lc135

CHECKING THE BULBS AND BULB SOCKETS ELEC

CHECKING THE CONDITION OF THE
BULB SOCKETS

The following procedure applies to all of the
bulb sockets.

1. Check:
9bulb socket (for continuity)
(with the pocket tester)
No continuity → Replace.

Pocket tester
90890-03112

NOTE:
Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.

@@@@@@@@@@@@@@@@@@@@@@@@
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the
respective leads of the bulb socket.
c. Check the bulb socket for continuity. If any
of the readings indicate no continuity,
replace the bulb socket.

999999999999999999999999

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Downloaded from www.Manualslib.com manuals search engine OFF R R Br B/L P B G/W L EAS00734
ON Br Br G/R W O W/Y Y
IGNITION SYSTEM
1 (BLACK) (BLACK)
CIRCUIT DIAGRAM
Br R WR RW

2 WW 9 W W O q
Y/R Y/R O B w
R B
R å T135SE WW
R R/W WB Y/R Y
Br L/W R Y/R
BB
3 R/W R
L/W Br Br Br BR
L/W L/W B/L L Y

Br Br 6 L L 0 Br Br
RR Y Y r W/Y L
7
R/W R/W e G/R Br Br
L/W L/W L/W L/W (BLACK)
R R/W R/W BB tB/L G/R
Br L/W W/Y L
4R R R/W L/W G/R B/L
W/Y
5 OFF G/W L
START B/L P
y
8
LL
BB

8-10 B/L Br B B

http://www.motorcycle.in.th B

Br Br Br IGNITION SYSTEM ELEC

p oBr/W u i
Br
G/Y B Br
Y B G/Y
(BLACK) (BLACK)
; Br L Ch Dg
G/Y ∫ T135S
Br/W
R
Y/W Sb Sb Y/W v b n m, . / ! @ P Br Y/R Br/W
G/W W W G/W z 3
L/W P P L/W aP d f P Dg Dg P
s B Br/W Br/W B
(BLACK) (BLACK) HI L L/B Ch Ch Y/R
OFF LO N
R (RED) (RED)
PUSH

L Br Br L
Dg Ch Ch Dg
BG GB

GB Sb W P Y/W L/W G /W B Ch Dg
YG

Sb W P Y/W L/W

1 Main switch G YY G Ch Dg L G/Y R
3 Fuse
x l Ch L Dg L 4R

4 Battery GG B jk jk g
BB
L L
9 (BLACK) (BLACK) cW Ch Dg
A. C. magneto B B
B W
LB BL
0 C. D. I. unit P Sb Sb P Ch Dg BL
B B Y
Y/W L/W L/W Y/W hh
Ch Dg
q Ignition coil
w Spark plug
B LB
G/Y
Dg Ch

EAS00736 IGNITION SYSTEM ELEC

TROUBLESHOOTING EAS00739

The ignition system fails to operate (no 2. Battery
spark or intermittent spark). 9Check the condition of the battery.

Check: Refer to “CHECKING AND CHARGING THE
1. fuse BATTERY” in chapter 3.
2. battery
3. spark plug Minimum open-circuit voltage
4. ignition spark gap 12.8 V or more at 20° C
5. spark plug cap resistance
6. ignition coil resistance 9Is the battery OK?
7. pickup coil resistance
8. main switch YES NO
9. wiring connections (of the entire ignition
system) 9Clean the battery
terminals.
NOTE:
9Before troubleshooting, remove the following 9Recharge or
replace the battery.
part(s):
1. side cowlings (left and right) EAS00740
2. front cowling
3. center panels (upper and lower) 3. Spark plug
4. rear cowlings (left and right)
5. inner panel 9Check the condition of the spark plug.
9Troubleshoot with the following special tool(s). 9Check the spark plug type.
9Measure the spark plug gap.
Ignition checker
90890-06754 Refer to “CHECKING THE SPARK PLUG” in
chapter 3.
Pocket tester
90890-03112 Standard spark plug
CPR8EA-9 (NGK)
EAS00738
Spark plug gap
1. Fuse 0.8–0.9 mm (0.031–0.035 in)
9Check the fuse for continuity.
9Is the spark plug in good condition, is it of
Refer to “CHECKING THE FUSE” in chapter the correct type, and is its gap within spec-
3. ification?
9Is the fuse OK?
YES NO

Re-gap or replace
the spark plug.

YES NO

Replace the fuse.

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EAS00742 IGNITION SYSTEM ELEC

4. Ignition spark gap EAS00744

9Disconnect the spark plug cap from the 5. Spark plug cap resistance
spark plug. 9Remove the spark plug cap from the spark

9Connect the ignition checker 1 as shown. plug lead.
2 Spark plug cap 9Connect the pocket tester (“ Ω⋅ 1k” range) to

9Set the main switch to “ON”. the spark plug cap as shown.
9Crank the engine by pushing the start switch 9Measure the spark plug cap resistance.

and gradually increase the spark gap until a
misfire occurs.
9Measure the ignition spark gap a .

a 1 Spark plug cap resistance
2 5 kΩ at 20° C (68° F)

9Is the spark plug cap OK?

Minimum ignition spark gap YES NO
6 mm (0.24 in)
Replace the spark
9Is there a spark and is the spark gap within plug cap.
specification?

NO YES

The ignition system
is OK.

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EAS00746 IGNITION SYSTEM ELEC

6. Ignition coil resistance EAS00748

9Disconnect the ignition coil connector from 7. Pickup coil resistance
the ignition coil terminal. 9Disconnect the pickup coil coupler from the

9Connect the pocket tester ( Ω⋅ 1) to the igni- wire harness.
tion coil as shown. 9Connect the pocket tester ( Ω⋅ 100) to the

Positive tester probe →→terminal 11 pickup coil terminal as shown.
Negative tester probe →→ Positive tester probe →→white 11
Negative tester probe →→red 22
ignition coil base 22

2 B YW RW

1 21

9Measure the primary coil resistance. 9Measure the pickup coil resistance.

Primary coil resistance Pickup coil resistance
0.32–0.48 Ω at 20° C (68° F) 248–372 Ω at 20° C (68° F)

9Connect the pocket tester ( Ω⋅ 1k) to the (between white and red)
ignition coil as shown.
9Is the pickup coil OK?
Negative tester probe →→terminal 11
Positive tester probe →→spark plug lead 22 YES NO

Replace the stator
coil/pickup coil
assembly.

21 EAS00749

9Measure the secondary coil resistance. 8. Main switch
9Check the main switch for continuity.
Secondary coil resistance
5.68–8.52 kΩ at 20° C (68° F) Refer to “CHECKING THE SWITCHES”.
9Is the main switch OK?
9Is the ignition coil OK?
YES NO

Replace the main
switch.

YES NO

Replace the ignition
coil.

