Yamaha Mt 01 T 2005 Manual

TRANSMISSION
5-92
EAS26240
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
Order Job/Parts to remove Q’ty Remarks
CrankcaseSeparate.
Refer to “CRANKCASE” on page 5-74.
1 Shift fork guide bar 2
2 Shift drum assembly 1
3 Shift fork-L 1
4 Shift fork-R 1
5 Shift fork-C 1
6 Drive axle assembly 1
7 Main axle assembly 1
8 Spacer 1
For installation, reverse the removal 
procedure. 

TRANSMISSION
5-93
Disassembling the main axle assembly
Order Job/Parts to remove Q’ty Remarks
1 Circlip 1
2Washer 1
3 5th pinion gear 1
4Collar 1
5Washer 1
6 2nd/3rd pinion gear 1
7 Circlip 1
8Washer 1
9 4th pinion gear 1
10 Collar 1
11 Main axle/1st pinion gear 1
For assembly, reverse the disassembly 
procedure. 

TRANSMISSION
5-94
Disassembling the drive axle assembly
Order Job/Parts to remove Q’ty Remarks
1 5th wheel gear 1
2 Circlip 1
3Washer 1
4 2nd wheel gear 1
5Collar 1
6 Circlip 1
7Washer 1
8 1st wheel gear 1
9Collar 1
10 Washer 1
11 4th wheel gear 1
12 Circlip 1
13 Washer 1
14 3rd wheel gear 1
15 Collar 1
16 Drive axle 1
For assembly, reverse the disassembly 
procedure. 

TRANSMISSION
5-95
EAS26260CHECKING THE SHIFT FORKS
The following procedure applies to all of the shift 
forks.
1. Check:
Shift fork cam follower “1”
Shift fork pawl “2”
Bends/damage/scoring/wear → Replace the 
shift fork.
2. Check:
Shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends → Replace.
WARNING
EWA12840
Do not attempt to straighten a bent shift fork 
guide bar.
3. Check:
Shift fork movement
(along the shift fork guide bar)
Rough movement → Replace the shift forks 
and...

TRANSMISSION
5-96
Transmission gear dogs
Cracks/damage/rounded edges → Replace 
the defective gear(s).
4. Check:
Transmission gear engagement
(each pinion gear to its respective wheel 
gear)
Incorrect → Reassemble the transmission 
axle assemblies.
5. Check:
Transmission gear movement
Rough movement → Replace the defective 
part(s).
6. Check:
Circlips
Bends/damage/looseness → Replace.
ET5YU1024ASSEMBLING THE MAIN AXLE AND DRIVE 
AXLE
1. Install:
Washer “1”
Circlip “2” 
NOTE:
Be sure the circlip...

FUEL
6 

6
FUEL SYSTEM
FUEL TANK..................................................................................................... 6-1
REMOVING THE FUEL TANK .................................................................. 6-2
REMOVING THE FUEL PUMP ................................................................. 6-2
CHECKING THE FUEL PUMP BODY....................................................... 6-2
CHECKING THE FUEL PUMP OPERATION............................................ 6-2
INSTALLING THE FUEL PUMP...

FUEL TANK
6-1
EAS26620
FUEL TANK
Removing the fuel tank and fuel pump
Order Job/Parts to remove Q’ty Remarks
SeatRefer to “GENERAL CHASSIS” on page 
4-1.
1 Fuel tank cover 1
2 Fuel pump coupler 1 Disconnect.
3 Fuel sender coupler 1 Disconnect.
4 Fuel tank overflow hose 1 Disconnect.
5 Fuel tank breather hose 1 Disconnect.
6 Fuel hose 1 Disconnect.
7 Fuel return hose 1 Disconnect.
8Fuel tank 1
9 Fuel pump 1
For installation, reverse the removal 
procedure.
7 4
3
2 5
698 1
T R..7 Nm (0.7 m • 
kg, 5.1 ft •...

FUEL TANK
6-2
EAS26630REMOVING THE FUEL TANK
1. Extract the fuel in the fuel tank through the 
fuel tank cap with a pump.
2. Disconnect:
Fuel hose
Fuel return hose
CAUTION:
EC5YU1029
Although the fuel has been removed from 
the fuel tank be careful when removing the 
fuel hoses, since there may be fuel remain-
ing in them.
NOTE:
To remove the fuel hose from the fuel pump, 
slide the fuel hose connector cover “1” on the 
end of the hose in the direction of the arrow 
shown, press the two buttons “2” on...