1990-2000 RT100 Service Manual

7/17/2019 1990-2000 RT100 Service Manual

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T

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


3/170

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

n

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 ma-

chine

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

MOTORCYCLEGROUP

Y M H

MOTOR CO. L TO.

PARTICULARLY IMPORT

NT

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.


4/170

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

infor

mation 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


5/170

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~ ~ ~ ~

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@

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ENG

I

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ooLI

:

:

I

cA

Rslfl

Q

@

I

H SI

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L cla

~

~

W ~ I

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I

@

~

~

@

~

@

~

[

8]

@

m

m

G

@

@

~

E .

~ E

.

~ .

_

@

a

IL

LUSTR TE

D SYMBO

LS

Re

fer to

th

i l lustration

)

Illustrated sym

bols G to

are designed as

thum

tabs to

indicate the cha

pte r s number a

nd

c

ontent .

D

General information

Sp

ecifications

I

er

iodic inspection

and adjustment

Engine

Cooling sy

stem

Carburetion

Q

Chassis

@ E

lectrical

Troubleshoo

ting

I

llustrated sym b

ols

to are

use d to ident i f

y

the specificatio

ns appearing i

n th e text.

I

illing fluid

L

ubricant

Specia

l tool

@

Tighteni

ng

@

Wear limit, clea

rance

Eng

ine speed

@ fl , V A

I l lustrated

s y mbols

to

@

in the explo

deddia-

gram ind

ic ate grade of

lubr icant and lo

cation of

lubr icat ion

point.

@

App ly engin

e oil

A

pply gear oil

A

pply molybdenu

m disulfide oil

Apply wheel bearing grease

Ap

ply l ightweight l i

thium-soap

base

grease

@

Apply mo

lybdenum disulfi

de grease

Apply lockin

g agent (LOCTIT

E)


6/170

INDEX

GENERAL

INFORM TION

SPECIFICATIONS

PERIODIC INSPECTION

ND

DJUSTMENT

ENGINE

OVERH UL

CARBURETION

CH SSIS

ELECTRICAL

TROUBLESHOOTING

SPEC

NG

?


7/170

CONTENTS

CHAPTER 1.

GENERAL INFORMATION

M CHINE

IDENTIFICATION -1

VEHICLE IDENTIFICATION NUMBER 1-1

ENGINE SERIAL NUMBER

1-1

IMPORT NT 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

ND

LUBRICANT TYPE 2 13

ENGINE 2 13

CHASSIS 2 13

CABLE ROUTING 2 14


8/170

CHAPTER3

PERIODIC INSPECTION

ND

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

G N

INFO

SPE

NG

ELE

?


9/170

CHAPTER4

ENGINE OVERHAUL

ENGINE REMOVAL -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 ND 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

ND DJUSTMENT

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


10/170

CHAPTERS

CARBURETION

C RBURETOR 5 1

REMOVAL 5 2

DISASSEMBLY 5 2

INSPECTION 5 3

ASSEMBLY 5 5

INSTALLATION 5 6

ADJUSTMENT 5 7

REED

V LVE

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

RE R WHEEL 6 8

REMOVAL 6 9

NG

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

HE D AND

H NDLEB R 6 18

REMOVAL 6 19

INSPECTION 6 20

INSTALLATION 6 21

RE R SHOCK BSORBER

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


11/170

CHAPTER7.

ELECTRICAL

IGNITION SYSTEM 7 1

TROUBLESHOOTING 7 3

CHAPTERS.

TROUBLESHOOTING

STARTING FAILURE/HARD STARTING 8 1

FUEL SYSTEM

8 1

ELECTRICAL SYSTEM

8 2

COMPRESSION SYSTEM

8 2

POOR IDLE SPEED PERFORMANCE 8 3

POOR IDLE SPEED PERFORMANCE 8 3

POOR MEDIUM ND HIGH SPEED PERFORMANCE 8 3

FUEL

SYSTEM

8 3

ELECTRICAL SYSTEM 8 3

COMPRESSION SYSTEM 8 4

FAULTV GEAR SHIFTING 8 4

HARD SHIFTING 8 4

CHANGE PEDAL

DOES NOT MOVE

8 5

JUMP OUT GEAR

8 5

CLUTCH SLIPPING/DRAGGING 8 5

CLUTCH

SLIPPING 8 5

CLUTCH DRAGGING

8 5

IMPROPER KICKING 8 6

SLIPPING 8 6

HARD KICKING 8 6

KICK CRANK NOT

RETURNING 8 6

FAULTV BRAKE 8 7

POOR

BRAKING EFFECT

8 7

FRONT FORK OIL LEAKAGE

ND

FRONT FORK M LFUNCTION 8 7

OIL

LEAKAGE

8 7

MALFUNCTION

8 7

INSTABLE

H NDLING

8 8

INSTABLE HANDLING 8 8

OVERHEATING 8 9

OVERHEATING

8 9

RT1

OOA WIRING DIAGRAM


12/170

MACHINE IDENTIFICATION 1 ~ ~ ~

I

1 1

YB111001

GENERAL

INFORMATION

MACHINE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number D is stam

ped

into the

steering head pipe.

Starting serial number:

RT100A JYA3ULWO LC000101

NOTE

The vehicle identification number

is used

to

identify

your machine and may be used to re-

gister your machine with the licensing au-

thority in your state.

ENGINE SERIAL NUMBER

The engine serial number D is

stamped into

the left

of

the

engine

Starting serial number:

RT100A

.........

3UL-000101

NOTE

The

first

three

digits

of these numbers

are

for model

identifications; the

remaining

digits are

the

unit

production number.

Designs and

specifications

are

subject

to

change

without

notice.


13/170

M _ P _ o _ R _ T _ N _ T _ I N _ F _ o _ R _ M _ _ T a _ o _ N _ I ~ ~ ~ ~ ~

YB112001

IMPORT NT INFORM TION

PREP R TION FOR REMOV L ND DIS S-

SEMBLY

1. Remove all

dirt

mud

dust

and foreign ma

terial before removing

and disassembling.

2. Use

proper tools

and cleaning equipment.

Refer

to

WSPECI L

TOOLw

3. When disassembling the machine keep

mated parts together. This

includes gears

cylinders pistons

and

other

mated

parts

that

have

been wm tedw

through

normal

wear. Mated parts

must

be reused as an

assembly or replaced.

4.

During

the

machine disassembly clean all

parts

and place

them

in

trays

in

the order

of disassembly.

This will

speed

up

assemb

ly time

and help assure

that

all

parts

are

correctly

reinstalled.

5. Keep

away from fire.

1-2


14/170

I

IMPORTANT INFORMATION

I

~

I

300 000

300 003

1-3

YB112002

ALL REPLACEMENT PARTS

1.

We recommend

to use Yamaha genuine

parts for all

replacements.

Use oil

and/or

grease

recommended

by Yamaha for asse

mbly

and

adjustment.

YB112003

GASKETS, OIL SEALS,

AND

0-RINGS

1.

All

gaskets, seals and

0-rings

should be re

placed

when

an engine is overhauled.AII ga

skets surfaces,

oil seal lips and

0-rings

must

be cleaned.

2.

Properly

oil all

mating

parts and bearing

during reassembly.

Apply

grease

to

the

oil

seal lips.

YB112004

LOCK WASHERS/PLATES

AND

COTTER

PINS

1.

All

Jock

washers/plates

( ) and

cotter

pins

must

be replaced

when they

are remo

ved.

Lock tab(s) should be bent along the

bolt

or nut flat(s) after the

bolt

or nut has

been properly

tightened.

YB112005

BEARINGS AND OIL SEALS

1. Install

the

bearing(s) and oil seal(s) with

their

manufacturer's marks

or numbers

facing outward.(ln other

words, the stam

ped letters must be

on the

side exposed

to

view.) When

installing oil seal(s), apply

a

light coating

of

light-weight lithium

base

grease to

the seallip(s).

Oil

the

bearings li

berally when installing.

( ) Oil seal

c :;

_

Do

not

use compressed air to spin

the

bearings dry.

This causes damage to

the

bearing surfaces.

( ) Bearing


15/170

300 001

0

1 4

SPECIAL TOOLS

I

~

I

YB112006

CIRCLIPS

1.

All

circlips should be

inspected

carefully

before

reassembly.

Always

replace piston

pin clips after one use. Replace distorted

circlips. When installing a circlip D make

sure

that the sharp edged

corner

is po-

sitioned opposite

to

the thrust

@

it

recei-

ves. See

the sectional view.

