Yamaha MT110 User manual

SERVICE MANUAL
MT110
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FORWORD
This manual was written by the Yamaha Motor
Company primarily 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 persons using this
book to perform maintenance and repairs on
Yamaha engine have a basic understanding of
the mechanical precepts and procedures inher-
ent to engine repair tochology. Without such
knowledge, attempted repairs or service to this
model may render it unfit for use and/ or unsafe.
Yamaha Motor Company Ltd. is continually striv-
ing to further improve all models manufactured
by Yamaha. Modifications and significant
changes in specifications or procedures will be
forwarded to all Authorized Yamaha dealers and
will, where applicable, appear in future editions
of this manual.
MT110
SERVICE MANUAL
©1996 by Yamaha Motor Co., Ltd.
1 st Edition, November 2004.
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is exprssly prohibited.
Printed in Japan
HOW TO USE THIS MANUAL
PARTICULARLY IMPORTANT
INFORMATION
This material is distinguished by the following
notation.
Q
The Safety Alert Symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS IN-
VOLVED!
w
Failure to follow WARNING instructions could re-
sult in severe injury or death to the machine op-
erator, a bystander, or a person inspecting or re-
pairing the machine.
cC
A CAUTION indicates special precautions that
must be taken to avoid damage to the machine.
NOTE:
A NOTE provides key information to make pro-
cedures easier or clearer.
MANUAL FORMAT
The procedures in this manual are organized in
a sequential, step-by-step format. The informa-
tion has been compiled to provide the mechanic
with an easy to read, handy reference that con-
tains comprehensive explanations of all disas-
sembly, repair, assembly, and inspection opera-
tions.
In this revised format, the condition of a faulty
component will precede an arrow symbol and
the course of action required will follow the sym-
bol, e.g.,
9Bearings
Pitting/Damage→Replace.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams be-
fore each disassembly section for ease in identi-
fying correct disassembly and assembly proce-
dures.
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GEN
INFO
INSP
ADJ
ENG ELEC
T
R
.
.
E
M
LS
LT New
12
34
5
SPEC
6 7
+
89
0q
w
e
yu
rt
ILLUSTRATEDSYMBOLS
(Refer to the illustration)
Illustrated symbols 1to 5are designed as
thumb tabs to indicate the chapter’s number
and content.
1General information
2Periodic inspection and adjustment
3Engine
4Electrical
5Specifications
Illustrated symbols 6to ware used to iden-
tify the specifications appearing.
6Special tool
7Filling fluid
8Lubricant
9Tightening
0Wear limit, clearance
qEngine speed
wΩ, V, A
Illustrated symbols eto uin the exploded
diagram indicate grade of lubricant and loca-
tion of lubrication point.
eApply molybdenum disulfide oil
rApply engine oil
tApply lightweight lithium soap base grease
yApply locking agent (LOCTITE®)
uUse New one
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CONTENTS
GENERAL INFORMATION
MACHINE IDENTIFICATION...............................................................................................1-1
SPECIAL TOOLS LIST........................................................................................................1-1
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION .................................................................................................................2-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS..................................................2-1
ENGINE ...............................................................................................................................2-3
ENGINE
FUEL TANK, AIR CLEANER...............................................................................................3-1
CARBURETOR....................................................................................................................3-3
MUFFLER............................................................................................................................3-5
GOVERNOR ........................................................................................................................3-7
RECOIL STATER/ FAN/ AIR SHROUD...............................................................................3-9
T.C.I. ROTOR .....................................................................................................................3-11
CYLINDER/ PISTON/CRANKCASE/ CRANK ..................................................................3-13
ENGINE DISASSEMBLY...................................................................................................3-15
ENGINE ASSEMBLY.........................................................................................................3-17
ELECTRICAL
ELECTRICAL COMPONENTS ...........................................................................................4-1
CIRCUIT DIAGRAM ............................................................................................................4-1
IGINITION SYSTEM ............................................................................................................4-3
SPECIFICATIONS
GENERAL SPECIFICATIONS.............................................................................................5-1
MAINTENANCE SPECIFICATIONS....................................................................................5-2
TIGHTENING TORQUE .......................................................................................................5-3
GENERAL TORQUE SPECIFICATIONS.............................................................................5-3
DEFINITION OF UNITS.......................................................................................................5-3
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