engine YAMAHA MT-03 2006 Owner's Manual

OPERATION AND IMPORTANT RIDING POINTS
NOTE:
When the transmission is in the neu-
tral position, the neutral indicator light
should be on, otherwise have a Yama-
ha dealer check the electrical circuit.
3. Start the engine by pushing the
start switch.
NOTE:
If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any one
attempt.
ECA11040CAUTION:
For maximum engine life, never ac-
celerate hard when the engine is
cold!
NOTE:
The engine is warm when it quickly re-
sponds to the throttle.
EAU16671
Shifting
1. Shift pedal
N. Neutral position
Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing
hills, etc.
The gear positions are shown in the il-
lustration.
NOTE:
To shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.
5-2
1
2
3
4
5
6
7
8
9
10
MY03 04-06 ING 6-10-2005 9:24 Pagina 5-2

1
2
3
4
5
6
7
8
9
10
OPERATION AND IMPORTANT RIDING POINTS
ECA10260CAUTION:
Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long
distances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.
Always use the clutch while
changing gears to avoid dam-
aging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
EAU16810
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the follow-
ing tips to reduce fuel consumption:
Shift up swiftly, and avoid high en-
gine speeds during acceleration.
Do not rev the engine while shift-
ing down, and avoid high engine
speeds with no load on the en-
gine.
Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at traf-
fic lights or at railroad crossings).
EAU16841
Engine break-in
There is never a more important peri-
od in the life of your engine than the
period between 0 and 1600 km (1000
mi). For this reason, you should read
the following material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts
in the engine wear and polish them-
selves to the correct operating clear-
ances. During this period, prolonged
full-throttle operation or any condition
that might result in engine overheating
must be avoided.
5-3
MY03 04-06 ING 6-10-2005 9:24 Pagina 5-3

OPERATION AND IMPORTANT RIDING POINTS
EAU17100
0-1000 km (0-600 mi)
Avoid prolonged operation above
4500 r/min.
1000-1600 km (600-1000 mi)
Avoid prolonged operation above
6000 r/min.
ECA11150CAUTION:
After 1000 km (600 mi) of operation,
the engine oil must be changed,
and the oil filter element replaced.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.
5-4
1
2
3
4
5
6
7
8
9
10
ECA10310CAUTION:
Keep the engine speed out of
the tachometer red zone.
If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the
vehicle.
EAU17212
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EWA10310
WARNING0
Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.
Do not park on a slope or on
soft ground, otherwise the ve-
hicle may overturn.
ECA10380CAUTION:
Never park in an area where there
are fire hazards such as grass or
other flammable materials.
MY03 04-06 ING 6-10-2005 9:24 Pagina 5-4

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
1
2
3
4
5
6
7
8
9
10
• Check operation and for oil leakage.
• Check operation and shock absorber for oil
leakage.
• Check operation.
• Lubricate with lithium-soap-based grease.
• Adjust engine idling speed.
• Change.
• Check oil level and vehicle for oil leakage.
• Replace.
• Check coolant level and vehicle for coolant leakage.
• Change.
• Check operation.
• Lubricate.
• Check operation and free play.
• Adjust the throttle cable free play if necessary.
• Lubricate the throttle grip housing and cable. Front fork
Shock absorber
assembly
Side suspension
relay arm and
connecting arm
pivoting points
Fuel injection
Engine oil
Engine oil filter
element
Cooling system
Front and rear brake
switches
Moving parts and
cables
Throttle grip housing
and cable
√√√√
√√√√
√√√√
√√
√√√√√ √
√√√√√ √
√√√
√√√√ √
√√√√√ √
√√√√ √
√√√√ √18✻
19✻
20✻
21✻
22
23
24
✻
25✻
26
27
✻
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUAL
CHECK
Every 3 years
MY03 04-06 ING 6-10-2005 9:24 Pagina 6-4

