Yamaha Mt 01 T 2005 Manual

CLUTCH
5-62
1. Check:
Clutch release cylinder body
Cracks/damage → Replace the clutch re-
lease cylinder.
2. Check:
Clutch release cylinder
Clutch release cylinder piston
Rust/scratches/wear → Replace the clutch 
release cylinder and clutch release cylinder 
piston as a set.
EAS25340ASSEMBLING THE CLUTCH RELEASE 
CYLINDER
WARNING
EW5YU1007
Before installation, all internal clutch com-
ponents must be cleaned and lubricated 
with clean or new clutch fluid.
Never use solvents on internal clutch com-...

CLUTCH
5-63
5. Check:
Clutch lever operation
Soft or spongy feeling → Bleed the clutch 
system.
Refer to “BLEEDING THE HYDRAULIC 
CLUTCH SYSTEM” on page 3-14.
a 

SHIFT SHAFT
5-64
EAS25410
SHIFT SHAFT
Removing the shift shaft and stopper lever
Order Job/Parts to remove Q’ty Remarks
Clutch housing Refer to “CLUTCH” on page 5-46.
1 Shift shaft 1
2 Circlip 2
3 Shift shaft spring 1
4 Shift shaft spring stopper 1
5Washer 1
6 Stopper lever 1
7 Stopper lever spring 1
For installation, reverse the removal 
procedure.
LS
LTLT
T R..10 Nm (1.0 m • 
kg, 7.2 ft • Ib)T R..22 Nm (2.2 m • 
kg, 16 ft • Ib)
1
3
2
7 6
5
4
New 

SHIFT SHAFT
5-65
EAS25420CHECKING THE SHIFT SHAFT
1. Check:
Shift shaft
Bends/damage/wear → Replace.
Shift shaft spring
Damage/wear → Replace.
EAS25430
CHECKING THE STOPPER LEVER
1. Check:
Stopper lever
Bends/damage → Replace.
Roller turns roughly → Replace the stopper 
lever.
Stopper lever spring
Damage/wear → Replace.
EAS25450
INSTALLING THE SHIFT SHAFT
1. Install:
Stopper lever “1”
Stopper lever bolt “2”
Stopper lever spring “3”
NOTE:
Hook the ends of the stopper lever spring onto 
the stopper...

GENERATOR AND STARTER CLUTCH
5-66
EAS24480
GENERATOR AND STARTER CLUTCH
Removing the stator coil assembly
Order Job/Parts to remove Q’ty Remarks
Engine oilDrain.
Refer to “CHANGING THE ENGINE OIL” on 
page 3-11.
Oil tank/Front exhaust pipe Refer to “ENGINE REMOVAL” on page 5-1.
1 Stator coil assembly coupler 1 Disconnect.
2 Rectifier/regulator 1
3 Oil pipe 2 1 From oil pump to generator cover.
4 Generator cover 1
5 Generator cover gasket 1
6 Dowel pin 2
7 Stator coil assembly lead holder 1
8 Stator coil...

GENERATOR AND STARTER CLUTCH
5-67
Removing the generator rotor
Order Job/Parts to remove Q’ty Remarks
1 Starter clutch idle gear shaft #2 1
2 Starter clutch idle gear shaft #1 1
3 Starter clutch idle gear #2 1
4 Starter clutch idle gear #1 1
5 Generator rotor 1
6 Woodruff key 1
7 Starter clutch gear 1
For installation, reverse the removal 
procedure.
ER..80 Nm (8.0 m • 
kg, 58 ft • Ib)T 
24 3
1 57
6
E
E 

GENERATOR AND STARTER CLUTCH
5-68
EAS24490REMOVING THE GENERATOR
1. Remove:
Generator rotor bolt “1”
Washer
NOTE:
While holding the generator rotor “2” with the 
sheave holder “3”, loosen the generator rotor 
bolt.
2. Remove:
Generator rotor “1”
(with the rotor puller “2”)
Woodruff key
EAS24570
CHECKING THE STARTER CLUTCH
1. Check:
Starter clutch idle gears
Starter clutch gear
Burrs/chips/roughness/wear → Replace the 
defective part(s).2. Check:
Starter clutch gear’s contacting surfaces...

GENERATOR AND STARTER CLUTCH
5-69
2. Tighten:
Generator rotor bolt “1”
NOTE:
Tighten the generator rotor bolt “1” while holding 
the generator rotor “2” with a sheave holder “3”.
3. Apply:
Sealant
(onto the stator coil assembly lead grommet)
T R.. 
Generator rotor bolt
80 Nm (8.0 m·kg, 58 ft·lb)
 
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
 
Yamaha bond No. 1215
90890-85505
231 

ELECTRIC STARTER
5-70
EAS24780
ELECTRIC STARTER
Removing the starter motor
Order Job/Parts to remove Q’ty Remarks
Oil tank Refer to “ENGINE REMOVAL” on page 5-1.
1 Starter motor lead 1 Disconnect.
2 Starter motor assembly 1
For installation, reverse the removal 
procedure.
21 

ELECTRIC STARTER
5-71
Disassembling the starter motor
Order Job/Parts to remove Q’ty Remarks
1 Circlip 1
2 Starter motor gear 1
3 Starter motor rear cover 1
4 Bearing 1
5 Oil seal 1
6 Circlip 1
7 Starter motor front cover 1
8 Brush 2
9 Brush holder (along with the brushes) 1
10 Brush seat (along with the brushes) 1
11 Bearing 1
12 Gasket 2
13 Armature assembly 1
14 Starter motor yoke 1
For assembly, reverse the disassembly 
procedure.
84 5
7 3 2 1
6
LS
New
NewNew
New
New
New12
11
12 10 9 14 13
NewLS