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Yamaha BT1100 2002 User Manual

Yamaha BT1100 2002
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BT1100
SERVICE MANUAL
2002
5JN1-AE1

Table of Contents

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Yamaha BT1100 2002 Specifications

General IconGeneral
Displacement1063 cc
Compression ratio8.3:1
Transmission5-speed
Final driveShaft
Front suspensionTelescopic fork
Rear suspensionSwingarm
Front brakesDual disc
Rear brakesSingle disc
Front tire120/70-ZR17
Rear tire170/60-ZR17
Fuel capacity20 liters
Engine typeAir-cooled, 4-stroke
Length2215mm
Height1175mm
Fuel systemCarburetor

Summary

NOTICE

IMPORTANT MANUAL INFORMATION

Explains how critical information is highlighted using symbols like WARNING and CAUTION.

HOW TO USE THIS MANUAL

ILLUSTRATED SYMBOLS

CHAPTER 1. GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION

Details how to find the Vehicle Identification Number and Model Label for vehicle recognition.

IMPORTANT INFORMATION

Outlines essential precautions for maintenance, including preparation, parts, gaskets, seals, and circlips.

CHECKING OF CONNECTIONS

Provides steps for inspecting electrical connectors for cleanliness, moisture, and proper connection.

SPECIAL TOOLS

Lists and illustrates specialized tools required for specific maintenance and repair tasks.

CHAPTER 2. SPECIFICATIONS

GENERAL SPECIFICATIONS

Lists general dimensions, weight, engine type, displacement, bore, stroke, and other basic vehicle data.

MAINTENANCE SPECIFICATIONS

Details specific measurements and tolerances for engine, chassis, and electrical systems during maintenance.

GENERAL TORQUE SPECIFICATIONS

Provides standard torque values for common fasteners and general tightening principles.

LUBRICATION POINTS AND LUBRICANT TYPES

Identifies lubrication points and recommends specific lubricants for engine and chassis components.

CHAPTER 3. PERIODIC INSPECTIONS AND ADJUSTMENTS

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

Provides a schedule for routine checks and lubrication based on odometer readings and annual intervals.

ENGINE

Covers periodic inspections and adjustments related to the motorcycle's engine components.

CHASSIS

Details periodic inspections and adjustments for the motorcycle's chassis and related systems.

ELECTRICAL SYSTEM

Outlines periodic checks and adjustments for the motorcycle's electrical system components.

CHAPTER 4. ENGINE

ENGINE REMOVAL

Steps for removing the engine, including associated components like fuel tank and exhaust system.

CYLINDER HEADS

Procedures for removing, checking, and installing the front and rear cylinder heads.

CLUTCH

Procedures for removing, checking, and installing the clutch assembly and its components.

CRANKSHAFT AND CONNECTING RODS

Procedures for disassembling, checking, and installing the crankshaft and connecting rods.

CHAPTER 5. CARBURETION

CARBURETOR

Details the process of checking, disassembling, assembling, and installing the carburetors.

AIR INDUCTION SYSTEM (AIS)

Covers the function, components, and inspection of the Air Induction System.

CHAPTER 6. CHASSIS

FRONT AND REAR BRAKES

Instructions for replacing brake pads, servicing master cylinders, and calipers for both front and rear brakes.

FRONT FORK

Procedures for removing, disassembling, checking, assembling, and installing the front fork legs.

REAR SHOCK ABSORBER AND SWINGARM

Instructions for handling, removing, checking, and installing the rear shock absorber and swingarm.

SHAFT DRIVE

Troubleshooting and maintenance procedures for the shaft drive system, including oil checks and backlash adjustment.

CHAPTER 7. ELECTRICAL

IGNITION SYSTEM

Covers the ignition system's circuit diagram and troubleshooting procedures.

ELECTRIC STARTING SYSTEM

Explains the starting system's circuit diagram, operation, and troubleshooting.

CHARGING SYSTEM

Details the charging system's circuit diagram and troubleshooting steps.

LIGHTING SYSTEM

Provides circuit diagrams and troubleshooting for headlights, indicators, and other lights.

CHAPTER 8. TROUBLESHOOTING

STARTING FAILURE/HARD STARTING

Lists potential causes and troubleshooting steps for starting issues, categorized by fuel, electrical, and compression systems.

FAULTY GEAR SHIFTING

Details common causes and solutions for hard shifting, stuck shift pedals, and gears jumping out.

OVERHEATING

Lists possible causes for engine overheating, spanning ignition, fuel, compression, and oil systems.

FAULTY LIGHTING AND SIGNAL SYSTEMS

Provides troubleshooting for lighting failures (headlight, tail, license plate, meter) and signaling system issues (flashers, horn).

BT1100 WIRING DIAGRAM

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