Yamaha Mt 01 T 2005 Manual

							ELECTRICAL COMPONENTS
7-96



 





 
 








 
 



 
 



 



Charging method using a constant volt-
age charger
a. Measure the open-circuit voltage prior to 
charging.
NOTE:
Voltage should be measured 30 minutes after 
the engine is stopped.
b. Connect a charger and ammeter to the bat-
tery and start charging.
c. Make sure that the current is higher than the 
standard charging current written on the bat-
tery.
NOTE:
If the current is lower than the standard charging 
current written on the battery, this type of battery 
charger cannot charge the MF battery. A vari-
able voltage charger is recommended.
d. Charge the battery until the battery’s charg-
ing voltage is 15 V.
NOTE:
Set the charging time at 20 hours (maximum).
e. Measure the battery open-circuit voltage after 
leaving the battery unused for more than 30 
minutes.
        
6. Install:
Battery
Battery band
7. Connect:
Battery leads
(to the battery terminals)
CAUTION:
ECA13630
First, connect the positive battery lead “1”, 
and then the negative battery lead “2”.8. Check:
Battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
9. Lubricate:
Battery terminals
10.Install:
Seat
Refer to “GENERAL CHASSIS” on page 4-1.
EAS28040CHECKING THE RELAYS
Check each switch for continuity with the pocket 
tester. If the continuity reading is incorrect, re-
place the relay.
1. Disconnect the relay from the wire harness.
2. Connect the pocket tester (Ω × 1) and battery 
(12 V) to the relay terminal as shown.
Check the relay operation.
Out of specification → Replace.
Starter relay 12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
2
1
 
Recommended lubricant
Dielectric grease
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
 
Result
Continuity
(between “3” and “4”)
R
B
R
R/WL
21
43 
						

							ELECTRICAL COMPONENTS
7-97
Relay unit (starting circuit cut-off relay)
Relay unit (fuel pump relay)
Headlight relayMuffler cooling fan motor relay
ET5YU1021
CHECKING THE TURN SIGNAL/HAZARD 
RELAY
1. Check:
Turn signal/hazard relay input voltage
Out of specification → The wiring circuit from 
the main switch to the turn signal/hazard re-
lay coupler is faulty and must be repaired.



 





 
 



 
 



 
 



 
 



 



a. Connect the pocket tester (DC 20 V) to the 
turn signal/hazard relay terminal as shown.
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
 
Result
Continuity
(between “3” and “4”)
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
 
Result
Continuity
(between “3” and “4”)
1. Positive battery terminal
Sb/W
L/GL/YSb
B/YL/W R/LL/R
R B/R
L
+
13 24
Sb/W
L/GL/YSb
B/YL/W R/LL/R
R B/R
L
+
1324
+
R/Y
G/L
R/YY/B
1 2 3
4
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
 
Result
Continuity
(between “3” and “4”)
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
 
Result
Continuity
(between “3” and “4”)
 
Turn signal/hazard relay input 
voltage
DC 12 V
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Positive tester probe →
brown/green “1”
Negative tester probe →
ground
+
Br/W
L
R/BG/Y
1 2 3
4 
						

							ELECTRICAL COMPONENTS
7-98
b. Turn the main switch to “ON”.
c. Measure the turn signal/hazard relay input 
voltage.
        
2. Check:
Turn signal/hazard relay output voltage
Out of specification → Replace.



 





 
 








 
 



 
 



 



a. Connect the pocket tester (DC 20 V) to the 
turn signal/hazard relay terminal as shown.
b. Turn the main switch to “ON”.
c. Measure the turn signal/hazard relay output 
voltage.
        
EAS28050CHECKING THE RELAY UNIT (DIODE)
1. Check:
Relay unit (diode)
Out of specification → Replace.
NOTE:
The pocket tester and the analog pocket tester 
readings are shown in the following table.
 
