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Yamaha 2005 BT1100 User Manual

Yamaha 2005 BT1100
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BT1100
SUPPLEMENTARY
SERVICE MANUAL
2005
5JN4-AE1
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Yamaha 2005 BT1100 Specifications

General IconGeneral
Displacement1063 cc
Compression Ratio8.3:1
Transmission5-speed
Final DriveShaft
Front SuspensionTelescopic fork
Rear SuspensionSwingarm
Front Tire120/70-ZR17
Rear Tire170/60-ZR17
Fuel Capacity20 liters
Engine TypeAir-cooled, 4-stroke, V-twin
Bore x Stroke95 x 75 mm
IgnitionTCI
Front BrakesDual disc
Rear BrakesSingle disc

Summary

FOREWORD

NOTICE

IMPORTANT INFORMATION

Explains how important information is distinguished in the manual.

HOW TO USE THIS MANUAL

ILLUSTRATED SYMBOLS

SPECIFICATIONS

GENERAL SPECIFICATIONS

Detailed technical specifications for the motorcycle model.

MAINTENANCE SPECIFICATIONS

ENGINE

Maintenance specifications for the engine components.

LUBRICATION CHART

Visual diagram illustrating engine lubrication points and flow.

TIGHTENING TORQUES

Specifies torque values for various fasteners across different assemblies.

LUBRICATION POINTS AND LUBRICANT TYPES

Lists lubrication points and symbols for engine and chassis components.

LUBRICATION DIAGRAMS

Diagrams showing lubrication flow paths for engine components.

CHASSIS

Steering system

Specifications related to the motorcycle's steering system.

Front suspension

Specifications for the front suspension components.

Rear suspension

Specifications for the rear suspension components.

Front brake

Specifications for the front brake system, including discs and pads.

Rear brake

Specifications for the rear brake system, including disc and pads.

ELECTRICAL

Voltage

Specifies the voltage for the motorcycle's electrical system.

Ignition system

Specifications for the ignition system, including T.C.I. and coils.

Electric starter system

Specifications for the electric starter motor and relay.

Circuit breaker

Details on fuses used in the circuit breaker system.

PERIODIC INSPECTIONS AND ADJUSTMENTS

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

Table detailing recommended periodic maintenance and lubrication intervals based on mileage.

ENGINE

ENGINE REMOVAL

Procedure for removing the engine from the motorcycle.

CARBURETOR

CARBURETOR

Procedure for removing the carburetors and associated components.

FRONT BRAKE MASTER CYLINDER

Removing the front brake master cylinder

Procedure for removing the front brake master cylinder assembly.

Disassembling the front brake master cylinder

Steps for disassembling the front brake master cylinder.

FRONT BRAKE CALIPERS

Removing the front brake calipers

Procedure for removing the front brake calipers.

Disassembling the front brake calipers

Steps for disassembling the front brake calipers.

HANDLEBAR

Removing the handlebar

Procedure for removing the motorcycle's handlebar and related parts.

INSTALLING THE HANDLEBAR

Step-by-step guide for installing the motorcycle handlebar.

STEERING HEAD - LOWER BRACKET

Removing the lower bracket

Procedure for removing the steering head lower bracket.

ELECTRICAL COMPONENTS

ELECTRICAL COMPONENTS

Identifies and illustrates key electrical components on the motorcycle.

SWITCHES

CHECKING SWITCH CONTINUITY

Procedure for testing switch continuity using a pocket tester.

CHECKING THE SWITCHES

Instructions for checking various switches for damage, connections, and continuity.

BULBS AND BULB SOCKETS

TYPES OF BULBS

Illustrates and describes different types of bulbs used on the motorcycle.

CHECKING THE CONDITION OF THE BULBS

Procedure for checking the condition of motorcycle bulbs.

CHECKING THE CONDITION OF THE BULB SOCKETS

Procedure for checking the condition and continuity of bulb sockets.

IMMOBILIZER SYSTEM

IMMOBILIZER SYSTEM CIRCUIT DIAGRAM

Circuit diagram for the immobilizer system, showing component connections.

GENERAL INFORMATION

Explains the function and components of the immobilizer system.

KEY CODES REGISTRATION METHOD

Method for registering key codes to the immobilizer system.

TROUBLESHOOTING

IMMOBILIZER SYSTEM TROUBLESHOOTING

Troubleshooting guide for immobilizer system failures.

CHECKING THE IMMOBILIZER SYSTEM

Procedures for checking voltage at various points in the immobilizer system.

