Yamaha Spark 135 Manuals

Manuals and User Guides for Yamaha Spark 135. We have 1 Yamaha Spark 135 manual available for free PDF download: Service Manual

Yamaha Spark 135 Service Manual

Yamaha Spark 135 Service Manual (349 pages)

Manual Clutch and Automatic Sniper / Jupiter MX / Spark 135 / Exciter / 135LC

Brand: Yamaha | Category: Motorcycle | Size: 8.18 MB

Table of Contents

Table of Contents

9
- How to Use this Manual
  5
- 1 General Information
  7
- 5 Cooling System
  7
- 8 Electrical System
  7
- Carburetor
  7
- Chassis
  7
- Engine
  7
- Periodic Checks and Adjustments
  7
- Specifications
  7
- Troubleshooting
  7
  - Table of Contents
    9
  - Gen Info
    11
  - Vehicleidentification
    13
- Chapter 1
  
  13
  - Engine Serialnumber
    13
  - Vehicle Identification Number
    13
  - Important Information
    14
    
    Gaskets, Oilseals and O-Rings
    14
    
    Preparation for Removaland Disassembly
    14
    
    Replacementparts
    14
    
    Bearings and Oilseals
    15
    
    Circlips
    15
    
    Lock Washers/Plates and Cotter Pins
    15
  - Checking the Connections
    16
  - Specialtools
    17
Spec Chapter 2 Specifications

21
- Spec
  21
- Chapter 2 Specifications
  
  23
  - Generalspecifications
    23
  - Maintenance Specifications
    26
    
    Engine
    26
    
    Tightening Torques
    31
    
    Chassis
    33
    
    Tightening Torques
    35
    
    Electrical
    37
    
    Electrical Specifications
    37
  - Conversion Table
    39
  - Generaltightening Torque Specifications
    39
  - Lubrication Points and Lubricant Types
    40
    
    Engine
    40
    
    Chassis
    42
  - Cooling System Diagrams
    43
  - Cable Routing
    44
Adj Chapter 3 Periodic Checks and Adjustments

53
- Chapter 3 Periodic Checks and Adjustments
  
  55
  - Introduction
    55
  - Periodic Maintenance and Lubrication Intervals
    55
  - Covers
    57
    
    Installing the Frontcowling
    57
    
    Installing the Side Cowlings
    57
    
    Removing the Frontcowling
    57
    
    Removing the Side Cowlings
    57
    
    Installing the Center Panels
    58
    
    Removing the Center Panels
    58
    
    Removing the Rear Cowlings
    58
    
    Installing the Rear Cowlings
    59
    
    Installing the Headlightassembly
    60
    
    Removing the Headlightassembly
    60
  - Engine
    61
    
    Adjusting the Valve Clearance
    61
    
    Adjusting the Valve Clearance
    63
    
    Adjusting the Engine Idling Speed
    65
    
    Adjusting the Throttle Cable Free Play
    66
  - Chk Adj
    68
    
    Checking the Spark Plug
    68
    
    Measuring the Compression Pressure
    69
    
    Checking the Engine Oillevel
    71
    
    Changing the Engine Oil
    72
    
    Checking the Exhaustsystem
    73
    
    Checking the Oilfilter
    73
    
    Exhaust Pipe
    73
    
    Cleaning the Air Filter Element
    74
    
    Adjusting the Clutch Release System
    75
    
    Checking the Carburetor Jointand Intake Manifold
    75
    
    Checking the Fueland Vacuum Hoses
    76
    
    Checking the Crankcase Breather Pipe
    77
    
    Checkingthecoolantlevel
    77
    
    Checkingthecoolingsystem
    78
    
    Changingthecoolant
    79
  - Chassis
    82
    
    Adjusting the Rear Brake
    82
    
    Checking the Frontbrake Pads
    83
    
    Checking the Rear Brake Shoes
    83
    
    Rear Brake Shoes/Light Switch
    83
    
    Adjusting the Rear Brake Lightswitch
    84
    
    Checking the Frontbrake Hose
    84
    
    Bleeding the Hydraulic Brake System
    85
    
    Adjusting the Drive Chain Slack
    86
    
    Checking the Brake Fluid Level
    88
    
    Lubricating the Drive Chain
    88
  - Checking and Adjusting the Steering Head
    89
  - Checking the Frontfork
    91
  - Checking the Tires
    92
  - Checking and Tightening the Spokes
    94
  - Checking and Lubricating the Cables
    95
  - Lubricating the Centerstand
    95
  - Lubricating the Lever and Pedals
    95
  - Lubricating the Sidestand
    95
  - Checking and Charging the Battery
    96
  - Electricalsystem
    96
  - Checking the Fuse
    100
  - Replacing the Headlightbulbs
    101
  - Adjusting the Headlightbeam
    102
Eng Chapter 4 Engine