Turn signal/hazard relay output 
voltage
DC 12 V
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Positive tester probe →
brown/white “1”
Negative tester probe →
ground
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
 
Continuity
Positive tester probe → sky blue 
“1”
Negative tester probe → 
black/yellow “2”
No continuity
Positive tester probe → 
black/yellow “2”
Negative tester probe → sky 
blue “1”
Continuity
Positive tester probe → sky blue 
“1”
Negative tester probe → 
blue/yellow “3”
No continuity
Positive tester probe → 
blue/yellow “3”
Negative tester probe → sky 
blue “1”
Continuity
Positive tester probe → sky blue 
“1”
Negative tester probe → sky 
blue/white “4”
No continuity
Positive tester probe → sky 
blue/white “4”
Negative tester probe → sky 
blue “1”
Continuity
Positive tester probe → 
blue/green “5”
Negative tester probe → 
blue/yellow “3”
No continuity
Positive tester probe → 
blue/yellow “3”
Negative tester probe → 
blue/green “5” 
						

							ELECTRICAL COMPONENTS
7-99



 





 
 








 
 



 
 



 



a. Disconnect the relay unit coupler from the 
wire harness.
b. Connect the pocket tester (Ω × 1) to the relay 
unit terminal as shown.
c. Check the relay unit (diode) for continuity.
d. Check the relay unit (diode) for no continuity.
        
EAS28070
CHECKING THE SPARK PLUG CAPS
The following procedure applies to all of the 
spark plug caps.
1. Check:
Spark plug cap resistance
Out of specification → Replace.



 





 
 








 
 



 
 



 



a. Remove the spark plug cap from the spark 
plug lead.
b. Connect the pocket tester (Ω × 1k) to the 
spark plug cap as shown.
c. Measure the spark plug cap resistance.
        
EAS28100CHECKING THE IGNITION COILS
The following procedure applies to all of the igni-
tion coils.
1. Check:
Primary coil resistance
Out of specification → Replace.



 





 
 



 
 



 
 



 
 



 



a. Disconnect the ignition coil connectors from 
the ignition coil terminals.
b. Connect the pocket tester (Ω × 1) to the igni-
tion coil as shown.
c. Measure the primary coil resistance.
          
2. Check:
Secondary coil resistance
Out of specification → Replace.



 





 
 



 
 



 
 



 
 



 



a. Disconnect the spark plug cap from the igni-
tion coil.
b. Connect the pocket tester (Ω × 1k) to the ig-
nition coil as shown.
 
Resistance
10.0 kΩ
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
L/GL/YSb
B/Y
Sb/W
L/W R/LL/R
R B/R
L
4 51
2 3
 
Primary coil resistance
2.16–2.64 Ω
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Positive tester probe →
black/red “1”
Negative tester probe →
orange or gray/red or gray/black “2”
 
Secondary coil resistance
8.64–12.96 kΩ
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C 
						

							ELECTRICAL COMPONENTS
7-100
c. Measure the secondary coil resistance.
        
ET5YU1032
CHECKING THE IGNITION SPARK GAP
1. Check:
Ignition spark gap
Out of specification → Perform the ignition 
system troubleshooting, starting with step 5.
Refer to “TROUBLESHOOTING” on page 
7-3.
NOTE:
If the ignition spark gap is within specification, 
the ignition system circuit is operating normally.



 





 
 








 
 



 
 



 



a. Disconnect the spark plug cap from the spark 
plug.
b. Connect the ignition checker “1” as shown.c. Turn the main switch to “ON” and engine stop 
switch to “”.
d. Measure the ignition spark gap “a”.
e. Crank the engine by pushing the start switch 
“” and gradually increase the spark gap un-
til a misfire occurs.
          
EAS28120
CHECKING THE CRANKSHAFT POSITION 
SENSOR
1. Disconnect:
Crankshaft position sensor coupler
(from the wire harness)
2. Check:
Crankshaft position sensor resistance
Out of specification → Replace the crank-
shaft position sensor.



 





 
 



 
 



 
 



 
 



 



a. Connect the pocket tester (Ω × 100) to the 
crankshaft position sensor coupler as shown.
b. Measure the crankshaft position sensor re-
sistance.
          
EAS28130
CHECKING THE LEAN ANGLE CUT-OFF 
SWITCH
1. Remove:
Lean angle cut-off switch Positive tester probe →
black/red “1”
Negative tester probe →
spark plug lead “2”
 
Minimum ignition spark gap
6.0 mm (0.24 in)
 
Ignition checker
90890-06754
Opama pet-4000 spark checker
YM-34487
2. Spark plug cap
 
Crankshaft position sensor 
resistance
248–372 Ω/gray-black
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Positive tester probe →
gray “1”
Negative tester probe →
black “2”
Gy
B
1 2 
						

							ELECTRICAL COMPONENTS
7-101
2. Check:
Lean angle cut-off switch output voltage
Out of specification → Replace.



