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Yamaha RT100 Owner'S Manual Download Page 39

L

6-13

PERIODIC MAINTENANCE AND MINOR REPAIR

/home/Imai/imai_data/YMC-om/AB9239_RT100-26/English/E-6.frame

1. Locknut 

2. Adjusting bolt 

c. Free play

EAU01472

Front brake lever free play 

adjustment

The front brake lever free play should

be adjusted to 10 ~ 15 mm.

1. Loosen the locknut at the brake le-

ver.

2. Turn the adjusting bolt at the brake

lever in direction 

a

 to increase

free play or in direction 

b

 to de-

crease free play.

3. Tighten the locknut at the brake le-

ver .

1. Adjusting nut

If the specified free play cannot be ob-

tained, proceed with the following

steps.

4. Loosen the locknut at the brake le-

ver.

5. Turn the adjusting bolt at the brake

lever in direction 

a

 to loosen the

cable.

6. Turn the adjusting nut at the brake

hub in direction 

a

 to increase free

play or in direction 

b

 to decrease

free play.

7. Tighten the locknut at the brake

hub and the brake lever.

a. Free play

EAU01510*

Rear brake pedal free play 

adjustment

The rear brake pedal free play should

be adjusted to 20 ~ 30 mm at the brake

pedal end.

Summary of Contents for RT100

Page 1: ...3UL 28199 26 RT100M OWNER S MANUAL ...

Page 2: ... of fine sporting touring and pacesetting racing machines It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields This manual will give you an understanding of the operation inspection and basic maintenance of this machine If you have any questions about the operation or mainte nance of your machine please consult a Yamaha dealer INTRODUCTION ...

Page 3: ...recautions that must be taken to avoid damage to the machine NOTE A NOTE provides key information to make procedures easier or clearer l This manual should be considered a permanent part of this machine and should remain with it even if the machine is subsequently sold l Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current produc...

Page 4: ...IS DESIGNED AND MANUFACTURED FOR OFF ROAD USE ONLY IT IS ILLE GAL TO OPERATE THIS MACHINE ON ANY PUBLIC STREET ROAD OR HIGHWAY SUCH USE IS PROHIBITED BY LAW THIS MACHINE COMPLIES WITH ALMOST ALL STATE OFF HIGHWAY NOISE LEVEL AND SPARK ARRESTER LAWS AND REGULATIONS PLEASE CHECK YOUR LOCAL RIDING LAWS AND REGULATIONS BEFORE OPERATING THIS MA CHINE IMPORTANT MANUAL INFORMATION ...

Page 5: ...nglish E INT frame EAU00008 RT100M OWNERÕS MANUAL 1999 by Yamaha Motor Co Ltd 1st Edition May 1999 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan ...

Page 6: ...ear brake pedal 3 2 Fuel tank cap 3 2 Fuel 3 3 Two stroke engine oil 3 3 Fuel cock 3 4 Starter choke 3 5 Kick starter 3 5 Seat 3 6 Rear shock absorber adjustment 3 7 PRE OPERATION CHECKS 4 1 Pre operation check list 4 1 OPERATION AND IMPORTANT RIDING POINTS 5 1 Starting and warming up a cold engine 5 1 Starting a warm engine 5 1 Shifting 5 2 Engine break in 5 2 Parking 5 3 PERIODIC MAINTENANCE AND...

Page 7: ...6 Throttle cable and grip lubrication 6 17 Autolube pump adjustment 6 17 Brake and shift pedal lubrication 6 17 Brake and clutch lever lubrication 6 18 Sidestand lubrication 6 18 Rear suspension lubrication 6 18 Front fork inspection 6 19 Steering inspection 6 19 Wheel bearings 6 20 Supporting the machine 6 20 Front wheel removal 6 21 Front wheel installation 6 21 Rear wheel removal 6 22 Rear whee...

Page 8: ... home Imai imai_data YMC om AB9239_RT100 26 English EETOC frame ...

