Yamaha Mt 01 T 2005 Manual

							FRONT FORK
4-49
16 Inner tube 1
For assembly, reverse the disassembly 
procedure.
Disassembling the front fork legs
Order Job/Parts to remove Q’ty Remarks
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 
						

							FRONT FORK
4-50
EAS22960REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
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. Loosen:
Upper bracket pinch bolt “1”
Cap bolt “2”
Lower bracket pinch bolt “3”
WARNING
EWA13640
Before loosening the upper and lower brack-
et pinch bolts, support the front fork leg.
EAS22990
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
1. Position the collar “1” as shown in the illustra-
tion by turning the spring preload adjusting 
bolt “2” counterclockwise until it stops.2. Remove:
Cap bolt “1”
(from the damper adjusting rod)
Spacer “2”
Nut “3”



 





 
 



 
 



 
 



 
 



 



a. Press down on the spacer with the fork spring 
compressor “4”.
b. Install the rod holder “5” between the nut “3” 
and the spacer “2”.
NOTE:
Use the side of the rod holder that is marked “B”.
c. Hold the spring preload adjusting bolt “6” and 
loosen the nut “3”.
CAUTION:
EC5YU1011
When loosening the nut “3”, be sure not to 
break the projections “a” on the collar “7” of 
the cap bolt “1”.
NOTE:
Loosen the nut using a proper tool that has a 
thickness of 3 mm (0.12 in) or less.
2
1
3
 
Fork spring compressor
90890-01441
YM-01441
Rod holder
90890-01434
Damper rod holder double ended
YM-01434
2
1
2
41
3
5 
						

							FRONT FORK
4-51
d. Remove the cap bolt.
e. Remove the rod holder and fork spring com-
pressor.
f. Remove the spacer and nut.
        
3. Drain:
Fork oil
NOTE:
Stroke the damper rod “1” several times while 
draining the fork oil.
4. Remove:
Damper rod assembly
NOTE:
Remove the damper rod assembly with the 
damper rod holder “1”.
5. Remove:
Oil seal clip “1”
(with a flat-head screwdriver)
EAS23010
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
1. Check:
Inner tube
Outer tube
Bends/damage/scratches → Replace.
WARNING
EWA13650
Do not attempt to straighten a bent inner 
tube as this may dangerously weaken it.
2. Measure:
Spring free length “a”
Out of specification → Replace.
3. Check:
Damper rod
Damage/wear → Replace.
Obstruction → Blow out all of the oil passag-
es with compressed air.
Damper adjusting rod
Bends/damage → Replace.
 
Damper rod holder
90890-01504
1 6
7
a
3
1
 
Fork spring free length
251.0 mm (9.88 in)
Limit
246.0 mm (9.69 in) 
						

							FRONT FORK
4-52
CAUTION:
ECA14200
The front fork leg has a built-in damper ad-
justing rod and a very sophisticated inter-
nal construction, which are particularly 
sensitive to foreign material.
When disassembling and assembling the 
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
4. Check:
Cap bolt O-ring “1”
Damage/wear → Replace.
Cap bolt collar projections “2”
Cracks/damage → Replace.
EAS23040
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
WARNING
EWA13660
Make sure the oil levels in both front fork 
legs are equal.
Uneven oil levels can result in poor han-
dling and a loss of stability.
NOTE:
When assembling the front fork leg, be sure to 
replace the following parts:
–Oil seal
–Dust seal
–O-ring
Before assembling the front fork leg, make 
sure all of the components are clean.
1. Install:
Damper rod assembly “1”
Inner tube “2”
CAUTION:
ECA14210
Allow the damper rod assembly to slide 
slowly down the inner tube “2” until it pro-
trudes from the bottom of the inner tube. Be 
careful not to damage the inner tube.2. Lubricate:
Inner tube’s outer surface
3. Tighten:
Damper rod assembly
NOTE:
Tighten the damper rod assembly with the 
damper rod holder “1”.
4. Install:
Dust seal “1” 
Oil seal clip “2” 
Oil seal “3” 
Washer “4”
CAUTION:
EC5YU1025
Make sure the numbered side of the oil seal 
faces bottom side.
NOTE:
Before installing the oil seal, lubricate its lips 
with lithium-soap-based grease.
1
2
 
