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Yamaha Spark 135 2005-2010 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Yamaha Model: Spark 135 Model Variant: Motorcycle (Underbone) Generation Generation Code: First Generation (Pre-Fuel Injection) Codes Chassis Code Range: LC135 / SE/SX/ES/GT (Specific codes vary by sub-model and region) 👋 Introduction Market Position Market Position: The Yamaha Spark 135 is a popular underbone motorcycle known for its reliability, fuel efficiency, and sporty performance, particularly in Asian markets. It serves as an everyday commuter and a capable light sport bike. Competitive Analysis Competitors: Honda Wave 125, Suzuki Raider 150, Modenas Kriss 120. Key Features Key Features: Liquid-cooled engine, underbone chassis, agile handling, durable construction, automatic clutch (on many variants), sporty styling. 📋 Manual Details Coverage Areas Years Covered: 2005, 2006, 2007, 2008, 2009, 2010 Page Count Page Count: 346 Manual Type Manual Type: Workshop Repair Service Manual Language Language: English (assumed based on common industry practice for downloadable manuals) Format Format: PDF (Downloadable) 📖 Manual Coverage Systems Covered Engine System: Complete engine overhaul, tuning, diagnostics, cooling system, lubrication system. Transmission System: Clutch operation, gear shifting mechanisms, internal transmission component inspection and repair. Electrical System: Ignition system, lighting, charging system (stator, regulator/rectifier), battery, starting system, wiring diagrams, fault diagnosis. Suspension System: Front fork (telescopic), rear shock absorber(s), swingarm inspection and maintenance. Brake System: Front and rear brake system inspection, maintenance, repair (drum and/or disc brakes depending on sub-model), hydraulic system (if applicable). Fuel System: Carburetor inspection, cleaning, adjustment, fuel tank, fuel lines. Chassis And Bodywork: Frame inspection, body panel removal and installation, seating, fairings, fenders. Wheels And Tires: Wheel bearing maintenance, tire inspection and replacement, spoke tension (if applicable). Procedures Included Maintenance: Routine maintenance checks, lubrication, filter replacement, spark plug replacement, valve clearance adjustment. Repair: Component-level repair and replacement for all major systems. Troubleshooting: Diagnostic charts and procedures for identifying and resolving common issues. Rebuild: Detailed procedures for engine and transmission rebuilds. Wiring Diagrams: Comprehensive electrical system wiring schematics. Technical Depth Depth: Comprehensive, covering all aspects from basic maintenance to complete engine and transmission rebuilds. Assumes intermediate mechanical knowledge. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High resolution for clear diagrams and text (assumed for professional service manuals). Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, 4-valve, Liquid-cooled Displacement: 135 cc Bore X Stroke: Approx. 52.0 x 60.5 mm (verify specific sub-model) Performance Horsepower: Approx. 11-12 PS (varies slightly by sub-model and tuning) Torque: Approx. 10-11 Nm (varies slightly by sub-model and tuning) Fuel System Fuel Delivery: Carburetor (e.g., Mikuni VM24 or similar, specific model may vary) Ignition System Ignition Type: CDI (Capacitor Discharge Ignition) Cooling System Cooling Method: Liquid Cooling 🔧 Transmission Standard Transmission Type: Automatic Clutch with Manual Gear Shifting (4-speed or 5-speed, depending on sub-model) Optional Optional Transmission: N/A (Automatic clutch is standard for this model range) Features Clutch Type: Wet, multi-plate automatic clutch 📐 Dimensions Exterior Length: Approx. 1900 mm (variable by sub-model) Width: Approx. 700 mm (variable by sub-model) Height: Approx. 1050 mm (variable by sub-model) Weights Dry Weight: Approx. 100-105 kg (variable by sub-model) Fuel Tank Capacity: Approx. 4.0 liters 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycle safety is typically assessed differently than cars, focusing on rider protection and handling dynamics). Active Features Active Safety Features: Responsive braking system (disc front, drum/disc rear depending on variant), agile chassis for evasive maneuvers. Passive Features Passive Safety Features: Robust frame construction, durable body panels. 