@ Shaft

YB113001

SPECI L TOOLS

The prepare special tools are necessary for

complete and

accurate

tune up and assemb-

ly. Using

the correct

special

tool

will help pre-

vent

damage caused

by the

use

of

improper

tools or

improvised

techniques.

FOR TUNE UP

1. Inductive timing light

P/N. YM 33277

This tool is

necessary for

adjusting

ignition

timing.

2. Fuel level gauge

P/N.

YM 01312

This tool

is used to

measure the fuel

level in

the float chamber.

3. Inductive tachometer

P/N. YU 08036

This tool is needed for detecting engine

rpm.


16/170

1 5

SPECI L TOOLS

~ ~ ~ I

FOR ENGINE SERVI E

1.

Universal clutch holder

P/N. YM 91042

This tool

is used

to

hold

the clutch when

loo-

sening or tightening

the clutch

boss

locknut.

2. Universal

rotor holder

P/N. YU 01235

This

tool

is used

when

loosening or

tigh-

tening the flywheel magneto

securing

bolt.

3.

Flywheel

puller

P/N. YM 01189

This tool

is used

for

removing

the flywheel.

4. Piston pin puller

P/N. YU 01304

This tool

is used to remove

the

piston pin.

5. Crankshaft

separating tool

P/N. YU 01135

This tool is used to split the crankcase as

well as remove the crankshaft

from

either

case.


17/170

1 6

SPECIAL TOOLS ~ ~ ~ I

6.

Crankshaft

installing

tool

D

P/N. YU 90050

Adapter

P/N. YM-90063

These tools

are used

to

install

the

cranksha

ft

FOR CHASSIS SERVICE

1.

Front fork

seal

driver

Weight) D

P/N. YM-33963

Adapter

P/N. YM 33281

This

tools

used

when

installing

the fork

seal.

2. Slide hammer

set

P/N. YU 01047

This

tool is used

when

disassembling

the

front

fork.

3.

Ring nut

wrench

P/N. YU 33975

This tool

is used to loosen and

tighten the

steering

ring

nut.

FOR ELECTRICAL COMPONENTS

1 .

Dynamic spark

tester

P/N. YM-34487

This instrument

is necessary for checking

the ignition

system

components.


18/170

1

7

S

PECIAL T O

OLS

'i

2.

P

ocket teste

r

P/N .

YU-03112

This

tester

is invaluable

for

checking

the ele

ctrical syst

em


19/170

~ ~ ~ ~ ~ ~

1 8


20/170

~ ~ ~ ~ ~ ~ ~ ~ ~ G E _ N _ E _ R _ A L _ s _ P _ E _ c i _ R _ ~ _ T _ I O _ N _ s ~ I S P E C ~

SPECIFIC TIONS

GENER L SPECIFIC TIONS

Model

RT100A

Model Code Number: 3UL1

Vehicle Identification Number:

JYA3ULWO*LC0001

01

Engine Starting Number: 3UL-000101

Dimensions:

Overall Length

1,795

mm

70.7 in}

Overall

Width

760 mm (29.9 in}

Overall Height

960 mm (37.8 in}

Seat Height 730 mm 28.7 in}

Wheelbase 1,190

mm 46.9

in}

Minimum

Ground Clearance

200 mm

7.9

in}

Basic Weight:

With Oil and Full Fuel Tank 79 kg (1741b}

Minimum

Turning Radius:

1,810

mm 71.3

in}

Engine:

Engine Type

Air cooled 2-stroke

Induction System

Reed

valve

Cylinder Arrangement

Forward inclined single cylinder

Displacement 97cm

Bore

X

Stroke

52.0

X

45.6

mm 2.05 X 1.80

in}

Compression Ratio 6.7:1

Starting System Kick starter

Lubrication System:

Type

Separate lubrication (Yamaha Autolube}

Engine Oil Type Yamalube 2

or

air cooled 2 stroke engine oil

with

BIA certified for service TC-W

Transmission Oil Type

Yamalube

4 , SAE

10W30 type

SE motor

oil

or

GL gear oil

Oil Capacity:

Engine Oil (Oil Tank}

1.0

L

0.88

Imp qt,

1.06 US

qt}

Transmission Oil:

Periodic Oil Change 0.65 L (0.57 Imp qt, 0.69 US qt}

Total

Amount

0.65 L 0.57 Imp qt,

0.69 US

qt}

Air Filter

Type Wet

type element

2-1


21/170

Model

Fuel:

Type

Fuel Tank Capaci ty

Full Amount

Reserve

Amount

Carburetor:

Type Quantity

Manufacturer

Spark Plug:

Type Quantity

Manufacturer

Plug Gap

Clutch:

Type

Transmission:

Type

Primary Reduction System

Primary Reduction Ratio

Secondary Reduction System

Secondary Reduction Ratio

Operation

Gear Ratio

1st

2nd

3rd

4th

5th

Chassis:

Frame

Type

Caster Angle

Trail

Tire:

Type

Size

Front

Rear

Tire Pressure Cold Tire):

Basic Weight:

With

Oil and Full Fuel Tank

Cold Tire Pressure:

GENERALSPECIFICATIONS

I

PEC IP

RT100A

For USA) Unleaded fuel recommended

For CON) Regular unleaded gasoline

5 0

L 1.10

Imp

gal, 1.32 US gal)

1 5

L 0.33

Imp

gal, 0.39 US gal)

VM22SS/1 pc.

MIKUNI

For USA) 87ES

For CON)

BR7ES

NGK

0 5

- 0.6

mm

0.020 - 0.024 in)

Wet,

multiple

disc

Constant mesh 5-speed

Helical gear

74 19

3.895)

Chain drive

48 14

3.429)

Left

foot

operation

35/11 3.182)

30/15 2.000)

26/19 1.368)

23/23 1.000)

20/25 0.800)

Double cradle

29

103

mm

4.06 in)

With tube

2.50-184PR

3.00-164PR

79

kg

1741b)

FRONT

125 kPa

1.25

kg cm

2

18 psi)

? ?

REAR

125

kPa

1.25 kg cm

2

, 18 psi)


22/170

GENE

RALSPECI

FICATIONS

PEC P7

Model

R

T100A

Bra

ke:

Front Brake Ty

pe

D

rum brake

Fron t Brake

Operation

Right hand op

erat ion

Rear Brake T

ype

Drum brake

Rear Brake Operation Right

oot

operat ion

Suspensi

on:

Front

Suspension Ty

pe

Telesco

pic fork

Re

ar Suspension T

ype

Swin

garm

Shock Absorbe

r:

Front Shoc

kAbsorber

Coil spring/O

i l damper

Rear Shoc k

Absorber Coil sprin

g/Oi l damp er

Wheel

Travel:

Fr

ont Wheel Trav

el

110

mm 4.3

in

Rear Wh eel Tra

vel

84

mm

{3.3 in

Electrical:

Ignit ion

System

CDI Magn

eto

Gener

ator System

Flywhee

l magneto

2-3


23/170

MAIN

TENANCE

SPECIFICAT

IONS I

PE I

I

M INTE N

NCE S PECI

FIC TIONS

NGIN

Cylinder He

ad:

Warpag

e Limit

Cylinder:

Bore

Size

Ta

per Lim it

Model

Out of Round

Limit

Piston:

Piston

Size

D

Mea

suring Point a

Piston Off-Set

Piston-t

o-Cylinder Clear

ance

Ove

rsize 1st

Oversize 2nd

O

versize 3rd

Oversize 4th

Piston R

ing:

Se c

tional Sketch

End

G

ap (Installed)

S

ide Clearance

Top

ing

C]]

s

1

T

2nd Ring

DJs

1

Top Ring

2

nd Ring

Top Ring

2nd Ring

RT100A

0

.03

m

m 0.0012

in)

*

Lines indicate s

traightedge mea

surement.

52.00- 52.02

mm 2.047- 2.

048 in

0.05 mm

0.002 in)

0.

01mm

0.0004 in)

51.94- 52.00 mm

2.045- 2.047

in)

10 mm 0.39 in)

0.5

mm 0.020 in)

0.0

50 - 0.055mm

0.00 20 - 0.00

22

in

)

5

2.25 mm 2.057

in)

52.50 m

m

2

.067 in)

52.75

mm 2.077 in)

53 .00

mm

2.087

in)

K

eystone type

8=1.2 mm 0.

047 in).