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IGNITION SYSTEM ELEC

EAS00754

9. Wiring
9Check the entire ignition system wiring.

Refer to “CIRCUITDIAGRAM”.
9Is the ignition system wiring properly con-

nected and without defects?

YES NO

Replace the C.D.I. Properly connect or
unit. repair the ignition
system wiring.

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Downloaded from www.Manualslib.com manuals search engine OFF R R Br B/L P B G/W L ELECTRIC STARTING SYSTEM (T135SE) ELEC
ON Br Br G/R W O W/Y Y
EAS00755
1 (BLACK) (BLACK)
ELECTRIC STARTING SYSTEM (T135SE)
Br R WR RW
CIRCUIT DIAGRAM
2 WW 9 W W O q
Y/R Y/R O B w
R
R WW
R R/W WB Y/R Y
Br L/W R Y/R
BB
3 R/W R
L/W Br Br Br B BR
L/W L/W B/L L Y
6
Br Br 7 L L 0 Br Br
RR Y Y r W/Y L
L/W L/W
R/W R/W BB e G/R Br Br
L/W L/W (BLACK)
R R/W R/W B tB/L G/R
Br L/W W/Y L
4R R R/W L/W G/R B/L
W/Y
5 OFF G/W L
START B/L P
y
8
LL
BB

8-15 B/L Br B B

http://www.motorcycle.in.th Br Br Br

p oBr/W u i
Br
G/Y B Br
Y B G/Y
(BLACK) (BLACK)
; Br L Ch Dg
G/Y
Br/W

Y/W Sb Sb Y/W v b n m, . / ! @ P Br Y/R Br/W
G/W W W G/W z
L/W P P L/W aP d f P Dg Dg P
s B Br/W Br/W B
(BLACK) (BLACK) HI L L/B Ch Ch Y/R
OFF LO N
R (RED) (RED)
PUSH

L Br Br L
Dg Ch Ch Dg
BG GB

GB Sb W P Y/W L/W G/W B Ch Dg
YG

Sb W P Y/W L/W

1 Main switch G YY G Ch Dg L G/Y
3 Fuse G G
x l Ch L Dg L

4 Battery B B B jk jk g
5 (BLACK) (BLACK) cW
W L L
Starter motor B Ch Dg
6 Starter relay P Sb Sb P B B BL
Y
Y/W L/W L/W Y/W LB BL hh
Ch Dg Ch Dg
7 Right handlebar switch B B
8 Start switch B LB
G/Y
Dg Ch

ELECTRIC STARTING SYSTEM (T135SE) ELEC

EAS00757 EAS00739

TROUBLESHOOTING 2. Battery
9Check the condition of the battery.
The starter motor fails to turn.
Refer to “CHECKING AND CHARGING THE
Check: BATTERY” in chapter 3.
1. fuse
2. battery Minimum open-circuit voltage
3. starter motor 12.8 V or more at 20 ° C
4. starter relay
5. main switch 9Is the battery OK?
6. start switch
7. wiring connections YES NO
(of the entire starting system)
9Clean the battery
NOTE: terminals.
9Before troubleshooting, remove the following
9Recharge or
part(s): replace the bat-
1. side cowlings (left and right) tery.
2. front cowling
3. center panels (upper and lower) EAS00758
4. rear cowlings (left and right)
5. inner panel 3. Starter motor
9Troubleshoot with the following special tool(s). 9Connect the positive battery terminal 1 and

starter motor lead 2 with a jumper lead 3 .

Pocket tester w
90890-03112
9Awire that is used as a jumper lead must
EAS00738
have at least the same capacity or more
1. Fuse
9Check the fuse for continuity. as that of the battery lead, other-wise the

Refer to “CHECKING THE FUSE” in chapter jumper lead may burn.
3. 9This check is likely to produce sparks,
9Is the fuse OK?
therefore make sure nothing flammable is
YES NO
in the vicinity.
Replace the fuse.

9Does the starter motor turn?

YES NO

Repair or replace
the starter motor.

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ELECTRIC STARTING SYSTEM (T135SE) ELEC

EAS00761 EAS00764

4. Starter relay 6. Start switch
9Check the start switch for continuity.
9Remove the starter relay from the starter
relay coupler on the wire harness. Refer to “CHECKING THE SWITCHES”.
9Is the start switch OK?
9Connect the pocket tester ( Ω⋅ 1) and bat-
tery (DC 12 V) to the starter relay coupler as YES NO
shown.
Replace the right
Positive battery terminal →→brown 11 handlebar switch.
Negative battery terminal →→blue/white 22
EAS00766
Positive tester probe →→red 33
Negative tester probe →→red/white 44 7. Wiring
9Check the entire starting system wiring.
3
Refer to “CIRCUITDIAGRAM”.
R 9Is the starting system wiring properly con-

R/W R R R/W nected and without defects?
L/W Br Br L/W

R/W 2 1 YES NO
4
The starting sys- Properly connect or
9Does the starter relay have continuity tem circuit is OK. repair the starting
between red and red/white? system wiring.

YES NO

Replace the starter
relay.

EAS00749

5. Main switch
9Check the main switch for continuity.

Refer to “CHECKING THE SWITCHES”.
9Is the main switch OK?

YES NO

Replace the main
switch.

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STARTER MOTOR (T135SE) ELEC

EASF0061

STARTER MOTOR (T135SE)

1 Starter motor yoke
2 Armature
3 Brush set
4 Starter motor lead
5 Starter motor front cover

1

2

5
3

4

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STARTER MOTOR (T135SE) ELEC

REMOVING THE STARTER MOTOR

1. Remove:
9breather pipe 1

1 2. Remove:
1 9starter motor 1

1 3. Remove:
9starter motor lead 1

2 DISASSEMBLING THE STARTER
3 MOTOR

1 1. Remove:
9starter motor front cover bolts
(with washers)
9starter motor front cover 1
9O-ring 2
9armature 3

EAS00769

CHECKING THE STARTER MOTOR

1. Check:
9commutator
Dirt → Clean with 600-grit sandpaper.

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STARTER MOTOR (T135SE) ELEC

2. Measure:
9commutator diameter a
Out of specification → Replace the starter
motor.

Commutator wear limit
16.6 mm (0.65 in)

3. Measure:
9mica undercut a
Out of specification → Scrape the mica to
the proper measurement with a hacksaw
blade that has been grounded to fit the
commutator.

Mica undercut
1.35 mm (0.05 in)

NOTE:
The mica of the commutator must be undercut
to ensure proper operation of the commutator.

Downloaded from www.Manualslib.com manuals search engine 4. Measure:
9armature assembly resistances (commuta-
tor and insulation)
Out of specification → Replace the starter
motor.

@@@@@@@@@@@@@@@@@@@@@@@@
a. Measure the armature assembly resis-
tances with the pocket tester.

