Yamaha 2005 BT1100 Manual

BT1100
SUPPLEMENTARY
SERVICE MANUAL
2005
5JN4-AE1

BT1100 2005
SUPPLEMENTARY SERVICE MANUAL
© 2004 by Yamaha Motor Italia S.p.A.
First edition, September 2004
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Italia S.p.A.
is expressly prohibited.
Printed in Italy
FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the Yamaha
BT1100 (2005).
For complete service information procedures it is necessary to use this Supplementary Service Manual to-
gether with the following manuals.
BT1100 SERVICE MANUAL: 5JN1-AE1

NOTICE
This manual was produced by the Yamaha Motor Italia S.p.A. primarily for use by Yamaha dealers and
their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so
it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha motorcy-
cles has a basic understanding of the mechanical ideas and the procedures of motorcycle repair. Repairs
attempted by anyone without this knowledge are likely to render the motorcycle unsafe and unfit for use.
Yamaha Motor Italia S.p.A. is continually striving to improve all its models. Modifications and significant
changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will ap-
pear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFE-
TY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person inspecting or repairing the mo-
torcycle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:

EAS00007
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive ex-
planations of all installation, removal, disassembly, assembly, repair and check procedures are laid out
with the individual steps in sequential order.
1The manual is divided into chapters.An abbreviation and symbol in the upper right corner of each page
indicate the current chapter.
Refer to "SYMBOLS".
2Each chapter is divided into sections. The current section title is shown at the top of each page, except
in Chapter 3 ("PERIODIC CHECKS AND ADJUSTMENTS"), where the sub-section title(s) appears.
3Sub-section titles appear in smaller print than the section title.
4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each re-
moval and disassembly section.
5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a dis-
assembly step.
6Symbols indicate parts to be lubricated or replaced.
Refer to "SYMBOLS".
7Ajob instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts,
notes in jobs, etc.
8Jobs requiring more information (such as special tools and technical data) are described sequentially.

ILLUSTRATED SYMBOLS
The following symbols are not relevant to every
vehicle.
Illustrated symbols 1to 8are printed on the top
right of each page and indicate the subject of
each chapter.
1General information
2Specifications
3Periodic inspections and adjustments
4Engine
5Carburetor
6Chassis
7Electrical system
8Troubleshooting
Illustrated symbols 9to yare used to identify
the specifications appearing in the text.
9Can be serviced with engine mounted
0Filling fluid
qLubricant
wSpecial tool
eTorque
rWear limit, clearance
tEngine speed
yElectrical data
Illustrated symbols uto sin the exploded dia-
grams indicate the types of lubricants and lubrica-
tion points.
uApply engine oil
iApply gear oil
oApply molybdenum disulfide oil
pApply wheel bearing grease
aApply lightweight lithium-soap base grease
sApply molybdenum disulfide grease
Illustrated symbols dto fin the exploded dia-
grams indicate the following:
dApply locking agent (LOCTITE®)
fReplace the part
GEN
INFO SPEC
INSP
ADJ ENG
CARB CHAS
ELEC TRBL
SHTG
New
12
34
?
56
78
90
qw
er
ty
uoi
psa
df

CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS.................................................................................... 1
MAINTENANCE SPECIFICATIONS – ENGINE ........................................................ 4
LUBRICATION CHART .............................................................................................. 10
TIGHTENING TORQUES – ENGINE ........................................................................ 11
MAINTENANCE SPECIFICATIONS – CHASSIS ...................................................... 14
TIGHTENING TORQUES – CHASSIS ...................................................................... 16
MAINTENANCE SPECIFICATIONS – ELECTRICAL ................................................ 18
GENERAL TORQUE SPECIFICATIONS .................................................................. 20
CONVERSION TABLE .............................................................................................. 20
LUBRICATION POINTS AND LUBRICANT TYPES .................................................. 21
LUBRICATION DIAGRAMS ...................................................................................... 23
CABLE ROUTING...................................................................................................... 26
PERIODIC INSPECTIONS AND ADJUSTMENTS
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ........................................ 29
CHASSIS – ADJUSTING THE FRONT BRAKE ........................................................ 31
CHECKING THE FUSES .......................................................................................... 32
ENGINE
ENGINE REMOVAL .................................................................................................. 34
CARBURETION
CARBURETOR .......................................................................................................... 36
CHASSIS
FRONT BRAKE MASTER CYLINDER ...................................................................... 37
FRONT BRAKE CALIPERS ...................................................................................... 39
HANDLEBAR.............................................................................................................. 41
STEERING HEAD – LOWER BRACKET .................................................................. 45
ELECTRICAL
ELECTRICAL COMPONENTS .................................................................................. 47
SWITCHES ................................................................................................................ 49
CHECKING THE BULBS AND BULB SOCKETS ...................................................... 52
IMMOBILIZER SYSTEM ............................................................................................ 55
SELF-DIAGNOSIS DEVICE ...................................................................................... 63
IGNITION SYSTEM.................................................................................................... 68
ELECTRIC STARTING SYSTEM .............................................................................. 73
CHARGING SYSTEM ................................................................................................ 83
LIGHTING SYSTEM .................................................................................................. 86
SIGNALING SYSTEM................................................................................................ 91
FUEL PUMP SYSTEM .............................................................................................. 99
CARBURETOR HEATER SYSTEM .......................................................................... 104
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING.................................................................... 107
WIRING DIAGRAM

1
SPEC
GENERAL SPECIFICATIONS
Item Standard
Model code: BT1100: 5JN4
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
Weight:
Dry (without oil and fuel) 233 kg
Wet (with oil and a full fuel tank) 254 kg
Bias weight (dry) front 109.5 kg
Bias weight (dry) rear 123.5 kg
Bias weight (wet) front 122 kg
Bias weight (wet) rear 132 kg
Maximum load-except motorcycle: 200 kg
Engine:
Engine type Air cooled 4-stroke,
SOHC
Cylinder arrangement V-type 2-cylinder
Displacement 1,063 L
Bore stroke 95 75 mm
Compression ratio 8.3 : 1
Compression pressure (STD) 1,000 kPa (10 kg/cm2, 10 bar) at 400 r/min
Starting system Electric starter
Lubrication system: Wet sump
Engine oil:
Type Temp. °C SAE20W40SE or SAE10W30SE
Recommended engine oil classification:
API Service SE, SF, SG or higher
Final gear oil: Hypoid gear oil SAE 80 (API GL4)
Oil quantity:
Engine oil
Periodic oil change 3.0 L
With oil filter replacement 3.1 L
Total amount 3.6 L
Final gear case oil
Total amount 0.2 L
SPECIFICATIONS
GENERAL SPECIFICATIONS

2
SPEC
GENERAL SPECIFICATIONS
Item Standard
Air filter: Dry type element
Fuel:
Type Regular unleaded gasoline
Fuel tank capacity 20 L
Fuel reserve amount 5.8 L
Carburetor:
Type/quantity BSR37/2
Manufacturer MIKUNI
Spark plug:
Type BPR7ES/W22EPR-U
Manufacturer NGK/DENSO
Spark plug gap 0.7 0.8 mm
Clutch type: Wet, multiple-disc
Transmission:
Primary reduction system Spur gear
Primary reduction ratio 78/47 (1.660)
Secondary reduction system Shaft drive
Secondary reduction ratio 44/47 19/18 32/11 (2.875)
Transmission type Constant mesh 5-speed
Operation Left foot operation
Gear ratio 1st 40/17 (2.353)
2nd 40/24 (1.667)
3rd 36/28 (1.286)
4th 32/31 (1.032)
5th 29/34 (0.853)
Chassis:
Frame type Twin tube Backbone
Caster angle 25°
Trail 106 mm
Tire:
Type Tubeless
Size front 120/70-ZR17 (58W)
rear 170/60-ZR17 (72W)
Manufacturer front DUNLOP / METZELER
rear DUNLOP / METZELER
Type front D205F TL / MEZ3F TL
rear D205 TL / MEZ3 TL
Tire pressure (cold tire):
0 ~ 90 kg load * front 230 kPa (2.30 kg/cm2) (2.30 bar)
rear 250 kPa (2.50 kg/cm2) (2.50 bar)
90 kg (198 lb) ~ Maximum load * front 250 kPa (2.50 kg/cm2) (2.50 bar)
rear 270 kPa (2.70 kg/cm2) (2.70 bar)
* Load is the total weight of the cargo, rider,
passenger and accessories.
Maximum load: 200 kg (total weight of rider, passenger,
cargo and accessories)

