2003 YAMAHA BT1100 fuel

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

5
Starting the engine .............................................................................. 5-1
Starting a warm engine ...................................................................... 5-3
Shifting ................................................................................................ 5-3
Tips for reducing fuel consumption .................................................... 5-4
Engine break-in .................................................................................. 5-4
Parking ................................................................................................ 5-5
OPERATION AND IMPORTANT RIDING POINTSEAU00372

OPERATION AND IMPORTANT RIDING POINTS
EAU00373WARNING0
•Become thoroughly familiar with
all operating controls and their
functions before riding. Consult a
Yamaha dealer regarding any con-
trol or function that you do not
thoroughly understand.
•Never start the engine or operate it
in a closed area for any length of
time. Exhaust fumes are poiso-
nous, and inhaling them can cause
loss of consciousness and death
within a short time. Always make
sure that there is adequate ventila-
tion.
•Before starting out, make sure that
the sidestand is up. If the side-
stand is not raised completely, it
could contact the ground and dis-
tract the operator, resulting in a
possible loss of control.
EAU03818
Starting the engine
In order for the ignition circuit cut-off sys-
tem to enable starting, one of the following
conditions must be met:
•The transmission is in the neutral po-
sition.
•The transmission is in gear with the
clutch lever pulled and the sidestand
up.
EW000054WARNING0
•Before starting the engine, check
the function of the ignition circuit
cut-off system according to the
procedure described on page 3-18.
•Never ride with the sidestand
down.
1. Turn the key to “I” (ON) and make
sure that the engine stop switch is set
to “
I”.
EC000035
If the fuel level warning light comes on,
check the fuel level, and, if necessary,
refuel as soon as possible.
2. Shift the transmission into the neutral
position.
When the transmission is in the neu-
tral position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical
circuit.
3. Turn the starter (choke) on and com-
pletely close the throttle. (See page
3-12 for starter (choke) operation).
CAUTION:
5-1
5
EAU00372

OPERATION AND IMPORTANT RIDING POINTS
1
b
a
4. Start the engine by pushing the start
switch.
NOTE:
If the engine fails to start, release the start
switch, wait a few seconds, and then try
again. Each starting attempt should be as
short as possible to preserve the battery.
Do not crank the engine more than 10 sec-
onds on any one attempt.
1. Starter (choke) lever
a. Starter (choke) turned on
b. Starter (choke) turned off
EC000038
The oil level warning light and fuel lev-
el warning light should come on when
the start switch is pushed, and they
should go off when the start switch is
released.
If the oil level warning light flickers or
remains on after starting, immediately
stop the engine, and then check the
engine oil level and the vehicle for oil
leakage. If necessary, add engine oil,
and then check the warning light again.
If the warning light does not come on
when pushing the start switch, or if it
does not go off after starting with suffi-
cient engine oil, have a Yamaha dealer
check the electrical circuit.
If the fuel level warning light remains
on after starting, stop the engine, and
then check the fuel level. If necessary,
refuel as soon as possible, and then
check the warning light again. If the
warning light does not come on when
pushing the start switch, or if it does
not go off after starting with sufficient
fuel, have a Yamaha dealer check the
electrical circuit.
CAUTION:5. After starting the engine, move the
starter (choke) knob/lever back
halfway.
ECA00045
For maximum engine life, never accel-
erate hard when the engine is cold!
6. When the engine is warm, turn the
starter (choke) off.
NOTE:
The engine is warm when it responds nor-
mally to the throttle with the starter (choke)
turned off.
CAUTION:
EAU00372
5-2
5

OPERATION AND IMPORTANT RIDING POINTS
EAU00424
Tips for reducing fuel
consumption
Fuel consumption depends largely on your
riding style. Consider the following tips to
reduce fuel consumption:
•Thoroughly warm up the engine.
•Turn the starter (choke) off as soon
as possible.
•Shift up swiftly, and avoid high engine
speeds during acceleration.
•Do not rev the engine while shifting
down, and avoid high engine speeds
with no load on the engine.
•Turn the engine off instead of letting it
idle for an extended length of time
(e.g., in traffic jams, at traffic lights or
at railroad crossings).
5-4
5
EAU00372
EAU01128
Engine break-in
There is never a more important period in
the life of your engine than the period be-
tween 0 and 1,600 km (1,000 mi). For this
reason, you should read the following ma-
terial carefully.
Since the engine is brand new, do not put
an excessive load on it for the first 1,600
km (1,000 mi). The various parts in the en-
gine wear and polish themselves to the
correct operating clearances. During this
period, prolonged full-throttle operation or
any condition that might result in engine
overheating must be avoided.
EAU01171
0-1,000 km (0-600 mi)
Avoid prolonged operation above 1/3 throt-
tle.
1,000-1,600 km (600-1,000 mi)
Avoid prolonged operation above 1/2 throt-
tle.
EC000056
After 1,000 km (600 mi) of operation,
the engine oil and final gear oil must be
changed, and the oil filter cartridge/ele-
ment replaced.
1,600 km (1,000 mi) and beyond
The vehicle can now be operated normal-
ly.
EC000049
If any engine trouble should occur dur-
ing the engine break-in period, immedi-
ately have a Yamaha dealer check the
vehicle.
CAUTION:
CAUTION:

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

EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR
2 1
6. Check the final gear case for oil leak-
age. If oil is leaking, check for the
cause.
EAUB0008
Cleaning the air filter element
The air filter element should be cleaned at
the intervals specified in the periodic main-
tenance and lubrication chart. Clean the
air filter element more frequently if you are
riding in unusually wet or dusty areas. 4. Add the recommended final gear oil
to the brim of the filler hole.
NOTE:
GL4 is a quality rating. Hypoid gear oils
rated GL5 or GL6 may also be used.
5. Install and tighten the oil filler bolt.1. Remove the seat. (See page 3-13 for
seat removal and installation proce-
dures).
2. Remove panels 1 and 2. (See page
6-5 for panel removal and installation
procedures).
3. Remove the fuel tank bolts.
6-10
6
Tightening torque:
Final gear oil drain bolt:
23 Nm (2.3 m·kgf)
Recommended final gear oil:
Hypoid gear oil SAE 80 (API GL4)
or multi-grade hypoid gear oil
SAE 80W-90
Oil quantity:
0.2 L
3. Install the final gear oil drain bolt, and
then tighten it to the specified torque.
1. Fuel tank right bolt (x 2)
2. Fuel tank left bolt (x 2)


1. Left panel
2. Right panel

PERIODIC MAINTENANCE AND MINOR REPAIR
23
1
5. Remove the air filter case cover by
removing the screws.
6. Pull the air filter element out.
7. Lightly tap the air filter element to re-
move most of the dust and dirt, and
then blow the remaining dirt out with
compressed air as shown. If the air fil-
ter element is damaged, replace it.
8. Insert the air filter element into the air
filter case.
1. Screw
2. Air filter case cover
3. Air filter
ECA00089
The engine should never be operated
without the air filter element installed,
otherwise the piston(s) and/or cylin-
der(s) may become excessively worn.
9. Install the air filter case cover by in-
stalling the screws.
10. Install the fuel tank by installing the
bolts.
11. Install the panels.
CAUTION:
EAU00462
6-11
6
4. Lift the fuel tank to position it away
from the air filter case. (Do not dis-
connect the fuel hoses!).
EW000071WARNING0
Make sure that the fuel tank is well sup-
ported.
Do not tilt or pull the fuel tank too much,
otherwise the fuel hoses may come
loose, which could cause fuel leakage.