Yamaha BT1100 2002 Manuals

Yamaha BT1100 2002 Manuals

Manuals and User Guides for Yamaha BT1100 2002. We have 2 Yamaha BT1100 2002 manuals available for free PDF download: Service Manual

Yamaha BT1100 2002 Service Manual

Yamaha BT1100 2002 Service Manual (356 pages)

Brand: Yamaha | Category: Motorcycle | Size: 9.81 MB

Table of Contents

Table of Contents

6
- How to Use this Manual
  4
- General Information
  5
- Periodic Inspection
  5
  - Table of Contents
    6
- Chapter 1. General Information
  11
- Motorcycle Identification
  11
  - Vehicle Identification Number
    11
  - Model Label
    11
- Important Information
  12
  - Preparation for Removal Procedures
    12
  - Replacement Parts
    12
  - Gaskets, Oil Seals and O-Rings
    12
  - Lock Washers/Plates and Cotter Pins
    13
  - Bearings and Oil Seals
    13
  - Circlips
    13
- Checking of Connections
  14
- Special Tools
  15
Spec Chapter 2. Specifications

20
- Chapter 2. Specifications
  22
- General Specifications
  22
- Engine
  25
  - Maintenance Specifications
    25
  - Lubrication Chart
    31
- Chassis
  35
- Electrical
  39
  - General Torque Specifications
    41
  - Conversion Table
    41
  - Lubrication Points and Lubricant Types
    42
    
    Engine
    42
    
    Chassis
    43
  - Lubrication Diagrams
    44
  - Cable Routing
    47
- Insp Adj
  52
Adj Periodic Inspections and Adjustments Chapter 3.

53
- Chapter 3. Periodic Inspections and Adjustments
  55
- Introduction
  55
- Periodic Maintenance/Lubrication Intervals
  55
- Seat, Side Covers and Fuel Tank
  57
  - Removal
    57
- Engine
  58
- Chassis
  75
- Electrical System
  91
  - Checking and Charging the Battery
    91
  - Checking the Fuses
    97
  - Replacing the Headlight Bulb
    98
  - Adjusting the Headlight Beam
    100
- Eng
  101
Eng Chapter 4. Engine

102
- Chapter 4. Engine
  106
- Engine Removal
  106
- Cylinder Heads
  111
  - Rear Cylinder Head
    111
  - Front Cylinder Head
    113
  - Removing the Cylinder Heads
    115
  - Checking the Cylinder Heads
    117
  - Checking the Timing Chain Tensioner
    118
  - Installing the Cylinder Heads
    118
- Rocker Arms and Camshaft
  121
- Valves and Valve Springs
  126
  - Removing the Valves
    127
  - Checking the Valves and Valve Guides
    127
  - Checking the Valve Seats
    129
  - Checking the Valve Springs
    131
  - Installing the Valves
    131
- Cylinders and Pistons
  133
  - Removing the Pistons
    134
  - Checking the Cylinders and Pistons
    134
  - Checking the Piston Rings
    136
  - Checking the Piston Pins
    137
  - Installing the Pistons and Cylinders
    137
- Timing Gears
  139
  - Removing the Timing Drive Gears
    140
  - Checking the Timing Chains, Camshaft
    140
  - Checking the Primary Drive
    141
  - Installing the Timing Drive Gears
    141
  - Right Crankcase Cover
    143
  - Clutch Assembly
    145
  - Removing the Clutch
    147
  - Checking the Friction Plates
    147
  - Checking the Pressure Plate
    148
  - Checking the Clutch Boss
    148
  - Checking the Clutch Push Rods
    148
  - Checking the Clutch Plates
    149
  - Checking the Clutch Spring and Clutch Spring Seat Plate
    149
  - Checking the Clutch Housing
    149
  - Installing the Clutch
    150
- Generator and Starter Clutch
  152
  - Stator Coil and Pickup Coil
    152
  - Removing the Generator
    154
  - Checking the Starter Clutch
    155
  - Installing the Generator
    156
- Shift Shaft
  158
  - Checking the Shift Shaft
    159
  - Checking the Stopper Lever
    159
  - Installing the Shift Shaft
    159
- Oil Pump
  160
  - Checking the Oil Pump
    162
  - Checking the Oil Delivery Pipes
    162
  - Checking the Oil Strainer
    162
- Crankshaft and Connecting Rods
  164
  - Crankcase
    164
  - Disassembling the Crankcase
    166
  - Removing the Connecting Rods
    167
  - Checking the Crankshaft and Connecting Rods
    167
  - Checking the Bearing and Oil Seals
    170
  - Installing the Crankshaft
    170
  - Assembling the Crankcase
    171
- Transmission
  173
  - Checking the Shift Forks
    174
  - Checking the Shift Drum Assembly
    174
  - Checking the Transmission
    175
  - Installing the Transmission
    176
- Middle Gear
  177
- Carb
  188
Carb Chapter 5. Carburetion

