Yamaha Mt 01 T 2005 Manual

							CABLE ROUTING
2-55
B
A
B
A
C
C
A
A
BC
D
E
J
1
2345
8
6
7
8
910
11
12
13
G
H
I
K
L
M
N
F
1415
16
17
10E3 
						

							CABLE ROUTING
2-56
1. Cylinder-#2 intake air pressure sensor
2. Cylinder-#2 ISC (idle speed control) unit outlet 
hose
3. ISC (idle speed control) unit
4. Intake solenoid vacuum hose (one-way valve to 
throttle body)
5. Cylinder-#1 ISC (idle speed control) unit outlet 
hose
6. Throttle position sensor
7. Throttle body
8. Cylinder-#1 intake air pressure sensor hose
9. Fuel return hose
10. Pressure regulator
11. Cylinder-#1 intake air pressure sensor
12. Clutch hose
13. Cylinder-#2 intake air pressure sensor hose
14. Fuel hose
15. Air filter case
16. Pressure regulator joint
17. Fuel hose (intake manifold assembly to pressure 
regulator)
A. Face the ends of the hose clamp outward.
B. Face the ends of the hose clamp rearward.
C. Install the end of the cylinder-#1 ISC (idle speed 
control) unit outlet hose with a white paint mark 
onto the throttle body.
D. Face the ends of the hose clamp to the left, angled 
45
° towards the rear of the vehicle.
E. Face the ends of the hose clamp forward.
F. Install the end of the cylinder-#1 intake air pressure 
sensor hose with a white paint mark onto the 
throttle body.
G. Face the ends of the hose clamp inward.
H. Face the ends of the hose clamp forward.
I. Face the ends of the hose clamp to the right, 
angled 45
° towards the front of the vehicle.
J. Face the ends of the hose clamp forward.
K. Face the ends of the hose clamp inward.
L. Install the end of the intake solenoid vacuum hose 
(one-way valve to throttle body) with a white paint 
mark onto the throttle body. Be sure to install the 
end of the hose all the way onto the throttle body 
and position the hose clamp as shown in the 
illustration.
M. 45
°
N. 1 mm (0.04 in) 
						

							CHK
ADJ
3 
						

							3
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE............................................................................ 3-1
INTRODUCTION ....................................................................................... 3-1
PERIODIC MAINTENANCE AND LUBRICATION CHART ....................... 3-1
ENGINE........................................................................................................... 3-3
ADJUSTING THE VALVE CLEARANCE .................................................. 3-3
SYNCHRONIZING THE THROTTLE BODIES.......................................... 3-5
ADJUSTING THE THROTTLE CABLE FREE PLAY ................................ 3-7
CHECKING THE SPARK PLUGS ............................................................. 3-8
CHECKING THE IGNITION TIMING ......................................................... 3-8
MEASURING THE COMPRESSION PRESSURE .................................... 3-9
CHECKING THE ENGINE OIL LEVEL.................................................... 3-11
CHANGING THE ENGINE OIL ............................................................... 3-11
ADJUSTING THE CLUTCH LEVER........................................................ 3-13
CHECKING THE CLUTCH FLUID LEVEL .............................................. 3-14
BLEEDING THE HYDRAULIC CLUTCH SYSTEM ................................. 3-14
REPLACING THE AIR FILTER ELEMENT ............................................. 3-15
CHECKING THE THROTTLE BODY JOINTS ........................................ 3-16
CHECKING THE FUEL LINE .................................................................. 3-16
CHECKING THE CYLINDER HEAD BREATHER HOSES ..................... 3-16
CHECKING THE OIL TANK BREATHER HOSE .................................... 3-17
CHECKING THE EXHAUST SYSTEM.................................................... 3-17
ADJUSTING THE EXUP CABLES .......................................................... 3-18
CHASSIS....................................................................................................... 3-20
ADJUSTING THE FRONT DISC BRAKE ................................................ 3-20
ADJUSTING THE REAR DISC BRAKE .................................................. 3-20
CHECKING THE BRAKE FLUID LEVEL................................................. 3-21
CHECKING THE FRONT BRAKE PADS ................................................ 3-21
CHECKING THE REAR BRAKE PADS .................................................. 3-22
CHECKING THE FRONT BRAKE HOSES ............................................. 3-22
CHECKING THE REAR BRAKE HOSE .................................................. 3-22
ADJUSTING THE REAR BRAKE LIGHT SWITCH ................................. 3-22
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-23
ADJUSTING THE SHIFT PEDAL ............................................................ 3-24
ADJUSTING THE DRIVE CHAIN SLACK ............................................... 3-24
LUBRICATING THE DRIVE CHAIN ........................................................ 3-25
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-25
CHECKING THE FRONT FORK ............................................................. 3-26
ADJUSTING THE FRONT FORK LEGS ................................................. 3-27
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY .................. 3-28
CHECKING THE TIRES .......................................................................... 3-30
CHECKING THE WHEELS ..................................................................... 3-31
CHECKING AND LUBRICATING THE CABLES .................................... 3-32
LUBRICATING THE LEVERS ................................................................. 3-32
LUBRICATING THE PEDAL ................................................................... 3-32
LUBRICATING THE SIDESTAND........................................................... 3-32
LUBRICATING THE REAR SUSPENSION............................................. 3-32 
						

