801 9 Set the main switch to “ON”. 9 Set the turn signal switch to “ 4 ” or “ 6 ”. 4. The gear position indicator lights fail to 9 Measure the voltage (DC 12 V) of the come on.
Page 330 ELEC SIGNALING SYSTEM EAS00804 3. Voltage 5. The fuel level gauge fails to operate. 9 Connect the pocket tester (DC 20 V) to the 1. Fuel sender meter assembly coupler (wire harness side) 9 Remove the fuel sender from the fuel tank. as shown.
Page 331 ELEC SIGNALING SYSTEM 2. Voltage 3. Fuel level gauge 9 Set the main switch to “ON”. 9 Connect the pocket tester (DC 20 V) to the 9 Move the float up 1 or down 2 . meter assembly coupler (wire harness side) 9 Check that the fuel level gauge needle as shown.
Page 332: Cooling System
ELEC COOLING SYSTEM COOLING SYSTEM CIRCUIT DIAGRAM 8-40 http://www.motorcycle.in.th...
Page 333: Troubleshooting
ELEC COOLING SYSTEM EAS00739 TROUBLESHOOTING 2. Battery 9 The radiator fan motor fails to turn. 9 Check 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 °...
Page 334 ELEC COOLING SYSTEM 4. Radiator fan motor 5. Radiator fan motor relay 9 Disconnect the radiator fan motor coupler 9 Disconnect the radiator fan motor relay cou- from the wireharness. pler. 9 Connect the battery (12 V) as shown. 9 Connect the pocket tester to the radiator fan →→...
Page 335 ELEC COOLING SYSTEM 6. Thermo sensor 9 Remove the thermo sensor from the cylinder. 9 Connect the digital circuit tester ( Ω⋅ 100) to the thermo switch 1 as shown. 9 Immerse the thermo sensor in a container filled with coolant 2 . NOTE: Make sure that the thermo sensor terminals do not get wet.
Page 336: Self-Diagnosis
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 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 2 1 second ∫ Light off 3 1.5 seconds 4 0.5 seconds 5 0.5 seconds...
Page 338 ELEC SELF-DIAGNOSIS TROUBLESHOOTING 1. Wire harness The coolant temperature warning indicator 9 Check the wire harness for continuity. light starts to display the self-diagnosis Refer to “CIRCUITDIAGRAM”. sequence. 9 Is the wire harness OK? Check: 1. throttle position sensor 2. thermo sensor Repair or replace the NOTE: 9 Before troubleshooting, remove the following...
Page 339 ELEC SELF-DIAGNOSIS 2. Thermo sensor 2. Thermo sensor CIRCUITDIAGRAM 9 Check the thermo sensor. Refer to “COOLING SYSTEM”. 9 Is the thermo sensor OK? W/Y Y (BLACK) (BLACK) Replace the C.D.I. Replace the thermo unit. sensor. (BLACK) B/L Br 0 C.D.I. unit t Thermo sensor 1.
Page 340 ELEC http://www.motorcycle.in.th...
Page 341: Trbl Shtg
TRBL SHTG CHAPTER 9 TROUBLESHOOTING TROUBLESHOOTING ...................9-1 ELECTRICALSYSTEM ..................9-1 COMPRESSION SYSTEM ................9-2 INTAKE AND EXHAUSTSYSTEM ..............9-3 http://www.motorcycle.in.th...
Page 342 TRBL SHTG http://www.motorcycle.in.th...
Page 343: Troubleshooting
TRBL TROUBLESHOOTING SHTG EASF0062 TROUBLESHOOTING TROUBLESHOOTING ELECTRICALSYSTEM *CHECK ALLWIRES 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 8 Spark plug wire is faulty 8 Spark plug cap is faulty C.D.I.
Page 344: Compression System
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 http://www.motorcycle.in.th...
Page 345: Intake And Exhaustsystem
TRBL TROUBLESHOOTING SHTG INTAKE AND EXHAUST SYSTEM FUELCOCK 8 Clogged FUELTANK CAP DRYTYPE 8 Clogged FUELHOSE AIR FILTER ELEMENT 8 Dirty or clogged 8 Clogged, damaged or kinked SILENCER EXHAUST PIPE 8 Clogged 8 Cracked or broken 8 Carbon deposits NEEDLE SET 8 Improperly adjusted (medium speed)
Page 346 TRBL SHTG http://www.motorcycle.in.th...
Page 347 http://www.motorcycle.in.th...
Page 348 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN http://www.motorcycle.in.th...
Page 349 T135SE/ T135S WIRING DIAGRAM W/Y Y (BLACK) (BLACK) Br R å T135SE START B/L Br Br/W Br/W SbY/W Br/W m , . /! P L/W (BLACK) (BLACK) PUSH Br/W Br/W (RED) (RED) Y/W L/W LG/Y (BLACK) (BLACK) Y/W L/W Ch Dg...

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Yamaha T135SE Service Manual

Table of Contents

Chapter 1

Spec Chapter 2 Specifications

Chapter 2 Specifications

Adj Chapter 3 Periodic Checks and Adjustments

Chapter 3 Periodic Checks and Adjustments

Eng Chapter 4 Engine

Chapter 4

Cool Chapter 5 Coolingsystem

Chapter 5

Carb Chapter 6 Carburetor

Chapter 6 Carburetor

Chas Chapter 7 Chassis

Chapter 7

Elec Chapter 8 Electricalsystem

Chapter 8

Chapter 9

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Yamaha T135SE