Page 9: ...ESSARY BY MECHANICAL CONDITIONS Safe riding 1 Always make pre operation checks Careful checks may help prevent an accident 2 This machine is designed for off road use only It is illegal for this machine to be operated on any public street road or highway Off road use on public lands may be illegal Please check local regulations be fore riding 3 This machine is designed to carry the operator only N...

Page 10: ...head injuries 1 Always wear an approved helmet 2 Wear a face shield or goggles Wind on your unprotected eyes could contribute to an impairment of vi sion which could delay seeing a hazard 3 The use of heavy boots jacket trousers gloves etc is effective in preventing or reducing abrasions or lacerations 4 Never wear loose fitting clothing It could catch on the control levers footrests or wheels and...

Page 11: ...l accessories or carry cargo that would impair the performance of your machine Carefully inspect the accessory before using it to make sure it does not in any way reduce ground clearance or cornering clearance limit suspension travel steering travel or control operation or obscure lights or re flectors a Accessories fitted to the handlebar or the front fork area can create instability due to impro...

Page 12: ...equate ventilation 3 Always turn off the engine before leaving the machine unattended and remove the ignition key When parking the machine note the following a The engine and exhaust system may be hot Park the machine in a place where pedestrians or chil dren are not likely to touch these hot areas b Do not park the machine on a slope or soft ground the machine may fall over c Do not park the mach...

Page 13: ...ta YMC om AB9239_RT100 26 English E 1 frame EAU01277 Location of the important label Please read the following label carefully before operating this machine 1 WARNING Before you operate this vehicle read the ownerÕs manual English 3HP 21568 00 ...

Page 14: ... 2 Starter choke page 3 5 3 Air filter page 6 7 4 Oil tank page 3 4 5 Oil level window page 3 3 6 Shift pedal page 3 1 7 Seat page 3 6 8 Kick starter page 3 5 9 Fuel tank cap page 3 2 10 Fuel tank breather hose 11 Rear brake pedal page 3 2 12 Clutch lever page 3 1 13 Engine stop switch page 3 1 14 Front brake lever page 3 2 15 Throttle grip page 6 9 ...

Page 15: ...NÓ to start the engine In case of emergency turn the switch to ÒOFFÓ to stop the engine 1 Clutch lever EAU00155 Clutch lever The clutch lever is located on the left handlebar Pull the clutch lever to the handlebar to disengage the clutch and release the lever to engage the clutch The lever should be pulled rapidly and released slowly for smooth clutch oper ation 1 Shift pedal EAU00157 Shift pedal ...

Page 16: ...brake lever is located on the right handlebar Pull it toward the han dlebar to apply the front brake 1 Rear brake pedal EAU00162 Rear brake pedal The rear brake pedal is on the right side of the machine Press down on the brake pedal to apply the rear brake 1 Fuel tank cap 2 Open EAU00179 Fuel tank cap Remove the fuel tank cap by turning it counterclockwise ...

Page 17: ... Do not fill the fuel tank above the bot tom of the filler tube or it may over flow when the fuel heats up later and expands EAU00185 CAUTION Always wipe off spilled fuel immedi ately with a dry and clean soft cloth Fuel may deteriorate painted surfac es or plastic parts EAU00192 Recommended fuel Regular gasoline For Australia Unleaded fuel only Fuel tank capacity Total 5 0 L Reserve 1 5 L 1 Oil l...

Page 18: ...mark positioned over ÒOFFÓ EAU01121 Fuel cock The fuel cock supplies fuel from the tank to the carburetor while filtering it also The fuel cock has three positions OFF With the lever in this position fuel will not flow Always return the lever to this position when the engine is not run ning 1 Arrow mark positioned over ÒONÓ ON With the lever in this position fuel flows to the carburetor Normal rid...

Page 19: ...a cold engine requires a richer air fuel mixture A separate starter cir cuit supplies this mixture Move in direction a to turn on the starter choke Move in direction b to turn off the starter choke 1 Kick starter EAU00212 Kick starter Rotate the kick starter away from the engine Push the starter down lightly with your foot until the gears engage then kick smoothly and forcefully to start the engin...

