Yamaha Mt 01 T 2005 Manual

							FRONT BRAKE
4-29
2. Check:
Brake master cylinder kit
Damage/scratches/wear → Replace.
3. Check:
Brake fluid reservoir
Cracks/damage → Replace.
Brake fluid reservoir diaphragm
Cracks/damage → Replace.
4. Check:
Brake hoses
Cracks/damage/wear → Replace.
EAS22520
ASSEMBLING THE FRONT BRAKE MASTER 
CYLINDER
WARNING
EWA13520
Before installation, all internal brake com-
ponents should be cleaned and lubricated 
with clean or new brake fluid.
Never use solvents on internal brake com-
ponents.
EAS22540
INSTALLING THE FRONT BRAKE MASTER 
CYLINDER
1. Install:
Front brake master cylinder “1”
Front brake master cylinder holder
NOTE:
Align the end of the brake master cylinder hold-
er with the punch mark “a” on the handlebar.
First, tighten the upper bolt, then the lower bolt.
2. Install:
Copper washers 
Front brake hose “1”Front brake hose union bolt “2”
WARNING
EWA13530
Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to “CABLE 
ROUTING” on page 2-41.
NOTE:
Install the brake hose at a right angle to the 
front brake master cylinder as shown in the il-
lustration.
While holding the brake hose, tighten the union 
bolt.
Turn the handlebar to the left and right to make 
sure the brake hose does not touch other parts 
(e.g., wire harness, cables, leads). Correct if 
necessary.
3. Fill:
Brake fluid reservoir
(with the specified amount of the recom-
mended brake fluid)
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.
 
Recommended fluid
DOT 4
T R.. 
Front brake master cylinder 
holder bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
1
a
New
T R.. 
Front brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
 
Recommended fluid
DOT 4
90˚
1
2 
						

							FRONT BRAKE
4-30
CAUTION:
ECA13540
Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean up 
any spilt brake fluid immediately.
4. Bleed:
Brake system
Refer to “BLEEDING THE HYDRAULIC 
BRAKE SYSTEM” on page 3-23.
5. Check:
Brake fluid level
Below the minimum level mark “a” → Add the 
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID 
LEVEL” on page 3-21.
6. Check:
Brake lever operation
Soft or spongy feeling → Bleed the brake sys-
tem.
Refer to “BLEEDING THE HYDRAULIC 
BRAKE SYSTEM” on page 3-23.
a 
						

							REAR BRAKE
4-31
EAS22550
REAR BRAKE
Removing the rear brake pads
Order Job/Parts to remove Q’ty Remarks
1 Screw plug 1
2 Brake pad pin 1
3 Rear brake caliper 1
4 Brake pad shim 2
5 Brake pad insulator 2
6 Rear brake pad 2
7 Brake pad spring 2
For installation, reverse the removal 
procedure.
T R..3 Nm (0.3 m • kg, 2.2 ft • Ib)
T R..22 Nm (2.2 m • 
kg, 16 ft • Ib)
T R..27 Nm (2.7 m • 
kg, 19 ft • Ib)
T R..6 Nm (0.6 m • 
kg, 4.3 ft • Ib)
T R..17 Nm (1.7 m • 
kg, 12 ft • Ib)
LS
LT
3
2
1
7
7
6
5
4 5 4 
						

							REAR BRAKE
4-32
Removing the rear brake master cylinder
Order Job/Parts to remove Q’ty Remarks
Brake fluidDrain.
Refer to “BLEEDING THE HYDRAULIC 
BRAKE SYSTEM” on page 3-23.
Seat/Battery box/Lead holderRefer to “GENERAL CHASSIS” on page 
4-1.
Drive sprocket cover Refer to “CHAIN DRIVE” on page 4-69.
1 Brake fluid reservoir cap holder 1
2 Brake fluid reservoir cap 1
3 Brake fluid reservoir diaphragm holder 1
4 Brake fluid reservoir diaphragm 1
5 Brake fluid reservoir 1
6 Brake fluid reservoir hose 1
7 Rear brake hose union bolt 1
8 Copper washer 2
9 Rear brake hose 1
10 Rear brake master cylinder 1
For installation, reverse the removal 
procedure.
T R..30 Nm (3.0 m • 
kg, 22 ft • Ib)New
New
T R..23 Nm (2.3 m • 
kg, 17 ft • Ib)
T R..7 Nm (0.7 m • 
kg, 5.1 ft • Ib)
T R..7 Nm (0.7 m • 
kg, 5.1 ft • Ib)
2
13
4
5
7
8 9 10
6 
						