T=2.0 mm

0.079 in)

Plain type

8=1 .2

mm 0.047 in)

T=1.6

mm 0.063 in)

0.3 - 0.5

mm

0.01

- 0.02 in)

0.3 - 0.5 mm

0.01 - 0.02 in)

0.03 - 0.0

5

mm

0.001 -

0.002 in)

0.03 -

0.05 mm 0.001

- 0.002 in)

2-4


24/170

Cranksha

ft:

Cran

k Width A

R

unout Limit B

Model

Big End Side C

learance C

Small

End

Free

Play

D

D

Clutch:

Friction Pla

te:

Th

ickness

Quant i ty

Wear L imi t

Clutch Plat

e:

Thickn

ess

Quan

tity

Warpage Lim

it

Clutch S pring

:

F

ree Length

Quant i ty

M in i

m u m Free Lengt

h

Clu

tch Release Me

thod

Transmission

:

Main Axle

Runout Limit

Dr

ive Axle R unou

tLimit

Shifter:

Type

Guid

e Bar Bending

Limit

Kick

S tarter:

Type

MAINT

ENANCESP

ECIFICATIO

NS I

PEC I

? 7

I

RT100A

49.90-

49.95

mm (1.965- 1.967

in)

0.0

3 mm

(0.00

12 in)

0.2 - 0.7 mm

0.008 -

0.028 in)

0.8 - 1.0

mm 0.032

- 0.039 in)

3.0 mm 0.120 in)

5

p

es.

2.7

m

m

(0.1

06 in)

1.2 m

m

0.047

in)

4 pes.

0.05

mm (0.002

in)

31.

5 mm

1.24

in)

5 pes.

30.5 mm

1.20 in)

Inne

r push, cam pu

sh

0

.08 mm (0.

003 in)

0.08 mm 0.00

3 in)

Cam d

rumand guide bar

0.025

mm

0.001

in)

Kick

and Mesh type

2-5


25/170

M

INTEN NC

ESPECIFIC

TIONS

I PEC

I 7 1

Model

RT

100A

Air

Filter:

Oil Grade

Foam-A

ir-Filter oil

or

Ya

malube 2

Carbu

retor:

I.

D. Mark 3

ULOO

M a

in Jet (M.J.)

140

Air

Jet

A.J.)

~ 2 5

Je

t

Needle

-Posit ion

J.

N.) 4L 6-3

Needle J

et N.J.) 0-6

Cutaw

ay (C A)

2.0

Pilot O

ut let

P.O.)

Pilot Je t

P.J.)

17.5

AirScrew

A.S.) 1-1/2

Valve Sea

t Size

V.S

.)

~ 1 5

Starter

Jet

G.S.) 30

Fuel Le

vel F.L.)

-0.5 - +0.5 m

m (-0.02 - +0.02

in)

Float

Height F.H.)

20 - 22

mm

(

0.79 - 0.87 in)

Id

l ing Speed 1,3

00- 1,450 r/min

Reed Valve:

Valve T

hickness 0.2 mm

(0.008in)

Valve

Stopper Heig

ht

6.7 - 7.3 mm 0.26

- 0.29 in)

Va

lve Bending Lim

it 0.3 mm(0.012

in)

Lubrication

System:

Autolub

e Pump

Color Code

Green

Minimu

m

Strok

e 0.20- 0.25 m

m (0.008- 0.010

in)

Maximu

m

S

troke 1.85

-

2.05

mm (0.073- 0.081

in)

Minimum Outpu t

0.50

-

0.62

cm

per

200

strokes

Maximum O utput 4.6

4 - 5.15cm

p

er

200

st rokes

Pul

ley Adju st ing M

ark At idle

2-6


26/170

M INTEN

NCESPEC

IFIC TION

S IPEC

I 1)5/ I

T IG H T N ING T

ORQU

Tightening t

orque

Part to

be t ightened

Bolt Nut

size

Nm

mkg

ftlb

Sparkplug

M14

X 1.25 2

5 2.5

18

Cylinder h

ead

M8 X 1.25

22

2.2

1

6

Auto lube

pump

M 5

X

0.8

4

0.4

2.9

In t

ake man ifold

M6

X

1.0

10 1

.0 7.2

Muffl

er Front)

M6

X

1.0

8

0

.8

5.8

Muffler Rear)

M 8

X

1.25

18

1.8

13

Crankcase

M6

X 1.0

8

0.8

5.8

Crankcase

cover Right)

M6

X 1.0

10

1

.0

7.2

Crankcas

e cover Left)

M6

X 1.0

7

0.7

5.1

Transmis

sion oil drain

bolt

M

12 X

1.5

20

2.0 14

A

utolube

pump

c

over

M6

X 1.0

8

0.8

5.

8

Kic

k crank assemb

ly

M8

X

1

25 16

1.6

11

P

rimary dr ive ge

ar

M12

X 1.0

60

6.0

43

Clutchboss

M12

X 1.0 45

4 5

32

Pressure

plate

M 5

X 0.8

6

0.6 4.3

Stoppe

r plate Bearing

)

M6

X

1.0

10 1

.0

7.2

Sh

if t cam stopper

bolt Neutral)

M14

X

1.5

25

2.5 18

Change pedal

M6 X 1.0 11

1.1

8.0

Drive sproke

t

M16

X 1.0

55 5.5

40

Stato r

M6 X 1.0 8

0.8

5.8

COl

m a

gneto

M

12 X 1.0

50 5.0

36

2 7


27/170

MAINTE

NANCESPE

CIFICATION

S I PEC I

>7

CH

SSIS

Model

RT

100A

Steering Sy

stem:

Bearing

Type

Ball Bea r

ing

Bearing

Size Quantity)

Upp

er

3/16 in 22 pes.)

Lower 1/4 in

19

pes.)

Front Suspens

ion:

Front Fork

Travel

110

mm

4.33 in)

Fork Sp

ring FreeLength

Left side only)

418.5 mm

16.5 in)

Sp

ring Rate

K,)

4.2

N/m

m 0.42 kg/mm

, 23.5lb/ in)

K2)

5.

7

N

/mm 0.57 kg

/mm, 31.91b/

in)

Stroke

K,) 0.0 -

70.0 mm 0.0 - 2.8 i

n)

K2)

7

110

mm 2.8 - 4.3 in

)

Optional S

pring No.

Oil Cap

acity

110

cm

3.87

Imp oz,

3

.72 US oz

)

Oil

Grade

Yam

aha forkoii

10WT or equivalen

t

Rear

Suspens

ion:

Shock Ab

sorber Travel

75 mm

2.95 in)

Spring

Free Length

205.6 m

m 8.09 in)

Fi t

t ing Length

201.

6 mm 7.94 in)

Spring Rate K

,)

11

N

/mm

1.1 kg/mm

,

61.61b/in)

K2)

17.4 N/mm 1.

74 kg/mm, 97.4

lb/ in)

Stroke

K,)

0.0-

50

mm

0.0

-

1.9

7

in)

K2)

50

-

75 mm 1.97 -

2.95 in)

Optional

Spring No.

Swingarm:

Free Play Lim

it Swingarm en

d)

1

.0 mm 0.0

39 in)

M ove sw

ingarm end sid

e to side

Fro nt Whe

el:

T

ype

Sp

orke whee l

Rim Size

18 X

MT1.40

Rim Materia

l Steel

Rim Run

out Limit

Ve

rtical 2.0

mm 0.08 in)

Lateral

2.0

mm 0.08 in)

2-8


28/170

~ ~ ~ ~ ~ ~ ~ - M _ A _ I N _ T _ E N _ A _ N _ c _ E _ s _ P _ ~ _ I F _ I C _ A _ T _ I o _ N _ s _ I S P E C I I

Model RT100A

Rear Wheel:

Type Sporke wheel

Rim Size

16 X MT1.60

Rim Material

Steel

Rim Runout Limit

Vertical

2.0

mm

0.08 in)

Lateral 2.0

mm 0.08

in)

Drive Chain:

Type/Manufacturer

RS420/TSUBAKIMOTO

Number of Links

103

Links

+ oint

Chain Free Play

20

30 mm 0.8- 1.2 in)

Front Drum Brake:

Type

Leading, trailing

Drum Inside Diameter

110 mm

4.33

in)

< 111 mm

4.37

in)>

Shoe Spring Free Length

34.5

mm

1.36 in)

Lining thickness

4

mm

0.16 in)

Rear Drum Brake:

Type Leading, Trailing

Brake Drum Inside Diameter

110 mm 4.33 in)

< 111 mm 4.37 in)>

Shoe Spring Free Length 34.5 mm 1.36 in)

