Yamaha Mt 01 T 2005 Manual
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CHASSIS
3-26
a. Remove the lock washer “1”, the upper ring
nut “2”, and the rubber washer “3”.
b. Loosen the lower ring nut “4”, and then tight-
en it to the specified torque with a steering nut
wrench “5”.
NOTE:
Set a torque wrench at a right angle to the steer-
ing nut wrench.
c. Loosen the lower ring nut completely, and
then tighten it to specification with a steering
nut wrench.
WARNING
EWA13140
Do not overtighten the lower ring nut.d. Check the steering head for looseness or
binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the lower bracket and check the upper and
lower bearings.
Refer to “STEERING HEAD” on page 4-57.
e. Install the rubber washer “3”.
f. Install the upper ring nut “2”.
g. Finger tighten the upper ring nut “2”, then
align the slots of both ring nuts. If necessary,
hold the lower ring nut and tighten the upper
ring nut until their slots are aligned.
h. Install the lock washer “1”.
NOTE:
Make sure the lock washer tabs “a” sit correctly
in the ring nut slots “b”.
5. Install:
Upper bracket
Refer to “STEERING HEAD” on page 4-57.
EAS21530
CHECKING THE FRONT FORK
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there is
no danger of it falling over.
2. Check:
Inner tube “1”
Damage/scratches → Replace.
Oil seal “2”
Oil leakage → Replace.
Steering nut wrench
90890-01403
Spanner wrench
YU-33975
T R..
Lower ring nut (initial tightening
torque)
52 Nm (5.2 m·kg, 37 ft·lb)
T R..
Lower ring nut (final tightening
torque)
23 Nm (2.3 m·kg, 17 ft·lb)
CHASSIS
3-27
3. Hold the vehicle upright and apply the front
brake.
4. Check:
Front fork operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Rough movement → Repair.
Refer to “FRONT FORK” on page 4-47.
EAS21580ADJUSTING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
WARNING
EW5YU1008
Always adjust both front fork legs evenly.
Uneven adjustment can result in poor han-
dling and loss of stability.
Securely support the vehicle so that there
is no danger of it falling over.
Spring preload
CAUTION:
ECA13570
Grooves are provided to indicate the ad-
justment position.
Never go beyond the maximum or mini-
mum adjustment positions.
1. Adjust:
Spring preload
a. Turn the adjusting bolt “1” in direction “a” or
“b”.
Rebound damping
CAUTION:
ECA13590
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
Rebound damping
12Direction “a”
Spring preload is increased
(suspension is harder).
Direction “b”
Spring preload is decreased
(suspension is softer).
Spring preload adjusting positions
Minimum
0
Standard
2
Maximum
5
2. Current setting
3. Cap bolt collar
1
ba
CHASSIS
3-28
a. Turn the adjusting screw “1” in direction “a” or
“b”.
Compression damping
CAUTION:
ECA13590
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
Compression damping
a. Turn the adjusting screw “1” in direction “a” or
“b”.
EAS21620
ADJUSTING THE REAR SHOCK ABSORBER
ASSEMBLY
WARNING
EWA13120
Securely support the vehicle so that there is
no danger of it falling over.
Spring preload
CAUTION:
ECA13590
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
Spring preload
NOTE:
Adjust the spring preload with the special
wrench “1”.
a. Loosen the locknut “2”.
b. Turn the adjusting nut “3” in direction “a” or
“b”. Direction “a” (turn in)
Rebound damping is increased
(suspension is harder).
Direction “b” (turn out)
Rebound damping is decreased
(suspension is softer).
Rebound damping adjusting
positions
Minimum
17 click(s) out*
Standard
15 click(s) out*
Maximum
1 click(s) out*
* With the adjusting screw fully turned in
Direction “a” (turn in)
Compression damping is increased
(suspension is harder).
Direction “b” (turn out)
Compression damping is decreased
(suspension is softer).
