1977 – 1983 Yamaha DT80 GT80 GTMXE DT100 Motorcycle Service Manual

Description

This 226 page, 1982-1983 Yamaha DT80 GT80 DT100 Service Manual is a reproduction of the original, out of print manual. This printed and bound book provides detailed service information, step-by-step repair instruction and maintenance specifications for 1982 Yamaha DT80J, 1983 Yamaha DT80K, 1982 Yamaha DT100J and 1983 Yamaha DT100K motorcycles.

The cover on this book is a little confusing because it also contains information for Yamaha 1980 GT80G, DT100G, 1978 GT80E, GTMXE,  and 1977 DT100D motorcycles.

Books Included

DT80J/DT100J SUPPLEMENT
GT80G SUPPLEMENT
GT80E/MXE SERVICE MANUAL
DT100G SUPPLEMENT
DT100D SERVICE MANUAL

Table of Contents

GENERAL INFORMATION

PERIODIC INSPECTION AND ADJUSTMENT
2-1. INTRODUCTION
2-2. MAINTENANCE INTERVALS CHARTS
A. Maintenance Intervals
B. Lubrication Intervals
2-3. ENGINE.
A. Carburetor
B. Air Cleaner
C. Autolube Pump
D. Engine Transmission Oil
E. Clutch
F. Cylinder Head
2-4. CHASSIS
A. Fuel Petcock
B. Brakes and Wheels
C. Drive Chain
D. Front Fork Oil Change
E. Steering Head Suspension and Swing Arm

2-5. ELECTRICAL
A. Contact Breaker Points
B. Ignition Timing
C. SparkPlug
D. Battery
E. Headlight

ENGINE OVERHAUL
3-1. REMOVAL
A. Preparation for Removal
B. Exhaust
C. Gear Change Pedal
D. Wiring and Cables
E. Carburetor
F. Flywheel Magneto
G. Drive Chain
H. Removal

3-2. DISASSEMBLY
A. Reed Valve Assembly
B. Cylinder Head Cylinder
C. Piston Pin and Piston
D. Kick Crank (Kick Starter)
E. Crankcase Cover.
F. Clutch Assembly and Primary
Drive Gear
G. Kick Axle Assembly
H. Change Shaft Assembly
I. Clutch Push Rod
J. Stopper Plate
K. Shift Cam Stopper
L. Crankcase.
M. Transmission and Shifter
N. Crankshaft

3-3. INSPECTION AND REPAIR
A. Cylinder Head
B. Cylinder
C. Piston Pin and Bearing
D. Piston
E. Piston Rings
F. Autolube Pump
G. Clutch
H. Primary Drive
I. Kick Starter
J. Transmission
K. Crankshaft
L. Bearing and Oil Seals
M. Crankcase

3-4. ENGINE ASSEMBLY AND ADJUSTMENT
A. Crankshaft Installation
B. Transmission and Shifter
Installation
C. Crankcase
D. Change Shaft Assembly
E. Kick Starter Assembly
F. Kick Idle Gear, Primary Drive
Gear and Clutch Assembly
G. Crankcase Cover
H. Piston
I. Cylinder
J. Cylinder Head
K. Reed Valve
3-5. REMOUNTING ENGINE

CARBURETION
4-1. CARBURETOR
A. Inspection and Repair
4-2. REED VALVE ASSEMBLY
A. Removal and Inspection

CHASSIS
5-1. FRONT WHEEL
A. Removal.
B. Front Axle Inspection.
C. Front Wheel Inspection
D. Brake Shoe Wear Inspection
E. Brake Drum Inspection
F. Brake Shoe Plate Inspection
G. Replacing Wheel Bearings
H. Installing Front Wheel
5-2. REAR WHEEL
A. Removal.
B. Roar Axle Inspection
C. Rear Wheel Inspection
D. Brake Shoe Wear Inspection
E. Rear Drum Inspection
F. Brake Shoe Plate Inspection
G. Replacing Wheel Bearings
H. Installing Rear Wheel
5-3. TIRES AND TUBES
A. Removal
B. Installation
5-4. DRIVE CHAIN AND SPROCKETS
A. Drive Sprocket
B. Driven Sprocket
C. Chain Inspection
D. Chain Maintenance
5-5. FRONT FORKS
A. Removal and Disassembly
B. Inspection
C. Assembly and Installation
5-6. STEERING HEAD
A. Adjustment
B. Removal.
C. Inspection
D. Installation
5-7. SWING ARM
A. Inspection
B. Lubrication
C. Removal and Installation
5-8. REAR SHOCK ABSORBER
A. Removal
B. Inspection
5-9. CABLES AND FITTINGS
A. Cable Maintenance.
B. Throttle Maintenance
C. Cable Junction.Maintenance

ELECTRICAL
6-1. IGNITION SYSTEM
A. Ignition Timing
B. Ignition Coil
C. Condenser Test
6-2. CHARGING SYSTEM
A. Chraging Circuit Test
B. Checking Silicon Rectifier
C. Battery
6-3. LIGHTING AND SIGNAL SYSTEM
A. Lighting Tests and Checks
A.C. Circuit
B. Lighting Tests and Checks
D.C. Circuit

APPENDICES
7-1. GENERAL SPECIFICATION
A. General
B. Engine
C. Chassis
D. Electrical
7-2. CABLE ROUTING DIAGRAM
7-3. CIRCUIT DIAGRAM