Yamaha Mt 01 T 2005 Manual

							ENGINE
3-16
EAS21010CHECKING THE THROTTLE BODY JOINTS
1. Remove:
Seat
Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tank
Refer to “FUEL TANK” on page 6-1.
Air filter case
Refer to “GENERAL CHASSIS” on page 4-1.
2. Check:
Throttle body joints “1”
Cracks/damage → Replace.
3. Install:
Air filter case
Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tank
Refer to “FUEL TANK” on page 6-1.
Seat
Refer to “GENERAL CHASSIS” on page 4-1.
EAS21030
CHECKING THE FUEL LINE
1. Remove:
Seat
Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tank
Refer to “FUEL TANK” on page 6-1.
Air filter case
Refer to “GENERAL CHASSIS” on page 4-1.
2. Check:
Fuel hoses “1”
Breather hose “2”
Vacuum hose
Cracks/damage → Replace.
Loose connection → Connect properly.
CAUTION:
ECA14940
Make sure the fuel tank breather hose is rout-
ed correctly.3. Install:
Air filter case
Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tank
Refer to “FUEL TANK” on page 6-1.
Seat
Refer to “GENERAL CHASSIS” on page 4-1.
EAS21050
CHECKING THE CYLINDER HEAD 
BREATHER HOSES
1. Remove:
Seat
Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tank
Refer to “FUEL TANK” on page 6-1.
Air filter case
Refer to “GENERAL CHASSIS” on page 4-1.
2. Check:
Cylinder head breather hose (air filter case to 
oil catch tank) “1”
Cylinder head breather hose (cylinder head 
to oil catch tank) “2”
Cracks/damage → Replace.
Loose connection → Connect properly.
CAUTION:
EC5YU1028
Make sure the cylinder head breather hoses 
are routed correctly.
3. Install:
Air filter case
Refer to “GENERAL CHASSIS” on page 4-1.
1
1
21
21 
						

							ENGINE
3-17
Fuel tank
Refer to “FUEL TANK” on page 6-1.
Seat
Refer to “GENERAL CHASSIS” on page 4-1.
EAS21060
CHECKING THE OIL TANK BREATHER 
HOSE
1. Check:
Oil tank breather hose “1”
Cracks/damage → Replace.
Loose connection → Connect properly.
CAUTION:
ECA14930
Make sure the oil tank breather hose is rout-
ed correctly.
EAS21080
CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of the ex-
haust pipes and gaskets.
1. Remove:
Seat
Refer to “GENERAL CHASSIS” on page 4-1.
2. Check:
Front exhaust pipe “1”
Rear exhaust pipe “2”
Catalyst pipe “3”
Mufflers “4”
Cracks/damage → Replace.
Gaskets “5”
Exhaust gas leaks → Replace.
3. Check:
Tightening torques
Front exhaust pipe and front exhaust pipe 
joint bolts “6”
Front exhaust pipe and rear exhaust pipe bolt 
“7”
Rear exhaust pipe and rear exhaust pipe joint 
bolt “8”
Rear exhaust pipe bolt “9”
Rear exhaust pipe and catalyst pipe bolt “10”
Catalyst pipe nut “11”
Catalyst pipe and muffler bolts “12”Muffler bolts “13”
NOTE:
When installing the EXUP cables, make sure 
they are parallel and not twisted.
Upper cable: Black metal section “14”
Lower cable: White metal section “15”
1
T R.. 
Front exhaust pipe and front 
exhaust pipe joint bolt
20 Nm (2.0 m·kg, 14 ft·lb)
Front exhaust pipe and rear 
exhaust pipe bolt
20 Nm (2.0 m·kg, 14 ft·lb)
Rear exhaust pipe and rear 
exhaust pipe joint bolt
20 Nm (2.0 m·kg, 14 ft·lb)
Rear exhaust pipe bolt
20 Nm (2.0 m·kg, 14 ft·lb)
Rear exhaust pipe and catalyst 
pipe bolt
20 Nm (2.0 m·kg, 14 ft·lb)
Catalyst pipe nut
20 Nm (2.0 m·kg, 14 ft·lb)
Catalyst pipe and muffler bolt
20 Nm (2.0 m·kg, 14 ft·lb)
Muffler bolt
24 Nm (2.4 m·kg, 17 ft·lb)
10
4
45
351
5
2 55
5 9 12
11
7
6
12
13
13
8 
						

							ENGINE
3-18
4. Install:
Seat
Refer to “GENERAL CHASSIS” on page 4-1.
EAS21100
ADJUSTING THE EXUP CABLES
1. Remove:
EXUP valve pulley cover “1”
2. Check:
EXUP system operation



 





 
 








 
 



 
 



 



a. Turn the main switch to “ON”.
b. Check that the EXUP valve operates proper-
ly.
NOTE:
Check that the projections “a” on the EXUP 
valve pulley contact the stopper “b” (fully-open 
position) and the stopper “c” (fully-closed posi-
tion).
        
