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MAZDA R100 R 100 COUPE 1968-1973 Service Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: R100 Body Style: Coupe Production Years Covered: 1968-1973 Codes Internal Model Code: M10A 👋 Introduction Market Position Segment: Compact Sports Coupe / Personal...
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MAZDA R100 R 100 COUPE 1968-1973 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mazda
Model:
R100
Body Style:
Coupe
Production Years Covered:
1968-1973
Codes
Internal Model Code:
M10A
👋 Introduction
Market Position
Segment:
Compact Sports Coupe / Personal Luxury Car
Target Audience:
Enthusiasts, collectors, and owners of classic Mazda R100 models
Competitive Analysis
Key Competitors Era:
Toyota Corolla Levin, Datsun 240Z, Ford Capri, smaller European coupes
Key Features
Rotary Engine:
Pioneering use of the Wankel rotary engine in a compact Japanese car, offering unique performance characteristics.
Styling:
Sporty, distinctive coupe styling, a departure from more utilitarian Japanese vehicles of the era.
Manual Value:
Essential resource for maintaining and restoring a rare and technologically significant classic.
📋 Manual Details
Coverage Areas
Comprehensive Coverage:
Full factory service and repair
Page Count
Estimated Page Count:
High (typically 500+ pages for comprehensive factory manuals of this era)
Manual Type
Manual Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine System:
Rotary engine (10A) overhaul, diagnosis, fuel, ignition, lubrication, cooling
Transmission System:
Manual transmission (4-speed) overhaul, maintenance, diagnosis
Drivetrain System:
Rear axle, driveshaft, CV joints
Suspension System:
Front and rear suspension, steering, alignment specifications
Brake System:
Hydraulic system, calipers, drums, master cylinder, troubleshooting
Electrical System:
Wiring diagrams, lighting, charging system, ignition, starter, accessories
Body And Chassis:
Body construction, doors, windows, interior trim, seat adjustments
Fuel System:
Carburetor (Hitachi) specifications, adjustment, overhaul
Cooling System:
Radiator, water pump, thermostat, coolant specifications
Lubrication System:
Oil pump, oil filter, oil specifications
Procedures Included
Engine Overhaul:
Complete step-by-step engine rebuilding procedures
Transmission Repair:
Detailed transmission disassembly and reassembly
Brake Service:
Brake pad/shoe replacement, bleeding procedures, component replacement
Tune Up Procedures:
Ignition timing, carburetor adjustments, spark plug replacement
Troubleshooting:
Diagnostic charts and symptom-based problem resolution
Electrical Diagnostics:
Component testing, wiring harness repair
Suspension Alignment:
Alignment angles and procedures
Technical Depth
Depth:
Comprehensive: Covers routine maintenance to complete engine and transmission rebuilds, with detailed diagnostic information.
