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MAZDA R100 R 100 COUPE 1968-1973 Workshop Repair Manual

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The Mazda R100, also known as the Mazda Familia Rotary Coupe, is a distinctive compact sports coupe produced from 1968 to 1973. This pioneering vehicle showcased Mazda's innovative 2-rotor Wankel rotary engine, the 10A, offering a unique blend of smooth power delivery and nimble handling. With its clean coupe styling and sporty proportions, the R100 carved out a niche in the automotive market, competing with other performance-oriented vehicles of its era. Its engineering quality and the revolutionary rotary powertrain have cemented its status as a significant and collectible piece of automotive history. This workshop service and repair manual provides comprehensive guidance for the Mazda R100, covering model years 1968 through 1973. It details essential maintenance procedures, diagnostic troubleshooting for common issues, and in-depth repair instructions for all major vehicle systems, including the rotary engine, transmission, brakes, suspension, and electrical components. The manual also includes crucial technical specifications, torque values, and detailed wiring diagrams. Its purpose is to empower owners, mechanics, and technicians with the knowledge necessary to maintain, repair, and preserve the R100, ensuring its continued operation and historical integrity. 🏷️ Basic Information Identification Make: Mazda Model: R100 (R 100 Coupe) Body Style: Coupe Generation: First Generation (Mazda Familia Rotary Coupe) Codes Chassis Code: Often referred to by its platform derivative, e.g., derived from the Mazda Familia series Engine Code: 10A (Rotary) 👋 Introduction Market Position Positioning: The Mazda R100 was a pioneering compact sports coupe that introduced the rotary engine to a wider audience, competing with small European sports cars and domestic performance coupes. Competitive Analysis Competitors: Datsun 240Z, Toyota Corolla Levin/Sprinter Trueno (early generations), Alfa Romeo Giulia GT, Ford Capri. Key Features Engine Type: Unique 2-rotor (10A) Wankel rotary engine, offering a compact, high-revving, and smooth power delivery. Design: Distinctive coupe styling with clean lines, sporty proportions, and often a characteristic 'bubble' rear window. Driving Experience: Known for its nimble handling, lightweight feel, and the unique sound and acceleration characteristics of the rotary engine. Manual Value Proposition Usefulness: Essential for owners and mechanics maintaining the iconic R100, providing crucial technical data and procedures for preserving this unique vehicle. 📋 Manual Details Coverage Areas Years Covered: 1968, 1969, 1970, 1971, 1972, 1973 Regions Covered: Global (primarily based on North American and Japanese specifications) Page Count Estimated Pages: 300-500 (typical for comprehensive workshop manuals of this era) Manual Type Type: Workshop Service and Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Rotary Engine (10A), including apex seals, rotor housing, rotor, eccentric shaft, lubrication, cooling, and combustion. Lubricating System: Oil pump, oil filter, oil passages, oil pressure testing, and oil type specifications. Cooling System: Radiator, water pump, thermostat, coolant hoses, coolant type and capacity, and system pressure testing. Fuel System: Carburetor (likely Hitachi or Mikuni side-draft), fuel pump, fuel filter, fuel lines, and emissions control components (if applicable). Electrical System: Ignition system (distributor, coil, spark plugs), starting system (starter motor, solenoid), charging system (alternator, regulator), lighting, instrumentation, wiring diagrams, and component testing. Clutch: Clutch disc, pressure plate, release bearing, clutch pedal adjustment, hydraulic system (if applicable), and removal/installation. Transmission: Manual transmission (likely 4-speed or 5-speed), gear lubrication, internal components, shift linkage, and removal/installation. Propeller Shaft: Driveshaft, universal joints, balancing, and inspection. Rear Axle: Differential, axle shafts, bearings, and fluid specifications. Suspension: Front and rear suspension components (springs, shock absorbers, control arms, ball joints, bushings), alignment specifications, and replacement procedures. Steering: Steering box, tie rods, steering column, linkage, and adjustment procedures. Brakes: Front and rear brake systems (drum or disc), master cylinder, wheel cylinders, brake lines, pads/shoes, hydraulic fluid specifications, bleeding procedures, and parking brake. Body And Trim: Body panel repair, door mechanisms, window mechanisms, interior trim, and weather stripping. Chassis And Frame: Frame inspection, rust repair, and structural components. Heating And Air Conditioning: Heater core, blower motor, ducting (if factory AC equipped). Emissions Control: Early emissions systems, PCV valve, air injection (if equipped). Procedures Included Maintenance: Routine checks, fluid changes, filter replacements, lubrication points, spark plug replacement, and ignition timing adjustment. Troubleshooting: Diagnostic charts, symptom-based troubleshooting for engine performance, electrical issues, and mechanical failures. Repair: Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation. Overhaul: Detailed instructions for complete engine, transmission, and differential rebuilds. Adjustment: Carburetor tuning, ignition timing, clutch pedal, brakes, and suspension alignment. Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems. Torques Specifications: Torque values for critical fasteners across all vehicle systems. Technical Depth Depth: Comprehensive and detailed, suitable for professional mechanics and experienced DIY enthusiasts. Diagnostics: Advanced diagnostic procedures, including electrical testing, compression testing (adapted for rotary), and visual inspections. Rebuild Procedures: Full rebuild procedures for major mechanical components like the rotary engine and transmission. 📊 Manual Specifications File Format Digital Format: PDF Searchable Text: Likely to be searchable if OCR processed, but older scans may be image-based....