							REAR BRAKE
4-33
Disassembling the rear brake master cylinder
Order Job/Parts to remove Q’ty Remarks
1 Brake master cylinder kit 1
2 Brake hose joint 1
3Bush 1
4 Brake master cylinder body 1
For assembly, reverse the disassembly 
procedure. 
						

							REAR BRAKE
4-34
Removing the rear brake caliper
Order Job/Parts to remove Q’ty Remarks
Brake fluidDrain.
Refer to “BLEEDING THE HYDRAULIC 
BRAKE SYSTEM” on page 3-23.
1 Rear brake hose union bolt 1
2 Copper washer 2
3 Rear brake hose 1
4 Rear brake caliper 1
For installation, reverse the removal 
procedure.
T R..22 Nm (2.2 m • 
kg, 16 ft • Ib)
T R..30 Nm (3.0 m • 
kg, 22 ft • Ib)
T R..27 Nm (2.7 m • 
kg, 19 ft • Ib)
LS
LT
New
1
2
4
3 
						

							REAR BRAKE
4-35
Disassembling the rear brake caliper
Order Job/Parts to remove Q’ty Remarks
1 Screw plug 1
2 Brake pad pin 1
3 Brake pad shim 2
4 Brake pad insulator 2
5 Rear brake pad 2
6 Brake pad spring 2
7 Brake caliper piston 2
8 Brake caliper piston seal 4
9 Bleed screw 1
For assembly, reverse the disassembly 
procedure.
LS
New
New
9
2
1
6
4 3
5
4
3
7 6
88
T R..3 Nm (0.3 m • kg, 2.2 ft • Ib)
T R..17 Nm (1.7 m • 
kg, 12 ft • Ib)
T R..6 Nm (0.6 m • 
kg, 4.3 ft • Ib) 
						

							REAR BRAKE
4-36
EAS22560INTRODUCTION
WARNING
EWA14100
Disc brake components rarely require disas-
sembly. Therefore, always follow these pre-
ventive measures:
Never disassemble brake components un-
less absolutely necessary.
If any connection on the hydraulic brake 
system is disconnected, the entire brake 
system must be disassembled, drained, 
cleaned, properly filled, and bled after reas-
sembly.
Never use solvents on internal brake com-
ponents.
Use only clean or new brake fluid for clean-
ing brake components.
Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately.
Avoid brake fluid coming into contact with 
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING 
THE EYES:
Flush with water for 15 minutes and get im-
mediate medical attention.
EAS22570CHECKING THE REAR BRAKE DISC
1. Remove:
Rear wheel
Refer to “REAR WHEEL” on page 4-12.
2. Check:
Brake disc
Damage/galling → Replace.
3. Measure:
Brake disc deflection
Out of specification → Correct the brake disc 
deflection or replace the brake disc.
Refer to “CHECKING THE FRONT BRAKE 
DISCS” on page 4-24.
4. Measure:
Brake disc thickness
Measure the brake disc thickness at a few dif-
ferent locations.
Out of specification → Replace.
Refer to “CHECKING THE FRONT BRAKE 
DISCS” on page 4-24.5. Adjust:
Brake disc deflection
Refer to “CHECKING THE FRONT BRAKE 
DISCS” on page 4-24.
6. Install:
Rear wheel
Refer to “REAR WHEEL” on page 4-12.
EAS22580REPLACING THE REAR BRAKE PADS
NOTE:
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disassem-
ble the brake caliper.
1. Measure:
Brake pad wear limit “a”
Out of specification → Replace the brake 
pads as a set.
2. Install:
Brake pad shims
(onto the brake pads)
Brake pads
Brake pad spring
 
