Yamaha BT1100 2002 User manual

BT1100
SERVICE MANUAL
2002
5JN1-AE1

EASB0000
BT1100 2002
SERVICE MANUAL
© 2001 by Belgarda S.p.A.
First edition, November 2001
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Belgarda S.p.A.
is expressly prohibited.
Printed in Italy

EASB0001
NOTICE
This manual was produced by the Belgarda S.p.A. primarily for use by Yamaha dealers and their quali-
fied mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore,
anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic
understanding of mechanics and the techniques to repair these types of vehicles. Repair and mainte-
nance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit
for use.
Belgarda S.p.A. is continually striving to improve all of its models. Modifications and significant changes
in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in
future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
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 checking or repairing the
motorcycle.
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.
CAUTION:
WARNING

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.

EB003000
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
5Carburetion
6Chassis
7Electrical
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

GENERAL INFORMATION
TABLE OF CONTENTS
GEN
INFO 1
SPECIFICATIONS SPEC 2
PERIODIC INSPECTION
AND ADJUSTMENTS INSP
ADJ 3
ENGINE ENG 4
CARBURETION CARB 5
CHASSIS CHAS 6
ELECTRICAL ELEC 7
TROUBLESHOOTING TRBL
SHTG 8
?
E004000

1
GEN
INFO

GEN
INFO
CHAPTER 1.
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION ......................................................................................1-1
VEHICLE IDENTIFICATION NUMBER..........................................................................1-1
MODEL LABEL..............................................................................................................1-1
IMPORTANT INFORMATION ..............................................................................................1-2
PREPARATION FOR REMOVAL PROCEDURES ........................................................1-2
REPLACEMENT PARTS ..............................................................................................1-2
GASKETS, OIL SEALS AND O-RINGS ........................................................................1-2
LOCK WASHERS/PLATES AND COTTER PINS ........................................................1-3
BEARINGS AND OIL SEALS ........................................................................................1-3
CIRCLIPS ......................................................................................................................1-3
CHECKING OF CONNECTIONS ........................................................................................1-4
SPECIAL TOOLS..................................................................................................................1-5

GEN
INFO

GEN
INFO
MOTORCYCLE IDENTIFICATION
1-1
1
1
EB100010
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1is stamped
into the frame under the seat.
MODEL LABEL
The model label 1is affixed to the frame under
the seat.
This information will be needed to order spare
parts.

GEN
INFO
IMPORTANT INFORMATION
1-2
EB101000
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL PROCEDURES
1. Remove all dirt, mud, dust and foreign materi-
al before removal and disassembly.
2. Use proper tools and cleaning equipment.
Refer to the “SPECIAL TOOLS” section.
3. When disassembling the machine, always
keep mated parts together. This includes
gears, cylinders, pistons and other parts that
have been “mated” through normal wear.
Mated parts must always be reused or
replaced as an assembly.
4. During machine disassembly, clean all parts
and place them in trays in the order of disas-
sembly. This will speed up assembly and
allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EB101010
REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all
replacements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
EB101020
GASKETS, OIL SEALS AND O-RINGS
1. Replace all gaskets, seals and O-rings when
overhauling the engine. All gasket surfaces,
oil seal lips and O-rings must be cleaned.
2. Properly oil all mating parts and bearings dur-
ing reassembly. Apply grease to the oil seal
lips.

GEN
INFO
IMPORTANT INFORMATION
1-3
EB101030
LOCK WASHERS/PLATES AND COTTER PINS
1. Replace all lock washers/plates 1and cotter
pins after removal. Bend lock tabs along the
bolt or nut flats after the bolt or nut has been
tightened to specification.
EB101040
BEARINGS AND OIL SEALS
1. Install bearings and oil seals so that the man-
ufacturer’s marks or numbers are visible.
When installing oil seals, apply a light coating
of lightweight lithium base grease to the seal
lips. Oil bearings liberally when installing, if
appropriate.
1Oil seal
Do not use compressed air to spin the bear-
ings dry. This will damage the bearing sur-
faces.
1Bearing
CAUTION:
EB101050
CIRCLIPS
1. Check all circlips carefully before reassembly.
Always replace piston pin clips after one use.
Replace distorted circlips. When installing a
circlip 1, make sure that the sharp-edged
corner 2is positioned opposite the thrust 3
it receives. See sectional view.
4Shaft
OR

GEN
INFO
CHECKING OF CONNECTIONS
1-4
EB801000
CHECKING OF CONNECTIONS
Check the connectors for stains, rust, moisture,
etc.
1. Disconnect:
• connector
2. Check:
• connector
Moisture →Dry each terminal with an air
blower.
Stains/rust →Connect and disconnect the
terminals several times.
3. Check:
• connector leads
Looseness →Bend up the pin 1and con-
nect the terminals.
4. Connect:
• connector terminals
NOTE:
The two terminals “click” together.
5. Check:
• continuity (using a pocket tester)
NOTE:
• If there is no continuity, clean the terminals.
• When checking the wire harness be sure to per-
form steps 1 to 3.
• As a quick remedy, use a contact revitalizer
available at most part stores.
• Check the connector with a pocket tester as
shown.

