Yamaha Mt 01 T 2005 Manual

							FRONT BRAKE
4-19
Removing the front brake master cylinder
Order Job/Parts to remove Q’ty Remarks
Brake fluidDrain.
Refer to “BLEEDING THE HYDRAULIC 
BRAKE SYSTEM” on page 3-23.
1 Brake fluid reservoir cap holder 1
2 Brake fluid reservoir cap 1
3 Brake fluid reservoir diaphragm holder 1
4 Brake fluid reservoir diaphragm 1
5 Brake fluid reservoir 1
6 Brake fluid reservoir hose 1
7 Right rearview mirror 1
8 Brake fluid reservoir bracket 1
9Brake lever 1
10 Front brake light switch connector 2 Disconnect.
11 Front brake light switch 1
12 Front brake hose union bolt 1
13 Copper washer 2
14 Front brake hose 1
15 Front brake master cylinder holder 1
T R..10 Nm (1.0 m  
kg, 7.2 ft  Ib)
T R..30 Nm (3.0 m  
kg, 22 ft  Ib)
T R..14 Nm (1.4 m  
kg, 10 ft  Ib)
7
8 5 4 3
12
15
16
13
12
10
14 1196
New 
						

							FRONT BRAKE
4-20
*Apply silicon grease
16 Front brake master cylinder 1
For installation, reverse the removal 
procedure.
Removing the front brake master cylinder
Order Job/Parts to remove Q’ty Remarks
T R..10 Nm (1.0 m  
kg, 7.2 ft  Ib)
T R..30 Nm (3.0 m  
kg, 22 ft  Ib)
T R..14 Nm (1.4 m  
kg, 10 ft  Ib)
7
8 5 4 3
12
15
16
13
12
10
14 1196
New 
						

							FRONT BRAKE
4-21
Disassembling the front brake master cylinder
Order Job/Parts to remove Q’ty Remarks
1 Brake master cylinder kit 1
2 Bleed screw 1
3 Brake master cylinder body 1
For assembly, reverse the disassembly 
procedure. 
						

							FRONT BRAKE
4-22
Removing the front brake calipers
Order Job/Parts to remove Q’ty Remarks
The following procedure applies to both of 
the front brake calipers.
Brake fluidDrain.
Refer to “BLEEDING THE HYDRAULIC 
BRAKE SYSTEM” on page 3-23.
1 Front brake hose union bolt 1
2 Copper washer 2
3 Front brake hose 1
4 Front brake caliper 1
For installation, reverse the removal 
procedure.
T R..35 Nm (3.5 m  
kg, 25 ft  Ib)
T R..30 Nm (3.0 m  
kg, 22 ft  Ib)
T R..6 Nm (0.6 m  
kg, 4.3 ft  Ib)
1
4 2 3New 
						

							FRONT BRAKE
4-23
Disassembling the front brake calipers
Order Job/Parts to remove Q’ty Remarks
The following procedure applies to both of 
the front brake calipers.
1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad spring 1
4 Front brake pad 2
5 Brake caliper piston 4
6 Brake caliper piston seal 8
7 Bleed screw 1
For assembly, reverse the disassembly 
procedure. 
						

							FRONT BRAKE
4-24
EAS22220INTRODUCTION
WARNING
EWA14100
Disc brake components rarely require disas-
sembly. Therefore, always follow these pre-
ventive measures:
Never disassemble brake components un-
less absolutely necessary.
If any connection on the hydraulic brake 
system is disconnected, the entire brake 
system must be disassembled, drained, 
cleaned, properly filled, and bled after reas-
sembly.
Never use solvents on internal brake com-
ponents.
Use only clean or new brake fluid for clean-
ing brake components.
Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately.
Avoid brake fluid coming into contact with 
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING 
THE EYES:
Flush with water for 15 minutes and get im-
mediate medical attention.
EAS22240CHECKING THE FRONT BRAKE DISCS
The following procedure applies to both brake 
discs.
1. Remove:
Front wheel
Refer to “FRONT WHEEL” on page 4-6.
2. Check:
Brake disc
Damage/galling → Replace.
3. Measure:
Brake disc deflection
Out of specification → Correct the brake disc 
deflection or replace the brake disc.



