Yamaha MT-01 User manual

2005

SERVICE MANUAL

MT-01(T)

5YU1-AE1

Manuals by Motomatrix / www.motomatrix.co.uk

Email: [email protected]

EAS20040

MT-01(T) 2005

SERVICE MANUAL

First edition, December 2004

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

Manuals by Motomatrix / www.motomatrix.co.uk

Email: [email protected]

EAS20070

NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers

and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-

ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles

should have a basic understanding of mechanics and the techniques to repair these types of vehicles.

Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-

cle unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-

nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and

will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

EAS20080

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death

to the motorcycle operator, a bystander or a person checking or repairing the

motorcycle.

A CAUTION indicates special precautions that must be taken to avoid

damage to the motorcycle.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

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EAS20090

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid

out with the individual steps in sequential order.

• The manual is divided into chapters and each chapter is divided into sections. The current section title

“1” is shown at the top of each page.

• Sub-section titles “2” appear in smaller print than the section title.

• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each

removal and disassembly section.

• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-

sembly step.

• Symbols “5” indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-

tially.

Manuals by Motomatrix / www.motomatrix.co.uk

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EAS20100

SYMBOLS

The following symbols are used in this manual

for easier understanding.

NOTE:

The following symbols are not relevant to every

vehicle.

BLS M

91011

12 13 14

15 16

LT New

123

456

1. Serviceable with engine mounted

2. Filling fluid

3. Lubricant

4. Special tool

5. Tightening torque

6. Wear limit, clearance

7. Engine speed

8. Electrical data

9. Engine oil

10.Gear oil

11.Molybdenum disulfide oil

12.Wheel bearing grease

13.Lithium-soap-based grease

14.Molybdenum disulfide grease

15.Apply locking agent (LOCTITE®).

16.Replace the part with a new one.

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EAS20110 TABLE OF CONTENTS

GENERAL INFORMATION 1

SPECIFICATIONS 2

PERIODIC CHECKS AND

ADJUSTMENTS 3

CHASSIS 4

ENGINE 5

FUEL SYSTEM 6

ELECTRICAL SYSTEM 7

TROUBLESHOOTING 8

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GEN

INFO 1

Manuals by Motomatrix / www.motomatrix.co.uk

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GENERAL INFORMATION

IDENTIFICATION ............................................................................................1-1

VEHICLE IDENTIFICATION NUMBER .....................................................1-1

MODEL LABEL..........................................................................................1-1

FEATURES......................................................................................................1-2

OUTLINE OF THE FI SYSTEM................................................................. 1-2

FI SYSTEM................................................................................................1-3

INSTRUMENT FUNCTIONS .....................................................................1-4

IMPORTANT INFORMATION .........................................................................1-7

PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-7

REPLACEMENT PARTS...........................................................................1-7

GASKETS, OIL SEALS AND O-RINGS ....................................................1-7

LOCK WASHERS/PLATES AND COTTER PINS .....................................1-7

BEARINGS AND OIL SEALS ....................................................................1-8

CIRCLIPS ..................................................................................................1-8

CHECKING THE CONNECTIONS .................................................................. 1-9

SPECIAL TOOLS ..........................................................................................1-10

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Manuals by Motomatrix / www.motomatrix.co.uk

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IDENTIFICATION

1-1

EAS20130

IDENTIFICATION

EAS20140

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1”is stamped

on the right side of the steering head pipe.

EAS20150

MODEL LABEL

The model label “1”is affixed to the lead holder

under the seat. This information will be needed

to order spare parts.

Manuals by Motomatrix / www.motomatrix.co.uk

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