Yamaha Mt 01 T 2005 Manual
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CHAIN DRIVE 4-69 EAS23400 CHAIN DRIVE Removing the drive sprocket and drive chain Order Job/Parts to remove Q’ty Remarks Clutch fluidDrain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-23. 1 Drive sprocket cover 1 2 Clutch pipe union bolt cap 1 3 Clutch pipe union bolt 1 4 Copper washer 2 5 Clutch pipe 1 6 Clutch release cylinder 1 7 Dowel pin 2 8 Drive chain guard (drive sprocket side) 1 9 Drive sprocket nut 1 10 Washer 1 11 Drive sprocket 1 12 Drive chain 1 For installation, reverse the removal procedure. T R..10 Nm (1.0 m • kg, 7.2 ft • Ib) T R..10 Nm (1.0 m • kg, 7.2 ft • Ib) T R..95 Nm (9.5 m • kg, 68 ft • Ib) New New E LT LT 2 5 3 4 7 86 1110 9 1 T R..26 Nm (2.6 m • kg, 19 ft • Ib) T R..24 Nm (2.4 m • kg, 17 ft • Ib) 12
CHAIN DRIVE
4-70
EAS23410REMOVING THE DRIVE CHAIN
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:
Drive chain
(with the drive chain cutter)
NOTE:
Only cut the drive chain if it or the swingarm is to
be replaced.
EAS23440
CHECKING THE DRIVE CHAIN
1. Measure:
15-link section “a” of the drive chain
Out of specification → Replace the drive
chain.
NOTE:
While measuring the 15-link section, push
down on the drive chain to increase its tension.
Measure the length between drive chain roller
“1” and “16” as shown.
Perform this measurement at two or three dif-
ferent places.
2. Check:
Drive chain
Stiffness → Clean and lubricate or replace.3. Clean:
Drive chain
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove
any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.
CAUTION:
EC5YU1022
This vehicle has a drive chain with small
rubber O-rings “1” between the drive chain
side plates. Never use high-pressure water
or air, steam, gasoline, certain solvents
(e.g., benzine), or a coarse brush to clean
the drive chain. High-pressure methods
could force dirt or water into the drive
chain’s internals, and solvents will deterio-
rate the O-rings. A coarse brush can also
damage the O-rings. Therefore, use only
kerosene to clean the drive chain.
Do not soak the drive chain in kerosene for
more than ten minutes, otherwise the O-
rings can be damaged.
15-link length limit
239.3 mm (9.42 in)
CHAIN DRIVE
4-71
4. Check:
O-rings “1”
Damage → Replace the drive chain.
Drive chain rollers “2”
Damage/wear → Replace the drive chain.
Drive chain side plates “3”
Damage/wear → Replace the drive chain.
Cracks → Replace the drive chain and make
sure the battery breather hose is properly
routed away from the drive chain and below
the swingarm.
5. Lubricate:
Drive chain
EAS23460
CHECKING THE DRIVE SPROCKET
1. Check:
Drive sprocket
More than 1/4 tooth “a” wear → Replace the
drive chain sprockets as a set.
Bent teeth → Replace the drive chain sprock-
ets as a set.
EAS23470CHECKING THE REAR WHEEL SPROCKET
Refer to “CHECKING AND REPLACING THE
REAR WHEEL SPROCKET” on page 4-15.
EAS23480CHECKING THE REAR WHEEL DRIVE HUB
Refer to “CHECKING THE REAR WHEEL
DRIVE HUB” on page 4-15.
EAS28800INSTALLING THE DRIVE CHAIN
1. Lubricate:
Drive chain
2. Install:
Drive sprocket “1”
Washer “2”
Drive sprocket nut “3”
NOTE:
While applying the rear brake, tighten the drive
sprocket nut.
Install the washer “2” with its “OUT” mark “a”
facing outward.
Stake the drive sprocket nut “3” at a cutout “b”
in the drive axle.
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
b. Correct
1. Drive chain roller
2. Drive chain sprocket
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
T R..
