Yamaha Mt 01 T 2005 Manual

							CLUTCH
5-52
Disassembling the clutch master cylinder
Order Job/Parts to remove Q’ty Remarks
1 Clutch master cylinder push rod 1
2 Clutch master cylinder kit 1
3 Dust seal 1
4 Circlip 1
5 Clutch fluid reservoir hose joint 1
6O-ring 1
7 Clutch master cylinder body 1
For assembly, reverse the disassembly 
procedure.
New
New
LS
New
3
4
5
6
7
2
1 
						

							CLUTCH
5-53
Removing the clutch release cylinder
Order Job/Parts to remove Q’ty Remarks
Clutch fluidDrain.
Refer to “BLEEDING THE HYDRAULIC 
CLUTCH SYSTEM” on page 3-14.
1 Clutch pipe union bolt cap 1
2 Clutch pipe union bolt 1
3 Copper washer 2
4 Clutch pipe 1
5 Clutch release cylinder 1
6 Dowel pin 2
For installation, reverse the removal 
procedure.
T R..10 Nm (1.0 m • 
kg, 7.2 ft • Ib)T R..26 Nm (2.6 m • 
kg, 19 ft • Ib)New3 6
2
6
54
1 
						

							CLUTCH
5-54
Disassembling the clutch release cylinder
Order Job/Parts to remove Q’ty Remarks
1 Boots 1
2 Clutch release cylinder piston 1
3 Clutch release cylinder spring 1
4 Clutch release cylinder piston seal 1
5 Bleed screw 1
For assembly, reverse the disassembly 
procedure.
LS
LS
1
2
4
3
5
New
T R..6 Nm (0.6 m • 
kg, 4.3 ft • Ib) 
						

							CLUTCH
5-55
EAS25080REMOVING THE CLUTCH
1. Loosen:
Clutch boss nut “1”
NOTE:
While holding the clutch boss “2” with the univer-
sal clutch holder “3”, loosen the clutch boss nut.
2. Remove:
Clutch boss nut “1”
Washer “2”
Clutch boss assembly “3”
NOTE:
There is a built-in damper between the clutch 
boss and the clutch plate. It is not necessary to 
remove the wire circlip “4” and disassemble the 
built-in damper unless there is serious clutch 
chattering.
EAS25090
REMOVING THE PRIMARY DRIVE GEAR
1. Remove:
Primary drive gear bolt “1”
NOTE:
While holding the generator rotor “2” with the 
sheave holder “3”, loosen the primary drive gear 
bolt.
EAS25100
CHECKING THE FRICTION PLATES
The following procedure applies to all of the fric-
tion plates.
1. Check:
Friction plate
Damage/wear → Replace the friction plates 
as a set.
2. Measure:
Friction plate thickness
Out of specification → Replace the friction 
plates as a set.
NOTE:
Measure the friction plate at four places.
 
Universal clutch holder
90890-04086
YM-91042
3 
2
1
3
1
2
4
 
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
 
Friction plate thickness
2.92–3.08 mm (0.11–0.12 in)
Wear limit
2.82 mm (0.1110 in)
23 
						

							CLUTCH
5-56
EAS25110
CHECKING THE CLUTCH PLATES
The following procedure applies to all of the 
clutch plates.
1. Check:
Clutch plate
Damage → Replace the clutch plates as a 
set.
2. Measure:
Clutch plate warpage
(with a surface plate and thickness gauge “1”)
Out of specification → Replace the clutch 
plates as a set.
EAS25130
CHECKING THE CLUTCH SPRING PLATE
1. Check:
Clutch plate spring
Damage → Replace.
2. Check:
Clutch plate spring seat
Damage → Replace.
EAS25150CHECKING THE CLUTCH HOUSING
1. Check:
Clutch housing dogs
Damage/pitting/wear → Deburr the clutch 
housing dogs or replace the clutch housing.
NOTE:
Pitting on the clutch housing dogs will cause er-
ratic clutch operation.
2. Check:
Bearing
Damage/wear → Replace the bearing and 
clutch housing.
EAS25160
CHECKING THE CLUTCH BOSS
1. Check:
Clutch boss splines
Damage/pitting/wear → Replace the clutch 
boss.
NOTE:
Pitting on the clutch boss splines will cause er-
ratic clutch operation.
EAS25170
CHECKING THE PRESSURE PLATE
1. Check:
Pressure plate
Cracks/damage → Replace.
Bearing
Damage/wear → Replace.
 
