2006 YAMAHA T135 battery

TABLE OF CONTENTSSAFETY INFORMATION ..................1-1
DESCRIPTION ..................................2-1
Left view ..........................................2-1
Right view ........................................2-2
Controls and instruments.................2-3
INSTRUMENT AND CONTROL
FUNCTIONS.......................................3-1
Main switch/steering lock ................3-1
Indicator and warning lights ............3-2
Speedometer unit ...........................3-3
Fuel gauge ......................................3-3
Handlebar switches ........................3-3
Shift pedal .......................................3-4
Brake lever .....................................3-4
Brake pedal ....................................3-5
Fuel tank cap ..................................3-5
Fuel .................................................3-6
Catalytic converter ..........................3-6
Starter (choke) lever ........................3-7
Kickstarter .......................................3-7
Seat ................................................3-7
Helmet holders ...............................3-8
Storage compartment .....................3-8
Sidestand ........................................3-9
PRE-OPERATION CHECKS..............4-1
Pre-operation check list ..................4-2OPERATION AND IMPORTANT
RIDING POINTS................................. 5-1
Starting and warming up a
cold engine ................................. 5-1
Starting a warm engine .................. 5-2
Shifting ........................................... 5-2
Tips for reducing fuel
consumption ............................... 5-3
Engine break-in .............................. 5-3
Parking ........................................... 5-5
General note .................................. 5-6
PERIODIC MAINTENANCE AND
MINOR REPAIR................................. 6-1
Owner’s tool kit ............................... 6-1
Periodic maintenance and
lubrication chart .......................... 6-2
Removing and installing the
cowlings and panel ..................... 6-5
Checking the spark plug ................. 6-7
Engine oil and oil filter element ...... 6-9
Coolant ......................................... 6-11
Cleaning the air filter element ...... 6-13
Adjusting the carburetor ............... 6-14
Adjusting the engine idling
speed ........................................ 6-15
Adjusting the throttle cable
free play .................................... 6-15
Valve clearance ............................ 6-16
Tires ............................................. 6-16
Spoke wheels ............................... 6-18Checking the brake lever
free play .................................... 6-19
Adjusting the brake pedal
free play .................................... 6-19
Adjusting the rear brake light
switch ....................................... 6-20
Checking the front brake pads and
rear brake shoes ...................... 6-20
Checking the front brake
fluid level .................................. 6-21
Changing the brake fluid .............. 6-22
Drive chain slack .......................... 6-22
Cleaning and lubricating the
drive chain ................................ 6-23
Checking and lubricating the
cables ....................................... 6-24
Checking and lubricating the
throttle grip and cable ............... 6-24
Lubricating the brake lever .......... 6-25
Lubricating the brake pedal ......... 6-25
Checking and lubricating the
centerstand and sidestand ....... 6-25
Lubricating the
swingarm pivots ........................ 6-26
Checking the front fork ................. 6-26
Checking the steering .................. 6-27
Checking the wheel bearings ....... 6-27
Battery ......................................... 6-28
Replacing the fuse ....................... 6-29
Replacing a headlight bulb .......... 6-30U5YPE0E0.book Page 1 Wednesday, February 23, 2005 4:22 PM

DESCRIPTION
2-1
2
EAU10410
Left view1. Front turn signal/auxiliary lights (page 6-31)
2. Headlight (page 6-30)
3. Battery (page 6-28)
4. Storage compartment (page 3-8)
5. Owner’s tool kit (page 6-1)
6. Seat lock (page 3-7)
7. Tail/brake light (page 6-31)
8. Rear turn signal lights (page 6-31)9. Shift pedal (page 3-4)
10.Coolant reservoir (page 6-11)U5YPE0E0.book Page 1 Wednesday, February 23, 2005 4:22 PM

PRE-OPERATION CHECKS
4-3
4
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-16, 6-18
Brake pedalMake sure that operation is smooth.
Lubricate pedal pivoting point if necessary.6-25
Brake leverMake sure that operation is smooth.
Lubricate lever pivoting point if necessary.6-25
Centerstand, sidestandMake sure that operation is smooth.
Lubricate pivots if necessary.6-25
Chassis fastenersMake sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary.—
Instruments, lights, signals
and switchesCheck operation.
Correct if necessary.—
BatteryCheck fluid level.
Fill with distilled water if necessary.6-28 ITEM CHECKS PAGE
U5YPE0E0.book Page 3 Wednesday, February 23, 2005 4:22 PM

OPERATION AND IMPORTANT RIDING POINTS
5-1
5
EAU15950
WARNING
EWA10270


Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.


Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.


Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible lossof control.
EAU37640
Starting and warming up a
cold engine 1. Turn the key to “ON”.
2. Shift the transmission into the neu-
tral position.NOTE:
When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical cir-cuit.
3. Place the vehicle on the center-
stand.
WARNING
EWA14200
Before starting the engine, make
sure the transmission is in neutral
and that the vehicle is placed on thecenterstand.
4. Turn the starter (choke) on and
completely close the throttle. (See
page 3-7.)
5. Start the engine by pushing the
start switch or by pushing the kick-
starter lever down.
NOTE:If the engine fails to start by pushing the
start switch, release the switch, wait a
few seconds, and then try again. Each
starting attempt should be as short as
possible to preserve the battery. Do not
crank the engine more than 10 seconds
on any one attempt. If the engine does
not start with the starter motor, try usingthe kickstarter.CAUTION:
ECA15170
The coolant temperature warning
light should come on when the key
is turned to “ON”, and then go off af-
ter a few seconds. If the coolant tem-
perature warning light comes on
after starting, immediately stop the
engine, and have a Yamaha dealercheck the electrical circuit.
6. After starting the engine, move the
starter (choke) back halfway.
U5YPE0E0.book Page 1 Wednesday, February 23, 2005 4:22 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU17710
Periodic maintenance and lubrication chart NOTE:

The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.


