Yamaha Mt 01 T 2005 Manual

							ENGINE
3-6
2. Remove:
Seat
Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tank
Refer to “FUEL TANK” on page 6-1.
Air filter case
Refer to “GENERAL CHASSIS” on page 4-1.
3. Disconnect:
Intake solenoid vacuum hose (one-way valve 
to throttle body) “1”
Cylinder-#1 intake air pressure sensor hose 
“2”
4. Install:
Fuel hose “1” (Parts No.: 5JW-24311-00)
3-way joint “2” (Parts No.: 90413-05014)
Cylinder-#1 intake air pressure sensor hose 
“3”
Vacuum gauge hose for #1 “4”
Vacuum gauge hose for #2 “5”
Vacuum gauge
Digital tachometer
5. Install:
Air filter case
Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tank
Refer to “FUEL TANK” on page 6-1.
6. Adjust:
Throttle body synchronization


 





 
 



 
 



 
 



 
 



 



a. Start the engine, warm it up for several min-
utes, and then let it run at the specified en-
gine idling speed.
b. With throttle body #1 as standard, adjust 
throttle body #2 using the air screw “1” (for 
throttle body #2).
NOTE:
After each step, rev the engine two or three 
times, each time for less than a second, and 
check the synchronization again.
If the air screw is removed, turn the screw 3/4 
turn in and be sure to synchronize the throttle 
body.
CAUTION:
EC5YU1027
Do not use the throttle valve adjusting 
screws to adjust the throttle body synchroni-
zation.
NOTE:
The difference in vacuum pressure between two 
throttle bodies should not exceed 1.33 kPa (10 
mm Hg).
          
7. Stop the engine and remove the measuring 
equipment.
8. Adjust:
Throttle cable free play
Refer to “ADJUSTING THE THROTTLE CA-
BLE FREE PLAY” on page 3-7.
 
Vacuum gauge
90890-03094
Carburetor synchronizer
YU-44456
1
2
4
25
3
1
 
Engine idling speed
850–950 r/min
 
Intake vacuum
26.6 kPa (7.9 inHg) (200 mmHg)
 
Throttle cable free play
3.0–5.0 mm (0.12–0.20 in)
1 
						

							ENGINE
3-7
9. Install:
Air filter case
Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tank
Refer to “FUEL TANK” on page 6-1.
Seat
Refer to “GENERAL CHASSIS” on page 4-1.
EAS20630ADJUSTING THE THROTTLE CABLE FREE 
PLAY
1. Check:
Throttle cable free play “a”
Out of specification → Adjust.
2. Remove:
Pressure regulator cover “1”
3. Adjust:
Throttle cable free play
NOTE:
When the throttle is opened, the accelerator ca-
ble “1” is pulled.



 





 
 








 
 



 
 



 



Throttle body side
a. Loosen the locknut “2” on the decelerator ca-
ble.
b. Turn the adjusting nut “3” in direction “a” or “b” 
to take up any slack on the decelerator cable.
NOTE:
Apply locking agent (LOCTITE®) to the threads 
of the adjusting nut “3”.
c. Loosen the locknut “4” on the accelerator ca-
ble.
d. Turn the adjusting nut “5” in direction “a” or “b” 
until the specified throttle cable free play is 
obtained.
e. Tighten the locknuts “2”, “4”.
NOTE:
If the specified throttle cable free play cannot be 
obtained on the throttle body side of the cable, 
use the adjusting nut on the handlebar side.
          



 





 
 



 
 



 
 



 
 



 



Handlebar side
a. Loosen the locknut “1”.
b. Turn the adjusting nut “2” in direction “a” or “b” 
until the specified throttle cable free play is 
obtained.
 
Throttle cable free play
3.0–5.0 mm (0.12–0.20 in)
a
1
Direction “a”
Throttle cable free play is increased.
Direction “b”
Throttle cable free play is decreased.
Direction “a”
Throttle cable free play is increased.
Direction “b”
Throttle cable free play is decreased.
14
25
3
b
a
b
a 
						

							ENGINE
3-8
c. Tighten the locknut “1”.
WARNING
EWA12910
After adjusting the throttle cable free play, 
start the engine and turn the handlebar to the 
right and to the left to ensure that this does 
not cause the engine idling speed to change.
        