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MAZDA R100 R 100 COUPE 1968-1973 Workshop Repair ManualMAZDA R100 R 100 COUPE 1968-1973 Workshop Repair ManualMAZDA R100 R 100 COUPE 1968-1973 Workshop Repair ManualMAZDA R100 R 100 COUPE 1968-1973 Workshop Repair Manual
The Mazda R100, also known as the Mazda Familia Rotary Coupe, is a distinctive compact sports coupe produced from 1968 to 1973. This pioneering vehicle showcased Mazda's innovative 2-rotor Wankel rotary engine, the 10A, offering a unique blend of smooth power delivery and nimble handling. With its clean coupe styling and sporty proportions, the R100 carved out a niche in the automotive market, competing with other performance-oriented vehicles of its era. Its engineering quality and the revolutionary rotary powertrain have cemented its status as a significant and collectible piece of automotive history. This workshop service and repair manual provides comprehensive guidance for the Mazda R100, covering model years 1968 through 1973. It details essential maintenance procedures, diagnostic troubleshooting for common issues, and in-depth repair instructions for all major vehicle systems, including the rotary engine, transmission, brakes, suspension, and electrical components. The manual also includes crucial technical specifications, torque values, and detailed wiring diagrams. Its purpose is to empower owners, mechanics, and technicians with the knowledge necessary to maintain, repair, and preserve the R100, ensuring its continued operation and historical integrity.
🏷️ Basic Information
Identification
Make:
Mazda
Model:
R100 (R 100 Coupe)
Body Style:
Coupe
Generation:
First Generation (Mazda Familia Rotary Coupe)
Codes
Chassis Code:
Often referred to by its platform derivative, e.g., derived from the Mazda Familia series
Engine Code:
10A (Rotary)
👋 Introduction
Market Position
Positioning:
The Mazda R100 was a pioneering compact sports coupe that introduced the rotary engine to a wider audience, competing with small European sports cars and domestic performance coupes.
Competitive Analysis
Competitors:
Datsun 240Z, Toyota Corolla Levin/Sprinter Trueno (early generations), Alfa Romeo Giulia GT, Ford Capri.
Key Features
Engine Type:
Unique 2-rotor (10A) Wankel rotary engine, offering a compact, high-revving, and smooth power delivery.
Design:
Distinctive coupe styling with clean lines, sporty proportions, and often a characteristic 'bubble' rear window.
Driving Experience:
Known for its nimble handling, lightweight feel, and the unique sound and acceleration characteristics of the rotary engine.
Manual Value Proposition
Usefulness:
Essential for owners and mechanics maintaining the iconic R100, providing crucial technical data and procedures for preserving this unique vehicle.
📋 Manual Details
Coverage Areas
Years Covered:
1968, 1969, 1970, 1971, 1972, 1973
Regions Covered:
Global (primarily based on North American and Japanese specifications)
Page Count
Estimated Pages:
300-500 (typical for comprehensive workshop manuals of this era)
Manual Type
Type:
Workshop Service and Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Rotary Engine (10A), including apex seals, rotor housing, rotor, eccentric shaft, lubrication, cooling, and combustion.