Lining Thickness 4 mm

0.16

in)

Brake Lever and Brake Pedal:

Brake Lever

Free

Play 5 - 8 mm 0.20 -

0.31

in)

Brake Pedal Free Play

20 30

mm 0.8-

1.2

in)

Below top of footrest

Clutch Lever and Throttle Grip:

Clutch Lever

Free

Play

2

3 mm 0.08- 0.12 in)

Thrott le Cable

Free

Play 3 5 mm 0.12- 0.20 in)

At grip flange

2-9


29/170

MAINTENANCESPECIFICATIONS

I

PEC

I f I

TIGHT NING TORQU

Tightening torque

Part

to be

tightened

Bolt Nut

size

Nm

mkg ftlb

Chassis:

Engine mounting;

Front upper

M8

X

1.25 26

2.6

19

Rear upper

M8

X

1.25

26

2.6

19

Rear lower

M10

X

1.25

39

3.9 28

Pivot shaft and nut

M12 X 1.25

43 4.3

31

Rear shock absorber and frame Upper)

M12 X 1.25

39 3.9 28

Rear shock absorber and rear arm Lower)

M10 X 1.25

25 2.5

18

Handle crown and inner tube

M8

X

1.25

26

2.6 19

Handle crown and handlebar

M8

X 1.25

20

2.0 14

Under bracket and inner tube

M10

X

1.25

39

3.9 28

Under bracket and steering lock M5

X

0.8

6 0.6

4.3

Steering ring nut

M25 X 1.25

6 0.6

4.3

Refer

to

NOTE

Handle crown and steering shaft

M14 X 1.25

65

6.5

47

Front wheel axle and nut

M12 X 1.25 43 4.3

31

Brake cam lever and camshaft

M6

X 1.0

9

0.9

6.5

Rear wheel sprocket and wheel hub

M8

X 1.25

20 2.0

14

Tension bar and plate

M8

X 1.25

18

1.8

13

Tension bar and rear arm M8

X 1.25

18 1.8

13

Rear wheel axle and nut M10 X 1.25

39

3.9

28

Sproket shaft and rear arm M18 X 1.0 85 8.5

61

Footrest and frame

M8

X 1.25

18 1.8

13

NOTE

1.

First, tighten the ring nut approximately 36 Nm 3.6 mkg, 25 ftlb) by using the torque wrench,

then loosen the ring nut one turn.

2. Retighten the ring nut to specification.

2-10


30/170

MAINTENANCESPECIFICATIONS

I

PEC

I >7

ELECTRIC L

Model

RT100A

Ignition System:

Ignition

Timing

(B.T.D.C.)

27

at

2,000

r/min

Advancer

Type

Electrical type

30

< J

/

c i

.... :

~

&

g 20

E

;::;

c:

0

;::;

c

..2

10

0

1 2 3

4

5 6

7 8

Engine speed X1,000 r/min)

C.D.I.:

Magneto Model/Manufacturer

F3T1 0471 /MITSUBISHI

C.D.I. Unit Model/Manufacturer

F008T MITSUBISHI

Pickup Coil Resistance Color)

9 - 11Q at 2oc 68.F)

White/Red-Black)

Source Coil Resistance Color)

270 - 330Q at

2oc

68.F)

Brown-Black)

Ignition Coil:

Model/Manufacturer

F6T411 /MITSUBISHI

Minimum

Spark Gap

6

mm

0.24 in)

Primary Coil Resistance

0.9 -

1.1

Q at

2oc

68.F)

Secondary Coil Resistance

4.7 - 7.1

kQ

at 20c 68.F)

Spark Plug Cap:

Type

Resin

Type

Plug Cap Resistance

4 - 6kQ at

2oc

68.F)

2-11


31/170

GENERAL

TORQUE

SPECIFICATIONS/DEFINITION

OF

UNITS

I PEC I I

GENERAL TORQUE SPECIFICATIONS

This chart specifies torque for standard fas

teners with standard I.S.O. pitch threads. Torque

specifications for special components or assem

blies are included in the applicable sections

of

this book. To avoid warpage, tighten multi-fas

tener assemblies in a crisscross fashion, in pro

gressive stages, until full torque is reached. Un

less otherwise specified, torque specifications

call for clean, dry threads. Components should

be at room temperature.

A: Distance across flats

8: Outside thread diameter

DEFINITION

OF

UNITS

Unit

Read

A

(Nut)

10mm

12mm

14mm

17mm

19mm

22mm

Definition

mm millimeter

10-

3

meter

em centimeter

10

2

meter

kg kilogram 10

3

gram

N

Newton

1 kg X

m sec

2

Nm

Newton meter

Xm

mkg

Meter

kilogram

m X

kg

Pa Pascal N m

2

N mm

Newton per millimeter

N mm

L Liter

cm

3

Cubic centimeter

r min

Revolution per

minute

2 12

B

General torque

specifications

(Bolt)

Nm

mkg

ftlb

6mm

6 0.6 4.3

8mm 15 1.5

11

10mm

30 3.0 22

12mm

55 5.5

40

14mm

85 8.5 61

16mm

130

13.0

94

Measure

Length

Length

Weight

Force

Torque

Torque

Pressure

Spring rate

Volume or capacity

Engine speed


32/170

LUBRICATION POINTS AND LUBRICANT TYPE I PEC I p I

LUBRIC TION POINTS

ND

LUBRIC NT

TYPE

ENGINE

Lubrication Points Part name) Lubricant Type

Oil seal lip

0 ring

: . 1 ~

Small end/Big end bearing

Gl

Bearing

Gl

Piston ring

Gl

Piston

Gl

Cylinder inner surface

Gl

Piston pin

Gl

Kick axle

Gl

Primary driven/drive gear

Gl

Push rod

Push lever

Gl

Guide bar Shift fork)

Gl

Shift shaft

Gl

Shif t cam

Gl

CH SSIS

Lubrication Points Part name) Lubricant Type

Steering Upper/Lower balls

Front/Rear wheel oil seal lip

: . 1 ~

Brake cam shaft

Brake pedal pivot

Handlebar Right) end

Sidestand pivot

Gl

Clutch lever pivot/cable end

Gl

Brake lever pivot/cable end

Gl

Pivot shaft

2 13


33/170

C BLE R

OUTIN

CD

Handlebar sw

itch

Swi

tch lead band

Throttle grip

uel tank breather

hose

CA

BLE ROUTIN

G I

PEC I 7

[

]

Pass

the brake cable

outside o the c l

utch cable.

2 14


34/170

C BLE RO U

T I NG

D

Cable guide

Throt t le

cable

Clamp

DI m ag

neto lead

@

O

il hose

Clamp

J)

Engine breather

hose

@

Clutch cable holder

Clutch cabl

e

Clamp

2 15

CABLE

ROUT ING

I PE

I

7

lAJ

C

lamp the DI uni

t lead

[

B

Clamp the D

I m agneto lead a

nd engine breath

er

ho

se


35/170

C BLE ROUTING

D

Clamp

Oil tank breather hose

Carburetor overflow air bent hose

Oil delivery hose

CDI unit lead

@Clamp

j) Spark plug lead

Engine stop switch lead

Ignition coil lead

CABLE ROUTING

I PEC I f I

[A] Clamp the engine stop switch lead

[6] Do not clamp the oil delivery hose

[ J

To

CDI

unit

~

2 16


36/170

INTRODUCTION/PERIODIC MAINTENANCE :gj I

I

LUBRICATION INTERVALS

_ . _

PERIODIC INSPECTION ND ADJUSTMENT

INTRODUCTION

This chapter includes all information necessary

to

perform recommended inspections and adjust

ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle oper

ation and a longer service life. The need for costly overhaul work will be greatly reduced. This informa

tion applies to vehicles already in service as well as new vehicles that are being prepared for sale. All

service technicians should be familiar with this entire chapter.

PERIODIC MAINTENANCE LUBRICATION INTERVALS

ITEM REMARKS

Spark plug

Check condition. Clean or replace if necessary.

Air filter

Clean. Replace if necessary.

Carburetor*

Check idle speed/s tarter operation.

Adjust if necessary.

Fuel line

Check fuel hose

for

cracks or damage.

Replace if necessary.

Check oil level / oil leakage. Correct if necessary.

Transmission

oil

Replace every 4 months.

(Warm engine before draining.)

Autolube pump Check operation. Correct

if

necessary. Air bleeding.

Brakes* Check operation. Adjust if necessary.

Clutch Check operation. Adjust if necessary.

Check rear arm assembly for looseness.

