2002 YAMAHA BT1100 service

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1EAU00464
Safety is an obligation of the owner. Peri-
odic inspection, adjustment and lubrication
will keep your vehicle in the safest and
most efficient condition possible. The most
important points of inspection, adjustment,
and lubrication are explained on the fol-
lowing pages.
The intervals given in the periodic mainte-
nance and lubrication chart should be sim-
ply considered as a general guide under
normal riding conditions. However, DE-
PENDING ON THE WEATHER, TER-
RAIN, GEOGRAPHICAL LOCATION,
AND INDIVIDUAL USE, THE MAINTE-
NANCE INTERVALS MAY NEED TO BE
SHORTENED.
EW000060WARNING0
If you are not familiar with motorcycle
maintenance work, have a Yamaha
dealer do it for you.
1. Owner’s tool kit
EAU01129
Owner’s tool kit
The owner’s tool kit is located inside the
storage compartment (see page 3-13 for
storage compartment opening proce-
dures).
The service information included in this
manual and the tools provided in the own-
er’s tool kit are intended to assist you in
the performance of preventive mainte-
nance and minor repairs. However, addi-
tional tools such as a torque wrench may
be necessary to perform certain mainte-
nance work correctly.
NOTE:
If you do not have the tools or experience
required for a particular job, have a Yama-
ha dealer perform it for you.
EW000063WARNING0
Modifications not approved by Yamaha
may cause loss of performance and
render the vehicle unsafe for use. Con-
sult a Yamaha dealer before attempting
any changes.
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EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR
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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.
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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.

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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.
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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.

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1. Nut (x 2) 1. Bulb socket
2. Bulb
PERIODIC MAINTENANCE AND MINOR REPAIR
1
1 2
1. Brake caliper (x 2)
2. Wheel axle pinch bolt
3. Wheel axle
4. Spacer (x 2)








EAUB0019
Replacing the license plate
light bulb
1. Remove the license plate light by re-
moving the nuts.
2. Remove the bulb socket from the li-
cense plate light by pulling it out.
3. Remove the defective bulb by pulling
it out.
4. Insert a new bulb into the socket.
5. Install the bulb socket into the license
plate light.
6. Install the license plate light by in-
stalling the nuts.
EAUB0015
Front wheel
To remove the front wheel
EW000122WARNING0
It is advisable to have a Yamaha dealer
service the wheel.
Securely support the motorcycle so
that there is no danger of it falling over.
1. Mark either side of the wheel so that it
can be installed in the original running
direction.
2. Remove the brake calipers by remov-
ing the bolts.
ECA00047
Do not pull the brake lever after the
brake caliper has been removed, other-
wise the brake pads will be forced shut.
3. Loosen the front wheel axle pinch
bolt, then the wheel axle.
4. Pull the wheel axle out together with
the spacers, and then remove the
wheel.
CAUTION:
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EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR
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To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Install the spacers and insert the
wheel axle.
3. Lower the front wheel so that it is on
the ground.
4. Install the brake calipers by installing
the bolts.
NOTE:
Make sure that there is enough space
between the brake pads before installing
the brake calipers onto the brake discs.5. Tighten the wheel axle, then the front
wheel axle pinch bolt, and the brake
caliper bolts to the specified torques.EAUB0017
Rear wheel
To remove the rear wheel
EW000122WARNING0
It is advisable to have a Yamaha dealer
service the wheel.
Securely support the motorcycle so
that there is no danger of it falling over.
1. Loosen the rear wheel axle pinch
bolt, and then remove the axle nut.
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6
6. Push down hard on the handlebar
several times to check for proper fork
operation. Tightening torques:
Wheel axle:
75 Nm (7.5 m·kgf)
Front wheel axle pinch bolt:
25 Nm (2.5 m·kgf)
Brake caliper bolt:
42 Nm (4.2 m·kgf)
1. Wheel axle pinch bolt
2. Axle nut
3. Brake torque rod bolt



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Troubleshooting
Although Yamaha motorcycles receive a
thorough inspection before shipment from
the factory, trouble may occur during oper-
ation. Any problem in the fuel, compres-
sion, or ignition systems, for example, can
cause poor starting and loss of power.
The following troubleshooting chart repre-
sents a quick and easy procedure for
checking these vital systems yourself.However, should your motorcycle require
any repair, take it to a Yamaha dealer,
whose skilled technicians have the neces-
sary tools, experience, and know-how to
service the motorcycle properly.
Use only genuine Yamaha replacement
parts. Imitation parts may look like Yama-
ha parts, but they are often inferior, have a
shorter service life and can lead to expen-
sive repair bills.
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SPECIFICATIONSEAU01038
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Specifications
ModelBT1100
Dimensions
Overall length 2,200 mm
Overall width 800 mm
Overall height 1,140 mm
Seat height 812 mm
Wheelbase 1,530 mm
Ground clearance 168 mm
Minimum turning radius 2,980 mm
Basic weight
(with oil and full fuel tank)250.5 kg
Engine
Engine type Air-cooled 4-stroke,
SOHC
Cylinder arrangement V type 2-cylinder
Displacement 1,063 cm
3
Bore x stroke 95.0 x 75.0 mm
Compression ratio 8.3 : 1
Starting system Electric starter
Lubrication system Wet sumpEngine oil
Ty p e
Recommended API Service SE, SF, SG or
engine oil classification higher
Be sure to use motor oils that do not contain anti-friction modifiers.
Passenger car motor oils (often labeled “ENERGY CONSERVING II”)
contain anti-friction additives which will cause clutch and/ or starter
clutch slippage, resulting in reduced component life and poor
engine performance.8
Quantity
Without oil filter
cartridge replacement 3.0 L
With oil filter cartridge
replacement 3.1 L
Total amount
(dry engine) 3.6 L
CAUTION:
-20-10 0 1020304050°C
SAE 10W-30
SAE 10W-40
SAE 20W-40
SAE 15W-50
SAE 15W-40