Page 20: ...IONS home Imai imai_data YMC om AB9239_RT100 26 English E 3 frame 1 Open EAU02991 Seat To open the seat Turn the lever as shown To lock the seat Install the seat in its original position NOTE Make sure that the seat is securely fit ted ...

Page 21: ...pring preload as follows Turn the ad justing ring in direction a to increase spring preload and in direction b to de crease spring preload Make sure that the appropriate notch in the adjusting ring is aligned with the position indica tor on the rear shock absorber Soft Standard Hard Adjusting position 1 2 3 4 5 EW000040 Always adjust each shock absorber to the same setting Uneven adjust ment can c...

Page 22: ... LIST ITEM ROUTINE PAGE Front and rear brakes Check operation condition and free play Adjust if necessary 6 13 6 14 Clutch Check operation condition and free play Adjust if necessary 6 12 Throttle grip and housing Check for smooth operation Lubricate Adjust if necessary 6 9 6 10 6 17 2 stroke engine oil Check oil level Fill with oil as required 6 17 Transmission oil Check oil level Fill with oil a...

Page 23: ...an worth the time involved If any item in the PRE OPERATION CHECK is not working properly have it inspected and repaired before operating the machine Brake and clutch lever pivots Check for smooth operation Lubricate if necessary 6 18 Sidestand pivot Check for smooth operation Lubricate if necessary 6 18 Chassis fasteners Check the tightness of all chassis nuts bolts and screws Tighten if necessar...

Page 24: ...try to turn a corner EAU00372 EAU02992 Starting and warming up a cold engine 1 Turn the fuel cock to ÒONÓ 2 Turn the engine stop switch to ÒRUNÓ 3 Shift transmission into neutral 4 Turn on the starter choke and completely close the throttle grip 5 Kick the kick starter to start the en gine 6 After starting the engine move the starter choke halfway back to the warming up position NOTE For maximum e...

Page 25: ...ion and driveline are not designed to withstand the shock of forced shifting and can be damaged by shifting without using the clutch EAU00437 Engine break in There is never a more important period in the life of your machine than the pe riod between zero and 20 hours of riding For this reason we ask that you carefully read the following material Because the engine is brand new you must not put an ...

Page 26: ...the machine freely through the gears but do not use full throttle at any time After break in Avoid prolonged full throttle operation Vary speed occasionally EC000049 CAUTION If any engine trouble should occur during the break in period consult a Yamaha dealer immediately EAU00459 Parking When parking the machine stop the engine Turn the fuel cock to ÒOFFÓ whenever the engine is stopped EW000059 Th...

Page 27: ...ent and lubrication are explained in the follow ing pages EW000060 If you are not familiar with machine service this work should be done by a Yamaha dealer EAU00462 1 Tool kit EAU00469 Tool kit The service information included in this manual is intended to provide you the owner with the necessary information for completing some of your own pre ventive maintenance and minor re pairs The tools provi...

Page 28: ... necessary 5 Air filter Clean or replace if necessary 6 Clutch Check operation Adjust or replace cable 7 Front brake Check operation Adjust brake lever free play and replace brake shoes if necessary 8 Rear brake Check operation Adjust brake pedal free play and replace brake shoes if necessary 9 Wheels Check balance runout spoke tightness and for damage Tighten spokes and rebalance replace if neces...

Page 29: ... with lithium soap base grease every 24 months 15 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary 16 Sidestand Check operation Lubricate and repair if necessary 17 Front fork Check operation and for oil leakage Correct accordingly 18 Rear shock absorber assemblies Check operation and shock absorbers for oil leakage Replace shock absorber assem...

Page 30: ...perform some of the mainte nance described in this chapter Refer to this section each time the panel has to be removed or installed 1 Panel A 2 Screw EAU03021 Panel A To remove 1 Remove the seat See page 3 6 for seat removal and installation procedures 2 Remove the screw and pull up ward on the areas shown To install 1 Place the panel in the original po sition and install the screw 2 Install the s...

