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m Ya Manual Clutch and Automatic O C 13 aT ah T135SE T135S M T135 SERVICE MANUAL Sniper / Jupiter MX / Spark 135 / Exciter / 135LC YamahaT135.COM 03212007 5YP-F8197-E0 Yamaha T135 Service Manual m Ya O C 13 aT ah M YamahaT135.COM Yamaha T135 Service Manual m Ya O C 13 aT ah M EAS00000 T135SE/T135S SERVICE MANUAL ©2005 by Yamaha Motor Co., Ltd First edition, April, 2005 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd is expressly prohibited YamahaT135.COM Yamaha T135 Service Manual 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 manual 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 vehicle unsafe and unfit for use Yamaha Motor Company, Ltd is continually striving to improve all of its models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable EAS00004 m Ya NOTE: Designs and specifications are subject to change without notice ah IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following aT The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! w Failure 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 cC A CAUTION indicates special precautions that must be taken to avoid damage to the vehicle NOTE: A NOTE provides key information to make procedures easier or clearer M YamahaT135.COM O C 13 Q Yamaha T135 Service Manual EASF0001 HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects (See “Illustrated symbols”) 1st title 1:This is a chapter with its symbol on the upper right of each page 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 rd title appears.) 3rd title 3:This is a final title MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step - by - step format The information 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 A set of particularly important procedure is placed between a line of mark “▼” or “▲” with each procedure preceded by “8” m Ya IMPORTANT FEATURES EXPLODED DIAGRAM aT ah 8Data and a special tool are framed in a box preceded by a relevant symbol 8An encircled numeral indicates a part name, and an encircled alphabetical letter date or an alignment mark 7, the others being indicated by an alphabetical letter in a box 8A condition of a faulty component will precede an arrow symbol and the course of action required the symbol O C 13 Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures M YamahaT135.COM Yamaha T135 Service Manual m Ya O C 13 aT ah M YamahaT135.COM Yamaha T135 Service Manual GEN INFO SYMBOLS SPEC The following symbols are not relevant to every vehicle Symbols to indicate the subject of each chapter CHK ADJ ENG CARB COOL General information Specifications Periodic checks and adjustments Engine Cooling system Carburetor Chassis Electrical system Troubleshooting Symbols to u indicate the following m Ya ELEC CHAS aT ah TRBL SHTG w q Symbols i to d in the exploded diagrams indicate the types of lubricants and lubrication points C u i o p a s d Engine oil Gear oil Molybdenum-disulfide oil Wheel-bearing grease Lithium-soap-based grease Molybdenum-disulfide grease O y t Serviceable with engine mounted Filling fluid Lubricant Special tool Tightening torque Wear limit, clearance Engine speed Electrical data 13 r e q w e r t y u M Symbols f to g in the exploded diagrams indicate the following i o a p s f d g LT YamahaT135.COM New f Apply locking agent (LOCTITE®) g Replace the part Yamaha T135 Service Manual m Ya O C 13 aT ah M YamahaT135.COM Yamaha T135 Service Manual EAS00011 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS m Ya PERIODIC CHECKS AND ADJUSTMENTS SPEC CHK ADJ ENG COOL CARB CHAS ELEC TRBL SHTG COOLING SYSTEM CHASSIS ELECTRICAL SYSTEM TROUBLESHOOTING YamahaT135.COM M CARBURETOR O C 13 aT ah ENGINE GEN INFO Yamaha T135 Service Manual m Ya O C 13 aT ah M YamahaT135.COM Yamaha T135 Service Manual COOLING SYSTEM ELEC Thermo sensor 9Remove the thermo sensor from the cylinder 9Connect the digital circuit tester (Ω × 100) to the thermo switch as shown 9Immerse the thermo sensor in a container filled with coolant NOTE: Make sure that the thermo sensor terminals not get wet 9Place a thermometer in the coolant 9Slowly heat the coolant, then let it cool to the