Rear arm

pivot

Correct

if

necessary.

Moderately repack every 24 months.

Wheels*

Check balance/damage/runout/spoke tighteness.

Repair if necessary.

Wheel bearings*

Check bearings assembly for looseness/damage.

Replace if damaged.

Steering bearing* Check bearings assembly

for

looseness. Correct

if

necessary. Moderately repack every 4 months.**

Front forks Check operation/oil leakage. Repair if necessary.

Rear shock absorber* Check operat ion/oi l leakage. Repair if necessary.

Drive chain

Check chain slack/alignment.

Adjust

necessary.

Clean and lube.

Fittings/Fasteners*

Check all chassis fittings and fasteners.

Correct

if necessary.

Sidestand* Check operation. Repair if necessary.

It is recommended

that

these items be serviced by a Yamaha dealer.

Medium weight wheel bearing grease.

3 1

BREAK-IN

EVERY

1 month 6 months

12 months

REPLACE

Every Ride

(More often in

wet

or dusty areas)


37/170

-

ji

ANDSJP

j uj

IDLING S

PEED

A

DJUSTMEN

T

. . lr:i

.

3 2

YB1AE 4

ENGINE

ID LING SPE

ED

ADJUSTM

ENT

1. Start the en

gine and le

t i t warm

up for se -

vera

l minutes.

2

. Attach:

I

nductive tachome

ter

(to

th

e spar

k

plug le

ad .

Inductive

tachometer:

Y

U-08036

3

. C

heck:

Eng

ine id l ing spee d

Out of

specifica

tion

-

Adjus

t.

Engine

idlin

g

speed

1,

300 1

,4 50 r/min

4. Adjust:

Engine idl ing

s peed

Adj

ustment

steps:

T

urn

in t

he pilot air s

crew

D

until it is l igh-

t ly seated.

Turn

out

the

pi l

ot

air

screw for the spec i -

fied num

ber

o

f turns

.

Pilo

t air

scr

ew:

1 and

1/2 turns out

Tur

n

the thro

ttle

stop scre

w

in

or out

until s

pecified

id

l ing speed

is obtained.

Turni

ng in

Idling

speed

be-

comes hi

gher.

T

urning ou t

Id l

ing

sp

eed be-

com

es

lowe

r.


38/170

_

____

____

____

___

___

I

1

ANDS

JPI al

HROTT

LEC BLE

DJUSTMEN

T _ ~

_

3 3

5 Adjust:

T

hrottle ca

ble free play

Refe r

to

T HRO T T

LE CABLE FRE

E PLAY

ADJU

STMENT section.

Free play:

YB1A

E 008

3

5 mm 0

.12

0

.20 in}

at

throttle

grip

flange

THROTTLE

CABLE

ADJUSTMEN

T

NOTE

E

ngine idling sp

eed shou ld b

e adjusted p r

o-

per ly

before adjus t

ing the

thro

tt le

cable fr

ee

play

1. Check:

Thr

ottle cabl

e free play @

Out

of

specific

ation - Adjus

t.

Fr

ee play:

3 _ 5

mm 0.12 _ 0.20

in}

at throttle

grip

flange

2 Adju

st:

Thrott

le cable fr

ee play

********************

************

*****

Adjus

tment steps:

Loosen the

locknut

D

.

Tu

rn the

adjuster in or out

until the

specif

ied

free

play is obta i

ned

Turning in

Turn

ing

out

Free pla

y

is

increased

.

Free

play

is

decreased

Tighten

th

e locknu

t.

_

WARNING

After

adjusti

ng

turn

the h

and lebar to

right

and

le

ft and

m

ake sure

th

at t

he eng

ine

id

ling does

not

runfa

ster.

************

************

************

*


39/170

3 4

Y81AC002

UTOLU

BEPUMPC B

LE DJUSTM

ENT

NOTE

Engine id

l ing speed an

d throt

tle

ca b

le

free

play should be

adjusted

proper l

y before

ad

ju -

sting

the

auto

lube pum

p

cabl

e

1.

Re

move:

Auto

lube

pump

co

ver

D

2 Close

the throttle

complete

ly

3 Check

:

Align

ment mark @

No

t l i g n e d ~ Adju

st Autolube

pump cable

4 Adjust:

Autolube pump cable

Adjustme

nt steps:

L

oosen th

e locknu

t

D .

Turn

the

adjuster

in

or out until

the

alig-

nment mark is al igned

with

the

pin

Tighten the

locknut

5

1nstal l :

A

utolube pump c

over

YB 1A C004

UTOLUBE

PUMPSTROK

E DJUSTMEN

T

1

R

emove:

Autolu

be

pump

cov

er

D

2

Start

the

engine and

le tit w

arm up fo r se-

veral m

inutes


40/170

3 5

3.

W

hile r

unn ing the en

gine at

idle , observe

th

e pump adjusting

p la t

e

carefu

lly.

Stop

the engine the

momentthat t

he ad jus t i

ng

plate D mo

ves out to

it s

l

imit.

4. M e

asure :

Gap

Out

of c i f i

c a t i o n ~ A d j u s t

Measure th

e gap with

the thickness ga

uge

betwee

n

th

e ra ised os

s

on

the

pump

ad

just ing pu l le y

and

t

he ad jus t

ing p la te D.

Minimum pumpstro

ke:

0

.20-0.25 m

m

0.008-0.010

in

NOT

E

W

hen inserting

the thick

ness gauge

bet-

ween

t

he

adju

sting

p la te and

the

ad jus t in g

pu

lley, be careful t

hat neither the

p la te nor

th

e

p

ul ley is moved.

In othe

r

w

ords do not

force

th

e thic

kness gauge

in to

the

gap.

5. A

djust:

Autol

ube

pu

mp minimum

stroke

*******

************

************

******

A

djustment st

eps:

Remove

th e

locknut

D

spring

washer

and adjusting

p la te

.

Adj

us t

the pum

p

st roke by adding

or

remo-

ving

a

sh

im

@


41/170

AUTOLUBE

PUMP

AIR BLEEDING

3-6

Adding shim

Pump stroke is increa-

sed

Removing shim

Pump stroke is dec-

reased

Install

the

adjusting plate, spring washer

and

locknut.

Locknut:

7Nm 0.7m kg 5.1f t lb)

Recheck the minimum

pump stroke. If

out

of specification, perform the above steps

again.

6.1nstall:

Autolube pump

cover

YB1AC005

AUTOLUBE PUMP AIR BLEEDING

glliiiiJ

The Autolube pump

and

delivery

lines

must

be bled

on

the

following occasions:

Setting up

a new

machine out of the crate.

Whenever the oil

tank has run

dry.

Whenever any

portion

of the engine

oil

system is disconnected.

1.1nspect:

Engine oil level

Oil level

low-+Add

oil

to proper

level.

Refer

to the

W NGIN OIL LEVEL INSPEC

TIOW section.

2. Remove:

Autolube

pump

cover

D

3. Air bleed:

Pump case and/or oil

hose


42/170

3-7

Air

bleeding steps:

Place a .rag

under the Autolube

pump

to

catch

oil.

Remove

the

bleed

screw G .

Keep

the

oil running out

until

air bubbles di

sappear.

When

air bubbles are expelled

completely

tighten the

bleed

screw.

NOTE

Check

the

bleed screw gasket.

If

damaged

replace with a new one.

4.

Air bleed:

Pump distributor and/or delivery

hose

Air bleeding

steps:

Start the

engine.

Pull the pump cable G all the way out to

set

the pump stroke to a maximum.

NOTE

It

is difficult

to

bleed

the distributor

comple

tely with the pump stroke at

a minimum and

therefore the

pump

stroke

should be

set

to a

maximum.

Keep

the

engine running at about 2 000 r/

min for two minutes or

so

then both

dis

tributor and

delivery

hose can be complete-

ly bled.

5.1nstall:

Autolube pump cover


43/170

N

DSJP I ~

PARKPLU

G INSPECT

ION

11 ':/

3 8

YB1AA009

SPARK

PLUG

INSPE CTION

1.

Remove

Spark plug

2

. Inspect:

Spark plug ty

pe

l n c o r r e c

e p l a c e

Standar

d

sp

ark

p lu

g:

For

USA . . B7ES/N

GK

For

CDN . .. BR7ES

/NGK

3.1

nspect:

Elec

trode CD

W

e a r / D a m a g e ~

R e p l a c e .

Insu

lator

Abnor

mal r ~ R e p l a c e

Nor m a l colo

r is a medium-

to-light

tan

co

lor.

