Yamaha Mt 01 T 2005 Manual

							ENGINE REMOVAL
5-2
ET5YU1027CHECKING THE OIL PIPES
1. Check:
Oil pipes
Damage → Replace.
Obstruction → Wash and blow out with com-
pressed air.
ET5YU1028
CHECKING THE OIL STRAINER
1. Check:
Oil strainer (oil tank)
Damage → Replace.
Contaminants → Clean with engine oil.
ET5YU1019
INSTALLING THE OIL TANK
1. Install:
Oil tank
NOTE:
Tighten the oil tank bolts in the proper tightening 
sequence as shown.
T R.. 
Oil tank bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
1
5
7
32
68
4
10
16
15
13
1114
12
9 
						

							ENGINE REMOVAL
5-3
Removing the exhaust pipe
Order Job/Parts to remove Q’ty Remarks
SeatRefer to “GENERAL CHASSIS” on page 
4-1.
1 EXUP valve pulley cover 1
2 EXUP cable 2 Disconnect.
3O
2 sensor cover
1
4O
2 sensor
1
5 Muffler end cover 2
6 Muffler end cover plate 2
7Muffler cover 2
8Muffler 2
9Gasket 2
10 Front exhaust pipe 1
11 Gasket 2
12 Rear exhaust pipe 1
13 Gasket 2
14 Catalyst pipe 1
For installation, reverse the removal 
procedure.
LTLT
T R..24 Nm (2.4 m • 
kg, 17 ft • Ib)
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..10 Nm (1.0 m • 
kg, 7.2 ft • Ib)
T R..45 Nm (4.5 m • 
kg, 32 ft • Ib)
T R..20 Nm (2.0 m • 
kg, 14 ft • Ib)
T R..20 Nm (2.0 m • 
kg, 14 ft • Ib)
R..20 Nm (2.0 m • 
kg, 14 ft • Ib)
T R..20 Nm (2.0 m • 
kg, 14 ft • Ib)
LT
New
New
New
New
New
New
(3)5
56
67
78
8
9
141310
11
12 1311
4
31
2 9 
						

							ENGINE REMOVAL
5-4
ET5YU1029REMOVING THE MUFFLER END COVERS
1. Remove:
Muffler end covers “1”
NOTE:
Before removing a muffler end cover, turn it in 
the direction of the arrow shown in the illustra-
tion.
ET5YU1030INSTALLING THE MUFFLER END COVERS
1. Install:
Muffler covers “1”
Muffler end cover plates “2”
NOTE:
When installing a muffler end cover plate, be 
sure to insert its hooks “a” (two locations) into 
the holes in the muffler cover and align its tabs 
“b” (four locations) with the grooves in the muf-
fler cover.
2. Install:
Muffler end covers “1”
NOTE:
When installing a muffler end cover, align its pro-
jections “a” (four locations) with the grooves “b” 
in the muffler cover, and then turn it in the direc-
tion of the arrow shown in the illustration.
1 1
1
2bb
b a
1
a
b
1 1 
						

							ENGINE REMOVAL
5-5
Removing the EXUP servo motor and rear exhaust pipe joint
Order Job/Parts to remove Q’ty Remarks
Fuel tank Refer to “FUEL TANK” on page 6-1.
Air filter case/Oil catch tank/Air ductRefer to “GENERAL CHASSIS” on page 
4-1.
Throttle body/Intake manifold/Rollover valve 
bracketRefer to “THROTTLE BODIES” on page 6-4.
ISC (idle speed control) unitRefer to “ISC (IDLE SPEED CONTROL) 
UNIT” on page 6-11.
Shift arm Refer to “CLUTCH” on page 5-46.
Starter motorRefer to “ELECTRIC STARTER” on page 
5-70.
Oil pipe 2Refer to “GENERATOR AND STARTER 
CLUTCH” on page 5-66.
Drive sprocket Refer to “CHAIN DRIVE” on page 4-69.
Rear shock absorber assemblyRefer to “REAR SHOCK ABSORBER 
ASSEMBLY” on page 4-61.
1 Rectifier/regulator coupler 1 Disconnect.
2 Stator coil assembly coupler 1 Disconnect.
3 Rectifier/regulator 1
4 Oil filter cartridge 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..30 Nm (3.0 m • 
kg, 22 ft • Ib)
T R..30 Nm (3.0 m • 
kg, 22 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)
New
New
LS
LS
LS
T R..24 Nm (2.4 m • 
kg, 17 ft • Ib)
LT
LS
T R..20 Nm (2.0 m • 
kg, 14 ft • Ib)
New
New
T R..17 Nm (1.7 m • 
kg, 12 ft • Ib)
12
34
6
5
87 21 14 1316
23 22151210
11
181920
17
24
9 
						

