Yamaha BT1100 2002 User manual

BT1100

SERVICE MANUAL

2002

5JN1-AE1

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EASB0000

BT1100 2002

SERVICE MANUAL

First edition, November 2001

unauthorized use without the written

permission of Belgarda S.p.A.

is expressly prohibited.

Printed in Italy

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EASB0001

NOTICE

This manual was produced by the Belgarda S.p.A. primarily for use by Yamaha dealers and their quali-

fied mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore,

anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic

understanding of mechanics and the techniques to repair these types of vehicles. Repair and mainte-

nance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit

for use.

Belgarda S.p.A. is continually striving to improve all of its models. Modifications and significant changes

in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in

future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFE-

TY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to

the motorcycle operator, a bystander or a person checking or repairing the

motorcycle.

A CAUTION indicates special precautions that must be taken to avoid damage

to the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

CAUTION:

WARNING

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EAS00007

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive ex-

planations of all installation, removal, disassembly, assembly, repair and check procedures are laid out

with the individual steps in sequential order.

1The manual is divided into chapters.An abbreviation and symbol in the upper right corner of each page

indicate the current chapter.

Refer to "SYMBOLS".

2Each chapter is divided into sections. The current section title is shown at the top of each page, except

in Chapter 3 ("PERIODIC CHECKS AND ADJUSTMENTS"), where the sub-section title(s) appears.

3Sub-section titles appear in smaller print than the section title.

4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each re-

moval and disassembly section.

5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a dis-

assembly step.

6Symbols indicate parts to be lubricated or replaced.

Refer to "SYMBOLS".

7Ajob instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts,

notes in jobs, etc.

8Jobs requiring more information (such as special tools and technical data) are described sequentially.

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EB003000

ILLUSTRATED SYMBOLS

The following symbols are not relevant to every

vehicle.

Illustrated symbols 1to 8are printed on the top

right of each page and indicate the subject of

each chapter.

1General information

2Specifications

3Periodic inspections and adjustments

4Engine

5Carburetion

6Chassis

7Electrical

8Troubleshooting

Illustrated symbols 9to yare used to identify

the specifications appearing in the text.

9Can be serviced with engine mounted

0Filling fluid

qLubricant

wSpecial tool

eTorque

rWear limit, clearance

tEngine speed

yElectrical data

Illustrated symbols uto sin the exploded dia-

grams indicate the types of lubricants and lubrica-

tion points.

uApply engine oil

iApply gear oil

oApply molybdenum disulfide oil

pApply wheel bearing grease

aApply lightweight lithium-soap base grease

sApply molybdenum disulfide grease

Illustrated symbols dto fin the exploded dia-

grams indicate the following:

dApply locking agent (LOCTITE®)

fReplace the part

GEN

INFO SPEC

INSP

ADJ ENG

CARB CHAS

ELEC TRBL

SHTG

New

uoi

psa

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GENERAL INFORMATION

TABLE OF CONTENTS

GEN

INFO 1

SPECIFICATIONS SPEC 2

PERIODIC INSPECTION

AND ADJUSTMENTS INSP

ADJ 3

ENGINE ENG 4

CARBURETION CARB 5

CHASSIS CHAS 6

ELECTRICAL ELEC 7

TROUBLESHOOTING TRBL

SHTG 8

E004000

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GEN

INFO

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GEN

INFO

CHAPTER 1.

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION ......................................................................................1-1

VEHICLE IDENTIFICATION NUMBER..........................................................................1-1

MODEL LABEL..............................................................................................................1-1

IMPORTANT INFORMATION ..............................................................................................1-2

PREPARATION FOR REMOVAL PROCEDURES ........................................................1-2

REPLACEMENT PARTS ..............................................................................................1-2

GASKETS, OIL SEALS AND O-RINGS ........................................................................1-2

LOCK WASHERS/PLATES AND COTTER PINS ........................................................1-3

BEARINGS AND OIL SEALS ........................................................................................1-3

CIRCLIPS ......................................................................................................................1-3

CHECKING OF CONNECTIONS ........................................................................................1-4

SPECIAL TOOLS..................................................................................................................1-5

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GEN

INFO

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