SELF-DIAGNOSIS ERROR CODE INDICATION

SELF-DIAGNOSIS DEVICE

SELF-DIAGNOSIS DEVICE

Explains the self-diagnosis device and error codes related to specific circuits.

TROUBLESHOOTING

Troubleshooting for throttle position sensor and speed sensor error codes.

SELF-DIAGNOSIS DEVICE

Troubleshooting for speed sensor and wire harness issues.

SELF-DIAGNOSIS DEVICE

Troubleshooting for ignition coil resistance and wiring.

SELF-DIAGNOSIS DEVICE

Troubleshooting for fuel-cut solenoid circuits and wiring.

IGNITION SYSTEM

IGNITION SYSTEM CIRCUIT DIAGRAM

Circuit diagram for the motorcycle's ignition system.

TROUBLESHOOTING

Troubleshooting steps for ignition system failures (no spark).

IGNITION SYSTEM

Checks for ignition spark gap, spark plug cap, and ignition coil resistance.

IGNITION SYSTEM

Checks for pickup coil, main switch, engine stop, neutral, and sidestand switches.

ELECTRIC STARTING SYSTEM

ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM

Circuit diagram for the electric starting system.

STARTING CIRCUIT OPERATION

Explains how the electric starting circuit operates under different conditions.

TROUBLESHOOTING

Troubleshooting guide for the electric starting system when the motor fails to turn.

ELECTRIC STARTING SYSTEM

Checks for starting circuit cut-off relay and starter relay continuity.

ELECTRIC STARTING SYSTEM

Checks main switch, engine stop, neutral, sidestand, clutch, start switches, and wiring.

STARTER MOTOR

Removing the starter motor

Procedure for removing the starter motor and its assembly.

Disassembling the starter motor

Steps for disassembling the starter motor components.

Checking the starter motor

Procedure for checking the starter motor's commutator, diameter, and resistances.

ELECTRIC STARTING SYSTEM

Checking starter motor brush length, spring force, gear teeth, and oil seal.

ELECTRIC STARTING SYSTEM

Installing starter motor components during assembly.

CHARGING SYSTEM

CHARGING SYSTEM CIRCUIT DIAGRAM

Circuit diagram for the charging system, showing connections.

TROUBLESHOOTING

Troubleshooting guide for the charging system when the battery is not charging.

CHARGING SYSTEM

Checks stator coil resistance and charging system wiring.

LIGHTING SYSTEM

LIGHTING SYSTEM CIRCUIT DIAGRAM

Circuit diagram for the motorcycle's lighting system.

TROUBLESHOOTING

Troubleshooting guide for lighting system failures (lights not working).

LIGHTING SYSTEM

Checks for pass switch, dimmer switch relay, igniter unit, and wiring issues.

LIGHTING SYSTEM

Checks voltage for turn signal lights and neutral indicator light.

LIGHTING SYSTEM

Checks tail/brake light and license plate light circuits.

SIGNALING SYSTEM

SIGNALING SYSTEM CIRCUIT DIAGRAM

Circuit diagram for the signaling system (turn signals, brake lights, horn).

TROUBLESHOOTING

Troubleshooting guide for signaling system failures and horn issues.

SIGNALING SYSTEM

Checks horn switch, voltage, and wiring for the signaling system.

SIGNALING SYSTEM

Checks tail/brake light and brake light switches.

SIGNALING SYSTEM

Checks turn signal lights, flasher relay, and related wiring.

SIGNALING SYSTEM

Checks turn signal switch, voltage for turn signals, and neutral indicator light.

SIGNALING SYSTEM

Checks oil level warning light and oil level switch.

FUEL PUMP SYSTEM

FUEL PUMP SYSTEM CIRCUIT DIAGRAM

Circuit diagram for the fuel pump system.

TROUBLESHOOTING

Troubleshooting guide for the fuel pump system when it fails to operate.

FUEL PUMP SYSTEM

Checks starting circuit cutoff relay, fuel pump resistance, and wiring.

FUEL PUMP TEST

Procedure for testing the fuel pump operation and ensuring it functions correctly.

CARBURETOR HEATER SYSTEM

CARBURETOR HEATER SYSTEM CIRCUIT DIAGRAM

Circuit diagram for the carburetor heater system.

TROUBLESHOOTING

Troubleshooting guide for the carburetor heater system when it fails to operate.

CARBURETOR HEATER SYSTEM

Checks the thermo switch and carburetor heater resistance.

TROUBLESHOOTING

STARTING FAILURE/HARD STARTING

Troubleshooting guide for engine starting failures or hard starting issues.

WIRING DIAGRAM

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