							ENGINE REMOVAL
5-6
5 Horn connector 2 Disconnect.
6Horn 1
7 Oil pump outlet pipe 1
8 Oil pump inlet pipe 1
9 Sidestand switch coupler 1 Disconnect.
10 Shift rod 1
11 Left rider footrest assembly 1
12 Sidestand assembly 1
13 Right rider footrest assembly 1
14 Drive sprocket case assembly 1
15 Left side panel assembly 1
16 Right side panel 1
17 EXUP servo motor coupler 1 Disconnect.
18 EXUP servo motor 1
19O
2 sensor coupler
1
20 Neutral switch coupler 1 Disconnect.
21 Neutral switch 1
Removing the EXUP servo motor and rear exhaust pipe joint
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..30 Nm (3.0 m • 
kg, 22 ft • Ib)
T R..30 Nm (3.0 m • 
kg, 22 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)
New
New
LS
LS
LS
T R..24 Nm (2.4 m • 
kg, 17 ft • Ib)
LT
LS
T R..20 Nm (2.0 m • 
kg, 14 ft • Ib)
New
New
T R..17 Nm (1.7 m • 
kg, 12 ft • Ib)
12
34
6
5
87 21 14 1316
23 22151210
11
181920
17
24
9 
						

							ENGINE REMOVAL
5-7
22 Rear exhaust pipe joint cover 1
23 Rear exhaust pipe joint 1
24 Gasket 1
For installation, reverse the removal 
procedure.
Removing the EXUP servo motor and rear exhaust pipe joint
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..30 Nm (3.0 m • 
kg, 22 ft • Ib)
T R..30 Nm (3.0 m • 
kg, 22 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)
New
New
LS
LS
LS
T R..24 Nm (2.4 m • 
kg, 17 ft • Ib)
LT
LS
T R..20 Nm (2.0 m • 
kg, 14 ft • Ib)
New
New
T R..17 Nm (1.7 m • 
kg, 12 ft • Ib)
12
34
6
5
87 21 14 1316
23 22151210
11
181920
17
24
9 
						

							ENGINE REMOVAL
5-8
Removing the leads
Order Job/Parts to remove Q’ty Remarks
1 Stator coil assembly lead 1
2 Horn lead 1
3 Wire harness 1
4 Decompression solenoid coupler 2 Disconnect.
5 Speed sensor coupler 1 Disconnect.
6 Starter motor connector 1
7 Starter motor lead 1
8 Crankshaft position sensor coupler 1 Disconnect.
9 Negative battery lead 1 Disconnect.
10 Engine temperature sensor coupler 1 Disconnect.
11 Spark plug cap 4
For installation, reverse the removal 
procedure.
3 6 11
11 9
5
8
4
1
2
10
7
T R..10 Nm (1.0 m • 
kg, 7.2 ft • Ib) 
						