Pocket tester
90890-03112

Armature coil
Commutator resistance 11
0.0315–0.0385 Ω at 20° C (68° F)
Insulation resistance 22
Above 1 MΩ at 20° C (68° F)

b. If any resistance is out of specification,
replace the starter motor.

999999999999999999999999

8-20

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STARTER MOTOR (T135SE) ELEC

5. Measure:
9brush length a
Out of specification → Replace the brush-
es as a set.

Brush length wear limit
3.5 mm (0.14 in)

a

6. Measure:
9brush spring force
Out of specification → Replace the brush
springs as a set.

Brush spring force
3.92–5.88 N (400–600 gf)

7. Check:
9gear teeth
Damage/wear → Replace the armature.

Downloaded from www.Manualslib.com manuals search engine EAS00772

ASSEMBLING THE STARTER MOTOR

1. Install:
9O-ring
9armature
(in start motor front cover 1 )
9O-ring
9starter motor yoke
9starter motor front cover bolts
(with washers)
9O-ring

NOTE:
Align the mark a on the starter motor yoke with
the mark b on the starter motor front cover.

INSTALLING THE STARTER MOTOR

For installation, reverse the removal procedure.

8-21

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Downloaded from www.Manualslib.com manuals search engine OFF R R Br B/L P B G/W L EAS00773
ON Br Br G/R W O W/Y Y
CHARGING SYSTEM
1 (BLACK) (BLACK)
CIRCUIT DIAGRAM
Br R WR RW

2 WW 9 W WO O q
Y/R Y/R B w
R B
R å T135SE WW
R R/W WB Y/R Y
Br L/W R Y/R
BB
3 R/W R
L/W Br Br Br BR
L/W L/W B/L L Y

Br Br 6 L L 0 Br Br
RR Y Y r W/Y L
7
R/W R/W e G/R Br Br
L/W L/W L/W L/W (BLACK)
R R/W R/W BB tB/L G/R
Br L/W W/Y L
4R R R/W L/W G/R B/L
W/Y
5 OFF G/W L
START B/L P
y
8
LL
BB

8-22 B/L Br B B

http://www.motorcycle.in.th B

Br Br Br CHARGING SYSTEM ELEC

p oBr/W u i
Br
G/Y B Br
; Br L Y B G/Y
(BLACK) (BLACK)
Ch Dg
G/Y ∫ T135S
Br/W
R
Y/W Sb Sb Y/W v b n m, . / ! @ P Br Y/R Br/W
G/W W W G/W z 3
L/W P P L/W aP d f P Dg Dg P
s B Br/W Br/W B
(BLACK) (BLACK) HI L L/B Ch Ch Y/R
OFF LO N
R (RED) (RED)
PUSH

L Br Br L
Dg Ch Ch Dg
BG GB

GB Sb W P Y/W L/W G/W B Ch Dg
YG

Sb W P Y/W L/W

G YY G Ch Dg L G/Y R

x l Ch L Dg L 4R

GG B jk jk

BB L L g
Ch Dg
2 Rectifie(BrLA/CrKe) (gBLuAClKa) tor cW W B B
3 Fuse B
P Sb Sb P LB BL BL
Ch Dg Y
4 Battery Y/W L/W L/W Y/W B B hh
Ch Dg
9 A. C. magneto
B LB
G/Y
Dg Ch

CHARGING SYSTEM ELEC

EAS00774 EAS00739

TROUBLESHOOTING 2. Battery
9Check the condition of the battery.
The battery cannot be charged.
Refer to “CHECKING AND CHARGING THE
Check: BATTERY” in chapter 3.
1. fuse
2. battery Minimum open-circuit voltage
3. charging voltage 12.8 V or more at 20 ° C
4. charging coil resistance
5. wiring connections 9Is the battery OK?
(of the entire charging system)
YES NO
NOTE:
9Before troubleshooting, remove the following 9Clean the battery

part(s): terminals.
1. side cowlings (left and right) 9Recharge or
2. front cowling
3. center panels (upper and lower) replace the bat-
4. rear cowlings (left and right)
5. inner panel tery.
9Troubleshoot with the following special tool(s).

Engine tachometer
90890-03113

Pocket tester
90890-03112

EAS00738

1. Fuse
9Check the fuse for continuity.

Refer to “CHECKING THE FUSE” in chapter
3.
9Is the fuse OK?

YES NO

Replace the fuse.

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CHARGING SYSTEM ELEC

EAS00775 EAS00776

3. Charging voltage 4. Charging coil resistance

9Connect the engine tachometer to the spark 9Disconnect the stator coil coupler from the
plug lead. wire harness.

9Connect the pocket tester (DC 20 V) to the 9Connect the pocket tester ( Ω⋅ 1) to the
battery as shown. charging coil terminals as shown.

Positive tester probe →→ Positive tester probe →→white 11
positive battery terminal 11 Negative tester probe →→black 22

Negative tester probe →→
negative battery terminal 22

9Start the engine and let it run at approxi- B Y W RW
mately 5,000 r/min.
21
9Measure the charging voltage.
Charging voltage 9Measure the charging coil resistances.
14 V at 5,000 r/min
Charging coil resistance
NOTE: 0.38–0.58 Ω at 20° C (68° F) (W – B)
Make sure the battery is fully charged.
9Is the charging coil OK?
9Is the charging voltage within specification?
YES NO
NO YES
Replace the stator
The charging circuit coil/pickup coil
is OK. assembly.

EAS00779

5. Wiring

9Check the wiring connections of the entire
charging system.
Refer to “CIRCUITDIAGRAM”.

9Is the charging system wiring properly con-
nected and without defects?

YES NO

Replace the rectifi- Properly connect or
er/regulator. repair the charging
system wiring.

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Downloaded from www.Manualslib.com manuals search engine 2 Rectifier/ regulator EAS00780
Br B/L P B G/W L 9 A. C. magneto
OFF R R G/R W O W/Y Y d Dimmer switch LIGHTING SYSTEM
ON Br Br (BLACK) (BLACK)
CIRCUIT DIAGRAM
1 WR RW W O g Tail/ brake light

Br R 2 WW 9 W k OAuxiliary lighqt
Y/R Y/R
R B
R å T135SE WW l MHBeeatedrlilgighht tw
R R/W WB Y/R Y v
Br L/W R Y/R
BB
3 R/W R b High beam indicator light
L/W Br Br Br BR
L/W L/W B/L L Y Br Br

