Yamaha BT1100 - Workshop Manual - Manuale di Officina - Reparaturanleitung

YAMAHA BT1100 - SERVICE MANUAL

- English, German and Italian Workshop Manual, in PDF format, to motorcycles Yamaha model BT1100.


INDEX:

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