2002 YAMAHA BT1100 brake

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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
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6

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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.

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.
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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
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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
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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.
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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.
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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.
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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
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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
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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.
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6

PERIODIC MAINTENANCE AND MINOR REPAIR
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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.
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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.
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6
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)