service YAMAHA MT-03 2006 Owners Manual

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SAFETY INFORMATION
EAU10281
MOTORCYCLES ARE SINGLE
TRACK VEHICLES. THEIR SAFE
USE AND OPERATION ARE DEPEN-
DENT UPON THE USE OF PROPER
RIDING TECHNIQUES AS WELL AS
THE EXPERTISE OF THE OPERA-
TOR. EVERY OPERATOR SHOULD
KNOW THE FOLLOWING REQUIRE-
MENTS BEFORE RIDING THIS MO-
TORCYCLE.
HE OR SHE SHOULD:
OBTAIN THOROUGH INSTRUC-
TIONS FROM A COMPETENT
SOURCE ON ALL ASPECTS OF
MOTORCYCLE OPERATION.
OBSERVE THE WARNINGS
AND MAINTENANCE REQUIRE-
MENTS IN THE OWNER'S MAN-
UAL.
OBTAIN QUALIFIED TRAINING
IN SAFE AND PROPER RIDING
TECHNIQUES.
OBTAIN PROFESSIONAL TECH-
NICAL SERVICE AS INDICATED
BY THE OWNER'S MANUAL
AND/OR WHEN MADE NECES-
SARY BY MECHANICAL CONDI-
TIONS.Safe riding
Always make pre-operation
checks. Careful checks may help
prevent an accident.
This motorcycle is designed to
carry the operator and a passen-
ger.
The failure of motorists to detect
and recognize motorcycles in traf-
fic is the predominating cause of
automobile/motorcycle accidents.
Many accidents have been
caused by an automobile driver
who did not see the motorcycle.
Making yourself conspicuous ap-
pears to be very effective in re-
ducing the chance of this type of
accident.
Therefore:
• Wear a brightly colored jacket.
• Use extra caution when you are
approaching and passing
through intersections, since in-
tersections are the most likely
places for motorcycle accidents
to occur.• Ride where other motorists can
see you. Avoid riding in another
motorist's blind spot.
Many accidents involve inexperi-
enced operators. In fact, many
operators who have been in-
volved in accidents do not even
have a current motorcycle li-
cense.
• Make sure that you are quali-
fied and that you only lend your
motorcycle to other qualified
operators.
• Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
• We recommend that you prac-
tice riding your motorcycle
where there is no traffic until
you have become thoroughly
familiar with the motorcycle and
all of its controls.
Many accidents have been
caused by error of the motorcycle
operator. A typical error made by
the operator is veering wide on a
turn due to EXCESSIVE SPEED
or undercornering (insufficient
lean angle for the speed).
MY03 01-03 ING 6-10-2005 13:52 Pagina 8

EAU15301
Sidestand
1. Sidestand
The sidestand is located on the left
side of the frame. Raise the sidestand
or lower it with your foot while holding
the motorcycle upright.
NOTE:
The built-in sidestand switch is part of
the ignition circuit cut-off system,
which cuts the ignition in certain situa-
tions. (See further down for an expla-
nation of the ignition circuit cut-off sys-
tem.)
INSTRUMENT AND CONTROL FUNCTIONS
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3. Tighten the locknut to the speci-
fied torque.
ECA11240CAUTION:
Always tighten the locknut against
the adjusting nut, and then tighten
the locknut to the specified torque.
EWA10220
WARNING0
This shock absorber contains high-
ly pressurized nitrogen gas. For
proper handling, read and under-
stand the following information be-
fore handling the shock absorber.
The manufacturer cannot be held
responsible for property damage or
personal injury that may result from
improper handling.
Do not tamper with or attempt
to open the gas cylinder.
Do not subject the shock ab-
sorber to an open flame or oth-
er high heat sources, otherwise
it may explode due to exces-
sive gas pressure.
Do not deform or damage the
gas cylinder in any way, as this
will result in poor damping per-
formance.
Always have a Yamaha dealer
service the shock absorber.
Tightening torque:
Locknut:
45 Nm (4.5 m·kgf, 32.5 ft·lbf)
MY03 01-03 ING 6-10-2005 13:53 Pagina 3-18

