air filter YAMAHA T135 2006 Owners Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2006, Model line: T135, Model: YAMAHA T135 2006Pages: 84, PDF Size: 5.06 MB
Page 6 of 84
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
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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)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU17710
Periodic maintenance and lubrication chart NOTE:
The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.
From 30000 km, repeat the maintenance intervals starting from 6000 km.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technicalskills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)
ANNUAL
CHECK
1 6 12 18 24
1*Fuel lineCheck fuel and vacuum hoses for cracks or damage.√√√√ √
2 Spark plugCheck condition.
Clean and regap.√√
Replace.√√
3*ValvesCheck valve clearance.
Adjust.√√√√
4 Air filter elementClean.√√
Replace.√√
5*BatteryCheck electrolyte level and specific gravity.
Make sure that the breather hose is properly routed.√√√√ √
6*Front brakeCheck operation, fluid level and vehicle for fluid leakage.√√√√√ √
Replace brake pads. Whenever worn to the limit
7*Rear brakeCheck operation and adjust brake pedal free play.√√√√√ √
Replace brake shoes. Whenever worn to the limit
8*Brake hoseCheck for cracks or damage.√√√√ √
Replace. Every 4 years
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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
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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
6-9
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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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
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-14
6 4. Insert the air filter element into the
air filter case.
CAUTION:
ECA10480
Make sure that the air filter ele-
ment is properly seated in the
air filter case.
The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) maybecome excessively worn.
5. Install the air filter case cover by in-
stalling the clamp and screws.
NOTE:
Make sure that the carburetor air
vent hose is routed as shown.
If dust or water collects in the air fil-
ter check hose, remove the clamp
from it, and then remove the plugto drain the hose.
6. Install the panel.
EAU21280
Adjusting the carburetor The carburetor is an important part of
the engine and requires very sophisti-
cated adjustment. Therefore, most car-
buretor adjustments should be left to a
Yamaha dealer, who has the neces-
sary professional knowledge and expe-
rience. The adjustment described in the
following section, however, may be ser-
viced by the owner as part of routine
maintenance.CAUTION:
ECA10550
The carburetor has been set and ex-
tensively tested at the Yamaha fac-
tory. Changing these settings
without sufficient technical knowl-
edge may result in poor perfor-mance of or damage to the engine.
1. Carburetor air vent hose
1. Air filter check hose
2. Clamp
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