💡 Technology Features Infotainment Infotainment System: N/A (Basic motorcycle with analog instrumentation). Driver Assistance Driver Assistance Features: N/A Connectivity Connectivity Options: N/A Instrumentation Instrumentation: Analog speedometer, tachometer, fuel gauge, engine temperature gauge, turn signal indicators, high beam indicator. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000 - 5,000 km or 6 months, whichever comes first (refer to manual for precise recommendation). Spark Plug Replacement: Every 10,000 - 15,000 km. Air Filter Cleaning Replacement: Clean every 5,000 km, replace as needed or every 10,000 km. Valve Clearance Adjustment: Every 10,000 - 15,000 km. Fluid Specifications Engine Oil Type: SAE 10W-40 API SG or higher (recommend semi-synthetic or fully synthetic for best performance and protection). Engine Oil Capacity: Approx. 1.0 - 1.2 liters (dry fill), 0.9 - 1.1 liters (oil change only) - verify with dipstick/level check. Coolant Type: Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio) - refer to manual for specific Yamaha coolant recommendation. Brake Fluid Type: DOT 3 or DOT 4 (if disc brakes are equipped) - verify with manual. Known Issues Known Issues: Carburetor jetting can be sensitive to altitude and modifications. Occasional electrical connector corrosion in humid climates. Normal wear and tear on clutch plates and suspension components over high mileage. 📚 Vehicle History Brand Heritage Brand Heritage: Yamaha has a long-standing reputation for building reliable and performance-oriented motorcycles, dating back to its...
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Yamaha Spark 135 2005-2010 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
Spark 135
Model Variant:
Motorcycle (Underbone)
Generation
Generation Code:
First Generation (Pre-Fuel Injection)
Codes
Chassis Code Range:
LC135 / SE/SX/ES/GT (Specific codes vary by sub-model and region)
👋 Introduction
Market Position
Market Position:
The Yamaha Spark 135 is a popular underbone motorcycle known for its reliability, fuel efficiency, and sporty performance, particularly in Asian markets. It serves as an everyday commuter and a capable light sport bike.
Competitive Analysis
Competitors:
Honda Wave 125, Suzuki Raider 150, Modenas Kriss 120.
Key Features
Key Features:
Liquid-cooled engine, underbone chassis, agile handling, durable construction, automatic clutch (on many variants), sporty styling.
📋 Manual Details
Coverage Areas
Years Covered:
2005, 2006, 2007, 2008, 2009, 2010
Page Count
Page Count:
346
Manual Type
Manual Type:
Workshop Repair Service Manual
Language
Language:
English (assumed based on common industry practice for downloadable manuals)
Format
Format:
PDF (Downloadable)
📖 Manual Coverage
Systems Covered
Engine System:
Complete engine overhaul, tuning, diagnostics, cooling system, lubrication system.
Transmission System:
Clutch operation, gear shifting mechanisms, internal transmission component inspection and repair.
Electrical System:
Ignition system, lighting, charging system (stator, regulator/rectifier), battery, starting system, wiring diagrams, fault diagnosis.
Suspension System:
Front fork (telescopic), rear shock absorber(s), swingarm inspection and maintenance.
Brake System:
Front and rear brake system inspection, maintenance, repair (drum and/or disc brakes depending on sub-model), hydraulic system (if applicable).
Fuel System:
Carburetor inspection, cleaning, adjustment, fuel tank, fuel lines.
Chassis And Bodywork:
Frame inspection, body panel removal and installation, seating, fairings, fenders.
Wheels And Tires:
Wheel bearing maintenance, tire inspection and replacement, spoke tension (if applicable).
Procedures Included
Maintenance:
Routine maintenance checks, lubrication, filter replacement, spark plug replacement, valve clearance adjustment.
Repair:
Component-level repair and replacement for all major systems.
Troubleshooting:
Diagnostic charts and procedures for identifying and resolving common issues.