4

.

C

lean the spar

k plug wi

th

a

spark plug

c le

aner or wir

e

b

rush.

5.

M e a s

ure :

Plug

g p

Use a Wir

e Gauge or Fee

ler Gauge.

Out

of

specification Re

-gap.

Spark p lu g gap:

0 . 5 ~ 0 . 6

mm

0 . 0 2 0

~ 0 . 0 2 4 in}

6 .

Tighten:

Spark plug

Spark plug:

25

N

m 2.5

m

kg, 18 f t

lb}

NOT

E

Bef

ore

in

stall in g a

spark plug, cle

an the

g

asket

s

urface and plug

surface.


44/170

3 9

YB1AA012

IGNITION

TIMING

CHECK

NOTE

Engine idling speed and

throttle

cable

free

play should be adjusted properly

before

chec

king the ignition

timing.

1. Remove:

Crankcase

cover

left) D

2. Attach:

Timing light and inductive tachometer

Timing

light:

YM-33277

Inductive tachometer:

YU-08036

3.

Check:

Ignition

timing

Checking steps:

Warm

up

the

engine and keep

it

at

the spe

cified speed.

I

ngine speed:

. 2,000 r/min.

Visually

check

the stationary

pointer

D

to

verify

i t is within

the

required firing

range indicated on

the

timing plate.

Incorrect

firing

range-+Check

timing

plate

and/or pickup assembly.

4.1nstall:

Crankcase cover

{left)


45/170

ENGINE OIL LEVEL INSPECTION/TRANSMISSION

OIL

LEVEL

IINSP I

I

INSPECTION DJ

...:......::=;.... j..._

YB1AC007

ENGINE OIL LEVEL INSPECTION

NOTE

Position the

machine

straight up when

inspe-

cting

the

oil level

1 Place

the

machine on a level

surface.

NOTE

Piace a suitable

stand

under

the

engine

2

Check:

Oil level

Oillevellow-+Add

sufficient

oil

D

Oil level window

Recommended oil:

Yamalube 2 or

air cooled

2

stroke

engine

oil

with

BIA cer

ti f ied for service TC-W

Oil

tank

capacity:

1 0

L(0.88 Imp

qt,

1.06

US qt)

Always use the same type of engine

oil;

mixing oils

may

result in a harmful

chemical

reaction and lead to

poor

performance.

YB1AC039

TRANSMISSION OIL LEVEL INSPECTION

1. Place the machine on a level place

N O T E ~ -

Piace a suitable stand under

the

engine

3-10


46/170

2.

Inspect:

Oil level

Oil level should be

between maximum D

and minimum marks.

Oil level is

low

-

Add

oil to proper level.

NOTE

Do

not screw

the dipstick

Insert the

dip

stick

lightly

when

inspecting

the

oil level.

Recommended oil:

Yamalube 4

or

SAE 10W30

type SE motor

oil

NOTE

Recommended oil classification; API Service

se, sF type or

equivalent (e.g.

sF-se,

SF-SE-cc,

SF-SE-SD

etc .

Do

not add any

chemical additives. Trans

mission oil

also

lubricates the clutch and

additives

could cause clutch

slippage.

Do not allow foreign material to enter

the

crankcase.

A WARNING

Never attempt to remove the dipstick

just

after high

speed

operation. The heated oil

could spout

out,

causing

danger. Wait until

the oil cools down.

3.

Start

the engine and

let

i t

warm up

for se

veral minutes.

4.

Stop the

engine and

inspect the

oil level

once again.

NOTE

Wait a few minutes until settles before inspe

cting the

oil level.

3-11


47/170

TRANSMISSION OIL REPLACEMENT/

~ ~

I

CLUTCH

ADJUSTMENT

_ . _

YB1AC042

TRANSMISSION OIL REPLACEMENT

1

Start

the

engine and

Jet

i t

warm up for

se

veral minutes.

2.

Stop the

engine and place an oil pan under

the engine.

3.

Remove:

Oil

filler

plug

Drain plug D

Drain the transmission case of its oil.

4.1nstall:

Drain plug

'

Drain

plug:

~ 20 Nm 2.0 m

kg,

14ft lb)

NOTE

Check the gasket

(drain plug).

If

damaged, re

place i t with a

new

one.

5 Fill:

Transmission

case

Oil

quantity periodic oil

change):

0.65

L

0.57

lmpqt,

0.69

USqt)

Refer to the

TRANSMISSION OIL LEVEL

INSPECTION

section.

YB1AF002

CLUTCH ADJUSTMENT

1 Check:

Clutch

cable free play

Out of specification-+ Adjust.

3-12


48/170

AIR FILTER CLEANING

Free play:

INSP

ADJ

2 3 mm 0.08 0.12

in)

at clutch lever pivot

2 Adjust:

Clutch cable free play

Adjustment steps:

Loosen the locknut s) G .

Turn

the adjuster s)

in or

out

until the

specified free play is

obtained.

Turning

in

Turning

out

Free play is increased.

Free

play is decreased.

Tighten the locknut s).

YB1AB003

AIR FILTER CLEANING

1 Remove:

Seat

G

Side cover

left)

2 Remove:

Air filter case cover G

3 13


49/170

___________________

i

1

ANDSJPJ nJ

IR FILTER CLEANING

_ _

350 000

3. Remove:

Air

filter element D

Element guide

Never operate the

engine with the air

f i lter

element removed. This

will

allow

unfiltered

air to enter causing rapid

wear

and possible

engine damage.

Additionally operation

wi-

thout

the

filter element will affect carbure-

tor tuning

with

subsequent poor performan-

ce

and possible engine

overheating.

4.1nspect:

Air filter

element

Damage ~ Replace.

5

Clean:

Air filter

element

Cleaning

steps:

Wash

the

element gently but thoroughly

in solvent

D

A

WARNING

Use parts cleaning solvent only. Never use

gasoline

or low flash point

solvents which

may

lead

to

a

fire or explosion.

Squeeze the excess

solvent out of the

ele-

ment

and let

dry.

Do

not

twist

or wring

out

the foam

element.

This could damage the foam material.

Apply the

engine oil .

Squeeze out

the

excess oil.

NOTE

The element

should be wet

but not

dripping.

3 14


50/170


51/170

FRONT BRAKE ADJUSTMENT

2.

Inspect:

Muffler s)

D

Cracks/Damage-+Replace.

Gasket(s)

Exhaust gas leaks-+Replace.

3.1nstall:

Side cover (right)

Seat

YB1A3002

CHASSIS

FRONT BRAKE ADJUSTMENT

1. Check:

Brake lever free play

Out of

specification-+Adjust.

Free play:

2.

Adjust:

5 8 mm 0.2 0.3 in)

at

brake lever pivot

Brake lever free

play

Adjustment

steps:

Loosen the locknut

D

.

Turn the

adjust er(s)

in

or out until the

specified free

play is obtained.

~ ~ t t ~ i ~ t

Make sure that the brake does not

drag

after adjusting it.

Tighten the locknut.

3-16


52/170

YB1A3006

REAR BRAKE

ADJUSTMENT

1.

Check:

Brake pedal

free

play

Out of specification- Adjust.

~

Free play:

20 30

mm

0.8

1 2

in)

3-17

2. Adjust:

Brake pedal free play

*************************************

Adjustment

steps:

Turn the

adjuster s) D in

or out until

the

specified free

play is obtained.

Turning

in

Free play

is

decreased.

Turning

Free play

is increased.

out

Make sure

that the

brake

does not drag

after

adjusting

it.

*************************************

YB1A4022

DRIVE CHAIN

SLACK

ADJUSTMENT

NOTE

Before

checking and/

or

adjusting, rotate

the

rear

wheel

several

revolutions

and

check

slack

at

several

points to find the tightest

point.

Check and/or adjust

the

chain slack

with the

rear

wheel

in this wtightestw

position.

Too

little

of

chain slack

will

overload

the

engine and

other

vital parts;

keep

the

slack

within the

specified

limits.

A WARNING

Securely support the machine so there is no

danger of i t falling

over.


53/170

I

I N

DSJP ~

I

RIVE CHA IN

SLACK A

DJUSTMEN

T

1. Place the

m achine o

n a level pla

ce, and

hold i t in

an u

pright position.

NO

TE

Both

wheels shou ld be on

the ground

wi

thout the rider on

it.

2 Che

ck:

Drive chain s la

ck

Out of

specification

-+Adjust.

