2006 YAMAHA T135 engine oil

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
2-2
2
EAU10420
Right view1. Kickstarter (page 3-7)
2. Fuel tank cap (page 3-5)
3. Fuse (page 6-29)
4. Helmet holder (page 3-8)
5. Air filter element (page 6-13)
6. Front brake fluid reservoir (page 6-21)
7. Engine oil filter element (page 6-9)
8. Brake pedal (page 3-5)9. Engine oil drain bolt (page 6-9)
10.Engine oil filler cap (page 6-9)
U5YPE0E0.book Page 2 Wednesday, February 23, 2005 4:22 PM

PRE-OPERATION CHECKS
4-2
4
EAU15603
Pre-operation check list
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-6
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-9
CoolantCheck coolant level in reservoir.
If necessary, add recommended coolant to specified level.
Check cooling system for leakage.6-11
Front brakeCheck operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.6-20, 6-21
Rear brakeCheck operation.
Check pedal free play.
Adjust if necessary.6-20
Throttle gripMake sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.6-15, 6-24
Control cablesMake sure that operation is smooth.
Lubricate if necessary.6-24
Drive chainCheck chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.6-22, 6-23
U5YPE0E0.book Page 2 Wednesday, February 23, 2005 4:22 PM

OPERATION AND IMPORTANT RIDING POINTS
5-4
5Avoid prolonged operation above 1/3
throttle.
After every hour of operation, stop the
engine, and then let it cool for five to ten
minutes.
Vary the engine speed from time to
time. Do not operate the engine at one
set throttle position.
150–500 km (90–300 mi)
Avoid prolonged operation above 1/2
throttle.
Rev the engine freely through the
gears, but do not use full throttle at any
time.500–1000 km (300–600 mi)
Avoid prolonged operation above 3/4
throttle.
1000 km (600 mi) and beyond
Avoid prolonged full-throttle operation.
Vary the engine speed occasionally.
CAUTION:
ECA10361


After 1000 km (600 mi) of opera-
tion, the engine oil must be
changed, the oil filter cartridge
or element replaced, and the oil
strainer cleaned.


If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the vehi-cle.
U5YPE0E0.book Page 4 Wednesday, February 23, 2005 4:22 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
9*WheelsCheck runout, spoke tightness and for damage.
Tighten spokes if necessary.√√√√
10*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√ √
11*Wheel bearingsCheck bearing for looseness or damage.√√√√
12*SwingarmCheck operation and for excessive play.√√√√
Lubricate with lithium-soap-based grease. Every 24000 km
13 Drive chainCheck chain slack, alignment and condition.
Adjust and thoroughly lubricate chain with engine oil.Every 500 km and after washing the motorcycle or
riding in the rain
14*Steering bearingsCheck bearing play and steering for roughness.√√√√√
Lubricate with lithium-soap-based grease. Every 24000 km
15*Chassis fastenersMake sure that all nuts, bolts and screws are properly
tightened.√√√√ √
16 Sidestand, centerstandCheck operation.
Lubricate.√√√√ √
17*Front forkCheck operation and for oil leakage.√√√√
18*Shock absorber assem-
blyCheck operation and shock absorber for oil leakage.√√√√
19*CarburetorCheck starter (choke) operation.
Adjust engine idling speed.√√√√√ √
20 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √
21 Engine oil filter elementReplace.√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 6 12 18 24
U5YPE0E0.book Page 3 Wednesday, February 23, 2005 4:22 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
EAU37570
Engine oil and oil filter
element The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart.
To check the engine oil level
1. Place the vehicle on the center-
stand.NOTE:
Make sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in afalse reading.
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil set-
tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in), and then remove it
again to check the oil level.
NOTE:
The engine oil should be between theminimum and maximum level marks.4. If the engine oil is at or below the
minimum level mark, add sufficient
oil of the recommended type to
raise it to the correct level.
5. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.
To change the engine oil (with or
without oil filter element replace-
ment)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap
and drain bolt along with the O-
ring, compression spring, and en-
gine oil strainer, to drain the oil
from the crankcase.1. Engine oil filler cap
1. Dipstick
2. Maximum level mark
3. Minimum level mark
U5YPE0E0.book Page 9 Wednesday, February 23, 2005 4:22 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6
CAUTION:
ECA11000
When removing the engine oil drain
bolt, the O-ring, compression
spring, and oil strainer will fall out.Take care not to lose these parts.NOTE:Check the O-ring for damage and re-place it if necessary.
4. Clean the engine oil strainer with
solvent.
NOTE:Skip steps 5–7 if the oil filter element isnot being replaced.
5. Remove the oil filter element cover
by removing the bolts.
6. Remove and replace the oil filter
element and O-ring.7. Install the oil filter element cover by
installing the bolts, then tightening
them to the specified torque.
NOTE:Make sure that the O-ring is properlyseated.
8. Install the engine oil strainer, com-
pression spring, O-ring and engine
oil drain bolt, and then tighten the
drain bolt to the specified torque.
1. Engine oil drain bolt
2. O-ring
3. Compression spring
4. Strainer
5. Oil pan
1. Bolt
2. Oil filter element cover
1. Oil filter element
2. O-ring
Tightening torque:
Oil filter element cover bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
U5YPE0E0.book Page 10 Wednesday, February 23, 2005 4:22 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
6
CAUTION:
ECA10420
Before installing the engine oil drain
bolt, do not forget to install the O-
ring, compression spring, and oilstrainer in position.
9. Add the specified amount of the
recommended engine oil, and then
install and tighten the oil filler cap.CAUTION:
ECA11620


In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Donot use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.


Make sure that no foreign mate-rial enters the crankcase.
10. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.
11. Turn the engine off, and then
check the oil level and correct it if
necessary.
EAU20070
Coolant The coolant level should be checked
before each ride. In addition, the cool-
ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU37510
To check the coolant level
The coolant level should be checked as
follows before each ride. In addition,
the coolant must be changed at the in-
tervals specified in the periodic mainte-
nance and lubrication chart.
1. Place the vehicle on the center-
stand.NOTE:

The coolant level must be checked
on a cold engine since the level
varies with engine temperature.


Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to theside can result in a false reading.
2. Check the coolant level in the cool-
ant reservoir.
Tightening torque:
Engine oil drain bolt:
32 Nm (3.2 m·kgf, 23 ft·lbf)
Recommended engine oil:
See page 8-1.
Oil quantity:
With oil filter element replacement:
0.90 L (0.95 US qt) (0.79 Imp.qt)
Without oil filter element replace-
ment:
0.80 L (0.85 US qt) (0.70 Imp.qt)
U5YPE0E0.book Page 11 Wednesday, February 23, 2005 4:22 PM