Yamaha Mt 01 T 2005 Manual

							OIL PUMP
5-82
Disassembling the oil pump
Order Job/Parts to remove Q’ty Remarks
1 Spring retainer 1
2Spring 1
3Relief valve 1
4 Oil pump housing cover 1 1
5Pin 2
6Spring 1
7Collar 1
8Ball 1
9 Oil pump outer rotor 1 1
10 Oil pump inner rotor 1 1
11 Pin 1
12 Oil pump housing cover 2 1
13 Pin 2
14 Oil pump shaft 1
15 Pin 1
16 Oil pump inner rotor 2 1
17 Oil pump outer rotor 2 1 
						

							OIL PUMP
5-83
18 Oil seal 2
19 Oil pump housing 1
For assembly, reverse the disassembly 
procedure.
Disassembling the oil pump
Order Job/Parts to remove Q’ty Remarks 
						

							OIL PUMP
5-84
EAS24960CHECKING THE OIL PUMP
1. Check:
Oil pump housing
Oil pump housing cover
Cracks/damage/wear → Replace the defec-
tive part(s).
2. Measure:
Inner-rotor-to-outer-rotor-tip clearance “a”
Outer-rotor-to-oil-pump-housing clearance 
“b”
Oil-pump-housing-to-inner-rotor-and-outer-
rotor clearance “c”
Out of specification → Replace the oil pump.3. Check:
Oil pump operation
Rough movement → Repeat steps (1) and 
(2) or replace the defective part(s).
EAS24970
CHECKING THE RELIEF VALVE
1. Check:
Relief valve body
Relief valve
Spring
Damage/wear → Replace the defective 
part(s).
2. Check:
Ball
Collar
Spring
Oil seal
Damage/wear → Replace the defective 
part(s).
EAS24990
CHECKING THE OIL STRAINER
1. Check:
Oil strainer (crankcase)
Damage → Replace.
Contaminants → Clean with solvent.
EAS25000ASSEMBLING THE OIL PUMP
1. Lubricate:
Inner rotor
Outer rotor
Oil pump shaft
(with the recommended lubricant)
2. Install:
Oil pump housing “1”
Oil seal “2” 
Oil pump outer rotor 2 “3”
Oil pump inner rotor 2 “4”
Pin “5”
 
Inner-rotor-to-outer-rotor-tip 
clearance
0.12 mm (0.0047 in) or less
Limit
0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing 
clearance
0.09–0.15 mm (0.0035–0.0059 in)
Limit
0.220 mm (0.0087 in)
Oil-pump-housing-to-inner-and-
outer-rotor clearance
0.03–0.08 mm (0.0012–0.0031 in)
Limit
0.150 mm (0.0059 in)
1. Inner rotor
2. Outer rotor
3. Oil pump housing
 
Recommended lubricant
Engine oil
New 
						

							OIL PUMP
5-85
Oil pump shaft “6”
Pins “7”
Oil pump housing cover 2 “8”
Pin “9”
Oil pump inner rotor 1 “10”
Oil pump outer rotor 1 “11”
Ball “12”
Collar “13”
Spring “14”
Pins “15”
Oil pump housing cover 1 “16”
Relief valve “17”
Spring “18”
Spring retainer “19”
NOTE:
When installing the inner rotor, align the pin in 
the oil pump shaft with the groove in the inner ro-
tor.3. Check:
Oil pump operation
Refer to “CHECKING THE OIL PUMP” on 
page 5-84.
EAS25020
INSTALLING THE OIL PUMP
1. Install:
Oil pump “1”
CAUTION:
ECA13890
After tightening the bolts, make sure the oil 
pump turns smoothly.
T R.. 
Oil pump housing cover 2 screw
2 Nm (0.2 m·kg, 1.4 ft·lb)
T R.. 
Oil pump housing cover 1 screw
2 Nm (0.2 m·kg, 1.4 ft·lb)
T R.. 
Spring retainer bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
T R.. 
Oil pump bolt
10 Nm (1.0 m·kg, 7.2 ft·lb) 
						

							CRANKSHAFT
5-86
EAS25960
CRANKSHAFT
Removing the crankshaft
Order Job/Parts to remove Q’ty Remarks
CrankcaseSeparate.
Refer to “CRANKCASE” on page 5-74.
1 Crankshaft 1
2 Generator shaft 1
3 Connecting rod cap 2
4 Big end lower bearing 2
5 Connecting rod 2
6 Big end upper bearing 2
For installation, reverse the removal 
procedure. 
						

