Yamaha Mt 01 T 2005 Manual

ELECTRIC STARTER
5-72
EAS24790CHECKING THE STARTER MOTOR
1. Check:
Commutator
Dirt → Clean with 600 grit sandpaper.
2. Measure:
Commutator diameter “a”
Out of specification → Replace the starter 
motor.
3. Measure:
Mica undercut “a”
Out of specification → Scrape the mica to the 
proper measurement with a hacksaw blade 
that has been grounded to fit the commutator.
NOTE:
The mica of the commutator must be undercut to 
ensure proper operation of the commutator.
4. Measure:
Armature assembly resistances...

ELECTRIC STARTER
5-73
7. Check:
Gear teeth
Damage/wear → Replace the gear.
8. Check:
Bearing
Oil seal
Damage/wear → Replace the defective 
part(s).
EAS24800ASSEMBLING THE STARTER MOTOR
1. Install:
Brush seat “1”
NOTE:
Align the slot “a” on the brush seat with the tab 
“b” in the starter motor front cover.
2. Install:
Starter motor yoke “1”
NOTE:
Align the tab “a” on the brush holder with the slot 
“b” in the starter motor yoke.3. Install:
Starter motor yoke “1”
Starter motor front cover “2”...

CRANKCASE
5-74
EAS25540
CRANKCASE
Separating the crankcase
Order Job/Parts to remove Q’ty Remarks
Engine Refer to “ENGINE REMOVAL” on page 5-1.
Camshafts Refer to “CAMSHAFTS” on page 5-16.
PistonsRefer to “CYLINDERS AND PISTONS” on 
page 5-41.
Shift shaft Refer to “SHIFT SHAFT” on page 5-64.
Generator rotorRefer to “GENERATOR AND STARTER 
CLUTCH” on page 5-66.
1 Speed sensor 1
2 Oil filter cartridge bracket 1
3 Generator shaft end cover 1
4 Oil delivery pipe 2 1
5 Oil pump driven gear stopper 1
6 Oil...

CRANKCASE
5-75
10 Right crankcase 1
For installation, reverse the removal 
procedure.
Separating the crankcase
Order Job/Parts to remove Q’ty Remarks 

CRANKCASE
5-76
Removing the oil baffle plate and bearings
Order Job/Parts to remove Q’ty Remarks
Oil pump Refer to “OIL PUMP” on page 5-81.
Crankshaft Refer to “CRANKSHAFT” on page 5-86.
Transmission Refer to “TRANSMISSION” on page 5-92.
1 Oil baffle plate 1
2 Bearing retainer 1
3 Bearing retainer 1
4 Oil seal 1
5 Bearing 4
For installation, reverse the removal 
procedure. 

CRANKCASE
5-77
EAS25570DISASSEMBLING THE CRANKCASE
NOTE:
Loosen the generator shaft bolt before removing 
the generator rotor.
1. Loosen:
Generator shaft bolt “1”
NOTE:
While the holding the generator rotor “2” with the 
primary sheave holder “3”, loosen the generator 
shaft bolt.
2. Remove:
Crankcase bolts
NOTE:
Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern. After all of the 
bolts are fully loosened, remove them.
Loosen the bolts in decreasing numerical order...

CRANKCASE
5-78
Tap on one side of the crankcase with a 
soft-face hammer. Tap only on reinforced 
portions of the crankcase, not on the crank-
case mating surfaces. Work slowly and 
carefully and make sure the crankcase 
halves separate evenly.
EAS25580CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in a 
mild solvent.
2. Thoroughly clean all the gasket surfaces and 
crankcase mating surfaces.
3. Check:
Crankcase
Cracks/damage → Replace.
Oil delivery passages
Obstruction → Blow out with...

CRANKCASE
5-79
Tap lightly on the left crankcase with a soft-
face hammer.
4. Install:
Crankcase bolts (M8)
Crankcase bolts (M6)
NOTE:
Lubricate the bolt threads with engine oil.
Tighten each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern.
Tighten the bolts in numerical order (refer to 
the numbers in the illustration).
M8 × 100 mm bolts: “1”, “2”
M8 × 80 mm bolt: “3”
M6 × 105 mm bolt: “21”
M6 × 85 mm bolts: “9”, “13”
M6 × 75 mm bolts: “14”, “15”
M6 × 60 mm bolts:...

CRANKCASE
5-80 

OIL PUMP
5-81
EAS24910
OIL PUMP
Removing the oil pump
Order Job/Parts to remove Q’ty Remarks
CrankcaseSeparate.
Refer to “CRANKCASE” on page 5-74.
1 Oil strainer (crankcase) 1
2 Oil pump assembly 1
For installation, reverse the removal 
procedure.