Lubricating System:
Oil pump, oil filter, oil passages, oil pressure testing, and oil type specifications.
Cooling System:
Radiator, water pump, thermostat, coolant hoses, coolant type and capacity, and system pressure testing.
Fuel System:
Carburetor (likely Hitachi or Mikuni side-draft), fuel pump, fuel filter, fuel lines, and emissions control components (if applicable).
Electrical System:
Ignition system (distributor, coil, spark plugs), starting system (starter motor, solenoid), charging system (alternator, regulator), lighting, instrumentation, wiring diagrams, and component testing.
Clutch:
Clutch disc, pressure plate, release bearing, clutch pedal adjustment, hydraulic system (if applicable), and removal/installation.
Transmission:
Manual transmission (likely 4-speed or 5-speed), gear lubrication, internal components, shift linkage, and removal/installation.
Propeller Shaft:
Driveshaft, universal joints, balancing, and inspection.
Rear Axle:
Differential, axle shafts, bearings, and fluid specifications.
Suspension:
Front and rear suspension components (springs, shock absorbers, control arms, ball joints, bushings), alignment specifications, and replacement procedures.
Steering:
Steering box, tie rods, steering column, linkage, and adjustment procedures.
Brakes:
Front and rear brake systems (drum or disc), master cylinder, wheel cylinders, brake lines, pads/shoes, hydraulic fluid specifications, bleeding procedures, and parking brake.
Body And Trim:
Body panel repair, door mechanisms, window mechanisms, interior trim, and weather stripping.
Chassis And Frame:
Frame inspection, rust repair, and structural components.
Heating And Air Conditioning:
Heater core, blower motor, ducting (if factory AC equipped).
Emissions Control:
Early emissions systems, PCV valve, air injection (if equipped).
Procedures Included
Maintenance:
Routine checks, fluid changes, filter replacements, lubrication points, spark plug replacement, and ignition timing adjustment.
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting for engine performance, electrical issues, and mechanical failures.
Repair:
Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation.
Overhaul:
Detailed instructions for complete engine, transmission, and differential rebuilds.
Adjustment:
Carburetor tuning, ignition timing, clutch pedal, brakes, and suspension alignment.
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle systems.
Torques Specifications:
Torque values for critical fasteners across all vehicle systems.
Technical Depth
Depth:
Comprehensive and detailed, suitable for professional mechanics and experienced DIY enthusiasts.
Diagnostics:
Advanced diagnostic procedures, including electrical testing, compression testing (adapted for rotary), and visual inspections.
Rebuild Procedures:
Full rebuild procedures for major mechanical components like the rotary engine and transmission.
📊 Manual Specifications
File Format
Digital Format:
PDF
Searchable Text:
Likely to be searchable if OCR processed, but older scans may be image-based.
Print Quality
Quality:
Variable, depending on the original source and scanning process. Aim for clear, legible text and diagrams.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Mazda 10A (Wankel Rotary)
Displacement:
984 cc (equivalent to approx. 1.0L, but rotary displacement is calculated differently)
Configuration:
Two-rotor, naturally aspirated
Performance
Horsepower:
Approximately 100-110 hp (net, depending on market and tuning)
Torque:
Approximately 100-110 lb-ft (net, depending on market and tuning)
Redline:
Typically around 6,000-7,000 RPM
Compression Ratio:
Typically around 9.4:1 to 9.8:1 (rotary specific) - actual effective compression is different from piston engines.
Fuel System
Carburetor:
Single Hitachi or Mikuni side-draft downdraft carburetor (e.g., 40mm or 45mm).
Fuel Type:
Unleaded gasoline (premium recommended for optimal performance and longevity, though leaded was common when new).
Lubrication
Oil Type:
API SG or higher, SAE 10W-30 or 20W-50 (refer to manual for exact specification). Rotary engines often require specific oil properties.
Oil Capacity:
Approximately 4-5 US quarts (refer to manual for exact capacity and filter refill).
Cooling
Coolant Type:
Ethylene glycol-based coolant (typically 50/50 mix with distilled water).
🔧 Transmission
Standard
Type:
4-speed or 5-speed manual transmission.
Optional
Type:
Rarely offered with an automatic transmission in this model.
Features
Gear Ratios:
Specific gear ratios will be detailed in the manual, crucial for performance tuning.
