2002 YAMAHA BT1100 Owners Manual

PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03370
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.
EAU03164
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.
EAU00462
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Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)

EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR
EAU02939
Checking the front fork
The condition and operation of the front
fork must be checked as follows at the in-
tervals specified in the periodic mainte-
nance and lubrication chart.
To check the condition
EW000115WARNING0
Securely support the motorcycle so
that there is no danger of it falling over.
Check the inner tubes for scratches, dam-
age and excessive oil leakage.
To check the operation
1. Place the motorcycle on a level sur-
face and hold it in an upright position.
2. While applying the front brake, push
down hard on the handlebars several
times to check if the front fork com-
presses and rebounds smoothly.
EC000098
If any damage is found or the front fork
does not operate smoothly, have a
Yamaha dealer check or repair it.
CAUTION:
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6
EAU03165
Checking and lubricating the
sidestand
The operation of the sidestand should be
checked before each ride, and the side-
stand pivot and metal-to-metal contact sur-
faces should be lubricated if necessary.
EW000113WARNING0
If the sidestand does not move up and
down smoothly, have a Yamaha dealer
check or repair it.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)

EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00794
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the operation of
the steering must be checked as follows at
the intervals specified in the periodic main-
tenance and lubrication chart.
1. Place a stand under the engine to
raise the front wheel off the ground.
EW000115WARNING0
Securely support the motorcycle so
that there is no danger of it falling over.
2. Hold the lower ends of the front fork
legs and try to move them forward
and backward. If any free play can be
felt, have a Yamaha dealer check or
repair the steering.
EAU01144
Checking the wheel bearings
The front and rear wheel bearings must be
checked at the intervals specified in the
periodic maintenance and lubrication
chart. If there is play in the wheel hub or if
the wheel does not turn smoothly, have a
Yamaha dealer check the wheel bearings.
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EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00800
Battery
This motorcycle is equipped with a sealed-
type (MF) battery, which does not require
any maintenance. There is no need to
check the electrolyte or to add distilled wa-
ter.
EC000101
Never attempt to remove the battery
cell seals, as this would permanently
damage the battery.
EW000116WARNING0
•Electrolyte is poisonous and dan-
gerous since it contains sulfuric
acid, which causes severe burns.
Avoid any contact with skin, eyes
or clothing and always shield your
eyes when working near batteries.
In case of contact, administer the
following FIRST AID.
CAUTION:
•EXTERNAL: Flush with plenty of
water.
•INTERNAL: Drink large quanti-
ties of water or milk and imme-
diately call a physician.
•EYES: Flush with water for 15
minutes and seek prompt med-
ical attention.
•Batteries produce explosive
hydrogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and provide
sufficient ventilation when charg-
ing it in an enclosed space.
•KEEP THIS AND ALL BATTERIES
OUT OF THE REACH OF CHIL-
DREN.
6-26
6
12
1
2
+
-
1. Screw (x 2)
2. Storage compartment1. Positive battery terminal
2. Negative battery terminal

EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR
To charge the battery
Have a Yamaha dealer charge the battery
as soon as possible if it seems to have dis-
charged. Keep in mind that the battery
tends to discharge more quickly if the mo-
torcycle is equipped with optional electrical
accessories.To store the battery
1. If the motorcycle will not be used for
more than one month, remove the
battery, fully charge it, and then place
it in a cool, dry place.
2. If the battery will be stored for more
than two months, check it at least
once a month and fully charge it if
necessary.
3. Fully charge the battery before instal-
lation.
4. After installation, make sure that the
battery leads are properly connected
to the battery terminals.EC000102
•Always keep the battery charged.
Storing a discharged battery can
cause permanent battery damage.
•To charge a sealed-type (MF) bat-
tery, a special (constant-voltage)
battery charger is required. Using
a conventional battery charger will
damage the battery. If you do not
have access to a sealed-type (MF)
battery charger, have a Yamaha
dealer charge your battery.
CAUTION:
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EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR
128
1
7
9
2
3
546
EAUB0012
Replacing the fuses
The fuse box is located under the seat.
(See page 3-13 for seat removal and in-
stallation procedures). If a fuse is blown,
replace it as follows.
1. Turn the key to “
B” (OFF) and turn
off the electrical circuit in question.
2. Remove the blown fuse, and then in-
stall a new fuse of the specified am-
perage.
1. Screw (x 2)
2. Storage compartment
EC000103
Do not use a fuse of a higher amperage
rating than recommended to avoid
causing extensive damage to the elec-
trical system and possibly a fire.
3. Turn the key to “
I” (ON) and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows again,
have a Yamaha dealer check the
electrical system.
CAUTION:
1. Fuse box cover
2. Main fuse
3. Headlight fuse
4. Signaling system fuse
5. Ignition fuse
6. Backup fuse (odometer)
7. Carburetor heater fuse
8. Spare fuse (x 4)
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Specified fuses:
Main fuse: 30 A
Backup fuse
(odometer): 5 A
Ignition fuse: 10 A
Headlight fuse: 15 A
Carburetor heater fuse 15 A
Signaling system fuse: 10 A

1. Screw (x 2)
2. Cowling
PERIODIC MAINTENANCE AND MINOR REPAIR
2
1
1
2
1
1
EAUB0013
Replacing the headlight and
auxiliary light bulb
This motorcycle is equipped with a quartz
bulb headlight. If the headlight bulb or aux-
iliary light bulb burns out, replace it as fol-
lows.
NOTE:
Skip steps 6-10 if only the headlight bulb is
being replaced. Skip steps 2-5 if only the
auxiliary light bulb is being replaced.1. Remove the headlight by removing
the screws, then tilt the cowling for-
ward.
2. Disconnect the headlight coupler and
the auxiliary light leads, and then re-
move the headlight bulb cover.
3. Remove the headlight bulb holder by
turning it counterclockwise, and then
remove the defective bulb.
EW000119WARNING0
Headlight bulbs get very hot. There-
fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled down.
4. Place a new bulb into position, and
then secure it with the bulb holder.
EAU00462
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1. Headlight bulb cover
2. Auxiliary light bulb holder1. Headlight coupler

PERIODIC MAINTENANCE AND MINOR REPAIR
1
1
2
EC000105
Do not touch the glass part of the head-
light bulb to keep it free from oil, other-
wise the transparency of the glass, the
luminosity of the bulb, and the bulb life
will be adversely affected.
Thoroughly clean off any dirt and fin-
gerprints on the headlight bulb using a
cloth moistened with alcohol or thin-
ner.
CAUTION:5. Install the headlight bulb cover, and
then connect the coupler and auxil-
iary light leads.
6. Remove the socket (together with the
bulb) by turning it counterclockwise.
7. Remove the defective bulb by push-
ing it in and turning it counterclock-
wise.
8. Insert a new bulb into the socket,
push it in, and then turn it clockwise
until it stops.
9. Install the socket (together with the
bulb) by turning it clockwise.10. Connect the auxiliary light bulb leads.
11. Tilt the cowling back to the original
position, and then install the headlight
by installing the screws.
EAU00462
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1. Headlight bulb holder 1. Do not touch this area 1. Auxiliary light bulb holder
2. Auxiliary light bulb