 





 
 








 
 



 
 



 



a. Place the vehicle on a suitable stand so that 
the front wheel is elevated.
b. Before measuring the front brake disc deflec-
tion, turn the handlebar to the left or right to 
ensure that the front wheel is stationary.c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against 
the brake disc surface.
e. Measure the deflection 1.5 mm (0.06 in) be-
low the edge of the brake disc.
          
4. Measure:
Brake disc thickness
Measure the brake disc thickness at a few dif-
ferent locations.
Out of specification → Replace.
5. Adjust:
Brake disc deflection



 





 
 



 
 



 
 



 
 



 



a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
NOTE:
Tighten the brake disc bolts in stages and in a 
crisscross pattern.
 
Brake disc deflection limit
0.10 mm (0.0039 in)
 
Brake disc thickness limit
4.0 mm (0.16 in)
T R.. 
Front brake disc bolt
18 Nm (1.8 m·kg, 13 ft·lb)
LOCTITE
® 
						

							FRONT BRAKE
4-25
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment 
steps until the brake disc deflection is within 
specification.
f. If the brake disc deflection cannot be brought 
within specification, replace the brake disc.
        
6. Install:
Front wheel
Refer to “FRONT WHEEL” on page 4-6.
EAS22270REPLACING THE FRONT BRAKE PADS
The following procedure applies to both brake 
calipers.
NOTE:
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disassem-
ble the brake caliper.
1. Measure:
Brake pad wear limit “a”
Out of specification → Replace the brake 
pads as a set.2. Install:
Brake pads
Brake pad spring
NOTE:
Always install new brake pads and a brake pad 
spring as a set.



 





 
 



 
 



 
 



 
 



 



a. Connect a clear plastic hose “1” tightly to the 
bleed screw “2”. Put the other end of the hose 
into an open container.
b. Loosen the bleed screw and push the brake 
caliper pistons into the brake caliper with your 
finger.
c. Tighten the bleed screw.
d. Install new brake pads and a new brake pad 
spring.
NOTE:
The arrow mark “a” on the brake pad spring 
must point in the direction of disc rotation.
 
Brake pad lining thickness 
(inner)
4.5 mm (0.18 in)
Limit
0.5 mm (0.02 in)
Brake pad lining thickness 
(outer)
4.5 mm (0.18 in)
Limit
0.5 mm (0.02 in)
T R.. 
Bleed screw (front brake caliper)
6 Nm (0.6 m·kg, 4.3 ft·lb)
a
21 
						

							FRONT BRAKE
4-26
        
3. Install:
Brake pad pin
Brake pad clips
Front brake caliper
4. Check:
Brake fluid level
Below the minimum level mark “a” → Add the 
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID 
LEVEL” on page 3-21.
5. Check:
Brake lever operation
Soft or spongy feeling → Bleed the brake sys-
tem.
Refer to “BLEEDING THE HYDRAULIC 
BRAKE SYSTEM” on page 3-23.
EAS22300
REMOVING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the 
brake calipers.
NOTE:
Before removing the brake caliper, drain the 
brake fluid from the entire brake system.
1. Remove:
Front brake hose union bolt “1”
Copper washers “2”
Front brake hose “3”
NOTE:
Put the end of the brake hose into a container 
and pump out the brake fluid carefully.
EAS22350
DISASSEMBLING THE FRONT BRAKE 
CALIPERS
The following procedure applies to both of the 
brake calipers.
1. Remove:
Brake caliper pistons “1”
Brake caliper piston seals “2”
WARNING
EW5YU1006
Do not loosen the bolts “3”.



 





 
 



 
 



 
 



 
 



 



a. Blow compressed air into the brake hose joint 
opening “a” to force out the piston from the 
brake caliper.
WARNING
EWA13580
Cover the brake caliper piston with a rag. 
Be careful not to get injured when the pis-
ton is expelled from the brake master cylin-
der.
Never try to pry out the brake caliper pis-
ton.
T R.. 
Front brake caliper bolt
35 Nm (3.5 m·kg, 25 ft·lb)
a
3
1
2  
						

							FRONT BRAKE
4-27
b. Remove the brake caliper piston seals.
        