3
SPEC
GENERAL SPECIFICATIONS
Item Standard
Brake:
Front brake type Dual disc brake
operation Right hand operation
Rear brake type Single disc brake
operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (link suspension)
Shock absorber:
Front shock absorber Coil spring/Oil damper
Rear shock absorber Coil spring/Gas-oil damper/Spring preload
adjustable
Wheel travel:
Front wheel travel 130 mm
Rear wheel travel 113 mm
Electrical system:
Ignition system T.C.I. (digital)
Generator system A.C. magneto
Battery type GT14B-4
Battery capacity 12V 12Ah
Headlight type: Quartz bulb (halogen)
Bulb voltage, wattage x quantity:
Headlight 12 V 60 W/55 W x 1
Auxiliary light 12 V 5 W x 1
Tail/brake light 12 V 5 W / 21 W x 1
License plate light 12 V 5 W x 1
Front turn signal indicator light 12 V 10 W x 2
Rear turn signal indicator light 12 V 10 W x 2
Meter lighting LED x 12
Neutral indicator light LED x 1
Turn signal light LED x 1
Oil level warning light LED x 1
High beam indicator light LED x 1
Fuel level warning light LED x 1
Immobilizer system light LED x 1

4
SPEC
MAINTENANCE SPECIFICATIONS
Item Standard Limit
Cylinder head:
Volume 57.0 58.4 cm3•••
Warp limit ••• 0.03 mm
Cylinder:
Bore size 95.00 95.01 mm 95.1 mm
Measuring point 40 mm •••
Max. out of round ••• 0.01 mm
Camshaft:
Drive method Chain drive (left & right) •••
Cam cap inside diameter 25.000 25.021 mm •••
Camshaft outside diameter 24.96 24.98 mm •••
Shaft-to-cap clearance 0.020 0.061 mm •••
Cam dimensions:
Intake “A” 39.112 39.212 mm 39.012 mm
“B” #1: 32.093 32.193 mm #1: 31.993 mm
#2: 32,127 32.227 mm #2: 32.027 mm
“C” 7.162 mm 7.012 mm
Exhaust “A” 39.145 39.245 mm 39.045 mm
“B” 32.200 32.300 mm 32.100 mm
“C” 7.195 mm 7.045 mm
Camshaft runout limit ••• 0.03 mm
MAINTENANCE SPECIFICATIONS
ENGINE

5
SPEC
MAINTENANCE SPECIFICATIONS
Item Standard Limit
Timing chain:
Timing chain type/No. of links SILENT 98L •••
Timing chain adjustment method Automatic •••
Rocker arm/rocker arm shaft:
Bearing inside diameter 14.000 mm 14.018 mm 14.036 mm
Shaft outside diameter 13.985 mm 13.991 mm 13.95 mm
Arm-to-shaft clearance 0.009 mm 0.033 mm 0.086 mm
Valve, valve seat, valve guide:
Valve clearance (cold) IN 0.07 0.12 mm •••
EX 0.12 0.17 mm •••
Valve dimensions:
Head Diameter Face Width Seat Width Margin Thickness
“A” head diameter IN 47.0 47.2 mm •••
EX 39.0 39.2 mm •••
“B” face width IN 2.1 mm •••
EX 2.1 mm •••
“C” seat width IN 1.2 1.4 mm 1.8 mm
EX 1.2 1.4 mm 1.8 mm
“D” margin thickness IN 1.1 1.5 mm 0.8 mm
EX 1.1 1.5 mm 0.8 mm
Stem outside diameter IN 7.975 7.990 mm 7.955 mm
EX 7.960 7.975 mm 7.935 mm
Guide inside diameter IN 8.000 8.012 mm 8.042 mm
EX 8.000 8.012 mm 8.042 mm
Stem-to-guide clearance IN 0.010 0.037 mm 0.08 mm
EX 0.025 0.052 mm 0.10 mm

