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Yamaha 2005 BT1100 Supplementary Service Manual

Yamaha 2005 bt1100 motorcycle supplementary service manual.
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2005
BT1100
5JN4-AE1
SUPPLEMENTARY
SERVICE MANUAL

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   Summary of Contents for Yamaha 2005 BT1100

  • Page 1

    2005 BT1100 5JN4-AE1 SUPPLEMENTARY SERVICE MANUAL...

  • Page 3

    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...

  • Page 4

    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.

  • Page 5: How To Use This Manual

    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. 1 The manual is divided into chapters.

  • Page 6

    ILLUSTRATED SYMBOLS The following symbols are not relevant to every vehicle. SPEC INFO Illustrated symbols 1 to 8 are printed on the top right of each page and indicate the subject of each chapter. 1 General information INSP 2 Specifications 3 Periodic inspections and adjustments 4 Engine 5 Carburetor...

  • Page 7: Table Of Contents

    CONTENTS SPECIFICATIONS GENERAL SPECIFICATIONS..................MAINTENANCE SPECIFICATIONS – ENGINE ............LUBRICATION CHART ....................TIGHTENING TORQUES – ENGINE ................ MAINTENANCE SPECIFICATIONS – CHASSIS ............TIGHTENING TORQUES – CHASSIS ..............MAINTENANCE SPECIFICATIONS – ELECTRICAL ..........GENERAL TORQUE SPECIFICATIONS ..............CONVERSION TABLE ....................LUBRICATION POINTS AND LUBRICANT TYPES ..........LUBRICATION DIAGRAMS ..................

  • Page 9: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS 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...

  • Page 10

    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 0.8 mm Clutch type: Wet, multiple-disc Transmission:...

  • Page 11

    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...

  • Page 12: Maintenance Specifications Engine

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Volume 57.0 58.4 cm ••• 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 &...

  • Page 13

    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...

  • Page 14

    SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Stem runout limit ••• 0.03 mm Valve seat width 1.4 mm 2.0 mm 1.4 mm 2.0 mm Valve spring: Free length 44.6 mm 43.5 mm 44.6 mm 43.5 mm Set length (valve closed) 40 mm •••...

  • Page 15

    SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Piston rings: Top ring: Type Plain ••• Dimensions (B x T) 3.8 mm ••• End gap (installed) 0.5 mm 0.8 mm Side clearance (installed) 0.04 0.08 mm 0.1 mm ring: Type Taper ••• Dimensions (B x T) 3.8 mm •••...

  • Page 16

    SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Clutch: Friction plate thickness 3.1 mm 2.8 mm Quantity ••• Clutch plate thickness 2.7 mm 0.1 mm Quantity ••• Clutch plate thickness 2.1 mm 0.1 mm Quantity ••• Clutch spring free length 7.2 mm 6.5 mm Quantity •••...

  • Page 17

    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 120 kPa (0.8 ~ 1.2 kgf/cm •••...

  • Page 18: Lubrication Chart

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

  • Page 19: Tightening Torques - Engine

    SPEC MAINTENANCE SPECIFICATIONS Cylinder head tightening sequence: Crankcase tightening sequence: Left crankcase Right crankcase...

  • Page 20

    SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening Part Thread Part to be tightened Q’ty torque Remarks name size · · Cylinder head Cylinder head Plate Bolt Cylinder head cover Screw Cylinder head (exhaust pipe) Stud bolt 12.5 1.25 Rocker arm shaft Union 37.5 3.75...

  • Page 21

    SPEC MAINTENANCE SPECIFICATIONS Tightening Part Thread Part to be tightened Q’ty torque Remarks name size · · Crankcase (cylinder) Stud bolt Crankcase (cylinder) Stud bolt Crankcase Bolt 38.5 3.85 Crankcase Bolt Bearing retainer (middle drive pinion gear) Bolt Crankcase cover (left) Bolt Crankcase cover (right) Bolt...

