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...