Yamaha Mt 01 T 2005 Manual

CYLINDERS AND PISTONS
5-42
EAS24380REMOVING THE PISTONS
The following procedure applies to all of the pis-
tons.
1. Remove:
Piston pin clips “1”
Piston pin “2”
Piston “3”
CAUTION:
ECA13810
Do not use a hammer to drive the piston pin 
out.
NOTE:
Before removing the piston pin clip, cover the 
crankcase opening with a clean rag to prevent 
the piston pin clip from falling into the crank-
case.
For reference during installation, put an identi-
fication mark on each piston crown.
Before removing the...

CYLINDERS AND PISTONS
5-43
b. If out of specification, rebore or replace the 
cylinder, and replace the piston and piston 
rings as a set.
c. Measure piston skirt diameter D “a” with the 
micrometer.
d. If out of specification, replace the piston and 
piston rings as a set.
e. Calculate the piston-to-cylinder clearance 
with the following formula.
f. If out of specification, rebore or replace the 
cylinder, and replace the piston and piston 
rings as a set.
        ...

CYLINDERS AND PISTONS
5-44
3. Measure:
Piston ring end gap
Out of specification → Replace the piston 
ring.
NOTE:
The oil ring expander spacer’s end gap cannot 
be measured. If the oil ring rail’s gap is exces-
sive, replace all three piston rings.
EAS24440
CHECKING THE PISTON PINS
The following procedure applies to all of the pis-
ton pins.
1. Check:
Piston pin
Blue discoloration/grooves → Replace the 
piston pin and then check the lubrication sys-
tem.
2. Measure:
Piston pin outside diameter “a”
Out...

CYLINDERS AND PISTONS
5-45
2. Install:
Piston “1”
Piston pin “2”
Piston pin clips “3” 
NOTE:
Apply engine oil onto the piston pin.
Make sure the arrow mark “a” on the piston fac-
es towards the front of the vehicle.
Before installing the piston pin clip, cover the 
crankcase opening with a clean rag to prevent 
the clip from falling into the crankcase.
Reinstall each piston into its original cylinder 
(numbering order starting from the left: #1 to 
#2).
3. Lubricate:
Piston
Piston rings...

CLUTCH
5-46
EAS25060
CLUTCH
Removing the clutch cover
Order Job/Parts to remove Q’ty Remarks
Engine oilDrain.
Refer to “CHANGING THE ENGINE OIL” on 
page 3-11.
Battery box/Air ductRefer to “GENERAL CHASSIS” on page 
4-1.
Oil tank/Shift rod Refer to “ENGINE REMOVAL” on page 5-1.
1 Crankshaft position sensor coupler 1 Disconnect.
2 Shift arm 1
3 Oil tank bracket 1
4 Clutch cover 1
5 Clutch cover gasket 1
6 Dowel pin 2
For installation, reverse the removal 
procedure.
T R..10 Nm (1.0 m • 
kg, 7.2 ft • Ib)
T...

CLUTCH
5-47
Removing the crankshaft position sensor
Order Job/Parts to remove Q’ty Remarks
1 Oil seal 1
2 Bearing 1
3 Crankshaft position sensor lead holder 3
4 Crankshaft position sensor 1
For installation, reverse the removal 
procedure.
2
13
3
3
4
LTLT
LT
LTLT
LTLT
LS
T R..10 Nm (1.0 m • 
kg, 7.2 ft • Ib)
New 

CLUTCH
5-48
Removing the clutch
Order Job/Parts to remove Q’ty Remarks
1 Clutch spring plate retainer 1
2 Clutch spring plate 1
3 Clutch spring plate seat 1
4 Pressure plate 1
5 Short clutch push rod 1
6 Friction plate 1 9
7 Clutch plate 8
8 Conical spring washer 1
9 Wire circlip 1
10 Clutch plate 1
11 Friction plate 2 1
12 Clutch damper spring 1
13 Clutch damper spring seat 1
14 Clutch boss 1
15 Thrust washer 1 1
16 Bearing 1
17 Clutch housing 1
LS
LS
New
New
New
E
T R..100 Nm (10.0 m • 
kg, 72 ft •...

CLUTCH
5-49
18 Washer 1
19 Circlip 1
20 Oil pump drive gear 1
21 Dowel pin 1
22 Collar 1
23 Thrust washer 2 1
24 Ball 1
25 Long clutch push rod 1
26 Spacer 1
27 Crankshaft position sensor rotor 1
28 Primary drive gear 1
29 Straight key 1
For installation, reverse the removal 
procedure.
Removing the clutch
Order Job/Parts to remove Q’ty Remarks
LS
LS
New
New
New
E
T R..100 Nm (10.0 m • 
kg, 72 ft • lb)
LT
New
T R..125 Nm (12.5 m • 
kg, 90 ft • lb)
E
E
76
18 19
2024 25
23
22
2117
16
15
14
13
12
11
109
8
1...

CLUTCH
5-50
Removing the clutch master cylinder
Order Job/Parts to remove Q’ty Remarks
Clutch fluidDrain.
Refer to “BLEEDING THE HYDRAULIC 
CLUTCH SYSTEM” on page 3-14.
1 Clutch fluid reservoir cap holder 1
2 Clutch fluid reservoir cap 1
3 Clutch fluid reservoir diaphragm holder 1
4 Clutch fluid reservoir diaphragm 1
5 Clutch fluid reservoir 1
6 Clutch fluid reservoir hose 1
7 Left rearview mirror 1
8 Clutch fluid reservoir bracket 1
9 Clutch lever 1
10 Bushing 1
11 Clutch switch coupler 1 Disconnect.
12...

CLUTCH
5-51
16 Clutch master cylinder holder 1
17 Clutch master cylinder 1
For installation, reverse the removal 
procedure.
Removing the clutch master cylinder
Order Job/Parts to remove Q’ty Remarks
T R..13 Nm (1.3 m • 
kg, 9.4 ft • Ib)
T R..14 Nm (1.4 m • 
kg, 10 ft • Ib)
T R..30 Nm (3.0 m • 
kg, 22 ft • Ib)
LS
LS
New
7
8 1
2
3
4
5 6
9 10
11
12 17 1516 13
14