Yamaha Mt 01 T 2005 Manual

							FEATURES
1-2
EAS20170
FEATURES
ET5YU1009
OUTLINE OF THE FI SYSTEM
The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum 
air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In 
the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion 
chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the 
respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating con-
ditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter the 
fuel through the use of jets have been provided with various auxiliary devices, so that an optimum air-
fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the en-
gine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases increase, 
it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accom-
modate this need, this model has adopted an electronically controlled fuel injection (FI) system, in place 
of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required by 
the engine at all times by using a microprocessor that regulates the fuel injection volume according to 
the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response, 
better fuel economy, and reduced exhaust emissions.
12
223 4 5 6 7 8 9 101112131415 16
17
19 18 27
26 25 24 23 22 21 20
1. Air temperature sensor
2. Cylinder-#1 intake air pressure sensor
3. Cylinder-#2 intake air pressure sensor
4. Cylinder-#2 left ignition coil
5. Cylinder-#2 right ignition coil
6. Throttle position sensor
7. Intake solenoid
8. ISC (idle speed control) unit
9. Fuel pump
10.EXUP servo motor
11.Lean angle cut-off switch
12.Fuel pump relay
13.Muffler cooling fan motor relay
14.ECU (electronic control unit)15.Relay unit (fuel pump relay)
16.Muffler cooling fan temperature sensor
17.Muffler cooling fan motor
18.Cylinder-#1 right ignition coil
19.Cylinder-#1 left ignition coil
20.Speed sensor
21.O
2 sensor
22.Spark plug
23.Decompression solenoid
24.Crankshaft position sensor
25.Injector #2
26.Injector #1
27.Engine temperature sensor 
						

							FEATURES
1-3
ET5YU1010FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the 
fuel pressure that is applied to the fuel injector at only 392 kPa (3.92 kg/cm², 55.7 psi). Accordingly, 
when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing 
the fuel to be injected into the intake manifold only during the time the passage remains open. There-
fore, the longer the length of time the fuel injector is energized (injection duration), the greater the vol-
ume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized 
(injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from the 
throttle position sensor, crankshaft position sensor, intake air pressure sensor, air temperature sensor, 
engine temperature sensor, speed sensor and O
2 sensor enable the ECU to determine the injection 
duration. The injection timing is determined through the signals from the crankshaft position sensor. As 
a result, the volume of fuel that is required by the engine can be supplied at all times in accordance with 
the driving conditions.
Illustration is for reference only.
15 A1
2
3
4 C
587 6
10
11
12 1314 B #1 #2
9
1. Pressure regulator
2. Fuel pump
3. Fuel injector
4. Ignition coil
5. ECU (electronic control unit)
6. Air temperature sensor
7. ISC (idle speed control) unit
8. Throttle position sensor
9. O
2 sensor
10.Catalytic converter
11.Engine temperature sensor
12.Crankshaft position sensor13.Intake air pressure sensor
14.Throttle body
15.Air filter case
A. Fuel system
B. Air system
C. Control system 
						

							FEATURES
1-4
ET5YU1011INSTRUMENT FUNCTIONS
Multifunction display
WARNING
EW5YU1005
Be sure to stop the vehicle before making 
any setting changes to the multifunction dis-
play.
The multifunction display is equipped with the 
following:
a speedometer (which shows the riding speed)
a tachometer (which shows engine speed)
an odometer (which shows the total distance 
traveled)
two tripmeters (which show the distance trav-
eled since they were last set to zero)
a fuel reserve tripmeter (which shows the dis-
tance traveled since the fuel level warning light 
come on)
a clock
a self-diagnosis device
a brightness control mode
NOTE:
Be sure to turn the key to “ON” before using the 
“SELECT” and “RESET” buttons except for 
setting the brightness control.
For the U.K. only: To switch the speedometer 
and odometer/tripmeter/fuel reserve tripmeter 
displays between kilometers and miles, press 
the “SELECT” button for at least two seconds.Tachometer
The electric tachometer allows the rider to mon-
itor the engine speed and keep it within the ideal 
power range.
When the key is turned to “ON”, the tachometer 
needle will sweep once across the r/min range 
and then return to zero r/min in order to test the 
electrical circuit.
CAUTION:
EC5YU1009
Do not operate the engine in the tachometer 
red zone.
Red zone: 5500 r/min and above
The tachometer needle flashes when it reaches 
and exceeds the red zone.
Clock mode
1. Clock
2.“RESET” button
3. Tachometer
4.“SELECT” button
5. Speedometer
6. Odometer/Tripmeter/Fuel reserve tripmeter
3
4
5
6 12
1. Tachometer
2. Tachometer red zone
1. Clock
2 1
1 
						

