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...

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...

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
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...

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”.
  ...

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...