Yamaha RT100 RT 100 90-00 Service Repair Workshop Manual

RT100A 174 .......... · .. . LIT-11616-07 -35

RT 100A SERVICE MANUAL © 1990 by Yamaha Motor Corporation, U.S.A. 1st Edition, January 1990 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N: LIT-11616-07-35

NOTICE This manual was by the Yamaha Motor Company primary for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic's education into one manual, so it is assumed that person using this book to perform maintenance and repairs on Yamaha ma- chines have a basic understanding of the mechanical concepts and procedures inherent in machine repair technology. Without such knowledge, attempt repairs or service to this model may render it unfit to use and/or unsafe. Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, there applicable, appear in future editions of this manual. TECHNICAL PUBLICATIONS SERVICE DIVISION MOTORCYCLE GROUP YAMAHA MOTOR CO.,L TO. PARTICULARLY IMPORT ANT INFORMATION This material is distinguished by the following notation. A WARNING CAUTIO,.: NOTE: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or re- pairing the machine. A CAUTION indicates special precautions that must be taken to avoid damage to the machine. A NOTE provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL CONSTRACTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See "Illustrated symbols") 1st title CD : 2nd title ®: This is a chapter with its symbol on the upper right of each page. This title appears on the upper of each page on the left of the chapter symbol. (For the chapter "Periodic inspection and adjustment" the 3rd title appears.) 3rd title @: This is a final title. MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspections. A set of particularly important procedure C!> is placed between a line of asterisks .. * .. with each procedure preceded by " • ... IMPORTANT FEATURES • Data and a special tool are framed in a box preceded by a relevant symbol ® . • An encircled numeral ® indicates a part name, and an encircled alphabetical letter data or an alignment mark (j) , the others being indicated by an alphabetical letter in a box ® . • A condition of a faulty component will precede an arrow symbol and the course of action re- quired the symbol ® . EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identif- ying correct disassembly and assembly procedures. 2.,__., •Crlftkt:Mtc <D liM theC:f .. IIU:-NHf'4Kinetool li:1 iNSPECTION AND REPAIR =-- 1.EIImlnM•: •Cwtlof!MPOM• T•• c.,, 10 evoictl.......,.. tl'le "*k-.. ttlfNdi.Donot-· ...... w .. ,... _....... - ,_._ -.. .... : (i) Mdltl'llckM- ." m. - ..... ill out of ...ofC.Ciofl, , .. .-1-thloc.,..,.........,.., '-----'-----!::.1 •'*-•400-eiOOtritw.t ..... ,on ___ --::-:::--;,.- ..... , ,.-:; I ' • 1 ol ' I j -"' $.1....tlrii:Me: •Dri¥ec:hlin

CD ® lsPEcl pf I @ @ I ENG I \,·1 @ ® lcooLI :1: I lcARslfl Q) @ I CHASI r#Y01 1 ELEcl a 1 ® ® ? I • @ © @ @ ® [8] ® @ ® ® 1 1 l m m G) ® @ @ @ ' a ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols G) to ® are designed as thumb tabs to indicate the chapter's number and content. CD General information ® Specifications I Periodic inspection and adjustment Engine Cooling system Carburetion Q) Chassis @ Electrical ®Troubleshooting Illustrated symbols ® to ® are used to identify the specifications appearing in the text. I Filling fluid Lubricant Special tool @ Tightening @ Wear limit, clearance ® Engine speed @ fl, V, A Illustrated symbols @to @ in the exploded diagram indicate grade of lubricant and location of lubrication point. @ Apply engine oil ® Apply gear oil ® Apply molybdenum disulfide oil ® Apply wheel bearing grease ® Apply lightweight lithium-soap base grease @ Apply molybdenum disulfide grease @Apply locking agent (LOCTITE®)

INDEX GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL CARBURETION CHASSIS ELECTRICAL TROUBLESHOOTING SPEC 0 ENG 4 • ? •

