YAMAHA BT1100 2002 Workshop Manual

EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR
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1 2
To check the final gear oil level
1. Place the motorcycle on a level sur-
face and hold it in an upright position.
NOTE:
•The final gear oil level must be
checked on a cold engine.
•Make sure that the motorcycle is posi-
tioned straight up when checking the
oil level. A slight tilt to the side can
result in a false reading.2. Remove the oil filler bolt, and then
check the oil level in the final gear
case.
NOTE:
The oil level should be at the brim of the
filler hole.
3. If the oil is below the brim of the filler
hole, add sufficient oil of the recom-
mended type to raise it to the correct
level.
To change the final gear oil
1. Place an oil pan under the final gear
case to collect the used oil.
2. Remove the oil filler bolt and drain
bolt to drain the oil from the final gear
case.
6-9
6
1. Final gear oil drain bolt
2. Final gear oil filler bolt
3. Oil level
EAU04083
Final gear oil
The final gear case must be checked for oil
leakage before each ride. If any leakage is
found, have a Yamaha dealer check and
repair the motorcycle. In addition, the final
gear oil level must be checked and the oil
changed as follows at the intervals speci-
fied in the periodic maintenance and lubri-
cation chart.
EW000066WARNING0
•Make sure that no foreign material
enters the final gear case.
• Make sure that no oil gets on the
tire or wheel.

EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR
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6. Check the final gear case for oil leak-
age. If oil is leaking, check for the
cause.
EAUB0008
Cleaning the air filter element
The air filter element should be cleaned at
the intervals specified in the periodic main-
tenance and lubrication chart. Clean the
air filter element more frequently if you are
riding in unusually wet or dusty areas. 4. Add the recommended final gear oil
to the brim of the filler hole.
NOTE:
GL4 is a quality rating. Hypoid gear oils
rated GL5 or GL6 may also be used.
5. Install and tighten the oil filler bolt.1. Remove the seat. (See page 3-13 for
seat removal and installation proce-
dures).
2. Remove panels 1 and 2. (See page
6-5 for panel removal and installation
procedures).
3. Remove the fuel tank bolts.
6-10
6
Tightening torque:
Final gear oil drain bolt:
23 Nm (2.3 m·kgf)
Recommended final gear oil:
Hypoid gear oil SAE 80 (API GL4)
or multi-grade hypoid gear oil
SAE 80W-90
Oil quantity:
0.2 L
3. Install the final gear oil drain bolt, and
then tighten it to the specified torque.
1. Fuel tank right bolt (x 2)
2. Fuel tank left bolt (x 2)


1. Left panel
2. Right panel

PERIODIC MAINTENANCE AND MINOR REPAIR
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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
EAU00630
Adjusting the carburetors
The carburetors are important parts of the
engine and require very sophisticated ad-
justment. Therefore, most carburetor ad-
justments should be left to a Yamaha deal-
er, who has the necessary professional
knowledge and experience. The adjust-
ment described in the following section,
however, may be serviced by the owner as
part of routine maintenance.
EC000095
The carburetors have been set and
extensively tested at the Yamaha facto-
ry. Changing these settings without
sufficient technical knowledge may
result in poor performance of or dam-
age to the engine.
CAUTION:
EAU01168
Adjusting the engine idling
speed
The engine idling speed must be checked
and, if necessary, adjusted as follows at
the intervals specified in the periodic main-
tenance and lubrication chart.
NOTE:
A diagnostic tachometer is needed to
make this adjustment.
1. Attach the tachometer to the spark
plug lead.
2. Start the engine and warm it up for
several minutes at 1,000-2,000 r/min
while occasionally revving it to
4,000-5,000 r/min.
NOTE:
The engine is warm when it quickly
responds to the throttle.
6-12
6
1
2
1. Pin (x 2)
2. Pin seat (x 2)
EWA00052WARNING0
Before installing the fuel tank, make
sure that the fuel hoses are not dam-
aged. If any fuel hose is damaged, do
not start the engine but have a Yamaha
dealer replace the hose, otherwise fuel
may leak.
Make sure that the fuel hoses are prop-
erly connected and routed, and not
pinched.
Be sure to place the fuel tank breather
hose in the original position.
12. Install the seat.

EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU00635
Adjusting the throttle
cable free play
The throttle cable free play should mea-
sure 3-5 mm at the throttle grip. Periodical-
ly check the throttle cable free play and, if
necessary, have a Yamaha dealer adjust
it.
EAU00637
Adjusting the valve clearance
The valve clearance changes with use, re-
sulting in improper air-fuel mixture and/or
engine noise. To prevent this from occur-
ring, the valve clearance must be adjusted
by a Yamaha dealer at the intervals speci-
fied in the periodic maintenance and lubri-
cation chart.
6-13
6
a. Throttle cable free play
1
ba
3. Check the engine idling speed and, if
necessary, adjust it to specification by
turning the throttle stop screw. To in-
crease the engine idling speed, turn
the screw in direction a. To decrease
the engine idling speed, turn the screw
in direction b.
Engine idling speed:
950-1,050 r/min
NOTE:
If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment.
1. Throttle stop screw

EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR
EWA00012WARNING0
Because loading has an enormous
impact on the handling, braking, per-
formance and safety characteristics of
your motorcycle, you should keep the
following precautions in mind.
•NEVER OVERLOAD THE MOTOR-
CYCLE! Operation of an over-
loaded motorcycle may result in
tire damage, loss of control, or
severe injury. Make sure that the
total weight of rider, passenger,
cargo, and accessories does not
exceed the specified maximum
load for the vehicle.
•Do not carry along loosely packed
items, which can shift during a
ride.
•Securely pack the heaviest items
close to the center of the motorcy-
cle and distribute the weight even-
ly on both sides.
•Adjust the suspension and tire air
pressure with regard to the load.
•Check the tire condition and air
pressure before each ride.
6-14
6
EAU00658
Tires
To maximize the performance, durability,
and safe operation of your motorcycle,
note the following points regarding the
specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
EW000082WARNING0
•The tire air pressure must be
checked and adjusted on cold tires
(i.e., when the temperature of the
tires equals the ambient tempera-
ture).
•The tire air pressure must be
adjusted in accordance with the
riding speed and with the total
weight of rider, passenger, cargo,
and accessories approved for this
model.
Tire air pressure(measured on cold tires)
Load* Front Rear
230 kPa 250 kPa
Up to 90 kg 2.30 kg/cm
22.50 kg/cm2
2.30 bar 2.50 bar
250 kPa 270 kPa
90 kg-maximum 2.50 kg/cm
22.70 kg/cm2
2.50 bar 2.70 bar
Maximum load* 200 kg
* Total weight of rider, passenger, cargo and acces-
sories.

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
EAU00684WARNING0
•This motorcycle is fitted with
super-high-speed tires. Note the
following points in order to make
the most efficient use of these
tires.
•Use only the specified replace-
ment tires. Other tires may run the
danger of bursting at super high
speeds.
•Brand-new tires can have a rela-
tively poor grip on certain road
surfaces until they have been
“broken in”.
•Therefore, it is advisable before
doing any high-speed riding to
ride conservatively for approxi-
mately 100 km (60 mi) after
installing a new tire.
•The tires must be warmed up
before a high-speed run.
•Always adjust the tire air pressure
according to the operating condi-
tions.
EAU03773
Cast wheels
To maximize the performance, durability,
and safe operation of your motorcycle,
note the following points regarding the
specified wheels.
The wheel rims should be checked for
cracks, bends or warpage before each
ride. If any damage is found, have a Yama-
ha dealer replace the wheel. Do not at-
tempt even the smallest repair to the
wheel. A deformed or cracked wheel must
be replaced.
The wheel should be balanced whenever
either the tire or wheel has been changed
or replaced. An unbalanced wheel can re-
sult in poor performance, adverse han-
dling characteristics, and a shortened tire
life.
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FRONT
REAR
Manufacturer Size Type
Dunlop 120/70-ZR17 (58W) D205F TL
Metzeler 120/70-ZR17 (58W) MEZ3F TL
Manufacturer Size Type
Dunlop 170/60-ZR17 (72W) D205 TL
Metzeler 170/60-ZR17 (72W) MEZ3 TL

EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR
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c
b
a
Ride at moderate speeds after changing a
tire since the tire surface must first be “bro-
ken in” for it to develop its optimal charac-
teristics.
1. Locknut
2. Free play adjusting bolt
c. Clutch lever free play
EAU00692
Adjusting the clutch lever
free play
The clutch lever free play should measure
5-10 mm as shown. Periodically check the
clutch lever free play and, if necessary, ad-
just it as follows.1. Loosen the locknut at the clutch lever.
2. To increase the clutch lever free play,
turn the adjusting bolt in direction a.
To decrease the clutch lever free play,
turn the adjusting bolt in direction b.
3. Tighten the locknut.
NOTE:
If the specified free play cannot be
obtained as described above or if the
clutch does not operate correctly, have a
Yamaha dealer check the internal clutch
mechanism.
6-17
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EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR
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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
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