2005–2013 Yamaha T135SE/T135S Service Manual (P/N 5YP-F8197-E0)

• Model coverage: Yamaha T135SE (5YP1) and T135S (5YP2), with T135SE-specific electric-start material; first-edition Yamaha manual P/N 5YP-F8197-E0 (April 2005), supplied as a 346-page PDF.
• Documents engine removal and installation, cylinder-head and camshaft work, valve and valve-guide service, piston and cylinder inspection, and timing-chain setup.
• Details crankcase separation, crankshaft installation, oil-pump service, clutch inspection and assembly, shift-shaft repair, kickstarter work, and four-speed transmission teardown and checking.
• Covers Mikuni carburetor overhaul, throttle-position-sensor adjustment, fuel-cock testing, air-induction diagnosis, radiator testing, thermostat inspection, and water-pump repair.
• Includes wheel and hub service, front caliper and master-cylinder overhaul, hydraulic brake bleeding, rear drum-brake work, fork-leg rebuilding, steering-head service, swingarm inspection, and drive-chain and sprocket replacement.
• Provides ignition, T135SE electric-start, charging, lighting, signaling, and cooling-system circuit diagrams, plus switch tests, starter-motor repair, sensor self-diagnosis, fault isolation, and the full T135SE/T135S wiring diagram.
• Supplies engine and chassis torque tables, fluid and lubrication data, clearances, wear limits, electrical test specifications, cable-routing drawings, exploded views, and Yamaha special-tool numbers.

This Yamaha factory service manual is specific to the 134.4 cc liquid-cooled SOHC single-cylinder engine and VM22 carburetor used in the covered 5YP builds. It also matches the DC-CDI ignition, wet multiple-disc and centrifugal automatic clutch, and constant-mesh four-speed transmission. Its fuel-system repair information is for the carbureted configuration; it is not a fuel-injection manual. Yamaha states that the book was produced primarily for its dealers and qualified mechanics. It assumes the user already understands basic motorcycle repair methods and has access to the specified measuring equipment and special tools.

Engine, Fuel, and Cooling Work

The top-end chapters go beyond routine valve adjustment. They cover camshaft and rocker-arm inspection, valve-guide replacement and reaming, valve-seat checking and lapping, spring inspection, piston-ring and piston-pin checks, cylinder measurement, cam timing, and tensioner installation. Bottom-end coverage includes crankcase separation, crankshaft and connecting-rod inspection, bearing checks, and crankshaft installation.

Clutch material addresses the plates and springs, housing, boss, pressure plate, push rods, centrifugal shoe and housing, cage, and release arm. The transmission section follows the shift forks, guide bar, drum, gears, main axle, and drive axle through disassembly, inspection, and reassembly. T135SE-only procedures identify the starter clutch and starter motor so those parts are not confused with the shared T135S repair coverage.

The carburetor chapter breaks down the accelerator pump, coasting enricher, float, needle valve, jets, pilot-air circuit, and throttle valve, then covers float-height and throttle-position-sensor adjustment. Cooling-system work includes radiator and cap pressure checks, thermostat testing, fan-system diagnosis, and water-pump disassembly with mechanical-seal replacement. One engine-specific caution warns that moving the crankshaft during camshaft installation can damage components or leave the valve timing incorrect.

Chassis and Electrical Diagnosis

Wheel procedures add bearing and seal replacement, speedometer-drive service, rear-hub inspection, brake-disc measurement, and rear brake-shoe work. The suspension material takes the telescopic fork through damper-rod and oil-seal service, then covers the steering bearings, rear shock assemblies, swingarm, and chain drive. The brake chapter warns that solvent can swell and distort internal piston seals, and it calls for new caliper piston seals whenever the caliper is disassembled.

Electrical fault tracing is organized by circuit rather than as a single undifferentiated schematic. It includes component-location views, switch-continuity charts, coil and relay tests, charging and lighting checks, cooling-fan and thermo-sensor tests, and indicator-light self-diagnosis for the throttle-position and thermo-sensor circuits. The final troubleshooting chapter adds electrical, compression, and intake/exhaust fault charts for hard-start and no-start diagnosis.

The named visual references include Cooling System Diagrams, multi-page Cable Routing drawings, and Air Induction System Diagrams. Electrical examples include the Ignition System Circuit Diagram, T135SE Electric Starting System Circuit Diagram, and full T135SE/T135S Wiring Diagram.

Specifications, Tools, and File Scope

The factory tables provide component-specific torque specifications, service limits, running clearances, fluid capacities, lubrication points, carburetor settings, suspension data, and electrical resistance and output checks. Named Yamaha tools include the crankcase separator 90890-01135; crankshaft installer pot, bolt, and adapter 90890-01274 / 90890-01275 / 90890-01278; radiator-cap tester and adapter 90890-01325 / 90890-01352; fork-seal drivers 90890-01184 / 90890-01186; mechanical-seal installer 90890-04145; and ignition checker 90890-06754.

The file contains 346 PDF pages and begins with Yamaha's Notice page rather than the title/copyright leaf. Internal engine pages 4-15 through 4-24 are duplicated once; the technical content otherwise continues through all nine listed chapters and the final model-specific wiring diagram.

Follow the manual's specific precautions for gasoline, hydraulic brake fluid, batteries, and the hot, pressurized cooling system. Improper service in these areas can damage components or leave the motorcycle unsafe.