CONTENTS CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION ............................................ 1-1 VEHICLE IDENTIFICATION NUMBER ................................... 1-1 ENGINE SERIAL NUMBER ........................................... 1-1 IMPORTANT INFORMATION ........................................... 1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY ...................... 1-2 ALL REPLACEMENT PARTS .......................................... 1-3 GASKETS, OIL SEALS, AND 0-RINGS .................................. 1-3 LOCK WASHERS/PLATE AND COTIER PINS ............................ 1-3 BEARINGS AND OIL SEALS .......................................... 1-3 CIRCLIPS ......................................................... 1-4 SPECIAL TOOLS ..................................................... 1-4 FOR TUNE UP ..................................................... 1-4 FOR ENGINE SERVICE .............................................. 1-5 FOR CHASSIS SERVICE ............................................. 1-6 FOR ELECTRICAL COMPONENTS ..................................... 1-6 CHAPTER2. SPECIFICATIONS GENERAL SPECIFICATIONS ........................................... 2-1 MAINTENANCE SPECIFICATIONS ...................................... 2-4 ENGINE .......................................................... 2-4 CHASSIS .................................... ; .................... 2-8 ELECTRICAL ..................................................... 2-11 GENERAL TORQUE SPECIFICATIONS .................................. 2-12 DEFINITION OF UNITS ............................................... 2-12 LUBRICATION POINTS AND LUBRICANT TYPE .......................... 2-13 ENGINE ......................................................... 2-13 CHASSIS ........................................................ 2-13 CABLE ROUTING .................................................... 2-14

CHAPTER3. PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION ............................................ 3-1 PERIODIC MAINTENANCE/LUBRICATION INTERVALS . ........... 3-1 ENGINE ................................................... 3-2 IDLING SPEED ADJUSTMENT ............................... 3-2 THROTTLE CABLE ADJUSTMENT ............................ 3-3 AUTOLUBE PUMP CABLE ADJUSTMENT ..................... 3-4 AUTOLUBE PUMP STROKE ADJUSTMENT .................... 3-4 AUTOLUBE PUMP AIR BLEEDING ............................ 3-6 SPARK PLUG INSPECTION ................................. 3-8 IGNITION TIMING CHECK .................................. 3-9 ENGINE OIL LEVEL CHECK ................................. 3-10 TRANSMISSION OIL LEVEL INSPECTION ..................... 3-10 TRANSMISSION OIL REPLACEMENT ........................ 3-12 CLUTCH ADJUSTMENT ................................... 3-12 AIR FILTER CLEANING .................................... 3-13 CARBURETOR JOINT INSPECTION .......................... 3-15 FUEL LINE INSPECTION ................................... 3-15 EXHAUST SYSTEM INSPECTION ........................... 3-15 CHASSIS. ................................................. 3-16 FRONT BRAKE ADJUSTMENT .............................. 3-16 REAR BRAKE ADJUSTMENT ............................... 3-17 DRIVE CHAIN SLACK ADJUSTMENT ........................ 3-17 DRIVE CHAIN LUBRICATION ............................... 3-19 STEERING HEAD ADJUSTMENT ............................ 3-20 TIRE INSPECTION ........................................ 3-22 WHEEL INSPECTION ........................... , ......... 3-24 SPOKES INSPECTION AND TIGHTENING ..................... 3-24 FRONT FORK INSPECTION ................................ 3-24 REAR SHOCK ABSORBER ADJUSTMENT ..................... 3-25 CABLE INSPECTION AND LUBRICATION ..................... 3-25 LEVER AND PEDAL LUBRICATION .......................... 3-25 SIDESTAND LUBRICATION ................................ 3-26 GEN INFO •• SPEC ENG ELEC ? • 2