103
- Eng
  103
- Chapter 4
  
  107
  - Cooling System
    107
  - Engine Oil
    107
  - Carburetor
    107
  - Footrest
    108
  - Muffler
    108
  - Brake Pedal
    108
  - Shiftpedal
    108
  - Side Cowling Bracket
    109
  - Wire, Cable and Hose
    109
  - Engine Assembly
    110
  - Removing the Engine
    107
  - Installing the Engine
    111
    
    Engine Assembly
    111
    
    Brake Pedal
    112
    
    Muffler
    112
    
    Shiftpedal
    112
    
    Sidecowlingbracket
    112
    
    Wire, Cable and Hose
    112
    
    Carburetor
    113
    
    Cooling System
    113
    
    Engine Oil
    113
    
    Footrest
    113
  - Cylinder Head
    114
    
    Removing the Cylinder Head
    115
    
    Checking the Cylinder Head
    117
    
    Checking Timing Chain Guide
    118
    
    Checking the Timing Chain Tensioner
    119
    
    Installing the Cylinder Head
    119
  - Camshaft
    123
    
    Removing the Rocker Arms and Camshaft
    124
    
    Checking the Camshaft
    125
    
    Checking the Rocker Arms and Rocker Arm Shafts
    125
    
    Checking the Camshaftsprocket
    127
    
    Installing the Camshaftand Rocker Arms
    127
  - Valves and Valve Springs
    128
    