6
SPEC
MAINTENANCE SPECIFICATIONS
Item Standard Limit
Stem runout limit ••• 0.03 mm
Valve seat width IN 1.2 1.4 mm 2.0 mm
EX 1.2 1.4 mm 2.0 mm
Valve spring:
Free length IN 44.6 mm 43.5 mm
EX 44.6 mm 43.5 mm
Set length (valve closed) IN 40 mm •••
EX 40 mm •••
Compressed pressure (installed) IN 160.7 N (16.4 kg) •••
EX 160.7 N (16.4 kg) •••
Spring rate (K1) IN 35.28 N/mm (3.6 kgf/mm) •••
EX 35.28 N/mm (3.6 kgf/mm) •••
Spring rate (K2) IN 45.37 N/mm (4.63 kgf/mm) •••
EX 45.37 N/mm (4.63 kgf/mm) •••
Tilt limit IN ••• 2.5°/1.9 mm
EX ••• 2.5°/1.9 mm
Direction of winding
(top view) IN Clockwise •••
EX Clockwise •••
Piston:
Piston to cylinder clearance 0.025 0.050 mm 0.15 mm
Piston size “D” 94.960 94.975 mm •••
Measuring point “H” 5 mm •••
Piston off-set 0 mm •••
Piston pin bore inside diameter 22.004 22.015 mm 22.045
Piston pin outside diameter 21.991 22.000 mm 21.975

7
SPEC
MAINTENANCE SPECIFICATIONS
Item Standard Limit
Piston rings:
Top ring:
Type Plain •••
Dimensions (B x T) 1.5 3.8 mm •••
End gap (installed) 0.3 0.5 mm 0.8 mm
Side clearance (installed) 0.04 0.08 mm 0.1 mm
2nd ring:
Type Taper •••
Dimensions (B x T) 1.2 3.8 mm •••
End gap (installed) 0.30 0.45 mm 0.8 mm
Side clearance 0.03 0.07 mm 0.1 mm
Oil ring:
Dimensions (B x T) 2.5 3.4 mm •••
End gap (installed) 0.2 0.7 mm •••
Connecting rod:
Oil clearance 0.044 0.073 mm •••
Color code (corresponding size) 1Blue 2Black 3Brown •••
4Green 5Yellow
Crankshaft:
Crank width “A” 101.95 102.00 mm •••
Runout limit “C” ••• 0.02 mm
Big end side clearance “D” 0.320 0.474 mm •••

8
SPEC
MAINTENANCE SPECIFICATIONS
Item Standard Limit
Clutch:
Friction plate thickness 2.9 3.1 mm 2.8 mm
Quantity 8 •••
Clutch plate thickness 2.5 2.7 mm 0.1 mm
Quantity 1 •••
Clutch plate thickness 1.9 2.1 mm 0.1 mm
Quantity 7 •••
Clutch spring free length 7.2 mm 6.5 mm
Quantity 1 •••
Clutch housing thrust clearance 0.05 0.40 mm •••
Clutch housing radial clearance 0.010 0.044 mm •••
Clutch release method Inner push, screw push •••
Push rod bending limit ••• 0.5 mm
Transmission:
Main axle deflection limit ••• 0.08 mm
Drive axle deflection limit ••• 0.08 mm
Shifter:
Shifter type Guide bar •••
Shift fork thickness 5.76 5.89 mm •••
Carburetor:
I. D. mark 5JN4 10 •••
Main jet (M.J) #1:#128.8 - #2:#127.5 •••
Main air jet (M.A.J) #55 •••
Jet needle (J.N) 5DL49-3 •••
Needle jet (N.J) P-0M (826) •••
Pilot air jet (P.A.J.1) #63.8 •••
(P.A.J.2) #142.5 •••
Pilot outlet (P.O) 1.0 •••
Pilot jet (P.J) #17.5 •••
Bypass 1 (B.P.1) 0.8 •••
Bypass 2 (B.P.2) 0.8 •••
Bypass 3 (B.P.3) 0.8 •••
Pilot screw (P.S) 3.0 •••
Valve seat size (V.S) 1.2 •••
Starter jet (G.S.1) #45 •••
Starter jet (G.S.2) 0,9 •••
Throttle valve size (TH.V) #125 •••
Float height (F.H) 11 12 mm •••
Engine idle speed 950 1.050 r/min •••
CO% 4 5% •••
Intake vacuum 32.2 33.6 kPa (-242 -252 mmHg) •••
Engine oil temperature 75 85 °C •••
Fuel pump:
Type Electrical type
Model/manufacturer UC-Z61B/MITSUBISHI •••
Consumption amperage <max> 0.8 A •••
Output pressure 12 kPa (0.12 kf/cm2) •••