							FEATURES
1-5
To set the clock:
1. Push the “SELECT” button and “RESET” but-
ton together for at least two seconds.
2. When the hour digits start flashing, push the 
“RESET” button to set the hours.
3. Push the “SELECT” button, and the minute 
digits will start flashing.
4. Push the “RESET” button to set the minutes.
5. Push the “SELECT” button and then release 
it to start the clock.
Odometer and tripmeter modes
Pushing the “SELECT” button switches the dis-
play between the odometer mode “ODO” and 
the tripmeter modes “TRIP 1” and “TRIP 2” in the 
following order:
ODO → TRIP 1 → TRIP 2 → ODO
If the fuel level warning light comes on, the 
odometer display will automatically change to 
the fuel reserve tripmeter mode “F-TRIP” and 
start counting the distance traveled from that 
point. In that case, pushing the “SELECT” button 
switches the display between the various tripme-
ter and odometer modes in the following order:
F-TRIP → TRIP 1 → TRIP 2 → ODO → F-TRIP
To reset a tripmeter, select it by pushing the “SE-
LECT” button, and then push the “RESET” but-
ton for at least one second. If you do not reset 
the fuel reserve tripmeter manually, it will reset 
itself automatically and the display will return to 
the prior mode after refueling and traveling 5 km 
(3 mi).
Self-diagnosis device
This model is equipped with a self-diagnosis de-
vice for various electrical circuits.
If any of those circuits are defective, the engine 
trouble warning light will come on, and then the 
multifunction display will indicate a two-digit er-
ror code (e.g., 12, 13, 14).If the multifunction display indicates an error 
code, note the code number, and then check the 
vehicle. Refer to “FUEL INJECTION SYSTEM” 
on page 7-25.
CAUTION:
EC5YU1010
If the multifunction display indicates an error 
code, the vehicle should be checked as soon 
as possible in order to avoid engine damage.
This model is also equipped with a self-diagno-
sis device for the immobilizer system.
If any of the immobilizer system circuits are de-
fective, the immobilizer system indicator light will 
flash, and then the multifunction display will indi-
cate a two-digit error code (e.g., 51, 52, 53) 
when the key is turned to “ON”.
NOTE:
If the multifunction display indicates error code 
52, this could be caused by transponder interfer-
ence. If this error appears, try the following.
1. Use the code re-registering key to start the 
engine.
NOTE:
Make sure there are no other immobilizer keys 
close to the main switch, and do not keep more 
than one immobilizer key on the same key ring! 
Immobilizer system keys may cause signal inter-
ference, which may prevent the engine from 
starting.
2. If the engine starts, turn it off, and try starting 
the engine with the standard keys.
3. If one or both of the standard keys do not start 
the engine, re-register the standard keys.
If the multifunction display indicates an error 
code, note the code number, and then check the 
vehicle. Refer to “IMMOBILIZER SYSTEM” on 
page 7-75.
Brightness control mode
1. Odometer/Tripmeter/Fuel reserve tripmeter
1
1. Tachometer panel
2. LCD
1
2 3 
						

							FEATURES
1-6
The brightness can be adjusted for the following:
the tachometer panel (item number “1”)
the LCD (item number “2”)
the tachometer needle (item number “3”)
Select the brightness control mode as follows.
1. Turn the key to “OFF”.
2. Push and hold the “SELECT” button.
3. Turn the key to “ON”, and then release the 
“SELECT” button after five seconds.
Item number “1” is displayed.
4. Adjust the tachometer panel brightness level 
by pushing the “RESET” button.
5. Push the “SELECT” button to select the LCD.
Item number “2” is displayed.
Adjust the LCD brightness level by pushing 
the “RESET” button.
6. Push the “SELECT” button to select the ta-
chometer needle.
Item number “3” is displayed.
Adjust the tachometer needle brightness lev-
el by pushing the “RESET” button.7. Push the “SELECT” button and the multi-
function display will return to the odometer or 
tripmeter mode.
3. Tachometer needle
1. Tachometer panel
2. Item number
3. Brightness level
1. LCD
2. Item number
3. Brightness level
1
23
1
23
1. Tachometer needle
2. Item number
3. Brightness level
1
23 
						

