2006 YAMAHA T135 maintenance

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU18660
NOTE:

The air filter needs more frequent service if you are riding in unusually wet or dusty areas.


Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.Replace the brake hoses every four years and if cracked or damaged.
22*Cooling systemCheck coolant level and vehicle for coolant leakage.√√√√ √
Change. Every 3 years
23*Front and rear brake
switchesCheck operation.√√√√√ √
24Moving parts and ca-
blesLubricate.√√√√ √
25*Throttle grip housing
and cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√√√√ √
26*Air induction systemCheck the air cut-off valve, reed valve, and hose for dam-
age.
Replace any damaged parts if necessary.√√√√ √
27*Lights, signals and
switchesCheck operation.
Adjust headlight beam.√√√√√ √ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 6 12 18 24
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-5
6
EAU18730
Removing and installing the
cowlings and panel
The cowlings and panel shown above
need to be removed to perform some of
the maintenance jobs described in this
chapter. Refer to this section each time
a cowling or the panel needs to be re-
moved and installed.
EAU37700
Cowlings A and B
To remove one of the cowlingsRemove the cowling bolts, and then
pull the cowling off as shown.
To install the cowlingPlace the cowling in the original posi-
tion, and then install the bolts.
EAU37710
Cowling C
To remove the cowlingRemove the bolts and screw shown,
and then take the cowling off.
1. Cowling A
2. Cowling C
3. Cowling D
1. Cowling B
2. Panel A
1. Cowling A
2. Bolt
1. Bolt
1. Bolt
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6
To install the cowling
Place the cowling in the original posi-
tion, and then install the bolts and
screw.
EAU37730
Cowling D
To remove the cowling1. Remove cowlings A and B. (See
page 6-5.)
2. Remove the bolts and screws shown, and then take the license
bracket plate and teh cowling off. To install the cowling
1. Place the cowling in the original
position, and then install the bolts
and screws.
2. Install cowlings A and B.
EAU37500
Panel A
To remove the panel1. Open the seat. (See page 3-7.)
2. Remove the screw and bolts, and then pull the panel off as shown.
1. Screw
1. Bolt
1. Screw and license bracket plate
2. Cowling A
1. Panel A
2. Screw
3. Bolt
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6To install the panel
Place the panel in the original position,
and then install the screw and bolts.
EAU37560
Checking the spark plug The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic mainte-
nance and lubrication chart. In addition,
the condition of the spark plug can re-
veal the condition of the engine.
To remove the spark plug
1. Remove cowling B. (See page
6-5.)
2. Remove the resonator bolt.
3. Move the resonator away as
shown.4. Remove the spark plug cap.
5. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner’s tool kit.1. Resonator bolt
1. Resonator
2. Spark plug cap
1. Spark plug wrench
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6
To check the spark plug
1. Check that the porcelain insulator around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the vehicle is
ridden normally).
NOTE:If the spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have aYamaha dealer check the vehicle.
2. Check the spark plug for electrode erosion and excessive carbon or
other deposits, and replace it if
necessary.
To install the spark plug 1. Measure the spark plug gap with a wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion. 2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
3. Install the spark plug with the spark plug wrench, and then tight-
en it to the specified torque.
NOTE:If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4 –1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-fied torque as soon as possible.
4. Install the spark plug cap.
5. Place the resonator in the original position, and then tighten the bolt
to the specified torque.
6. Install the cowling.
Specified spark plug: NGK/CPR8EA-9/DENSO U24EPR-9
1. Spark plug gap
Spark plug gap: 0.8 –0.9 mm (0.031 –0.035 in)
Tightening torque: Spark plug:12.5 Nm (1.25 m ·kgf, 9.0 ft ·lbf)
Tightening torque:
Resonator bolt: 10 Nm (1.0 m ·kgf, 7.2 ft ·lbf)
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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
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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)
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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)
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