							ELECTRICAL SYSTEM................................................................................. 3-33
CHECKING AND CHARGING THE BATTERY ....................................... 3-33
CHECKING THE FUSES ........................................................................ 3-33
REPLACING THE HEADLIGHT BULBS ................................................. 3-33
ADJUSTING THE HEADLIGHT BEAM ................................................... 3-34 
						

							PERIODIC MAINTENANCE
3-1
EAS20450
PERIODIC MAINTENANCE
EAS20460
INTRODUCTION
This chapter includes all information necessary to perform the recommended checks and adjustments. 
If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a 
longer service life and reduce the need for costly overhaul work. This information applies to vehicles 
already in service as well as to new vehicles that are being prepared for sale. All service technicians 
should be familiar with this entire chapter.
EAU17705
PERIODIC MAINTENANCE AND LUBRICATION CHART
NOTE:
•The annual checks must be performed every year, except if a kilometer-based maintenance is 
performed instead.
 From 50000 km, repeat the maintenance intervals starting from 10000 km.
 Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, 
data and technical skills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)ANNU-
AL 
CHECK
1 10203040
1*Fuel line Check fuel hoses for cracks or damage.
√√√√ √
2*Spark plugs Check condition.
 Clean and regap.√√
 Replace.√√
3*Valves Check valve clearance.
Adjust.√√
4*Air filter element Replace.√
5*Clutch Check operation, fluid level and vehicle for fluid 
leakage.√√√√√
6*Front brake Check operation, fluid level and vehicle for fluid 
leakage.√√√√√ √
 Replace brake pads. Whenever worn to the limit
7*Rear brake Check operation, fluid level and vehicle for fluid 
leakage.
√√√√√ √
 Replace brake pads. Whenever worn to the limit
8*Brake hoses Check for cracks or damage.
√√√√ √
 Replace. Every 4 years
9*Wheels Check runout and for damage.
√√√√
10*Tires Check tread depth and for damage.
 Replace if necessary.
 Check air pressure.
 Correct if necessary.√√√√ √
11*Wheel bearings Check bearing for looseness or damage.√√√√
12*Swingarm Check operation and for excessive play.√√√√
13 Drive chain Check chain slack, alignment and condition.
 Adjust and lubricate chain with a special O-ring 
chain lubricant thoroughly.Every 1000 km and after washing the motor-
cycle or riding in the rain
14*Steering bearings Check bearing play and steering for roughness.
√√√√√
 Lubricate with lithium-soap-based grease. Every 20000 km
15*Chassis fasteners Make sure that all nuts, bolts and screws are prop-
erly tightened.
√√√√ √
16 Sidestand Check operation.
 Lubricate.√√√√ √
17*Sidestand switch Check operation.√√√√√ √
18*Front fork Check operation and for oil leakage.√√√√ 
						

							PERIODIC MAINTENANCE
3-2
EAU36771
NOTE:
Air filter
This model’s air filter is equipped with a disposable oil-coated paper element, which must not be 
cleaned with compressed air to avoid damaging it.
The air filter element needs to be replaced more frequently when riding in unusually wet or dusty 
areas.
Hydraulic brake and clutch service
Regularly check and, if necessary, correct the brake fluid and clutch fluid levels.
Every two years replace the internal components of the brake master cylinders and calipers as well 
as clutch master and release cylinders, and change the brake and clutch fluids.
Replace the brake and clutch hoses every four years and if cracked or damaged.
19*Shock absorber as-
semblyCheck operation and shock absorber for oil leakage.√√√√
20*Rear suspension re-
lay arm and connect-
ing arm pivoting 
pointsCheck operation.√√√√
21*Fuel injection systemAdjust synchronization.√√√√ √
22 Engine oilChange.
Check oil level and vehicle for oil leakage.√√√√√ √
23Engine oil filter car-
tridgeReplace.√√√
24*Front and rear brake 
switchesCheck operation.√√√√√ √
25Moving parts and ca-
blesLubricate.√√√√ √
26*Throttle grip hous-
ing and cableCheck operation and free play.
Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.√√√√ √
27*Muffler and exhaust 
pipeCheck the screw clamp for looseness.√√√√√
28*Lights, signals and 
switchesCheck operation.
Adjust headlight beam.√√√√√ √
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km)ANNU-
AL 
CHECK
1 10203040 
						

