Yamaha T135 SE Service Manual Page 103
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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
MUFFLER .........................................................................................................4-6
FOOTREST......................................................................................................4-7
CARBURETOR .................................................................................................4-7
COOLING SYSTEM ..........................................................................................4-7
ENGINE OIL......................................................................................................4-7
CYLINDER HEAD ..................................................................................................4-8
REMOVING THE CYLINDER HEAD ................................................................4-9
CHECKING THE CYLINDER HEAD .................................................................4-11
CHECKING TIMING CHAIN GUIDE .................................................................4-12
CHECKING THE TIMING CHAIN TENSIONER ...............................................4-13
INSTALLING THE CYLINDER HEAD ...............................................................4-13
CAMSHAFT ............................................................................................................4-17
REMOVING THE ROCKER ARMS AND CAMSHAFT......................................4-18
CHECKING THE CAMSHAFT..........................................................................4-19
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ..................4-19
CHECKING THE CAMSHAFTSPROCKET.....................................................4-21
INSTALLING THE CAMSHAFTAND ROCKER ARMS ....................................4-21
VALVES AND VALVE SPRINGS ............................................................................4-22
REMOVING THE VALVES ................................................................................4-23
CHECKING THE VALVES AND VALVE GUIDES .............................................4-24
CHECKING THE VALVE SEATS ......................................................................4-26
CHECKING THE VALVE SPRINGS ..................................................................4-28
INSTALLING THE VALVES ...............................................................................4-29
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- T135 SERVICE MANUAL 1
- EAS00000 3
- IMPORTANT MANUALINFORMATION 4
- HOW TO USE THIS MANUAL 5
- TABLE OF CONTENTS 9
- CHAPTER 1 11
- GENERALINFORMATION 11
- IMPORTANT INFORMATION 14
- CHECKING THE CONNECTIONS 16
- SPECIALTOOLS 17
- CHAPTER 2 21
- SPECIFICATIONS 21
- GENERALSPECIFICATIONS 24
- MAINTENANCE SPECIFICATIONS 26
- TIGHTENING TORQUES 31
- EAS00029 39
- EAS00028 39
- COOLINGSYSTEM DIAGRAMS 43
- COOLING SYSTEM DIAGRAMS 43
- CABLE ROUTING 44
- CHAPTER 3 53
- INTRODUCTION/ 55
- INTRODUCTION 55
- EAU18660 56
- INSTALLING THE FRONT COWLING 57
- REMOVING THE SIDE COWLINGS 57
- INSTALLING THE SIDE COWLINGS 57
- REMOVING THE FRONT COWLING 57
- REMOVING THE CENTER PANELS 58
- INSTALLING THE CENTER PANELS 58
- REMOVING THE REAR COWLINGS 58
- INSTALLING THE REAR COWLINGS 59
- INSTALLING THE HEADLIGHT 60
- ASSEMBLY 60
- REMOVING THE HEADLIGHT 60
- ADJUSTING THE VALVE CLEARANCE 61
- 10Nm (1.0 m•kg, 7.2 ft•lb) 64
- 12.5Nm (1.25 m•kg, 9.0 ft•lb) 64
- ADJUSTING THE ENGINE 65
- IDLING SPEED 65
- ADJUSTING THE THROTTLE CABLE 66
- FREE PLAY 66
- CHECKING THE SPARK PLUG 68