  • Page 22: Maintenance Specifications - Chassis

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Steering bearing type Angular bearing ••• Front suspension: Front fork travel 130 mm ••• Fork spring free length 364.8 mm ••• Fitting length 339.8 mm ••• Collar length 150 mm ••• Spring rate (K1) 7.5 N/mm (0.75 kg/mm)

  • Page 23

    SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Front brake: Type Dual disc ••• Disc outside diameter thickness 5 mm 4.5 mm Disc deflection limit ••• 0.1 mm Pad thickness inner 4.5 mm 0.5 mm outer 4.5 mm 0.5 mm Master cylinder inside diameter 15 mm •••...

  • Page 24: Tightening Torques - Chassis

    SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening Thread torque Part to be tightened Remarks size · · Headlight assembly/Cowling: Lower headlight support Upper headlight support (right and left) Headlight bracket (right and left) Plastic cover Front flasher lights (right and left) Handlebar/Front fork assembly: Upper bracket and inner tube Lower bracket and inner tube...

  • Page 25

    SPEC MAINTENANCE SPECIFICATIONS Tightening Thread torque Part to be tightened Remarks size · · Rear brake/Footrests: Brake caliper torque rod Rear brake adjuster Rear brake pedal fastening screw (special) Rear master cylinder fastening screw Rear brake fluid reservoir fastening screw Special screw for fastening rear brake hose to brake caliper Special screw for fastening rear brake...

  • Page 26: Maintenance Specifications - Electrical

    SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Item Standard Limit Voltage: 12 V ••• Ignition system: Ignition timing (B.T.D.C.) 10° at 1,000 r/min ••• Advancer type Digital type ••• T.C.I.: 231 Ω at 20 °C / Gray–Black Pickup coil resistance/color ••• T.C.I. unit model/manufacturer J4T157/MITSUBISHI •••...

  • Page 27

    SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Horn: Type Plane type ••• Quantity ••• Model/manufacturer K80 L-12V/LEB ••• Maximum amperage ••• Flasher relay: Type Full transistor ••• Model/manufacturer FE218BH/DENSO ••• Self cancelling device ••• Hazard flasher device ••• Flasher frequency 95 cycle/min •••...

  • Page 28: General Torque Specifications

    GENERAL TORQUE SPECIFICATIONS/ SPEC CONVERSION TABLE GENERAL TORQUE SPECIFICATIONS CONVERSION TABLE This chart specifies torque for standard fasteners All specification data in this manual are listed in SI with standard I.S.O. pitch threads. Torque specifi- and METRIC UNITS. Use this table to convert cations for special components or assemblies are METRIC unit data to IMPERIAL unit data.

  • Page 29: Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Symbol Oil seal lips O-ring Bearing Connecting rod bolt/nut Connecting rod small end and big end Crankshaft pin Crankshaft journal/big end Piston surface Piston pin Camshaft cam lobe/journal Rocker arm shaft Valve stem (IN, EX) Valve stem end (IN, EX)

  • Page 30

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES CHASSIS Lubrication point Symbol Steering head pipe (upper/lower), bearing Steering head pipe, bearing cover lip Steering head pipe, oil seal lip Front wheel oil seal lip (right/left) Rear wheel oil seal lip Clutch hub fitting area Rear brake pedal shaft Shift pedal shaft Sidestand bolt, sidestand sliding surface...

  • Page 31: Lubrication Diagrams

    SPEC LUBRICATION DIAGRAMS EB205000 LUBRICATION DIAGRAMS Rocker arm shaft (intake) Oil filter Drive axle Rocker arm shaft (exhaust) Oil pump Middle drive shaft...

  • Page 32

    SPEC LUBRICATION DIAGRAMS Oil pump Oil filter Releaf valve Middle drive shaft...

  • Page 33

    SPEC LUBRICATION DIAGRAMS Camshaft Middle drive shaft Crankshaft Drive axle Main axle Connecting rod big end...