From 30000 km, repeat the maintenance intervals starting from 6000 km.


Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technicalskills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 6 12 18 24
1*Fuel lineCheck fuel and vacuum hoses for cracks or damage.√√√√ √
2 Spark plugCheck condition.
Clean and regap.√√
Replace.√√
3*ValvesCheck valve clearance.
Adjust.√√√√
4 Air filter elementClean.√√
Replace.√√
5*BatteryCheck electrolyte level and specific gravity.
Make sure that the breather hose is properly routed.√√√√ √
6*Front brakeCheck operation, fluid level and vehicle for fluid leakage.√√√√√ √
Replace brake pads. Whenever worn to the limit
7*Rear brakeCheck operation and adjust brake pedal free play.√√√√√ √
Replace brake shoes. Whenever worn to the limit
8*Brake hoseCheck for cracks or damage.√√√√ √
Replace. Every 4 years
U5YPE0E0.book Page 2 Wednesday, February 23, 2005 4:22 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
6
EAU37530
Battery A poorly maintained battery will corrode
and discharge quickly. The electrolyte
level, battery lead connections and
breather hose routing should be
checked before each ride and at the in-
tervals specified in the periodic mainte-
nance and lubrication chart.
To check the electrolyte level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.NOTE:Make sure that the vehicle is positioned
straight up when checking the electro-lyte level.
2. Open the seat. (See page 3-7.)
3. Check the electrolyte level in the
battery.NOTE:The electrolyte should be between theminimum and maximum level marks.4. If the electrolyte is at or below the
minimum level mark, remove the
battery band, and then lift the bat-
tery cover up.
5. Add distilled water to raise the
electrolyte to the maximum level
mark.
WARNING
EWA10770


Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al-ways shield your eyes when
working near batteries. In case
of contact, administer the fol-
lowing FIRST AID.
EXTERNAL: Flush with plenty
of water.
INTERNAL: Drink large quan-
tities of water or milk and im-
mediately call a physician.
EYES: Flush with water for 15
minutes and seek prompt
medical attention.


Batteries produce explosive hy-
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro-
vide sufficient ventilation when
charging it in an enclosed
space.


Take care not to spill electrolyte
on the drive chain, as this may
weaken it, shorten chain life and
possibly result in an accident.


KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OFCHILDREN.
1. Battery band
2. Battery cover
3. Maximum level mark
4. Minimum level mark
5. Battery
U5YPE0E0.book Page 28 Wednesday, February 23, 2005 4:22 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
6
CAUTION:
ECA10610
Use only distilled water, as tap water
contains minerals that are harmfulto the battery.
6. Check and, if necessary, tighten
the battery lead connections and
correct the breather hose routing.
7. Place the battery cover in the orig-
inal position, and then install the
battery band.
8. Close the seat.To store the battery
1. If the vehicle will not be used for
more than one month, remove the
battery, fully charge it, and then
place it in a cool, dry place.
2. If the battery will be stored for more
than two months, check the specif-
ic gravity of the electrolyte at least
once a month and fully charge the
battery whenever necessary.
3. Fully charge the battery before in-
stallation.
4. After installation, make sure that
the battery leads are properly con-
nected to the battery terminals and
that the breather hose is properly
routed, in good condition, and not
obstructed.
CAUTION:
ECA10600
If the breather hose is positioned in
such a way that the frame is ex-
posed to electrolyte or gas expelled
from the battery, the frame could
suffer structural and external dam-ages.
EAU23481
Replacing the fuse The fuse holder is located under the
seat. (See page 3-7.)
If the fuse is blown, replace it as fol-
lows.
1. Turn the key to “OFF” and turn off
all electrical circuits.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
1. Battery breather hose
1. Spare fuse
2. FuseSpecified fuse:
10.0 A
U5YPE0E0.book Page 29 Wednesday, February 23, 2005 4:22 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-36
6
EAU37620
Troubleshooting charts Starting problems or poor engine performance
WARNING
EWA10840
Keep away open flames and do not smoke while checking or working on the fuel system.
Check the fuel level in
the fuel tank.1. Fuel
There is
enough fuel.
There is
no fuel.
Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the
electric starter or the
kickstarter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plug
and check the electrodes.3. Ignition
Wet
Dry
Wipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Have a Yamaha dealer check the vehicle.
The engine does not start. Have a
Yamaha dealer check the vehicle.The engine does not start.
Check the battery.Open the throttle halfway and
operate the electric starter.
Operate the
electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.
The battery is good.Check the electrolyte and battery
lead connections, and charge the
battery if necessary.
U5YPE0E0.book Page 36 Wednesday, February 23, 2005 4:22 PM