engine YAMAHA BT1100 2002 User Guide

INSTRUMENT AND CONTROL FUNCTIONS
1
EAU00185
Immediately wipe off spilled fuel with a
clean, dry, soft cloth, since fuel may
deteriorate painted surfaces or plastic
parts.
CAUTION:
EAU00191
NOTE:
If knocking (or pinging) occurs, use gaso-
line of a different brand or with a higher
octane grade.Recommended fuel:
Regular unleaded gasoline with a
research octane number of 91 or
higher
Fuel tank capacity:
Total amount:
20 L
Reserve amount:
5.8 L
1. Fuel tank breather hose
EAU02955
Fuel tank breather hose
Before operating the motorcycle:
Check the fuel tank breather hose connec-
tion.
Check the fuel tank breather hose for
cracks or damage, and replace it if dam-
aged.
Make sure that the end of the fuel tank
breather hose is not blocked, and clean it if
necessary.
EAU03839
Starter (choke) lever
Starting a cold engine requires a richer air-
fuel mixture, which is supplied by the
starter (choke).
Move the lever in direction bto turn on
the starter (choke).
Move the lever in direction ato turn off
the starter (choke).
1
b
a
1. Starter (choke) lever
3-12
3
EAU00027

INSTRUMENT AND CONTROL FUNCTIONS
EW000044WARNING0
The motorcycle must not be ridden
with the sidestand down, or if the side-
stand cannot be properly moved up (or
does not stay up), otherwise the side-
stand could contact the ground and
distract the operator, resulting in a pos-
sible loss of control.
Yamaha’s ignition circuit cut-off sys-
tem has been designed to assist the
operator in fulfilling the responsibility
of raising the sidestand before starting
off. Therefore, check this system regu-
larly as described below and have a
Yamaha dealer repair it if it does not
function properly.
EAU03720
Ignition circuit cut-off system
The ignition circuit cut-off system (com-
prising the sidestand switch, clutch switch
and neutral switch) has the following func-
tions.
•It prevents starting when the trans-
mission is in gear and the sidestand
is up, but the clutch lever is not
pulled.
•It prevents starting when the trans-
mission is in gear and the clutch lever
is pulled, but the sidestand is still
down.
•It cuts the running engine when the
transmission is in gear and the side-
stand is moved down.Periodically check the operation of the ig-
nition circuit cut-off system according to
the following procedure.
EW000045WARNING0
If a malfunction is noted, have a Yamaha
dealer check the system before riding.
3-17
3
EAU00027

INSTRUMENT AND CONTROL FUNCTIONSEAU00027
3-18
3
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is set to “
I”.
3. Turn the key to “
I” (ON).
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
The neutral switch may be defective.
The motorcycle should not be riddenuntil checked by a
Yamaha dealer.
The sidestand switch may be defective.
The motorcycle should not be riddenuntil checked by a
Yamaha dealer.
The clutch switch may be defective.
The motorcycle should not be riddenuntil checked by a
Yamaha dealer.
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
The system is OK. The motorcycle can be ridden.
NOTE:
This check is most reliable if performed with a warmed-up
engine.
NO YES
NO YES
NO YES

EAU01114PRE-OPERATION CHECKS
4-1
The condition of a vehicle is the owner’s responsibility.
Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of ex-
posure to the elements).
Any damage, fluid leakage or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a
thorough visual inspection, to check the following points before each ride.
EAU03439
Pre-operation check list
ITEM CHECK PAGE
• Check fuel level in fuel tank.
Fuel• Refuel if necessary.3-11
• Check fuel line for leakage.
• Check oil level in engine.
Engine oil• If necessary, add recommended oil to specified level. 6-6
• Check vehicle for oil leakage.
Final gear oil• Check vehicle for oil leakage.6-8
• Check operation.
• If soft or spongy, have Yamaha dealer bleed
hydraulic system.
Front brake
• Check fluid level in reservoir.3-10, 6-19
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed
hydraulic system.
Rear brake
• Check fluid level in reservoir.3-10, 6-19
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
4