							ENGINE
3-3
EAS20470
ENGINE
EAS20530
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the 
valves.
NOTE:
The valve clearance is automatically adjusted 
by the hydraulic valve lifter. However, there are 
times that the valve clearance needs to be ad-
justed manually. If this is the case, adjust the 
clearance of the two maladjusted or worn 
valves using the adjusting screw on the rocker 
arm.
If clearance is on the slip side “1”, loosen the 
adjusting screw and bring the valve clearance 
“a” within specification. Check if the valve 
clearance “b” on the adjusting screw “2” side is 
within specification.
If clearance is on the adjusting screw “2” side, 
tighten the adjusting screw and bring the valve 
clearance “b” within specification.
Valve clearance adjustment should be made 
on a cold engine, at room temperature.
When the valve clearance is to be measured or 
adjusted, the piston must be at top dead center 
(TDC) on the compression stroke.
1. Remove:
Seat
Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tank
Refer to “FUEL TANK” on page 6-1.Air filter case
Refer to “GENERAL CHASSIS” on page 4-1.
2. Disconnect:
Spark plug caps
3. Remove:
Spark plugs
4. Remove:
Oil catch tank “1”
Tappet covers “2”
Front cylinder head cover “3”
5. Remove:
Air duct “1”
Timing mark accessing screw “2”
Crankshaft end cover “3”
6. Remove:
Camshaft sprocket cover “1”
7. Measure:
Valve clearance
Out of specification → Adjust.
3
2
2 1
1
23
1 
						

							ENGINE
3-4



 





 
 








 
 



 
 



 



Piston #1 TDC (rear cylinder)
a. Turn the crankshaft counterclockwise.
b. When piston #1 is at TDC on the compres-
sion stroke, align the TDC mark “a” on the 
crankshaft position sensor rotor with the 
pointer “b” on the clutch cover.
c. Check the camshaft drive gear mark “c” posi-
tion and camshaft driven gear mark “d” posi-
tion as shown.
If the marks are not aligned, turn the crank-
shaft counterclockwise 360 degrees and re-
check step (b).d. Measure the valve clearance with a thickness 
gauge.          



 





 
 



 
 



 
 



 
 



 



Piston #2 TDC (front cylinder)
a. Turn the crankshaft counterclockwise from 
the piston #1 TDC by 408 degrees.
b. When piston #2 is at TDC on the compres-
sion stroke, align the TDC mark “e” on the 
crankshaft position sensor rotor with the 
pointer “b” on the clutch cover.
c. Check the camshaft drive gear mark “c” posi-
tion and camshaft driven gear mark “d” posi-
tion as shown.
d. Measure the valve clearance with a thickness 
gauge.
          
8. Adjust:
Valve clearance
 
Valve clearance (cold)
Intake
0.00–0.04 mm (0.0000–0.0016 in)
Exhaust
0.00–0.04 mm (0.0000–0.0016 in)
ba
c d
 
Thickness gauge
90890-03079
Narrow gauge set
YM-34483
 
Thickness gauge
90890-03079
Narrow gauge set
YM-34483
be
d
c 
						

							ENGINE
3-5



 





 
 








 
 



 
 



 



a. Loosen the locknut “1” with the locknut 
wrench “2”.
b. Insert a thickness gauge “3” between the end 
of the adjusting screw and the valve tip.
c. Turn the adjusting screw “4” in direction “a” or 
“b” with the tappet adjusting tool “5” until the 
specified valve clearance is obtained.d. Hold the adjusting screw to prevent it from 
moving and tighten the locknut to specifica-
tion with the locknut wrench “6”.
NOTE:
Set the torque wrench at a right angle to the 
locknut wrench.
e. Measure the valve clearance again.
f. If the valve clearance is still out of specifica-
tion, repeat all of the valve clearance adjust-
ment steps until the specified clearance is 
obtained.
          
9. Install:
All removed parts
NOTE:
For installation, reverse the removal procedure.
Front cylinder head cover
Tappet covers
Refer to “CAMSHAFTS” on page 5-16.
EAS20570SYNCHRONIZING THE THROTTLE BODIES
NOTE:
Prior to synchronizing the throttle bodies, the 
valve clearance and the engine idling speed 
should be properly adjusted and the ignition tim-
ing should be checked.
1. Stand the vehicle on a level surface.
NOTE:
Place the vehicle on a suitable stand.
 
Locknut wrench
90890-04150
 
Thickness gauge
90890-03079
Narrow gauge set
YM-34483
 
Tappet adjusting tool
90890-04149
Adjusting 
screw sideSlip side
Direction “a”Va l ve  
clearance is 
increased.Va l ve  
clearance is 
decreased.
Direction “b”Va l ve  
clearance is 
decreased.Va l ve  
clearance is 
increased.
1 2
a
b
4
5
3
T R.. 
Locknut (rocker arm adjusting 
screw)
20 Nm (2.0 m·kg, 14 ft·lb)
 
Locknut wrench
90890-04150
6