Yamaha Mt 01 T 2005 Manual

							STEERING HEAD
4-59
EAS23110REMOVING THE LOWER BRACKET
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:
Upper ring nut “1”
Rubber washer
Lower ring nut “2”
Lower bracket
WARNING
EWA13730
Securely support the lower bracket so that 
there is no danger of it falling.
NOTE:
Hold the lower ring nut with the ring nut wrench 
“3”, and then remove the upper ring nut with the 
steering nut wrench “4”.
EAS23120
CHECKING THE STEERING HEAD
1. Wash:
Bearings
Bearing races
2. Check:
Bearings
Bearing races
Damage/pitting → Replace.3. Replace:
Bearings
Bearing races



 





 
 



 
 



 
 



 
 



 



a. Remove the bearing races from the steering 
head pipe with a long rod “1” and hammer.
b. Remove the bearing race from the lower 
bracket with a floor chisel “2” and hammer.
c. Install new bearing races.
CAUTION:
ECA14270
If the bearing race is not installed properly, 
the steering head pipe could be damaged.
NOTE:
Always replace the bearings and bearing races 
as a set.
          
4. Check:
Upper bracket
Lower bracket
(along with the steering stem)
Bends/cracks/damage → Replace.
EAS23140
INSTALLING THE STEERING HEAD
1. Lubricate:
Upper bearing
Lower bearing
Bearing races
 
Ring nut wrench
90890-01268
Spanner wrench
YU-01268
Steering nut wrench
90890-01403
Spanner wrench
YU-33975
 
Recommended cleaning solvent
Kerosene
1
2 4
3
 
Recommended lubricant
Lithium-soap-based grease 
						

							STEERING HEAD
4-60
2. Install:
Lower ring nut “1”
Rubber washer “2”
Upper ring nut “3”
Lock washer “4”
Refer to “CHECKING AND ADJUSTING 
THE STEERING HEAD” on page 3-25.
3. Install:
Front brake hose joint bracket “1”
Front brake hose joint “2”
NOTE:
Make sure that the tab “a” on the front brake 
hose joint bracket “1” contacts the side “b” of the 
front brake hose joint “2”.
4. Install:
Upper bracket
Steering stem nut
NOTE:
Temporarily tighten the steering stem nut.
5. Install:
Front fork legs
Refer to “FRONT FORK” on page 4-47.
NOTE:
Temporarily tighten the upper and lower bracket 
pinch bolts.
6. Tighten:
Steering stem nut
T R.. 
Steering stem nut
110 Nm (11.0 m·kg, 80 ft·lb)
a1
2
b 
						

							REAR SHOCK ABSORBER ASSEMBLY
4-61
EAS23160
REAR SHOCK ABSORBER ASSEMBLY
Removing the rear shock absorber assembly
Order Job/Parts to remove Q’ty Remarks
1 Self-locking nut/Bolt 1/1
2 Self-locking nut/Bolt/Spacer 1/1/1
3 Self-locking nut/Bolt 1/1
4 Rear shock absorber assembly 1
5 Collar/Spacer/Oil seal/Bearing 2/1/2/1
6 Self-locking nut/Bolt/Washer 1/1/2
7 Spacer 1
8 Oil seal/Bearing 2/1
9 Relay arm 1
10 Spacer/Oil seal/Bearing 2/8/4
11 Connecting arm 1
12 Collar/Spacer 2/1
For installation, reverse the removal 
procedure.
T R..40 Nm (4.0 m • 
kg, 29 ft • Ib)
T R..40 Nm (4.0 m • 
kg, 29 ft • Ib)
T R..49 Nm (4.9 m • 
kg, 35 ft • Ib)
LS
LS
LS
LS
LS
LS
5
12
12
4
2
106
10
6
10 10
11
7 1 3
8
8 9
3
1 25 
						