							IMPORTANT INFORMATION
1-7
EAS20180
IMPORTANT INFORMATION
EAS20190
PREPARATION FOR REMOVAL AND 
DISASSEMBLY
1. Before removal and disassembly, remove all 
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning equip-
ment.
Refer to “SPECIAL TOOLS” on page 1-10.
3. When disassembling, always keep mated 
parts together. This includes gears, cylinders, 
pistons and other parts that have been “mat-
ed” through normal wear. Mated parts must 
always be reused or replaced as an assem-
bly.
4. During disassembly, clean all of the parts and 
place them in trays in the order of disassem-
bly. This will speed up assembly and allow for 
the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS20200REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by 
Yamaha for all lubrication jobs. Other brands 
may be similar in function and appearance, but 
inferior in quality.
EAS20210
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all 
gaskets, seals and O-rings. All gasket surfac-
es, oil seal lips and O-rings must be cleaned.
2. During reassembly, properly oil all mating 
parts and bearings and lubricate the oil seal 
lips with grease.
EAS20220
LOCK WASHERS/PLATES AND COTTER 
PINS
After removal, replace all lock washers/plates 
“1” and cotter pins. After the bolt or nut has been 
tightened to specification, bend the lock tabs 
along a flat of the bolt or nut.
1. Oil
2. Lip
3. Spring
4. Grease 
						

							IMPORTANT INFORMATION
1-8
EAS20230BEARINGS AND OIL SEALS
Install bearings “1” and oil seals “2” so that the 
manufacturer’s marks or numbers are visible. 
When installing oil seals, lubricate the oil seal 
lips with a light coat of lithium-soap-based 
grease. Oil bearings liberally when installing, if 
appropriate.
CAUTION:
ECA13300
Do not spin the bearing with compressed air 
because this will damage the bearing surfac-
es.
EAS20240
CIRCLIPS
Before reassembly, check all circlips carefully 
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use. 
When installing a circlip “1”, make sure the 
sharp-edged corner “2” is positioned opposite 
the thrust “3” that the circlip receives. 
						

							CHECKING THE CONNECTIONS
1-9
EAS20250
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for 
stains, rust, moisture, etc.
1. Disconnect:
Lead
Coupler
Connector
2. Check:
Lead
Coupler
Connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect sev-
eral times.
3. Check:
All connections
Loose connection → Connect properly.
NOTE:
If the pin “1” on the terminal is flattened, bend it 
up.
4. Connect:
Lead
Coupler
Connector
NOTE:
Make sure all connections are tight.
5. Check:
Continuity
(with the pocket tester)
NOTE:
If there is no continuity, clean the terminals.
When checking the wire harness, perform 
steps (1) to (3).
As a quick remedy, use a contact revitalizer 
available at most part stores.
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C 
						

							SPECIAL TOOLS
1-10
EAS20260
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only 
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools 
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
NOTE:
For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
For others, use part number starting with “90890-”.
Tool name/Tool No. Illustration Reference pages
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C1-9, 5-72, 7-91, 
7-92, 7-93, 7-96, 
7-97, 7-98, 7-99, 
7-100, 7-101, 
7-102, 7-103, 
7-104, 7-106, 
7-107, 7-108
Thickness gauge
90890-03079
Narrow gauge set
YM-344833-4, 3-5, 5-56
Locknut wrench
90890-041503-5
Tappet adjusting tool
90890-041493-5
Vacuum gauge
90890-03094
Carburetor synchronizer
YU-444563-6
Timing light
90890-03141
Inductive clamp timing light
YU-031413-9
10
4
YU-44456 
						

							SPECIAL TOOLS
1-11
Compression gauge
90890-03081
Engine compression tester
YU-332233-10
Extension
90890-040823-10
Oil filter wrench
90890-01426
YU-384113-12
Steering nut wrench
90890-01403
Spanner wrench
YU-339753-26, 4-59
Vacuum/pressure pump gauge set
90890-067564-5, 6-9
Fork spring compressor
90890-01441
YM-014414-50, 4-55
Rod holder
90890-01434
Damper rod holder double ended
YM-014344-50, 4-55
Damper rod holder
90890-015044-51, 4-52
Fork seal driver
90890-01442
Adjustable fork seal driver (36–46 mm)
YM-014424-53 Tool name/Tool No. Illustration Reference pages