Yamaha Mt 01 T 2005 Manual

							REAR BRAKE
4-39
EAS22670INSTALLING THE REAR BRAKE CALIPER
1. Install:
Rear brake caliper “1”
(temporarily)
Copper washers 
Rear brake hose “2”
Rear 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:
Rear brake caliper
3. Install:
Rear brake pads
Brake pad springs
Brake pad pin
Rear brake caliper
Refer to “REPLACING THE REAR BRAKE 
PADS” on page 4-36.
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 pedal operation
Soft or spongy feeling → Bleed the brake sys-
tem.
Refer to “BLEEDING THE HYDRAULIC 
BRAKE SYSTEM” on page 3-23.
T R.. 
Rear brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
T R.. 
Rear brake caliper bolt (M12)
27 Nm (2.7 m·kg, 19 ft·lb)
Rear brake caliper bolt (M8)
22 Nm (2.2 m·kg, 16 ft·lb)
LOCTITE
®
New
3
a
1 2
b
 
Recommended fluid
DOT 4
a 
						

							REAR BRAKE
4-40
EAS22700REMOVING THE REAR BRAKE MASTER 
CYLINDER
NOTE:
Before removing the rear brake master cylinder, 
drain the brake fluid from the entire brake sys-
tem.
1. Remove:
Rear brake hose union bolt “1”
Copper washers “2”
Rear brake hose “3”
NOTE:
To collect any remaining brake fluid, place a 
container under the master cylinder and the end 
of the brake hose.
EAS22720CHECKING THE REAR 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.
2. Check:
Brake master cylinder kit
Damage/scratches/wear → Replace.
3. Check:
Brake fluid reservoir
Cracks/damage → Replace.
Brake fluid reservoir diaphragm
Cracks/damage → Replace.
4. Check:
Brake hoses
Cracks/damage/wear → Replace.
EAS22730ASSEMBLING THE REAR BRAKE MASTER 
CYLINDER
WARNING
EWA13520
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.
EAS22740
INSTALLING THE REAR BRAKE MASTER 
CYLINDER
1. Install:
Copper washers 
Rear brake hose “1”
Rear brake hose union bolt “2”
WARNING
EWA13530
Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to “CABLE 
ROUTING” on page 2-41.
CAUTION:
ECA14160
When installing the brake hose onto the 
brake master cylinder, make sure the brake 
pipe touches the projection “a” as shown.
2. Fill:
Brake fluid reservoir
(with the specified amount of the recom-
mended brake fluid)
1
3
2
 
Recommended fluid
DOT 4
T R.. 
Rear brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
 
Recommended fluid
DOT 4
New
a
1
2 
						

							REAR BRAKE
4-41
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.
3. Bleed:
Brake system
Refer to “BLEEDING THE HYDRAULIC 
BRAKE SYSTEM” on page 3-23.
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 pedal operation
Soft or spongy feeling → Bleed the brake sys-
tem.
Refer to “BLEEDING THE HYDRAULIC 
BRAKE SYSTEM” on page 3-23.
6. Adjust:
Brake pedal position
Refer to “ADJUSTING THE REAR DISC 
BRAKE” on page 3-20.7. Adjust:
Rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE 
LIGHT SWITCH” on page 3-22.
a 
						

							HANDLEBAR
4-42
EAS22840
HANDLEBAR
Removing the handlebar
Order Job/Parts to remove Q’ty Remarks
1 Rearview mirror 2
2 Front brake light switch connector 2 Disconnect.
3 Front brake master cylinder holder 1
4 Front brake master cylinder assembly 1
5 Right handlebar switch 1
6 Throttle cable 2 Disconnect.
7 Grip end 2
8 Throttle grip 1
9 Clutch switch coupler 1 Disconnect.
10 Clutch master cylinder holder 1
11 Clutch master cylinder assembly 1
12 Left handlebar switch 1
13 Handlebar grip 1
14 Upper handlebar holder 2
15 Handlebar 1
1
24
3
16
LS
T R..10 Nm (1.0 m • 
kg, 7.2 ft • Ib)
T R..40 Nm (4.0 m • 
kg, 29 ft • Ib)T R..40 Nm (4.0 m • 
kg, 29 ft • Ib)
T R..29 Nm (2.9 m • 
kg, 21 ft • Ib)
T R..29 Nm (2.9 m • 
kg, 21 ft • Ib)
7
T R..20 Nm (2.0 m • 
kg, 14 ft • Ib)T R..14 Nm (1.4 m • 
kg, 10 ft • Ib)
T R..14 Nm (1.4 m • 
kg, 10 ft • Ib)
T R..13 Nm (1.3 m • 
kg, 9.4 ft • Ib)
155
587
6 1
1112
10914
14
13
16
LS
LS
12 
						

							HANDLEBAR
4-43
16 Lower handlebar holder 2
For installation, reverse the removal 
procedure.
Removing the handlebar
Order Job/Parts to remove Q’ty Remarks
1
24
3
16
LS
T R..10 Nm (1.0 m • 
kg, 7.2 ft • Ib)
T R..40 Nm (4.0 m • 
kg, 29 ft • Ib)T R..40 Nm (4.0 m • 
kg, 29 ft • Ib)
T R..29 Nm (2.9 m • 
kg, 21 ft • Ib)
T R..29 Nm (2.9 m • 
kg, 21 ft • Ib)
7
T R..20 Nm (2.0 m • 
kg, 14 ft • Ib)T R..14 Nm (1.4 m • 
kg, 10 ft • Ib)
T R..14 Nm (1.4 m • 
kg, 10 ft • Ib)
T R..13 Nm (1.3 m • 
kg, 9.4 ft • Ib)
155
587
6 1
1112
10914
14
13
16
LS
LS
12 
						