  • Page 34: Cable Routing

    SPEC CABLE ROUTING CABLE ROUTING Relays group Filler tank cap fuel drain pipe Clutch cable Flasher relay Filler tank cap fuel drain pipe Front brake cable (left) Speed sensor Fuel hose (carburetor-3 way) Carburetor pipe vent Sidestand switch Handlebar switch leads (left) Pipe drain Fuel drain hose Rectifier/regulator...

  • Page 35

    SPEC CABLE ROUTING Rubber cap for front wiring Ignition coil (rear cylinder) Throttle cables connections Starter relay assy Brake cable Horn (front master cylinder) Depression fuel cock Front brake hose (right) Thermo swicth Spark plug cap (rear cylinder) A.I.S. pipe to the front cylinder A.I.S.

  • Page 36

    SPEC CABLE ROUTING Carburetor pipe vent Battery negative (-) terminal Rubber cap for front wiring connections Depression fuel cock Igniter unit Spark plug lead (front) Battery Fuel filter Throttle cable Fuel hose Fuel pump ´ Position the spark plug wire of Spark plug lead (rear) Fuel sender the rear cylinder below the fuel...

  • Page 37: Periodic Inspections And Adjustments

    INSP INTRODUCTION/PERIODIC MAINTENANCE/ LUBRICATION INTERVALS PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.

  • Page 38

    • Check operation. and switches • Adjust headlight beam. * Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. NOTE: • The annual checks must be performed every year, except if a kilometer-based maintenance is per- formed instead.

  • Page 39: Chassis - Adjusting The Front Brake

    INSP ADJUSTING THE FRONT BRAKE EB304001 CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: • brake lever position (distance a between the brake lever and the handlebar grip) M M M M M M M M M M M M M M M M M M M M M M M M M M M M M a.

  • Page 40: Checking The Fuses

    INSP CHECKING THE FUSES EAS00181 CHECKING THE FUSES The following procedure applies to all of the fuses. CAUTION: To avoid a short circuit, always turn the main switch to "OFF" when checking or replacing a fuse. 1. Remove: • seat •...

  • Page 41

    INSP CHECKING THE FUSES Amperage Fuses Quantity rating 1 Main fuse 30 A 2 Carburetor heater fuse 15 A 3 Headlight fuse 15 A 4 Signaling system fuse 10 A 5 Ignition fuse 10 A 6 Odometer fuse (backup) 10 A 7 Parking lighting fuse 10 A 8 Igniter fuse...

  • Page 42: Engine

    ENGINE REMOVAL ENGINE ENGINE REMOVAL SEAT, STORAGE COMPARTMENT, SIDE COVERS, FUEL TANK, AIR FILTER CASE ASSEMBLY, CARBURETOR ASSEMBLY AND EXHAUST SYSTEM Order Job name/Part name Q’ty Remarks Removing the seat, storage Remove the parts in the order listed. compartment, side covers, fuel tank, Stand the motorcycle on a level surface.

  • Page 43

    ENGINE REMOVAL Order Job name/Part name Q’ty Remarks Battery leads Disconnect NOTE: First, disconnect the negative lead, then disconnect the positive lead. Side covers Refer to "SEAT, SIDE COVERS AND Fuel tank FUEL TANK" in Chapter 3. Air filter case assembly Refer to "CARBURETOR"...

  • Page 44: Carburetion

    CARB CARBURETOR CARBURETION CARBURETOR Order Job name/Part name Q’ty Remarks Removing the carburetors Remove the parts in the order listed. Seat Refer to "SEAT, SIDE COVERS AND Fuel tank FUEL TANK" in Chapter 3. Air filter case assembly Air ducts Cylinder head breather hose Disconnect Cover...

  • Page 45: Chassis

    CHAS FRONT BRAKE CHASSIS FRONT BRAKE MASTER CYLINDER Order Job name/Part name Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder Drain the brake fluid Brake lever Front brake switch lead Front brake switch Union bolt Copper washers/brake hose Refer to “REMOVING/INSTALLING THE...

  • Page 46

    CHAS FRONT BRAKE Order Job name/Part name Q’ty Remarks Disassembling the front brake Remove the parts in the order listed. master cylinder Dust boot Circlip Master cylinder cup Spring For assembly, reverse the disassembly procedure.