3. Check:
EXUP cable free play (at the EXUP valve pul-
ley) “a”4. Adjust:
EXUP cable free play



 





 
 



 
 



 
 



 
 



 



a. Slide back the rubber cover.
b. Loosen both locknuts “1”.
c. Insert a 3.5 mm (0.14 in) pin “2” through the 
projections “a” in the EXUP valve pulley and 
into the hole “b” in the EXUP valve cover.
d. Turn both adjusting nuts “3” in or out until the 
specification.
15
14
1
b
c a
 
EXUP cable free play (at the 
EXUP valve pulley)
a: 3 mm (0.12 in) or less
b: 0 mm
Turn in “c” →
Free play is increased.
Turn out “d” →
Free play is decreased.
ab
ba
11
2
a
b 
						

							ENGINE
3-19
e. Tighten both locknuts and then slide the rub-
ber cover to its original position.
f. Remove the pin.
g. Turn the main switch to “ON”, check that the 
EXUP valve pulley contacts the stoppers (ful-
ly-open and fully-closed positions), and then 
check that the notch in the EXUP valve pulley 
is aligned with the hole in the EXUP valve 
cover.
        
5. Install:
EXUP valve pulley cover
T R.. 
EXUP valve pulley cover bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
33
d dc d dc c 
						

							CHASSIS
3-20
EAS21140
CHASSIS
EAS21160
ADJUSTING THE FRONT DISC BRAKE
1. Adjust:
Brake lever position
(distance “a” from the throttle grip to the brake 
lever)
NOTE:
While pushing the brake lever forward, turn the 
adjusting knob “1” until the brake lever is in the 
desired position.
Be sure to align the setting on the adjusting 
knob with the arrow mark “2” on the brake le-
ver.
WARNING
EWA13050
A soft or spongy feeling in the brake lever 
can indicate the presence of air in the brake 
system. Before the vehicle is operated, the 
air must be removed by bleeding the brake 
system. Air in the brake system will consid-
erably reduce braking performance.
CAUTION:
ECA13490
After adjusting the brake lever position, 
make sure there is no brake drag.
EAS21190ADJUSTING THE REAR DISC BRAKE
NOTE:
The brake pedal position is determined by the in-
stalled rear brake master cylinder length “a”.
1. Measure:
Installed rear brake master cylinder length “a”
Incorrect → Adjust.2. Adjust:
Installed rear brake master cylinder length



 





 
 



 
 



 
 



 
 



 



a. Loosen the locknut “1”.
b. Turn the adjusting bolt “2” in direction “a” or 
“b” until the specified installed rear brake 
master cylinder length is obtained.
WARNING
EW5YU1011
After adjusting the installed rear brake mas-
ter cylinder length, check that the end of the 
adjusting bolt “c” is visible through the hole 
“d”.
c. Tighten the locknut to specification. Direction “b”
Distance “a” increases.
Direction “c”
Distance “a” decreases.
1
a
2b
c
 
Installed rear brake master 
cylinder length
145.3–145.7 mm (5.72–5.74 in)
Direction “a”
Installed rear brake master cylinder 
length increases.
Direction “b”
Installed rear brake master cylinder 
length decreases.
T R.. 
Locknut (rear brake master 
cylinder)
16 Nm (1.6 m·kg, 11 ft·lb)
a
d
c
b
a
1
2 
						

							CHASSIS
3-21
WARNING
EW5YU1001
A soft or spongy feeling in the brake pedal 
can indicate the presence of air in the brake 
system. Before the vehicle is operated, the 
air must be removed by bleeding the brake 
system. Air in the brake system will consid-
erably reduce braking performance and 
could result in loss of control and possibly 
an accident. Therefore, check and, if neces-
sary, bleed the brake system.
CAUTION:
EC5YU1024
After adjusting the installed rear master cyl-
inder length, make sure there is no brake 
drag.
        