							CRANKSHAFT
5-87
EAS26010REMOVING THE CONNECTING RODS
The following procedure applies to all of the con-
necting rods.
1. Remove:
Connecting rod caps “1”
Connecting rod
Big end bearings
NOTE:
Identify the position of each big end bearing so 
that it can be reinstalled in its original place.
EAS26090
CHECKING THE CRANKSHAFT AND 
CONNECTING RODS
1. Measure:
Crankshaft runout
Out of specification → Replace the crank-
shaft.
2. Check:
Crankshaft journal surfaces
Crankshaft pin surfaces
Bearing surfaces
Scratches/wear → Replace the crankshaft.
Generator shaft drive gear “1”
Damage/wear → Replace the crankshaft.3. Measure:
Crankshaft-pin-to-big-end-bearing clearance
Out of specification → Replace the big end 
bearings.
The following procedure applies to all of the 
connecting rods.CAUTION:
ECA13930
Do not interchange the big end bearings and 
connecting rods. To obtain the correct 
crankshaft-pin-to-big-end-bearing clear-
ance and prevent engine damage, the big 
end bearings must be installed in their origi-
nal positions.



 





 
 



 
 



 
 



 
 



 



a. Clean the big end bearings, crankshaft pins, 
and the inside of the connecting rod halves.
b. Install the big end upper bearing into the con-
necting rod and the big end lower bearing into 
the connecting rod cap.
NOTE:
Align the projections “a” on the big end bearings 
with the notches “b” in the connecting rod and 
connecting rod cap.
 
Runout limit C
0.040 mm (0.0016 in)
 
Journal oil clearance (using 
plastigauge
®)
0.030–0.062 mm (0.0012–0.0024 
in) 
						

							CRANKSHAFT
5-88
c. Put a piece of Plastigauge® “1” on the crank-
shaft pin.
d. Assemble the connecting rod halves.
NOTE:
Do not move the connecting rod or crankshaft 
until the clearance measurement has been 
completed.
Lubricate the bolts threads and nut seats with 
molybdenum disulfide grease.
Make sure the projection “c” on the connecting 
rod faces towards the left side of the crank-
shaft.
Make sure the characters “d” on both the con-
necting rod and connecting rod cap are 
aligned.
e. Tighten the connecting rod bolts.
WARNING
EWA12890
Replace the connecting rod bolts with new 
ones.
Clean the connecting rod bolts.
NOTE:
The tightening procedure of the connecting rod 
bolts is angle controlled, therefore tighten the 
bolts using the following procedure.
f. Tighten the connecting rod bolts to the spec-
ified torque.g. Put a mark “1” on the connecting rod bolts “2” 
and the connecting rod cap “3”.
h. Tighten the connecting rod bolts further to 
reach the specified angle 120°–150°.
WARNING
EWA12900
When the bolts are tightened more than the 
specified angle, do not loosen the bolt and 
then retighten it.
Replace the bolt with a new one and perform 
the procedure again.
CAUTION:
EC5YU1008
Do not use a torque wrench to tighten the 
bolt to the specified angle.
Tighten the bolt until it is the specified an-
gle.
i. Remove the connecting rod and big end 
bearings.
Refer to “REMOVING THE CONNECTING 
RODS” on page 5-87.
j. Measure the compressed Plastigauge
® width 
“e” on the crankshaft pin.
If the crankshaft-pin-to-big-end-bearing 
clearance is out of specification, select re-
placement big end bearings.
T R.. 
Connecting rod bolt (1st)
15 Nm (1.5 m·kg, 11 ft·lb)
T R.. 
Connecting rod bolt (final)
Specified angle 120°–150° 
						

