Yamaha Mt 01 T 2005 Manual

CLUTCH
5-52
Disassembling the clutch master cylinder
Order Job/Parts to remove Q’ty Remarks
1 Clutch master cylinder push rod 1
2 Clutch master cylinder kit 1
3 Dust seal 1
4 Circlip 1
5 Clutch fluid reservoir hose joint 1
6O-ring 1
7 Clutch master cylinder body 1
For assembly, reverse the disassembly 
procedure.
New
New
LS
New
3
4
5
6
7
2
1 

CLUTCH
5-53
Removing the clutch release cylinder
Order Job/Parts to remove Q’ty Remarks
Clutch fluidDrain.
Refer to “BLEEDING THE HYDRAULIC 
CLUTCH SYSTEM” on page 3-14.
1 Clutch pipe union bolt cap 1
2 Clutch pipe union bolt 1
3 Copper washer 2
4 Clutch pipe 1
5 Clutch release cylinder 1
6 Dowel pin 2
For installation, reverse the removal 
procedure.
T R..10 Nm (1.0 m • 
kg, 7.2 ft • Ib)T R..26 Nm (2.6 m • 
kg, 19 ft • Ib)New3 6
2
6
54
1 

CLUTCH
5-54
Disassembling the clutch release cylinder
Order Job/Parts to remove Q’ty Remarks
1 Boots 1
2 Clutch release cylinder piston 1
3 Clutch release cylinder spring 1
4 Clutch release cylinder piston seal 1
5 Bleed screw 1
For assembly, reverse the disassembly 
procedure.
LS
LS
1
2
4
3
5
New
T R..6 Nm (0.6 m • 
kg, 4.3 ft • Ib) 

CLUTCH
5-55
EAS25080REMOVING THE CLUTCH
1. Loosen:
Clutch boss nut “1”
NOTE:
While holding the clutch boss “2” with the univer-
sal clutch holder “3”, loosen the clutch boss nut.
2. Remove:
Clutch boss nut “1”
Washer “2”
Clutch boss assembly “3”
NOTE:
There is a built-in damper between the clutch 
boss and the clutch plate. It is not necessary to 
remove the wire circlip “4” and disassemble the 
built-in damper unless there is serious clutch 
chattering.
EAS25090
REMOVING THE PRIMARY DRIVE GEAR
1....

CLUTCH
5-56
EAS25110
CHECKING THE CLUTCH PLATES
The following procedure applies to all of the 
clutch plates.
1. Check:
Clutch plate
Damage → Replace the clutch plates as a 
set.
2. Measure:
Clutch plate warpage
(with a surface plate and thickness gauge “1”)
Out of specification → Replace the clutch 
plates as a set.
EAS25130
CHECKING THE CLUTCH SPRING PLATE
1. Check:
Clutch plate spring
Damage → Replace.
2. Check:
Clutch plate spring seat
Damage → Replace.
EAS25150CHECKING THE CLUTCH HOUSING
1....

CLUTCH
5-57
EAS25190CHECKING THE CLUTCH PUSH RODS
1. Check:
O-ring
Short clutch push rod
Long clutch push rod
Ball
Cracks/damage/wear → Replace the defec-
tive part(s).
2. Measure:
Long clutch push rod bending limit
Out of specification → Replace the defective 
part(s).
EAS25200CHECKING THE PRIMARY DRIVE GEAR
1. Check:
Primary drive gear
Damage/wear → Replace the primary drive 
and primary driven gears as a set.
Excessive noise during operation → Replace 
the primary drive and primary driven gears...

CLUTCH
5-58
EAS25260INSTALLING THE CLUTCH
1. Install:
Clutch housing
Thrust washer
NOTE:
Lubricate the clutch housing bearings with en-
gine oil.
Make sure that the primary driven gear teeth 
and primary drive gear teeth mesh correctly.
Make sure that the oil pump drive gear teeth 
and oil pump driven gear teeth mesh correctly.
2. Install:
Clutch boss assembly “1”
NOTE:
If the wire circlip “2” has been removed, care-
fully install a new one.
Install the clutch damper spring “3” with the...

CLUTCH
5-59
6. Install:
Clutch spring plate “1”
Clutch spring plate retainer “2”
NOTE:
Tighten the clutch spring bolts in stages and in a 
crisscross pattern.
7. Install:
Shift arm “1”
NOTE:
Install the shift arm “1” with its punch mark “a” 
aligned with the notch “b” in end of the shift shaft.
EAS25280DISASSEMBLING THE CLUTCH MASTER 
CYLINDER
CAUTION:
ECA13840
Clutch components rarely require disas-
sembly.
Therefore, always follow these preventive 
measures:
Never disassemble clutch components...

CLUTCH
5-60
EAS25290CHECKING THE CLUTCH MASTER 
CYLINDER
1. Check:
Clutch master cylinder body
Cracks/damage → Replace the clutch mas-
ter cylinder.
Clutch fluid delivery passage
(clutch master cylinder body)
Obstruction → Blow out with compressed air.
2. Check:
Clutch master cylinder kit
Rust/scratches/wear → Replace the clutch 
master cylinder and clutch master cylinder kit 
as a set.
3. Check:
Clutch fluid reservoir hose joint
Cracks/damage → Replace.
4. Check:
Clutch fluid reservoir...

CLUTCH
5-61
3. Fill:
Clutch fluid reservoir
(with the specified amount of the recom-
mended clutch fluid)
WARNING
EWA13370
Use only the designated clutch fluid. Other 
clutch fluids may cause the rubber seals to 
deteriorate, causing leakage and poor 
clutch performance.
Refill with the same type of clutch fluid that 
is already in the system. Mixing clutch flu-
ids may result in a harmful chemical reac-
tion, leading to poor clutch performance.
When refilling, be careful that water does 
not enter...