Yamaha BT1100
SERVICE MANUAL
YAMAHA BT1100 - SERVICE MANUAL - English, German and Italian Service Manual, in PDF format, to motorcycles Yamaha model BT1100. CONTENTS: COMPLETE SM GENERAL INFORMATION MOTORCYCLE IDENTIFICATION Vehicle identification number Model label IMPORTANT INFORMATION Preparation for removal procedures Replacement parts Gaskets, oil seals and o-rings Lock washers/plates and cotter pins Bearings and oil seals Circlips CHECKING OF CONNECTIONS Special tools SPECIFICATIONS GENERAL SPECIFICATIONS MAINTENANCE SPECIFICATIONS Engine Chassis Electrical GENERAL TORQUE SPECIFICATIONS CONVERSION TABLE LUBRICATION POINTS AND LUBRICANT TYPES Engine Chassis LUBRICATION DIAGRAMS Cable routing PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION PERIODIC MAINTENANCE/LUBRICATION INTERVALS SEAT, SIDE COVERS AND FUEL TANK Removal Installation ENGINE Adjusting the valve clearance Synchronizing the carburetors Adjusting the engine idling speed Adjusting the throttle cable free play Checking the spark plugs Checking the ignition timing Measuring the compression pressure Checking the engine oil level Changing the engine oil Adjusting the clutch cable free play Cleaning the air filter element Checking the carburetor joint and intake manifold Checking the breather hose Checking the exhaust system CHASSIS Adjusting the front brake Adjusting the rear brake Checking the brake fluid level Checking the brake hoses Bleeding the hydraulic brake system Adjusting the shift pedal Checking the final drive oil level Changing the final drive oil Checking and adjusting the steering head Checking the front fork Adjusting the front fork legs Adjusting the rear shock absorber assembly Checking the tires Checking the wheels Checking and lubricating the cables Lubricating the levers and pedals Lubricating the sidestand ELECTRICAL SYSTEM Checking and charging the battery Checking the fuses Replacing the headlight bulb Adjusting the headlight beam ENGINE Engine removal Seat, storage compartment, side covers, fuel tank Air filter case assembly, carburetor assembly And exhaust system Leads, shift pedal and clutch cable Engine mounting bolts Installing the engine CYLINDER HEADS Rear cylinder head Front cylinder head Removing the cylinder heads Checking the cylinder heads Checking the timing chain tensioner Installing the cylinder heads ROCKER ARMS AND CAMSHAFT Removing the rocker arms and camshaft Checking the camshafts Checking the rocker arms and rocker arm shafts Installing the camshaft and rocker arms VALVES AND VALVE SPRINGS Removing the valves Checking the valves and valve guides Checking the valve seats Checking the valve springs Installing the valves CYLINDERS AND PISTONS Removing the pistons Checking the cylinders and pistons Checking the piston rings Checking the piston pins Installing the pistons and cylinders TIMING GEARS Removing the timing drive gears Checking the timing chains, camshaft Sprockets and timing guids Checking the primary drive Installing the timing drive gears CLUCTH Right crankcase cover Clutch assembly Removing the clutch Checking the friction plates Checking the pressure plate Checking the clutch boss Checking the clutch push rods Checking the clutch plates Checking the clutch spring and clutch spring seat plate Checking the clutch housing Installing the clutch GENERATOR AND STARTER CLUTCH Stator coil and pickup coil Generator and starter clutch Removing the generator Checking the starter clutch Installing the generator SHIFT SHAFT Checking the shift shaft Checking the stopper lever Installing the shift shaft OIL PUMP Checking the oil pump Checking the oil delivery pipes Checking the oil strainer Installing the oil pump CRANKSHAFT AND CONNECTING RODS Crankcase Crankshaft and connecting rods Disassembling the crankcase Removing the crankshaft assembly Removing the connecting rods Checking the crankshaft and connecting rods Checking the bearing and oil seals Installing the crankshaft Assembling the crankcase TRANSMISSION Checking the shift forks Checking the shift drum assembly Checking the transmission Installing the transmission MIDDLE GEAR Middle drive pinion gear Middle driven pinion gear Removing the middle drive shaft assembly Disassembling the middle drive shaft assembly Removing the middle driven shaft assembly Checking the middle drive shaft assembly Checking the middle driven shaft assembly Assembling the middle drive shaft assembly Assembling the middle driven shaft assembly Installing the middle gear assembly and adjusting The backlash Installing the universal joint Aligning the middle gear CARBURETION CARBURETOR Checking the carburetors Assembling the carburetors Installing the carburetors Measuring and adjusting the fuel level Checking and adjusting the throttle position sensor AIR INDUCTION SYSTEM (AIS) Air induction Air cut-off valve Air induction system inspection CHASSIS FRONT WHEEL AND BRAKE DISCS Removing the front wheel Checking the front wheel Checking the brake discs Installing the front wheel Adjusting the front wheel static balance REAR WHEEL AND BRAKE