9
SPEC
MAINTENANCE SPECIFICATIONS
Item Standard Limit
Lubrication system:
Oil filter type Paper type •••
Oil pump type Trochoid type •••
Tip clearance “A” or “B” 0.03  0.09 mm 0.15 mm
Side clearance 0.03  0.08 mm 0.15 mm
Bypass valve opening pressure 80 120 kPa (0.8 ~ 1.2 kgf/cm2) •••
Relief valve operating pressure 450  550 kPa (4.5 5.5 kgf/cm2) •••
Shaft drive:
Middle gear backlash 0.1  0.2 mm •••
Final gear backlash 0.1  0.2 mm •••

10
SPEC
MAINTENANCE SPECIFICATIONS
Item Standard
Lubrication chart:
Needle bearing (starter) Connecting rod big end
Crankshaft
Main axle
Drive axle
Pinin drive
Middle driveshaft
Rocker arm (IN)
Camshaft (IN)Camshaft (EX) Rocker arm (IN)Rocker arm (EX)Rocker arm (EX)
Oil filter
Oil pump
Relief valve
Oil pan
Pressure feed
Splashed
Orifice

11
SPEC
MAINTENANCE SPECIFICATIONS
Cylinder head tightening sequence:
Crankcase tightening sequence:
Right crankcaseLeft crankcase

12
SPEC
MAINTENANCE SPECIFICATIONS
Part Thread Tightening
Part to be tightened name size Q’ty torque Remarks
N·mm
·kg
Cylinder head Nut M12 8 50 5.0
Cylinder head Nut M10 2 35 3.5
Plate Bolt M8 2 20 2.0
Cylinder head cover Screw M6 4 4 0.4
Cylinder head (exhaust pipe) Stud bolt M8 4 12.5 1.25
Rocker arm shaft Union M16 2 37.5 3.75
bolt
Camshaft sprocket cover Bolt M6 4 10 1.0
Tappet cover Bolt M6 8 10 1.0
Rocker arm shaft Bolt M16 4 38 3.8
(oil passage)
Stopper plate (camshaft) Bolt M8 4 20 2.0 Use lock
washer
Spark plug – M14 2 20 2.0
Cylinder Bolt M6 2 10 1.0
Lower cylinder head cover Bolt M6 6 10 1.0
Upper cylinder head cover Screw M6 8 5 0.5
Connecting rod Nut M9 4 48 4.8
Rotor Nut M16 1 175 17.5
Valve adjusting locknut Nut M8 4 27 2.7
Camshaft sprocket Bolt M10 2 55 5.5
Timing chain tensioner Bolt M6 4 10 1.0
Timing chain tentioner cap Bolt M6 2 8 0.8
Timing chain guide Bolt M6 4 10 1.0
Oil pump Bolt M6 3 10 1.0
Oil strainer cover Bolt M6 3 10 1.0
Oil filter cover Bolt M6 5 10 1.0
Oil pump gear Bolt M6 1 12 1.2
Oil pump cap Bolt M6 1 10 1.0
Oil delivery pipe (cylinder head) Union M16 2 20 2.0
bolt
(crankcase) Union M10 1 20 2.0
bolt
Oil drain bolt – M14 1 43 4.3
Air filter:
Air filter cover fastener Screw M5 2 2 0.2
Carburetor cover fastener Screw M5 4 4.5 0.45
A.I.S. system:
A.I.S. system fastener
(pump and piping) Screw M6 4 10 1.0
A.I.S. system pipe fastener
to engine starter Screw M6 1 10 1.0
A.I.S. pump fastener
to A.I.S. bracket Screw M5 2 8 0.8
Exhaust system:
Cylinder head and exhaust pipe joint Nut M8 4 20 2.0
Exhaust pipe bracket Screw M8 2 25 2.5
Exhaust pipe/exhaust pipe
guard fastener (rear) Screw M8 2 20 2.0
Exhaust pipe strap Screw M8 3 18 1.8
Silencer fastener to passenger
board support Screw M10 2 47 4.7
Exhaust pipe guard fastener Screw M6 2 7 0.7
Tightening torques