Br Br 6 L 0L
RR Y rY W/Y L
7
R/W R/W e Br Br
L/W L/W L/W L/W
BB G/R (BLACK)
Br L/W
R R/W R/W L/W tB/L G/R W/Y L

4R R R/W OFF W/Y
START L
5
8 G/R B/L y

G/W LL
B/L P BB

8-25 B/L Br B B

http://www.motorcycle.in.th B

Br Br Br LIGHTING SYSTEM ELEC

p oBr/W u i
Br
G/Y B Br
; Br L Y B G/Y
(BLACK) (BLACK)
Ch Dg
G/Y ∫ T135S
Br/W
R
Y/W Sb Sb Y/W v b n m, . / ! @ P Br Y/R Br/W
G/W W W G/W z 3
L/W P P L/W aP d f P Dg Dg P
s B Br/W Br/W B
(BLACK) (BLACK) HI L L/B Ch Ch Y/R
OFF LO N
R (RED) (RED)
PUSH

L Br Br L
Dg Ch Ch Dg
BG GB

GB Sb W P Y/W L/W G/W B Ch Dg
YG

Sb W P Y/W L/W

G YY G Ch Dg L G/Y R

x l Ch L Dg L 4R

GG cW B jk jk g
BB
(BLACK) (BLACK) W L L
Ch Dg
B P Sb Sb P B B BL
Y
Y/W L/W L/W Y/W LB BL hh
Ch Dg Ch Dg
B B
B LB
G/Y
Dg Ch

EAS00781 LIGHTING SYSTEM ELEC

TROUBLESHOOTING EAS00776

Any of the following fail to light: head- 1. Lighting coil resistance
light, high beam indicator light, taillight, 9Disconnect the stator coil coupler from the
auxiliary light, or meter light.
wire harness.
Check: 9Connect the pocket tester ( Ω⋅ 1) to the
1. lighting coil resistance
2. wiring connections lighting coil terminals as shown.
(of the entire lighting system) Positive tester probe →→yellow 11
Negative tester probe →→black 22
NOTE:
9Before troubleshooting, remove the following B Y W RW

part(s): 21
1. side cowlings (left and right) 9Measure the lighting coil resistances.
2. front cowling
3. center panels (upper and lower) Lighting coil resistance
4. rear cowling (right) 0.29–0.43 Ω at 20° C (68° F) (Y– B)
5. inner panel
6. headlight assembly 9Is the lighting coil OK?
9Troubleshoot with the following special tool(s).

Pocket tester
90890-03112

YES NO

Replace the stator
coil/pickup coil
assembly.

EAS00787

2. Wiring

9Check the entire lighting system wiring.
Refer to “CIRCUITDIAGRAM”.

9Is the lighting system wiring properly con-
nected and without defects?

YES NO

Check the condi- Properly connect or
tion of each of the repair the lighting
lighting system cir- system wiring.
cuits.
Refer to “CHECK-
ING THE LIGHT-
ING SYSTEM”.

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EAS00788 LIGHTING SYSTEM ELEC

CHECKING THE LIGHTING SYSTEM 3. Voltage
9Connect the pocket tester (AC 20 V) to the
1. The headlight and the high beam indicator
light fail to come on. headlight and high beam indicator light con-
nectors as shown.
EAS00784 å When the dimmer switch is set to “ % ”.
∫ When the dimmer switch is set to “ & ”.
1. Dimmer switch
9Check the dimmer switch for continuity.

Refer to “CHECKING THE SWITCHES”.
9Is the dimmer switch OK?

YES NO

The dimmer switch Headlight
is faulty. Replace Positive tester probe →→
the left handlebar
switch. green 11or yellow 22
Negative tester probe →→black 33
2. Headlight bulb and socket

9Check the headlight bulb and socket for con-
tinuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.

9Are the headlight bulb and socket OK?

YES NO

Replace the head- High beam indicator light
light bulb, socket or Positive tester probe →→yellow 44
both. Negative tester probe →→black 55

9Set the main switch to “ON”.

9Start the engine.

9Set the dimmer switch to “ % ” or “& ”.

9Measure the voltage (AC 12 V) of green 1
(yellow 2 ) on the headlight connector (wire
harness side) and yellow 4 on the meter

assembly connector (wire harness side).

9Is the voltage within specification?

YES NO
This circuit is OK.
Replace the rectifi-
er/regulator.

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EAS00789 LIGHTING SYSTEM ELEC

2. The meter light fails to come on. EAS00790

1. Meter light bulb and socket 3. The tail/brake light fails to come on.
9Check the meter light bulb and socket for
1. Tail/brake light bulb and socket
continuity. 9Check the tail/brake light bulb and socket for
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”. continuity.
9Are the meter light bulb and socket OK? Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
9Are the tail/brake light bulb and socket OK?

YES NO YES NO

Replace the meter Replace the tail/
light bulb, socket or brake light bulb,
both. socket or both.

2. Voltage 2. Voltage

9Connect the pocket tester (AC 20 V) to the 9Connect the pocket tester (AC 20 V) to the
meter light coupler (wire harness side) as tail/brake light coupler (wire harness side) as
shown. shown.

Positive tester probe →→blue 11 Positive tester probe →→blue 11
Negative tester probe →→black 22 Negative tester probe →→black 22

1 12

Br L L Br BL LB
Ch Dg Dg Ch Y G/Y
GB BG Dg Ch
Ch Dg

2

9Set the main switch to “ON”. 9Set the main switch to “ON”.
9Start the engine. 9Start the engine.
9Measure the voltage (AC 12 V) of blue lead 9Measure the voltage (AC 12 V) of blue lead

terminal 1 on the meter light coupler (wire terminal 1 on the tail/brake light coupler

harness side). (wire harness side).
9Is the voltage within specification? 9Is the voltage within specification?

YES NO YES NO
This circuit is OK. This circuit is OK.
Replace the rectifi- Replace the rectifi-
er/regulator. er/regulator.

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LIGHTING SYSTEM ELEC

4. The auxiliary light fails to come on.

1. Meter light bulb and socket

9Check the meter light bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.

9Are the meter light bulb and socket OK?

YES NO

Replace the auxil-
iary light bulb,
socket or both.

2. Voltage

9Connect the pocket tester (AC 20 V) to the
auxiliary light coupler (wire harness side) as
shown.

Positive tester probe →→blue 11
Negative tester probe →→black 22

[L] 1

[R] LL
Ch Ch
BB

1

LL
Dg Dg
BB

9Set the main switch to “ON”.
9Start the engine.
9Measure the voltage (AC 12 V) of blue lead

terminal 1 on the auxiliary light coupler

(wire harness side).
9Is the voltage within specification?

YES NO
This circuit is OK.
Replace the rectifi-
er/regulator.