Page 31: ...t and deposits will cause the spark plug to slowly break down and erode If electrode erosion be comes excessive or if carbon and oth er deposits are excessive the spark plug should be replaced with the speci fied plug Before installing the spark plug mea sure the electrode gap with a wire thickness gauge and adjust it to speci fication When installing the plug the gasket surface should always be c...

Page 32: ...n false readings 2 With the engine stopped unscrew the dipstick and rest it on the threads of the oil filler hole NOTE Wait a few minutes until the oil level settles before checking 3 The oil level should be between the maximum and minimum level marks as shown If the level is low add sufficient oil to raise it to the proper level 1 Drain bolt Transmission oil replacement 1 Warm up the engine for s...

Page 33: ...age If oil leakage is found stop the engine immedi ately and check for cause Recommended oil See page 8 1 Oil quantity Total amount 0 7 L Periodic oil change 0 65 L 1 Screw EAU02995 Air filter The air filter element should be cleaned at the specified intervals It should be cleaned more frequently if you are riding in unusually wet or dusty areas 1 Remove panel A See page 6 4 for panel removal and ...

Page 34: ...d in the filter case l The engine should never be run without the air filter installed Excessive piston and or cylin der wear may result EAU00629 Carburetor adjustment The carburetor is a vital part of the en gine and requires very sophisticated adjustment Most adjustments should be left to a Yamaha dealer who has the professional knowledge and experi ence to do so However the following may be ser...

Page 35: ... Throttle stop screw 2 Set the idle to the specified engine speed by adjusting the throttle stop screw Turn the screw in di rection a to increase engine speed and in direction b to de crease engine speed NOTE If the specified idle speed cannot be obtained by performing the above ad justment consult a Yamaha dealer Standard idle speed 1 300 1 450 r min EAU00634 Throttle cable free play adjustment N...

Page 36: ...heck and adjust the tire pres sure before operating the machine EW000091 Tire inflation pressure should be checked and adjusted when the temperature of the tire equals the ambient air temperature Cold tire pressure Front Rear Off road riding 125 kPa 1 25 kgf cm2 1 25 bar 125 kPa 1 25 kgf cm2 1 25 bar 1 Side wall 2 Wear indicator a Tread depth Tire inspection Always check the tires before operating...

Page 37: ...place the tube as soon as possible with a good quality replacement EAU00685 Wheels To ensure maximum performance long service and safe operation note the following l Always inspect the wheels before a ride Check for cracks bends or warpage of the wheel Be sure the spokes are tight and undamaged If any abnormal condition exists in a wheel consult a Yamaha dealer Do not attempt even small repairs to...

Page 38: ... 15 mm 1 Loosen the locknut 1 2 Turn the adjusting bolt 2 in direction a to increase free play or in direction b to decrease free play 3 Tighten the locknut 1 If the specified free play cannot be ob tained proceed with the following steps 4 Loosen the locknut 1 5 Turn the adjusting bolt 2 in direction a to loosen the cable 6 Loosen the locknut 3 7 Turn the adjusting nut 4 in direction a to increas...

Page 39: ... de crease free play 3 Tighten the locknut at the brake le ver 1 Adjusting nut If the specified free play cannot be ob tained proceed with the following steps 4 Loosen the locknut at the brake le ver 5 Turn the adjusting bolt at the brake lever in direction a to loosen the cable 6 Turn the adjusting nut at the brake hub in direction a to increase free play or in direction b to decrease free play 7...

Page 40: ... dealer EAU01387 Checking the front and rear brake shoes Check the brake shoes for damage and wear If the thickness is less than 2 mm have a Yamaha dealer replace the shoes as a set a Chain slack EAU00744 Drive chain slack check NOTE Spin the wheel several times and find the tightest position of the chain Check and or adjust the chain slack while itÕs in this tightest position To check the chain s...