CHAPTER4. ENGINE OVERHAUL ENGINE REMOVAL . .................................................. 4-1 TRANSMISSION OIL ............................................... 4-1 SEAT AND SIDE COVER ............................................. 4-1 FUEL TANK ....................................................... 4-2 MUFFLER ........................................................ 4-2 CARBURETOR ................................................... • 4-2 AUTOLUBE PUMP CABLE AND HOSE .................................. 4-3 LEADS ........................................................... 4-3 CLUTCH CABLE ................................................... 4-3 DRIVE CHAIN ..................................................... 4-3 ENGINE REMOVAL. ................................................ 4-4 ENGINE DISASSEMBLY ............................................... 4-4 CYLINDER HEAD, CYLINDER AND PISTON ............................. 4-4 CLUTCH AND PRIMARY DRIVE GEAR. ................................. 4-6 KICK AXLE ....................................................... 4-7 SHIFT SHAFT ..................................................... 4-8 COl MAGNETO .................................................... 4-9 CLUTCH PUSH LEVER ............................................. 4-10 CRANKCASE ..................................................... 4-10 TRANSMISSION, SHIFTER AND CRANKSHAFT ......................... 4-11 INSPECTION AND REPAIR ............................................ 4-12 CYLINDER HEAD ................................................. 4-12 CYLINDER AND PISTON ........................................... 4-13 PISTON RINGS ................................................... 4-15 PISTON PIN AND BEARING ......................................... 4-16 CLUTCH ........................................................ 4-17 PRIMARY DRIVE .................................................. 4-19 KICK STARTER ................................................... 4-20 SHIFT SHAFT .................................................... 4-20 TRANSMISSION AND SHIFTER ...................................... 4-20 CRANKSHAFT ................................................... 4-22 CRANKCASE ..................................................... 4-23 AUTOLUBE PUMP ................................................ 4-23 ENGINE ASSEMBLY AND ADJUSTMENT ............................... 4-25 CRANKSHAFT, SHIFTER AND TRANSMISSION ......................... 4-28 CRANKCASE ..................................................... 4-29 CLUTCH PUSH LEVER ............................................. 4-30 COl MAGNETO ................................................... 4-30 SHIFT SHAFT .................................................... 4-32 KICK AXLE ...................................................... 4-35 CLUTCH AND PRIMARY DRIVE GEAR ................................. 4-35 CYLINDER HEAD, CYLINDER AND PISTON ............................ 4-38 REMOUNTING ENGINE ............................................ 4-41

CHAPTERS. CARBURETION CARBURETOR . ............................................ 5-1 REMOVAL .............................................. 5-2 DISASSEMBLY .......................................... 5-2 INSPECTION ............................................ 5-3 ASSEMBLY ............................................. 5-5 INSTALLATION .......................................... 5-6 ADJUSTMENT .......................................... 5-7 REED VALVE .............................................. 5-9 REMOVAL ............................................. 5-10 INSPECTION ..· ......................................... 5-10 INSTALLATION ......................................... 5-11 SPEC CHAPTERS. CHASSIS FRONT WHEEL ............................................ 6-1 REMOVAL .............................................. 6-2 INSPECTION ............................................ 6-2 INSTALLATION .......................................... 6-5 0 REAR WHEEL . ............................................. 6-8 REMOVAL .............................................. 6-9 4 ENG INSPECTION ........................................... 6-10 INSTALLATION ......................................... 6-10 FRONT FORK . ............................................ 6-12 REMOVAL ............................................. 6-13 DISASSEMBLY ......................................... 6-13 INSPECTION ........................................... 6-14 ASSEMBLY ............................................ 6-15 INSTALLATION ......................................... 6-17 STEERING HEAD AND HANDLEBAR .......................... 6-18 REMOVAL ............................................. 6-19 INSPECTION ........................................... 6-20 INSTALLATION ......................................... 6-21 REAR SHOCK ABSORBER AND SWINGARM . .................. 6-25 REMOVAL ............................................. 6-26 INSPECTION ........................................... 6-27 INSTALLATION ......................................... 6-28 ? DRIVE CHAIN AND SPROCKETS ............................. 6-30 • REMOVAL ............................................. 6-31 INSPECTION ........................................... 6-31 INSTALLATION ......................................... 6-32

Yamaha RT100 RT 100 90-00 Service Repair Workshop Manual

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