Yamaha BT1100 Bulldog 02-05 Workshop Service Manual

BT1100 SERVICE MANUAL 2002 5JN1-AE1

EASB0000 BT1100 2002 SERVICE MANUAL © 2001 by Belgarda S.p.A. First edition, November 2001 All rights reserved. Any reproduction or unauthorized use without the written permission of Belgarda S.p.A. is expressly prohibited. Printed in Italy

EASB0001 NOTICE This manual was produced by the Belgarda S.p.A. primarily for use by Yamaha dealers and their quali- fied mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. Belgarda S.p.A. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. NOTE: Designs and specifications are subject to change without notice. EAS00004 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFE- TY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person checking or repairing the motorcycle. A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. NOTE: A NOTE provides key information to make procedures easier or clearer. CAUTION: WARNING

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. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to "SYMBOLS". 2 Each chapter is divided into sections. The current section title is shown at the top of each page, except in Chapter 3 ("PERIODIC CHECKS AND ADJUSTMENTS"), where the sub-section title(s) appears. 3 Sub-section titles appear in smaller print than the section title. 4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step. 6 Symbols indicate parts to be lubricated or replaced. Refer to "SYMBOLS". 7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 8 Jobs requiring more information (such as special tools and technical data) are described sequentially.

EB003000 ILLUSTRATED SYMBOLS The following symbols are not relevant to every vehicle. Illustrated symbols 1 to 8 are printed on the top right of each page and indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic inspections and adjustments 4 Engine 5 Carburetion 6 Chassis 7 Electrical 8 Troubleshooting Illustrated symbols 9 to y are used to identify the specifications appearing in the text. 9 Can be serviced with engine mounted 0 Filling fluid q Lubricant w Special tool e Torque r Wear limit, clearance t Engine speed y Electrical data Illustrated symbols u to s in the exploded diagrams indicate the types of lubricants and lubrica- tion points. u Apply engine oil i Apply gear oil o Apply molybdenum disulfide oil p Apply wheel bearing grease a Apply lightweight lithium-soap base grease s Apply molybdenum disulfide grease Illustrated symbols d to f in the exploded diagrams indicate the following: d Apply locking agent (LOCTITE ® ) f Replace the part GEN INFO SPEC INSP ADJ ENG CARB CHAS ELEC TRBL SHTG New 1 2 3 4 ? 5 6 7 8 9 0 q w e r t y u o i p s a d f

GENERAL INFORMATION TABLE OF CONTENTS GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC INSPECTION AND ADJUSTMENTS INSP ADJ 3 ENGINE ENG 4 CARBURETION CARB 5 CHASSIS CHAS 6 ELECTRICAL ELEC 7 TROUBLESHOOTING TRBL SHTG 8 ? E004000

1 GEN INFO

GEN INFO CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ......................................................................................1-1 VEHICLE IDENTIFICATION NUMBER..........................................................................1-1 MODEL LABEL ..............................................................................................................1-1 IMPORTANT INFORMATION ..............................................................................................1-2 PREPARATION FOR REMOVAL PROCEDURES ........................................................1-2 REPLACEMENT PARTS ..............................................................................................1-2 GASKETS, OIL SEALS AND O-RINGS ........................................................................1-2 LOCK WASHERS/PLATES AND COTTER PINS ........................................................1-3 BEARINGS AND OIL SEALS ........................................................................................1-3 CIRCLIPS ......................................................................................................................1-3 CHECKING OF CONNECTIONS ........................................................................................1-4 SPECIAL TOOLS..................................................................................................................1-5

GEN INFO

Yamaha BT1100 Bulldog 02-05 Workshop Service Manual

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