							REAR SHOCK ABSORBER ASSEMBLY
4-62
EAS23180HANDLING THE REAR SHOCK ABSORBER
WARNING
EWA13740
This rear shock absorber contains highly 
compressed nitrogen gas. Before handling 
the rear shock absorber, read and make sure 
you understand the following information. 
The manufacturer cannot be held responsi-
ble for property damage or personal injury 
that may result from improper handling of 
the rear shock absorber.
Do not tamper or attempt to open the rear 
shock absorber.
Do not subject the rear shock absorber to 
an open flame or any other source of high 
heat. High heat can cause an explosion due 
to excessive gas pressure.
Do not deform or damage the rear shock 
absorber in any way. Rear shock absorber 
damage will result in poor damping perfor-
mance.
EAS23190
DISPOSING OF A REAR SHOCK ABSORBER
1. Gas pressure must be released before dis-
posing of a rear shock absorber. To release 
the gas pressure, drill a 2–3-mm (0.079–
0.118 in) hole through the rear shock absorb-
er at a point 40 mm (1.57 in) from its end as 
shown.
WARNING
EWA13760
Wear eye protection to prevent eye damage 
from released gas or metal chips.
EAS23230
REMOVING THE REAR SHOCK ABSORBER 
ASSEMBLY
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 
rear wheel is elevated.
2. Remove:
Relay arm bolt (relay arm and swingarm) “1”
Rear shock absorber assembly bolt (front 
side) “2”
NOTE:
While removing the relay arm bolt (relay arm and 
swingarm), hold the swingarm so that it does not 
drop down.
EAS23240CHECKING THE REAR SHOCK ABSORBER 
ASSEMBLY
1. Check:
Rear shock absorber rod
Bends/damage → Replace the rear shock 
absorber assembly.
Rear shock absorber
Gas leaks/oil leaks → Replace the rear shock 
absorber assembly.
Spring
Damage/wear → Replace the rear shock ab-
sorber assembly.
Bearing
Oil seals
Damage/wear → Replace.
Collars
Spacer
Damage/scratches → Replace.
Bolts
Bends/damage/wear → Replace.
EAS23260
CHECKING THE CONNECTING ARM AND 
RELAY ARM
1. Check:
Connecting arm
Relay arm
Damage/wear → Replace.
2. Check:
Bearings
1
1
2 
						

							REAR SHOCK ABSORBER ASSEMBLY
4-63
Oil seals
Damage/pitting → Replace.
3. Check:
Collars
Spacers
Damage/scratches → Replace.
EAS23270
INSTALLING THE CONNECTING ARM AND 
RELAY ARM
1. Lubricate:
Spacers
Bearings
2. Install:
Bearing “1”
(to the relay arm)
Bearings “2”
(to the connecting arm)
Oil seals “3”
(to the relay arm)
Oil seals “4”
(to the connecting arm)
3. Install:
Relay arm “1”
(to the connecting arm)
NOTE:
Install the relay arm with its “R” mark “a” facing 
to the right and its arrow mark “b” facing upward.
4. Tighten:
Rear shock absorber assembly nut (rear 
side)
Relay arm nut (relay arm and connecting 
arm)
 
Recommended lubricant
Lithium-soap-based grease
 
Installed depth “a”
8.0 mm (0.31 in)
Installed depth “b”
4.0 mm (0.16 in)
Installed depth “c”
7.0 mm (0.28 in)
Installed depth “d”
0.5–1.0 mm (0.02–0.04 in)
5. Relay arm
6. Connecting arm
7. Rear shock absorber
A. Left side
B. Right side
T R.. 
Rear shock absorber assembly 
nut (rear side)
40 Nm (4.0 m·kg, 29 ft·lb)
4
62 431342
4
5
46
2
4
4 2
4
d
cd
b
b
d
ab
d 7
AB
R
1
a
b 
						

							REAR SHOCK ABSORBER ASSEMBLY
4-64
EAS23310
INSTALLING THE REAR SHOCK 
ABSORBER ASSEMBLY
1. Lubricate:
Spacers
Bearings
2. Install:
Relay arm
(to the swingarm)
NOTE:
When installing the relay arm, lift up the swing-
arm.
3. Tighten:
Rear shock absorber assembly nut (front 
side)
Relay arm nut (relay arm and swingarm)
4. Adjust:
Drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN 
SLACK” on page 3-24.
T R.. 
Relay arm nut (relay arm and 
connecting arm)
49 Nm (4.9 m·kg, 35 ft·lb)
 
Recommended lubricant
Lithium-soap-based grease
T R.. 
Rear shock absorber assembly 
nut (front side)
49 Nm (4.9 m·kg, 35 ft·lb)
T R.. 
Relay arm nut (relay arm and 
swingarm)
40 Nm (4.0 m·kg, 29 ft·lb)
 
Drive chain slack
40.0–50.0 mm (1.57–1.97 in) 
						

