Yamaha Mt 01 T 2005 Manual

							TRANSMISSION
5-92
EAS26240
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
Order Job/Parts to remove Q’ty Remarks
CrankcaseSeparate.
Refer to “CRANKCASE” on page 5-74.
1 Shift fork guide bar 2
2 Shift drum assembly 1
3 Shift fork-L 1
4 Shift fork-R 1
5 Shift fork-C 1
6 Drive axle assembly 1
7 Main axle assembly 1
8 Spacer 1
For installation, reverse the removal 
procedure. 
						

							TRANSMISSION
5-93
Disassembling the main axle assembly
Order Job/Parts to remove Q’ty Remarks
1 Circlip 1
2Washer 1
3 5th pinion gear 1
4Collar 1
5Washer 1
6 2nd/3rd pinion gear 1
7 Circlip 1
8Washer 1
9 4th pinion gear 1
10 Collar 1
11 Main axle/1st pinion gear 1
For assembly, reverse the disassembly 
procedure. 
						

							TRANSMISSION
5-94
Disassembling the drive axle assembly
Order Job/Parts to remove Q’ty Remarks
1 5th wheel gear 1
2 Circlip 1
3Washer 1
4 2nd wheel gear 1
5Collar 1
6 Circlip 1
7Washer 1
8 1st wheel gear 1
9Collar 1
10 Washer 1
11 4th wheel gear 1
12 Circlip 1
13 Washer 1
14 3rd wheel gear 1
15 Collar 1
16 Drive axle 1
For assembly, reverse the disassembly 
procedure. 
						

							TRANSMISSION
5-95
EAS26260CHECKING THE SHIFT FORKS
The following procedure applies to all of the shift 
forks.
1. Check:
Shift fork cam follower “1”
Shift fork pawl “2”
Bends/damage/scoring/wear → Replace the 
shift fork.
2. Check:
Shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends → Replace.
WARNING
EWA12840
Do not attempt to straighten a bent shift fork 
guide bar.
3. Check:
Shift fork movement
(along the shift fork guide bar)
Rough movement → Replace the shift forks 
and shift fork guide bar as a set.
EAS26270CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
Shift drum groove
Damage/scratches/wear → Replace the shift 
drum assembly.
Shift drum segment “1”
Damage/wear → Replace the shift drum as-
sembly.
Shift drum bearing “2”
Damage/pitting → Replace the shift drum as-
sembly.
EAS26300
CHECKING THE TRANSMISSION
1. Measure:
Main axle runout
(with a centering device and dial gauge “1”)
Out of specification → Replace the main axle.
2. Measure:
Drive axle runout
(with a centering device and dial gauge “1”)
Out of specification → Replace the drive axle.
3. Check:
Transmission gears
Blue discoloration/pitting/wear → Replace 
the defective gear(s).
 
Main axle runout limit
0.08 mm (0.0032 in)
 
Drive axle runout limit
0.08 mm (0.0032 in) 
						

							TRANSMISSION
5-96
Transmission gear dogs
Cracks/damage/rounded edges → Replace 
the defective gear(s).
4. Check:
Transmission gear engagement
(each pinion gear to its respective wheel 
gear)
Incorrect → Reassemble the transmission 
axle assemblies.
5. Check:
Transmission gear movement
Rough movement → Replace the defective 
part(s).
6. Check:
Circlips
Bends/damage/looseness → Replace.
ET5YU1024ASSEMBLING THE MAIN AXLE AND DRIVE 
AXLE
1. Install:
Washer “1”
Circlip “2” 
NOTE:
Be sure the circlip sharp-edged corner “a” is 
positioned opposite side to the toothed washer 
and gear.
Install the circlip so that both ends “b” rest on 
the sides of a spline “c” with both axles aligned.
EAS26320INSTALLING THE SHIFT FORKS AND SHIFT 
DRUM ASSEMBLY
1. Install:
Shift fork-R “1”
Shift fork-C “2”
Shift fork-L “3”
Shift drum assembly “4”
Shift fork guide bars “5”
NOTE:
The embossed marks on the shift forks should 
face towards the right side of the engine and be 
in the following sequence: “R”, “C”, “L”.
2. Check:
Transmission
Rough movement → Repair.
NOTE:
Oil each gear, shaft, and bearing thoroughly.
New
122New
a
b
c 
						

