light YAMAHA BT1100 2003 Owner's Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
23
1
5. Remove the air filter case cover by
removing the screws.
6. Pull the air filter element out.
7. Lightly tap the air filter element to re-
move most of the dust and dirt, and
then blow the remaining dirt out with
compressed air as shown. If the air fil-
ter element is damaged, replace it.
8. Insert the air filter element into the air
filter case.
1. Screw
2. Air filter case cover
3. Air filter
ECA00089
The engine should never be operated
without the air filter element installed,
otherwise the piston(s) and/or cylin-
der(s) may become excessively worn.
9. Install the air filter case cover by in-
stalling the screws.
10. Install the fuel tank by installing the
bolts.
11. Install the panels.
CAUTION:
EAU00462
6-11
6
4. Lift the fuel tank to position it away
from the air filter case. (Do not dis-
connect the fuel hoses!).
EW000071WARNING0
Make sure that the fuel tank is well sup-
ported.
Do not tilt or pull the fuel tank too much,
otherwise the fuel hoses may come
loose, which could cause fuel leakage.

EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR
128
1
7
9
2
3
546
EAUB0012
Replacing the fuses
The fuse box is located under the seat.
(See page 3-13 for seat removal and in-
stallation procedures). If a fuse is blown,
replace it as follows.
1. Turn the key to “
B” (OFF) and turn
off the electrical circuit in question.
2. Remove the blown fuse, and then in-
stall a new fuse of the specified am-
perage.
1. Screw (x 2)
2. Storage compartment
EC000103
Do not use a fuse of a higher amperage
rating than recommended to avoid
causing extensive damage to the elec-
trical system and possibly a fire.
3. Turn the key to “
I” (ON) and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows again,
have a Yamaha dealer check the
electrical system.
CAUTION:
1. Fuse box cover
2. Main fuse
3. Headlight fuse
4. Signaling system fuse
5. Ignition fuse
6. Backup fuse (odometer)
7. Carburetor heater fuse
8. Spare fuse (x 4)
6-28
6
Specified fuses:
Main fuse: 30 A
Backup fuse
(odometer): 5 A
Ignition fuse: 10 A
Headlight fuse: 15 A
Carburetor heater fuse 15 A
Signaling system fuse: 10 A

1. Screw (x 2)
2. Cowling
PERIODIC MAINTENANCE AND MINOR REPAIR
2
1
1
2
1
1
EAUB0013
Replacing the headlight and
auxiliary light bulb
This motorcycle is equipped with a quartz
bulb headlight. If the headlight bulb or aux-
iliary light bulb burns out, replace it as fol-
lows.
NOTE:
Skip steps 6-10 if only the headlight bulb is
being replaced. Skip steps 2-5 if only the
auxiliary light bulb is being replaced.1. Remove the headlight by removing
the screws, then tilt the cowling for-
ward.
2. Disconnect the headlight coupler and
the auxiliary light leads, and then re-
move the headlight bulb cover.
3. Remove the headlight bulb holder by
turning it counterclockwise, and then
remove the defective bulb.
EW000119WARNING0
Headlight bulbs get very hot. There-
fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled down.
4. Place a new bulb into position, and
then secure it with the bulb holder.
EAU00462
6-29
6
1. Headlight bulb cover
2. Auxiliary light bulb holder1. Headlight coupler

PERIODIC MAINTENANCE AND MINOR REPAIR
1
1
2
EC000105
Do not touch the glass part of the head-
light bulb to keep it free from oil, other-
wise the transparency of the glass, the
luminosity of the bulb, and the bulb life
will be adversely affected.
Thoroughly clean off any dirt and fin-
gerprints on the headlight bulb using a
cloth moistened with alcohol or thin-
ner.
CAUTION:5. Install the headlight bulb cover, and
then connect the coupler and auxil-
iary light leads.
6. Remove the socket (together with the
bulb) by turning it counterclockwise.
7. Remove the defective bulb by push-
ing it in and turning it counterclock-
wise.
8. Insert a new bulb into the socket,
push it in, and then turn it clockwise
until it stops.
9. Install the socket (together with the
bulb) by turning it clockwise.10. Connect the auxiliary light bulb leads.
11. Tilt the cowling back to the original
position, and then install the headlight
by installing the screws.
EAU00462
6-30
6
1. Headlight bulb holder 1. Do not touch this area 1. Auxiliary light bulb holder
2. Auxiliary light bulb