📊 Manual Specifications
File Format
File Quality:
High-resolution scans, suitable for printing
Searchability:
Likely text-searchable if converted from original digital format or OCR'd
Print Quality
Print Recommendation:
Printable, allowing for easy use in a workshop environment
Binding Type
Binding Recommendation:
Best printed and spiral-bound for durability and lay-flat usability
Paper Type
Paper Recommendation:
Durable paper stock recommended for workshop use
⚙️ Engine Specifications
Primary Engine
Engine Code:
Mazda 10A
Engine Type:
Two-rotor Wankel Rotary
Displacement:
982 cc (actual working volume)
Rotor Housing Design:
Epitrochoid
Performance
Horsepower Approx:
100-110 hp (net, depending on variant)
Torque Approx:
130-135 Nm (net, depending on variant)
Redline Approx:
6500-7000 RPM
Fuel System
Carburetor:
Hitachi DC360 twin-choke downdraft carburetor (or similar Hitachi variant)
Fuel Type:
Unleaded gasoline (premium recommended for optimal performance)
Ignition System
Ignition Type:
Distributorless Ignition System (DIS) or Distributor-based ignition with dual coils
Lubrication System
Oil Type:
API SE or SF classification, SAE 10W-30 or 10W-40 recommended (check manual for specific fill)
Oil Capacity:
Approx. 4.5-5.0 liters (including filter)
Cooling System
Coolant Type:
Ethylene glycol based antifreeze (50/50 mix with distilled water)
🔧 Transmission
Standard
Transmission Type:
4-speed Manual Transmission
Optional
Automatic Transmission:
Available (e.g., Toyo Kogyo 3-speed automatic, refer to specific model variants)
Features
Clutch Type:
Dry, single-plate, diaphragm spring clutch
Transmission Fluid:
GL-4, SAE 75W-90 or 80W-90 gear oil (check manual for exact specification)
📐 Dimensions
Exterior
Length:
Approx. 4,000 mm (157.5 in)
Width:
Approx. 1,575 mm (62.0 in)
Height:
Approx. 1,305 mm (51.4 in)
Wheelbase:
Approx. 2,285 mm (90.0 in)
Weights
Curb Weight:
Approx. 970 kg (2,138 lbs)
Gross Vehicle Weight Rating:
Approx. 1,300 kg (2,866 lbs)
🛡️ Safety Features
Ratings
Crash Test Data:
No formal crash test ratings available for this era by modern standards.
Active Features
Brakes:
Front disc brakes, Rear drum brakes
Parking Brake:
Mechanical, rear drum
Passive Features
Seat Belts:
Standard front seat belts (lap belts, possibly optional 3-point)
Windshield:
Laminated safety glass
💡 Technology Features
Infotainment
Radio:
Optional AM/FM radio
Speakers:
Typically 2 or 4 speakers
Driver Assistance
Features:
None by modern standards; basic driver controls.
Connectivity
Features:
None
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 km (3,000-5,000 miles) or 6 months (refer to manual for specific recommendation)
Spark Plug Replacement:
Inspect every 10,000 km (6,000 miles), replace as needed (specific rotary plugs required)
Air Filter Replacement:
Inspect every 5,000 km (3,000 miles), replace as needed
Timing Belt Replacement:
Not applicable (rotary engines do not have a timing belt)
Fluid Specifications
Engine Oil:
API SE/SF, SAE 10W-30 or 10W-40
Transmission Oil:
GL-4, SAE 75W-90 or 80W-90
Brake Fluid:
DOT 3 or DOT 4 (check manual for exact specification)
Coolant:
50% Ethylene Glycol Antifreeze / 50% Distilled Water
Known Issues
Apex Seal Wear:
Common issue in older rotary engines, requiring rebuild if worn excessively.
Carburetor Tuning:
Hitachi carburetors can be sensitive and require proper adjustment.
Rotor Housing Corrosion:
Can occur with improper coolant maintenance or storage.
Electrical Gremlins:
Aging wiring harnesses and components can lead to intermittent electrical issues.
📚 Vehicle History
Brand Heritage
Mazda Rotary Development:
Mazda's early adoption and development of the Wankel rotary engine, starting with the Cosmo.
Model Evolution
Series Introduction:
Introduced in 1967 as the Mazda Familia Rotary Coupe, later renamed R100 for export markets.
Design Inspiration:
Based on the Mazda Familia platform, but with unique styling and rotary powertrain.
Production
Manufacturing Plant:
Hiroshima, Japan
Production Volume:
Limited, considered a niche and somewhat collectible model today.
🏆 Awards & Recognition
Recognitions
Collectible Status:
Recognized as a classic Japanese sports car, often appreciated for its unique powertrain and styling.
Ratings
Original Reviews:
Generally praised for performance and handling for its era, though sometimes criticized for fuel consumption and rotary engine complexity.
Certifications
Historical Significance:
Significant for being one of Mazda's earliest rotary-powered production cars and for its role in popularizing the engine in compact vehicles.
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