3. Adjust:
Rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE 
LIGHT SWITCH” on page 3-22.
EAS21240
CHECKING THE BRAKE FLUID LEVEL
1. Stand the vehicle on a level surface.
NOTE:
Place the vehicle on a suitable stand.
Make sure the vehicle is upright.
2. Check:
Brake fluid level
Below the minimum level mark “a” → Add the 
recommended brake fluid to the proper level.
WARNING
EWA13090
Use only the designated brake fluid. Other 
brake fluids may cause the rubber seals to 
deteriorate, causing leakage and poor 
brake performance.
Refill with the same type of brake fluid that 
is already in the system. Mixing brake fluids 
may result in a harmful chemical reaction, 
leading to poor brake performance.
When refilling, be careful that water does 
not enter the brake fluid reservoir. Water 
will significantly lower the boiling point of 
the brake fluid and could cause vapor lock.
CAUTION:
ECA13540
Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean up 
any spilt brake fluid immediately.
NOTE:
In order to ensure a correct reading of the brake 
fluid level, make sure the top of the brake fluid 
reservoir is horizontal.
EAS21250
CHECKING THE FRONT BRAKE PADS
The following procedure applies to all of the 
brake pads.
1. Operate the brake.
2. Check:
Front brake pad
Wear indicators “1” almost touch the brake 
disc → Replace the brake pads as a set.
Refer to “FRONT BRAKE” on page 4-18.
 
Recommended fluid
DOT 4
a
A
A. Front brake
B. Rear brake
a
B 
						

							CHASSIS
3-22
EAS21260
CHECKING THE REAR BRAKE PADS
The following procedure applies to all of the 
brake pads.
1. Operate the brake.
2. Check:
Rear brake pad
Wear indicator grooves “1” almost disap-
peared → Replace the brake pads as a set.
Refer to “REAR BRAKE” on page 4-31.
EAS21280CHECKING THE FRONT BRAKE HOSES
The following procedure applies to all of the 
brake hoses and brake hose clamps.
1. Check:
Brake hoses “1”
Cracks/damage/wear → Replace.
2. Check:
Brake hose clamps “2”
Loose → Tighten the clamp bolt.3. Hold the vehicle upright and apply the brake 
several times.
4. Check:
Brake hoses
Brake fluid leakage → Replace the damaged 
hoses.
Refer to “FRONT BRAKE” on page 4-18.
EAS21290CHECKING THE REAR BRAKE HOSE
1. Remove:
Seat
Refer to “GENERAL CHASSIS” on page 4-1.
2. Check:
Brake hoses “1”
Cracks/damage/wear → Replace.
3. Check:
Brake hose guide “2”
Loose → Tighten the clamp bolt.
4. Hold the vehicle upright and apply the brake 
several times.
5. Check:
Brake hoses
Brake fluid leakage → Replace the damaged 
hose.
Refer to “REAR BRAKE” on page 4-31.
6. Install:
Seat
Refer to “GENERAL CHASSIS” on page 4-1.
EAS21330
ADJUSTING THE REAR BRAKE LIGHT 
SWITCH
NOTE:
The rear brake light switch is operated by move-
ment of the brake pedal. The rear brake light 
switch is properly adjusted when the brake light 
comes on just before the braking effect starts.
1. Check:
Rear brake light operation timing
Incorrect → Adjust.
2. Adjust:
Rear brake light operation timing
1
1
2
1
1
2
1
1 
						

							CHASSIS
3-23



 





 
 








 
 



 
 



 



a. Hold the main body “1” of the rear brake light 
switch so that it does not rotate and turn the 
adjusting nut “2” in direction “a” or “b” until the 
rear brake light comes on at the proper time.
        
EAS21360BLEEDING THE HYDRAULIC BRAKE 
SYSTEM
WARNING
EWA13100
Bleed the hydraulic brake system whenever:
the system is disassembled.
a brake hose is loosened, disconnected or 
replaced.
the brake fluid level is very low.
brake operation is faulty.
NOTE:
Be careful not to spill any brake fluid or allow 
the brake fluid reservoir to overflow.
When bleeding the hydraulic brake system, 
make sure there is always enough brake fluid 
before applying the brake. Ignoring this pre-
caution could allow air to enter the hydraulic 
brake system, considerably lengthening the 
bleeding procedure.
If bleeding is difficult, it may be necessary to let 
the brake fluid settle for a few hours. Repeat 
the bleeding procedure when the tiny bubbles 
in the hose have disappeared.
1. Bleed:
Hydraulic brake system



 





 
 



 
 



 
 



 
 



 



a. Fill the brake fluid reservoir to the proper level 
with the recommended brake fluid.
b. Install the brake fluid reservoir diaphragm.
c. Connect a clear plastic hose “1” tightly to the 
bleed screw “2”.
NOTE:
The bleeding order of the front hydraulic brake 
system is the following:
1. Front brake master cylinder
2. Front brake calipers
3. Front brake master cylinder
d. Place the other end of the hose into a con-
tainer.
e. Slowly apply the brake several times.
f. Fully pull the brake lever or fully press down 
the brake pedal and hold it in position.
g. Loosen the bleed screw. Direction “a”
Brake light comes on sooner.
Direction “b”
Brake light comes on later.
1
2
a
b
A. Front brake master cylinder
B. Front brake caliper
C. Rear brake caliper
1
1
2
A
1
2C 
						

							CHASSIS
3-24
NOTE:
Loosening the bleed screw will release the pres-
sure and cause the brake lever to contact the 
throttle grip or the brake pedal to fully extend.
h. Tighten the bleed screw and then release the 
brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air bub-
bles have disappeared from the brake fluid in 
the plastic hose.
j. Tighten the bleed screw to specification.
k. Fill the brake fluid reservoir to the proper level 
with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID 
LEVEL” on page 3-21.
WARNING
EWA13110
After bleeding the hydraulic brake system, 
check the brake operation.
        