Thickness gauge
90890-03079
Narrow gauge set
YM-34483
 
Clutch plate thickness
1.90–2.10 mm (0.07–0.08 in)
Warpage limit
0.20 mm (0.0079 in) 
						

							CLUTCH
5-57
EAS25190CHECKING THE CLUTCH PUSH RODS
1. Check:
O-ring
Short clutch push rod
Long clutch push rod
Ball
Cracks/damage/wear → Replace the defec-
tive part(s).
2. Measure:
Long clutch push rod bending limit
Out of specification → Replace the defective 
part(s).
EAS25200CHECKING THE PRIMARY DRIVE GEAR
1. Check:
Primary drive gear
Damage/wear → Replace the primary drive 
and primary driven gears as a set.
Excessive noise during operation → Replace 
the primary drive and primary driven gears as 
a set.
EAS25210
CHECKING THE PRIMARY DRIVEN GEAR
1. Check:
Primary driven gear “1”
Damage/wear → Replace the primary drive 
and primary driven gears as a set.
Excessive noise during operation → Replace 
the primary drive and primary driven gears as 
a set.
EAS24540INSTALLING THE CRANKSHAFT POSITION 
SENSOR
1. Apply:
Sealant
(onto the crankshaft position sensor lead 
grommet)
EAS25230
INSTALLING THE PRIMARY DRIVE GEAR
1. Install:
Straight key “1”
Primary drive gear “2”
Crankshaft position sensor rotor “3”
Spacer “4”
Primary drive gear bolt “5”
CAUTION:
EC5YU1014
The timing marks on the crankshaft position 
sensor rotor must face outside.
NOTE:
While holding the generator rotor “6” with the 
sheave holder “7”, tighten the primary drive gear 
bolt.
 
Long clutch push rod bending 
limit
0.15 mm (0.0059 in)
 
Yamaha bond No. 1215
90890-85505
T R.. 
Primary drive gear bolt
100 Nm (10.0 m·kg, 72 ft·lb)
LOCTITE
®
 
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A 
						

							CLUTCH
5-58
EAS25260INSTALLING THE CLUTCH
1. Install:
Clutch housing
Thrust washer
NOTE:
Lubricate the clutch housing bearings with en-
gine oil.
Make sure that the primary driven gear teeth 
and primary drive gear teeth mesh correctly.
Make sure that the oil pump drive gear teeth 
and oil pump driven gear teeth mesh correctly.
2. Install:
Clutch boss assembly “1”
NOTE:
If the wire circlip “2” has been removed, care-
fully install a new one.
Install the clutch damper spring “3” with the 
“OUTSIDE” mark facing out.3. Install:
Clutch boss “1”
Conical spring washer “2”
Clutch boss nut “3” 
NOTE:
Lubricate the clutch boss nut threads and con-
ical spring washer mating surfaces with engine 
oil.
Install the washer “2” with the “OUT” mark “a” 
facing out.
While holding the clutch boss with the univer-
sal clutch holder “4”, tighten the clutch boss 
nut.
Stake the clutch boss nut “3” at a cutout “b” in 
the main axle.
4. Lubricate:
Friction plates
Clutch plates
(with the recommended lubricant)
5. Install:
Friction plates
Clutch plates
NOTE:
First, install a friction plate and then alternate 
between a clutch plate and a friction plate.
Install the last friction plate “1” offset from the 
other friction plates “2”, making sure to align a 
projection on the friction plate with the punch 
mark “a” on the clutch housing.
67
1
3
2New
T R.. 
Clutch boss nut
125 Nm (12.5 m·kg, 90 ft·lb)
 
Universal clutch holder
90890-04086
YM-91042
 
Recommended lubricant
Engine oil
New
4 
1
3
2
a
b
New 
						

							CLUTCH
5-59
6. Install:
Clutch spring plate “1”
Clutch spring plate retainer “2”
NOTE:
Tighten the clutch spring bolts in stages and in a 
crisscross pattern.
7. Install:
Shift arm “1”
NOTE:
Install the shift arm “1” with its punch mark “a” 
aligned with the notch “b” in end of the shift shaft.
EAS25280DISASSEMBLING THE CLUTCH MASTER 
CYLINDER
CAUTION:
ECA13840
Clutch components rarely require disas-
sembly.
Therefore, always follow these preventive 
measures:
Never disassemble clutch components un-
less absolutely necessary.
If any connection on the hydraulic clutch 
system is disconnected, the entire clutch 
system must be disassembled, drained, 
cleaned, properly filled, and bled after reas-
sembly.
Never use solvents on internal clutch com-
ponents.
Use only clean or new clutch fluid for clean-
ing clutch components.
Clutch fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt fluid immediately.
Avoid clutch fluid coming into contact with 
the eyes as it can cause serious injury.
First aid for clutch fluid entering the eyes:
Flush with water for 15 minutes and get im-
mediate medical attention.
NOTE:
Before disassembling the clutch master cylinder, 
drain the clutch fluid from the entire clutch sys-
tem.
1. Remove:
Clutch hose union bolt “1”
Copper washers “2”
Clutch hose “3”
NOTE:
To collect any remaining clutch fluid, place a 
container under the master cylinder and the end 
of the clutch hose.
T R.. 
Clutch spring plate retainer bolt
8 Nm (0.8 m·kg, 5.8 ft·lb)
T R.. 
Shift arm bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
a
1 2
1
2
1
a
b
3
21 
						