4. Install:
Pressure regulator cover
EAS20680CHECKING THE SPARK PLUGS
The following procedure applies to all of the 
spark plugs.
1. Remove:
Seat
Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tank
Refer to “FUEL TANK” on page 6-1.
2. Disconnect:
Spark plug cap
3. Remove:
Spark plug
CAUTION:
ECA13320
Before removing the spark plugs, blow away 
any dirt accumulated in the spark plug wells 
with compressed air to prevent it from falling 
into the cylinders.
4. Check:
Spark plug type
Incorrect → Change.5. Check:
Electrode “1”
Damage/wear → Replace the spark plug.
Insulator “2”
Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.
6. Clean:
Spark plug
(with a spark plug cleaner or wire brush)
7. Measure:
Spark plug gap “a”
(with a wire thickness gauge)
Out of specification → Regap.
8. Install:
Spark plug
NOTE:
Before installing the spark plug, clean the spark 
plug and gasket surface.
9. Connect:
Spark plug cap
10.Install:
Fuel tank
Refer to “FUEL TANK” on page 6-1.
Seat
Refer to “GENERAL CHASSIS” on page 4-1.
EAS20700
CHECKING THE IGNITION TIMING
NOTE:
Prior to checking the ignition timing, check the 
wiring connections of the entire ignition system. 
Make sure all connections are tight and free of 
corrosion.
T R.. 
Pressure regulator cover bolt
9 Nm (0.9 m·kg, 6.5 ft·lb)
 
Manufacturer/model
NGK/DPR7EA-9
Manufacturer/model
DENSO/X22EPR-U9
1
2
ba
 
Spark plug gap
0.8–0.9 mm (0.031–0.035 in)
T R.. 
Spark plug
18 Nm (1.8 m·kg, 13 ft·lb) 
						

							ENGINE
3-9
1. Stand the vehicle on a level surface.
2. Remove:
Air duct “1”
Timing mark accessing screw “2”
3. Connect:
Timing light “1”
Digital tachometer
4. Check:
Ignition timing



 





 
 








 
 



 
 



 



a. Start the engine, warm it up for several min-
utes, and then let it run at the specified en-
gine idling speed.
b. Check that pointer “a” on the clutch cover is 
within the firing range “b” on the crankshaft 
position sensor.
Incorrect firing range → Check the ignition 
system.
NOTE:
The ignition timing is not adjustable.
          
5. Install:
Timing mark accessing screw
Air duct
EAS20710
MEASURING THE COMPRESSION 
PRESSURE
The following procedure applies to all of the cyl-
inders.
NOTE:
Insufficient compression pressure will result in a 
loss of performance.
1. Measure:
Valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-3.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Remove:
Seat
Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tank
Refer to “FUEL TANK” on page 6-1.
4. Disconnect:
Decompression solenoid couplers “1”
 
Timing light
90890-03141
Inductive clamp timing light
YU-03141
 
Engine idling speed
850–950 r/min
1
2
1
T R.. 
Timing mark accessing screw
8 Nm (0.8 m·kg, 5.8 ft·lb)
T R.. 
Air duct bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
Air duct bracket bolt
7 Nm (0.7 m·kg, 5.1 ft·lb)
ab 
						

							ENGINE
3-10
5. Disconnect:
Spark plug cap
6. Remove:
Spark plug
CAUTION:
ECA13340
Before removing the spark plugs, use com-
pressed air to blow away any dirt accumulat-
ed in the spark plug wells to prevent it from 
falling into the cylinders.
7. Install:
Compression gauge “1”
Extension “2”
8. Measure:
Compression pressure
Out of specification → Refer to steps (c) and 
(d).