Drive sprocket nut
95 Nm (9.5 m·kg, 68 ft·lb)
New
CHAIN DRIVE 4-72 3. Install: Clutch release cylinder Refer to “INSTALLING THE CLUTCH RE- LEASE CYLINDER” on page 5-62. a 1 2 3New b
5 ENGINE ENGINE REMOVAL........................................................................................ 5-1 CHECKING THE OIL PIPES ..................................................................... 5-2 CHECKING THE OIL STRAINER ............................................................. 5-2 INSTALLING THE OIL TANK .................................................................... 5-2 REMOVING THE MUFFLER END COVERS ............................................ 5-4 INSTALLING THE MUFFLER END COVERS........................................... 5-4 REMOVING THE ENGINE ...................................................................... 5-13 INSTALLING THE ENGINE..................................................................... 5-13 CAMSHAFTS................................................................................................. 5-16 REMOVING THE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ............................................................................ 5-21 REMOVING THE CAMSHAFTS.............................................................. 5-21 CHECKING THE CAMSHAFTS .............................................................. 5-22 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........ 5-24 CHECKING THE ROCKER ARM BASES ............................................... 5-24 CHECKING THE PUSH RODS ............................................................... 5-24 CHECKING THE VALVE LIFTERS AND VALVE LIFTER CASES ......... 5-25 CHECKING THE PUSH ROD COVER.................................................... 5-25 CHECKING THE DECOMPRESSION SYSTEM..................................... 5-26 CHECKING THE OIL DELIVERY PIPE................................................... 5-26 INSTALLING THE CAMSHAFTS ............................................................ 5-26 BLEEDING A VALVE LIFTER ................................................................. 5-27 INSTALLING THE VALVE LIFTERS ....................................................... 5-29 INSTALLING THE ROCKER ARMS AND PUSH RODS......................... 5-29 INSTALLING THE CYLINDER HEAD COVERS ..................................... 5-30 CYLINDER HEADS....................................................................................... 5-31 REMOVING THE CYLINDER HEADS .................................................... 5-32 CHECKING THE CYLINDER HEADS ..................................................... 5-32 CHECKING THE OIL PIPE ..................................................................... 5-32 INSTALLING THE CYLINDER HEADS ................................................... 5-33 VALVES AND VALVE SPRINGS.................................................................. 5-34 REMOVING THE VALVES ...................................................................... 5-35 CHECKING THE VALVES AND VALVE GUIDES .................................. 5-35 CHECKING THE VALVE SEATS ............................................................ 5-37 CHECKING THE VALVE SPRINGS........................................................ 5-38 INSTALLING THE VALVES .................................................................... 5-39 CYLINDERS AND PISTONS......................................................................... 5-41 REMOVING THE PISTONS .................................................................... 5-42 CHECKING THE CYLINDERS AND PISTONS ...................................... 5-42 CHECKING THE PISTON RINGS........................................................... 5-43 CHECKING THE PISTON PINS.............................................................. 5-44 INSTALLING THE PISTONS AND CYLINDERS .................................... 5-44
CLUTCH........................................................................................................ 5-46 REMOVING THE CLUTCH ..................................................................... 5-55 REMOVING THE PRIMARY DRIVE GEAR ............................................ 5-55 CHECKING THE FRICTION PLATES..................................................... 5-55 CHECKING THE CLUTCH PLATES ....................................................... 5-56 CHECKING THE CLUTCH SPRING PLATE........................................... 5-56 CHECKING THE CLUTCH HOUSING .................................................... 5-56 CHECKING THE CLUTCH BOSS ........................................................... 5-56 CHECKING THE PRESSURE PLATE .................................................... 5-56 CHECKING THE CLUTCH PUSH RODS ............................................... 5-57 CHECKING THE PRIMARY DRIVE GEAR ............................................. 5-57 CHECKING THE PRIMARY DRIVEN GEAR .......................................... 