PRE-OPERATION CHECKSEAU01114
4-2
4
ITEM CHECK PAGE
• Check operation.
• Lubricate cable if necessary.
Clutch
• Check lever free play.3-9, 6-17, 6-23
• Adjust if necessary.
• Make sure that operation is smooth.
• Lubricate throttle grip, housing and cables
Throttle gripif necessary.6-13, 6-22
• Check free play.
• If necessary, have Yamaha dealer make adjustment.
• Make sure that operation is smooth.
Control cables
• Lubricate if necessary.6-22
• Check for damage.
• Check tire condition and tread depth.
Wheels and tires
• Check air pressure.6-13, 6-16
• Correct if necessary.
Brake and shift • Make sure that operation is smooth.
pedals• Lubricate pedal pivoting points if necessary.6-23
Brake and clutch • Make sure that operation is smooth.
levers• Lubricate lever pivoting points if necessary.6-23
• Make sure that operation is smooth.
Sidestand
• Lubricate pivot if necessary.6-24
Chassis • Make sure that all nuts, bolts and screws are properly tightened.
fasteners• Tighten if necessary.–
Instruments, lights, • Check operation.
signals and switches• Correct if necessary.3-2, 3-3, 3-8, 3-9
Engine stop
switch• Check operation.3-9
Sidestand • Check operation of ignition circuit cut-off system.
switch• If system is defective, have Yamaha dealer check vehicle.3-18

5
Starting the engine .............................................................................. 5-1
Starting a warm engine ...................................................................... 5-3
Shifting ................................................................................................ 5-3
Tips for reducing fuel consumption .................................................... 5-4
Engine break-in .................................................................................. 5-4
Parking ................................................................................................ 5-5
OPERATION AND IMPORTANT RIDING POINTSEAU00372

OPERATION AND IMPORTANT RIDING POINTS
EAU00373WARNING0
•Become thoroughly familiar with
all operating controls and their
functions before riding. Consult a
Yamaha dealer regarding any con-
trol or function that you do not
thoroughly understand.
•Never start the engine or operate it
in a closed area for any length of
time. Exhaust fumes are poiso-
nous, and inhaling them can cause
loss of consciousness and death
within a short time. Always make
sure that there is adequate ventila-
tion.
•Before starting out, make sure that
the sidestand is up. If the side-
stand is not raised completely, it
could contact the ground and dis-
tract the operator, resulting in a
possible loss of control.
EAU03818
Starting the engine
In order for the ignition circuit cut-off sys-
tem to enable starting, one of the following
conditions must be met:
•The transmission is in the neutral po-
sition.
•The transmission is in gear with the
clutch lever pulled and the sidestand
up.
EW000054WARNING0
•Before starting the engine, check
the function of the ignition circuit
cut-off system according to the
procedure described on page 3-18.
•Never ride with the sidestand
down.
1. Turn the key to “I” (ON) and make
sure that the engine stop switch is set
to “
I”.
EC000035
If the fuel level warning light comes on,
check the fuel level, and, if necessary,
refuel as soon as possible.
2. Shift the transmission into the neutral
position.
When the transmission is in the neu-
tral position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical
circuit.
3. Turn the starter (choke) on and com-
pletely close the throttle. (See page
3-12 for starter (choke) operation).
CAUTION:
5-1
5
EAU00372

