YamahaT135.COM

T135 SERVICE MANUAL

5YP-F8197-E0

T135SE

T135S

Sniper / Jupiter MX / Spark 135 / Exciter / 135LC

YamahaT135.COM 03212007

Manual Clutch and Automatic

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Yamaha T135 Service Manual

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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.

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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 MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

Q

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.

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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.

MANUAL FORMAT

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.

A set of particularly important procedure 4 is placed between a line of mark “M” or “L” with each pro-

cedure preceded by “8”.

IMPORTANT FEATURES

8Data and a special tool are framed in a box preceded by a relevant symbol 5 .

8An encircled numeral 6 indicates a part name, and an encircled alphabetical letter date or an align-

ment mark 7, the others being indicated by an alphabetical letter in a box 8 .

8A condition 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 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

8 Electrical system

9 Troubleshooting

Symbols 0 to u indicate the following.

0 Serviceable with engine mounted

q Filling fluid

w Lubricant

e Special tool

r Tightening torque

t Wear limit, clearance

y Engine speed

u Electrical data

Symbols i to d in the exploded diagrams indi-

cate the types of lubricants and lubrication

points.

i Engine oil

o Gear oil

p Molybdenum-disulfide oil

a Wheel-bearing grease

s Lithium-soap-based grease

d Molybdenum-disulfide grease

Symbols f to g in the exploded diagrams indi-

cate the following.

f Apply locking agent (LOCTITE^®)

g Replace the part

1

2

3

4

y

u

i

o

p

a

s

d

f

g

GEN

INFO

SPEC

CHK

ADJ

ENG

LT

New

COOL

t

r

e

w

q

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

COOLING SYSTEM

COOL 5

CARBURETOR

CARB 6

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GEN

INFO

CHAPTER 1

GENERAL INFORMATION

VEHICLE IDENTIFICATION ...................................................................................1-1

VEHICLE IDENTIFICATION NUMBER .............................................................1-1

ENGINE SERIAL NUMBER...............................................................................1-1

IMPORTANT INFORMATION .................................................................................1-2

PREPARATION FOR REMOVAL AND DISASSEMBLY ...................................1-2

REPLACEMENT PARTS ..................................................................................1-2

GASKETS, OIL SEALS AND O-RINGS ............................................................1-2

LOCK WASHERS/PLATES AND COTTER PINS .............................................1-3

BEARINGS AND OIL SEALS ............................................................................1-3

CIRCLIPS .........................................................................................................1-3

CHECKING THE CONNECTIONS .........................................................................1-4

SPECIAL TOOLS ...................................................................................................1-5

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GEN

INFO

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1-1

GEN

INFO

VEHICLE IDENTIFICATION

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GENERAL INFORMATION

VEHICLE IDENTIFICATION

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VEHICLE IDENTIFICATION NUMBER

The number 1 is stamped into the center of the

frame.

ENGINE SERIAL NUMBER

The engine serial number 1 is stamped into the

crankcase.

NOTE:

Designs and specifications are subject to

change without notice.

1

1

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GEN

INFO

IMPORTANT INFORMATION

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IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND

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 “SPECIAL TOOLS”.

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.

EAS00022

GASKETS, OIL SEALS 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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BEARINGS AND OIL SEALS

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.

1 Oil seal

cC

Do not spin the bearing with compressed air

because this will damage the bearing sur-

faces.

1 Bearing

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CIRCLIPS

Before reassembly, check all circlips carefully

and replace damaged or distorted circlips.

Always replace piston pin clips after one use.

When installing a circlip 1, make sure the

sharp-edged corner 2 is positioned opposite

the thrust 3 that the circlip receives.

4 Shaft

GEN

INFO

IMPORTANT INFORMATION

1

300-000

300-003

1

300-002

1

300-001

3

4

1

2

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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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