- 32 Nm (3.2 m•kg, 23 ft•lb) 72
- 15 Nm (1.5 m•kg, 11 ft•lb) 73
- EAS00086 74
- 8 Nm (0.8 m•kg, 6.0 ft•lb) 75
- CHECKING THE FUELAND VACUUM 76
- CHECKINGTHECOOLANTLEVEL 77
- CHECKINGTHECOOLANTLEVEL/ 78
- CHECKINGTHECOOLINGSYSTEM 78
- CHANGINGTHECOOLANT 79
- ADJUSTING THE REAR BRAKE 82
- CHECKING THE FRONT BRAKE PADS 83
- CHECKING THE REAR BRAKE SHOES 83
- CHECKING THE FRONT BRAKE HOSE 84
- BLEEDING THE HYDRAULIC BRAKE 85
- EAS00140 86
- LUBRICATING THE DRIVE CHAIN/ 88
- CHECKING AND ADJUSTING THE 89
- CHECKING THE FRONT FORK 91
- CHECKING THE TIRES 92
- 3 Nm (0.3 m•kg, 2.2 ft•lb) 94
- CHECKING AND LUBRICATING THE 95
- LUBRICATING THE SIDESTAND 95
- LUBRICATING THE CENTERSTAND 95
- CHECKING THE FUSE 100
- REPLACING THE HEADLIGHT BULBS 101
- ADJUSTING THE HEADLIGHT BEAM 102
- CHAPTER 4 103
- REMOVING THE ENGINE 107
- INSTALLING THE ENGINE 111
- 23 Nm (2.3 m·kg, 17 ft•lb) 113
- CYLINDER HEAD 114
- 22 Nm (2.2 m·kg, 16 ft•lb) 120
- 10 Nm (1.0 m•kg, 7.2 ft•lb) 120
- 72 Nm (7.2 m•kg, 52 ft•lb) 120
- 30 Nm (3.0 m•kg, 22 ft•lb) 121
- 13 Nm (1.3 m•kg, 9.5 ft•lb) 122
- CAMSHAFT 123
- 7 Nm (0.7 m•kg, 5.0 ft•lb) 127
- VALVES AND VALVE SPRINGS 128
- CYLINDER AND PISTON 147
- GENERATOR AND STARTER CLUTCH 154
- 14 Nm (1.4 m•kg, 10 ft•lb) 158
- 70 Nm (7.0 m•kg, 50 ft•lb) 158
- EASF0035 160
- REMOVING THE OILPUMP 161
- DISASSEMBLING THE OILPUMP 161
- CHECKING THE OILPUMP 162
- 1 Nm (0.1 m•kg, 0.7 ft•lb) 163
- EASF0029 165
- REMOVING THE CLUTCH 166
- CHECKING THE FRICTION PLATES 168
- CHECKING THE CLUTCH PLATES 168
- CHECKING THE CLUTCH SPRINGS 169
- CHECKING THE CLUTCH HOUSING 169
- CHECKING THE CLUTCH BOSS 169
- CHECKING THE CLUTCH PRESSURE 170
- CHECKING THE CLUTCH PUSH RODS 170
- CHECKING THE PRIMARYDRIVEN 170
- CHECKING THE CLUTCH SHOE 171
- CHECKING THE CAGE 171
- 50 Nm (5.0 m•kg, 30 ft•lb) 172
- 12 Nm (1.2 m•kg, 9.0 ft•lb) 173
- SHIFT SHAFT 174
- CRANKCASE AND CRANKSHAFT 179
- 4 Nm (0.4 m•kg, 3.0 ft•lb) 185
- KICKSTARTER 186
- TRANSMISSION 192
- CHAPTER 5 199
- COOLINGSYSTEM 199
- COOLING SYSTEM 201
- CHAPTER 6 211
- CARBURETOR 211
- 10 Nm (1.0 m·kg, 7.2 ft·lb) 222
- AIR INDUCTION SYSTEM 226
- CHAPTER 7 229
- FRONT WHEELAND BRAKE DISC 231
- 40 Nm (4.0 m·kg, 29 ft·lb) 237
- REAR WHEELAND BRAKE 238
- 19 Nm (1.9 m·kg, 14 ft·lb) 244
- 7 Nm (0.7 m·kg, 5.0 ft·lb) 244
- 60 Nm (6.0 m·kg, 43 ft·lb) 245
- FRONT BRAKE 246
- 35 Nm (3.5 m·kg, 25 ft·lb) 249
- 26 Nm (2.6 m·kg, 19 ft·lb) 252
- FRONT BRAKE MASTER CYLINDER 254
- 11 Nm (1.1 m·kg, 8.0 ft·lb) 257
- FRONT FORK 260
- 43 Nm (4.3 m·kg, 31 ft·lb) 267
- 50 Nm (5.0 m·kg, 36 ft·lb) 267
- HANDLEBAR 269
- 53 Nm (5.3 m·kg, 38 ft·lb) 272
- 23 Nm (2.3 m·kg, 17 ft·lb) 273
- STEERING HEAD 275
- REMOVING THE REAR SHOCK 280
- ABSORBER ASSEMBLIES AND 280
- SWINGARM 280
- CHECKING THE REAR SHOCK 282
- ABSORBER ASSEMBLIES 282
- CHECKING THE SWINGARM 283
- INSTALLING THE REAR SHOCK 283
- 66 Nm (6.6 m·kg, 48 ft·lb) 284
- 46 Nm (4.6 m·kg, 33 ft·lb) 284
- 16 Nm (1.6 m·kg, 12 ft·lb) 284
- DRIVE CHAIN AND SPROCKETS 285
- CHAPTER 8 291
- ELECTRICALSYSTEM 291
- ELECTRICALCOMPONENTS 294
- CHECKING SWITCH CONTINUITY 295
- CHECKING THE SWITCHES 297
- CHECKING THE BULBS AND 299
- BULB SOCKETS 299
- CHECKING THE CONDITION OF THE 300
- IGNITION SYSTEM 302
- Spark plug cap 304
- CIRCUIT DIAGRAM 307
- TROUBLESHOOTING 308
- EAS00761 309
- EAS00766 309
- EAS00749 309
- EAS00764 309
- STARTER MOTOR (T135SE) 310
- CHARGING SYSTEM 314
- LIGHTING SYSTEM 317
- SIGNALING SYSTEM 322
- (1.8 m•kg, 13 ft•lb) 335
- SELF-DIAGNOSIS 336
- CHAPTER 9 341
- YAMAHA MOTOR CO., LTD 348
- T135SE/ T135S WIRING DIAGRAM 349
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