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Downloaded from www.Manualslib.com manuals search engine OFF R R Br B/L P B G/W L EAS00793
ON Br Br G/R W O W/Y Y
SIGNALING SYSTEM
1 (BLACK) (BLACK)
CIRCUIT DIAGRAM
Br R WR RW

2 WW 9 W W O q
Y/R Y/R O B w
R B
R å T135SE WW
R R/W WB Y/R Y
Br L/W R Y/R
BB
3 R/W R
L/W Br Br Br BR
L/W L/W B/L L Y

Br Br 6 L L 0 Br Br
RR Y Y r W/Y L
7
R/W R/W e G/R Br Br
L/W L/W L/W L/W (BLACK)
R R/W R/W BB tB/L G/R
Br L/W W/Y L
4R R R/W L/W G/R B/L
W/Y
5 OFF G/W L
START B/L P
y
8
LL
BB

8-30 B/L Br B B

http://www.motorcycle.in.th B

Br Br Br SIGNALING SYSTEM ELEC

p oBr/W u i
Br
G/Y B Br
; Br L Y B G/Y
(BLACK) (BLACK)
ChDg
G/Y ∫ T135S
Br/W
R
Y/W Sb Sb Y/W v b n m, . / ! @ P Br Y/R Br/W
G/W W W G/W z 3
L/W P P L/W aP d f P Dg Dg P
s B Br/W Br/W B
(BLACK) (BLACK) HI L L/B Ch Ch Y/R
OFF LO N
R (RED) (RED)
PUSH

L Br Br L
Dg Ch Ch Dg
GB
BG

GB Sb W P Y/W L/W G/W B Ch Dg
YG

Sb W P Y/W L/W

G YY G Ch Dg L G/Y R

x l Ch L Dg L 4R

GG cW B jk jk g
BB
(BLACK) (BLACK) W LL
Ch Dg
B P Sb Sb P BL
BB Y
Y/W L/W L/W Y/W hh
Ch Dg
LB BL
Ch Dg B LB
B G/Y
B Dg Ch

SIGNALING SYSTEM ELEC

1 Main switch
3 Fuse
4 Battery
u Front brake light switch
i Rear brake light switch
o Turn signal relay
p Horn
s Horn switch
f Turn signal switch
g Tail/brake light
h Rear turn signal light
j Front turn signal light
z Fuel gauge
x Fuel sender
c Neutral switch
n Turn signal indicator light
m Neutral indicator light
, 1st gear position indicator light
. 2nd gear position indicator light
/ 3rd gear position indicator light
! 4th gear position indicator light

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SIGNALING SYSTEM ELEC

EAS00794 EAS00739

TROUBLESHOOTING 2. Battery
9Check the condition of the battery.
9A9ny of the following fail to light: turn sig-
nal light, brake light or an indicator light. Refer to “CHECKING AND CHARGING THE
BATTERY” in chapter 3.
9T9he horn fails to sound.
Minimum open-circuit voltage
Check: 12.8 V or more at 20 ° C (68 ° F)
1. fuse
2. battery 9Is the battery OK?
3. main switch
4. wiring connections YES NO
(of the entire signaling system)
9Clean the battery
NOTE: terminals.
9Before troubleshooting, remove the following
9Recharge or
part(s): replace the bat-
1. side cowling (right) tery.
2. front cowling
3. center panel (lower) EAS00783
4. rear cowling (right)
5. headlight assembly 3. Main switch
9Troubleshoot with the following special tool(s).
9Check the main switch for continuity.
Pocket tester Refer to “CHECKING THE SWITCHES”.
90890-03112
9Is the main switch OK?
EAS00738
YES NO
1. Fuse
9Check the fuse for continuity. Replace the main
switch.
Refer to “CHECKING THE FUSE” in chapter
3. EAS00795
9Is the fuse OK?
4. Wiring
YES NO 9Check the entire signaling system wiring.

Refer to “CIRCUITDIAGRAM”.
9Is the signaling system wiring properly con-

nected and without defects?

Replace the fuse.

YES NO

Check the condi- Properly connect or
tion of each of the repair the signaling
signaling system system wiring.
circuits.
Refer to “CHECK-
ING THE SIGNAL-
ING SYSTEM”.

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EAS00796 SIGNALING SYSTEM ELEC

CHECKING THE SIGNALING SYSTEM 3. Horn

1. The horn fails to sound. 9Disconnect the pink connector at the horn
terminal.
1. Horn switch
9Check the horn switch for continuity. 9Connect a jumper lead 1 to the horn termi-
nal and ground the jumper lead.
Refer to “CHECKING THE SWITCHES”.
9Is the horn switch OK? 9Set the main switch to “ON”.
9Does the horn sound?

YES NO Br

Replace the left han- 1
dlebar switch.

2. Voltage NO YES
The horn is OK.
9Connect the pocket tester (DC 20 V) to the
horn connector at the horn terminal as
shown.

Positive tester probe →→brown 11
Negative tester probe →→ground

Br P 4. Voltage
9Connect the pocket tester (DC 20 V) to the
1
horn connector at the pink terminal as
9Set the main switch to “ON”. shown.
9Measure the voltage (DC 12 V) of brown Positive tester probe →→pink 11
Negative tester probe →→ground
lead terminal at the horn terminal.
9Is the voltage within specification? Br P

1

YES NO

The wiring circuit 9Set the main switch to “ON”.
from the main switch 9Measure the voltage (DC 12 V) of pink lead
to the horn connec-
tor is faulty and must terminal 1 at the horn terminal.
be repaired. 9Is the voltage within specification?

YES NO

Repair or replace Replace the horn.
the horn.

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EAS00797 SIGNALING SYSTEM ELEC

2. The tail/brake light fails to come on. 3. Voltage
9Connect the pocket tester (DC 20 V) to the
1. Tail/brake light bulb and socket
9Check the tail/brake light bulb and socket for tail/brake light coupler (wire harness side) as
shown.
continuity. Positive tester probe →→green/yellow 11
Refer to “CHECKING THE BULBS AND Negative tester probe →→black 22
BULB SOCKETS”.
9Are the tail/brake light bulb and socket OK?

YES NO 12

Replace the tail/ BL LB
brake light bulb, Y G/Y
socket or both. Dg Ch
Ch Dg

2. Brake light switches 9Set the main switch to “ON”.
9Pull in the brake lever or push down on the
9Check the brake light switches for continuity.
Refer to “CHECKING THE SWITCHES”. brake pedal.
9Measure the voltage (DC 12 V) of green/yel-
9Is the brake light switch OK?
low lead terminal 1 on the tail/brake light
YES NO
coupler (wire harness side).
9Is the voltage within specification?

Replace the brake YES NO
light switch.

This circuit is OK. The wiring circuit
from the main
switch to the
tail/brake light cou-
pler is faulty and
must be repaired.

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SIGNALING SYSTEM ELEC

EAS00799 3. Voltage
9Connect the pocket tester (DC 20 V) to the
3. The turn signal light, turn signal indicator
light or both fail to blink. turn signal relay coupler as shown.
Positive tester probe →→brown 11
1. Turn signal indicator light bulb and socket Negative tester probe →→ground
9Check the turn signal light bulb and socket
Br/W
for continuity. 1 Br
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
9Are the turn signal light bulb and socket OK?