							ENGINE REMOVAL
5-9
Removing the down tube
Order Job/Parts to remove Q’ty Remarks
NOTE:
Place a suitable stand under the frame and engine.
1 Engine mounting bolt (right upper side) 1 l = 65 mm (2.56 in)
2 Engine mounting bolt (right upper side) 1 l = 80 mm (3.15 in)
3 Engine mounting bolt (left upper side) 2
4 Engine bracket bolt (right upper side) 2
5 Engine bracket bolt (left upper side) 2
6 Engine bracket (right upper side) 1
7 Engine bracket (left upper side) 1
8 Engine mounting nut (front upper side) 1
9 Engine mounting bolt (front upper side) 1
10 Engine bracket nut (front upper side) 4
11 Engine bracket bolt (front upper side) 4
12 Engine bracket (front upper side) 2
13 Down tube nut (rear side) 2
14 Down tube bolt (rear side) 2
T R..55 Nm (5.5 m • 
kg, 40 ft • Ib)
T R..53 Nm (5.3 m • 
kg, 38 ft • Ib)T R..53 Nm (5.3 m • 
kg, 38 ft • Ib)
T R..53 Nm (5.3 m • 
kg, 38 ft • Ib)
.74 Nm (7.4 m • 
kg, 53 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..8 Nm (0.8 m • 
kg, 5.8 ft • Ib)
T R..53 Nm (5.3 m • 
kg, 38 ft • Ib)T R..94 Nm (9.4 m • 
kg, 68 ft • Ib)
T R..94 Nm (9.4 m • 
kg, 68 ft • Ib)
E
LTLT
E
5 17
14 43
13
1
6
1515
237
16
18
11
12
1211
10 8
9
20
19 
						

							ENGINE REMOVAL
5-10
15 Down tube nut (front side) 2
16 Down tube spacer bolt 2 Loosen.
17 Down tube bolt (front side) 2
18 Engine mounting nut (front lower side) 1
19 Engine mounting bolt (front lower side) 1
20 Down tube 1
For installation, reverse the removal 
procedure.
Removing the down tube
Order Job/Parts to remove Q’ty Remarks
T R..55 Nm (5.5 m • 
kg, 40 ft • Ib)
T R..53 Nm (5.3 m • 
kg, 38 ft • Ib)T R..53 Nm (5.3 m • 
kg, 38 ft • Ib)
T R..53 Nm (5.3 m • 
kg, 38 ft • Ib)
.74 Nm (7.4 m • 
kg, 53 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..8 Nm (0.8 m • 
kg, 5.8 ft • Ib)
T R..53 Nm (5.3 m • 
kg, 38 ft • Ib)T R..94 Nm (9.4 m • 
kg, 68 ft • Ib)
T R..94 Nm (9.4 m • 
kg, 68 ft • Ib)
E
LTLT
E
5 17
14 43
13
1
6
1515
237
16
18
11
12
1211
10 8
9
20
19 
						

							ENGINE REMOVAL
5-11
Removing the engine
Order Job/Parts to remove Q’ty Remarks
NOTE:
Place a suitable stand under the frame and engine.
1 Engine mounting nut (rear upper side) 1
2 Engine mounting spacer bolt (rear upper side) 1 Loosen.
3 Engine mounting bolt (rear upper side) 1
4 Engine bracket nut (rear upper side) 2
5 Engine bracket bolt (rear upper side) 2
6 Engine mounting nut (rear lower side) 1
7 Engine mounting spacer bolt (rear lower side) 1 Loosen.
8 Engine mounting bolt (rear lower side) 1
9 Engine 1
10 Right side panel bracket 1
11 Cylinder-#1 right ignition coil 1
12 Cylinder-#1 left ignition coil 1
13 Ignition coil bracket 1
T R..8 Nm (0.8 m • 
kg, 5.8 ft • Ib)
T R..8 Nm (0.8 m • 
kg, 5.8 ft • Ib)
T R..7 Nm (0.7 m • 
kg, 5.1 ft • Ib)
T R..53 Nm (5.3 m • 
kg, 38 ft • Ib)
E
E
T R..74 Nm (7.4 m • 
kg, 53 ft • lb)
2 1
3
10
1411
13
12
6
7
4
5
8
9
T R..74 Nm (7.4 m • 
kg, 53 ft • lb)