							FUEL
6 
						

							6
FUEL SYSTEM
FUEL TANK..................................................................................................... 6-1
REMOVING THE FUEL TANK .................................................................. 6-2
REMOVING THE FUEL PUMP ................................................................. 6-2
CHECKING THE FUEL PUMP BODY....................................................... 6-2
CHECKING THE FUEL PUMP OPERATION............................................ 6-2
INSTALLING THE FUEL PUMP ................................................................ 6-2
INSTALLING THE FUEL TANK................................................................. 6-2
THROTTLE BODIES....................................................................................... 6-4
CHECKING THE INJECTORS .................................................................. 6-9
CHECKING THE THROTTLE BODIES ..................................................... 6-9
CHECKING THE ROLLOVER VALVES .................................................... 6-9
CHECKING THE PRESSURE REGULATOR ........................................... 6-9
CHECKING THE PRESSURE REGULATOR OPERATION ..................... 6-9
ADJUSTING THE THROTTLE POSITION SENSOR.............................. 6-10
INSTALLING THE FUEL PIPE ................................................................ 6-10
ISC (IDLE SPEED CONTROL) UNIT............................................................ 6-11
CHECKING THE ISC (IDLE SPEED CONTROL) SYSTEM ................... 6-13 
						

							FUEL TANK
6-1
EAS26620
FUEL TANK
Removing the fuel tank and fuel pump
Order Job/Parts to remove Q’ty Remarks
SeatRefer to “GENERAL CHASSIS” on page 
4-1.
1 Fuel tank cover 1
2 Fuel pump coupler 1 Disconnect.
3 Fuel sender coupler 1 Disconnect.
4 Fuel tank overflow hose 1 Disconnect.
5 Fuel tank breather hose 1 Disconnect.
6 Fuel hose 1 Disconnect.
7 Fuel return hose 1 Disconnect.
8Fuel tank 1
9 Fuel pump 1
For installation, reverse the removal 
procedure.
7 4
3
2 5
698 1
T R..7 Nm (0.7 m • 
kg, 5.1 ft • Ib)
T R..4 Nm (0.4 m • 
kg, 2.9 ft • Ib)
(6)
New 
						

							FUEL TANK
6-2
EAS26630REMOVING THE FUEL TANK
1. Extract the fuel in the fuel tank through the 
fuel tank cap with a pump.
2. Disconnect:
Fuel hose
Fuel return hose
CAUTION:
EC5YU1029
Although the fuel has been removed from 
the fuel tank be careful when removing the 
fuel hoses, since there may be fuel remain-
ing in them.
NOTE:
To remove the fuel hose from the fuel pump, 
slide the fuel hose connector cover “1” on the 
end of the hose in the direction of the arrow 
shown, press the two buttons “2” on the sides 
of the connector, and then remove the hose.
Remove the fuel hose manually without using 
any tools.
Before removing the hoses, place a few rags in 
the area under where they will be removed.
3. Remove:
Fuel tank
NOTE:
Do not set the fuel tank down on the installation 
surface of the fuel pump. Be sure to lean the fuel 
tank against a wall or the like.
EAS26640
REMOVING THE FUEL PUMP
1. Remove:
Fuel pump
CAUTION:
ECA14720
Do not drop the fuel pump or give it a 
strong shock.
Do not touch the base section of the fuel 
sender.
EAS26670CHECKING THE FUEL PUMP BODY
1. Check:
Fuel pump body
Obstruction → Clean.
Cracks/damage → Replace fuel pump as-
sembly.
2. Check:
Diaphragms and gaskets
Tears/fatigue/cracks → Replace fuel pump 
assembly.
EAS26690CHECKING THE FUEL PUMP OPERATION
1. Check:
Fuel pump operation
Refer to “CHECKING THE FUEL PUMP” on 
page 7-104.
EAS26710
INSTALLING THE FUEL PUMP
1. Tighten:
Fuel pump
NOTE:
Do not damage the installation surfaces of the 
fuel tank when installing the fuel pump.
Always use a new fuel pump gasket.
Install the fuel pump as shown in the illustra-
tion.
Align the projection “a” on the fuel pump with 
the slot in the fuel pump bracket.
Tighten the fuel pump bolts in the proper tight-
ening sequence as shown.
ET5YU1025INSTALLING THE FUEL TANK
1. Connect:
Fuel return hose
Fuel hose
12
T R.. 
Fuel pump bolt
4 Nm (0.4 m·kg, 2.9 ft·lb)
FWD
a
64
1
35
2