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Yamaha Mt 01 T 2005 Manual

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Page 161

REAR BRAKE
4-39
EAS22670INSTALLING THE REAR BRAKE CALIPER
1. Install:
Rear brake caliper “1”
(temporarily)
Copper washers 
Rear brake hose “2”
Rear brake hose union bolt “3”
WARNING
EWA13530
Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to “CABLE 
ROUTING” on page 2-41.
CAUTION:
ECA14170
When installing the brake hose onto the 
brake caliper “1”, make sure the brake pipe 
“a” touches the projection “b” on the brake 
caliper.
2. Remove:
Rear brake caliper
3....

Page 162

REAR BRAKE
4-40
EAS22700REMOVING THE REAR BRAKE MASTER 
CYLINDER
NOTE:
Before removing the rear brake master cylinder, 
drain the brake fluid from the entire brake sys-
tem.
1. Remove:
Rear brake hose union bolt “1”
Copper washers “2”
Rear brake hose “3”
NOTE:
To collect any remaining brake fluid, place a 
container under the master cylinder and the end 
of the brake hose.
EAS22720CHECKING THE REAR BRAKE MASTER 
CYLINDER
1. Check:
Brake master cylinder
Damage/scratches/wear → Replace.
Brake fluid...

Page 163

REAR BRAKE
4-41
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...

Page 164

HANDLEBAR
4-42
EAS22840
HANDLEBAR
Removing the handlebar
Order Job/Parts to remove Q’ty Remarks
1 Rearview mirror 2
2 Front brake light switch connector 2 Disconnect.
3 Front brake master cylinder holder 1
4 Front brake master cylinder assembly 1
5 Right handlebar switch 1
6 Throttle cable 2 Disconnect.
7 Grip end 2
8 Throttle grip 1
9 Clutch switch coupler 1 Disconnect.
10 Clutch master cylinder holder 1
11 Clutch master cylinder assembly 1
12 Left handlebar switch 1
13 Handlebar grip 1
14 Upper...

Page 165

HANDLEBAR
4-43
16 Lower handlebar holder 2
For installation, reverse the removal 
procedure.
Removing the handlebar
Order Job/Parts to remove Q’ty Remarks
1
24
3
16
LS
T R..10 Nm (1.0 m • 
kg, 7.2 ft • Ib)
T R..40 Nm (4.0 m • 
kg, 29 ft • Ib)T R..40 Nm (4.0 m • 
kg, 29 ft • Ib)
T R..29 Nm (2.9 m • 
kg, 21 ft • Ib)
T R..29 Nm (2.9 m • 
kg, 21 ft • Ib)
7
T R..20 Nm (2.0 m • 
kg, 14 ft • Ib)T R..14 Nm (1.4 m • 
kg, 10 ft • Ib)
T R..14 Nm (1.4 m • 
kg, 10 ft • Ib)
T R..13 Nm (1.3 m • 
kg, 9.4 ft • Ib)
155...

Page 166

HANDLEBAR
4-44
EAS22860REMOVING THE HANDLEBAR
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there is 
no danger of it falling over.
2. Remove:
Handlebar grip “1”
NOTE:
Blow compressed air between the handlebar 
and the left handlebar grip, and gradually push 
the grip off the handlebar.
EAS22880
CHECKING THE HANDLEBAR
1. Check:
Handlebar
Bends/cracks/damage → Replace.
WARNING
EWA13690
Do not attempt to straighten a bent handle-
bar as this may...

Page 167

HANDLEBAR
4-45
        
a. Apply a thin coat of rubber adhesive onto the 
left end of the handlebar.
b. Slide the handlebar grip over the left end of 
the handlebar.
c. Wipe off any excess rubber adhesive with a 
clean rag.
WARNING
EWA13700
Do not touch the handlebar grip until the rub-
ber adhesive has fully dried.
NOTE:
There should be 1–3 mm (0.04–0.12 in) of clear-
ance “a” between the handlebar grip and the grip 
end. 
        
6....

Page 168

HANDLEBAR
4-46
9. Install:
Front brake master cylinder assembly
Front brake master cylinder holder “1”
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.
10.Adjust:
Throttle cable free play
Refer to “ADJUSTING THE THROTTLE CA-
BLE FREE PLAY” on page 3-7.
T R.. 
Front brake master cylinder 
holder bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
 
Throttle cable free play
3.0–5.0 mm (0.12–0.20 in)
1
a 

Page 169

FRONT FORK
4-47
EAS22950
FRONT FORK
Removing the front fork legs
Order Job/Parts to remove Q’ty Remarks
The following procedure applies to both of 
the front fork legs.
Front wheel Refer to “FRONT WHEEL” on page 4-6.
1 Front fork guard 2
2 Front fender 1
3 Cap bolt 1 Loosen.
4 Upper bracket pinch bolt 1 Loosen.
5 Lower bracket pinch bolt 2 Loosen.
6Front fork leg 1
For installation, reverse the removal 
procedure.
6
5 1
4
123
T R..26 Nm (2.6 m • 
kg, 19 ft • Ib)
T R..20 Nm (2.0 m • 
kg, 14 ft • Ib)
T...

Page 170

FRONT FORK
4-48
Disassembling the front fork legs
Order Job/Parts to remove Q’ty Remarks
The following procedure applies to both of 
the front fork legs.
1 Cap bolt 1
2O-ring 1
3Washer 1
4 Damper adjusting rod 1
5 Spacer 1
6Nut 1
7 Upper spring seat 1
8 Fork spring 1
9 Lower spring seat 1
10 Outer tube 1
11 Dust seal 1
12 Oil seal clip 1
13 Oil seal 1
14 Washer 1
15 Damper rod assembly 1
T R..35 Nm (3.5 m • 
kg, 25 ft • Ib)
1
2
3
6
5
7
8
94
11 12 13 14 10
15
16
LS
New
New
New
T R..20 Nm (2.0 m • 
kg, 14...
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