EAU00462
1. Screw
2. Turn signal light len
PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
1. Screw (x 2)
11
NOTE:
Before installing the headlight, be sure to
hook the headlight and auxiliary light bulb
leads into the guide to the left of the head-
light as shown.
12. Have a Yamaha dealer adjust the
headlight beam if necessary.
EAU03497
Replacing a turn signal light
bulb
1. Remove the turn signal light lens by
removing the screw.
2. Remove the defective bulb by push-
ing it in and turning it counterclock-
wise.
3. Insert a new bulb into the socket,
push it in, and then turn it clockwise
until it stops.
4. Install the lens by installing the screw.
EC000065
Do not overtighten the screw, other-
wise the lens may break.
CAUTION:
EAU01623
Replacing the tail/brake light
bulb
1. Remove the tail/brake light lens by re-
moving the screws.
2. Remove the defective bulb by push-
ing it in and turning it counterclock-
wise.
3. Insert a new bulb into the socket,
push it in, and then turn it clockwise
until it stops.
4. Install the lens by installing the
screws.
EC000108
Do not overtighten the screws, other-
wise the lens may break.
CAUTION:
6-31
6
1
1. Leads guide

EAU00462
1. Nut (x 2) 1. Bulb socket
2. Bulb
PERIODIC MAINTENANCE AND MINOR REPAIR
1
1 2
1. Brake caliper (x 2)
2. Wheel axle pinch bolt
3. Wheel axle
4. Spacer (x 2)








EAUB0019
Replacing the license plate
light bulb
1. Remove the license plate light by re-
moving the nuts.
2. Remove the bulb socket from the li-
cense plate light by pulling it out.
3. Remove the defective bulb by pulling
it out.
4. Insert a new bulb into the socket.
5. Install the bulb socket into the license
plate light.
6. Install the license plate light by in-
stalling the nuts.
EAUB0015
Front wheel
To remove the front wheel
EW000122WARNING0
It is advisable to have a Yamaha dealer
service the wheel.
Securely support the motorcycle so
that there is no danger of it falling over.
1. Mark either side of the wheel so that it
can be installed in the original running
direction.
2. Remove the brake calipers by remov-
ing the bolts.
ECA00047
Do not pull the brake lever after the
brake caliper has been removed, other-
wise the brake pads will be forced shut.
3. Loosen the front wheel axle pinch
bolt, then the wheel axle.
4. Pull the wheel axle out together with
the spacers, and then remove the
wheel.
CAUTION:
6-32
6

EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR
2. Remove the brake torque rod bolt
from the brake caliper bracket, and
then turn the caliper up, away from
the disc.
3. Remove the wheel axle together with
the spacers.
4. Pull the wheel to the right to separate
it from the final gear case, and then
remove it.
ECA00062
Do not push the brake pedal after the
wheel has been removed together with
the brake disc, otherwise the brake
pads will be forced shut.
CAUTION:
EAUB0018
To install the rear wheel
1. Apply a light coating of lithium-soap-
based grease to the splines of the fi-
nal gear case and wheel hub.
2. Install the wheel by inserting the
wheel axle, then installing the axle
nut.
3. Turn the caliper down so that it fits
over the brake disc.
NOTE:
Make sure that there is enough space
between the brake pads before installing
the brake caliper onto the brake disc.
4. Install the wheel axle pinch bolt.
5. Install the brake torque rod bolt at the
brake caliper bracket.6. Install the wheel axle pinch bolt.
7. Lower the rear wheel so that it is on
the ground.
8. Tighten the axle nut, wheel axle pinch
bolt, and brake torque rod bolt to the
specified torques.
6-34
6
Tightening torques:
Axle nut:
110 Nm (11.0 m·kgf)
Wheel axle pinch bolt:
22 Nm (2.2 m·kgf)
Brake torque rod bolt:
35 Nm (3.5 m·kgf)