189
- Carburetor
  191
- Chapter 5. Carburetion
  191
- Air Induction System (Ais)
  200
  - Air Induction
    200
  - Air Cut-Off Valve
    200
  - Air Induction System Inspection
    201
- Chas
  203
Chas Chapter 6. Chassis

204
- Chapter 6. Chassis
  206
- Front Wheel and Brake Discs
  206
  - Removing the Front Wheel
    208
  - Checking the Front Wheel
    208
  - Checking the Brake Discs
    209
  - Installing the Front Wheel
    211
  - Adjusting the Front Wheel Static Balance
    212
- Rear Wheel and Brake Disc
  214
  - Rear Wheel
    214
  - Removing the Rear Wheel
    216
  - Checking the Rear Wheel
    217
  - Checking the Rear Wheel Drive Hub
    217
  - Installing the Rear Wheel
    217
  - Adjusting the Rear Wheel Static Balance
    218
- Front and Rear Brakes
  219
  - Front Brake Pads
    219
  - Rear Brake Pads
    220
  - Replacing the Front Brake Pads
    221
  - Replacing the Rear Brake Pads
    223
  - Front Brake Master Cylinder
    225
  - Rear Brake Master Cylinder
    227
  - Removing the Front Brake Master Cylinder
    229
  - Removing the Rear Brake Master Cylinder
    229
  - Checking the Front and Rear Brake Master Cylinder
    230
  - Installing the Front Brake Master Cylinder
    231
  - Installing the Rear Brake Master Cylinder
    233
  - Front Brake Calipers
    235
  - Rear Brake Caliper
    237
  - Removing the Rear Brake Caliper
    237
  - Checking the Front and Rear Brake Calipers
    241
  - Installing the Front Brake Calipers
    242
  - Installing the Rear Brake Caliper
    244
- Front Fork
  246
  - Removing the Front Fork Legs
    249
  - Checking the Front Fork Legs
    251
  - Assembling the Front Fork Legs
    252
  - Installing the Front Fork Legs
    255
- Handlebar
  256
  - Removing the Handlebar
    258
  - Checking the Handlebar
    258
  - Installing the Handlebar
    259
- Steering Head
  262
  - Removing the Lower Bracket
    264
  - Checking the Steering Head
    264
  - Installing the Steering Head
    265
- Rear Shock Absorber and Swingarm
  266
- Shaft Drive
  274
- Elec
  292
Elec Chapter 7. Electrical

293
- Chapter 7. Electrical
  295
- Electrical Components
  295
- Switches
  297
  - Checking Switch Continuity
    297
- Checking the Switches
  298
- Checking the Bulbs and Bulb Sockets
  300
- Ignition System
  303
  - Circuit Diagram
    303
  - Troubleshooting
    304
- Electric Starting System
  308
  - Circuit Diagram
    308
  - Starting Circuit Operation
    309
  - Troubleshooting
    310
  - Starter Motor
    314
- Charging System
  319
  - Circuit Diagram
    319
  - Troubleshooting
    320
- Lighting System
  322
  - Circuit Diagram
    322
  - Troubleshooting
    323
  - Checking the Lighting System
    324
- Signaling System
  329
  - Circuit Diagram
    329
  - Troubleshooting
    329
- Fuel Pump System
  335
  - Circuit Diagram
    335
  - Fuel Pump Circuit Operation
    336
  - Troubleshooting
    337
  - Fuel Pump Test
    339
- Trbl Shtg
  347
Trbl ?

348
- Troubleshooting Trbl
  348
- Chapter 8. Troubleshooting
  350
- Starting Failure/Hard Starting
  350
  - Fuel System
    350
  - Electrical System
    350
  - Compression System
    351
- Poor Idle Speed Performance
  351
- Poor Medium-And High-Speed Performance
  351
- Clutch Slipping/Dragging
  352
  - Clutch Slipping
    352
  - Clutch Dragging
    352
- Faulty Gear Shifting
  352
  - Hard Shifting
    352
  - Shift Pedal Does Not Move
    352
  - Jumps-Out-Of Gear
    352
- Faulty Brake
  353
  - Poor Braking Performance
    353
- Front Fork Oil Leakage and Front Fork Malfunction
  353
  - Malfunction
    353
  - Oil Leakage
    353
- Overheating
  353
- Faulty Lighting and Signal Systems
  354
  - Headlight Does Not Light
    354
  - Bulb Burnt out
    354
  - Flasher Does Not Light
    354
  - Flasher Blinks Slowly
    354
  - Flasher Remains Lit
    354
  - Flasher Blilnks Quickly
    354
  - Horn Does Not Sound
    354
- Unstable Handling
  354

