Yamaha Mt 01 T 2005 Manual
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4 CHASSIS GENERAL CHASSIS....................................................................................... 4-1 CHECKING THE AIR FILTER CASE VALVE............................................ 4-5 FRONT WHEEL............................................................................................... 4-6 REMOVING THE FRONT WHEEL............................................................ 4-8 DISASSEMBLING THE FRONT WHEEL .................................................. 4-8 CHECKING THE FRONT WHEEL ............................................................ 4-8 ASSEMBLING THE FRONT WHEEL ........................................................ 4-9 ADJUSTING THE FRONT WHEEL STATIC BALANCE ........................... 4-9 CHECKING THE FRONT BRAKE DISCS ............................................... 4-10 INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS) ............... 4-10 REAR WHEEL............................................................................................... 4-12 REMOVING THE REAR WHEEL ............................................................ 4-15 DISASSEMBLING THE REAR WHEEL .................................................. 4-15 CHECKING THE REAR WHEEL............................................................. 4-15 CHECKING THE REAR WHEEL DRIVE HUB ........................................ 4-15 CHECKING AND REPLACING THE REAR WHEEL SPROCKET ......... 4-15 ASSEMBLING THE REAR WHEEL ........................................................ 4-16 ADJUSTING THE REAR WHEEL STATIC BALANCE............................ 4-16 CHECKING THE REAR BRAKE DISC.................................................... 4-16 INSTALLING THE REAR WHEEL (REAR BRAKE DISC) ...................... 4-16 FRONT BRAKE............................................................................................. 4-18 INTRODUCTION ..................................................................................... 4-24 CHECKING THE FRONT BRAKE DISCS ............................................... 4-24 REPLACING THE FRONT BRAKE PADS .............................................. 4-25 REMOVING THE FRONT BRAKE CALIPERS ....................................... 4-26 DISASSEMBLING THE FRONT BRAKE CALIPERS.............................. 4-26 CHECKING THE FRONT BRAKE CALIPERS ........................................ 4-27 ASSEMBLING THE FRONT BRAKE CALIPERS.................................... 4-27 INSTALLING THE FRONT BRAKE CALIPERS ...................................... 4-27 REMOVING THE FRONT BRAKE MASTER CYLINDER ....................... 4-28 CHECKING THE FRONT BRAKE MASTER CYLINDER........................ 4-28 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 4-29 INSTALLING THE FRONT BRAKE MASTER CYLINDER...................... 4-29 REAR BRAKE............................................................................................... 4-31 INTRODUCTION ..................................................................................... 4-36 CHECKING THE REAR BRAKE DISC.................................................... 4-36 REPLACING THE REAR BRAKE PADS................................................. 4-36 REMOVING THE REAR BRAKE CALIPER ............................................ 4-37 DISASSEMBLING THE REAR BRAKE CALIPER .................................. 4-37 CHECKING THE REAR BRAKE CALIPER ............................................. 4-38 ASSEMBLING THE REAR BRAKE CALIPER ........................................ 4-38 INSTALLING THE REAR BRAKE CALIPER ........................................... 4-39 REMOVING THE REAR BRAKE MASTER CYLINDER ......................... 4-40 CHECKING THE REAR BRAKE MASTER CYLINDER .......................... 4-40 ASSEMBLING THE REAR BRAKE MASTER CYLINDER...................... 4-40 INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 4-40
HANDLEBAR................................................................................................ 4-42 REMOVING THE HANDLEBAR .............................................................. 4-44 CHECKING THE HANDLEBAR .............................................................. 4-44 INSTALLING THE HANDLEBAR ............................................................ 4-44 FRONT FORK................................................................................................ 4-47 REMOVING THE FRONT FORK LEGS .................................................. 4-50 DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-50 CHECKING THE FRONT FORK LEGS .................................................. 4-51 ASSEMBLING THE FRONT FORK LEGS .............................................. 