2003 YAMAHA BT1100 ABS

12
3
456
1. Starter (choke) lever(page 3-12)
2. Storage compartment(page 3-14)
3. Tool kit(page 6-1)
4. Spring preload adjusting ring (shock absorber assembly) (page 3-15)
5. Shift pedal(page 3-10)
6. Engine oil level window (page 6-6)
DESCRIPTION
Left view
EAU00026
2-1
2

3
Main switch/steering lock .................................................................... 3-1
Indicator and warning lights ................................................................ 3-2
Speedometer unit ................................................................................ 3-3
Tachometer ........................................................................................ 3-6
Self-diagnosis device .......................................................................... 3-6
Anti-theft alarm (optional) .................................................................... 3-8
Handlebar switches ............................................................................ 3-8
Clutch lever ........................................................................................ 3-9
Shift pedal ........................................................................................ 3-10
Brake lever ........................................................................................ 3-10
Brake pedal ...................................................................................... 3-10
Fuel tank cap .................................................................................... 3-11
Fuel .................................................................................................. 3-11
Fuel tank breather hose .................................................................... 3-12
Starter (choke) lever ........................................................................ 3-12
Seat .................................................................................................. 3-13
Helmet holders .................................................................................. 3-14
Storage compartment ...................................................................... 3-14
Adjusting the front fork ...................................................................... 3-15
Adjusting the shock absorber assembly .......................................... 3-15
Sidestand .......................................................................................... 3-16
Ignition circuit cut-off system ............................................................ 3-17
INSTRUMENT AND CONTROL FUNCTIONSEAU00027

INSTRUMENT AND CONTROL FUNCTIONS
1. Spring preload adjusting bolt 1. Setting
2. Front fork cap bolt




1. Spring preload adjusting nut
2. Locknut
EAU00285
Adjusting the front fork
This front fork is equipped with spring pre-
load adjusting bolts.
EW000035WARNING0
Always adjust both fork legs equally,
otherwise poor handling and loss of
stability may result.
Adjust the spring preload as follows.
To increase the spring preload and thereby
harden the suspension, turn the adjusting
bolt on each fork leg in direction a. To de-
crease the spring preload and thereby
soften the suspension, turn the adjusting
bolt on each fork leg in direction b.
NOTE:
Align the appropriate groove on the adjust-
ing mechanism with the top of the front
fork cap bolt.
EAUB0007
Adjusting the shock absorber
assembly
This shock absorber assembly is equipped
with a spring preload adjusting nut.
EC000015
Never attempt to turn an adjusting
mechanism beyond the maximum or
minimum settings.
Adjust the spring preload as follows.
1. Loosen the locknut.
2. To increase the spring preload and
thereby harden the suspension, turn
the adjusting nut in direction a. To
CAUTION:
3-15
3
EAU00027
Minimum (soft) Standard Maximum (hard)
Setting 1 2 3 4 5 6 7

INSTRUMENT AND CONTROL FUNCTIONS
decrease the spring preload and
thereby soften the suspension, turn
the adjusting nut in direction b.
NOTE:
Use the special wrench included in the
owner’s tool kit to make the adjustment.
The spring preload setting is determined
by measuring distance A, shown in the
illustration. The longer distance A is, the
higher the spring preload; the shorter dis-
tance A is, the lower the spring preload.
With each complete turn of the adjusting
nut, distance A changes by 1.5 mm.3. Tighten the locknut to the specified
torque.• Always have a Yamaha dealer ser-
vice the shock absorber.
EAU00330
Sidestand
The sidestand is located on the left side of
the frame. Raise the sidestand or lower it
with your foot while holding the motorcycle
upright.
NOTE:
The built-in sidestand switch is part of the
ignition circuit cut-off system, which cuts
the ignition in certain situations. (See fur-
ther down for an explanation of the ignition
circuit cut-off system).
3-16
3
Spring preload:
Minimum (soft):
Distance A = 170 mm
Standard:
Distance A = 162 mm
Maximum (hard):
Distance A = 154 mm
Tightening torque:
Locknut:
45 Nm (4.5 m•kg)
EAU00315WARNING0
This shock absorber contains highly
pressurized nitrogen gas. For proper
handling, read and understand the fol-
lowing information before handling the
shock absorber. The manufacturer can-
not be held responsible for property
damage or personal injury that may
result from improper handling.
•Do not tamper with or attempt to
open the gas cylinder.
•Do not subject the shock absorber
to an open flame or other high heat
sources, otherwise it may explode
due to excessive gas pressure.
•Do not deform or damage the gas
cylinder in any way, as this will
result in poor damping perfor-
mance.
EAU00027