specified temperature as indicated in the table 9Check the thermo sensor for continuity at the temperatures indicated in the table m Ya 9Does the thermo sensor operate properly as described above? Thermo sensor resistance 2.32–2.59 kΩ at 20°C (68°F) 310–326 Ω at 80°C (176°F) 140–144 Ω at 110°C (230°F) YES 18 Nm (1.8 m•kg, 13 ft•lb) EAS00795 C 9Handle the thermo sensor with special care 9Never subject the thermo sensor to strong shocks If the thermo sensor is dropped, replace it Replace the thermo sensor 13 aT ah w Tighten the thermo sensor to specified torque NO Wiring O 9Check the entire signaling system wiring Refer to “CIRCUIT DIAGRAM” 9Is the signaling system wiring properly connected and without defects? M YES Check the condition of each of the cooling system circuits Refer to “CHECKING THE COOLING SYSTEM” YamahaT135.COM 8-43 NO Properly connect or repair the cooling system wiring Yamaha T135 Service Manual SELF-DIAGNOSIS ELEC SELF-DIAGNOSIS The T135SE/S features a self-diagnosing system for following circuit (-s) Throttle position sensor (TPS) Thermo sensor 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 running or not) Item Condition Disconnected Short-circuit Throttle position sensor (TPS) m Ya Locked Display condition code Blinks in Fault code [1] Blinks in Fault code [2] Blinks in Fault code [3] O C 13 aT ah Thermo sensor Disconnected Short-circuit Response 9Enables the vehicle to run so that the ignition timing is fixed when the throttle is fully opened 9Displays the condition code on the coolant temperature warning indicator light 9Enables the vehicle to run so that the ignition timing is fixed 9Displays the condition code on the coolant temperature warning indicator light M YamahaT135.COM 8-44 Yamaha T135 Service Manual SELF-DIAGNOSIS ELEC Display order on the coolant temperature warning indicator light When one item being monitored Fault code Condition å [1] ∫ 3 45 Repetition 45 45 å [2] ∫ 1 45 Repetition m Ya å [3] ah ∫ 3 å Light on ∫ Light off seconds second 1.5 seconds 0.5 seconds 0.5 seconds When more than one item is being monitored O C 13 aT Repetition Light off (seconds) Light on (seconds) Light off (seconds) Light on (seconds) Light off (seconds) cycle cycle M sconds scond 1.5 sconds 0.5 sconds 0.5 sconds Fault code [1] Fault code [2] å ∫ Repetition 45 45 YamahaT135.COM 8-45 Yamaha T135 Service Manual ELEC SELF-DIAGNOSIS TROUBLESHOOTING Wire harness The coolant temperature warning indicator light starts to display the self-diagnosis sequence 9Check the wire harness for continuity Refer to “CIRCUIT DIAGRAM” 9Is the wire harness OK? Check: throttle position sensor thermo sensor YES Repair or replace the wire harness NOTE: 9Before troubleshooting, remove the following part(s): side cowlings (left and right) front cowling center panel (lower) 9Troubleshoot with the following special tool(s) Throttle position sensor m Ya 9Check the throttle position sensor for continuity Refer to “CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR” in chapter 9Is the throttle position sensor OK? Pocket tester 90890-03112 ah Throttle position sensor CIRCUIT DIAGRAM YES B O G/W L W/Y Y (BLACK) (BLACK) W O O B w R O B B/L L Y L L Y Y W/Y L Br Br (BLACK) G/R B/L M e Br Br r G/R W/ Y L t W/ Y L G/R B/L y G/W B/L L B P B/L Br B L B B Br C.D.I unit e Throttle position sensor YamahaT135.COM C W Replace the C.D.I unit 13 aT Br B /L P G/R W NO 8-46 NO Replace the throttle position sensor Yamaha T135 Service Manual SELF-DIAGNOSIS Thermo sensor CIRCUIT DIAGRAM ELEC Thermo sensor 9Check the thermo sensor Refer to “COOLING SYSTEM” 9Is the thermo sensor OK? Br B /L P G/R W B O G/W L W/Y Y (BLACK) W (BLACK) W YES B B R Replace the C.D.I unit B/L L Y L L Y Y e Br Br r W/Y L Br Br (BLACK) G/R B/L G/R W/ Y L t W/ Y L G/R B/L m Ya y G/W B/L L B P B/L Br B B Wireharness 9Check the wireharness for continuity Refer to “CIRCUIT DIAGRAM” 9Is the wireharness OK? YES C 13 aT C.D.I unit t Thermo sensor L B ah Br NO O M Repair or replace the wireharness YamahaT135.COM NO O O 8-47 Replace the thermo sensor Yamaha T135 Service Manual ELEC m Ya O C 13 aT ah M YamahaT135.COM Yamaha T135 Service Manual TRBL SHTG CHAPTER