Rebuild:
Detailed procedures for engine and transmission rebuilds.
Wiring Diagrams:
Comprehensive electrical system wiring schematics.
Technical Depth
Depth:
Comprehensive, covering all aspects from basic maintenance to complete engine and transmission rebuilds. Assumes intermediate mechanical knowledge.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High resolution for clear diagrams and text (assumed for professional service manuals).
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, SOHC, 4-valve, Liquid-cooled
Displacement:
135 cc
Bore X Stroke:
Approx. 52.0 x 60.5 mm (verify specific sub-model)
Performance
Horsepower:
Approx. 11-12 PS (varies slightly by sub-model and tuning)
Torque:
Approx. 10-11 Nm (varies slightly by sub-model and tuning)
Fuel System
Fuel Delivery:
Carburetor (e.g., Mikuni VM24 or similar, specific model may vary)
Ignition System
Ignition Type:
CDI (Capacitor Discharge Ignition)
Cooling System
Cooling Method:
Liquid Cooling
🔧 Transmission
Standard
Transmission Type:
Automatic Clutch with Manual Gear Shifting (4-speed or 5-speed, depending on sub-model)
Optional
Optional Transmission:
N/A (Automatic clutch is standard for this model range)
Features
Clutch Type:
Wet, multi-plate automatic clutch
📐 Dimensions
Exterior
Length:
Approx. 1900 mm (variable by sub-model)
Width:
Approx. 700 mm (variable by sub-model)
Height:
Approx. 1050 mm (variable by sub-model)
Weights
Dry Weight:
Approx. 100-105 kg (variable by sub-model)
Fuel Tank Capacity:
Approx. 4.0 liters
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycle safety is typically assessed differently than cars, focusing on rider protection and handling dynamics).
Active Features
Active Safety Features:
Responsive braking system (disc front, drum/disc rear depending on variant), agile chassis for evasive maneuvers.
Passive Features
Passive Safety Features:
Robust frame construction, durable body panels.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic motorcycle with analog instrumentation).
Driver Assistance
Driver Assistance Features:
N/A
Connectivity
Connectivity Options:
N/A
Instrumentation
Instrumentation:
Analog speedometer, tachometer, fuel gauge, engine temperature gauge, turn signal indicators, high beam indicator.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 - 5,000 km or 6 months, whichever comes first (refer to manual for precise recommendation).
Spark Plug Replacement:
Every 10,000 - 15,000 km.
Air Filter Cleaning Replacement:
Clean every 5,000 km, replace as needed or every 10,000 km.
Valve Clearance Adjustment:
Every 10,000 - 15,000 km.
Fluid Specifications
Engine Oil Type:
SAE 10W-40 API SG or higher (recommend semi-synthetic or fully synthetic for best performance and protection).
Engine Oil Capacity:
Approx. 1.0 - 1.2 liters (dry fill), 0.9 - 1.1 liters (oil change only) - verify with dipstick/level check.
Coolant Type:
Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio) - refer to manual for specific Yamaha coolant recommendation.
Brake Fluid Type:
DOT 3 or DOT 4 (if disc brakes are equipped) - verify with manual.
Known Issues
Known Issues:
Carburetor jetting can be sensitive to altitude and modifications. Occasional electrical connector corrosion in humid climates. Normal wear and tear on clutch plates and suspension components over high mileage.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Yamaha has a long-standing reputation for building reliable and performance-oriented motorcycles, dating back to its inception. The Spark 135 builds upon this legacy.
Model Evolution
Model Evolution:
The Spark 135 (LC135) was introduced as a premium underbone model, offering advanced features like liquid cooling and a more powerful engine compared to its air-cooled predecessors and competitors. It has seen several minor updates and sub-model variations (SE, SX, ES, GT) during its production run.
Production
Production Region:
Primarily manufactured in Southeast Asia (e.g., Malaysia, Indonesia).
🏆 Awards & Recognition
Recognitions
Recognitions:
Highly regarded in its segment for performance and durability, often winning 'Best Underbone' polls in regional automotive publications.
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