							CRANKSHAFT
5-89
        
4. Select:
Big end bearings (“P
1”–“P2”)
NOTE:
The numbers “a” stamped into the crankshaft 
web and the numbers “b” on the connecting 
rods are used to determine the replacement 
big end bearing sizes.
“P
1”–“P2” refer to the bearings shown in the 
crankshaft illustration.For example, if the connecting rod “P
1” and 
the crankshaft web “P” numbers are “5” and 
“2” respectively, then the bearing size for “P
1” 
is:
5. Measure:
Crankshaft journal diameter “a”
Out of specification → Replace the crank-
shaft.
NOTE:
Measure the diameter of each crankshaft journal 
at two places.
6. Measure:
Crankshaft journal bearing inside diameter 
“a”
Out of specification → Replace the crank-
case assembly.
NOTE:
Measure the inside diameter of each crankshaft 
journal bearing at two places.
P1P2
a
“P1” (connecting rod) - “P” (crankshaft)
=
5 - 2 = 3 (brown)
 
Bearing color code
1.Blue 2.Black 3.Brown 4.Green 
5.Yellow
 
Crankshaft journal diameter
49.968–49.980 mm (1.9672–
1.9677 in)
 
Crankshaft journal bearing inside 
diameter
50.010–50.030 mm (1.9689–
1.9697 in) 
						

							CRANKSHAFT
5-90
7. Calculate:
Crankshaft journal-to-crankshaft journal 
bearing clearance
Out of specification → Replace the crank-
shaft and crankshaft journal bearings as a 
set.
NOTE:
Calculate the clearance by subtracting the 
crankshaft journal diameter from the crankshaft 
journal bearing inside diameter.
EAS26150INSTALLING THE CONNECTING RODS
1. Lubricate:
Bolt threads
Nut seats
(with the recommended lubricant)
2. Lubricate:
Crankshaft pins
Big end bearings
Connecting rod inner surface
(with the recommended lubricant)
3. Install:
Big end bearings
Connecting rods
Connecting rod caps
(onto the crankshaft pins)
NOTE:
Align the projections “a” on the big end bear-
ings with the notches “b” in the connecting rods 
and connecting rod caps.Be sure to reinstall each big end bearing in its 
original place.
Make sure the projections “c” on the connect-
ing rods face towards the left side of the crank-
shaft.
Make sure the characters “d” on both the con-
necting rod and connecting rod cap are 
aligned.
4. Tighten:
Connecting rod bolts “1”



 





 
 



 
 



 
 



 
 



 



WARNING
EWA12890
Replace the connecting rod bolts with new 
ones.
Clean the connecting rod bolts.
NOTE:
The tightening procedure of the connecting rod 
bolts is angle controlled, therefore tighten the 
bolts using the following procedure.
 
Crankshaft journal-to-crankshaft 
journal bearing clearance
0.030–0.062 mm (0.0012–0.0024 
in)
 
Recommended lubricant
Molybdenum disulfide grease
 
Recommended lubricant
Engine oil 
						

							CRANKSHAFT
5-91
a. Tighten the connecting rod bolts to the spec-
ified torque.
b. Put a mark “1” on the connecting rod bolts “2” 
and the connecting rod cap “3”.
c. Tighten the connecting rod bolts further to 
reach the specified angle 120°–150°.
WARNING
EWA12900
When the bolts are tightened more than the 
specified angle, do not loosen the bolt and 
then retighten it.
Replace the bolt with a new one and perform 
the procedure again.
CAUTION:
EC5YU1008
Do not use a torque wrench to tighten the 
bolt to the specified angle.
Tighten the bolt until it is the specified an-
gle.
        
EAS26210INSTALLING THE CRANKSHAFT 
ASSEMBLY
1. Install:
Crankshaft assembly
CAUTION:
ECA13970
To avoid scratching the crankshaft and to 
ease the installation procedure, lubricate the 
oil seal lips with lithium-soap-based grease 
and each bearing with engine oil.
NOTE:
Make sure that the generator shaft drive gear 
teeth and generator shaft driven gear teeth 
mesh correctly.
Align the right connecting rod with the front cyl-
inder sleeve hole.
T R.. 
Connecting rod bolt (1st)
15 Nm (1.5 m·kg, 11 ft·lb)
T R.. 
Connecting rod bolt (final)
Specified angle 120°–150°