1
ab
Compression damping adjusting
positions
Minimum
16 click(s) out*
Standard
7 click(s) out*
Maximum
1 click(s) out*
* With the adjusting screw fully turned in
Direction “a”
Spring preload is increased
(suspension is harder).
Direction “b”
Spring preload is decreased
(suspension is softer).
1 ba
CHASSIS
3-29
c. Tighten the locknut to specification.
CAUTION:
ECA13600
Always tighten the locknut against the ad-
justing nut and torque it to specification.
Rebound damping
CAUTION:
ECA13590
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
Rebound damping
a. Turn the adjusting knob “1” in direction “a” or
“b”.
Compression damping
CAUTION:
ECA13590
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
Compression damping
a. Turn the adjusting screw “1” in direction “a” or
“b”.
Spring preload adjusting
positions
Installed spring length
Minimum
155.0 mm (6.10 in)
Standard
150.0 mm (5.91 in)
Maximum
145.0 mm (5.71 in)
c. Installed spring length
T R..
Locknut (rear shock absorber
spring preload adjusting nut)
42 Nm (4.2 m·kg, 30 ft·lb)
a
b
1
3
2
c
Direction “a” (turn in)
Rebound damping is increased
(suspension is harder).
Direction “b” (turn out)
Rebound damping is decreased
(suspension is softer).
Rebound damping adjusting
positions
Minimum
20 click(s) out*
Standard
12 click(s) out*
Maximum
3 click(s) out*
* With the adjusting knob fully turned in
Direction “a” (turn in)
Compression damping is increased
(suspension is harder).
Direction “b” (turn out)
Compression damping is decreased
(suspension is softer).
1
a
b
CHASSIS
3-30
EAS21650
CHECKING THE TIRES
The following procedure applies to both of the
tires.
1. Check:
Tire pressure
Out of specification → Regulate.
WARNING
EWA13180
The tire pressure should only be checked
and regulated when the tire temperature
equals the ambient air temperature.
The tire pressure and the suspension must
be adjusted according to the total weight
(including cargo, rider, passenger and ac-
cessories) and the anticipated riding
speed.
Operation of an overloaded vehicle could
cause tire damage, an accident or an injury.
NEVER OVERLOAD THE VEHICLE.
WARNING
EWA13190
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit, re-
place the tire immediately.
2. Check:
Tire surfaces
Damage/wear → Replace the tire.
Compression damping adjusting
positions
Minimum
12 click(s) out*
Standard
10 click(s) out*
Maximum
1 click(s) out*
* With the adjusting screw fully turned in
1a
b
Tire air pressure (measured on
cold tires)
Loading condition
0–90 kg (0–198 lb)
Front
250 kPa (36 psi) (2.50 kgf/cm²)
(2.50 bar)
Rear
290 kPa (42 psi) (2.90 kgf/cm²)
(2.90 bar)
Loading condition
90–202 kg (198–445 lb)
Front
250 kPa (36 psi) (2.50 kgf/cm²)
(2.50 bar)
Rear
290 kPa (42 psi) (2.90 kgf/cm²)
(2.90 bar)
High-speed riding
Front
250 kPa (36 psi) (2.50 kgf/cm²)
(2.50 bar)
Rear
290 kPa (42 psi) (2.90 kgf/cm²)
(2.90 bar)
Maximum load
202 kg (445 lb)
* Total weight of rider, passenger, cargo
and accessories
Wear limit (front)
1.6 mm (0.06 in)
Wear limit (rear)
1.6 mm (0.06 in)
1. Tire tread depth
CHASSIS 3-31 WARNING EWA14080 Do not use a tubeless tire on a wheel de- signed only for tube tires to avoid tire fail- ure and personal injury from sudden deflation. When using a tube tire, be sure to install the correct tube. Always replace a new tube tire and a new tube as a set. To avoid pinching the tube, make sure the wheel rim band and tube are centered in the wheel groove. Patching a punctured tube is not recom- mended. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality re- placement. WARNING EWA14090 After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design. No guarantee con- cerning handling characteristics can be giv- en if a tire combination other than one approved by Yamaha is used on this vehicle. WARNING EWA13210 New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. NOTE: For tires with a direction of rotation mark “1”: Install the tire with the mark pointing in the di- rection of wheel rotation. Align the mark “2” with the valve installation point. EAS21670CHECKING THE WHEELS The following procedure applies to both of the wheels. 1. Check: Wheel Damage/out-of-round → Replace. WARNING EWA13260 Never attempt to make any repairs to the wheel. 2. Side wall 3. Wear indicator A. Tire B. Wheel Tube wheel Tube tire only Tubeless wheel Tube or tubeless tire Front tire Size 120/70 ZR17 M/C (58W) Manufacturer/model METZELER/MEZ4J FRONT (Europe) MICHELIN/PILOT ROAD S (AUS) Rear tire Size 190/50 ZR17 M/C (73W) Manufacturer/model METZELER/MEZ4 (Europe) MICHELIN/PILOT ROAD (AUS)
CHASSIS 3-32 NOTE: After a tire or wheel has been changed or re- placed, always balance the wheel. EAS21690CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the in- ner and outer cables. WARNING EWA13270 Damaged outer cable may cause the cable to corrode and interfere with its movement. Re- place damaged outer cable and inner cables as soon as possible. 1. Check: Outer cable Damage → Replace. 2. Check: Cable operation Rough movement → Lubricate. NOTE: Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit- able lubricating device. EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal-to-metal moving parts of the levers. EAS21710 LUBRICATING THE PEDAL Lubricate the pivoting point and metal-to-metal moving parts of the pedal. EAS21720LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. EAS21740LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal-to-metal moving parts of the rear suspension. Recommended lubricant Engine oil or a suitable cable lubricant Recommended lubricant Lithium-soap-based grease Recommended lubricant Lithium-soap-based grease Recommended lubricant Lithium-soap-based grease Recommended lubricant Lithium-soap-based grease
ELECTRICAL SYSTEM
3-33
EAS21750
ELECTRICAL SYSTEM
EAS21760
CHECKING AND CHARGING THE BATTERY
Refer to “ELECTRICAL COMPONENTS” on
page 7-85.
EAS21770
CHECKING THE FUSES
Refer to “ELECTRICAL COMPONENTS” on
page 7-85.
EAS21790
REPLACING THE HEADLIGHT BULBS
1. Remove:
Headlight assembly bolts “1”
2. Replace:
Low beam headlight bulb
a. Disconnect:
Headlight coupler “1”
b. Remove:
Headlight bulb “2”
WARNING
EWA13320
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
c. Install:
Headlight bulb
Secure the new headlight bulb with the head-
light bulb holder.
CAUTION:
ECA13690
Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
d. Connect:
Headlight coupler
3. Replace:
High beam headlight bulb
a. Remove:
Headlight bulb cover “1”
b. Disconnect:
Headlight coupler “1”
c. Detach:
Headlight bulb holder “2”
d. Remove:
Headlight bulb
WARNING
EWA13320
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
e. Install:
Headlight bulb
Secure the new headlight bulb with the head-
light bulb holder.
1
1
1
2
New
1
12
New
ELECTRICAL SYSTEM
3-34
CAUTION:
ECA13690
Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
f. Attach:
Headlight bulb holder
g. Connect:
Headlight coupler
h. Install:
Headlight bulb cover
4. Install:
Headlight assembly
EAS21810ADJUSTING THE HEADLIGHT BEAM
1. Adjust:
Headlight beam (vertically)
a. Turn the adjusting screw “1” in direction “a” or
“b”.
2. Adjust:
Headlight beam (horizontally)
a. Turn the adjusting screw “1” in direction “a” or
“b”.
T R..
Headlight assembly bolt
7 Nm (0.7 m·kg, 5.1 ft·lb)
Direction “a”
Headlight beam is raised.
Direction “b”
Headlight beam is lowered.
b
a1
Direction “a”
Headlight beam moves to the right.
Direction “b”
Headlight beam moves to the left.
b
a
1