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Yamaha BT1100 2002 Service Manual

Yamaha BT1100 2002 Service Manual (356 pages)

Brand: Yamaha | Category: Motorcycle | Size: 9.87 MB

Table of Contents

Table of Contents

6
- How to Use this Manual
  4
- General Information
  5
- Periodic Inspection
  5
  - Table of Contents
    6
- Chapter 1. General Information
  11
- Motorcycle Identification
  11
  - Vehicle Identification Number
    11
  - Model Label
    11
- Important Information
  12
  - Preparation for Removal Procedures
    12
  - Replacement Parts
    12
  - Gaskets, Oil Seals and O-Rings
    12
  - Lock Washers/Plates and Cotter Pins
    13
  - Bearings and Oil Seals
    13
  - Circlips
    13
- Checking of Connections
  14
- Special Tools
  15
Spec Chapter 2. Specifications

20
- Chapter 2. Specifications
  22
- General Specifications
  22
- Engine
  25
  - Maintenance Specifications
    25
- Chassis
  35
- Electrical
  39
  - General Torque Specifications
    41
  - Conversion Table
    41
  - Lubrication Points and Lubricant Types
    42
    
    Engine
    42
    
    Chassis
    43
  - Lubrication Diagrams
    44
  - Cable Routing
    47
Insp Adj Periodic Inspections and Adjustments Chapter 3.

53
- Insp Adj
  53
- Chapter 3. Periodic Inspections and Adjustments
  55
- Introduction
  55
- Periodic Maintenance/Lubrication Intervals
  55
- Seat, Side Covers and Fuel Tank
  57
  - Removal
    57
- Engine
  58
- Chassis
  75
- Electrical System
  91
  - Checking and Charging the Battery
    91
  - Checking the Fuses
    97
  - Replacing the Headlight Bulb
    98
  - Adjusting the Headlight Beam
    100
- Eng
  101
Eng Chapter 4. Engine

102
- Chapter 4. Engine
  106
- Engine Removal
  106
- Cylinder Heads
  111
  - Rear Cylinder Head
    111
  - Front Cylinder Head
    113
  - Removing the Cylinder Heads
    115
  - Checking the Cylinder Heads
    117
  - Checking the Timing Chain Tensioner
    118
  - Installing the Cylinder Heads
    118
- Rocker Arms and Camshaft
  121
- Valves and Valve Springs
  126
  - Removing the Valves
    127
  - Checking the Valves and Valve Guides
    127
  - Checking the Valve Seats
    129
  - Checking the Valve Springs
    131
  - Installing the Valves
    131
- Cylinders and Pistons
  133
  - Removing the Pistons
    134
  - Checking the Cylinders and Pistons
    134
  - Checking the Piston Rings
    136
  - Checking the Piston Pins
    137
  - Installing the Pistons and Cylinders
    137
- Timing Gears
  139
  - Removing the Timing Drive Gears
    140
  - Checking the Timing Chains, Camshaft
    140
  - Checking the Primary Drive
    141
  - Installing the Timing Drive Gears
    141
  - Right Crankcase Cover
    143
  - Clutch Assembly
    145
  - Removing the Clutch
    147
  - Checking the Friction Plates
    147
  - Checking the Pressure Plate
    148
  - Checking the Clutch Boss
    148
  - Checking the Clutch Push Rods
    148
  - Checking the Clutch Plates
    149
  - Checking the Clutch Spring and Clutch Spring Seat Plate
    149
  - Checking the Clutch Housing
    149
  - Installing the Clutch
    150
- Generator and Starter Clutch
  152
  - Stator Coil and Pickup Coil
    152
  - Removing the Generator
    154
  - Checking the Starter Clutch
    155
  - Installing the Generator
    156
- Shift Shaft
  158
  - Checking the Shift Shaft
    159
  - Checking the Stopper Lever
    159
  - Installing the Shift Shaft
    159
- Oil Pump
  160
  - Checking the Oil Pump
    162
  - Checking the Oil Delivery Pipes
    162
  - Checking the Oil Strainer
    162
- Crankshaft and Connecting Rods
  164
  - Crankcase
    164
  - Disassembling the Crankcase
    166
  - Removing the Connecting Rods
    167
  - Checking the Crankshaft and Connecting Rods
    167
  - Checking the Bearing and Oil Seals
    170
  - Installing the Crankshaft
    170
  - Assembling the Crankcase
    171
- Transmission
  173
  - Checking the Shift Forks
    174
  - Checking the Shift Drum Assembly
    174
  - Checking the Transmission
    175
  - Installing the Transmission
    176
- Middle Gear
  177
- Carb
  188
Carb Chapter 5. Carburetion

