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2005 Yamaha MT 01 Service Repair Manual

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🏷️ Basic Information Identification Make: Yamaha Model: MT-01 Year: 2005 Engine Variant: V-Twin 4-stroke, air-cooled 👋 Introduction Market Position Market Segment: Sport Heritage / Naked Muscle Bike Competitive Analysis Key...

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Type: Motorcycle

Vendor:

Sku: 257062

Tags: 2005 Motorcycle Motorcycles MT 01 MT Series Yamaha

Product variants

Description

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

MT-01

Year:

2005

Engine Variant:

V-Twin 4-stroke, air-cooled

👋 Introduction

Market Position

Market Segment:

Sport Heritage / Naked Muscle Bike

Competitive Analysis

Key Competitors:

Buell XB9/XB12, Triumph Bonneville T100/Speedmaster, Harley-Davidson Sportster models.

Key Features

Engine Emphasis:

Large displacement V-twin engine focused on torque and character.

Chassis Design:

Stiff aluminum frame and advanced suspension components.

Braking System:

High-performance radial-mount brake calipers and large diameter discs.

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive service and repair

Page Count

Page Count:

Estimated 300-400 pages (typical for this class of manual)

Manual Type

Manual Type:

Service Repair Manual

Manual Scope Detail:

Covers all aspects of maintenance, repair, and troubleshooting.

Language

Language:

English

Format

Format:

PDF Download

Accessibility:

Instant download, accessible on various devices.

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, inspection, torque specifications, valve clearance adjustment, piston/cylinder inspection, crankshaft/connecting rod inspection.

Fuel System:

Fuel injection system, throttle body, fuel pump, injectors, fuel filter, fuel tank, lines, evaporative emissions control system (EVAP).

Ignition System:

Ignition coils, spark plugs, CDI unit, wiring, ignition timing.

Cooling System:

Radiator, cooling fan, thermostat, coolant hoses, water pump, coolant specifications.

Exhaust System:

Exhaust pipes, mufflers, catalytic converter (if applicable), gaskets, mounting hardware.

Transmission Drivetrain:

Clutch assembly, gearbox, shift mechanism, final drive (belt drive system for MT-01), oil specifications, troubleshooting.

Suspension Front:

Front forks (USD), oil level and type, spring preload adjustment, damping adjustments, seals, bushings, fork leg disassembly and assembly.

Suspension Rear:

Rear shock absorber, linkage, swingarm, bearings, lubrication, adjustment procedures, shock absorber overhaul.

Brakes Front:

Brake calipers (e.g., radial-mount Brembo), brake discs, master cylinder, brake lines, brake fluid type and bleeding procedure, pad replacement.

Brakes Rear:

Rear brake caliper, disc, master cylinder, brake fluid, bleeding, pad replacement.

Wheels Tires:

Wheel specifications, bearings, tire fitment, pressure, balancing, recommended tire sizes.

Electrical System Charging:

Stator, rectifier/regulator, battery, wiring diagrams, testing procedures.

Electrical System Lighting:

Headlight, taillight, turn signals, brake lights, instrument cluster illumination, bulb specifications.

Electrical System Starting:

Starter motor, starter solenoid, battery testing, wiring.

Electrical System Instruments:

Speedometer, tachometer, indicator lights, diagnostic functions.

Frame Bodywork:

Frame inspection, subframe, fuel tank removal/installation, seat, body panels, fairings, decals, mounting points.

Steering:

Handlebars, steering stem, headstock bearings, lubrication, adjustment, troubleshooting.

Troubleshooting:

Diagnostic flowcharts, common problems, symptom-based troubleshooting guides.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter cleaning/replacement, chain adjustment (if applicable, though MT-01 has belt drive), spark plug replacement, brake fluid flush, coolant flush, lubrication points.

Engine Rebuild:

Complete engine overhaul procedures, piston ring replacement, valve seat grinding, crankshaft balancing verification.

Suspension Servicing:

Fork seal replacement, fork oil changes, rear shock service, bearing replacement.

Brake System Repair:

Caliper rebuild, master cylinder replacement, line replacement, bleeding procedures.

Electrical Diagnostics:

Wiring harness testing, component testing (stator, CDI, starter), sensor diagnosis.