YES NO

Replace the turn sig- 9Set the main switch to “ON”.
nal light bulb, socket 9Measure the voltage (DC 12 V) on brown
or both.
lead terminal 1 at the turn signal relay cou-
2. Turn signal switch
pler.
9Check the turn signal switch for continuity. 9Is the voltage within specification?
Refer to “CHECKING THE SWITCHES”.
YES NO
9Is the turn signal switch OK?

YES NO The wiring circuit
from the main switch
Replace the left han- to the turn signal
dlebar switch. relay coupler is
faulty and must be
repaired.

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SIGNALING SYSTEM ELEC

4. Voltage 5. Voltage
9Connect the pocket tester (DC 20 V) to the
9Connect the pocket tester (DC 20 V) to the
turn signal relay coupler as shown.
Positive tester probe →→brown/white 11 turn signal light coupler (wire harness side)
Negative tester probe →→ground
as shown.
1 Br/W
Br Turn signal light
åå Rear
9Set the main switch to “ON”. ∫∫ Front
9Measure the voltage (DC 12 V) on
Left turn signal light
brown/white lead terminal 1 at the turn sig- Positive tester probe →→chocolate 11
Negative tester probe →→ground
nal relay coupler.
9Is the voltage within specification? Right turn signal light
Positive tester probe →→dark green 22
Negative tester probe →→ground

çç Turn signal indicator light
Positive tester probe →→chocolate 33
Negative tester probe →→ground
Positive tester probe →→dark green 44
Negative tester probe →→ground

A

YES NO

The turn signal relay BL LB
is faulty and must be Y G/Y
replaced. Dg Ch
Ch Dg
21

B
[L]

LL

Ch Ch

B B1

[R]
LL
Dg Dg
B B2

C
43

Br L L Br
Ch Dg Dg Ch
GB BG

Sb Y/W Y/WSb
W G/W G/WW
P L/W L/W P

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9Set the main switch to “ON”. SIGNALING SYSTEM ELEC
9Set the turn signal switch to “ 4 ” or “6 ”.
9Measure the voltage (DC 12 V) of the EAS00801

chocolate 1 or dark green lead terminal 2 4. The gear position indicator lights fail to
come on.
at the turn signal light coupler (wire har-
ness side) and chocolate 3 or dark green 1. Gear position indicator light bulb and socket
4 at the turn signal indicator light coupler 9Check the gear position indicator light bulb

(wire harness side). and socket for continuity.
9Is the voltage within specification? Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
9Are the gear position indicator light bulb and
socket OK?

YES NO

YES NO

This circuit is OK. The wiring circuit
from the turn signal
switch to the turn Replace the gear
signal light coupler position indicator
is faulty and must light bulb, socket or
be repaired. both.

2. Neutral switch

9Check the neutral switch for continuity.
Refer to “CHECKING THE SWITCHES”.

9Is the neutral switch OK?

YES NO

Replace the neutral
switch.

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SIGNALING SYSTEM ELEC

3. Voltage EAS00804

9Connect the pocket tester (DC 20 V) to the 5. The fuel level gauge fails to operate.

meter assembly coupler (wire harness side) 1. Fuel sender
9Remove the fuel sender from the fuel tank.
as shown. 9Connect the pocket tester to the fuel sender

Neutral indicator light coupler (fuel sender side) as shown.
Positive tester probe →→sky blue 11 Positive tester probe →→green 11
Negative tester probe →→ground Negative tester probe →→black 22

1st gear position indicator light 12
Positive tester probe →→white 22
Negative tester probe →→ground BG

2nd gear position indicator light å
Positive tester probe →→pink 33
Negative tester probe →→ground ∫

3rd gear position indicator light 9Measure the fuel sender resistances.
Positive tester probe →→yellow/white 44
Negative tester probe →→ground Fuel sender resistance
(up position åå)
4th gear position indicator light
Positive tester probe →→blue/white 55 (Ω ⋅⋅ 1)
Negative tester probe →→ground 4–10 Ω at 20° C (68° F)
Fuel sender resistance
Br L L Br (down position ∫∫ )
(Ω ⋅⋅ 10)
Ch Dg Dg Ch 90–100 Ω at 20° C (68° F)
9Is the fuel sender OK?
GB BG

1

Sb Y/W Y/WSb

W G/WG /W W

2P L/W L/W P
45 3

9Set the main switch to “ON”. YES NO
9Shift the transmission into each gear.
9Measure the voltage (DC 12 V) of the sky Replace the fuel
sender.
blue 1 , white 2 , pink 3 , yellow/white 4 , or
blue/white 5 lead terminal at the meter

assembly coupler (wire harness side).
9Is the voltage within specification?

YES NO

This circuit is OK. The wiring circuit
from the main
switch to the meter
assembly coupler
is faulty and must
be repaired.

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SIGNALING SYSTEM ELEC

2. Voltage 3. Fuel level gauge
9Connect the pocket tester (DC 20 V) to the
9Set the main switch to “ON”.
meter assembly coupler (wire harness side) 9Move the float up 1 or down 2 .
as shown. 9Check that the fuel level gauge needle
Positive tester probe →→brown 11
Negative tester probe →→ground moves to “F” or “E”.

1 NOTE:
Before reading the fuel level gauge, leave the
float in one position (either up or down) for at
least three minutes.

Br L L Br 1
Ch Dg Dg Ch
GB BG

9Set the main switch to “ON”. 2
9Measure the voltage (DC 12 V) of brown
9Does the fuel level gauge needle move
lead terminal 1 on the meter assembly cou- appropriately?

pler (wire harness side).
9Is the voltage within specification?

YES NO

YES NO

Check the wiring Replace the fuel
connections of the level gauge.
entire signaling sys-
tem

4. Wiring
Check the entire signaling system’s wiring.

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Downloaded from www.Manualslib.com manuals search engine OFF R R Br B/L P B G/W L COOLING SYSTEM
ON Br Br G/R W O W/Y Y
CIRCUIT DIAGRAM
1 (BLACK) (BLACK)

Br R WR RW

2 WW 9 W WO O q
Y/R Y/R B w
R B
R å T135SE WW
R R/W WB Y/R Y
Br L/W R Y/R
BB
3 R/W R
L/W Br Br Br BR
L/W L/W B/L L Y

Br Br 6 L L 0 Br Br
RR Y Y r W/Y L
7
R/W R/W e G/R Br Br
L/W L/W L/W L/W (BLACK)
R R/W R/W BB B/L G/R
Br L/W W/Y L
4R R R/W L/W t W/Y

