Yamaha Rx 135 Service Manual

For maintaining the iconic Yamaha RX 135, owners typically rely on a combination of the Owner’s Manual , which covers routine adjustments, and the more technical Workshop/Service Manual

for deep mechanical repairs. While official printed copies are rare today, digital versions are widely available through enthusiast communities. Key Manual Resources Owner’s Manual (4-Speed & 5-Speed)

: Focuses on basic operations, control functions, and periodic maintenance schedules. You can find the RX 135 5-Speed Manual yamaha rx 135 service manual

, which includes details on brake adjustments and lubrication. Parts Catalogue

: Essential for identifying correct part numbers when ordering replacements. A detailed RX 135 Illustrated Parts List is hosted on Supplementary Service Manuals For maintaining the iconic Yamaha RX 135, owners

: For specific technical deep-dives (like the RXZ variant), supplements like the Yamaha RXZ135 2001 SP provide torque specs and exploded engine diagrams. Critical Maintenance Specifications Specification Transmission Oil Multigrade 20W40 (Approx. 0.65 Litre) Spark Plug Gap 0.7 – 0.8 mm Chain Slackness 20 – 30 mm Tyre Pressure Front: 25 psi / Rear: 28 psi Fuel-to-Oil Ratio 16:1 to 20:1 (for pre-mix/injected systems) Routine Service Intervals Every 500 km : Clean and lubricate the drive chain. Every 1,500 – 2,000 km : General engine service and oil check. Every 10,000 km : Service or replace spark plugs and air filters. Top-End Service

: Inspect cylinder bore and piston rings every 8,000 – 10,000 km; bores typically require a rebore or replacement between 35,000 km (5-speed) and 50,000 km (4-speed). DIY Maintenance Tips Step-by-step cylinder head removal – torque sequence and

Yamaha RX 135 Cylinder Kit - 58mm High-Quality Engine Repair Part

I cannot directly provide a PDF file or a direct download link for the Yamaha RX 135 service manual due to copyright restrictions.

However, I can guide you to the best resources where you can find it and provide you with the essential technical specifications and tuning guides often found within the manual.

3. Engine Overhaul (The Heart of the Manual)

This is where the RX 135 manual shines. Two-stroke engines are deceptively simple yet require obsessive precision. The manual provides:

  • Step-by-step cylinder head removal – torque sequence and values (typically 20–22 Nm).
  • Piston and ring replacement – critical orientation of the piston arrow pointing toward the exhaust port. Ring end gap tolerance: 0.3–0.5 mm.
  • Crankshaft inspection – runout limit: 0.03 mm. Crank seal replacement procedure, as leaking seals cause erratic idling and seizure.
  • Cylinder bore measurement – standard bore: 56.0 mm; service limit: 56.10 mm. Oversize piston options (0.25 mm, 0.50 mm, 0.75 mm, 1.00 mm).

3) Top‑End Inspection & Piston Replacement

  1. Remove seat, tank, exhaust, and head covers per manual.
  2. Remove cylinder head and cylinder; inspect piston, rings, skirt for scoring.
  3. Measure cylinder bore and piston clearance with micrometer/caliper; check for taper/out‑of‑round.
  4. Replace piston/rings if beyond spec; hone cylinder if necessary or re‑bore to oversize.
  5. Replace gaskets, apply correct assembly lube, torque head nuts in specified sequence.

Engine Specifications

  • Engine Type: Air-cooled, 2-stroke, reed valve inductions.
  • Displacement: 132 cc.
  • Bore x Stroke: 54.0 mm x 57.8 mm.
  • Compression Ratio: 7.0 : 1.
  • Carburetor: Mikuni VM22 (Round slide).
    • Note: The main jet and pilot jet sizes vary between the RX-K (4-speed) and RX-Z (5-speed) models.
  • Spark Plug: NGK B8ES or Champion L82Y.
  • Spark Plug Gap: 0.6 – 0.7 mm (0.024 – 0.028 in).