Yamaha Mt 01 T 2005 Manual

							CLUTCH
5-62
1. Check:
Clutch release cylinder body
Cracks/damage → Replace the clutch re-
lease cylinder.
2. Check:
Clutch release cylinder
Clutch release cylinder piston
Rust/scratches/wear → Replace the clutch 
release cylinder and clutch release cylinder 
piston as a set.
EAS25340ASSEMBLING THE CLUTCH RELEASE 
CYLINDER
WARNING
EW5YU1007
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 seal 
to swell and distort.
Whenever a clutch release cylinder is dis-
assembled, replace the piston seal.
EAS25350INSTALLING THE CLUTCH RELEASE 
CYLINDER
1. Check:
Copper washers “1” 
Clutch pipe “2”
Clutch pipe union bolt “3”
WARNING
EW5YU1010
Proper clutch hose routing is essential to in-
sure safe vehicle operation. Refer to “CABLE 
ROUTING” on page 2-41.
CAUTION:
EC5YU1007
When installing the clutch pipe onto the 
clutch release cylinder, make sure the pipe 
“a” touches the projection “b”.2. 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 that the top of the reservoir 
is horizontal.
3. Bleed:
Clutch system
Refer to “BLEEDING THE HYDRAULIC 
CLUTCH SYSTEM” on page 3-14.
4. 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.
 
Recommended clutch fluid
Brake fluid DOT4
T R.. 
Clutch pipe union bolt
26 Nm (2.6 m·kg, 19 ft·lb)
New
 
Recommended clutch fluid
Brake fluid DOT4
12
3 a
bNew 
						

							CLUTCH
5-63
5. Check:
Clutch lever operation
Soft or spongy feeling → Bleed the clutch 
system.
Refer to “BLEEDING THE HYDRAULIC 
CLUTCH SYSTEM” on page 3-14.
a 
						

							SHIFT SHAFT
5-64
EAS25410
SHIFT SHAFT
Removing the shift shaft and stopper lever
Order Job/Parts to remove Q’ty Remarks
Clutch housing Refer to “CLUTCH” on page 5-46.
1 Shift shaft 1
2 Circlip 2
3 Shift shaft spring 1
4 Shift shaft spring stopper 1
5Washer 1
6 Stopper lever 1
7 Stopper lever spring 1
For installation, reverse the removal 
procedure.
LS
LTLT
T R..10 Nm (1.0 m • 
kg, 7.2 ft • Ib)T R..22 Nm (2.2 m • 
kg, 16 ft • Ib)
1
3
2
7 6
5
4
New 
						

							SHIFT SHAFT
5-65
EAS25420CHECKING THE SHIFT SHAFT
1. Check:
Shift shaft
Bends/damage/wear → Replace.
Shift shaft spring
Damage/wear → Replace.
EAS25430
CHECKING THE STOPPER LEVER
1. Check:
Stopper lever
Bends/damage → Replace.
Roller turns roughly → Replace the stopper 
lever.
Stopper lever spring
Damage/wear → Replace.
EAS25450
INSTALLING THE SHIFT SHAFT
1. Install:
Stopper lever “1”
Stopper lever bolt “2”
Stopper lever spring “3”
NOTE:
Hook the ends of the stopper lever spring onto 
the stopper lever and the crankcase boss “4”.
Install the stopper lever spring as shown in the 
illustration.
Mesh the stopper lever with the shift drum seg-
ment assembly.
2. Install:
Shift shaft spring “1”
Circlips
Shift shaft “2”
NOTE:
Lubricate the oil seal lips with lithium-soap-
based grease.Hook the end of the shift shaft spring onto the 
shift shaft spring stopper “3”.
T R.. 
Stopper lever bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE
® 
						

							GENERATOR AND STARTER CLUTCH
5-66
EAS24480
GENERATOR AND STARTER CLUTCH
Removing the stator coil assembly
Order Job/Parts to remove Q’ty Remarks
Engine oilDrain.
Refer to “CHANGING THE ENGINE OIL” on 
page 3-11.
Oil tank/Front exhaust pipe Refer to “ENGINE REMOVAL” on page 5-1.
1 Stator coil assembly coupler 1 Disconnect.
2 Rectifier/regulator 1
3 Oil pipe 2 1 From oil pump to generator cover.
4 Generator cover 1
5 Generator cover gasket 1
6 Dowel pin 2
7 Stator coil assembly lead holder 1
8 Stator coil assembly 1
For installation, reverse the removal 
procedure.
LT
(9)
LTLT
T R..7 Nm (0.7 m • 
kg, 5.1 ft • Ib)
8
5
46
37
21
6
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..10 Nm (1.0 m • 
kg, 7.2 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 
						