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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17240
Safety is an obligation of the owner.
Periodic inspection, adjustment and
lubrication will keep your vehicle in the
safest and most efficient condition
possible. The most important points of
inspection, adjustment, and lubrica-
tion are explained on the following
pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON
THE WEATHER, TERRAIN, GEO-
GRAPHICAL LOCATION, AND INDI-
VIDUAL USE, THE MAINTENANCE
INTERVALS MAY NEED TO BE
SHORTENED.
EWA10320
WARNING0
If you are not familiar with motorcy-
cle maintenance work, have a
Yamaha dealer do it for you.
EAUB1400
Owner’s tool kit
1. Owner’s tool kit
2. Fastening strap
The owner’s tool kit is located on the
bottom of the passenger seat (See
page 3-14) and it held in place with an
O-ring.
The service information included in
this manual and the tools provided in
the owner’s tool kit are intended to as-
sist you in the performance of preven-
tive maintenance and minor repairs.
However, additional tools such as a
torque wrench may be necessary to
perform certain maintenance work
correctly.
NOTE:
If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
EWA10350
WARNING0
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any
changes.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-56-5
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUAL
CHECK
• Check the air cut-off valve, reed valve, and hose
for damage.
• Check fuel hoses for cracks or damage.
• Check the screw clamp for looseness.
• Check operation.
• Adjust headlight beam. Air induction system
Muffler and exhaust
pipe
Lights, signals and
switches 28
✻
29✻
30✻
EAU18670
NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.
Replace the brake hoses every four years and if cracked or damaged.√√√√ √
√√√√√
√√√√√ √
MY03 04-06 ING 6-10-2005 9:24 Pagina 6-5

PERIODIC MAINTENANCE AND MINOR REPAIR
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1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Alignment marks
ECA10570
CAUTION:
Improper drive chain slack will
overload the engine as well as oth-
er vital parts of the motorcycle and
can lead to chain slippage or break-
age. To prevent this from occurring,
keep the drive chain slack within
the specified limits.
Tightening torques:
Locknut:
16 Nm (1.6 m·kgf, 11 ft·lbf)
Axle nut:
150 Nm (15.0 m·kgf, 108 ft·lbf)
EAU23022
Cleaning and lubricating
the drive chain
The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly
wear out, especially when riding in
dusty or wet areas. Service the drive
chain as follows.
ECA10581CAUTION:
The drive chain must be lubricated
after washing the motorcycle and
riding in the rain.
1. Clean the drive chain with
kerosene and a small soft brush.
ECA11120CAUTION:
To prevent damaging the O-rings,
do not clean the drive chain with
steam cleaners, high-pressure
washers or inappropriate solvents. 3. Tighten the locknuts, then the
axle nut to their specified torques.
MY03 04-06 ING 6-10-2005 9:25 Pagina 6-24

PERIODIC MAINTENANCE AND MINOR REPAIR
EAUB1410
Replacing the license plate
light bulb
1. Reinforcement plate
2. Bulb socket
3. License plate light bulb
1. Remove the reinforcement plate
by removing the bolts and nuts.
2. Remove the license plate light
bulb socket by pulling it out.
NOTE:
When removing the license plate light
bulb socket, be careful not to pull too
hard.
EAU24350
Supporting the motorcycle
Since this model is not equipped with
a centerstand, follow these precau-
tions when removing the front and rear
wheel or performing other mainte-
nance requiring the motorcycle to
stand upright. Check that the motorcy-
cle is in a stable and level position be-
fore starting any maintenance. A
strong wooden box can be placed un-
der the engine for added stability.
To service the front wheel
1. Stabilize the rear of the motorcy-
cle by using a motorcycle stand
or, if an additional motorcycle
stand is not available, by placing
a jack under the frame in front of
the rear wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
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3. Remove the defective bulb by
pulling it out of the socket.
4. Insert a new bulb into the socket.
5. Install the bulb socket by pushing
it in.
6. Install the reinforcement plate in
the original position, and then
tighten bolts and nuts to the spec-
ified torque.
Tightening torque:
Reinforcement plate nut:
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Reinforcement plate bolt (centre):
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Reinforcement plate bolt (upper):
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-37
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a mo-
torcycle stand is not available, by plac-
ing a jack either under each side of the
frame in front of the rear wheel or un-
der each side of the swingarm.EAU24360
Front wheelEAU34390
To remove the front wheel
EWA10820
WARNING0
It is advisable to have a Yama-
ha dealer service the wheel.
Securely support the motorcy-
cle so that there is no danger of
it falling over.
1. Front wheel axle pinch bolt
2. Wheel axle bolt
3. Brake caliper bolts
4. Brake hose holder bolt
1. Lift the front wheel off the ground
according to the procedure on
page 6-36.
2. Loosen the front wheel axle pinch
bolt, then the wheel axle and the
brake caliper bolts.
3. Remove the brake hose holder on
each side by removing the bolts.
4. Remove the brake caliper on
each side by removing the bolts.
ECA11050CAUTION:
Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will be
forced shut.
5. Pull the wheel axle out, and then
remove the wheel.
EAU24860
To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Insert the wheel axle.
3. Lower the front wheel so that it is
on the ground.
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PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU25080
Rear wheelEAU25311
To remove the rear wheelEWA10820
WARNING0
It is advisable to have a Yama-
ha dealer service the wheel.
Securely support the motorcy-
cle so that there is no danger of
it falling over.
1. Wheel axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Drive chain
1. Wheel axle
2. Brake caliper bracket
1. Loosen the axle nut.
2. Lift the rear wheel off the ground
according to the procedure on
page 6-36.
3. Remove the axle nut.
4. Loosen the locknut on each side
of the swingarm.
5. Turn the drive chain slack adjust-
ing bolts fully in direction (a) and
push the wheel forward.
6. Remove the drive chain from the
rear sprocket.
4. Install the brake calipers by in-
stalling the bolts.
NOTE:
Make sure that there is enough space
between the brake pads before in-
stalling the brake calipers onto the
brake discs.
5. Install the brake hose holders by
installing the bolts.
6. Tighten the wheel axle, the front
wheel axle pinch bolt and the
brake caliper bolts to the speci-
fied torques.
Tightening torques:
Wheel axle:
72 Nm (7.2 m·kgf, 52 ft·lbf)
Front wheel axle pinch bolt:
14 Nm (1.4 m·kgf, 10 ft·lbf)
Brake caliper bolt:
40 Nm (4.0 m·kgf, 29 ft·lbf)
7. Push down hard on the handlebar
several times to check for proper
fork operation.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-39
NOTE:
If the drive chain is difficult to re-
move, remove the wheel axle first,
and then lift the wheel upward
enough to remove the drive chain
from the rear sprocket.
The drive chain cannot be disas-
sembled.
7. While supporting the brake
caliper bracket, pull the wheel
axle out, and then remove the
wheel.
ECA11070CAUTION:
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
EAU34430
To install the rear wheel
1. Install the wheel and the brake
caliper bracket by inserting the
wheel axle from the right-hand
side.
NOTE:
Make sure that the retainer on the
swingarm is inserted into the slot
in the brake caliper bracket.
Make sure that there is enough
space between the brake pads
before installing the wheel.
2. Install the drive chain onto the
rear sprocket.
3. Install the axle nut, and then low-
er the rear wheel so that it is on
the ground.
4. Adjust the drive chain slack. (See
page 6-23.)
5. Tighten the axle nut to the speci-
fied torque.
Tightening torque:
Axle nut:
150 Nm (15.0 m·kgf, 108 ft·lbf)
EAU25870
Troubleshooting
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur
during operation. Any problem in the
fuel, compression, or ignition systems,
for example, can cause poor starting
and loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.
MY03 04-06 ING 6-10-2005 9:26 Pagina 6-39