OPERATION AND IMPORTANT RIDING POINTS
1
b
a
4. Start the engine by pushing the start
switch.
NOTE:
If the engine fails to start, release the start
switch, wait a few seconds, and then try
again. Each starting attempt should be as
short as possible to preserve the battery.
Do not crank the engine more than 10 sec-
onds on any one attempt.
1. Starter (choke) lever
a. Starter (choke) turned on
b. Starter (choke) turned off
EC000038
The oil level warning light and fuel lev-
el warning light should come on when
the start switch is pushed, and they
should go off when the start switch is
released.
If the oil level warning light flickers or
remains on after starting, immediately
stop the engine, and then check the
engine oil level and the vehicle for oil
leakage. If necessary, add engine oil,
and then check the warning light again.
If the warning light does not come on
when pushing the start switch, or if it
does not go off after starting with suffi-
cient engine oil, have a Yamaha dealer
check the electrical circuit.
If the fuel level warning light remains
on after starting, stop the engine, and
then check the fuel level. If necessary,
refuel as soon as possible, and then
check the warning light again. If the
warning light does not come on when
pushing the start switch, or if it does
not go off after starting with sufficient
fuel, have a Yamaha dealer check the
electrical circuit.
CAUTION:5. After starting the engine, move the
starter (choke) knob/lever back
halfway.
ECA00045
For maximum engine life, never accel-
erate hard when the engine is cold!
6. When the engine is warm, turn the
starter (choke) off.
NOTE:
The engine is warm when it responds nor-
mally to the throttle with the starter (choke)
turned off.
CAUTION:
EAU00372
5-2
5

OPERATION AND IMPORTANT RIDING POINTS
1
5
4
3
2
N
1
EAU01258
Starting a warm engine
Follow the same procedure as for starting
a cold engine with the exception that the
starter (choke) is not required when the
engine is warm.
EAU00423
Shifting
Shifting gears lets you control the amount
of engine power available for starting off,
accelerating, climbing hills, etc.
The gear positions are shown in the illus-
tration.
NOTE:
To shift the transmission into the neutral
position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.
EC000048
•Even with the transmission in the
neutral position, do not coast for
long periods of time with the
engine off, and do not tow the
motorcycle for long distances. The
transmission is properly lubricat-
ed only when the engine is run-
ning. Inadequate lubrication may
damage the transmission.
•Always use the clutch while
changing gears to avoid damaging
the engine, transmission, and dri-
ve train, which are not designed to
withstand the shock of forced
shifting.
CAUTION:
5-3
5
1. Shift pedal
N. Neutral position
EAU00372

OPERATION AND IMPORTANT RIDING POINTS
EAU00424
Tips for reducing fuel
consumption
Fuel consumption depends largely on your
riding style. Consider the following tips to
reduce fuel consumption:
•Thoroughly warm up the engine.
•Turn the starter (choke) off as soon
as possible.
•Shift up swiftly, and avoid high engine
speeds during acceleration.
•Do not rev the engine while shifting
down, and avoid high engine speeds
with no load on the engine.
•Turn the engine off instead of letting it
idle for an extended length of time
(e.g., in traffic jams, at traffic lights or
at railroad crossings).
5-4
5
EAU00372
EAU01128
Engine break-in
There is never a more important period in
the life of your engine than the period be-
tween 0 and 1,600 km (1,000 mi). For this
reason, you should read the following ma-
terial carefully.
Since the engine is brand new, do not put
an excessive load on it for the first 1,600
km (1,000 mi). The various parts in the en-
gine wear and polish themselves to the
correct operating clearances. During this
period, prolonged full-throttle operation or
any condition that might result in engine
overheating must be avoided.
EAU01171
0-1,000 km (0-600 mi)
Avoid prolonged operation above 1/3 throt-
tle.
1,000-1,600 km (600-1,000 mi)
Avoid prolonged operation above 1/2 throt-
tle.
EC000056
After 1,000 km (600 mi) of operation,
the engine oil and final gear oil must be
changed, and the oil filter cartridge/ele-
ment replaced.
1,600 km (1,000 mi) and beyond
The vehicle can now be operated normal-
ly.
EC000049
If any engine trouble should occur dur-
ing the engine break-in period, immedi-
ately have a Yamaha dealer check the
vehicle.
CAUTION:
CAUTION: