2005 Yamaha MT-01(T) Service & Repair Manual (P/N 5YU1-AE1)

This Yamaha OEM service manual covers maintenance, troubleshooting, and repair for the 2005 Yamaha MT-01(T). Publication 5YU1-AE1, first edition December 2004, includes vehicle identification, FI-system fundamentals, and factory service information across eight chapters.

• Engine repair: Engine removal, crankcase separation, camshaft timing, hydraulic valve-lifter bleeding, cylinder-head service, and piston and crankshaft inspection.

• Clutch and transmission: Clutch-pack inspection, hydraulic master and release cylinder service, clutch bleeding, and gearbox shaft, shift-fork, and shift-drum work.

• Fuel and intake systems: Throttle-body synchronization, pressure-regulator testing, throttle-position sensor adjustment, rollover-valve checks, and ISC unit inspection.

• Chassis service: Front-fork disassembly and reassembly, brake caliper and master-cylinder repair, wheel balancing, steering-head service, and swingarm inspection.

• Electrical troubleshooting: Ignition, starting, charging, lighting, signaling, and immobilizer fault tracing, plus EXUP servo, decompression solenoid, and muffler cooling-system tests.

• Workshop references: Exploded assembly views, component torque tables, wear limits, lubrication diagrams, cable-routing views, and system-specific circuit diagrams.

Yamaha wrote this manual primarily for its dealers and qualified mechanics; it assumes basic mechanical knowledge and familiarity with vehicle repair techniques.

Engine Internals, Clutch, and Gearbox

Camshaft timing illustrations and valve-lifter bleeding instructions accompany rocker-arm, push-rod, valve-guide, and valve-seat work. Crankshaft coverage includes Plastigauge clearance measurement and bearing selection using the crankshaft and connecting-rod markings.

The connecting-rod procedures specify new bolts and angle-controlled tightening. Bolts tightened beyond the specified angle require replacement rather than loosening and retightening.

Clutch documentation covers the built-in boss damper and friction and steel plates. The hydraulic sections warn that unsuitable solvents can swell and distort piston seals. Gearbox exploded views identify the main and drive shafts and their gear assemblies.

Fuel Injection, ISC, and EXUP

The fault-code tables distinguish cylinder-specific intake-pressure sensor wiring faults from blocked or detached sensor hoses. Matching those entries to the diagnostic-mode tables helps separate a hose problem from a sensor fault before replacing parts.

Pressure-regulator testing uses the listed fuel-pressure adapter 90890-03176 / YM-03176. Throttle-body removal and cleaning are covered, but Yamaha explicitly prohibits disassembling the throttle body. EXUP cable adjustment is documented alongside electrical servo-motor checks.

Forks, Brakes, and Rear Suspension

Front-fork procedures cover seal replacement, damper-rod work, bleeding, and reassembly with the specified spring compressor. Brake sections include disc inspection, caliper and master-cylinder service, and hydraulic bleeding.

Rear-suspension coverage includes shock removal and linkage inspection; the pressurized shock itself must not be opened. Always verify equipment load limits and secure the motorcycle properly before starting heavy chassis or suspension teardowns.

Electrical Fault Tracing and Immobilizer Keys

Starting-circuit cut-off diagrams explain the interlock logic, while charging and signaling flowcharts connect component tests with wiring checks. Other references include the engine-oil lubrication chart, cable-routing views, self-diagnostic function tables, and complete MT-01(T) wiring diagram.

The immobilizer chapter provides parts-replacement/key-registration tables and indicator fault codes. Losing the red code re-registering key prevents registration of new keys, although existing registered standard keys can still start the motorcycle. If re-registration later becomes necessary, the ECU and main switch/immobilizer unit require replacement.

Valve, Fuel-Pressure, and Final-Drive Specification Preview

These examples are a small selection of the manual's service data. The valve-clearance section specifies 0.00–0.04 mm for both intake and exhaust with the engine cold. Fuel-pump specifications list an output pressure of 392.0 kPa.

The chain-drive installation section gives a drive sprocket nut torque of 95 Nm, alongside illustrations identifying the associated washer and replacement nut.

Searchable Text, Chapter Bookmarks, and PDF Contents

Search and diagram detail: Text search is available across the text chapters, with bookmarks for all eight chapters and the wiring diagram. Two legacy return bookmarks reference separate files outside this PDF. Small wire-color codes and connector labels in the detailed circuit diagrams require zooming.

One printable English-language PDF contains 435 pages. This total already includes the original cover, introductory material, chapter dividers, seven blank pages, wiring-diagram legend, rear cover, and final wiring diagram.