 





 
 



 
 



 
 



 
 



 



a. Set the main switch to “ON”.
b. With the throttle wide open, crank the engine 
until the reading on the compression gauge 
stabilizes.
WARNING
EWA12940
To prevent sparking, ground all spark plug 
leads before cranking the engine.
NOTE:
The difference in compression pressure be-
tween cylinders should not exceed 100 kPa (1 
kg/cm², 14 psi).
c. If the compression pressure is above the 
maximum specification, check the cylinder 
head, valve surfaces and piston crown for 
carbon deposits.
Carbon deposits → Eliminate.
d. If the compression pressure is below the min-
imum specification, pour a teaspoonful of en-
gine oil into the spark plug bore and measure 
again.
Refer to the following table.
          
9. Install:
Spark plug
10.Connect:
Spark plug cap
11.Connect:
Decompression solenoid couplers
12.Install:
Fuel tank
Refer to “FUEL TANK” on page 6-1.
Seat
Refer to “GENERAL CHASSIS” on page 4-1.
 
Compression gauge
90890-03081
Engine compression tester
YU-33223
Extension
90890-04082
 
Standard compression pressure 
(at sea level)
1200 kPa/200 r/min (170.7 
psi/200 r/min) (12.0 kgf/cm²/200 
r/min)
Minimum–maximum
1000–1400 kPa (142.2–199.1 psi) 
(10.0–14.0 kgf/cm²)
1
2
1
Compression pressure (with oil applied into 
the cylinder)
Reading Diagnosis
Higher than without 
oilPiston ring(s) wear or 
damage → Repair.
Same as without oilPiston ring(s), valves, 
cylinder head gasket 
or piston possibly 
defective → Repair.
T R.. 
Spark plug
18 Nm (1.8 m·kg, 13 ft·lb) 
						

							ENGINE
3-11
EAS20730CHECKING THE ENGINE OIL LEVEL
1. Stand the vehicle on a level surface.
NOTE:
Place the vehicle on a suitable stand.
Make sure the vehicle is upright.
2. Start the engine, warm it up for approximately 
15 minutes until the oil temperature rises to 
60 °C (140 °F), and then turn it off.
3. Remove:
Dipstick “1”
4. Check:
Engine oil level
The engine oil level should be between the 
minimum level mark “a” and maximum level 
mark “b”.
Below the minimum level mark → Add the 
recommended engine oil to the proper level.
NOTE:
Before checking the engine oil level, wait a few 
minutes until the oil has settled.
Do not screw the dipstick in when inspecting 
the oil level.
CAUTION:
EC5YU1003
Since engine oil also lubricates the clutch, 
the wrong oil types or additives could 
cause clutch slippage. Therefore, do not 
add any chemical additives, or use engine 
oils with a grade of CD “a” or higher, and do 
not use oils labeled “ENERGY CONSERV-
ING II” “b”.
Do not allow foreign materials to enter the 
crankcase.5. Start the engine, warm it up for several min-
utes, and then turn it off.
6. Check the engine oil level again.
NOTE:
Before checking the engine oil level, wait a few 
minutes until the oil has settled.
7. Install:
Dipstick
EAS20780
CHANGING THE ENGINE OIL
1. Start the engine, warm it up for several min-
utes, and then turn it off.
2. Remove:
Bottom cover
Refer to “GENERAL CHASSIS” on page 4-1.
3. Place a container under the engine oil drain 
bolts.
4. Remove:
Engine oil filler cap “1”
5. Remove:
Engine oil drain bolt (oil tank) “1”
 
Ty p e
SAE20W40
Recommended engine oil grade
API standard:
SE or higher grade
ACEA standard:
G4 or G5
b
a
1
1
1 
						

							ENGINE
3-12
6. Remove:
Engine oil drain bolt (crankcase) “1”
7. Drain:
Engine oil
(completely from the oil tank and crankcase)
8. If the oil filter cartridge is also to be replaced, 
perform the following procedure.



