Yamaha T135 SE Service Manual Page 119
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- TROUBLESHOOTING
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4-13
ENG
CYLINDER HEAD
1
3
1
2
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. Remove the screwdriver and slowly release
the timing chain tensioner rod.
c. Make sure that the timing chain tensioner
rod comes out of the timing chain tensioner
housing smoothly. If there is rough move-
ment, replace the timing chain tensioner.
✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬✬
2. Check:
9
cap bolt
9
one-way cam
9
timing chain tensioner rod
Damage/wear
→
Replace the defective
part(s).
EAS00232
INSTALLING THE CYLINDER HEAD
1. Install:
9
timing chain guide (exhaust side)
1
9
dowel pins
2
9
gasket
3
2. Install:
9
cylinder head
9
washers
9
cylinder head bolts
9
cylinder head bolts
9
engine mount bolt
9
washer
9
engine mount nut
NOTE:
Pass the timing chain through the timing chain
cavity.
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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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