189
- Carburetor
  191
- Chapter 5. Carburetion
  191
- Air Induction System (Ais)
  200
  - Air Induction
    200
  - Air Cut-Off Valve
    200
  - Air Induction System Inspection
    201
- Chas
  203
Chas Chapter 6. Chassis

204
- Chapter 6. Chassis
  206
- Front Wheel and Brake Discs
  206
  - Removing the Front Wheel
    208
  - Checking the Front Wheel
    208
  - Checking the Brake Discs
    209
  - Installing the Front Wheel
    211
  - Adjusting the Front Wheel Static Balance
    212
- Rear Wheel and Brake Disc
  214
  - Rear Wheel
    214
  - Removing the Rear Wheel
    216
  - Checking the Rear Wheel
    217
  - Checking the Rear Wheel Drive Hub
    217
  - Installing the Rear Wheel
    217
  - Adjusting the Rear Wheel Static Balance
    218
- Front and Rear Brakes
  219
  - Front Brake Pads
    219
  - Rear Brake Pads
    220
  - Replacing the Front Brake Pads
    221
  - Replacing the Rear Brake Pads
    223
  - Front Brake Master Cylinder
    225
  - Removing the Front Brake Master Cylinder
    225
  - Checking the Front and Rear Brake Master Cylinder
    230
  - Installing the Front Brake Master Cylinder
    231
  - Installing the Rear Brake Master Cylinder
    233
  - Front Brake Calipers
    235
  - Removing the Front Brake Calipers
    235
  - Removing the Rear Brake Caliper
    237
  - Checking the Front and Rear Brake Calipers
    241
  - Installing the Front Brake Calipers
    242
  - Installing the Rear Brake Caliper
    244
- Front Fork
  246
  - Removing the Front Fork Legs
    249
  - Checking the Front Fork Legs
    251
  - Assembling the Front Fork Legs
    252
  - Installing the Front Fork Legs
    255
- Handlebar
  256
  - Removing the Handlebar
    258
  - Checking the Handlebar
    258
  - Installing the Handlebar
    259
- Steering Head
  262
  - Removing the Lower Bracket
    264
  - Checking the Steering Head
    264
  - Installing the Steering Head
    265
- Rear Shock Absorber and Swingarm
  266
- Shaft Drive
  274
- Elec
  292
Elec Chapter 7. Electrical

293
- Chapter 7. Electrical
  295
- Electrical Components
  295
- Switches
  297
  - Checking Switch Continuity
    297
- Checking the Switches
  298
- Checking the Bulbs and Bulb Sockets
  300
- Ignition System
  303
  - Circuit Diagram
    308
  - Troubleshooting
    310
  - Starter Motor
    314
- Charging System
  319
  - Circuit Diagram
    319
  - Troubleshooting
    320
- Lighting System
  322
  - Circuit Diagram
    322
  - Troubleshooting
    323
  - Checking the Lighting System
    324
- Signaling System
  327
  - Circuit Diagram
    327
  - Troubleshooting
    329
  - Checking the Signaling System
    330
- Fuel Pump System
  335
  - Circuit Diagram
    335
  - Fuel Pump Circuit Operation
    336
  - Troubleshooting
    337
  - Fuel Pump Test
    339
- Trbl Shtg
  347
Trbl ?

348
- Troubleshooting Trbl
  348
- Chapter 8
  350
- Electrical System
  350
- Fuel System
  350
- Starting Failure/Hard Starting
  350
- Compression System
  351
- Poor Idle Speed Performance
  351
- Poor Medium-And High-Speed Performance
  351
- Clutch Slipping/Dragging
  352
  - Clutch Slipping
    352
  - Clutch Dragging
    352
- Faulty Gear Shifting
  352
  - Hard Shifting
    352
  - Shift Pedal Does Not Move
    352
  - Jumps-Out-Of Gear
    352
- Faulty Brake
  353
  - Poor Braking Performance
    353
- Front Fork Oil Leakage and Front Fork Malfunction
  353
  - Oil Leakage
    353
- Overheating
  353
- Faulty Lighting and Signal Systems
  354
  - Headlight Does Not Light
    354
  - Bulb Burnt out
    354
  - Flasher Does Not Light
    354
  - Flasher Blinks Slowly
    354
  - Flasher Remains Lit
    354
  - Flasher Blilnks Quickly
    354
  - Horn Does Not Sound
    354
- Unstable Handling
  354

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