							SWINGARM
4-65
EAS23330
SWINGARM
Removing the swingarm
Order Job/Parts to remove Q’ty Remarks
Rear wheelRefer to “GENERAL CHASSIS” on page 
4-1.
Rear shock absorberRefer to “REAR SHOCK ABSORBER 
ASSEMBLY” on page 4-61.
Drive chain guard (drive sprocket side) Refer to “CHAIN DRIVE” on page 4-69.
1 Footrest cover 1
2 Drive chain guard (swingarm side) 1
3 Rear brake hose guide 1 1
4 Rear brake hose holder 1
5 Drive chain adjusting bolt/Locknut 2/2
6 Footrest bracket pinch bolt 2 Loosen.
7 Swingarm pivot shaft nut 1
8 Swingarm pivot shaft 1
9Collar 2
10 Spacer 1
11 Spacer 1
12 Drive chain 1
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..7 Nm (0.7 m • 
kg, 5.1 ft • Ib)
T R..7 Nm (0.7 m • 
kg, 5.1 ft • Ib)
T R..125 Nm (12.5 m • 
kg, 90 ft • lb)
LS
LS
LS
LS
LT
13
2
8
19
9
9 23 14
11
24
25
24 181621
17
10 20
7 225 54
3
6 6
112
1915New
T R..25 Nm (2.5 m • 
kg, 18 ft • Ib)
T R..25 Nm (2.5 m • 
kg, 18 ft • Ib)
LTLT
LT 
						

							SWINGARM
4-66
13 Rear fender 1
14 Drive chain guide 1
15 Swingarm 1
16 Spacer 1
17 Oil seal 1
18 Oil seal 1
19 Oil seal 2
20 Circlip 1
21 Bearing 1
22 Bearing 1
23 Bearing 1
24 Oil seal 2
25 Bearing 1
For installation, reverse the removal 
procedure.
Removing the swingarm
Order Job/Parts to remove Q’ty Remarks
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..7 Nm (0.7 m • 
kg, 5.1 ft • Ib)
T R..7 Nm (0.7 m • 
kg, 5.1 ft • Ib)
T R..125 Nm (12.5 m • 
kg, 90 ft • lb)
LS
LS
LS
LS
LT
13
2
8
19
9
9 23 14
11
24
25
24 181621
17
10 20
7 225 54
3
6 6
112
1915New
T R..25 Nm (2.5 m • 
kg, 18 ft • Ib)
T R..25 Nm (2.5 m • 
kg, 18 ft • Ib)
LTLT
LT 
						

							SWINGARM
4-67
EAS23350REMOVING THE SWINGARM
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 
rear wheel is elevated.
2. Measure:
Swingarm side play
Swingarm vertical movement



 





 
 








 
 



 
 



 



a. Measure the tightening torque of the pivot 
shaft nut.
b. Measure the swingarm side play “A” by mov-
ing the swingarm from side to side.
c. If the swingarm side play is out of specifica-
tion, check the spacers, bearings, washers, 
and dust covers.
d. Check the swingarm vertical movement “B” 
by moving the swingarm up and down.
If swingarm vertical movement is not smooth 
or if there is binding, check the spacers, bear-
ings, washers, and dust covers.
        
3. Remove:
Drive chain
Refer to “REMOVING THE DRIVE CHAIN” 
on page 4-70.
EAS23360CHECKING THE SWINGARM
1. Check:
Swingarm
Bends/cracks/damage → Replace.
2. Check:
Pivot shaft
Roll the pivot shaft on a flat surface.
Bends → Replace.
WARNING
EWA13770
Do not attempt to straighten a bent pivot 
shaft.
3. Wash:
Pivot shaft
Spacer
Washer
Bearings
Collars
4. Check:
Oil seals
Damage/wear → Replace.
Bearings
Damage/pitting → Replace.
Collars
Spacers
Damage/scratches → Replace.
EAS23380INSTALLING THE SWINGARM
1. Lubricate:
Bearings
Spacer
Pivot shaft
2. Install:
Bearings “1”
Oil seals “2”
T R.. 
Swingarm pivot shaft nut
125 Nm (12.5 m·kg, 90 ft·lb)
 
Swingarm side play (at the end of 
the swingarm)
1.0 mm (0.04 in)
A B
 
Recommended cleaning solvent
Kerosene
 
Recommended lubricant
Lithium-soap-based grease 
						

							SWINGARM
4-68
Bearing “3”
Oil seal “4”
3. Adjust:
Drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN 
SLACK” on page 3-24.
 
Installed depth of bearing “a”
6.3 mm (0.25 in)
Installed depth of bearing “b”
5.7 mm (0.22 in)
Installed depth of oil seal “c”
0.5–1.0 mm (0.02–0.04 in)
Installed depth of oil seal “d”
0.5 mm (0.02 in)
Installed depth of bearing “e”
4.0 mm (0.16 in)
Installed depth of oil seal “f”
1.0 mm (0.04 in)
5. Swingarm
6. Swingarm pivot shaft
7. Relay arm
8. Bolt
A. Left side
B. Right side
 
Drive chain slack
40.0–50.0 mm (1.57–1.97 in)
1
1
22
5
6
d
c
a d
b
AB
e
f
3
47
5
8
AB