4-52 INSTALLING THE FRONT FORK LEGS ................................................ 4-56 STEERING HEAD.......................................................................................... 4-57 REMOVING THE LOWER BRACKET..................................................... 4-59 CHECKING THE STEERING HEAD ....................................................... 4-59 INSTALLING THE STEERING HEAD ..................................................... 4-59 REAR SHOCK ABSORBER ASSEMBLY.................................................... 4-61 HANDLING THE REAR SHOCK ABSORBER ........................................ 4-62 DISPOSING OF A REAR SHOCK ABSORBER ..................................... 4-62 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY................... 4-62 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 4-62 CHECKING THE CONNECTING ARM AND RELAY ARM ..................... 4-62 INSTALLING THE CONNECTING ARM AND RELAY ARM ................... 4-63 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ................. 4-64 SWINGARM................................................................................................... 4-65 REMOVING THE SWINGARM................................................................ 4-67 CHECKING THE SWINGARM ................................................................ 4-67 INSTALLING THE SWINGARM .............................................................. 4-67 CHAIN DRIVE................................................................................................ 4-69 REMOVING THE DRIVE CHAIN............................................................. 4-70 CHECKING THE DRIVE CHAIN ............................................................. 4-70 CHECKING THE DRIVE SPROCKET..................................................... 4-71 CHECKING THE REAR WHEEL SPROCKET ........................................ 4-71 CHECKING THE REAR WHEEL DRIVE HUB ........................................ 4-71 INSTALLING THE DRIVE CHAIN ........................................................... 4-71
GENERAL CHASSIS 4-1 EAS21830 GENERAL CHASSIS Removing the seat and battery Order Job/Parts to remove Q’ty Remarks 1 Seat 1 2 Lead holder 1 3 Negative battery lead 1 Disconnect. 4 Positive battery lead 1 Disconnect. 5 Main fuse 1 6 Battery band 1 7Battery 1 8 Battery seat 1 9 Battery box 1 For installation, reverse the removal procedure. (4) 5 7 84 31 6 9 2 T R..7 Nm (0.7 m • kg, 5.1 ft Ib) T R..7 Nm (0.7 m kg, 5.1 ft Ib) T R..10 Nm (1.0 m kg, 7.2 ft Ib) LT
GENERAL CHASSIS 4-2 Removing the side covers and headlight assembly Order Job/Parts to remove Q’ty Remarks 1 Left side cover 1 2 Right side cover 1 3 Left side cover inner panel 1 4 Right side cover inner panel 1 5 Air duct 1 6Bottom cover 1 7 Sub-wire harness 3 coupler (wire harness side) 1 Disconnect. 8 Headlight assembly coupler 1 Disconnect. 9 Air temperature sensor coupler 1 Disconnect. 10 Headlight assembly 1 For installation, reverse the removal procedure. 879 T R..7 Nm (0.7 m kg, 5.1 ft Ib) T R..7 Nm (0.7 m kg, 5.1 ft Ib) T R..9 Nm (0.9 m kg, 6.5 ft Ib) T R..9 Nm (0.9 m kg, 6.5 ft Ib) LT LT LT LT T R..10 Nm (1.0 m kg, 7.2 ft Ib) 61 3 5 4 2 10
GENERAL CHASSIS 4-3 Removing the tail/brake light assembly Order Job/Parts to remove Q’ty Remarks SeatRefer to “GENERAL CHASSIS” on page 4-1. 1 Muffler cooling fan motor coupler 1 Disconnect. 2 Tail/brake light coupler 1 Disconnect. 3 Rear right turn signal light coupler 1 Disconnect. 4 Rear left turn signal light coupler 1 Disconnect. 5 License plate light coupler 1 Disconnect. 6 Tail/brake light assembly 1 7 Muffler cooling fan motor assembly 1 For installation, reverse the removal procedure. T R..7 Nm (0.7 m kg, 5.1 ft Ib)T R..7 Nm (0.7 m kg, 5.1 ft Ib) LT 76 1 2 345
GENERAL CHASSIS 4-4 Removing the air filter case and oil catch tank Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 6-1. 1 Air filter case cover 1 2 Air filter element 1 3Cylinder head breather hose (air filter case to oil catch tank)1 4Cylinder head breather hose (cylinder head to oil catch tank)1 5 Air filter case joint clamp screw 2 Loosen. 6 Air filter case bracket 1 7 ISC (idle speed control) unit inlet hose 1 Disconnect. 8Intake solenoid vacuum hose (air filter case valve to intake solenoid)1 Disconnect. 9 Air filter case 1 10 Air filter case valve 1 11 Oil catch tank breather hose 1 12 Oil catch tank 1 For installation, reverse the removal procedure. 1 2 9 5 5 7 8 6 4 12 11 3 (5) T R..9 Nm (0.9 m kg, 6.5 ft Ib) T R..10 Nm (1.0 m kg, 7.2 ft Ib) LT 10
GENERAL CHASSIS
4-5
ET5YU1013CHECKING THE AIR FILTER CASE VALVE
1. Check:
Air filter case valve operation
a. Remove the air filter case (with the air filter
case valve).
