2006 YAMAHA T135 service

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SAFETY INFORMATION
EAU10272
MOTORCYCLES ARE SINGLE
TRACK VEHICLES. THEIR SAFE USE
AND OPERATION ARE DEPENDENT
UPON THE USE OF PROPER RIDING
TECHNIQUES AS WELL AS THE EX-
PERTISE OF THE OPERATOR. EV-
ERY OPERATOR SHOULD KNOW
THE FOLLOWING REQUIREMENTS
BEFORE RIDING THIS MOTOR-
CYCLE.
HE OR SHE SHOULD:

OBTAIN THOROUGH INSTRUC-
TIONS FROM A COMPETENT
SOURCE ON ALL ASPECTS OF
MOTORCYCLE OPERATION.


OBSERVE THE WARNINGS AND
MAINTENANCE REQUIRE-
MENTS IN THE OWNER’S MAN-
UAL.


OBTAIN QUALIFIED TRAINING
IN SAFE AND PROPER RIDING
TECHNIQUES.


OBTAIN PROFESSIONAL TECH-
NICAL SERVICE AS INDICATED
BY THE OWNER’S MANUALAND/OR WHEN MADE NECES-
SARY BY MECHANICAL CONDI-
TIONS.
Safe riding


Always make pre-operation
checks. Careful checks may help
prevent an accident.


This motorcycle is designed to car-
ry the operator and a passenger.


The failure of motorists to detect
and recognize motorcycles in traf-
fic is the predominating cause of
automobile/motorcycle accidents.
Many accidents have been caused
by an automobile driver who did
not see the motorcycle. Making
yourself conspicuous appears to
be very effective in reducing the
chance of this type of accident.
Therefore:
Wear a brightly colored jacket.
Use extra caution when you are
approaching and passing
through intersections, since in-
tersections are the most likely
places for motorcycle accidents
to occur.Ride where other motorists can
see you. Avoid riding in another
motorist’s blind spot.


Many accidents involve inexperi-
enced operators. In fact, many op-
erators who have been involved in
accidents do not even have a cur-
rent motorcycle license.
Make sure that you are qualified
and that you only lend your
motorcycle to other qualified op-
erators.
Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
We recommend that you prac-
tice riding your motorcycle
where there is no traffic until you
have become thoroughly famil-
iar with the motorcycle and all of
its controls.


Many accidents have been caused
by error of the motorcycle opera-
tor. A typical error made by the op-
erator is veering wide on a turn
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PERIODIC MAINTENANCE AND MINOR REPAIR
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6
EAU17240
Safety is an obligation of the owner. Pe-
riodic inspection, adjustment and lubri-
cation will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.
WARNING
EWA10320
If you are not familiar with mainte-
nance work, have a Yamaha dealerdo it for you.
EAU17520
Owner’s tool kit The owner’s tool kit is located inside the
storage compartment under the seat.
(See page 3-7.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.NOTE:If you do not have the tools or experi-
ence required for a particular job, havea Yamaha dealer perform it for you.
WARNING
EWA10350
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any chang-es.
1. Owner’s tool kit
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
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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
6-23
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)
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PERIODIC MAINTENANCE AND MINOR REPAIR
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6
EAU24360
Front wheel
EAU37760
To remove the front wheel
WARNING
EWA10820


It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no dangerof it falling over.
1. Place the motorcycle on the cen-
terstand.
2. Disconnect the speedometer ca-
ble from the front wheel.
3. Remove the axle nut and the
washer.4. Pull the wheel axle out, and then
remove the wheel.
CAUTION:
ECA11070
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise thebrake pads will be forced shut.
EAU37770
To install the front wheel
1. Install the speedometer gear unit
into the wheel hub so that the pro-
jection on the wheel hub fits in ei-
ther slot of the speedometer gear
unit.2. Lift the wheel up between the fork
legs.
NOTE:
Make sure that there is enough space
between the brake pads before insert-
ing the brake disc and that the retainer
in the speedometer gear unit fits overthe slot on the fork leg.
1. Speedometer cable
1. Axle nut
2. Washer
1. Speedometer gear unit
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
63. Insert the wheel axle, and then in-
stall the washer and the axle nut.
4. Take the motorcycle off the center-
stand so that the front wheel is on
the ground.
5. Tighten the axle nut to the speci-
fied torque.
NOTE:When tightening the axle nut, hold the
wheel axle with a wrench to keep it fromturning.6. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
7. Connect the speedometer cable.
EAU25080
Rear wheel
EAU37781
To remove the rear wheel
WARNING
EWA10820


It is advisable to have a Yamaha
dealer service the wheel.


Securely support the motor-
cycle so that there is no dangerof it falling over.
1. Loosen the axle nut.
2. Loosen the locknut and the drive
chain slack adjusting nut on both
ends of the swingarm.
1. Retainer
2. SlotTightening torque:
Axle nut:
40 Nm (4.0 m·kgf, 29 ft·lbf)
1. Axle nut
2. Washer
3. Drive chain slack adjusting nut
4. Locknut
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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

SPECIFICATIONS
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Dimensions:Overall length:1945 mm (76.6 in)
Overall width:
705 mm (27.8 in)
Overall height: 1065 mm (41.9 in)
Seat height: 770 mm (30.3 in)
Wheelbase:
1245 mm (49.0 in)
Ground clearance: 140 mm (5.51 in)
Minimum turning radius: 1900 mm (74.8 in)Weight:With oil and fuel:109,0 kg (240 lb)Engine:Engine type:Liquid cooled 4-stroke, SOHC
Cylinder arrangement:
Forward-inclined single cylinder
Displacement: 134.4 cm ³ (8.20 cu.in)
Bore × stroke:
54.0 × 58.7 mm (2.13 × 2.31 in)
Compression ratio:
10.90 :1
Starting system: Electric starter and kickstarter Lubrication system:
Wet sump
Engine oil:Type:
SAE20W40 or SAE20W50
Recommended engine oil grade: API service SF, SG type or higher
JASO MA
Engine oil quantity: Without oil filter element replacement:
0.80 L (0.85 US qt) (0.70 Imp.qt)
With oil filter element replacement: 0.90 L (0.95 US qt) (0.79 Imp.qt)Cooling system:Coolant reservoir capacity (maximum
level) YAMAHA GENUINE COOLANT: 0.28 L (0.30 US qt) (0.25 Imp.qt)
Radiator capacity (including all routes):
0.62 L (0.66 US qt) (0.55 Imp.qt)Air filter:Air filter element:Dry elementFuel:Recommended fuel:Regular unleaded gasoline only
Fuel tank capacity: 4.0 L (1.06 US gal) (0.88 Imp.gal)Carburetor:Manufacturer:MIKUNI
Type × quantity:
VM22 x 1
Spark plug (s):Manufacturer/model: NGK CPR8EA-9/ DENSO U24EPR-9
Spark plug gap:
0.8 –0.9 mm (0.031 –0.035 in)Clutch:Clutch type:
Wet, multiple-disc and centrifugal
automaticTransmission:Primary reduction system:
Spur gear
Primary reduction ratio: 69/24 (2.875)
Secondary reduction system: Chain drive
Secondary reduction ratio:
39/15 (2.600)
Transmission type: Constant mesh 4-speed
Operation: Left foot operation
Gear ratio:
1st:34/12 (2.833)
2nd:
30/16 (1.875)
3rd: 23/17 (1.353)
4th: 23/22 (1.045)Chassis:Frame type: Diamond
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