GEN
INFO
SPECIAL TOOLS
1-5
EB102001
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only the
appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or
improvised techniques. Special tools may differ by shape and part number from country to country. In
such a case, two types are provided.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No.
Weight
90890-01084
Bolt
90890-01085
Slide hammer bolt/weight
These tools are used to remove the rocker
arm shaft.
90890-01135
Crankcase separating tool
This tool is used to remove the crankshaft.
90890-01229
Coupling gear/middle shaft tool
This tool is needed when removing or
installing the final pinion shaft nut.
Final gear
backlash band
90890-01230
Middle gear
backlash band
90890-01231
Final gear backlash band
This tool is needed when measuring final
gear/middle gear backlash.
Installer pot
90890-01274
Bolt
90890-01275
Adapter
90890-04130
Spacer
90890-04060
Crankshaft installer pot/bolt/adapter/spacer
These tools are used to install the crankshaft.
90890-01304
Piston pin puller
This tool is used to remove the piston pin.
90890-01312
Fuel level gauge
This gauge is used to measure the fuel level
in the float chamber.
Tool name/How to use Illustration

GEN
INFO
SPECIAL TOOLS
1-6
Tool No.
Puller
90890-01362
Adapter
90890-04131
Flywheel puller/adapter
These tools are needed to remove the
rotor.
Weight
90890-01367
Adapter
90890-01374
Fork seal driver weight/adapter
(Ø 43 mm)
These tools are needed when
installing the slide metal, oil seal and
dust seal into the fork.
Ring nut wrench
90890-01403
Exhaust nut
wrench
90890-01268
Ring nut wrench/exhaust and steering
nut wrench
This tool is needed to loosen and tight-
en the steering stem ring nut.
90890-01701
Sheave holder
This tool is needed to hold the rotor
when removing or installing the rotor
bolt.
90890-03081
Compression gauge set
These tools are needed to measure
engine compression.
90890-03094
Vacuum gauge
This gauge is needed for carburetor
synchronization.
90890-03112
Pocket tester
This instrument is needed for checking
the electrical system.
90890-03113
Engine tachometer
This tool is needed for observing
engine r/min.
Tool name/How to use Illustration
T-handle
90890-01326
Holder
90890-01327
T-handle/front fork damper rod holder
These tools are needed to loosen and
tighten the front fork damper rod
holding bolt.

GEN
INFO
SPECIAL TOOLS
1-7
Tool No.
90890-04014
Valve guide remover & installer
This tool is needed to remove and
install the valve guide.
90890-04019
Valve spring compressor
This tool is needed to remove and
install the valve assemblies.
Adapter
90890-01277
Shock puller
90890-01290
Weight
90890-01291
Crankshaft installer bolt adapter/arma-
ture shock puller/weight
These tools are needed when remov-
ing the final pinion shaft.
90890-04137
Bearing retainer wrench
This tool is needed when removing or
installing the middle drive shaft
assembly.
Wrench
90890-04138
Holder
90890-04055
Middle drive shaft nut wrench/Middle
drive shaft holder
These tools are needed when remov-
ing or installing the middle drive shaft
bearing.
90890-04062
Universal joint holder
This tool is needed when removing or
installing the driven pinion gear nut.
90890-04077
Bearing retainer wrench
This tool is needed when removing or
installing the final drive pinion gear
assembly.
Tool name/How to use Illustration
90890-04050
Bearing retainer wrench
This tool is needed when removing or
installing the final shaft drive bearing
retainer.
90890-03141
Timing light
This tool is necessary for checking
ignition timing.

GEN
INFO
ATTREZZI SPECIALI
1-8
Tool No.
90890-04090
Damper spring compressor
This tool is needed when removing or
installing the damper spring.
90890-06754
Dynamic spark tester
Ignition checker
This instrument is necessary for
checking the ignition system compo-
nents.
90890-85505
Yamaha bond No.1215
This sealant (bond) is used on
crankcase mating surfaces, etc.
Tool name/How to use Illustration
90890-04086
Clutch holding tool
This tool is needed to hold the clutch
when removing or installing the clutch
boss nut.

2
SPEC

SPEC
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS ............................................................................................ 2-1
MAINTENANCE SPECIFICATIONS ....................................................................................2-4
ENGINE ........................................................................................................................2-4
CHASSIS ....................................................................................................................2-14
ELECTRICAL ..............................................................................................................2-18
GENERAL TORQUE SPECIFICATIONS............................................................................2-20
CONVERSION TABLE........................................................................................................2-20
LUBRICATION POINTS AND LUBRICANT TYPES..........................................................2-21
ENGINE ......................................................................................................................2-21
CHASSIS ....................................................................................................................2-22
LUBRICATION DIAGRAMS ..............................................................................................2-23
CABLE ROUTING ..............................................................................................................2-26