Recommended oil
Suspension oil 01
T R.. 
Damper rod assembly
35 Nm (3.5 m·kg, 25 ft·lb)
 
Damper rod holder
90890-01504
2
1
1
New
New
New 
						

							FRONT FORK
4-53
Lubricate the outer surface of the inner tube 
with fork oil.
Before installing the oil seal, cover the top of 
the front fork leg with a plastic bag to protect 
the oil seal during installation.
5. Install:
Outer tube
(to the inner tube)
6. Install:
Washer
Oil seal “1”
(with the fork seal driver “2”)
7. Install:
Oil seal clip “1”
NOTE:
Adjust the oil seal clip so that it fits into the outer 
tube’s groove.
8. Install:
Dust seal “1”
(with the fork seal driver weight “2”)
9. Install:
Rod puller “1”
Rod puller attachment “2”
(onto the damper rod “3”)
 
Fork seal driver
90890-01442
Adjustable fork seal driver (36–46 
mm)
YM-01442
43
2
1
1 2
 
Fork seal driver
90890-01442
Adjustable fork seal driver (36–46 
mm)
YM-01442
 
Rod puller
90890-01437
Universal damping rod bleeding 
tool set
YM-A8703
Rod puller attachment (M10)
90890-01436
Universal damping rod bleeding 
tool set
YM-A8703 
						

							FRONT FORK
4-54
10.Fully compress the front fork leg.
11.Fill:
Front fork leg
(with the specified amount of the recom-
mended fork oil)
CAUTION:
ECA14230
Be sure to use the recommended fork oil. 
Other oils may have an adverse effect on 
front fork performance.
When disassembling and assembling the 
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
12.After filling the front fork leg, slowly stroke the 
damper rod “1” up and down (at least ten 
times) to distribute the fork oil.
NOTE:
Be sure to stroke the damper rod slowly be-
cause the fork oil may spurt out.
13.Before measuring the fork oil level, wait ten 
minutes until the oil has settled and the air 
bubbles have dispersed.
NOTE:
Be sure to bleed the front fork leg of any residual 
air.14.Measure:
Front fork leg oil level “a”
(from the top of the inner tube, with the outer 
tube fully compressed and without the fork 
spring)
Out of specification → Correct.
15.Install:
Lower spring seat “1”
Fork spring “2”
Upper spring seat “3”
Nut “4”
Spacer “5”
Damper adjusting rod “6”
Washer “7”
Cap bolt “8”
(with O-ring)



 





 
 



 
 



 
 



 
 



 



a. Remove the rod puller attachment.
b. Install the lower spring seat.
c. Install the fork spring.
NOTE:
Install the spring with the smaller pitch “a” facing 
up “A”.
 
Quantity
583.0 cm³ (19.71 US oz) (20.56 
Imp.oz)
Recommended oil
Suspension oil 01
 
Level
65.0 mm (2.56 in)
a
4
7
85
6 321 
						

							FRONT FORK
4-55
d. Install the upper spring seat and nut.
e. Reinstall the rod puller attachment.
f. Install the spacer.
g. Press down on the spacer with the fork spring 
compressor “9”.
h. Pull up the rod puller and install the rod holder 
“10” between the nut “4” and the spacer “5”.
NOTE:
Use the side of the rod holder that is marked “B”.
i. Remove the rod puller and rod puller attach-
ment.j. Install the nut “4” all the way onto the damper 
rod assembly.
k. Install the damper adjusting rod.
l. Install the washer and cap bolt, and then fin-
ger tighten the cap bolt.
m. Hold the nut and tighten the spring preload 
adjusting bolt “11” into the cap bolt to specifi-
cation.
WARNING
EWA13670
Always use a new cap bolt O-ring.
CAUTION:
EC5YU1012
When tightening the spring preload adjust-
ing bolt “11” into the cap bolt, be sure not to 
break the projections “c” on the collar “12”.
NOTE:
Hold the nut “4” using a proper tool that has a 
thickness of 3 mm (0.12 in) or less.
n. Remove the rod holder and fork spring com-
pressor.
          
