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Yamaha 135LC User Manual

Yamaha 135LC
349 pages
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T135 SERVICE MANUAL
5YP-F8197-E0
T135SE
T135S
Sniper / Jupiter MX / Spark 135 / Exciter / 135LC
Manual Clutch and Automatic
http://www.motorcycle.in.th

Table of Contents

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Yamaha 135LC Specifications

General IconGeneral
Compression Ratio10.9 : 1
Front SuspensionTelescopic Fork
Front Tire70/90-17M/C 38P
Curb Weight105 kg
Bore x Stroke54.0 mm x 58.7 mm
Transmission5-speed
Starter SystemElectric & Kick
Rear SuspensionSwingarm
Front BrakeDisc
Rear BrakeDrum
Fuel Tank Capacity4.0 L

Summary

General Information

Vehicle Identification

Details for identifying the motorcycle's VIN and engine serial number.

Important Information for Maintenance

Key precautions for removal, disassembly, and parts replacement.

Special Tools Required

List of specialized tools and their part numbers for service.

Specifications

General Specifications

Key dimensional, weight, and engine type details for the T135SE/T135S.

Engine Maintenance Specifications

Detailed service limits and standards for engine components.

Engine and Chassis Tightening Torques

Specifies torque values for engine and chassis fasteners.

Engine Lubrication Points

Identifies lubrication points and recommended lubricant types for the engine.

Cable Routing Diagrams

Illustrates the correct routing for wiring, cables, and hoses.

Periodic Checks and Adjustments

Periodic Maintenance Schedule

Outlines service intervals and jobs based on odometer readings.

Removing and Installing Covers

Procedures for removing and installing side, front, and rear cowlings.

Engine Checks and Adjustments

Procedures for valve clearance, idling speed, and oil level checks.

Chassis Checks and Adjustments

Procedures for brake, chain, and steering head adjustments.

Electrical System Checks

Procedures for checking battery, fuses, and bulbs.

Engine Service

Removing the Engine

Steps for detaching the engine from the frame and its components.

Cylinder Head Service

Procedures for removing, checking, and installing the cylinder head.

Camshaft Service

Procedures for removing, checking, and installing camshaft and rocker arms.

Valves and Valve Springs Service

Procedures for checking and replacing valves, guides, and springs.

Cylinder and Piston Service

Procedures for removing, checking, and installing cylinder and piston.

Generator and Starter Clutch Service

Procedures for removing and installing generator and starter clutch.

Oil Pump Service

Procedures for removing, disassembling, checking, and assembling the oil pump.

Clutch Service

Procedures for removing, checking, and installing clutch components.

Shift Shaft Service

Procedures for removing, checking, and installing the shift shaft assembly.

Crankcase and Crankshaft Service

Procedures for disassembling, checking, and assembling crankcase and crankshaft.

Kickstarter Service

Procedures for removing, checking, and installing the kickstarter.

Transmission Service

Procedures for removing, disassembling, checking, and installing the transmission.

Cooling System Service

Radiator Service

Procedures for removing and checking the radiator and fan motor.

Water Pump Service

Procedures for disassembling, checking, assembling, and installing the water pump.

Cooling System Checks

Procedures for checking thermostat, hoses, and radiator cap.

Carburetor Service

Carburetor Assembly Diagram

Exploded view and parts identification for the carburetor.

Removing the Carburetor

Steps for safely removing the carburetor from the motorcycle.

Disassembling the Carburetor

Procedures for dismantling the carburetor components.

Checking Carburetor Components

Procedures for checking carburetor body, float, jets, and throttle valve.

Assembling the Carburetor

Procedures for reassembling the carburetor, including float height.

Installing the Carburetor

Steps for reinstalling the carburetor and its related components.

Throttle Position Sensor Check

Procedures for checking and adjusting the TPS resistance and angle.

Fuelcock Operation Check

Procedure to check the fuelcock for proper fuel flow.

Air Induction System Overview

Explanation of air injection and air cut-off valve functions.

Chassis Service

Front Wheel and Brake Disc Assembly

Exploded view and installation of front wheel and brake disc.

Rear Wheel and Brake Assembly

Exploded view and procedures for rear wheel and brake components.

Front Brake Caliper Service

Procedures for servicing the front brake caliper and pads.

Front Fork Service

Procedures for removing, disassembling, checking, and assembling front forks.

Handlebar Service

Procedures for removing, checking, and installing the handlebar.

Steering Head Service

Procedures for removing, checking, and installing the steering head.

Rear Shock Absorber & Swingarm Service

Procedures for removing, checking, and installing rear suspension components.

Drive Chain and Sprockets Service

Procedures for removing, checking, and installing drive chain and sprockets.

Electrical System Service

Electrical Components Overview

Identifies key electrical components and their locations.

Switch Continuity Checks

Procedures for testing switch continuity using a pocket tester.

Checking Various Switches

Procedures for checking switches for damage, connections, and continuity.

Bulb and Socket Checks

Procedures for checking bulb and socket condition and continuity.

Ignition System Troubleshooting

Troubleshooting guide for ignition system failures.

Electric Starting System Troubleshooting

Troubleshooting guide for the T135SE electric starting system.

Starter Motor (T135SE) Service

Procedures for removing, disassembling, checking, and assembling the starter motor.

Charging System Troubleshooting

Troubleshooting guide for charging system issues like battery not charging.

Lighting System Troubleshooting

Troubleshooting guide for lighting system failures.

Signaling System Troubleshooting

Troubleshooting guide for horn, lights, and indicators.

Cooling System Circuit Diagram

Circuit diagram for the cooling system, including fan and thermo sensor.

Self-Diagnosis System

Explanation of the self-diagnosis system for TPS and Thermo sensor.

Troubleshooting

Electrical System Troubleshooting

Common electrical faults and their causes/solutions.

Compression System Troubleshooting

Visual guide to potential issues in the engine's compression system.

Intake and Exhaust System Troubleshooting

Common issues related to fuel system and exhaust components.

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