Drive chain slack

:

20 30

mm

0.8

1.2 in }

at

both wh

eels on ground

witho

ut rider

3 .

Remove

Cotterp in

( )

4

.

L

oosen:

Ax

le nut

Sprocket shaft n

ut

5 Ad just:

D

rive

cha

in s lack

****

************

************

*********

Adjustme

nt steps:

Loo

sen the locknut

s) @

Turn

the

ad juster s

) in or

out until the

specified s la ck is ob

ta ined.

Turning in

S lack

is decreased.

Turning

out

Slack

is increased.

NO

TE

T

urn

each

adjuster

exactly the sam e a

mount

to

maintain

correct axle al ignm

ent. There

are

m

arks

o

n

each

side o

f swingarm and on

each c

hain pu ller; use

them

t

o

check fo r

prope

r

al ignm

ent. )

3-18


54/170

I NDSJP ~ I

RIVE

CH IN LUBRIC TION

Tighten

the sprocket

shaft

nut and axle

nut to

specification, while

pushing up or

down on the chain

to

zero slack.

Sprocket shaft

nut:

85Nm 8.5 m kg, 6 f t lb)

Axle

nut:

39 Nm

3.9

m kg, 28f t lb)

Tighten

the locknut s).

6. Install:

Cotter pin D

G,U1 : J(lf4;

Do

not

loosen

the

axle nut after torque

tigh-

tening.

If the

axle

nut groove is not

aligned

with

the cotter

pin

hole,

align

groove

with

the

hole

by tightening

up on

the axle nut.

A WARNING

Always

use a new

cotter

pin.

7. Adjust:

Rear brake

Refer

to

the

WRE R

BRAKE ADJUSTMENT

section.

YB1A4026

DRIVE CHAIN LUBRICATION

The chain consists

of

many parts which

work against each other. If the chain is not

maintained

properly,

it will

wear

out rapidly,

therefore,

form the

habit

of

periodically ser

vicing

the chain.

This service

is especially ne

cessary when riding in dusty conditions.

1. Use any brands

of

spray type chain lubri

cant. First, remove

all

dirt

and mud

from

the

chain

with

a brush or cloth, then spray

a lubricant between both rows

of

side

plates and on all

center

rollers.

2.

To

clean the chain, remove the chain from

the machine, dip it in solvent, and clean

out

as much

dirt

as possible. Take the

chain out

of

the solvent and

dry it.

lmme-

3-19


55/170

1

1

ANDSJPI ul

TEERING HEAD

ADJUSTMENT

_ .

l l : i '

_

diately lubricate the

chain to

prevent rust.

Recommended lubricant:

YB1A1000

Yamaha chain and

cable

lube

or SAE 10W30

motor

oil

STEERING HEAD ADJUSTMENT

AWARNING

Securely

support the

machine

so

there is no

danger of it

falling over.

1 Elevate the front wheel

by

placing a suitab

le

stand

under

the

engine.

2. Check:

Steering assembly bearings

Grasp

the

bottom of

the

forks and

gently

rock the

fork assembly

back

and forth.

Looseness-+Adjust steering head.

3.

Remove:

Front wheel

Refer to

the

FRONT WHEEL

section

in

the

CHAPTER

6.

Seat

Fuel tank

4. Adjust:

Steering head

Adjustment

steps:

3-20

Loosen

the bolt

(handle

crown .

Tighten the

ring

nut

using

the

ring

nut

wrench.


56/170

NOTE

Set the torque wrench

D to

the

ring

nut

wrench

so that they form

a

right

angle.

~

I

ing

nut

wrench:

YU-33975

Ring

nut

{initial tightening):

36

Nm 3.6

m

kg, 25f t

lb)

Loosen

the

ring

nut one turn.

Retighten

the

ring nut using

the

Ring nut

wrench.

WARNING

Avoid

over-tightening.

Ring nut final

tightening):

6 Nm 0.6 m

kg,

4.3 f t

lb)

NOTE -

Recheck

the

steering head

by turning the

steering

from

lock to lock,

after

adjusting

steering head.

If

steering is binded, loosen

the

ring nut

but

not

to

the extent of free play in bearing.

If steering is loosened, repeat

the

adjust

ment steps.

Tighten the bolt

handle

crown).

Bolt handle crown):

65Nm 6.5m

kg 4 7 f t

lb)

5.1nstall:

Fuel tank

Seat

Front wheel

3 21

Refer to

the WFRONT WHEEL section

in

the

CHAPTER 6.


57/170

TIRE INSPECTION

YB1A3014

TIRE INSPECTION

1

Measure:

Tire pressure

Out of specification-+Adjust.

A WARNING

Tire inflation pressure should

be

checked

and adjusted when the temperature of the

tire

equals

the ambient air temperature.

Cold

tire

pressure

Front

Rear

125kPa

125kPa

Off road

riding

1.25kg/oi

1.25kg/cnf

18psi)

2.1nspect:

Tire surfaces

Wear/Damage-+Replace.

Minimum tire tread depth:

front and rear)

4 5 mm

{0 18

in)

D Tread

depth

Sidewall

Wear indicator

A

WARNING

18psi)

It

is

dangerous to ride with a

wornout

tire.

3-22

When

a

t ire tread begins

to

show lines,

replace the tire immediately.

Patching

a

punctured tube is not recom

mended. If it is absolutely necessary to do

so, use great care and

replace

the tube

as

soon as possible with a good

quality

repla

cement.

Do not attempt

to

use tubeless

tires

on a

wheel

designed for

tube

type tires

only.

Tire

failure

and personal injury may

result

from sudden deflation.


58/170

I NDSJP

~ I

IRE INSPECTION _

341 009

3 23

Wheel

Tire

Tube type

Tube

type only

Tubeless Tube type or tubeless

Be

sure

to

install

the correct

tube when

using tube

type

tires.

After

extensive tests, the tires mentioned

below

have

been approved by Yamaha

motor Co.,

Ltd.

for this model. No

guaran

tee

for

handling

characteristics

can

be

given if tire combinations other

than

what

is approved are used on this

machine.

The

front and rear tires

should be of

the

same

manufacture

and design.

Manufacture

Size

Type

Front):

2.50-184PR

KNOBBY

CHENG SIGN

Rear):

3.00-164PR

KNOBBY

CHENG SIGN

WARNING

After

mounting

a tire, ride

conservatively

to

allow

proper

t ire to

rim

seating. Failure

to

do so may

cause an

accident

resulting

in

machine

damage

and

possible

operator

injury.

After a tire repair or replacement, be sure

to torque tighten

the

valve stem locknut

D

to specification.

Valve stem locknut:

1.5 Nm

0.15

m kg, 1.1 t lb}


59/170

WHEEL INSPECTION/SPOKES INSPECTION AND I : g ~ I

I

TIGHTENING/FRONT FORK INSPECTION _ . Ei ' _

YB1A3016

WHEEL INSPECTION

1.1nspect:

Wheels

Damage/Bends-+Replace.

NOTE

Aiways balance the

wheel when

a

tire or

wheel has been changed or replaced.

at

WARNING

Never

attempt

even

small

repairs

to

the

wheel.

YB1A3017

SPOKES INSPECTION

AND

TIGHTENING

1.1nspect:

Spokes

D

Bend/Damage-+Replace.

Loose spoke- Retighten.

2.

Tighten:

Spokes

Spoke wrench

NOTE

e sure to retighten these spokes before

and

after

Break-in.

YB1A1001

FRONT FORK INSPECTION

at WARNING

Securely

support

the machine

so

there is no

danger of

i t

falling over.

1. Place the machine on a level place.

3-24


60/170

I

I NDSJP ~

I

E

AR SHOCK

ABSORBER

AD

JUSTMENT

2 Ch

eck:

ln

nertube

S c r a t c h / D a

m a g e ~ R e p l a c e

Oil se

a l

E

xcessive

i l l e a k a g e ~ R e p

l a c e

3

old

th e machine

on

uprig

ht

p

osition and

apply

the

front bra

ke

4 Check

:

Operation

Pump

th e

front

fork up and

dow

n for

s

e-

veral times

Un

smooth p e r a t i

o n ~ R e p a

Refer to

t

he

W RON

T ORKW section

in the

CHA

PTER 6

YB 1A 2

001

R E A R

SHOCK A B S O

R B E RADJUST

MENT

AWARNING

Alway

s

a

djust each rear

shock absorber

preload to

the

same

settin

g

Uneven adj

us-

tm ent

ca

n

ca

use

poor

handlin

g and

lo

ss of

stability

Securely

supp

ort the

machine

so

there is

no

da

nger

o

f

it falling

over

1

Adjust:

Spr

ing

p

re load

Turn the

adjuste

r D to

direction

or

@

Turn

ing

Spring preload

is

decreased

T

urning@

Spr

ing pre

load

is

in

creased

Adjuster po

sition:

Standard 2

Minimum 1

Maximum 5

Never atte

mpt

to

turn th

e

ad

juster bey

ond

the

maximum

or minimum s

etting

3 25


61/170

CABLE

INSPECTIO

N AND

LU B

RICAT ION/L

EVER

AND PEDAL

NSP

I I

LUB

RICATION/S

IDE ST

AND LUBRICAT

ION DJ

~ . . . ; . ; ; ; ; ; ; ; . . . ; : ; . .