							HANDLEBAR
4-44
EAS22860REMOVING THE HANDLEBAR
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. Remove:
Handlebar grip “1”
NOTE:
Blow compressed air between the handlebar 
and the left handlebar grip, and gradually push 
the grip off the handlebar.
EAS22880
CHECKING THE HANDLEBAR
1. Check:
Handlebar
Bends/cracks/damage → Replace.
WARNING
EWA13690
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.
EAS22930
INSTALLING THE HANDLEBAR
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. Install:
Lower handlebar holders “1”
NOTE:
Temporarily tighten the nuts “2”.3. Install:
Handlebar “1”
Upper handlebar holders “2”
CAUTION:
ECA14250
First, tighten the bolts on the front side of 
the handlebar holder, and then on the rear 
side.
Turn the handlebar all the way to the left 
and right. If there is any contact with the 
fuel tank, adjust the handlebar position.
NOTE:
The upper handlebar holders should be in-
stalled with the punch marks “a” facing for-
ward.
Align the match mark “b” on the handlebar with 
the upper surface of the lower handlebar hold-
er.
4. Tighten:
Lower handlebar holder nuts
5. Install:
Handlebar grip “1”
Grip end “2”
T R.. 
Upper handlebar holder bolt
20 Nm (2.0 m·kg, 14 ft·lb)
T R.. 
Lower handlebar holder nut
40 Nm (4.0 m·kg, 29 ft·lb)
1
2
2
1
ab 
						

							HANDLEBAR
4-45



 





 
 








 
 



 
 



 



a. Apply a thin coat of rubber adhesive onto the 
left end of the handlebar.
b. Slide the handlebar grip over the left end of 
the handlebar.
c. Wipe off any excess rubber adhesive with a 
clean rag.
WARNING
EWA13700
Do not touch the handlebar grip until the rub-
ber adhesive has fully dried.
NOTE:
There should be 1–3 mm (0.04–0.12 in) of clear-
ance “a” between the handlebar grip and the grip 
end. 
        
6. Install:
Left handlebar switch “1”
NOTE:
Align the projection “a” on the left handlebar 
switch with the hole “b” in the handlebar.
7. Install:
Clutch master cylinder assembly
Clutch master cylinder holder “1”
NOTE:
Align the mating surfaces of the clutch master 
cylinder holder with the punch mark “a” on the 
handlebar.
First, tighten the upper bolt, then the lower bolt.
The clutch master cylinder holder has a punch 
mark “b” to distinguish it from the front brake 
master cylinder holder.
8. Install:
Throttle grip
Throttle cables
Right handlebar switch “1”
Grip end “2”
NOTE:
Align the projection “a” on the right handlebar 
switch with the hole “b” in the handlebar.
There should be 1–3 mm (0.04–0.12 in) of 
clearance “c” between the throttle grip and the 
grip end.
T R.. 
Grip end
29 Nm (2.9 m·kg, 21 ft·lb)
T R.. 
Clutch master cylinder holder 
bolt
13 Nm (1.3 m·kg, 9.4 ft·lb)
b
a
1
T R.. 
Grip end
29 Nm (2.9 m·kg, 21 ft·lb)
1
a
b
1 b
a 
						

							HANDLEBAR
4-46
9. Install:
Front brake master cylinder assembly
Front brake master cylinder holder “1”
NOTE:
Align the end of the brake master cylinder hold-
er with the punch mark “a” on the handlebar.
First, tighten the upper bolt, then the lower bolt.
10.Adjust:
Throttle cable free play
Refer to “ADJUSTING THE THROTTLE CA-
BLE FREE PLAY” on page 3-7.
T R.. 
Front brake master cylinder 
holder bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
 
Throttle cable free play
3.0–5.0 mm (0.12–0.20 in)
1
a 
						

							FRONT FORK
4-47
EAS22950
FRONT FORK
Removing the front fork legs
Order Job/Parts to remove Q’ty Remarks
The following procedure applies to both of 
the front fork legs.
Front wheel Refer to “FRONT WHEEL” on page 4-6.
1 Front fork guard 2
2 Front fender 1
3 Cap bolt 1 Loosen.
4 Upper bracket pinch bolt 1 Loosen.
5 Lower bracket pinch bolt 2 Loosen.
6Front fork leg 1
For installation, reverse the removal 
procedure.
6
5 1
4
123
T R..26 Nm (2.6 m • 
kg, 19 ft • Ib)
T R..20 Nm (2.0 m • 
kg, 14 ft • Ib)
T R..28 Nm (2.8 m • 
kg, 20 ft • Ib)
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..6 Nm (0.6 m • 
kg, 4.3 ft • Ib) 
						

							FRONT FORK
4-48
Disassembling the front fork legs
Order Job/Parts to remove Q’ty Remarks
The following procedure applies to both of 
the front fork legs.
1 Cap bolt 1
2O-ring 1
3Washer 1
4 Damper adjusting rod 1
5 Spacer 1
6Nut 1
7 Upper spring seat 1
8 Fork spring 1
9 Lower spring seat 1
10 Outer tube 1
11 Dust seal 1
12 Oil seal clip 1
13 Oil seal 1
14 Washer 1
15 Damper rod assembly 1
T R..35 Nm (3.5 m • 
kg, 25 ft • Ib)
1
2
3
6
5
7
8
94
11 12 13 14 10
15
16
LS
New
New
New
T R..20 Nm (2.0 m • 
kg, 14 ft • Ib)
T R..25 Nm (2.5 m • 
kg, 18 ft • Ib)
New