DISC Rear wheel Removing the rear wheel Checking the rear wheel Checking the rear wheel drive hub Installing the rear wheel Adjusting the rear wheel static balance FRONT AND REAR BRAKES Front brake pads Rear brake pads Replacing the front brake pads Replacing the rear brake pads Front brake master cylinder Rear brake master cylinder Removing the front brake master cylinder Removing the rear brake master cylinder Checking the front and rear brake master cylinder Installing the front brake master cylinder Installing the rear brake master cylinder Front brake calipers Rear brake caliper Removing the front brake calipers Removing the rear brake caliper Checking the front and rear brake calipers Installing the front brake calipers Installing the rear brake caliper FRONT FORK Removing the front fork legs Disassembly the front fork legs Checking the front fork legs Assembling the front fork legs Installing the front fork legs HANDLEBAR Removing the handlebar Checking the handlebar Installing the handlebar STEERING HEAD Removing the lower bracket Checking the steering head Installing the steering head REAR SHOCK ABSORBER AND SWINGARM Handling the rear shock absorber and gas cylinder Disposing of a rear shock absorber and gas cylinder Removing the rear shock absorber Removing the swingarm Checking the rear shgock absorber and gas cylinder Checking the swingarm Installing the rear shock absorber Installing the swingarm SHAFT DRIVE Troubleshooting Checking the final drive oil for contamination And inspecting the shaft drive for leaks Measuring the ring gear backlash Adjusting the ring gear backlash Final drive assembly and drive shaft Final gear Disassembling the final drive assembly Removing and installing the ring gear bearings Aligning the final drive pinion gear and ring gear Checking the drive shaft Installing the drive shaft ELECTRICAL ELECTRICAL COMPONENTS SWITCHES Checking switch continuity CHECKING THE SWITCHES CHECKING THE BULBS AND BULB SOCKETS Types of bulbs Checking the condition of the bulbs Checking the condition of the bulb sockets IGNITION SYSTEM Circuit diagram Troubleshooting ELECTRIC STARTING SYSTEM Circuit diagram Starting circuit operation Troubleshooting Starter motor CHARGING SYSTEM Circuit diagram Troubleshooting LIGHTING SYSTEM Circuit diagram Troubleshooting Checking the lighting system SIGNALING SYSTEM Circuit diagram Troubleshooting Checking the signaling system FUEL PUMP SYSTEM Circuit diagram Fuel pump circuit operation Troubleshooting Fuel pump test CARBURETOR HEATER SYSTEM Circuit diagram Troubleshooting SELF-DIAGNOSIS Troubleshooting TROUBLESHOOTING STARTING FAILURE/HARD STARTING Fuel system Electrical system Compression system POOR IDLE SPEED PERFORMANCE Poor idle speed performance POOR MEDIUM-AND HIGH-SPEED PERFORMANCE Poor medium-and high-speed performance FAULTY GEAR SHIFTING Hard shifting Shift pedal does not move Jumps-out-of gear CLUTCH SLIPPING/DRAGGING Clutch slipping Clutch dragging OVERHEATING Overheating FAULTY BRAKE Poor braking performance FRONT FORK OIL LEAKAGE AND FRONT FORK MALFUNCTION Malfunction Oil leakage UNSTABLE HANDLING Unstable handling FAULTY LIGHTING AND SIGNAL SYSTEMS Headlight does not light Bulb burnt out Flasher does not light Flasher blinks slowly Flasher remains lit Flasher blilnks quickly Horn does not sound ELECTRICAL SYSTEM 1 Pickup coil 2 Rectifier/regulator 3 Main switch 4 Starter relay 5 Battery 6 Wire minus lead 7 Starter motor 8 Starting circuit cut-off relay 9 Fuel pump 0 Igniter unit q Ignition coil 1 w Ignition coil 2 e Throttle position sensor r Sidestand switch t Ignition fuse y Right handlebar switch u Front brake switch i Headlight fuse Signal fuse p Carburetor heater fuse a Backup fuse s Left handlebar switch d Clutch switch f Horn g Flasher relay h Speedometer j Neutral switch lead k Neutral switch l Headlight ; Front turn signal light (left) z Front turn signal light (right) x Rear turn signal light (left) c Rear turn signal light (right) v Thermo switch b Carburetor heater earth n Carburetor heater 1 m Carburetor heater 2 , Fuel sender . Tail/brake light / Oil warning light ! Speed sensor @ Rear brake switch # Alarm system (Option) $ Diode % License plate light SUPPLEMENT SM1 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 Cable routing PERIODIC INSPECTIONS AND ADJUSTMENTS Periodic maintenance/lubrication intervals Chassis - adjusting the front brake Checking the fuses Engine Engine removal Carburetion Carburetor CHASSIS Front brake master cylinder Front brake calipers Handlebar Steering head - lower bracket ELECTRICAL Electrical components Switches Checking the bulbs and bulb sockets Immobilizer system Self-diagnosis device Ignition system Electric starting system Charging system Lighting system Signaling system Fuel pump system Carburetor heater system TROUBLESHOOTING Starting Failure/Hard Starting WIRING DIAGRAM
Yamaha BT1100 - Service Manual - Manuale di Officina - Reparaturanleitung
inicio - index
coche - car
moto
4x4
quad - buggy
cami?n - truck
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