Yamaha T135SE User manual

T135 SERVICE MANUAL
5YP-F8197-E0
T135SE
T135S
Sniper / Jupiter MX / Spark 135 / Exciter / 135LC
Manual Clutch and Automatic
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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.
EAS00000
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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.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT MANUALINFORMATION
Particularly important information is distinguished in this manual by the following.
QThe Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETYIS
INVOLVED!
wFailure to follow WARNING instructions could result in severe injury or death to the
vehicle operator, a bystander or a person checking or repairing the vehicle.
cCACAUTION indicates special precautions that must be taken to avoid damage to
the vehicle.
NOTE: ANOTE provides key information to make procedures easier or clearer.
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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. (For the
chapter “Periodic inspection and adjustment” the 3 rd title appears.)
3rd title 3:This is a final title.
MANUALFORMAT
All of the procedures in this manual are organized in a sequential, step - by - step format. The informa-
tion has been compiled to provide the mechanic with a easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspections.
Aset of particularly important procedure 4is placed between a line of mark “ ✭” or “✬” with each pro-
cedure preceded by “8”.
IMPORTANT FEATURES
8Data and a special tool are framed in a box preceded by a relevant symbol 5.
8An encircled numeral 6indicates a part name, and an encircled alphabetical letter date or an align-
ment mark 7, the others being indicated by an alphabetical letter in a box 8.
8Acondition of a faulty component will precede an arrow symbol and the course of action required the
symbol 9.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section for ease in identifying cor-
rect disassembly and assembly procedures.
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SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols 1to 9indicate the subject of each
chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Engine
5Cooling system
6Carburetor
7Chassis
8Electrical system
9Troubleshooting
Symbols 0to uindicate the following.
0Serviceable with engine mounted
qFilling fluid
wLubricant
eSpecial tool
rTightening torque
tWear limit, clearance
yEngine speed
uElectrical data
Symbols ito din the exploded diagrams indi-
cate the types of lubricants and lubrication
points.
iEngine oil
oGear oil
pMolybdenum-disulfide oil
aWheel-bearing grease
sLithium-soap-based grease
dMolybdenum-disulfide grease
Symbols fto gin the exploded diagrams indi-
cate the following.
fApply locking agent (LOCTITE®)
gReplace the part
12
34
yu
iop
asd
fg
GEN
INFO SPEC
CHK
ADJ ENG
LT New
COOL
t
r
e
wq
0
9
TRBL
SHTG
8
ELEC
7
CHAS
6
CARB
5
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SPECIFICATIONS
TROUBLESHOOTING
ELECTRICALSYSTEM
CHASSIS
ENGINE
PERIODIC CHECKS AND
ADJUSTMENTS
GENERALINFORMATION GEN
INFO
TRBL
SHTG
ELEC
CHAS
ENG
CHK
ADJ
SPEC
TABLE OF CONTENTS
4
7
8
9
3
2
1
COOLINGSYSTEM COOL 5
CARBURETOR CARB 6
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GEN
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
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GEN
INFO
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1-1
GEN
INFO
VEHICLE IDENTIFICATION
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GENERALINFORMATION
VEHICLEIDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
The number 1is stamped into the center of the
frame.
ENGINE SERIALNUMBER
The engine serial number 1is stamped into the
crankcase.
NOTE:
Designs and specifications are subject to
change without notice.
1
1
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GEN
INFO
IMPORTANT INFORMATION
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. This includes gears, cylin-
ders, pistons and other parts that have
been “mated” through normal wear. Mated
parts must always be reused or replaced as
an assembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of dis-
assembly. This will speed up assembly and
allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
1-2
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REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
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GASKETS, OILSEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket sur-
faces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.
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EAS00024
BEARINGS AND OILSEALS
Install bearings and oil seals so that the manu-
facturer’s marks or numbers are visible. When
installing oil seals, lubricate the oil seal lips with
a light coat of lithium-soap-based grease. Oil
bearings liberally when installing, if appropriate.
1Oil seal
cC
Do not spin the bearing with compressed air
because this will damage the bearing sur-
faces.
1Bearing
EAS00025
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip 1, make sure the
sharp-edged corner 2is positioned opposite
the thrust 3that the circlip receives.