Brake disc deflection limit
0.15 mm (0.0059 in)
 
Brake disc thickness limit
5.5 mm (0.22 in)
T R.. 
Rear brake disc bolt
18 Nm (1.8 m·kg, 13 ft·lb)
LOCTITE
®
 
Brake pad lining thickness 
(inner)
6.5 mm (0.26 in)
Limit
1.0 mm (0.04 in)
Brake pad lining thickness 
(outer)
6.5 mm (0.26 in)
Limit
1.0 mm (0.04 in)
a 
						

							REAR BRAKE
4-37
NOTE:
Always install new brake pads, brake pad shims, 
and a brake pad spring as a set.



 





 
 








 
 



 
 



 



a. Connect a clear plastic hose “1” tightly to the 
bleed screw “2”. Put the other end of the hose 
into an open container.
b. Loosen the bleed screw and push the brake 
caliper pistons into the brake caliper with your 
finger.
c. Tighten the bleed screw.
d. Install a new brake pad insulator and new 
brake pad shim “3” onto each new brake pad 
“4”.
        
3. Install:
Rear brake caliper
Brake pad pin
Screw plug4. Check:
Brake fluid level
Below the minimum level mark “a” → Add the 
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID 
LEVEL” on page 3-21.
5. Check:
Brake pedal operation
Soft or spongy feeling → Bleed the brake sys-
tem.
Refer to “BLEEDING THE HYDRAULIC 
BRAKE SYSTEM” on page 3-23.
EAS22590
REMOVING THE REAR BRAKE CALIPER
NOTE:
Before disassembling the brake caliper, drain 
the brake fluid from the entire brake system.
1. Remove:
Rear brake hose union bolt “1”
Copper washers “2”
Rear brake hose “3”
NOTE:
Put the end of the brake hose into a container 
and pump out the brake fluid carefully.
EAS22610
DISASSEMBLING THE REAR BRAKE 
CALIPER
1. Remove:
Brake caliper pistons “1”
Brake caliper piston seals “2”
T R.. 
Bleed screw (rear brake caliper)
6 Nm (0.6 m·kg, 4.3 ft·lb)
T R.. 
Rear brake caliper bolt (M12)
27 Nm (2.7 m·kg, 19 ft·lb)
Rear brake caliper bolt (M8)
22 Nm (2.2 m·kg, 16 ft·lb)
LOCTITE
®
1
2
3
4
a
31
2 
						

							REAR BRAKE
4-38



 





 
 








 
 



 
 



 



a. Blow compressed air into the brake hose joint 
opening “a” to force out the pistons from the 
brake caliper.
WARNING
EWA13550
Cover the brake caliper piston with a rag. 
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
Never try to pry out the brake caliper pis-
ton.
b. Remove the brake caliper piston seals.
        
EAS22640
CHECKING THE REAR BRAKE CALIPER
1. Check:
Brake caliper pistons “1”
Rust/scratches/wear → Replace the brake 
caliper pistons.
Brake caliper cylinders “2”
Scratches/wear → Replace the brake caliper 
assembly.Brake caliper body “3”
Cracks/damage → Replace the brake caliper 
assembly.
Brake fluid delivery passages
(brake caliper body)
Obstruction → Blow out with compressed air.
WARNING
EWA13610
Whenever a brake caliper is disassembled, 
replace the brake caliper piston seals.
2. Check:
Brake caliper bracket “1”
Cracks/damage → Replace.
EAS22650
ASSEMBLING THE REAR BRAKE CALIPER
WARNING
EWA13620
Before installation, all internal brake com-
ponents should be cleaned and lubricated 
with clean or new brake fluid.
Never use solvents on internal brake com-
ponents as they will cause the piston seals 
to swell and distort.
Whenever a brake caliper is disassembled, 
replace the brake caliper piston seals. Recommended brake component
replacement schedule
Brake pads If necessary
Piston seals Every two years
Brake hoses Every four years
Brake fluidEvery two years and 
whenever the brake 
is disassembled
1 22
a
 
Recommended fluid
DOT 4
11
22
3
1