EAS21380
ADJUSTING THE SHIFT PEDAL
NOTE:
The shift pedal position is determined by the in-
stalled shift rod length “a”.
1. Measure:
Installed shift rod length “a”
Incorrect → Adjust.
2. Adjust:
Installed shift rod length



 





 
 



 
 



 
 



 
 



 



a. Loosen both locknuts “1”.
b. Turn the shift rod “2” in direction “a” or “b” until 
the specified installed shift rod length is ob-
tained.
c. Tighten both locknuts to specification.
          
EAS21390
ADJUSTING THE DRIVE CHAIN SLACK
CAUTION:
ECA13550
A drive chain that is too tight will overload 
the engine and other vital parts, and one that 
is too loose can skip and damage the swing-
arm or cause an accident. Therefore, keep 
the drive chain slack within the specified lim-
its.
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there is 
no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that the 
rear wheel is elevated.
2. Check:
Drive chain slack “a”
Out of specification → Adjust.
T R.. 
Bleed screw (front brake master 
cylinder)
6 Nm (0.6 m·kg, 4.3 ft·lb)
Bleed screw (front brake caliper)
6 Nm (0.6 m·kg, 4.3 ft·lb)
Bleed screw (rear brake caliper)
6 Nm (0.6 m·kg, 4.3 ft·lb)
 
Installed shift rod length
309.2–311.2 mm (12.17–12.25 in)
a
Direction “a”
Installed shift rod length increases.
Direction “b”
Installed shift rod length decreases.
T R.. 
Locknut (shift rod)
7 Nm (0.7 m·kg, 5.1 ft·lb)
 
Drive chain slack
40.0–50.0 mm (1.57–1.97 in)
1
2
b
a 
						

							CHASSIS
3-25
NOTE:
Measure the drive chain slack 85 mm (3.35 in) 
“b” from the end of the drive chain guide.
3. Adjust:
Drive chain slack



 





 
 








 
 



 
 



 



a. Loosen the wheel axle nut “1”.
b. Loosen both locknuts “2”.
c. Turn both adjusting bolts “3” in direction “a” or 
“b” until the specified drive chain slack is ob-
tained.
NOTE:
To maintain the proper wheel alignment, adjust 
both sides evenly.
Push the rear wheel forward to make sure 
there is no clearance between the swingarm 
end plates and the ends of the swingarm.
d. Tighten the locknuts to specification.
e. Tighten the wheel axle nut to specification.
          
EAS21440LUBRICATING THE DRIVE CHAIN
The drive chain consists of many interacting 
parts. If the drive chain is not maintained proper-
ly, it will wear out quickly. Therefore, the drive 
chain should be serviced, especially when the 
vehicle is used in dusty areas.
This vehicle has a drive chain with small rubber 
O-rings between each side plate. Steam clean-
ing, high-pressure washing, certain solvents, 
and the use of a coarse brush can damage 
these O-rings. Therefore, use only kerosene to 
clean the drive chain. Wipe the drive chain dry 
and thoroughly lubricate it with engine oil or 
chain lubricant that is suitable for O-ring chains. 
Do not use any other lubricants on the drive 
chain since they may contain solvents that could 
damage the O-rings.
EAS21510
CHECKING AND ADJUSTING THE 
STEERING HEAD
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there is 
no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that the 
front wheel is elevated.
2. Check:
Steering head
Grasp the bottom of the front fork legs and 
gently rock the front fork.
Binding/looseness → Adjust the steering 
head. 
3. Remove:
Upper bracket
Refer to “STEERING HEAD” on page 4-57.
4. Adjust:
Steering head Direction “a”
Drive chain is tightened.
Direction “b”
Drive chain is loosened.
T R.. 
Locknut (drive chain adjusting 
bolt)
16 Nm (1.6 m·kg, 11 ft·lb)
a
b
1 23
ab
T R.. 
Rear wheel axle nut
150 Nm (15.0 m·kg, 110 ft·lb)
 
Recommended lubricant
Engine oil or chain lubricant 
suitable for O-ring chains