16.Install:
Cap bolt
(to the outer tube)
NOTE:
Temporarily tighten the cap bolt.
 
Rod puller
90890-01437
Universal damping rod bleeding 
tool set
YM-A8703
Rod puller attachment (M10)
90890-01436
Universal damping rod bleeding 
tool set
YM-A8703
Fork spring compressor
90890-01441
YM-01441
Rod holder
90890-01434
Damper rod holder double ended
YM-01434
5
94
10
T R.. 
Nut and cap bolt
25 Nm (2.5 m·kg, 18 ft·lb)
11
12
c
4 
						

							FRONT FORK
4-56
EAS23050INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
1. Install:
Front fork leg
Temporarily tighten the upper and lower 
bracket pinch bolts.
NOTE:
Make sure the outer tube is flush with the top of 
the handlebar holder.
2. Tighten:
Lower bracket pinch bolts “1”
Cap bolt “2”
Upper bracket pinch bolt “3”
WARNING
EWA13680
Make sure the brake hoses are routed prop-
erly.
3. Adjust:
Spring preload
Rebound damping
Compression damping
Refer to “ADJUSTING THE FRONT FORK 
LEGS” on page 3-27.
T R.. 
Lower bracket pinch bolt
28 Nm (2.8 m·kg, 20 ft·lb)
T R.. 
Cap bolt
20 Nm (2.0 m·kg, 14 ft·lb)
T R.. 
Upper bracket pinch bolt
26 Nm (2.6 m·kg, 19 ft·lb)
32
1 
						

							STEERING HEAD
4-57
EAS23090
STEERING HEAD
Removing the lower bracket
Order Job/Parts to remove Q’ty Remarks
Air filter case/Headlight assemblyRefer to “GENERAL CHASSIS” on page 
4-1.
Lower handlebar holder Refer to “HANDLEBAR” on page 4-42.
Front fork leg Refer to “FRONT FORK” on page 4-47.
1 Meter assembly coupler 2 Disconnect.
2 Meter assembly 1
3 Meter assembly bracket 1
4 Steering stem nut 1
5 Upper bracket 1
6 Headlight assembly bracket 1
7 Front brake hose joint 1
8 Front brake hose joint bracket 1
9 Lock washer 1
10 Upper ring nut 1
11 Rubber washer 1
12 Lower ring nut 1
T R..7 Nm (0.7 m • 
kg, 5.1 ft • Ib)T R..1st   52 Nm (5.2 m • 
kg, 37 ft • lb)
2nd  23 Nm (2.3 m 
• 
kg, 17 ft • lb)
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..110 Nm (11.0 m • 
kg, 80 ft • lb)
LS
LS
T R..7 Nm (0.7 m • 
kg, 5.1 ft • Ib)
68
712
18
19
20
21
21
15
1617149
10
115 4
13 3
1 2 
						

							STEERING HEAD
4-58
13 Lower bracket 1
14 Washer 1
15 Lower bearing 1
16 Lower bearing dust seal 1
17 Lower bearing inner race 1
18 Upper bearing cover 1
19 Upper bearing inner race 1
20 Upper bearing 1
21 Bearing outer race 2
For installation, reverse the removal 
procedure.
Removing the lower bracket
Order Job/Parts to remove Q’ty Remarks
T R..7 Nm (0.7 m • 
kg, 5.1 ft • Ib)T R..1st   52 Nm (5.2 m • 
kg, 37 ft • lb)
2nd  23 Nm (2.3 m 
• 
kg, 17 ft • lb)
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..110 Nm (11.0 m • 
kg, 80 ft • lb)
LS
LS
T R..7 Nm (0.7 m • 
kg, 5.1 ft • Ib)
68
712
18
19
20
21
21
15
1617149
10
115 4
13 3
1 2