Fuel System Calibration:

Throttle body synchronization, injector cleaning/testing (if covered).

Belt Drive Maintenance:

Belt tension adjustment, inspection for wear and damage, sprocket inspection.

Timing Chain Adjustment:

Inspection and adjustment procedures for camshaft timing chain tensioner.

Sensor Diagnosis:

Testing procedures for throttle position sensor (TPS), crank position sensor, etc.

Technical Depth

Diagnostic Capabilities:

Advanced diagnostic procedures, fault code interpretation (if ECU diagnostic port present), electrical circuit testing.

Repair Instructions:

Step-by-step repair instructions with detailed diagrams and illustrations for all major components.

Specification Data:

Precise torque values, clearances, fluid capacities, electrical resistance values, diagnostic parameters.

Wiring Diagrams:

Complete electrical wiring diagrams for all systems.

📊 Manual Specifications

File Format

File Format:

Portable Document Format (PDF)

Print Quality

Print Quality:

High-resolution, clear text and diagrams suitable for printing.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

1670cc (102 cubic inch) V-twin, four-stroke, SOHC, 4 valves per cylinder

Bore X Stroke:

97.0 mm x 115.0 mm

Compression Ratio:

8.4:1

Performance

Horsepower:

Approx. 90 HP @ 4,750 RPM

Torque:

Approx. 150 Nm (110 ft-lb) @ 3,750 RPM

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with twin-throttle body design

Fuel Type:

Unleaded gasoline (91 octane or higher recommended)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Final Drive:

Belt Drive

Features

Clutch Type:

Wet, multiple disc, cable-actuated

📐 Dimensions

Exterior

Length:

2,185 mm (86.0 in)

Width:

810 mm (31.9 in)

Height:

1,105 mm (43.5 in)

Wheelbase:

1,505 mm (59.3 in)

Weights

Dry Weight:

Approx. 230 kg (507 lbs)

Wet Weight:

Approx. 245 kg (540 lbs)

Fuel Tank Capacity:

15 L (3.96 US gal)

🛡️ Safety Features

Ratings

Safety Features Emphasis:

High-performance braking systems and stable chassis.

Active Features

Braking System Type:

Hydraulic disc brakes front and rear

Front Brake Specs:

Dual 320mm discs with radial-mount 4-piston calipers

Rear Brake Specs:

267mm disc with 2-piston caliper

Passive Features

Lighting System:

Halogen headlight, LED taillight, integrated turn signals.

💡 Technology Features

Infotainment

Instrument Cluster:

Analog tachometer with integrated digital speedometer, odometer, trip meters, and indicator lights.

Driver Assistance

Rider Aids:

No electronic rider aids such as ABS or traction control standard on this model.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first.

Air Filter Service:

Inspect every 6,000 km (3,700 miles), clean or replace as needed.

Spark Plug Replacement:

Every 12,000 km (7,500 miles).

Belt Drive Tension:

Check tension every 12,000 km (7,500 miles), adjust as per manual.

Fluid Specifications

Engine Oil Type:

Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher, JASO MA compliant.

Engine Oil Capacity:

3.60 L (without filter replacement), 3.80 L (with filter replacement).

Brake Fluid Type:

DOT 4 brake fluid.

Coolant Type:

Permanent type antifreeze coolant (ethylene glycol based) mixed with distilled water (50:50 ratio).

Fork Oil Type:

Approx. 400 ml of SAE 15W fork oil per leg (check manual for exact specification).

Known Issues

Common Wear Items:

Clutch plates, belt drive components, front fork seals, wheel bearings.

Potential Electrical Issues:

Occasional issues with rectifier/regulator or stator under high load/age.

📚 Vehicle History

Brand Heritage

Yamaha Legacy:

Yamaha's long-standing reputation for engineering excellence and performance motorcycles.

Model Evolution

Mt Series Introduction:

The MT-01 was part of Yamaha's 'Master of Torque' series, emphasizing raw power and a unique riding experience.

Production

Production Period:

Produced from 2005 to 2012.

🏆 Awards & Recognition

Recognitions

Industry Acclaim:

Praised for its characterful engine and unique styling, often featured in 'muscle bike' comparisons.