. . . r . . _ _ .

Y81A3018

C A B L EINSPE

CTION

AN

D L

UBRIC ATION

A WARNING

D a m a

ged cable sheath may

caus

e

corro

sion

and

interfere

with

the cable movemen

t. An

u

nsafe condi

tion may

resu

lt so

replace such

cable

as

soon

as possib le.

1 .1ns

pect :

Cable

sheath

Damage-

Replace.

2 Check:

Cable

ope

ration

Unsmooth

op

eration- Lubr

icate.

R eco m m e n

ded

lubricant:

Y amaha chain

and cable

lube

or

S A E

1

0W30 motor

oil

NOTE

Hold cable

end high and a

pp ly several drops

of

lub

ricant

to

cable.

YB

1A3019

L

EVER

AND

PE

DAL LUBRICA

TION

Lubricate the

l v r and peda

l

at their p

ivo

ting

points

.

Y B 1A 5000

R e c o m m

ended

lubric

ant:

Y a m a h

a

chain

and c

able lube

or

S

AE

10W30 moto

r

o il

S IDEST AND

LU BRICATIO

N

Lubricat

e

t

he s

idestand at pivoting

po in ts .

3 26

Recom

m e n ded

lubric

ant:

Y a m a h

a

chain

and c

able lube

or

SAE10W3

0 motor oil


62/170

4 1

ENGINEREMOVAL

I

NG

I I

YB141000

ENGINE OVERHAUL

ENGINE

REMOVAL

NOTE

It

is not necessary to remove the engine in

order to remove

the following components:

Cylinder

head

Cylinder

Piston

and

piston

ring

Primary

drive

gear

Kick

axle

Shift

shaft

CDI magneto

Autolube pump

YB141001

TRANSMISSION OIL

1 Drain:

Transmission

oil

Refer to cHAPTER 3-TRANSMISSION OIL

REPLACEMENT l

Y8141002

SEAT AND SIDE COVER

1

Remove:

Seat

Side covers

left

and right)


63/170

ENGINE REMOV L

NG

I

I

4 2

YB141003

FUEL T NK

1 Turn the fuel cock

to

oFFn position and

disconnect the

fuel

hose D

2 Remove:

Fuel tank

YB141004

MUFFLER

1 Remove:

Nuts

D

2 Remove:

Muffler

YB141005

C RBURETOR

1 Remove:

Carburetor assembly

Refer

to the

cHAPTER 5 CARBURETOR

section


64/170

ENGINE REMOV L

ENGI

1

YB141006

UTOLUBE PUMP C BLE ND HOSE

1.

Remove:

Autolube pump cover

D

2.

Disconnect:

Autolube pump

cable D

Oil hose

Oil

delivery

hose

N O T E

Piug

the

oil hose end with a suitable

screw

- ~ ~ ; : r ~ w j ; 1 vs141 7

LE DS

4-3

1.

Disconnect:

Spark plug lead

D

2.

Disconnect:

COl

magneto

leads

YB141008

CLUTCH C BLE

1.

Disconnect:

Clutch

cable handlebar side)

Clutch

cable engine side) D

YB141009

DRIVE CH IN

1. Remove:

Change pedal D

Crankcase cover left)


65/170

2. Remove:

Cotter pin

D

3

Loosen:

Sprocket

shaft nut

Rear

wheel

axle nut

Lock

nut @

Adjuster

4

Straighten:

Lock washer

D

5 Remove:

Nut

Lock washer D

Drive sprocket

Drive

chain @

YB141010

ENGINE REMOVAL

1. Removal:

Bolts

2. Remove:

Engine assembly from right side

YB142001

ENGINE DISASSEMBLY

CYLINDER HEAD CYLINDER AND PISTON

NO T E

With the engine mounted, the cylinder head,

cylinder and piston can be maintained by re

moving

the following

parts.

Fuel

tank

Muffler

4-4


66/170

EN

GINE DISAS

SEM BLY

I

NG I

~

1. Remove:

Spark p

lug D

Cyl

inder he

ad

2.

Re

move:

Gas

ket cy

linder head) D

Cylin

der

Gaske

t cyl inder )

Intake man

ifold

Reed valv

e

Gasket reed

valve)

3. Remove:

Piston

pin clip D

N

OTE

Before removing

piston

pin

c

irclip,

cover

crankcase

with ac lean ra

g to preve

nt circlip

fr o

m

fal l in

g intocrankcase

ca vity.

l

4.

R

emove:

Piston p

in

Piston

Small

end

be

ar ing

NOTE

Befo

re removing

th e

piston pin, d

ebar

the

clip gr

ooved and p in h

o le area.

If th

e

piston

pin groo

ve is debarred

an

d piston pin i

s

s

till

d

ifficult to rem

ove, use p

iston pin pu l ler .

I

iston

pinpuller:

'

YU 01304

t r o m :

_

4 5

Do not use a ha

mme r todriv

e the pis ton p

in

out.


67/170

E

NG

JNE

DISA

SS

EMB

LY

I

N

G

I

I

YB14

2 2

C

LUT

CH

ND

P RIM

R

Y DR

IV E

GE

R

N

O T

E

Wit

h the

eng

in emou

nted

,

the

clutc

h

and

pr i

-

mary

dr iv

e ge

ar c

an b

e

m

ainta

ined

b

y

r

emo-

v

ing th

efo l

lowin

g

parts

.

Aut

olube

pum

pc

able

and

hos

es

1.

R

emo

ve:

Ki

ckcra

nk

D

Cra

nkc

aseco

ver

(r ig

ht)

2 R

emo

ve :

B

olts

(pre

ssur

e

pla te

)

D

Y

S

pring

s(pr

essu

re

p la te

)

4-

6

3.Re

mov

e:

Pres

sure

p

late

D

Frict

ion

pla

te

C

lutc

hd

amp

er

C

lutc

h plat

e

Pus

h rod

1

B a

ll

P

ush

ro

d 2

j)


68/170

ENGINE DISASSEMBLY

E N G ~ ~ ~

4 7

4.

Remove:

Nut clutch boss)

D

Conical spring

washer

Clutch boss

Thrust

washer

Use

the

universal

clutch

holder to hold

the clutch boss.

Universal clutch holder

YM 91042

5

Remove:

Clutch

housing D

Spacer

Thrust washer

6. Remove:

Nut primary

drive

gear)

Conical spring

washer

NOTE

When

loosing

the

nut primary drive gear),

hold the COl magneto using universal rotor

holder.

Universal rotor holder

YU 01235

7. Remove:

Primary drive

gear D

Straight key

Collar

YB142003

KICK

AXLE

NOTE

With

the

engine

mounted, the kick

axle and

kick

idle gear can be maintained

by

removing

the

following parts.

Autolube pump cable and hoses

Crankcase cover right)

Clutch


69/170

ENGINE DIS SSEMBLY

NG

4-8

1.

Unhook the

spring D .

2. Remove:

Kick

axle assembly

3. Remove:

Circlips D

Washers

Kick

idle gear

YB142004

SHIFT SH FT

NOTE

With

the

engine

mounted, the shift shaft

can

be maintained

by removing the following

parts.

Autolube pump

cable and hoses

Crankcase cover right)

Clutch

1. Remove:

Change pedal shaft cover

D

Dowel

pins

2. Remove:

Circlip

D

Change pedal lever

Collar change pedal

shaft

Change pedal

shaft

Washers


70/170

_N_G

_IN_

e_o_ls

_ _s

_s_e_

M_B_

Lv_l

NG

_

4-9

3 . R e

m ov

e :

Shi f

t sh

aft D

Shif t

lev

er

YB 14200

5

C

Ol M G

1990-2000 RT100 Service Manual

Documents

Transcript of 1990-2000 RT100 Service Manual