EAS22390
CHECKING THE FRONT BRAKE CALIPERS
1. Check:
Brake caliper pistons “1”
Rust/scratches/wear → Replace the brake 
caliper pistons.
Brake caliper cylinders “2”
Scratches/wear → Replace the brake caliper 
assembly.
Brake caliper body “3”
Cracks/damage → Replace the brake caliper 
assembly.
Brake fluid delivery passages
(brake caliper body)
Obstruction → Blow out with compressed air.
WARNING
EWA13600
Whenever a brake caliper is disassembled, 
replace the piston seals.
EAS22410ASSEMBLING THE FRONT BRAKE 
CALIPERS
WARNING
EWA13620
Before installation, all internal brake com-
ponents should be cleaned and lubricated 
with clean or new brake fluid.
Never use solvents on internal brake com-
ponents as they will cause the piston seals 
to swell and distort.
Whenever a brake caliper is disassembled, 
replace the brake caliper piston seals.
EAS22450
INSTALLING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the 
brake calipers.
1. Install:
Front brake caliper “1”
(temporarily)
Copper washers 
Front brake hose “2”
Front brake hose union bolt “3”
WARNING
EWA13530
Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to “CABLE 
ROUTING” on page 2-41.
CAUTION:
ECA14170
When installing the brake hose onto the 
brake caliper “1”, make sure the brake pipe 
“a” touches the projection “b” on the brake 
caliper.
2. Remove:
Front brake caliper Recommended brake component replace-
ment schedule
Brake pads If necessary
Piston seals Every two years
Brake hoses Every four years
Brake fluidEvery two years and 
whenever the brake 
is disassembled
a
1
3
1
2
 
Recommended fluid
DOT 4
T R.. 
Front brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
New
2
3
a
b
1 
						

							FRONT BRAKE
4-28
3. Install:
Front brake pads
Brake pad spring
Brake pad pin
Brake pad clips
Front brake caliper
Refer to “REPLACING THE FRONT BRAKE 
PADS” on page 4-25.
4. Fill:
Brake fluid reservoir
(with the specified amount of the recom-
mended brake fluid)
WARNING
EWA13090
Use only the designated brake fluid. Other 
brake fluids may cause the rubber seals to 
deteriorate, causing leakage and poor 
brake performance.
Refill with the same type of brake fluid that 
is already in the system. Mixing brake fluids 
may result in a harmful chemical reaction, 
leading to poor brake performance.
When refilling, be careful that water does 
not enter the brake fluid reservoir. Water 
will significantly lower the boiling point of 
the brake fluid and could cause vapor lock.
CAUTION:
ECA13540
Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean up 
any spilt brake fluid immediately.
5. Bleed:
Brake system
Refer to “BLEEDING THE HYDRAULIC 
BRAKE SYSTEM” on page 3-23.
6. Check:
Brake fluid level
Below the minimum level mark “a” → Add the 
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID 
LEVEL” on page 3-21.7. Check:
Brake lever operation
Soft or spongy feeling → Bleed the brake sys-
tem.
Refer to “BLEEDING THE HYDRAULIC 
BRAKE SYSTEM” on page 3-23.
EAS22490
REMOVING THE FRONT BRAKE MASTER 
CYLINDER
NOTE:
Before removing the front brake master cylinder, 
drain the brake fluid from the entire brake sys-
tem.
1. Remove:
Front brake hose union bolt “1”
Copper washers “2”
Front brake hose “3”
NOTE:
To collect any remaining brake fluid, place a 
container under the master cylinder and the end 
of the brake hose.
EAS22510
CHECKING THE FRONT BRAKE MASTER 
CYLINDER
1. Check:
Brake master cylinder
Damage/scratches/wear → Replace.
Brake fluid delivery passages
(brake master cylinder body)
Obstruction → Blow out with compressed air.
T R.. 
Front brake caliper bolt
35 Nm (3.5 m·kg, 25 ft·lb)
 
Recommended fluid
DOT 4
a
3
1 2