2006 YAMAHA T135 light

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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PERIODIC MAINTENANCE AND MINOR REPAIR
6-13
6
NOTE:

The radiator fan is automatically
switched on or off according to the
coolant temperature in the radia-
tor.


If the engine overheats, see page6-36 for further instructions.
EAU33030
Changing the coolant
WARNING
EWA10380
Never attempt to remove the radiatorcap when the engine is hot.
The coolant must be changed at the in-
tervals specified in the periodic mainte-
nance and lubrication chart. Have a
Yamaha dealer change the coolant.
EAU37661
Cleaning the air filter element The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more fre-
quently if you are riding in unusually
wet or dusty areas.
1. Remove panel A. (See page 6-5.)
2. Remove the air filter case cover by
removing the screws and clamp,
and then pull the air filter element
out.3. Lightly tap the air filter element to
remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air as shown.
If the air filter element is damaged,
replace it.1. Air filter case cover
2. Screw
3. Clamp
1. Air filter element
1. Air filter element
U5YPE0E0.book Page 13 Wednesday, February 23, 2005 4:22 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
6
EAU37910
Checking the brake lever free
play There should be no free play at the
brake lever end. If there is free play,
have a Yamaha dealer inspect the
brake system.
WARNING
EWA14210
A soft or spongy feeling in the brake
lever can indicate the presence of air
in the hydraulic system. If there is air
in the hydraulic system, have a
Yamaha dealer bleed the system be-
fore operating the motorcycle. Air in
the hydraulic system will diminish
the braking performance, which may
result in loss of control and an acci-dent.
EAU22181
Adjusting the brake pedal free
play The brake pedal free play should mea-
sure 25.0–35.0 mm (0.98–1.38 in) at
the brake pedal end as shown. Period-
ically check the brake pedal free play
and, if necessary, adjust it as follows.
To increase the brake pedal free play,
turn the adjusting nut in direction (a). To
decrease the brake pedal free play,
turn the adjusting nut in direction (b).
WARNING
EWA10680


After adjusting the drive chain
slack or removing and installing
the rear wheel, always check the
brake pedal free play.


If proper adjustment cannot be
obtained as described, have a
Yamaha dealer make this ad-
justment.


After adjusting the brake pedal
free play, check the operation ofthe brake light.
1. Brake pedal free play
1. Brake pedal free play adjusting nut
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6
EAU22270
Adjusting the rear brake light
switch The rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction (a). To
make the brake light come on later, turn
the adjusting nut in direction (b).
EAU22380
Checking the front brake pads
and rear brake shoes The front brake pads and the rear brake
shoes must be checked for wear at the
intervals specified in the periodic main-
tenance and lubrication chart.
EAU22430
Front brake pads
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wearindicator grooves have almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
EAU22540
Rear brake shoes
The rear brake is provided with a wear
indicator, which allows you to check the
brake shoe wear without having to dis-
assemble the brake. To check the
brake shoe wear, check the position of
the wear indicator while applying the
brake. If a brake shoe has worn to the
point that the wear indicator reaches
the wear limit line, have a Yamaha
dealer replace the brake shoes as a
set.
1. Rear brake light switch
2. Rear brake light switch adjusting nut
1. Brake pad wear indicator groove
1. Brake shoe wear limit line
2. Brake shoe wear indicator
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6en the drive chain, turn the adjust-
ing nut at each end of the
swingarm in direction (b), and then
push the rear wheel forward.
NOTE:Using the alignment marks on each
side of the swingarm, make sure that
both chain pullers are in the same posi-tion for proper wheel alignment.CAUTION:
ECA10570
Improper drive chain slack will over-
load the engine as well as other vital
parts of the motorcycle and can leadto chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the
specified limits.
4. Tighten both locknuts, and then
tighten the axle nut and brake
torque rod nut to their specified
torques.NOTE:When tightening the axle nut, hold the
wheel axle with a wrench to keep it fromturning.
5. Adjust the brake pedal free play.
(See page 6-19.)
WARNING
EWA10660
After adjusting the brake pedal free
play, check the operation of thebrake light.
EAU23013
Cleaning and lubricating the
drive chain The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.CAUTION:
ECA10581
The drive chain must be lubricated
after washing the motorcycle andriding in the rain.
1. Remove all dirt and mud from the
drive chain with a brush or cloth.NOTE:For a thorough cleaning, have a
Yamaha dealer remove the drive chainand soak it in solvent.
2. Spray Yamaha Chain and Cable
Lube or a high-quality spray-type
drive chain lubricant on both sides
and on the middle of the chain,
1. Axle nut
2. Locknut
3. Drive chain slack adjusting nut
4. Alignment marks
Tightening torques:
Axle nut:
60 Nm (6.0 m·kgf, 43 ft·lbf)
Brake torque rod nut:
19 Nm (1.9 m·kgf, 14 ft·lbf)
U5YPE0E0.book Page 23 Wednesday, February 23, 2005 4:22 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6
CAUTION:
ECA10640
Do not use a fuse of a higher amper-
age rating than recommended to
avoid causing extensive damage to
the electrical system and possibly afire.
3. Turn the key to “ON” and turn on
the electrical circuits to check if the
devices operate.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
EAU37670
Replacing a headlight bulb If a headlight bulb burns out, replace it
as follows.
1. Remove cowling C. (See page
6-5.)
2. Remove the headlight bulb holder
by pushing it inward and turning it
counterclockwise, and then re-
move the defective bulb.
WARNING
EWA10790
Headlight bulbs get very hot. There-
fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooleddown.3. Place a new bulb into position, and
then secure it with the bulb holder.
CAUTION:
ECA10660
Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the bulb,
and the bulb life will be adversely af-
fected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with al-cohol or thinner.
4. Install the cowling.
5. Have a Yamaha dealer adjust the
headlight beam if necessary.
1. Headlight bulb holder
1. Do not touch the glass part of the bulb.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
6
EAU37680
Replacing a front turn signal
light bulb or an auxiliary light
bulb If a front turn signal light or an auxiliary
light bulb burns out, replace it as fol-
lows.
1. Remove cowlings A, B and D.
(See page 6-5.)
2. Remove the socket (together with
the bulb) by turning it counter-
clockwise.
3. Remove the defective bulb by pull-
ing it out.4. Insert a new bulb into the socket.
5. Install the socket (together with the
bulb) by turning it clockwise.
6. Install the cowlings.
EAU37741
Rear turn signal light and
tail/brake light If a rear turn signal light or the tail/brake
light does not come on, have a Yamaha
dealer check its electrical circuit or re-
place the bulb.
1. Turn signal light bulb socket
2. Auxiliary light bulb socket
1. Bulb
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-35
67. Take the motorcycle off the center-
stand so that the rear wheel is on
the ground.
8. Tighten the brake torque rod nut
and axle nut to the specified
torques.
NOTE:When tightening the axle nut, hold the
wheel axle with a wrench to keep it fromturning.
9. Insert a new cotter pin.
10. Adjust the brake pedal free play.
(See page 6-19.)
WARNING
EWA10660
After adjusting the brake pedal free
play, check the operation of thebrake light.
EAU25870
Troubleshooting Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi-
or, have a shorter service life and can
lead to expensive repair bills.
Tightening torques:
Brake torque rod nut:
19 Nm (1.9 m·kgf, 14 ft·lbf)
Axle nut:
60 Nm (6.0 m·kgf, 43 ft·lbf)
U5YPE0E0.book Page 35 Wednesday, February 23, 2005 4:22 PM