 





 
 








 
 



 
 



 



a. Remove the rectifier/regulator “1”.
b. Remove the oil filter cartridge “1” with an oil 
filter wrench “2”.
c. Lubricate the O-ring “1” of the new oil filter 
cartridge with a thin coat of engine oil.
CAUTION:
EC5YU1019
Make sure the O-ring “1” is positioned cor-
rectly in the groove of the oil filter cartridge.d. Tighten the new oil filter cartridge to specifi-
cation with an oil filter wrench.
e. Install the rectifier/regulator.
          
9. Check:
Engine oil drain bolt gaskets
Damage → Replace.
10.Install:
Engine oil drain bolt (crankcase)
(along with the gasket)
Engine oil drain bolt (oil tank)
(along with the gasket)
11.Fill:
Oil tank
(with the specified amount of the recom-
mended engine oil)
 
Oil filter wrench
90890-01426
YU-38411
1
11
1122
T R.. 
Oil filter cartridge
17 Nm (1.7 m·kg, 12 ft·lb)
T R.. 
Rectifier/regulator bolt
7 Nm (0.7 m·kg, 5.1 ft·lb)
T R.. 
Engine oil drain bolt (crankcase)
43 Nm (4.3 m·kg, 31 ft·lb)
T R.. 
Engine oil drain bolt (oil tank)
35 Nm (3.5 m·kg, 25 ft·lb)
 
Engine oil quantity
Total amount
5.00 L (5.29 US qt) (4.40 Imp.qt)
Without oil filter cartridge 
replacement
3.70 L (3.91 US qt) (3.26 Imp.qt)
With oil filter cartridge 
replacement
4.10 L (4.33 US qt) (3.61 Imp.qt) 
						

							ENGINE
3-13
NOTE:
Pour the engine oil in two stages. First, pour in 
2.5 L of oil, then start the engine and rev it 3 to 5 
times. Stop the engine, and then pour in the re-
mainder of the specified amount.
CAUTION:
EC5YU1004
When starting the engine make sure the dip-
stick is securely fitted into the oil tank.
12.Fill: (when engine is disassembled)
Crankcase and oil tank
(with the specified amount of the recom-
mended engine oil)
NOTE:
After the engine has been disassembled, pour 
the specified amount of engine oil into the crank-
case and the oil tank. When pouring engine oil 
into the crankcase, pour it into the hole of the re-
moved bolt “1”.
13.Install:
Engine oil filler cap
14.Start the engine, warm it up for several min-
utes, and then turn it off.
15.Check:
Engine
(for engine oil leaks)
16.Check:
Engine oil level
Refer to “CHECKING THE ENGINE OIL 
LEVEL” on page 3-11.
17.Check:
Engine oil pressure



 





 
 



 
 



 
 



 
 



 



a. Slightly loosen the oil gallery bolts “1”.
b. Start the engine and keep it idling until engine 
oil starts to seep from the oil gallery bolts. If 
no engine oil comes out after one minute, turn 
the engine off so that it will not seize.
c. Check the engine oil passages, the oil filter 
cartridge and the oil pump for damage or 
leakage. Refer to “OIL PUMP” on page 5-81.
d. Start the engine after solving the problem(s) 
and check the engine oil pressure again.
e. Tighten the oil gallery bolts to specification.
          
EAS20860
ADJUSTING THE CLUTCH LEVER
1. Adjust:
Clutch lever position
(distance “a” from the handlebar grip to the 
clutch lever)



 





 
 



 
 



 
 



 
 



 



a. While pushing the clutch lever forward, turn 
the adjusting dial “1” until the clutch lever is in 
the desired position.
NOTE:
Be sure to align the setting on the adjusting dial 
with the arrow mark “2” on the clutch lever hold-
er.
 