MOTORCYCLE CARE AND STORAGE
•Do not use any harsh chemical
products on plastic parts. Be sure
to avoid using cloths or sponges
which have been in contact with
strong or abrasive cleaning prod-
ucts, solvent or thinner, fuel (gaso-
line), rust removers or inhibitors,
brake fluid, antifreeze or elec-
trolyte.
•Do not use high-pressure washers
or steam-jet cleaners since they
cause water seepage and deterio-
ration in the following areas: seals
(of wheel and swingarm bearings,
fork and brakes), electric compo-
nents (couplers, connectors,
instruments, switches and lights),
breather hoses and vents.
•For motorcycles equipped with a
windshield: Do not use strong
cleaners or hard sponges as they
will cause dulling or scratching.
Some cleaning compounds for
plastic may leave scratches on the
windshield. Test the product on asmall hidden part of the wind-
shield to make sure that it does
not leave any marks. If the wind-
shield is scratched, use a quality
plastic polishing compound after
washing.
After normal use
Remove dirt with warm water, a mild deter-
gent, and a soft, clean sponge, and then
rinse thoroughly with clean water. Use a
toothbrush or bottlebrush for hard-to-reach
areas. Stubborn dirt and insects will come
off more easily if the area is covered with a
wet cloth for a few minutes before clean-
ing.After riding in the rain, near the sea or on
salt-sprayed roads
Since sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the fol-
lowing steps after each ride in the rain,
near the sea or on salt-sprayed roads.
NOTE:
Salt sprayed on roads in the winter may
remain well into spring.
1. Clean the motorcycle with cold water
and a mild detergent, after the engine
has cooled down.
ECA00012
Do not use warm water since it increas-
es the corrosive action of the salt.
2. After drying the motorcycle, apply a
corrosion protection spray on all met-
al, including chrome- and nickel-plat-
ed, surfaces to prevent corrosion.
CAUTION:
EAU03412
7-2
7

SPECIFICATIONS
8-4
8
EAU01038
Battery
Model GT14B-4
Voltage, capacity 12 V, 12 Ah
Headlight typeQuartz bulb (halogen)
Bulb voltage, wattage x quantity
Headlight 12 V 60 W / 55 W x 1
Auxiliary light 12 V 5 W x 1
Tail/brake light 12 V 5 W / 21 W
Turn signal indicator light 12 V 10 W x 4
Meter lighting 14 V - 1.2 W x 4
Oil level warning light LED x 1
Neutral indicator light LED x 1
Turn signal light LED x 1
High beam indicator light LED x 1
Fuel level warning light LED x 1
Fuses
Main fuse 30 A
Backup fuse (odometer) 5 A
Ignition fuse 10 A
Headlight fuse 15 A
Carburetor heater fuse 15 A
Signaling system fuse 10 A

INDEX
A
Air filter element, cleaning ....................6-10
Anti-theft alarm (optional) ......................3-8
Auxiliary light bulb, replacing ................6-29
B
Battery ..................................................6-26
Brake and clutch levers, checking
and Lubricating ..................................6-23
Brake and shift pedals, checking
and Lubricating ..................................6-23
Brake fluid, changing ............................6-21
Brake fluid level, checking ....................6-19
Brake lever ..........................................3-10
Brake pads, checking ..........................6-19
Brake pedal ..........................................3-10
Brake pedal position, adjusting ............6-18
C
Cables, checking and lubricating..........6-22
Carburetors, adjusting ..........................6-12
Care ........................................................7-1
Clock ......................................................3-5
Clutch lever ............................................3-9
Clutch lever free play, adjusting ..........6-17
Consumer information ............................9-1
Controls ..................................................2-3
Conversion table ....................................8-5
D
Description ..............................................2-1
Controls and instrument ......................2-3Left view ..............................................2-1
Right view ............................................2-2
E
Engine break-in ......................................5-4
Engine idling speed, adjusting..............6-12
Engine oil and oil filter element ..............6-7
Engine stop switch..................................3-9
F
Final gear oil ..........................................6-9
Front fork
Adjusting ............................................3-15
Checking ............................................6-24
Front wheel
Installing ............................................6-33
Removing ..........................................6-32
Fuel ......................................................3-11
Fuel consumption, tips for reducing ......5-4
Fuel level warning light ..........................3-3
Fuel tank breather hose ......................3-12
Fuel tank cap ........................................3-11
Fuses, replacing ..................................6-28
H
Handlebar switches ................................3-8
Headlight bulb, replacing ......................6-29
Helmet holders ....................................3-14
High beam indicator light ........................3-3
Horn switch ............................................3-8I
Identification numbers ............................9-1
Idling speed, adjusting ..........................6-12
Ignition circuit cut-off system ................3-17
Instrument and control functions ............2-3
Instruments ............................................2-3
K
Key identification number ......................9-1
L
License plate light bulb, replacing ........6-32
Light switch ............................................3-9
M
Main switch/steering lock ..........................3-1
Model label ................................................9-2
N
Neutral indicator light ..............................3-2
O
Oil level warning light ............................3-2
Operation and important riding points ....5-1
P
Panels, removing and installing..............6-5
Parking....................................................5-5
Pass switch ............................................3-8
Periodic maintenance and lubrication
chart ....................................................6-2