5 OFF G/R B/ L
START
G/W y
8 B/L P
LL
BB

8-40 B/L Br B B

http://www.motorcycle.in.th B

Br Br Br COOLING SYSTEM ELEC

p oBr/W u i
Br
G/Y B Br
; Br L Y B G/Y
(BLACK) (BLACK)
Ch Dg
G/Y ∫ T135S
Br/W
R
Y/W Sb Sb Y/W v b n m, . / ! @ P Br Y/R Br/W
G/W W W G/W z 3
L/W P P L/W aP d f P Dg Dg P
s B Br/W Br/W B
(BLACK) (BLACK) HI L L/B Ch Ch Y/R
OFF LO N
R (RED) (RED)
PUSH

L Br Br L
Dg Ch Ch Dg
BG GB

GB Sb W P Y/W L/W G/W B Ch Dg
YG

Sb W P Y/W L/W

G

1 Main switch x y Fan motor YY G Ch Dg L G/Y R
@ Coolant temperature
3 Fuse GG l Ch L Dg L 4R
4 BB
B jk jk g
Battery(BLACK) (BLACK) wcarnWing indicator light
0 C.D.I. unit B W L L
Ch Dg
P Sb Sb P B B BL
Y
r Fan motor relay Y/W L/W L/W Y/W LB BL hh
Ch Dg Ch Dg
t Thermo sensor B B
B LB
G/Y
Dg Ch

TROUBLESHOOTING COOLING SYSTEM ELEC

9The radiator fan motor fails to turn. EAS00739

Check: 2. Battery
1. fuse 9Check the condition of the battery.
2. battery
3. main switch Refer to “CHECKING AND CHARGING THE
4. fan motor BATTERY” in chapter 3.
5. fan motor relay
6. thermo sensor Minimum open-circuit voltage
7. wiring harness 12.8 V or more at 20 ° C (68 ° F)
(of the entire cooling system)
9Is the battery OK?
NOTE:
9Before troubleshooting, remove the following YES NO

part(s): 9Clean the battery
1. side cowlings (left and right) terminals.
2. center panel (lower)
3. rear cowling (right) 9Recharge or
4. coolant replace the bat-
9Troubleshoot with the following special service tery.
tool(s).
EAS00783

3. Main switch

9Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.

9Is the main switch OK?

Pocket tester YES NO
90890-03112
Replace the main
Digital circuit tester switch.
90890-03174

EAS00738

1. Fuse
9Check the fuse for continuity.

Refer to “CHECKING THE FUSE” in chapter
3.
9Is the fuse OK?

YES NO

Replace the fuse.

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COOLING SYSTEM ELEC

4. Radiator fan motor 5. Radiator fan motor relay

9Disconnect the radiator fan motor coupler 9Disconnect the radiator fan motor relay cou-

from the wireharness. pler.
9Connect the battery (12 V) as shown. 9Connect the pocket tester to the radiator fan
Battery positive lead →→blue 11
Battery negative lead →→black 22 motor relay coupler (relay side) as shown.
Battery positive lead →→brown 11
2 Battery negative lead →→white/yellow 22
Positive tester probe →→brown 33
Negative tester probe →→blue 44

L 42
B
W/Y L L W/Y
1 Br Br Br Br

3 1

9Does the radiator fan motor turn?

YES NO

The radiator fan 9Check the radiator fan motor relay blue and
motor is faulty and
must be replaced. brown for continuity.
9Does the coupler is OK?

YES NO

Replace the radiator
fan motor relay.

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COOLING SYSTEM ELEC

6. Thermo sensor 3

9Remove the thermo sensor from the cylinder. 1
9Connect the digital circuit tester ( Ω⋅ 100) to 2

the thermo switch 1 as shown. 9Does the thermo sensor operate properly as
9Immerse the thermo sensor in a container described above?

filled with coolant 2 . YES NO

NOTE: Tighten the thermo Replace the
Make sure that the thermo sensor terminals sensor to specified thermo sensor.
do not get wet. torque.

9Place a thermometer 3 in the coolant. 18 Nm
9Slowly heat the coolant, then let it cool to the (1.8 m•kg, 13 ft•lb)

specified temperature as indicated in the EAS00795
table.
9Check the thermo sensor for continuity at the 7. Wiring
temperatures indicated in the table. 9Check the entire signaling system wiring.

Thermo sensor resistance Refer to “CIRCUITDIAGRAM”.
2.32–2.59 kΩ at 20° C (68° F) 9Is the signaling system wiring properly con-
310–326 Ω at 80° C (176° F)
140–144 Ω at 110° C (230° F) nected and without defects?

w

9H9andle the thermo sensor with special
care.

9N9ever subject the thermo sensor to
strong shocks. If the thermo sensor is
dropped, replace it.

YES NO

Check the condi- Properly connect or
tion of each of the repair the cooling
cooling system cir- system wiring.
cuits.
Refer to “CHECK-
ING THE COOL-
ING SYSTEM”.

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SELF-DIAGNOSIS ELEC

SELF-DIAGNOSIS

The T135SE/S features a self-diagnosing system for following circuit (-s).
1. Throttle position sensor (TPS)
2. Thermo sensor

1. ENGINE TROUBLE INDICATOR LIGHT
When the main switch is turned to “ON”, the following items are monitored and the condition codes are
displayed on the coolant temperature warning indicator light (irrespective of whether the engine is run-
ning or not).

Item Condition Response Display condition code
9Enables the vehicle to run so Blinks in
Throttle position sen- Disconnected Fault code [1]
sor (TPS) Short-circuit that the ignition timing is
Blinks in
Locked fixed when the throttle is fully Fault code [2]

Thermo sensor Disconnected opened. Blinks in
Short-circuit 9Displays the condition code Fault code [3]

on the coolant temperature

warning indicator light.
9Enables the vehicle to run so

that the ignition timing is

fixed.
9Displays the condition code

on the coolant temperature

warning indicator light.

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SELF-DIAGNOSIS ELEC

Display order on the coolant temperature warning indicator light
When one item being monitored

Fault Condition
code

å Repetition
[1]

∫

1 2 3 45 1 2 3 45

å
[2]

∫

1 2 3 45 1 2 3 45 Repetition

å
[3]

∫

1 2 3 2 34 1 2 3 2 3 4 Repetition

1 3 seconds å Light on
2 1 second ∫ Light off
3 1.5 seconds
4 0.5 seconds
5 0.5 seconds

When more than one item is being monitored

1 Light off (seconds) 3 sconds
2 Light on (seconds) 1 scond
3 Light off (seconds) 1.5 sconds
0.5 sconds
4 Light on (seconds) 0.5 sconds
5 Light off (seconds) Fault code [1]
6 1 cycle Fault code [2]
7 1 cycle

å 1 2 3 45 Repetition
7
∫

1 2 3 45
6

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SELF-DIAGNOSIS ELEC

TROUBLESHOOTING 1. Wire harness

The coolant temperature warning indicator 9Check the wire harness for continuity.
light starts to display the self-diagnosis Refer to “CIRCUITDIAGRAM”.
sequence.
9Is the wire harness OK?
Check:
1. throttle position sensor YES NO
2. thermo sensor
Repair or replace the
NOTE: wire harness.
9Before troubleshooting, remove the following
2. Throttle position sensor
part(s):
1. side cowlings (left and right) 9Check the throttle position sensor for conti-
2. front cowling nuity.
3. center panel (lower) Refer to “CHECKING AND ADJUSTING THE
9Troubleshoot with the following special tool(s). THROTTLE POSITION SENSOR” in chapter
6.
Pocket tester
90890-03112 9Is the throttle position sensor OK?

