brake YAMAHA BT1100 2002 Owners Manual

78910
1211
DESCRIPTIONEAU00026
2-2
2
7. Fuse box (page 6-28)
8. Battery (page 6-26)
9. Helmet holders (page 3-14)
10. Air filter element (page 6-10)
11. Engine oil filter element (page 6-6)
12. Brake pedal (page 3-10)
Right view

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0 20
01
80 160 14
0
12
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1
0080
604020k
m
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h345
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7
2
1
0
3456721
8
DESCRIPTIONEAU00026
2-3
2
1. Clutch lever (page 3-9)
2. Left handlebar switches (page 3-8)
3. Instruments and warning lights (page 3-2)
4. Main switch and steering lock (page 3-1)
5. Right handlebar switches (page 3-9)
6. Throttle grip (page 6-13)
7. Front brake lever (page 3-10)
8. Fuel tank cap (page 3-11)
Controls and instruments

3
Main switch/steering lock .................................................................... 3-1
Indicator and warning lights ................................................................ 3-2
Speedometer unit ................................................................................ 3-3
Tachometer ........................................................................................ 3-6
Self-diagnosis device .......................................................................... 3-6
Anti-theft alarm (optional) .................................................................... 3-8
Handlebar switches ............................................................................ 3-8
Clutch lever ........................................................................................ 3-9
Shift pedal ........................................................................................ 3-10
Brake lever ........................................................................................ 3-10
Brake pedal ...................................................................................... 3-10
Fuel tank cap .................................................................................... 3-11
Fuel .................................................................................................. 3-11
Fuel tank breather hose .................................................................... 3-12
Starter (choke) lever ........................................................................ 3-12
Seat .................................................................................................. 3-13
Helmet holders .................................................................................. 3-14
Storage compartment ...................................................................... 3-14
Adjusting the front fork ...................................................................... 3-15
Adjusting the shock absorber assembly .......................................... 3-15
Sidestand .......................................................................................... 3-16
Ignition circuit cut-off system ............................................................ 3-17
INSTRUMENT AND CONTROL FUNCTIONSEAU00027

INSTRUMENT AND CONTROL FUNCTIONS
1
1
2
1
23
4
3
1
EAU00157
Shift pedal
The shift pedal is located on the left side of
the engine and is used in combination with
the clutch lever when shifting the gears of
the 5-speed constant-mesh transmission
equipped on this motorcycle.
EAU00161
Brake lever
The brake lever is located at the right han-
dlebar grip. To apply the front brake, pull
the lever toward the handlebar grip.
The brake lever is equipped with a position
adjusting dial. To adjust the distance be-
tween the brake lever and the handlebar
grip, turn the adjusting dial while holding
the lever pushed away from the handlebar
grip. Make sure that the appropriate set-
ting on the adjusting dial is aligned with the
arrow mark on the brake lever.
EAU00162
Brake pedal
The brake pedal is on the right side of the
motorcycle. To apply the rear brake, press
down on the brake pedal.
3-10
3
1. Shift pedal 1. Brake lever
2. Position adjusting dial
3. Arrow mark1. Brake pedal
EAU00027

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

6
Owner’s tool kit .............................................................. 6-1
Periodic maintenance and lubrication chart .................... 6-2
Removing and installing panels ...................................... 6-5
Checking the spark plugs ................................................ 6-5
Engine oil and oil filter element ........................................ 6-7
Final gear oil .................................................................... 6-9
Cleaning the air filter element .......................................... 6-10
Adjusting the carburetors ................................................ 6-12
Adjusting the engine idling speed .................................... 6-12
Adjusting the throttle cable free play................................ 6-13
Adjusting the valve clearance .......................................... 6-13
Tires ................................................................................ 6-14
Cast wheels .................................................................... 6-16
Adjusting the clutch lever free play .................................. 6-17
Adjusting the brake pedal position .................................. 6-18
Checking the front and rear brake pads .......................... 6-19
Checking the brake fluid level .......................................... 6-19
Changing the brake fluid .................................................. 6-21
Adjusting the shift pedal position .................................... 6-21
Checking and lubricating the cables ................................ 6-22Checking and lubricating the
throttle grip and cable ...................................................... 6-22
Checking and lubricating the brake and shift
pedals .............................................................................. 6-23
Checking and lubricating the brake and
clutch levers .................................................................... 6-23
Checking and lubricating the sidestand .......................... 6-24
Checking the front fork .................................................... 6-24
Checking the steering ...................................................... 6-25
Checking the wheel bearings .......................................... 6-25
Battery ............................................................................ 6-26
Replacing the fuses ........................................................ 6-28
Replacing the headlight and auxiliary light bulb .............. 6-29
Replacing a turn signal light bulb .................................... 6-31
Replacing the tail/brake light bulb .................................... 6-31
Replacing the license plate light bulb .............................. 6-32
Front wheel ...................................................................... 6-32
Rear wheel ...................................................................... 6-33
Troubleshooting .............................................................. 6-35
Troubleshooting chart ...................................................... 6-36
PERIODIC MAINTENANCE AND MINOR REPAIREAU00462

EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03685
Periodic maintenance and lubrication chart
NOTE:
•The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
•From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
•Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
6-2
6
ODOMETER READING (x 1,000 km)ANNUALN0. ITEM CHECK OR MAINTENANCE JOB
1 10203040CHECK
1*Fuel line•Check fuel hoses and vacuum hose for cracks
√√√√ √or damage.
2*Fuel filter•Check condition.√√
•Check condition.
√√
3 Spurk plugs•Clean and regap.
•Replace.√√
4
*Valves•Check valve clearance.
√√√√•Adjust.
5 Air filter element•Clean.√√•Replace.√√
6 Clutch•Check operation.
√√ √√ √
•Adjust.
•Check operation,fluid level and vehicle
for fluid leakeage. √√ √√ √ √
7*Front brake
(See NOTE on page 6-4).
•Replace brake pads. Whenever worm to the limit

EAU00462
ODOMETER READING (x 1,000 km)ANNUALN0. ITEM CHECK OR MAINTENANCE JOB
1 10203040CHECK
•Check operation, fluid level and vehicle
for fluid leakage. √√ √√ √ √
8*Rear brake(See NOTE on page 6-4).
•Replace brake pads. Whenever worm to the limit
9*Brake hoses•Check for cracks or damage.√√√√ √•Replace. (See NOTE on page 6-4). Every 4 years
10*Wheels•Check runout and for damage.√√√√
•Check tread depth and for
damage.
11
*Tires•Replace if necessary.√√√√
•Check air pressure.
•Correct if necessary.
12*Wheel bearings•Check bearing for looseness or damage.√√√√
13*Swingarm•Check operation and for excessive play.√√√√•Lubrificate with lithium-soap-based grease. Every 50,000 km
14*Steering bearings•Check bearing play and steering for roughness.√√ √√ √•Lubrificate with lithium-soap-based grease. Every 20,000 km
15
*Chassis fasteners•Make sure that all nuts, bolts and screws are properly
√√√√ √tightened.
16 Sidestand•Check operation.
√√√√ √
•Lubricate.
17
*Sidestand
•Check operation and for oil leakage.√√ √√ √ √switch
18*Front fork•Check operation and for oil leakage. √√√√
19
*Rear shock absorber
•Check operation and shock absorber for oil leakage.√√√√
assembly
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6

EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03884
NOTE:
•The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
•Hydraulic brake service
•Regularly check and, if necessary, correct the brake fluid level.
•Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.
•Replace the brake hoses every four years and if cracked or damaged.
6-4
6
ODOMETER READING (x 1,000 km)ANNUALN0. ITEM CHECK OR MAINTENANCE JOB
1 10203040CHECK
Rear suspension
•Check operation. √√√√
20*relay arm and
connecting arm
•Lubricate with lithium-soap-based grease.√√
pivoting points
•Check starter (choke) operation.
21
*Carburators•Adjust engine idling speed and √√ √√ √ √synchronization.
22 Engine oil•Change.√√ √√ √ √
23Engine oil filter
•Replace. √√√
element
•Check oil level and vehicle for oil
√√ √
24Final gear
leakage.oil
•Change.√√√
25Moving parts and
•Lubricate.√√√√ √
cables
•Check the air cut valve and reed valve for
26
*Air induction
damage.
√√√√ √
system
•Replace the entire air induction system if
necessary.
27
*Lights, signals and •Check operation.
√√ √√ √ √
switches•Adjust headlight beam.