							CLUTCH
5-60
EAS25290CHECKING THE CLUTCH MASTER 
CYLINDER
1. Check:
Clutch master cylinder body
Cracks/damage → Replace the clutch mas-
ter cylinder.
Clutch fluid delivery passage
(clutch master cylinder body)
Obstruction → Blow out with compressed air.
2. Check:
Clutch master cylinder kit
Rust/scratches/wear → Replace the clutch 
master cylinder and clutch master cylinder kit 
as a set.
3. Check:
Clutch fluid reservoir hose joint
Cracks/damage → Replace.
4. Check:
Clutch fluid reservoir
Cracks/damage → Replace.
Clutch fluid reservoir diaphragm
Damage/wear → Replace.
5. Check:
Clutch hose
Cracks/damage/wear → Replace.
EAS25300
ASSEMBLING THE CLUTCH MASTER 
CYLINDER
WARNING
EWA13340
Before installation, all internal clutch com-
ponents must be cleaned and lubricated 
with clean or new clutch fluid.
Never use solvents on internal clutch com-
ponents as they will cause the piston seals 
to swell and distort.
Whenever a clutch master cylinder is disas-
sembled, replace the piston seals.
EAS25310INSTALLING THE CLUTCH MASTER 
CYLINDER
1. Install:
Clutch master cylinder “1”
Clutch master cylinder holder “2”
NOTE:
Align the end of the clutch master cylinder 
holder with the punch mark “a” on the handle-
bar.
First, tighten the upper bolt, then the lower bolt.
2. Install:
Copper washers “1” 
Clutch hose “2”
Clutch hose union bolt “3”
CAUTION:
EC5YU1006
When installing the clutch hose onto the 
clutch master cylinder, make sure the pipe 
“a” touches the projection “b”.
NOTE:
Turn the handlebars to the left and to the right 
to make sure the clutch hose does not touch 
other parts (e.g., wire harness, cables, leads). 
Correct if necessary.
While holding the clutch hose, tighten the 
union bolt. Recommended clutch component replace-
ment schedule
Piston seals Every two years
Clutch hose Every four years
Clutch fluidEvery two years and 
whenever the clutch 
is disassembled
 
Recommended clutch fluid
Brake fluid DOT4
T R.. 
Clutch master cylinder holder 
bolt
13 Nm (1.3 m·kg, 9.4 ft·lb)
T R.. 
Clutch hose union bolt
13 Nm (1.3 m·kg, 9.4 ft·lb)
a1
2
New 
						

							CLUTCH
5-61
3. Fill:
Clutch fluid reservoir
(with the specified amount of the recom-
mended clutch fluid)
WARNING
EWA13370
Use only the designated clutch fluid. Other 
clutch fluids may cause the rubber seals to 
deteriorate, causing leakage and poor 
clutch performance.
Refill with the same type of clutch fluid that 
is already in the system. Mixing clutch flu-
ids may result in a harmful chemical reac-
tion, leading to poor clutch performance.
When refilling, be careful that water does 
not enter the clutch fluid reservoir. Water 
will significantly lower the boiling point of 
the clutch fluid and could cause vapor lock.
CAUTION:
ECA13420
Clutch fluid may damage painted surfaces or 
plastic parts. Therefore, always clean up any 
spilt clutch fluid immediately.
NOTE:
In order to ensure a correct reading of the clutch 
fluid level, make sure the top of the reservoir is 
horizontal.
4. Bleed:
Clutch system
Refer to “BLEEDING THE HYDRAULIC 
CLUTCH SYSTEM” on page 3-14.
5. Check:
Clutch fluid level
Below the minimum level mark “a” → Add the 
recommended clutch fluid to the proper level.
Refer to “CHECKING THE CLUTCH FLUID 
LEVEL” on page 3-14.6. Check:
Clutch lever operation
Soft or spongy feeling → Bleed the clutch 
system.
Refer to “BLEEDING THE HYDRAULIC 
CLUTCH SYSTEM” on page 3-14.
ET5YU1020
REMOVING THE CLUTCH RELEASE 
CYLINDER
1. Remove:
Clutch pipe union bolt “1”
Copper washers “2”
Clutch pipe “3”
NOTE:
Put the end of the clutch pipe into a container 
and pump out the clutch fluid carefully.
EAS25330CHECKING THE CLUTCH RELEASE 
CYLINDER
 
Recommended clutch fluid
Brake fluid DOT4
2
13
a
b
New
Recommended clutch component replace-
ment schedule
Piston seals Every two years
Clutch hose Every four years
Clutch fluidEvery two years and 
whenever the clutch 
is disassembled
a
1
2 3