EAU00462
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
6-3
6

MOTORCYCLE CARE AND STORAGE
After cleaning
1. Dry the motorcycle with a chamois or
an absorbing cloth.
2. Use a chrome polish to shine chrome,
aluminum and stainless-steel parts,
including the exhaust system. (Even
the thermally induced discoloring of
stainless-steel exhaust systems can
be removed through polishing).
3. To prevent corrosion, it is recom-
mended to apply a corrosion protec-
tion spray on all metal, including
chrome- and nickel-plated, surfaces.
4. Use spray oil as a universal cleaner
to remove any remaining dirt.
5. Touch up minor paint damage caused
by stones, etc.
6. Wax all painted surfaces.
7. Let the motorcycle dry completely be-
fore storing or covering it.EWA00031WARNING0
•Make sure that there is no oil or
wax on the brakes or tires.
•If necessary, clean the brake discs
and brake linings with a regular
brake disc cleaner or acetone, and
wash the tires with warm water
and a mild detergent. Before riding
at higher speeds, test the motorcy-
cle’s braking performance and cor-
nering behavior.
ECA00013
•Apply spray oil and wax sparingly
and make sure to wipe off any
excess.
•Never apply oil or wax to any rub-
ber and plastic parts, but treat
them with a suitable care product.
•Avoid using abrasive polishing
compounds as they will wear away
the paint.
NOTE:
Consult a Yamaha dealer for advice on
what products to use.
CAUTION:
7-3
7
EAU03412

SPECIFICATIONS
8-3
8
EAU01038
Tire air pressure
(measured on cold tires)
Up to 90 kg*
Front 230 kPa; 2.30 kg/cm
2; 2.30 bar
Rear 250 kPa; 2.50 kg/cm
2; 2.50 bar
90 kg–maximum*
Front 250 kPa; 2.50 kg/cm
2; 2.50 bar
Rear 270 kPa; 2.70 kg/cm
2; 2.70 bar
* Total weight of rider, passenger, cargo and accessories
Wheels
Front
Type Cast wheel
Size 17 x MT 3.50
Rear
Type Cast wheel
Size 17 x MT 5.50
Brakes
Front:
Type Dual disc brake
Operation Right hand
Fluid DOT 4Rear:
Type Single disc brake
Operation Right foot
Fluid DOT 4
Suspension
Front: Telescopic fork
Rear: Swingarm
(link suspension)
Spring/shock absorber
Front: Coil spring / oil damper
Rear: Coil spring / gas-oil damper,
spring preload adjustable
Wheel travel
Front: 130 mm
Rear: 113 mm
Electrical system
Ignition system Transistorized coil ignition
(digital)
Charging system
Type A.C. magneto
Standard output 14V, 350W at 5,000 r/min

INDEX
Periodic maintenance
and minor repair ..................................6-1
Pre-operation check list ..........................4-1
Pre-operation checks..............................4-1
R
Rear wheel
Installing ............................................6-34
Removing ..........................................6-33
S
Safety information ..................................1-1
Seat ......................................................3-13
Self-diagnosis device..............................3-6
Shift pedal ............................................3-10
Adjusting the pedal position ..............6-21
Shifting ....................................................5-3
Shock absorber assembly
adjusting ............................................3-15
Sidestand ..............................................3-16
Sidestand, checking
and lubricating ....................................6-24
Spark plugs, checking ............................6-5
Specifications..........................................8-1
Conversion table ..................................8-5
Speedometer unit ..................................3-3
Starter (choke) lever ............................3-12
Starting a cold engine ............................5-1
Starting a warm engine ..........................5-3
Start switch ............................................3-9
Steering, checking ................................6-25
Steering lock ..........................................3-1Storage ..................................................7-4
Storage compartment ..........................3-14
T
Tachometer ............................................3-6
Tail/brake light bulb, replacing ..............6-31
Throttle cable free play, adjusting ........6-13
Throttle grip and cable, checking and
lubricating ..........................................6-22
Tires ......................................................6-14
Air pressure ........................................6-14
Tool kit ....................................................6-1
Troubleshooting ....................................6-35
Troubleshooting chart ..........................6-36
Turn signal indicator light........................3-2
Turn signal light bulb, replacing............6-31
Turn signal switch ..................................3-8
V
Valve clearance, adjusting ....................6-13
Vehicle identification number ..................9-1
W
Wheel bearings, checking ....................6-25
Wheels, cast ........................................6-16