Fluid Type:
GL-4 or GL-5 gear oil (SAE 75W-90 or 80W-90 typically). Refer to manual for exact specification.
Fluid Capacity
Capacity:
Approximately 1.5-2.0 US quarts (refer to manual).
📐 Dimensions
Exterior
Length:
Approximately 3,995 mm (157.3 in)
Width:
Approximately 1,575 mm (62.0 in)
Height:
Approximately 1,295 mm (50.9 in)
Wheelbase:
Approximately 2,285 mm (89.9 in)
Weights
Curb Weight:
Approximately 850-950 kg (1,874-2,094 lbs)
Gross Vehicle Weight Rating:
Refer to manual for specific GVWR.
🛡️ Safety Features
Ratings
Crash Test Data:
No standardized crash test data available for this era and model. Safety features were minimal by modern standards.
Active Features
Brakes:
Front disc brakes, rear drum brakes (standard).
Steering:
Recirculating ball steering system, typically non-assisted.
Passive Features
Seatbelts:
Lap belts or three-point front seatbelts (depending on market and year).
Body Structure:
Unibody construction, but lacks modern crumple zones and safety cage reinforcement.
💡 Technology Features
Infotainment
Audio:
Basic AM/FM radio, often with a single speaker. Cassette players were not standard in early models.
Instrumentation:
Analog gauges for speedometer, tachometer, fuel level, coolant temperature, and oil pressure. Warning lights for various systems.
Driver Assistance
Features:
Virtually none by modern standards. Features would be limited to basic safety systems like seatbelts and potentially head restraints.
Connectivity
Features:
No electronic connectivity features. Focus is on mechanical operation.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000-5,000 miles or 6 months (refer to manual for exact interval and oil type).
Spark Plugs:
Inspect at 15,000 miles, replace as needed (specific plug types for rotary engines). Refer to manual for correct part numbers and gap.
Air Filter:
Inspect every 6 months or 7,500 miles, replace as needed.
Fuel Filter:
Replace as needed, typically every 15,000-20,000 miles or if symptoms of fuel starvation appear.
Coolant Flush:
Every 2 years or 30,000 miles.
Transmission Fluid:
Check level periodically, change every 30,000-50,000 miles or as recommended in the manual.
Fluid Specifications
Engine Oil Viscosity:
SAE 10W-30 or 20W-50 recommended (verify with manual).
Transmission Fluid Type:
GL-4 or GL-5, SAE 75W-90 or 80W-90 (verify with manual).
Brake Fluid:
DOT 3 or DOT 4 (verify with manual).
Known Issues
Rotary Engine Apex Seals:
Wear and failure of apex seals leading to loss of compression, rough idle, and smoking are common issues with older rotary engines. Proper lubrication and avoiding over-revving are critical.
Oil Consumption:
Rotary engines inherently consume some oil as part of their lubrication system. Excessive consumption can indicate seal wear.
Carburetor Issues:
Aging diaphragms, worn jets, and vacuum leaks in the carburetor can lead to poor running conditions.
Cooling System:
Radiator leaks, water pump seal failure, and degraded hoses can cause overheating.
Ignition System:
Distributor wear, coil failure, and incorrect spark plug types can affect engine performance and starting.
📚 Vehicle History
Brand Heritage
Mazda Rotary Development:
Mazda's commitment to the rotary engine, starting with the NSU license and their own development, was a bold move that defined their brand for decades.
Model Evolution
Predecessor:
Based on the Mazda Familia chassis, sharing many components with the piston-engined versions.
Successor:
The R100 was succeeded by other rotary coupes and sedans like the RX-2, RX-3, and later the iconic RX-7 series.
Production
Production Years:
1968-1973
Manufacturing Location:
Japan
Significance:
Key model in proving the viability of the rotary engine in a mass-produced passenger car and establishing Mazda's performance credentials.
🏆 Awards & Recognition
Recognitions
Historical Impact:
Recognized as a significant vehicle for introducing Mazda's rotary technology to the global market, paving the way for future rotary-powered icons like the RX-7.
Ratings
Contemporary Reviews:
Often praised for its performance and unique engine but sometimes criticized for fuel economy and reliability concerns associated with early rotary technology.
Certifications
Historical Significance:
Considered a collector's item and a landmark in automotive engineering for its rotary powertrain.
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