  • Page 47: Front Brake Calipers

    CHAS FRONT BRAKE FRONT BRAKE CALIPERS Order Job name/Part name Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed. Drain the brake fluid Union bolt Copper washers Refer to “REMOVING/INSTALLING THE Brake hose FRONT BRAKE CALIPERS”. Brake caliper assembly For installation, reverse the removal procedure.

  • Page 48

    CHAS FRONT BRAKE Order Job name/Part name Q’ty Remarks Disassembling the front brake Remove the parts in the order listed. calipers Pad pin clips Pad pin Refer to “REPLACING THE FRONT Pad spring BRAKE PADS”. Brake pads Bleed screw Brake caliper pistons Refer to “DISASSEMBLING THE FRONT Dust seals BRAKE CALIPER”.

  • Page 49: Handlebar

    CHAS HANDLEBAR HANDLEBAR Order Job name/Part name Q’ty Remarks Remove the parts in the order listed. Removing the handlebar Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. Plastic locking ties Clutch cable Handlebar switch (left)

  • Page 50

    CHAS HANDLEBAR Order Job name/Part name Q’ty Remarks Throttle grip assembly Refer to “INSTALLING THE HANDLEBAR”. Handlebar holders (upper) Handlebar Handlebar holders (lower) For installation, reverse the removal procedure.

  • Page 51

    CHAS HANDLEBAR EASB0025 INSTALLING THE HANDLEBAR 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Install: • handlebar • upper handlebar holders 23 Nm (2.3 m•kg) CAUTION: •...

  • Page 52

    CHAS HANDLEBAR 5. Install: • master cylinder holder 2 10 Nm (1.0 m•kg) NOTE: Install the master cylinder holder 2 with the mark "UP" facing up. 6. Install: • clutch lever holder 1 NOTE: Align the slit in the clutch lever a holder with the punch mark in the handlebar.

  • Page 53: Steering Head Lower Bracket

    CHAS STEERING HEAD STEERING HEAD LOWER BRACKET Order Job name/Part name Q’ty Remarks Removing the lower bracket Remove the parts in the order listed. Front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”. Front fork legs Refer to “FRONT FORK”. Handlebar Refer to ”HANDLEBAR”.

  • Page 54

    CHAS STEERING HEAD Order Job name/Part name Q’ty Remarks Bearing Dust seal Lower handlebar holder For installation, reverse the removal procedure.

  • Page 55: Electrical

    ELEC ELECTRICAL COMPONENTS ELECTRICAL ELECTRICAL COMPONENTS 1 Main switch 6 Oil level gauge assembly 2 Igniter unit 7 Neutral switch 3 Ignition coil (rear cylinder) 8 Sidestand switch 4 Ignition coil (front cylinder) 9 Speed sensor 5 Horn 0 Immobilizer control unit...

  • Page 56

    ELEC ELECTRICAL COMPONENTS q Fuel meter senser unit y Relay assembly w Battery u Fuse assembly e Starter relay i Rectifier/regulator r Relay assembly o Thermo switch t Flasher relay...

  • Page 57: Switches

    ELEC SWITCHES EAS0010 SWITCHES CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. CAUTION: Never insert the tester probes into the coupler terminal slots 1.

  • Page 58

    ELEC CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the termi- nals. Refer to “CHECKING SWITCH CONTINUITY”. ¡ Damage/wear Repair or replace the switch. ¡ Improperly connected Properly connect.

  • Page 59

    ELEC CHECKING THE SWITCHES 1 Clutch switch 8 Hazard switch 2 Pass switch 9 Engine stop switch 3 Horn switch 0 Start switch 4 Dimmer switch q Fuses 5 Turn switch w Rear brake switch 6 Main switch e Sidestand switch 7 Front brake switch r Neutral switch...

  • Page 60: Checking The Bulbs And Bulb Sockets

    ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00732 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. ¡ Damage/wear Repair or replace the bulb, bulb socket or both.