TROUBLESHOOTING TROUBLESHOOTING 9-1 ELECTRICAL SYSTEM 9-1 COMPRESSION SYSTEM .9-2 INTAKE AND EXHAUST SYSTEM 9-3 m Ya O C 13 aT ah M YamahaT135.COM Yamaha T135 Service Manual TRBL SHTG m Ya O C 13 aT ah M YamahaT135.COM Yamaha T135 Service Manual TROUBLESHOOTING TRBL SHTG EASF0062 TROUBLESHOOTING TROUBLESHOOTING ELECTRICAL SYSTEM *CHECK ALL WIRES CONNECTIONS IGNITION COIL (see page 8-13) Main switch is shorted Primary or secondary windings are broken or faulty Spark plug wire is faulty Spark plug cap is faulty m Ya C.D.I unit MAIN SWITCH (see page 8-5) C.D.I unit is broken O C 13 aT ah M SPARK PLUG 8 8 Wet carbon deposits Electrodes Improper gap Broken STARTER MOTOR(see page 8-18) Starter motor is broken or faulty Starter relay is broken Starter switch is broken YamahaT135.COM 9-1 CHARGING COIL (see page 8-24)/ PICKUP COIL (see page 8-13) Windings are broken Yamaha T135 Service Manual TROUBLESHOOTING TRBL SHTG COMPRESSION SYSTEM WEAR/SCRATCHES INSUFFICIENT TIGHTENING TORQUE DAMAGE INSUFFICIENT TIGHTENING TORQUE m Ya DAMAGE O C 13 aT ah WEAR/SCRATCH/DAMAGE M WEAR/STUCK/BROKEN DAMAGE WEAR/CARBON DEPOSITS INSUFFICIENT TIGHTENING TORQUE YamahaT135.COM 9-2 Yamaha T135 Service Manual TROUBLESHOOTING TRBL SHTG INTAKE AND EXHAUST SYSTEM FUEL COCK Clogged FUEL TANK CAP FUEL HOSE Clogged DRY TYPE AIR FILTER ELEMENT Dirty or clogged Clogged, damaged or kinked m Ya Clogged ah SILENCER EXHAUST PIPE 13 aT Cracked or broken Carbon deposits NEEDLE SET O C Improperly adjusted (medium speed) M PILOT JET Clogged (low speed) THROTTLE STOP SCREW MAIN JET Improperly adjusted (idling and starting) Incorrect size Clogged (high speed) FLOAT PILOT AIR SCREW Incorrect fuel level adjustment Puncture Improperly adjusted (idling and starting) NEEDLE VALVE ASSEMBLY FLOAT CHAMBER Wear Accumulated dust and/or water YamahaT135.COM 9-3 Yamaha T135 Service Manual TRBL SHTG m Ya O C 13 aT ah M YamahaT135.COM Yamaha T135 Service Manual m Ya O C 13 aT ah M YamahaT135.COM Yamaha T135 Service Manual m Ya O C 13 aT ah M YAMAHA MOTOR CO., LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN YamahaT135.COM Yamaha T135 Service Manual T135SE/ T135S WIRING DIAGRAM Main switch Rectifier/regurator OFF R Br ON Br B /L P G/R W R Br B O (BLACK) W Br R R R R Br åT135SE R/W L /W W B R Y/R R R W W Y/R Y/R Fuse G/W L W/Y Y (BLACK) W W W O O q B W Y/R B W Y B w B R/W L /W R Br Br L/W Br L/W Br Br R R R/W L/W R/W L/W B R B/L L Y 4R R R/W R/W (BLACK) W/ Y L t B/L L/W B START L/W B B W/ Y L y G/W L B P B/L Br B Br/W p o Br Br L Ch Dg Br/W Br P Sb Y/W W G/W P L/W (BLACK) (BLACK) L Br Dg Ch B G a s v bn m,./ !@ G PUSH Br/W d f HI LO N W P Y/W L/W G /W Sb W P Y/W L/W G Y Y G Dg P Br/W B Ch Y/R (RED) (RED) G B Ch Ch G B B c L jk W P Sb Y/W L/W l W Sb P L/W Y/W 4R g L Dg B B R L G/Y jk L Ch B L Ch B Dg L B L Dg B B L Y Ch Dg hh B L B G/Y Dg Ch Battery Starter motor Starter relay Right handlber switch Start switch A.C magneto C.D.I unit Ignition coil Spark plug Throttle position sensor Fan motor relay Thermo sensor Fan motor Front brake light switch Rear brake light switch Turn signal relay Horn Left handlebar switch Horn switch Dimmer switch Turn signal switch Tail/brake light Rear turn signal light Front turn signal light Auxilialy light Headlight Meter assembly Fuel gauge Fuel sender Neutral switch Meter light High beam indicator light Turn signal indicator light Nutral indicator light 1st gear position light 2nd gear position light 3rd gear position light 4th gear position light Coolant temparature warning indicator light M B Dg O (BLACK) (BLACK) ∫T135S Dg Ch Y P Dg B Br/W L/B Ch G x (BLACK) (BLACK) R L B Sb Br G/Y G/Y R B B B G/Y Y/R P OFF z Br L Ch Dg G B i C 13 Y/W Sb G/W W L/W P Br u Y L B B aT ah Br Br ; W/Y L Br Br G/R B/L L/W OFF Br Br r G/R G/R B/L Br L/W Y m Ya R/W L Y e R L q w e r t y u i o p a s d f g h j k l ; z x c v b n m , / ! @ COLOR CORD B Black Br Brown Ch Chocolate Dg Dark green G Green L Blue O Orange Sb Sky blue YamahaT135.COM P Pink R Red W White Y Yellow B/L Black/Blue Br/W Brown/White G/R .Green/Red G/W Green/White G/Y .Green/Yellow L/B Blue/Black L/W Blue/White R/W Red/White W/Y White/Yellow Y/R .Yellow/Red Y/W Yellow/White