Yamaha Mt 01 T 2005 Manual

FRONT FORK
4-49
16 Inner tube 1
For assembly, reverse the disassembly 
procedure.
Disassembling the front fork legs
Order Job/Parts to remove Q’ty Remarks
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 ft • Ib)
T R..25 Nm (2.5 m • 
kg, 18 ft • Ib)
New 

FRONT FORK
4-50
EAS22960REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there is 
no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that the 
front wheel is elevated.
2. Loosen:
Upper bracket pinch bolt “1”
Cap bolt “2”
Lower bracket pinch bolt “3”
WARNING
EWA13640
Before loosening the upper and lower brack-
et pinch bolts, support the...

FRONT FORK
4-51
d. Remove the cap bolt.
e. Remove the rod holder and fork spring com-
pressor.
f. Remove the spacer and nut.
        
3. Drain:
Fork oil
NOTE:
Stroke the damper rod “1” several times while 
draining the fork oil.
4. Remove:
Damper rod assembly
NOTE:
Remove the damper rod assembly with the 
damper rod holder “1”.
5. Remove:
Oil seal clip “1”
(with a flat-head screwdriver)
EAS23010
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the...

FRONT FORK
4-52
CAUTION:
ECA14200
The front fork leg has a built-in damper ad-
justing rod and a very sophisticated inter-
nal construction, which are particularly 
sensitive to foreign material.
When disassembling and assembling the 
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
4. Check:
Cap bolt O-ring “1”
Damage/wear → Replace.
Cap bolt collar projections “2”
Cracks/damage → Replace.
EAS23040
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of...

FRONT FORK
4-53
Lubricate the outer surface of the inner tube 
with fork oil.
Before installing the oil seal, cover the top of 
the front fork leg with a plastic bag to protect 
the oil seal during installation.
5. Install:
Outer tube
(to the inner tube)
6. Install:
Washer
Oil seal “1”
(with the fork seal driver “2”)
7. Install:
Oil seal clip “1”
NOTE:
Adjust the oil seal clip so that it fits into the outer 
tube’s groove.
8. Install:
Dust seal “1”
(with the fork seal driver weight “2”)
9....

FRONT FORK
4-54
10.Fully compress the front fork leg.
11.Fill:
Front fork leg
(with the specified amount of the recom-
mended fork oil)
CAUTION:
ECA14230
Be sure to use the recommended fork oil. 
Other oils may have an adverse effect on 
front fork performance.
When disassembling and assembling the 
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
12.After filling the front fork leg, slowly stroke the 
damper rod “1” up and down (at least ten 
times) to distribute the fork...

FRONT FORK
4-55
d. Install the upper spring seat and nut.
e. Reinstall the rod puller attachment.
f. Install the spacer.
g. Press down on the spacer with the fork spring 
compressor “9”.
h. Pull up the rod puller and install the rod holder 
“10” between the nut “4” and the spacer “5”.
NOTE:
Use the side of the rod holder that is marked “B”.
i. Remove the rod puller and rod puller attach-
ment.j. Install the nut “4” all the way onto the damper 
rod assembly.
k. Install the damper adjusting rod.
l. Install...

FRONT FORK
4-56
EAS23050INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
1. Install:
Front fork leg
Temporarily tighten the upper and lower 
bracket pinch bolts.
NOTE:
Make sure the outer tube is flush with the top of 
the handlebar holder.
2. Tighten:
Lower bracket pinch bolts “1”
Cap bolt “2”
Upper bracket pinch bolt “3”
WARNING
EWA13680
Make sure the brake hoses are routed prop-
erly.
3. Adjust:
Spring preload
Rebound damping
Compression damping...

STEERING HEAD
4-57
EAS23090
STEERING HEAD
Removing the lower bracket
Order Job/Parts to remove Q’ty Remarks
Air filter case/Headlight assemblyRefer to “GENERAL CHASSIS” on page 
4-1.
Lower handlebar holder Refer to “HANDLEBAR” on page 4-42.
Front fork leg Refer to “FRONT FORK” on page 4-47.
1 Meter assembly coupler 2 Disconnect.
2 Meter assembly 1
3 Meter assembly bracket 1
4 Steering stem nut 1
5 Upper bracket 1
6 Headlight assembly bracket 1
7 Front brake hose joint 1
8 Front brake hose joint bracket...

STEERING HEAD
4-58
13 Lower bracket 1
14 Washer 1
15 Lower bearing 1
16 Lower bearing dust seal 1
17 Lower bearing inner race 1
18 Upper bearing cover 1
19 Upper bearing inner race 1
20 Upper bearing 1
21 Bearing outer race 2
For installation, reverse the removal 
procedure.
Removing the lower bracket
Order Job/Parts to remove Q’ty Remarks
T R..7 Nm (0.7 m • 
kg, 5.1 ft • Ib)T R..1st   52 Nm (5.2 m • 
kg, 37 ft • lb)
2nd  23 Nm (2.3 m 
• 
kg, 17 ft • lb)
T R..7 Nm (0.7 m • 
kg, 5.1 ft • Ib)
T R..7 Nm...