  • Page 61

    ELEC CHECKING THE BULBS AND BULB SOCKETS WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: • Be sure to hold the socket firmly when removing the bulb.

  • Page 62

    ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) ¡ No continuity Replace. Pocket tester 90890-03112 NOTE: Check each bulb socket for continuity in the same...

  • Page 63: Immobilizer System

    ELEC IMMOBILIZER SYSTEM EB805000 IMMOBILIZER SYSTEM CIRCUIT DIAGRAM Main switch Battery Igniter unit Ignition fuse Backup fuse Multi-function display Anti-theft alarm (option) Igniter fuse Immobilizer control unit...

  • Page 64

    ELEC IMMOBILIZER SYSTEM GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with a black bow) that can be re-registered with new codes •...

  • Page 65

    ELEC IMMOBILIZER SYSTEM KEY CODES REGISTRATION METHOD In the course of use, you may encounter the following case where replace these parts and registration of code re-registering/ standard key is required. NOTE: Each standard key is registered during production, therefore re-registering at purchase is not neces-sary. Replacement parts on troubles Replacement parts Required key registration...

  • Page 66

    ELEC IMMOBILIZER SYSTEM 1. Check that the immobilizer system indicator light is flashing. It indicates the “standby mode”. To initiate the standby mode, turn “OFF” the main switch and then it will be the standby mode when it passes 30 seconds.

  • Page 67

    ELEC IMMOBILIZER SYSTEM EAS00781 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. Refer to The immobilizer system fail to operate. “CHECKING AND CHARGING THE BAT- (The immobilizer system indicator light TERY” in chapter 3. starts to blinking the self-diagnosis code se- quence.) Open-circuit voltage 12.8 V or more at 20 °C...

  • Page 68

    ELEC IMMOBILIZER SYSTEM CHECKING THE IMMOBILIZER SYSTEM • Set the main switch to “ON”. 1. Immobilizer system indicator light does not go • Measure the voltage (12 V) between red/ on when the main switch is turned “ON”. green and black on the immobilizer unit. •...

  • Page 69

    ELEC IMMOBILIZER SYSTEM 4. Voltage • Connect the pocket tester (DC 20 V) to the immobilizer unit couplers as shown. Tester positive probe – green/blue 1 Tester negative probe – black 2 RG B2 B B B2 RG RW GL YL YL GL RW •...

  • Page 70

    ELEC IMMOBILIZER SYSTEM SELF-DIAGNOSIS ERROR CODE INDICATION When the system failure occurred, the error code number is indicated in the immobilizer system indicator light blinks at the same time. The pattern of blinking also shows the error code. Error Detection Symptoms Trouble Measures...

  • Page 71: Self-diagnosis Device

    ELEC SELF-DIAGNOSIS DEVICE SELF-DIAGNOSIS DEVICE When the key is turned to "ON", the tachometer and 0 / r/min (for 3 seconds) speedometer needles should move to the maximum, then back to zero. In addition all the warning lights and the indicator lights should come on for a few seconds, then go off.

  • Page 72

    ELEC SELF-DIAGNOSIS DEVICE EASB0044 1. Wire harness TROUBLESHOOTING • Check the wire harness for continuity. The tachometer displays the throttle posi- Refer to "CIRCUIT DIAGRAM". tion sensor/speed sensor error code. • Is the wire harness OK? Check: 1. Throttle position sensor 2.

  • Page 73

    ELEC SELF-DIAGNOSIS DEVICE 1. Speed sensor CIRCUIT DIAGRAM RB L LB LR Lg LR YB Y L Gy1 LY RB RW B Br Or RL BL (BLACK) PUMP (BLACK) S.GND Y LR • Set the main switch to “ON”. MAIN HARNESS HEAD LIGHT SP RPM GND •...

  • Page 74

    ELEC SELF-DIAGNOSIS DEVICE 3. Ignition coil N. 1 and 2 1. Wiring • Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the ignition system’s wiring properly con- nected and without defects? Secondary coil resistance Repair or replace the 10.7 14.5 k at 20°C (68°F) wire harness.