Page 41: ...e chain adjusting bolt in direction a To loosen the chain turn the chain adjusting bolt in direction b and push the wheel forward Turn each adjusting nut exactly the same amount to main tain correct axle alignment There are marks on each side of the swingarm and a match mark on each chain puller Use these marks to align the rear wheel EC000096 CAUTION Too little chain slack will overload the engin...

Page 42: ... when riding in dusty areas 1 The drive chain should be lubricat ed every 6 months First remove all dirt and mud from the chain with a brush or cloth Then spray any of the many brands of spray type chain lubricant between both rows of side plates and on all center roll ers 2 To clean the chain thoroughly re move it from the machine dip it in solvent and clean out as much dirt as possible Then take...

Page 43: ... screws hold the end of the cable up in the air and put in several drops of lubricant With the throttle grip disassembled coat the metal surface of the grip assembly with a suitable all purpose grease EAU00774 Autolube pump adjustment The autolube pump is a vital part of the engine and requires very sophisticated adjustment Adjusting should be left to a Yamaha dealer who has the profes sional know...

Page 44: ...bricant Engine oil EAU02986 Sidestand lubrication Lubricate the sidestand pivoting point and metal to metal contact surfaces Check that the sidestand moves up and down smoothly EW000113 If the sidestand does not move smoothly consult a Yamaha dealer Recommended lubricant Engine oil EAU00791 Rear suspension lubrication Lubricate the pivoting parts Recommended lubricant Lithium soap base grease ...

Page 45: ...handle bars several times and check if the fork rebounds smoothly EC000098 CAUTION If any damage or unsmooth move ment is found with the front fork consult a Yamaha dealer EAU00794 Steering inspection Periodically inspect the condition of the steering Worn out or loose steering bearings may be dangerous Place a stand under the engine to raise the front wheel off the ground Hold the lower end of th...

Page 46: ...quiring the machine to stand upright Check that the machine is in a stable and level position before starting any maintenance A strong wooden box can be placed under the engine for added stability Front wheel service To stabilize the rear of the machine ei ther use a machine stand or place a machine jack under the frame in front of the rear wheel to prevent it from moving from side to side Then us...

Page 47: ...l hub 2 Remove the cotter pin and axle nut 3 Elevate the front wheel by placing a suitable stand under the engine 4 Remove the wheel axle Make sure the machine is properly sup ported EAU01471 Front wheel installation 1 Lift up the wheel between the front fork legs 2 Install the wheel axle make sure the slot in the brake shoe plate fits over the stopper on the front outer tube and let the machine d...

Page 48: ...ake rod EAU01732 Rear wheel removal EW000122 l It is advisable to have a Yamaha dealer service the wheel l Securely support the machine so there is no danger of it falling over 1 Cotter pin 2 Axle nut 1 Remove the cotter pin nut and the brake torque rod bolt from the brake shoe plate 2 Remove the brake free play ad justing nut and brake rod from the brake cam lever 3 Loosen the wheel axle nut 4 El...

Page 49: ...nstall the axle nut and let the ma chine down 3 Insert the brake rod into the brake cam lever and install the brake free play adjusting nut 4 Install the brake torque rod onto the brake shoe plate and tighten the bolt and axle nut to the speci fied tightening torque Then install a new cotter pin EW000124 Always use a new cotter pin Specified torque Brake torque rod bolt 18 Nm 1 8 mákg Axle nut 39 ...

Page 50: ...s can cause poor starting and loss of power The trouble shooting chart describes a quick easy procedure for making checks If your machine requires any repair bring it to a Yamaha dealer The skilled technicians at a Yamaha dealership have the tools experience and know how to properly service your machine Use only genuine Yamaha parts on your machine Imitation parts may look like Yamaha parts but th...

Page 51: ...ugh fuel No fuel Go to compression check Supply fuel Use the kick starter 2 Compression There is compression No compression Go to ignition check Ask a Yamaha dealer to inspect Remove spark plug and check electrodes 3 Ignition Wet Dry Wipe clean with dry cloth and correct spark gap or replace spark plug Ask a Yamaha dealer to inspect Engine doesnÕt start ask a Yamaha dealer to inspect Open throttle...