							GENERATOR AND STARTER CLUTCH
5-67
Removing the generator rotor
Order Job/Parts to remove Q’ty Remarks
1 Starter clutch idle gear shaft #2 1
2 Starter clutch idle gear shaft #1 1
3 Starter clutch idle gear #2 1
4 Starter clutch idle gear #1 1
5 Generator rotor 1
6 Woodruff key 1
7 Starter clutch gear 1
For installation, reverse the removal 
procedure.
ER..80 Nm (8.0 m • 
kg, 58 ft • Ib)T 
24 3
1 57
6
E
E 
						

							GENERATOR AND STARTER CLUTCH
5-68
EAS24490REMOVING THE GENERATOR
1. Remove:
Generator rotor bolt “1”
Washer
NOTE:
While holding the generator rotor “2” with the 
sheave holder “3”, loosen the generator rotor 
bolt.
2. Remove:
Generator rotor “1”
(with the rotor puller “2”)
Woodruff key
EAS24570
CHECKING THE STARTER CLUTCH
1. Check:
Starter clutch idle gears
Starter clutch gear
Burrs/chips/roughness/wear → Replace the 
defective part(s).2. Check:
Starter clutch gear’s contacting surfaces
Damage/pitting/wear → Replace the starter 
clutch gear.
3. Check:
Starter clutch operation



 





 
 



 
 



 
 



 
 



 



a. Install the starter clutch gear “1” onto the gen-
erator rotor “2” and hold the generator rotor.
b. When turning the starter clutch gear clock-
wise “A”, the starter clutch and the starter 
clutch gear should engage, otherwise the 
starter clutch is faulty and must be replaced.
c. When turning the starter clutch gear counter-
clockwise “B”, it should turn freely, otherwise 
the starter clutch is faulty and must be re-
placed.
          
EAS24510INSTALLING THE GENERATOR
1. Install:
Woodruff key
Generator rotor “1”
Washer
Generator rotor bolt “2”
NOTE:
Clean the tapered portion of the crankshaft and 
the generator rotor hub.
When installing the rotor, make sure the woo-
druff key is properly seated in the key way of 
the crankshaft.
Lubricate the generator rotor bolt threads and 
washer mating surfaces with engine oil.
 
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
 
Rotor puller
90890-01080
Stator rotor puller
YM-01080-A
123 
						

							GENERATOR AND STARTER CLUTCH
5-69
2. Tighten:
Generator rotor bolt “1”
NOTE:
Tighten the generator rotor bolt “1” while holding 
the generator rotor “2” with a sheave holder “3”.
3. Apply:
Sealant
(onto the stator coil assembly lead grommet)
T R.. 
Generator rotor bolt
80 Nm (8.0 m·kg, 58 ft·lb)
 
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
 
Yamaha bond No. 1215
90890-85505
231 
						

							ELECTRIC STARTER
5-70
EAS24780
ELECTRIC STARTER
Removing the starter motor
Order Job/Parts to remove Q’ty Remarks
Oil tank Refer to “ENGINE REMOVAL” on page 5-1.
1 Starter motor lead 1 Disconnect.
2 Starter motor assembly 1
For installation, reverse the removal 
procedure.
21 
						

							ELECTRIC STARTER
5-71
Disassembling the starter motor
Order Job/Parts to remove Q’ty Remarks
1 Circlip 1
2 Starter motor gear 1
3 Starter motor rear cover 1
4 Bearing 1
5 Oil seal 1
6 Circlip 1
7 Starter motor front cover 1
8 Brush 2
9 Brush holder (along with the brushes) 1
10 Brush seat (along with the brushes) 1
11 Bearing 1
12 Gasket 2
13 Armature assembly 1
14 Starter motor yoke 1
For assembly, reverse the disassembly 
procedure.
84 5
7 3 2 1
6
LS
New
NewNew
New
New
New12
11
12 10 9 14 13
NewLS