  • Page 75

    ELEC SELF-DIAGNOSIS DEVICE 4. Fuel-cut solenoid (EUR) CIRCUIT DIAGRAM LB LR Lg LR YB Y L Gy1 LY RB RW B Br Or RL BL PUMP (BLACK) S.GND SP RPM GND 0 Igniter unit * Fuel-cut solenoid 1 ( Fuel-cut solenoid 2 1.

  • Page 76: Ignition System

    ELEC IGNITION SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM...

  • Page 77

    ELEC IGNITION SYSTEM EASB0030 EAS00739 TROUBLESHOOTING 2. Battery The ignition system fails to operate (no • Check the condition of the battery. spark or intermittent spark). Refer to “CHECKING AND CHARGING THE BATTERY” in Chapter 3. Check: Min. open-circuit voltage 1.

  • Page 78

    ELEC IGNITION SYSTEM EAS00743 Spark plug cap resistance 4. Ignition spark gap 10 k at 20°C (68 °F) The following procedure applies to all of the • Is the spark plug cap OK? spark plugs. • Disconnect the spark plug cap from the spark plug.

  • Page 79

    ELEC IGNITION SYSTEM EAS00749 8. Main switch • Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the main switch OK? Replace the main switch. Secondary coil resistance 10.7 14.5 k at 20°C (68°F) EAS00750 • Is the ignition coil OK? 9.

  • Page 80

    ELEC IGNITION SYSTEM ✳ EAS00754 14. Wiring • Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the ignition system’s wiring properly con- nected and without defects? Properly connect or Replace the ignitor repair the ignition sys- unit.

  • Page 81: Electric Starting System

    ELEC ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM...

  • Page 82

    ELEC ELECTRIC STARTING SYSTEM EB803010 STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, and the starting circuit cut-off relay. If the engine stop switch is on “RUN” and the main switch is on “ON” (both switches are closed), the starter motor can operate only if: The transmission is in neutral (the neutral switch is closed).

  • Page 83

    ELEC ELECTRIC STARTING SYSTEM EASB0031 EAS00739 TROUBLESHOOTING 2. Battery The starter motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE Check: BATTERY” in Chapter 3. 1. Main and ignition fuses Min. open-circuit voltage: 2.

  • Page 84

    ELEC ELECTRIC STARTING SYSTEM EAS00739 EAS00761 4. Starting circuit cut-off relay 5. Starter relay • Disconnect the starter relay from the coupler. • Disconnect the relay unit from the coupler. • Connect the pocket tester ( 1) and bat- • Connect the pocket tester ( 1) and bat- tery (12V) to the relay unit terminals as tery (12V) to the starter relay coupler as...

  • Page 85

    ELEC ELECTRIC STARTING SYSTEM EAS00764 EAS00750 11. Start switch 7. Engine stop switch • Check the start switch for continuity. • Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. Refer to “CHECKING THE SWITCHES”. • Is the start switch OK? •...

  • Page 86

    ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR Order Job name/Part name Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Starter motor lead Starter motor assembly For installation, reverse the removal procedure. Disassembly the pats in the order listed. Disassembling the starter motor Circlip Starter motor drive gear...

  • Page 87

    ELEC ELECTRIC STARTING SYSTEM Order Job name/Part name Q’ty Remarks Washer set End bracket Refer to “Assembling the starter motor.” Planetary gears Armature assembly Brush holder/brush Refer to “Assembling the starter motor.” Starter motor yoke For assembly, reverse the disassembly procedure.

  • Page 88

    ELEC ELECTRIC STARTING SYSTEM EAS00769 Checking the starter motor 1. Check: • commutator ¡ Dirt Clean with 600 grit sandpaper. 2. Measure: • commutator diameter a ¡ Out of specification Replace the starter motor. Min. commutator diameter 27 mm 3. Measure: •...

  • Page 89

    ELEC ELECTRIC STARTING SYSTEM 5. Measure: • brush length a ¡ Out of specification Replace the brushes as a set. Min. brush length 5 mm 6. Measure: • brush spring force ¡ Out of specification Replace the brush springs as a set. Bruch spring force 7.65 10.01 N (780...