b. Connect the vacuum/pressure pump gauge
set “1” to the air filter case valve “2”.
c. Check that the air filter case valve operates
when vacuum pressure is applied to the valve
using the vacuum/pressure pump gauge set.
Faulty → Replace the air filter case valve.
Vacuum/pressure pump gauge
set
90890-06756
12
FRONT WHEEL 4-6 EAS21870 FRONT WHEEL Removing the front wheel and brake discs Order Job/Parts to remove Q’ty Remarks NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated. 1 Left front brake hose holder 1 2 Right front brake hose holder 1 3 Left front brake caliper 1 4 Right front brake caliper 1 5 Front wheel axle pinch bolt 1 Loosen. 6 Front wheel axle 1 7 Front wheel 1 8Collar 2 9Dust cover 2 10 Front brake disc 2 For installation, reverse the removal procedure. T R..23 Nm (2.3 m kg, 17 ft Ib) T R..72 Nm (7.2 m kg, 52 ft lb) T R..6 Nm (0.6 m kg, 4.3 ft Ib) T R..6 Nm (0.6 m kg, 4.3 ft Ib) LT LT T R..18 Nm (1.8 m kg, 13 ft Ib)T R..18 Nm (1.8 m kg, 13 ft Ib) LS LS 2 6 51 3 10 7 10 8 9 9 8 4 T R..35 Nm (3.5 m kg, 25 ft Ib)T R..35 Nm (3.5 m kg, 25 ft Ib) (6) (6)
FRONT WHEEL 4-7 Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks 1 Oil seal 2 2 Wheel bearing 2 3 Spacer 1 For assembly, reverse the disassembly procedure. 2 1 2 1 3 LS LS New New
FRONT WHEEL
4-8
EAS21900REMOVING THE FRONT WHEEL
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there is
no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that the
front wheel is elevated.
2. Remove:
Front brake calipers
NOTE:
Do not apply the brake lever when removing the
front brake calipers.
EAS21910DISASSEMBLING THE FRONT WHEEL
1. Remove:
Oil seals
Wheel bearings
a. Clean the outside of the front wheel hub.
b. Remove the oil seals “1” with a flat-head
screwdriver.
NOTE:
To prevent damaging the wheel, place a rag “2”
between the screwdriver and the wheel surface.
c. Remove the wheel bearings “3” with a gener-
al bearing puller.
EAS21920CHECKING THE FRONT WHEEL
1. Check:
Front wheel axle
Roll the wheel axle on a flat surface.
Bends → Replace.
WARNING
EWA13460
Do not attempt to straighten a bent wheel ax-
le.
2. Check:
Tire
Front wheel
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” on page
3-30 and “CHECKING THE WHEELS” on
page 3-31.
3. Measure:
Radial wheel runout “1”
Lateral wheel runout “2”
Over the specified limits → Replace.
4. Check:
Wheel bearings
Front wheel turns roughly or is loose → Re-
place the wheel bearings.
Radial wheel runout limit
1.0 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (0.02 in)