 





 
 








 
 



 
 



 



a. Connect the lean angle cut-off switch coupler 
to the lean angle cut-off switch.
b. Connect the pocket tester (DC 20 V) to the 
lean angle cut-off switch coupler as shown.
c. Turn the lean angle cut-off switch to 65°.
d. Measure the lean angle cut-off switch output 
voltage.
        
EAS28150CHECKING THE STATOR COIL
1. Disconnect:
Stator coil coupler
(from the wire harness)
2. Check:
Stator coil resistance
Out of specification → Replace the stator as-
sembly.



 





 
 



 
 



 
 



 
 



 



a. Connect the pocket tester (Ω × 1) to the stator 
coil coupler as shown.
b. Measure the stator coil resistance.
          
EAS28170CHECKING THE RECTIFIER/REGULATOR
1. Check:
Charging voltage
Out of specification → Replace the rectifi-
er/regulator.
 
Lean angle cut-off switch output 
voltage
Less than 65°: 0.4–1.4 V
More than 65°: 3.7–4.4 V
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Positive tester probe →
yellow/green “1”
Negative tester probe →
black/blue “2”
 
Stator coil resistance
0.1280–0.1920 Ω
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Positive tester probe →
black “1”
Negative tester probe →
black “2”
Positive tester probe →
black “1”
Negative tester probe →
black “3”
Positive tester probe →
black “2”
Negative tester probe →
black “3”
 
Charging voltage
14 V at 5000 r/min
BBB
231 
						

							ELECTRICAL COMPONENTS
7-102



 





 
 








 
 



 
 



 



a. Set the engine tachometer to the cylinder-#1 
left spark plug lead or right spark plug lead.
b. Connect the pocket tester (DC 20 V) to the 
rectifier/regulator coupler as shown.
c. Start the engine and let it run at approximate-
ly 5000 r/min.
d. Measure the charging voltage.
        
EAS28180
CHECKING THE HORN
1. Check:
Horn resistance
Out of specification → Replace.



 





 
 








 
 



 
 



 



a. Disconnect the horn leads from the horn ter-
minals.
b. Connect the pocket tester (Ω × 1) to the horn 
terminals.c. Measure the horn resistance.
          
2. Check:
Horn sound
Faulty sound → Adjust or replace.



 





 
 



 
 



 
 



 
 



 



a. Connect a battery (12 V) to the horn.
b. Turn the adjusting screw in direction “a” or “b” 
until the horn sound is obtained.
          
EAS28210
CHECKING THE ENGINE TEMPERATURE 
SENSOR
1. Remove:
Engine temperature sensor
(from the front cylinder head)
WARNING
EWA14140
Handle the engine temperature sensor with 
special care.
Never subject the engine temperature sen-
sor to strong shocks. If the engine temper-
ature sensor is dropped, replace it.
2. Check:
Engine temperature sensor resistance
Out of specification → Replace.
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Positive tester probe →
red “1”
Negative tester probe →
black “2”
 
Coil resistance
1.01–1.11 Ω at 20 °C (68 °F)
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Positive tester probe →
horn terminal “1”
Negative tester probe →
horn terminal “2”
B BB
21
B R
 
Engine temperature sensor 
resistance
0.90–1.10 kΩ at 100 °C (212 °F)
1
2
ab 
						

							ELECTRICAL COMPONENTS
7-103



 





 
 








 
 



 
 



 



a. Connect the pocket tester (Ω × 1k) to the en-
gine temperature sensor terminal as shown.
b. Immerse the engine temperature sensor “1” 
in a container filled with water “2”.
NOTE:
Make sure that the engine temperature sensor 
terminals do not get wet.
c. Place a thermometer “3” in the water.
d. Slowly heat the water, then let it cool down to 
the specified temperature.
e. Measure the engine temperature sensor re-
sistance.
        
3. Install:
Engine temperature sensor
EAS28230CHECKING THE FUEL SENDER
1. Disconnect:
Fuel pump coupler
Fuel sender coupler
(from the wire harness)
2. Remove:
Fuel tank
3. Remove:
Fuel pump
(from the fuel tank)
4. Check:
Fuel sender resistance
Out of specification → Replace the fuel pump 
assembly.



 





 
 



 
 



 
 



 
 



 



a. Connect the pocket tester (Ω × 1k) to the fuel 
sender terminal as shown.
b. Measure the fuel sender resistance.
          
EAS28240
CHECKING THE SPEED SENSOR
1. Check:
Speed sensor output voltage
Out of specification → Replace.