SPECIFICATIONS
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Engine oil:Type:
SAE10W30 or SAE10W40 or SAE15W40
or SAE20W40 or SAE20W50
Recommended engine oil grade:
API service SE, SF, SG type or higher
Engine oil quantity:
Without oil filter element replacement:
3.00 L (3.17 US qt) (2.64 Imp.qt)
With oil filter element replacement:
3.10 L (3.28 US qt) (2.72 Imp.qt)
Total amount (dry engine):
3.40 L (3.60 US qt) (2.99 Imp.qt)
Cooling system:Radiator capacity (including all routes):
1.0 L (1.05 US qt) (0.88 Imp.qt) (Radiator) +
0.25 L (0.26 US qt) (0.22 Imp.qt)
(Coolant reservoir)
Coolant reservoir capacity (up to the
maximum level mark):
0.25 L (0.26 US qt) (0.22 Imp.qt)
From low to full level:
0.15 L (0.16 US qt) (0.13 Imp.qt)
Air filter:Air filter element:
Oil-coated paper element
Fuel:Recommended fuel:
Premium unleaded gasoline only
Fuel tank capacity:
15.0 L (3.96 US gal) (3.30 Imp.gal)
Fuel reserve amount:
4.25 L (1.12 US gal) (0.93 Imp.gal)
Fuel injection:Manufacturer:
DENSO
Model:
297500-0390
Spark plug:Manufacturer/model:NGK/CR7EGap:
0.7-0.8 mm (0.028-0.032 in)
Clutch:Clutch type:
Wet, multiple-disc
Transmission:Primary reduction system:
Spur gear
Primary reduction ratio:
75/36 (2.083)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
47/15 (3.133)
Transmission type:
Constant mesh 5-speed
Dimensions:Overall length:
2070 mm (81.49 in)
Overall width:
860 mm (33.85 in)
Overall height:
1115 mm (43.89 in)
Seat height:
805 mm (31.69 in)
Wheelbase:
1420 mm (55.90 in)
Ground clearance:
200 mm (7.87 in)
Minimum turning radius:
2225 mm (87.59 in)
Basic weight:With oil and fuel:
192 kg (423 lb)
195.2 kg (429 lb) (EU3 version)
Engine:Engine type:
Liquid cooled 4-stroke, SOHC
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
660.0 cm
3(40.27 cu.in)
Bore x stroke:
100.0 x 84.0 mm (3.94 x 3.31 in)
Compression ratio:
10.00 : 1
Starting system:
Electric starter
Lubrication system:
Dry sump
-20-10 0 1020304050°C
SAE 10W-30
SAE 10W-40
SAE 20W-40
SAE 20W-50
SAE 15W-40