2003 YAMAHA BT1100 tires

PRE-OPERATION CHECKSEAU01114
4-2
4
ITEM CHECK PAGE
• Check operation.
• Lubricate cable if necessary.
Clutch
• Check lever free play.3-9, 6-17, 6-23
• Adjust if necessary.
• Make sure that operation is smooth.
• Lubricate throttle grip, housing and cables
Throttle gripif necessary.6-13, 6-22
• Check free play.
• If necessary, have Yamaha dealer make adjustment.
• Make sure that operation is smooth.
Control cables
• Lubricate if necessary.6-22
• Check for damage.
• Check tire condition and tread depth.
Wheels and tires
• Check air pressure.6-13, 6-16
• Correct if necessary.
Brake and shift • Make sure that operation is smooth.
pedals• Lubricate pedal pivoting points if necessary.6-23
Brake and clutch • Make sure that operation is smooth.
levers• Lubricate lever pivoting points if necessary.6-23
• Make sure that operation is smooth.
Sidestand
• Lubricate pivot if necessary.6-24
Chassis • Make sure that all nuts, bolts and screws are properly tightened.
fasteners• Tighten if necessary.–
Instruments, lights, • Check operation.
signals and switches• Correct if necessary.3-2, 3-3, 3-8, 3-9
Engine stop
switch• Check operation.3-9
Sidestand • Check operation of ignition circuit cut-off system.
switch• If system is defective, have Yamaha dealer check vehicle.3-18

6
Owner’s tool kit .............................................................. 6-1
Periodic maintenance and lubrication chart .................... 6-2
Removing and installing panels ...................................... 6-5
Checking the spark plugs ................................................ 6-5
Engine oil and oil filter element ........................................ 6-7
Final gear oil .................................................................... 6-9
Cleaning the air filter element .......................................... 6-10
Adjusting the carburetors ................................................ 6-12
Adjusting the engine idling speed .................................... 6-12
Adjusting the throttle cable free play................................ 6-13
Adjusting the valve clearance .......................................... 6-13
Tires ................................................................................ 6-14
Cast wheels .................................................................... 6-16
Adjusting the clutch lever free play .................................. 6-17
Adjusting the brake pedal position .................................. 6-18
Checking the front and rear brake pads .......................... 6-19
Checking the brake fluid level .......................................... 6-19
Changing the brake fluid .................................................. 6-21
Adjusting the shift pedal position .................................... 6-21
Checking and lubricating the cables ................................ 6-22Checking and lubricating the
throttle grip and cable ...................................................... 6-22
Checking and lubricating the brake and shift
pedals .............................................................................. 6-23
Checking and lubricating the brake and
clutch levers .................................................................... 6-23
Checking and lubricating the sidestand .......................... 6-24
Checking the front fork .................................................... 6-24
Checking the steering ...................................................... 6-25
Checking the wheel bearings .......................................... 6-25
Battery ............................................................................ 6-26
Replacing the fuses ........................................................ 6-28
Replacing the headlight and auxiliary light bulb .............. 6-29
Replacing a turn signal light bulb .................................... 6-31
Replacing the tail/brake light bulb .................................... 6-31
Replacing the license plate light bulb .............................. 6-32
Front wheel ...................................................................... 6-32
Rear wheel ...................................................................... 6-33
Troubleshooting .............................................................. 6-35
Troubleshooting chart ...................................................... 6-36
PERIODIC MAINTENANCE AND MINOR REPAIREAU00462

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

EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR
EWA00012WARNING0
Because loading has an enormous
impact on the handling, braking, per-
formance and safety characteristics of
your motorcycle, you should keep the
following precautions in mind.
•NEVER OVERLOAD THE MOTOR-
CYCLE! Operation of an over-
loaded motorcycle may result in
tire damage, loss of control, or
severe injury. Make sure that the
total weight of rider, passenger,
cargo, and accessories does not
exceed the specified maximum
load for the vehicle.
•Do not carry along loosely packed
items, which can shift during a
ride.
•Securely pack the heaviest items
close to the center of the motorcy-
cle and distribute the weight even-
ly on both sides.
•Adjust the suspension and tire air
pressure with regard to the load.
•Check the tire condition and air
pressure before each ride.
6-14
6
EAU00658
Tires
To maximize the performance, durability,
and safe operation of your motorcycle,
note the following points regarding the
specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
EW000082WARNING0
•The tire air pressure must be
checked and adjusted on cold tires
(i.e., when the temperature of the
tires equals the ambient tempera-
ture).
•The tire air pressure must be
adjusted in accordance with the
riding speed and with the total
weight of rider, passenger, cargo,
and accessories approved for this
model.
Tire air pressure(measured on cold tires)
Load* Front Rear
230 kPa 250 kPa
Up to 90 kg 2.30 kg/cm
22.50 kg/cm2
2.30 bar 2.50 bar
250 kPa 270 kPa
90 kg-maximum 2.50 kg/cm
22.70 kg/cm2
2.50 bar 2.70 bar
Maximum load* 200 kg
* Total weight of rider, passenger, cargo and acces-
sories.

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.
6-15
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
EAU00684WARNING0
•This motorcycle is fitted with
super-high-speed tires. Note the
following points in order to make
the most efficient use of these
tires.
•Use only the specified replace-
ment tires. Other tires may run the
danger of bursting at super high
speeds.
•Brand-new tires can have a rela-
tively poor grip on certain road
surfaces until they have been
“broken in”.
•Therefore, it is advisable before
doing any high-speed riding to
ride conservatively for approxi-
mately 100 km (60 mi) after
installing a new tire.
•The tires must be warmed up
before a high-speed run.
•Always adjust the tire air pressure
according to the operating condi-
tions.
EAU03773
Cast wheels
To maximize the performance, durability,
and safe operation of your motorcycle,
note the following points regarding the
specified wheels.
The wheel rims should be checked for
cracks, bends or warpage before each
ride. If any damage is found, have a Yama-
ha dealer replace the wheel. Do not at-
tempt even the smallest repair to the
wheel. A deformed or cracked wheel must
be replaced.
The wheel should be balanced whenever
either the tire or wheel has been changed
or replaced. An unbalanced wheel can re-
sult in poor performance, adverse han-
dling characteristics, and a shortened tire
life.
6-16
6
FRONT
REAR
Manufacturer Size Type
Dunlop 120/70-ZR17 (58W) D205F TL
Metzeler 120/70-ZR17 (58W) MEZ3F TL
Manufacturer Size Type
Dunlop 170/60-ZR17 (72W) D205 TL
Metzeler 170/60-ZR17 (72W) MEZ3 TL

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

MOTORCYCLE CARE AND STORAGE
6. Lubricate all control cables and the
pivoting points of all levers and ped-
als as well as of the sidestand/center-
stand.
7. Check and, if necessary, correct the
tire air pressure, and then lift the mo-
torcycle so that both of its wheels are
off the ground. Alternatively, turn the
wheels a little every month in order to
prevent the tires from becoming de-
graded in one spot.
8. Cover the muffler outlets with plastic
bags to prevent moisture from enter-
ing them.9. Remove the battery and fully charge
it. Store it in a cool, dry place and
charge it once a month. Do not store
the battery in an excessively cold or
warm place (less than 0 °C or more
than 30 °C). For more information on
storing the battery, see page 6-27.
NOTE:
Make any necessary repairs before stor-
ing the motorcycle.
7-5
7
EAU03412