1. Throttle position sensor YES NO
CIRCUITDIAGRAM

Br B/L P B G/W L Replace the C.D.I Replace the throttle
G/R W O W/Y Y unit. position sensor.

(BLACK) (BLACK)

9W WO O
B

w

BR
B/L LY

L L 0 Br Br
Y Y
r W/Y L
e Br Br
(BLACK)
G/R
tB/L G/R W/Y L

G/RB/L W/Y
L
G/W
B/L P y

LL
BB

B/L Br B B

Br

0 C.D.I. unit
e Throttle position sensor

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SELF-DIAGNOSIS ELEC

2. Thermo sensor 2. Thermo sensor
CIRCUITDIAGRAM
9Check the thermo sensor.
Refer to “COOLING SYSTEM”.

9Is the thermo sensor OK?

Br B/L P B G/W L YES NO
G/R W O W/Y Y

(BLACK) (BLACK)

9W WO O
B

Replace the C.D.I. Replace the thermo
unit. sensor.

BR
B/L LY

L L 0 Br Br
Y Y
e r W/Y L
tB/L G/R G/R Br Br
(BLACK)

G/RB/L W/Y L

G/W W/Y
B/L P L

y

LL
BB

B/L Br B B
Br

0 C.D.I. unit
t Thermo sensor

1. Wireharness

9Check the wireharness for continuity.
Refer to “CIRCUITDIAGRAM”.

9Is the wireharness OK?

YES NO

Repair or replace the
wireharness.

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ELEC

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TRBL
SHTG

CHAPTER 9
TROUBLESHOOTING

TROUBLESHOOTING ...........................................................................................9-1
ELECTRICALSYSTEM ....................................................................................9-1
COMPRESSION SYSTEM ...............................................................................9-2
INTAKE AND EXHAUSTSYSTEM ...................................................................9-3

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TRBL
SHTG

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EASF0062 TRBL
TROUBLESHOOTING SHTG
TROUBLESHOOTING TROUBLESHOOTING

ELECTRICALSYSTEM

*CHECK ALLWIRES CONNECTIONS IGNITION COIL(see page 8-13)
MAIN SWITCH (see page 8-5)
8 Main switch is shorted 8 Primary or secondary windings

C.D.I. unit are broken or faulty
8 C.D.I. unit is broken 8 Spark plug wire is faulty
8 Spark plug cap is faulty

SPARK PLUG CHARGING COIL(see page 8-24)/
PICKUPCOIL(see page 8-13)
8 Wet carbon deposits 8 Windings are broken
8 Electrodes
8 Improper gap
8 Broken

STARTER MOTOR(see page 8-18)

8 Starter motor is broken or faulty
8 Starter relay is broken
8 Starter switch is broken

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TRBL
TROUBLESHOOTING SHTG

COMPRESSION SYSTEM

INSUFFICIENT TIGHTENING TORQUE WEAR/SCRATCHES
INSUFFICIENT TIGHTENING TORQUE DAMAGE

DAMAGE

WEAR/SCRATCH/DAMAGE
WEAR/STUCK/BROKEN

DAMAGE
WEAR/CARBON DEPOSITS
INSUFFICIENT TIGHTENING TORQUE

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TRBL
TROUBLESHOOTING SHTG

INTAKE AND EXHAUST SYSTEM

FUELCOCK FUELTANK CAP DRYTYPE
8 Clogged 8 Clogged
AIR FILTER ELEMENT
FUELHOSE 8 Dirty or clogged
8 Clogged, damaged

or kinked

SILENCER EXHAUST PIPE
8 Clogged 8 Cracked or broken
8 Carbon deposits

NEEDLE SET
8 Improperly adjusted

(medium speed)

PILOT JET THROTTLE STOPSCREW
8 Clogged (low speed) 8 Improperly adjusted

MAIN JET (idling and starting)
8 Incorrect size
8 Clogged (high speed) PILOT AIR SCREW
8 Improperly adjusted
FLOAT
8 Incorrect fuel level adjustment (idling and starting)
8 Puncture
NEEDLE VALVE ASSEMBLY
FLOAT CHAMBER 8 Wear
8 Accumulated dust and/or water

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TRBL
SHTG

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YAMAHA MOTOR CO., LTD.

2500 SHINGAI IWATA SHIZUOKA JAPAN

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T135SE/ T135S WIRING DIAGRAM

OFF R R Br B/L P B G/W L
ON Br Br G/R W O W/Y Y

1 R R/W (BLACK) (BLACK)
Br L/W
Br R R/W R WR RW
L/W Br
2 WW 9 W WO O
R/W R/W Y/R Y/R B
R R/W R
R å T135SE WW
5 WB Y/R Y
R Y/R BB

B

3 Br Br BR
L/W L/W B/L LY

Br Br L L 0 Br Br
RR Y Y
e r W/Y L
R/W R/W tB/L G/R G/R Br Br
L/W L/W 6 (BLACK

R Br L/W 7 G/R B/L W/Y L
L/W
4R L/W L/W W/Y
OFF BB L
START G/W
B/L P y
8
L
B

B/L Br B B

B

Br Br Br

p oBr/W u i
Br
G/Y B
; Br L Y B
(BLACK)
Ch Dg
G/Y
Br/W

Y/W Sb SbY/W v bn m , . /! @ P Br Y/R Br/W
G/W W W G/W z
L/W P P L/W aP d f
(BLACK) (BLACK) s
HI L P Dg Dg P
L Br Br L OFF LO
Dg Ch Ch Dg N B Br/W Br/WB
BG GB PUSH

R L/B Ch Ch Y/R

(RED) (RED)

GB Sb W P Y/W L/W G/W B Ch Dg
YG

G Sb W P Y/W L/W YY G Ch Dg LG/Y

x c WW l Ch L Dg L L g
PP Sb Sb B Dg
GG Y/W L/W L/W Y/W B jj kk B BL
BB Y
(BLACK) (BLACK) L L
Ch Dg Ch Dg
B B B
B LB
LB hh G/Y
Ch Dg Ch
B

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