  • Page 90

    ELEC ELECTRIC STARTING SYSTEM 3. Install: • starter motor rear cover 1 NOTE: Align the match marks a on the rear cover with the match marks b on the front cover.

  • Page 91: Charging System

    ELEC CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM Pickup coil Rectifier/regulator Starter relay Battery Wire minus lead...

  • Page 92

    ELEC CHARGING SYSTEM EAS00774 EAS00739 TROUBLESHOOTING 2. Battery The battery is not being charged. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE Check: BATTERY” in Chapter 3. 1. Main fuse Min. open-circuit voltage 2. Battery 12.8 V or more at 20 °C (68 °F) 3.

  • Page 93

    ELEC CHARGING SYSTEM EAS00779 NOTE: 5. Wiring Make sure that the battery is fully charged. • Check the wiring connections of the entire • Is the charging voltage within specification? charging system. Refer to “CIRCUIT DIAGRAM”. • Is the charging system’s wiring properly conected and without defects? The charging circuit is OK.

  • Page 94: Lighting System

    ELEC LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM...

  • Page 95

    ELEC LIGHTING SYSTEM EASB0033 EAS00739 TROUBLESHOOTING 2. Battery Any of the following fail to light: headlight, • Check the condition of the battery. high beam indicator light, license plate light Refer to “CHECKING AND CHARGING THE or meter light. BATTERY” in Chapter 3. Min.

  • Page 96

    ELEC LIGHTING SYSTEM EAS00786 7. Igniter unit 5. Pass switch • Disconnect the igniter unit from the coupler • Check the pass switch for continuity. and connect a new one. Refer to “CHECKING THE SWITCHES”. • Is the lighting system’s OK ? •...

  • Page 97

    ELEC LIGHTING SYSTEM EAS00789 2. Voltage 2. A meter light fails to come on. • Connect the pocket tester (DC 20 V) to the 1. Meter light bulb and socket. headlight and high beam indicator light cou- plers as shown. •...

  • Page 98

    ELEC LIGHTING SYSTEM EAS00790 EASB0034 3. A tail/brake light fails to come on. 4. The license plate light fails to come on. 1. License plate light bulb and socket 1. Tail/brake light bulb and socket • Check the license plate light bulb and socket •...

  • Page 99: Signaling System

    ELEC SIGNALING SYSTEM SIGNALING SYSTEM CIRCUIT DIAGRAM...

  • Page 100

    ELEC SIGNALING SYSTEM Main switch Starter relay Battery Wire minus lead Ignition fuse Right handlebar switch Front brake switch Signal fuse Left handlebar switch Horn Flasher relay Multi-function display Neutral switch lead Neutral switch Front turn signal light (L) Front turn signal light (R) Rear turn signal light (L) Rear turn signal light (R) Tail/brake light...

  • Page 101

    ELEC SIGNALING SYSTEM EASB0035 EAS00739 TROUBLESHOOTING 2. Battery • Any of the following fail to light: turn signal • Check the condition of the battery. light, brake light or an indicator light. Refer to “CHECKING AND CHARGING THE • The horn fails to sound. BATTERY”...

  • Page 102

    ELEC SIGNALING SYSTEM EAS00795 2. Voltage 5. Wiring • Connect the pocket tester (DC 20 V) to the • Check the entire signaling system’s wiring. horn connector at the horn terminal as Refer to “CIRCUIT DIAGRAM”. shown. • Is the signaling system’s wiring properly con- ¡...

  • Page 103

    ELEC SIGNALING SYSTEM 4. Voltage 2. Brake light switches • Connect the pocket tester (DC 20 V) to the • Check the brake light switches for continuity. horn connecter at the black terminal as Refer to “CHECKING THE SWITCHES”. shown. •...