 





 
 



 
 



 
 



 
 



 



a. Connect the pocket tester (DC 20 V) to the 
speed sensor coupler (wire harness side) as 
shown.
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
T R.. 
Engine temperature sensor
20 Nm (2.0 m·kg, 14 ft·lb)
3
1
2
 
Fuel sender resistance
1.35–1.65 kΩ at 25 °C (77 °F)
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Positive tester probe →
green “1”
Negative tester probe →
black “2”
 
Output voltage reading cycle
0.6 V to 4.8 V to 0.6 V to 4.8 V
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Positive tester probe →
white/yellow “1”
Negative tester probe →
black/blue “2” 
						

							ELECTRICAL COMPONENTS
7-104
b. Turn the main switch to “ON”.
c. Elevate the rear wheel and slowly rotate it.
d. Measure the voltage of white/yellow and 
black/blue. With each full rotation of the rear 
wheel, the voltage reading should cycle from 
0.6 V to 4.8 V to 0.6 V to 4.8 V.
        
EAS28300CHECKING THE THROTTLE POSITION 
SENSOR
1. Remove:
Throttle position sensor
(from the throttle body)
2. Check:
Throttle position sensor maximum resistance
Out of specification → Replace the throttle 
position sensor.



 





 
 








 
 



 
 



 



a. Connect the pocket tester (Ω × 1k) to the 
throttle position sensor terminal as shown.b. Measure the throttle position sensor maxi-
mum resistance.
          
3. Install:
Throttle position sensor
NOTE:
When installing the throttle position sensor, ad-
just its angle properly. Refer to “ADJUSTING 
THE THROTTLE POSITION SENSOR” on page 
6-10.
EAS28350CHECKING THE FUEL PUMP
WARNING
EWA13850
Gasoline is extremely flammable and under 
certain circumstances there can be a danger 
of an explosion or fire. Be extremely careful 
and note the following points:
Stop the engine before refueling.
Do not smoke, and keep away from open 
flames, sparks, or any other source of fire.
If you do accidentally spill gasoline, wipe it 
up immediately with dry rags.
If gasoline touches the engine when it is 
hot, a fire may occur. Therefore, make sure 
the engine is completely cool before per-
forming the following test.
1. Disconnect:
Fuel pump coupler
Fuel sender coupler
(from the wire harness)
2. Remove:
Fuel tank
3. Check:
Fuel pump operation
Faulty/rough movement → Replace.
 
Resistance
4.0–6.0 kΩ/blue-black
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Positive tester probe →
blue “1”
Negative tester probe →
black “2”
B
L LW
B/W/Y
L
1
2
L
Y B
21 
						

							ELECTRICAL COMPONENTS
7-105



 





 
 








 
 



 
 



 



a. Insert a plug “1” into the fuel return hose end.
b. Fill the fuel tank.
c. Put the end of the fuel hose “2” into an open 
container.
d. Connect the battery (DC 12 V) to the fuel 
pump terminal as shown.
e. Check the fuel pump operation.
        
EAS28360
CHECKING THE EXUP SERVO MOTOR
1. Check:
EXUP servo motor operation
Out of specification → Replace.



 





 
 








 
 



 
 



 



a. Disconnect the EXUP cables from the EXUP 
servo motor pulley.
b. Disconnect the EXUP servo motor coupler 
from the EXUP servo motor.
c. Connect the battery leads to the EXUP servo 
motor terminal as shown.d. Check that the EXUP servo motor pulley ro-
tates several times in directions “a” and “b”.
CAUTION:
EC5YU1023
To prevent damaging the EXUP servo motor, 
perform this test within a few seconds of 
connecting the battery.
          
EAS28400
CHECKING THE DECOMPRESSION 
SOLENOID
1. Check:
Decompression solenoid (thermistor) resis-
tance
Out of specification → Replace.
NOTE:
The resistance value for the thermistor changes 
when the temperature changes; therefore, mea-
sure the decompression solenoid (thermistor) 
resistance at the specified temperature. Positive battery lead →
red/blue “3”
Negative battery lead →
black “4”
R/LB
G B
14 3
2
For counterclockwise rotation “a”
Positive battery lead →
black/green “1”
Negative battery lead →
black/red “2”
For clockwise rotation “b”
Positive battery lead →
black/red “2”
Negative battery lead →
black/green “1”
 
Decompression solenoid 
(thermistor) resistance
56–84 Ω at 25 °C (77 °F)
LB/L
B/R
B/GW/R
b
a2 1