Page 52: ... following cleaning and storing precautions Before cleaning 1 Cover up the muffler outlet with a plastic bag 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug cap are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets...

Page 53: ...lyte l Do not use high pressure wash ers or steam jet cleaners since they cause water seepage and deterioration in the following ar eas seals of wheel bearings swingarm bearings forks and brakes electric components couplers connectors instru ments switches and lights breather hoses and vents l For machines equipped with a windshield Do not use strong cleaners or hard sponges as they will cause dul...

Page 54: ...o prevent corrosion it is recom mended to apply a corrosion pro tection spray on all even chrome and nickel plated metal surfaces 5 Use spray oil as a universal clean er to remove any remaining dirt 6 Touch up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the machine dry completely before storing it or covering it EWA00001 Make sure that there is no oil or wax on the bra...

Page 55: ...equipped with a fuel cock which has an ÒOFFÓ posi tion Turn the fuel cock to ÒOFFÓ 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 5 Perform the following steps to pro tect the cylinder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug b...

Page 56: ...r pressure then raise the machine so that both of its wheels are off the ground Alternatively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover up the muffler outlet with a plastic bag to prevent moisture from entering NOTE Make any necessary repairs before storing the machine ...

Page 57: ... 97 cm3 Bore Stroke 52 0 45 6 mm Compression ratio 6 7 1 Starting system Kick starter Lubrication system Separate lubrication Yamaha Autolube Engine oil Type YAMALUBE 2 cycle oil or 2 stroke engine oil Quantity Total amount 1 0 L Transmission oil Type YAMALUBE 4 10W30 or SAE10W30 type SE motor oil Quantity Periodic oil change 0 65 L Total amount 0 7 L Air filter Wet type element Fuel Type Regular ...

Page 58: ... 3rd 1 368 4th 1 000 5th 0 800 Chassis Frame type Double cradle Caster angle 29û Trail 103 mm Tires Front Type With tube Size 2 50 18 4PR Manufacturer model CHENG SHIN KNOBBY Rear Type With tube Size 3 00 16 4PR Manufacturer model CHENG SHIN KNOBBY Air pressure cold tire Off road riding Front 125 kPa 1 25 kgf cm2 1 25 bar Rear 125 kPa 1 25 kgf cm2 1 25 bar Wheels Front Type Spoke Size 18 1 40 Rear...

Page 59: ...E 8 frame Suspension Front Type Telescopic fork Rear Type Swingarm Shock absorbers Front Coil spring oil damper Rear Coil spring oil damper Spring preload adjustable Wheel travel Front 110 mm Rear 80 mm Electrical system Ignition system C D I Generator system C D I magneto ...

Page 60: ...in 2 mm 0 03937 0 08 in CONVERSION TABLE METRIC TO IMPERIAL Metric unit Multiplier Imperial unit Torque mákg mákg cmákg cmákg 7 233 86 794 0 0723 0 8679 ftálb inálb ftálb inálb Weight kg g 2 205 0 03527 lb oz Speed km hr 0 6214 mph Distance km m m cm mm 0 6214 3 281 1 094 0 3937 0 03937 mi ft yd in in Volume Capacity cc cm3 cc cm3 lt liter lt liter 0 03527 0 06102 0 8799 0 2199 oz IMP liq cuáin qt...

Page 61: ...ed VEHICLE IDENTIFICATION NUMBER NOTE The vehicle identification number is used to identify your machine and may be used to register your machine with the licensing authority in your state 1 Model label EAU01050 Model label The model label is affixed to the frame under the seat See page 3 6 for seat removal procedures Record the infor mation on this label in the space pro vided This information wi...

Page 62: ... a The removal or rendering inopera tive by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the pur pose of noise control prior to its sale or delivery to the ultimate pur chaser or while it is in use and b The use of the vehicle after such device or element of design has been removed or rendered inope...

Page 63: ...PRINTED IN JAPAN 99 5 0 3 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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