    Removing the Valves
    129
    
    Checking the Valves and Valve Guides
    130
    
    Checking the Valve Seats
    142
    
    Checking the Valve Springs
    144
    
    Installing the Valves
    145
    
    Cylinder and Piston
    147
    
    Removing the Cylinder and Piston
    148
    
    Checking the Cylinder and Piston
    149
    
    Checking the Piston Rings
    150
    
    Checking the Piston Pin
    151
    
    Installing the Piston and Cylinder
    152
    
    Generator and Starter Clutch
    154
    
    Removing the Generator
    155
    
    Removing the Starter Clutch (T135Se)
    156
    
    Checking the Starter Clutch (T135Se)
    157
    
    Installing the Generator
    158
    
    Installing the Starter Clutch (T135Se)
    158
    
    Oilpump
    160
    
    Disassembling the Oilpump
    161
    
    Removing the Oilpump
    161
    
    Checking the Oilpump
    162
    
    Assembling the Oilpump
    163
    
    Installing the Oilpump
    164
    
    Clutch
    165
    
    Removing the Clutch
    166
    
    Checking the Clutch Plates
    168
    
    Checking the Friction Plates
    168
    
    Checking the Clutch Boss
    169
    
    Checking the Clutch Housing
    169
    
    Checking the Clutch Springs
    169
    
    Checking the Clutch Pressure Plate
    170
    
    Checking the Clutch Push Rods
    170
    
    Checking the Primarydriven Gear
    170
    
    Checking the Cage
    171
    
    Checking the Clutch Shoe
    171
    
    Checking the Clutch Shoe Housing
    171
    
    Checking the Clutch Release Shiftarm
    172
    
    Installing the Clutch
    172
    
    Shift Shaft
    174
    
    Removing the Shiftshaft
    175
    
    Checking the Oilseal
    177
    
    Checking the Shiftguide
    177
    
    Checking the Shiftshaft
    177
    
    Checking the Stopper Lever
    177
    
    Installing the Shiftshaft
    178
    
    Crankcase and Crankshaft
    179
    
    Disassembling the Crankcase
    180
    
    Checking the Crankshaftand Connecting Rod
    181
    
    Checking the Bearings
    183
    
    Checking the Crankcase
    183
    
    Checking the Timing Chain
    183
    
    Checking the Timing Chain Guide
    183
    
    Assembling the Crankcase
    184
    
    Installing the Crankshaft
    184
  - Kickstarter
    186
    
    Removing the Kickstarter
    187
    
    Checking the Kickstarter
    189
    
    Installing the Kickstarter
    190
  - Transmission
    192
    
    Disassembling the Transmission
    193
    
    Removing the Transmission
    193
    
    Checking the Shiftforks
    194
    
    Checking the Shiftdrum Assembly
    195
    
    Checking the Transmission
    195
    
    Installing the Transmission
    196
Cool Chapter 5 Coolingsystem

199
- Cool
  199
- Chapter 5
  
  201
  - Radiator
    201
  - Water Pump
    202
    
    Removing the Radiator
    203
    
    Checking the Radiator
    204
    
    Checking the Thermostat
    206
    
    Disassembling the Water Pump
    206
    
    Checking the Water Pump
    207
    
    Assembling the Water Pump
    208
    
    Installing the Thermostat
    208
    
    Installing the Radiator
    209
    
    Installing the Water Pump
    209
Carb Chapter 6 Carburetor

211
- Carb
  211
- Chapter 6 Carburetor
  
  213
  - Removing the Carburetor
    214
  - Disassembling the Carburetor
    217
  - Checking the Carburetor
    218
  - Assembling the Carburetor
    221
  - Installing the Carburetor
    222
  - Checking and Adjusting the Throttle Position Sensor
    223
  - Checking the Fuelcock Operation
    225
  - Air Cut-Off Valve
    226
  - Air Induction System
    226
  - Air Injection
    226
  - Air Induction System Diagrams
    227
  - Checking the Air Induction System
    228
  - Installing the Air Induction System
    228
  - Removing the Air Induction System
    228
Chas Chapter 7 Chassis

229
- Chas
  229
  - Front Wheeland Brake Disc
    231
- Chapter 7
  
  232
  - Removing the Frontwheel
    232
  - Checking the Frontwheel
    233
  - Checking the Brake Disc
    235
  - Checking the Speedometer Gear Unit
    236
  - Installing the Frontwheel
    237
  - Rear Wheeland Brake
    238
    
    Removing the Rear Wheel
    239
    
    Checking the Rear Wheel
    241
    
    Disassembling the Brake Shoe Plate
    241
    
    Checking the Rear Wheeldrive Hub
    242
    
    Checking the Brake
    243
    
    Assembling the Brake Shoe Plate
    244
    
    Installing the Rear Wheel
    244
  - Front Brake
    246
    
    Frontbrake Caliper
    246
    
    Replacing the Frontbrake Pads
    247
    
    Disassembling the Frontbrake Caliper
    249
    
    Checking the Frontbrake Caliper
    251
    
    Assembling and Installing the Frontbrake Caliper
    252
    
    Frontbrake Master Cylinder
    254
    
    Disassembling the Frontbrake Master Cylinder
    255
    
    Assembling and Installing the Frontbrake Master Cylinder
    257
  - Front Fork
    260
    
    Removing the Frontfork Legs
    261
    
    Disassembling the Frontfork Legs
    262
    
    Checking the Frontfork Legs
    264
    
    Assembling the Frontfork Legs
    265
    
    Installing the Frontfork Legs
    267
  - Handlebar
    272
    
    Checking the Handlebar
    272
    
    Installing the Handlebar
    272
  - Steering Head
    275
    
    Checking the Steering Head
    276
    
    Removing the Lower Bracket
    276
    
    Installing the Steering Head
    278
  - Rear Shock Absorber Assemblyand Swingarm
    279
    
    Removing the Rear Shock Absorber Assemblies and Swingarm
    280
    
    Checking the Rear Shock Absorber Assemblies
    282
    
    Checking the Swingarm
    283
    
    Installing the Rear Shock Absorber Assemblies and Swingarm
    283
  - Drive Chain and Sprockets
    285
    
    Removing the Drive Chain and Sprockets
    286
    
    Checking the Drive Chain
    287
    
    Installing the Drive Chain and Sprockets
    288
Elec Chapter 8 Electricalsystem

291
- Elec
  291
- Chapter 8
  
  293
  - Electricalcomponents
    293
  - Checking Switch Continuity
    295
  - Checking the Switches
    297
  - Checking the Bulbs and Bulb Sockets
    299
    
    Types of Bulbs
    299
    
    Checking the Condition of the Bulbs
    300
    
    Checking the Condition of the Bulb Sockets
    301
    
    Circuitdiagram
    302
    
    Ignition System
    302
    
    Troubleshooting
    303
    
    Circuitdiagram
    307
    
    Electric Starting System (T135Se)
    307
    
    Troubleshooting
    308
  - Starter Motor (T135Se)
    310
    
    Checking the Starter Motor
    311
    
    Disassembling the Starter Motor
    311
    
    Removing the Starter Motor
    311
    
    Assembling the Starter Motor
    313
    
    Installing the Starter Motor
    313
  - Charging System
    314
    
    Circuitdiagram
    314
    
    Troubleshooting
    315
  - Lighting System
    317
    
    Circuitdiagram
    317
    
    Troubleshooting
    318
    
    Checking the Lighting System
    319
  - Signaling System
    322
    
    Circuitdiagram
    322
    
    Troubleshooting
    324
    
    Checking the Signaling System
    325
  - Cooling System
    332
    
    Circuitdiagram
    332
    
    Troubleshooting
    333
  - Self-Diagnosis
    336
  - Trbl Shtg
    341
    
    Troubleshooting
    341
    
    Troubleshooting
    343
- Chapter 9
  
  343
  - Electricalsystem
    343
  - Compression System
    344
  - Intake and Exhaustsystem
    345

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