5-57 INSTALLING THE CRANKSHAFT POSITION SENSOR........................ 5-57 INSTALLING THE PRIMARY DRIVE GEAR ........................................... 5-57 INSTALLING THE CLUTCH .................................................................... 5-58 DISASSEMBLING THE CLUTCH MASTER CYLINDER ........................ 5-59 CHECKING THE CLUTCH MASTER CYLINDER................................... 5-60 ASSEMBLING THE CLUTCH MASTER CYLINDER .............................. 5-60 INSTALLING THE CLUTCH MASTER CYLINDER................................. 5-60 REMOVING THE CLUTCH RELEASE CYLINDER ................................ 5-61 CHECKING THE CLUTCH RELEASE CYLINDER ................................. 5-61 ASSEMBLING THE CLUTCH RELEASE CYLINDER............................. 5-62 INSTALLING THE CLUTCH RELEASE CYLINDER ............................... 5-62 SHIFT SHAFT................................................................................................ 5-64 CHECKING THE SHIFT SHAFT ............................................................. 5-65 CHECKING THE STOPPER LEVER ...................................................... 5-65 INSTALLING THE SHIFT SHAFT ........................................................... 5-65 GENERATOR AND STARTER CLUTCH...................................................... 5-66 REMOVING THE GENERATOR ............................................................. 5-68 CHECKING THE STARTER CLUTCH .................................................... 5-68 INSTALLING THE GENERATOR............................................................ 5-68 ELECTRIC STARTER................................................................................... 5-70 CHECKING THE STARTER MOTOR ..................................................... 5-72 ASSEMBLING THE STARTER MOTOR ................................................. 5-73 CRANKCASE................................................................................................ 5-74 DISASSEMBLING THE CRANKCASE.................................................... 5-77 CHECKING THE CRANKCASE .............................................................. 5-78 CHECKING THE BEARINGS AND OIL SEAL ........................................ 5-78 CHECKING THE OIL PIPE ..................................................................... 5-78 CHECKING THE OIL PUMP DRIVE ....................................................... 5-78 INSTALLING THE BEARING RETAINER ............................................... 5-78 ASSEMBLING THE CRANKCASE.......................................................... 5-78
OIL PUMP...................................................................................................... 5-81 CHECKING THE OIL PUMP ................................................................... 5-84 CHECKING THE RELIEF VALVE ........................................................... 5-84 CHECKING THE OIL STRAINER ........................................................... 5-84 ASSEMBLING THE OIL PUMP ............................................................... 5-84 INSTALLING THE OIL PUMP ................................................................. 5-85 CRANKSHAFT.............................................................................................. 5-86 REMOVING THE CONNECTING RODS ................................................ 5-87 CHECKING THE CRANKSHAFT AND CONNECTING RODS ............... 5-87 INSTALLING THE CONNECTING RODS ............................................... 5-90 INSTALLING THE CRANKSHAFT ASSEMBLY...................................... 5-91 TRANSMISSION............................................................................................ 5-92 CHECKING THE SHIFT FORKS............................................................. 5-95 CHECKING THE SHIFT DRUM ASSEMBLY .......................................... 5-95 CHECKING THE TRANSMISSION ......................................................... 5-95 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE .............................. 5-96 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY ...... 5-96
ENGINE REMOVAL 5-1 EAS23710 ENGINE REMOVAL Removing the oil tank Order Job/Parts to remove Q’ty Remarks Engine oilDrain. Refer to “CHANGING THE ENGINE OIL” on page 3-11. Air ductRefer to “GENERAL CHASSIS” on page 4-1. 1 Oil tank breather hose 1 Disconnect. 2 Dipstick 1 3 Oil tank inlet pipe 1 4 Oil tank outlet pipe 1 5Oil tank 1 6 Oil tank breather hose holder 1 7 Oil tank gasket 1 8 Oil strainer cover (oil tank) 1 9 Oil strainer (oil tank) 1 For installation, reverse the removal procedure. T R..13 Nm (1.3 m • kg, 9.4 ft • Ib) T R..13 Nm (1.3 m • kg, 9.4 ft • Ib) T R..13 Nm (1.3 m • kg, 9.4 ft • Ib) T R..10 Nm (1.0 m • kg, 7.2 ft • Ib) T R..10 Nm (1.0 m • kg, 7.2 ft • Ib) New New New New LS LS LS T R..13 Nm (1.3 m • kg, 9.4 ft • Ib) T R..13 Nm (1.3 m • kg, 9.4 ft • Ib) (16) 1 2 3 4 7 8 9 5 6 LS LS T R..35 Nm (3.5 m • kg, 25 ft • Ib) T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)