  • Page 104

    ELEC SIGNALING SYSTEM EAS00799 3. Voltage 3. A turn signal light, turn signal indicator light or both fail to blink. • Connect the pocket tester (DC 20 V) to the flasher relay coupler (wire harness side) as 1. Turn signal light bulb and socket shown.

  • Page 105

    ELEC SIGNALING SYSTEM ¡ Brown/White 1 Tester positive probe • Set the main switch to “ON”. ¡ Tester negative probe Ground • Set the turn signal switch to “Δ or “¥”. • Measure the voltage (12 V) of Chocolate 1 or Dark green 2 at the turn signal light con- nector (wire harness side).

  • Page 106

    ELEC SIGNALING SYSTEM 3. Voltage 2. Oil level switch • Connect the pocket tester (DC 20 V) to the • Drain the engine oil and remove the oil level meter assembly coupler (wire harness side) switch from the oil pan. as shown.

  • Page 107: Fuel Pump System

    ELEC FUEL PUMP SYSTEM FUEL PUMP SYSTEM CIRCUIT DIAGRAM...

  • Page 108

    ELEC FUEL PUMP SYSTEM EB808010 FUEL PUMP CIRCUIT OPERATION 1 Battery The fuel pump circuit consists of the fuel pump re- 2 Main fuse lay, fuel pump, engine stop switch and ignitor unit. 3 Main switch The ignitor unit includes the control unit for the fu- 4 Ignition fuse el pump.

  • Page 109

    ELEC FUEL PUMP SYSTEM EASB0037 EAS00739 TROUBLESHOOTING 2. Battery The fuel pump fails to operate. • Check the condition of the battery. Refer to "CHECKING AND CHARGING THE Check: BATTERY" in Chapter 3. 1. Main, and ignition fuses Open-circuit voltage 2.

  • Page 110

    ELEC FUEL PUMP SYSTEM EB803023 EB808021 5. Starting circuit cutoff relay (fuel pump relay) 6. Fuel pump resistance • Remove the relay unit from the wire harness. • Disconnect the fuel pump coupler from the • Connect the pocket tester ( 1) and bat- wire harness.

  • Page 111

    ELEC FUEL PUMP SYSTEM EASB0038 FUEL PUMP TEST WARNING Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or combustion. Be extremely careful and note the following points: • Stop the engine before refuelling. •...

  • Page 112: Carburetor Heater System

    ELEC CARBURETOR HEATER SYSTEM CARBURETOR HEATER SYSTEM CIRCUIT DIAGRAM Main switch Starter relay Battery Wire minus lead Carburetor heater fuse Thermo switch Carburetor heater earth Carburetor heater 1 Carburetor heater 2 Carburetor heater 3/4...

  • Page 113: Troubleshooting

    ELEC CARBURETOR HEATER SYSTEM EASB0039 EAS00739 TROUBLESHOOTING 2. Battery The carburetor heater fails to operate. • Check the condition of the battery. Refer to "CHECKING AND CHARGING THE Check: BATTERY" in Chapter 3. 1. Main and carburetor heater fuses Open-circuit voltage 2.

  • Page 114

    ELEC CARBURETOR HEATER SYSTEM EASB0041 5. Carburetor heater • Remove the carburetor heater from the car- buretor body. • Connect the pocket tester to the carburetor heater. ¡ Heater terminal 1 Tester (+) lead ¡ Heater body 2 Tester (–) lead •...

  • Page 115: Troubleshooting

    TRBL SHTG STARTING FAILURE/HARD STARTING TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of problems. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspec- tion, adjustment and replacement of parts.

  • Page 116

    YAMAHA MOTOR ITALIA S.P.A. PRINTED IN ITALY...

  • Page 117: Wiring Diagram

    BT1100 WIRING DIAGRAM WIRING DIAGRAM Pickup coil Rectifier/regulator RG B2 B B B2 RG YL GL RW RW GL YL Main switch Starter relay Battery Wire minus lead Starter motor Starting circuit cut-off relay Fuel pump (BLACK) Igniter unit RB L LB LR Ignition coil 1 Lg LR YB Y L Gy1 LY RB RW B Br Or...

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