Engine oil quantity
Total amount
5.00 L (5.29 US qt) (4.40 Imp.qt)
Engine
2.2 L (2.33 US qt) (1.94 Imp.qt)
Oil tank
2.8 L (2.96 US qt) (2.46 Imp.qt)
1
T R.. 
Oil gallery bolt
4 Nm (0.4 m·kg, 2.9 ft·lb)
Position #1
Distance “a” increases.
Position #4
Distance “a” decreases.
1 
						

							ENGINE
3-14
        
EAS20890CHECKING THE CLUTCH FLUID LEVEL
1. Stand the vehicle on a level surface.
NOTE:
Place the vehicle on a suitable stand.
Make sure the vehicle is upright.
2. Check:
Clutch fluid level
Below the minimum level mark “a” → Add the 
recommended clutch fluid to the proper level.
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 the clutch fluid reservoir. Water 
will significantly lower the boiling point of 
the clutch fluid and could cause vapor lock.
CAUTION:
ECA13420
Clutch fluid may damage painted surfaces or 
plastic parts. Therefore, always clean up any 
spilt clutch fluid immediately.
NOTE:
In order to ensure a correct reading of the clutch 
fluid level, make sure the top of the reservoir is 
horizontal.
EAS20910
BLEEDING THE HYDRAULIC CLUTCH 
SYSTEM
WARNING
EWA13000
Bleed the hydraulic clutch system whenever:
the system was disassembled,
a clutch hose was loosened or removed,
the clutch fluid level is very low,
clutch operation is faulty.
NOTE:
Be careful not to spill any clutch fluid or allow 
the clutch fluid reservoir to overflow.
When bleeding the hydraulic clutch system, 
make sure there is always enough clutch fluid 
before applying the clutch lever. Ignoring this 
precaution could allow air to enter the hydraulic 
clutch system, considerably lengthening the 
bleeding procedure.
If bleeding is difficult, it may be necessary to let 
the clutch fluid settle for a few hours. Repeat 
the bleeding procedure when the tiny bubbles 
in the hose have disappeared.
1. Bleed:
Hydraulic clutch system



 





 
 



 
 



 
 



 
 



 



a. Add the recommended clutch fluid to the 
proper level.
b. Install the clutch fluid reservoir diaphragm.
c. Connect a clear plastic hose “1” tightly to the 
bleed screw “2”.
 
Recommended clutch fluid
Brake fluid DOT4
1
a
2
a
1
2 
						

							ENGINE
3-15
d. Place the other end of the hose into a con-
tainer.
e. Slowly squeeze the clutch lever several 
times.
f. Fully squeeze the clutch lever without releas-
ing it.
g. Loosen the bleed screw. This will release the 
tension and cause the clutch lever to contact 
the handlebar grip.
h. Tighten the bleed screw and then release the 
clutch lever.
i. Repeat steps (e) to (h) until all of the air bub-
bles have disappeared from the clutch fluid in 
the plastic hose.
j. Tighten the bleed screw to specification.
k. Add the recommended clutch fluid to the 
proper level.
Refer to “CHECKING THE CLUTCH FLUID 
LEVEL” on page 3-14.
WARNING
EWA13010
After bleeding the hydraulic clutch system, 
check the clutch operation.
        
EAS20960REPLACING THE AIR FILTER ELEMENT
1. Remove:
Seat
Refer to “GENERAL CHASSIS” on page 4-1.
2. Lift the front of the fuel tank, and then tilt it 
back and away from the air filter case. (Do not 
disconnect the fuel hoses.)
3. Remove:
Air filter case cover “1”4. Remove:
Air filter element “1”
5. Check:
Air filter element
Damage → Replace.
NOTE:
Replace the air filter element every 40000 km 
of operation.
The air filter needs more frequent service if you 
are riding in unusually wet or dusty areas.
6. Install:
Air filter case cover
CAUTION:
EC5YU1005
Never operate the engine without the air filter 
element installed. Unfiltered air will cause 
rapid wear of engine parts and may damage 
the engine. Operating the engine without the 
air filter element will also affect the throttle 
body synchronization, leading to poor en-
gine performance and possible overheating.
NOTE:
When installing the air filter element into the air 
filter case, make sure that the sealing surfaces 
are aligned to prevent any air leaks.
7. Install:
Fuel tank
Seat
Refer to “GENERAL CHASSIS” on page 4-1.
T R.. 
Bleed screw (clutch release 
cylinder)
6 Nm (0.6 m·kg, 4.3 ft·lb)
1
1