brake YAMAHA BT1100 2002 User Guide

EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
The tire tread depth limits may differ from
country to country. Always comply with the
local regulations.
EW000079WARNING0
•Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the motor-
cycle with excessively worn tires
decreases riding stability and can
lead to loss of control.
•The replacement of all wheel- and
brake-related parts, including the
tires, should be left to a Yamaha
dealer, who has the necessary pro-
fessional knowledge and experi-
ence.
Tire information
This motorcycle is equipped with cast
wheels and tubeless tires with valves.
EW000080WARNING0
•The front and rear tires should be
of the same make and design, oth-
erwise the handling characteris-
tics of the motorcycle cannot be
guaranteed.
•After extensive tests, only the tires
listed below have been approved
for this model by Yamaha Motor
Co., Ltd.
•Always make sure that the valve
caps are securely installed to pre-
vent air pressure leakage.
•Use only the tire valves and valve
cores listed below to avoid tire
deflation during a high-speed ride.
6-15
6
Tire inspection
The tires must be checked before each ride.
If the center tread depth reaches the speci-
fied limit, if the tire has a nail or glass frag-
ments in it, or if the sidewall is cracked,
have a Yamaha dealer replace the tire im-
mediately.
1. Tire sidewall
a. Tire tread depth
Minimum tire
tread depth 1.6 mm
(front and rear)

EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR
A
a
EAU00712
Adjusting the brake pedal
position
The top of the brake pedal should be posi-
tioned approximately 43 mm below the top
of the footrest as shown. Periodically
check the brake pedal position and, if nec-
essary, have a Yamaha dealer adjust it.
EW000109WARNING0
A soft or spongy feeling in the brake
pedal can indicate the presence of air
in the hydraulic system. If there is air in
the hydraulic system, have a Yamaha
dealer bleed the system before operat-
ing the motorcycle. Air in the hydraulic
system will diminish the braking per-
formance, which may result in loss of
control and an accident.a. Distance between brake pedal and footrest
6-18
6

1. Front brake pad wear indicator groove
PERIODIC MAINTENANCE AND MINOR REPAIR
11
2
1
EAU00715
Checking the front and rear
brake pads
The front and rear brake pads must be
checked for wear at the intervals specified
in the periodic maintenance and lubrica-
tion chart. Each brake pad is provided with
a wear indicator, which allows you to
check the brake pad wear without having
to disassemble the brake. To check the brake pad wear, check the
position of the wear indicator while apply-
ing the brake. If a brake pad has worn to
the point that the wear indicator almost
touches the brake disc, have a Yamaha
dealer replace the brake pads as a set.
EAU03776
Checking the brake fluid level
Insufficient brake fluid may allow air to en-
ter the brake system, possibly causing it to
become ineffective.
Before riding, check that the brake fluid is
above the minimum level mark and replen-
ish if necessary.
A low brake fluid level may indicate worn
brake pads and/or brake system leakage.
If the brake level is low, be sure to check
the brake pads for wear and the brake sys-
tem for leakage.
EAU00462
6-19
6
1. Front brake master cylinder
2. Minimum level mark 1. Rear brake pad wear indicator groove

EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
Observe these precautions:
•When checking the fluid level, make
sure that the top of the brake fluid
reservoir is level.
•Use only the recommended quality
brake fluid, otherwise the rubber
seals may deteriorate, causing leak-
age and poor braking performance.
•Refill with the same type of brake flu-
id. Mixing fluids may result in a harm-
ful chemical reaction and lead to poor
braking performance.
•Be careful that water does not enter
the brake fluid reservoir when refill-
ing. Water will significantly lower the
boiling point of the fluid and may re-
sult in vapor lock.
•Brake fluid may deteriorate painted
surfaces or plastic parts. Always
clean up spilled fluid immediately.
•As the brake pads wear, it is normal
for the brake fluid level to gradually
go down. However, if the brake fluid
level goes down suddenly, have a
Yamaha dealer check the cause.
6-20
6
1. Screw (x 2)
2. Right panel
2
1
1. Pin (x 2)
2. Pin seat (x 2)
Recommended brake fluid: DOT 4
21
1. Rear brake fluid reservoir
2. Minimum level mark

EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR
a
A
EAU03976
Changing the brake fluid
Have a Yamaha dealer change the brake
fluid at the intervals specified in the NOTE
after the periodic maintenance and lubri-
cation chart. In addition, have the oil seals
of the master cylinders and calipers as
well as the brake hoses replaced at the in-
tervals listed below or whenever they are
damaged or leaking.
•Oil seals: Replace every two years.
•Brake hoses: Replace every four
years.
a. Distance between shift pedal and footrest
EAUB0011
Adjusting the shift pedal
position
The top of the shift pedal should be posi-
tioned approximately 45 mm below the top
of the footrest as shown. Periodically check the shift pedal position
and, if necessary, have a Yamaha dealer
adjust it.
6-21
6

PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03370
Checking and lubricating the
brake and shift pedals
The operation of the brake and shift pedals
should be checked before each ride, and
the pedal pivots should be lubricated if
necessary.
EAU03164
Checking and lubricating the
brake and clutch levers
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lubri-
cated if necessary.
EAU00462
6-23
6
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)

EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR
EAU02939
Checking the front fork
The condition and operation of the front
fork must be checked as follows at the in-
tervals specified in the periodic mainte-
nance and lubrication chart.
To check the condition
EW000115WARNING0
Securely support the motorcycle so
that there is no danger of it falling over.
Check the inner tubes for scratches, dam-
age and excessive oil leakage.
To check the operation
1. Place the motorcycle on a level sur-
face and hold it in an upright position.
2. While applying the front brake, push
down hard on the handlebars several
times to check if the front fork com-
presses and rebounds smoothly.
EC000098
If any damage is found or the front fork
does not operate smoothly, have a
Yamaha dealer check or repair it.
CAUTION:
6-24
6
EAU03165
Checking and lubricating the
sidestand
The operation of the sidestand should be
checked before each ride, and the side-
stand pivot and metal-to-metal contact sur-
faces should be lubricated if necessary.
EW000113WARNING0
If the sidestand does not move up and
down smoothly, have a Yamaha dealer
check or repair it.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)

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
EAB00016
To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Install the spacers and insert the
wheel axle.
3. Lower the front wheel so that it is on
the ground.
4. Install the brake calipers by installing
the bolts.
NOTE:
Make sure that there is enough space
between the brake pads before installing
the brake calipers onto the brake discs.5. Tighten the wheel axle, then the front
wheel axle pinch bolt, and the brake
caliper bolts to the specified torques.EAUB0017
Rear wheel
To remove the rear 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. Loosen the rear wheel axle pinch
bolt, and then remove the axle nut.
6-33
6
6. Push down hard on the handlebar
several times to check for proper fork
operation. Tightening torques:
Wheel axle:
75 Nm (7.5 m·kgf)
Front wheel axle pinch bolt:
25 Nm (2.5 m·kgf)
Brake caliper bolt:
42 Nm (4.2 m·kgf)
1. Wheel axle pinch bolt
2. Axle nut
3. Brake torque rod bolt