4Shaft
GEN
INFO
IMPORTANT INFORMATION
1
300-000
300-003
1
300-002
1
300-001
3
4
1
2
EAS00023
LOCK WASHERS/PLATES AND COT-
TER 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.
1-3
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GEN
INFO
CHECKING THE CONNECTIONS
1
EAS00026
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
9lead
9coupler
9connector
2. Check:
9lead
9coupler
9connector
Moisture →Dry with compressed air.
Rust/stains →Connect and disconnect
several times.
3. Check:
9all connections
Loose connection →Connect properly.
NOTE:
If the pin 1on the terminal is flattened, bend it
up.
4. Connect:
9lead
9coupler
9connector
NOTE:
Make sure all connections are tight.
5. Check:
9continuity
(with the pocket tester)
NOTE:
8If there is no continuity, clean the terminals.
8When checking the wire harness, perform
steps (1) to (3).
8As a quick remedy, use a contact revitalizer
available at most part stores.
1-4
Pocket tester
90890-03112
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GEN
INFO
SPECIALTOOLS
1-5
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.
90890-01135
Crankcase separating tool
This tool is necessary for separating the
crankcase.
90890-01184
Fork seal driver weight
This tool is used for to install the oil seal.
90890-01186
Fork seal driver attachment
This tool is used to install the oil seal.
90890-01268
Ring nut wrencht
This tool is used to loosen and tighten
the steering ring nut
Crankshaft instoller pot
This tool is necessary for installing the
crankshaft.
90890-01274
90890-01275
Crankcase installer bolt
This tool is necessary for installing the
crankshaft.
Tool No. Tool name/Usage Illustration
90890-01052
Meter gear bush tool
This tool is used to remove or install the
bushing.
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GEN
INFO
SPECIALTOOLS
1-6
90890-01278
Adoptor (M12)
This tool is necessary for installing the
crankshaft.
90890-01311
Tappet adjusting tool
This tool is necessary for adjusting
valve clearance.
Radiator cap tester
90890-01325
Radiator cap tester
adapter
90890-01352
Radiator cap tester
Radiator cap tester adapter
These tools are used to check the
cooling syatem.
T-handle
This tool is used for holding the damper
rod holder when removing or installing
the damper rod holder.
90890-01326
Flywheel puller
This tool is used for removing the roter.
90890-01362
90890-01403
Steering nut wrencht
This tool is used to loosen and tighten
the steering ring nut
R20
90890-01701
Sheave holder
This tool is used for holding the
generator roter.
90890-03079
Thickness gauge
This tool is used to measure the valve
clearance.
Tool No. Tool name/Usage Illustration
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GEN
INFO
SPECIALTOOLS
1-7
90890-03081
Compression gauge
These tools are used to measure the
engine compression.
90890-03112
Pocket tester
This instrument is necessary for
checking the electrical system.
90890-03113
Engine tachometer
This tool is needed for detecting engine
rpm.
Middle driven shaft
bearing driver
90890-04058
Mechanical seal
installer
90890-04145
Middle driven shaft bearing driver
Mechanical seal installer
These tools are used to install the water
pump seal.
Valve spring compressor Attachment
This tool is used when removing or
installing the valve and valve spring.
90890-04108
Ø22
Valve spring compressor
This tool is used when removing or
installing the valve and valve spring.
90890-04019 fl31 M6xP1.0
90890-04081
Spacer
This tool is necessary for insatlling the
crankshaft.
90890-04086
Universal clutch holder
This tool is needed to hold the clutch
when removing or installing the clutch
boss nut.
Tool No. Tool name/Usage Illustration
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GEN
INFO
SPECIALTOOLS
1-8
90890-04101
Valve lapper
This tool is used for removeing and
installing the lifter and for lapping the
valve.
90890-04116
Valve guide remover (4.5 mm)
This tool is needed to remove and
installing the valve guide.
90890-04117
Valve guide installer (4.5 mm)
This tool is needed to install the valve
guide.
90890-04118
Valve guide reamer (4.5 mm)
This tool is needed rebore the new
valve guide.
90890-06754
Ignition checker
This instrument is necessary for check-
ing the ignition system components.
Tool No. Tool name/Usage Illustration
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