PERIODIC MAINTENANCE AND MINOR REPAIR
EAU18771
Removing and installing
panels
The panels shown need to be re-
moved to perform some of the mainte-
nance jobs described in this chapter.
Refer to this section each time a panel
needs to be removed and installed.
EAUB1290
Panels A and B
1. Panel mounting bolts
A. Right panel
B. Left panel
To remove a panel
1. Remove the bolts.
2. Unhook the panel from the hook
by sliding the panel upward to re-
lease it.
T
o install a panel
1. Insert the panel on the hook, and
slide the panel downward to the
original position.
2. Install the bolts.
EAU19602
Checking the spark plug
The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause
any spark plug to slowly erode, the
spark plug should be removed and
checked in accordance with the peri-
odic maintenance and lubrication
chart. In addition, the condition of the
spark plug can reveal the condition of
the engine.
To remove the spark plug
1. Spark plug cap
2. Spark plug wrench
1. Remove the spark plug cap.
6-6
1
2
3
4
5
6
7
8
9
10
MY03 04-06 ING 6-10-2005 16:09 Pagina 6-6

1
2
3
4
5
6
7
8
9
10
PERIODIC MAINTENANCE AND MINOR REPAIR
2. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner’s tool kit.
To check the spark plug
1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light
tan (the ideal color when the vehi-
cle is ridden normally).
NOTE:
If the spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the vehicle.
2. Check the spark plug for elec-
trode erosion and excessive car-
bon or other deposits, and re-
place it if necessary.
6-7
Specified spark plug:
CR7E (NGK)
Spark plug gap:
0.7-0.8 mm (0.028-0.032 in)
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)
To install the spark plug
1. Measure the spark plug gap with
a wire thickness gauge and, if
necessary, adjust the gap to
specification.
1. Spark plug gap


2. Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
NOTE:
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is 1/4-
1/2 turn past finger tight. However, the
spark plug should be tightened to the
specified torque as soon as possible.
4. Install the spark plug cap.
MY03 04-06 ING 6-10-2005 9:24 Pagina 6-7

PERIODIC MAINTENANCE AND MINOR REPAIR
EAUB1350
Engine oil and oil filter
element
The engine oil level should be checked
before each ride. In addition, the oil must
be changed and the oil filter element re-
placed at the intervals specified in the pe-
riodic maintenance and lubrication chart.To check the engine oil level
1. Place the vehicle on a level surface
and hold it in an upright position.NOTE:
Make sure that the vehicle is posi-
tioned straight up when checking the
oil level. A slight tilt to the side can re-
sult in a false reading.
2. Start the engine, warm it up for
10-15 minutes, let it continue to
idle for 20-30 seconds, and then
turn it off.
3. Wait a few minutes until the oil
settles, remove the oil filler cap,
wipe the dipstick clean, insert it
back into the oil filler hole (without
screwing it in), and then remove it
again to check the oil level.
1. Engine oil filler cap
2. Maximum level mark
3. Minimum level mark
EWAB0010
WARNING0
The exhaust pipes are very hot dur-
ing and following operation. To pre-
vent burns when removing the oil
filler cap, use extra care not to
touch the exhaust pipes.
NOTE:
The engine oil tank is located in
front of the frame.
The engine oil should be between
the minimum and maximum level
marks.
6-8
1
2
3
4
5
6
7
8
9
10
MY03 04-06 ING 6-10-2005 9:24 Pagina 6-8

1
2
3
4
5
6
7
8
9
10
PERIODIC MAINTENANCE AND MINOR REPAIR
ECA10010CAUTION:
Do not operate the vehicle until you
know that the engine oil level is suf-
ficient.
EWA10360
WARNING0
Never remove the engine oil tank
cap after high-speed operation,
otherwise hot engine oil could
spout out and cause damage or in-
jury. Always let the engine oil cool
down sufficiently before removing
the oil tank cap.
4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
5. Install the oil filler cap.
To change the engine oil
(with or without oil filter element
replacement)
1. Start the engine, warm it up for
several minutes, and then turn
it off.
2. Place the motorcycle on its side
stand, then place an oil pan under
the oil tank and another under the
engine to collect the used oil.
3. Remove the engine oil filler cap
and the drain bolt to drain the oil
from the crankcase.
4. Remove the drain bolt to drain the
oil from the oil tank.
1. Engine oil crankcase drain bolt
2. Engine oil tank drain bolt
5. Remove the oil filter element
drain bolt to drain the oil from the
oil filter element.
6-9
MY03 04-06 ING 6-10-2005 9:24 Pagina 6-9

NOTE:
Make sure that the O-rings are proper-
ly seated.
9. Install the oil drain bolts, and then
tighten them to the specified
torques.
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Engine oil filter element drain bolt
2. Oil filter element cover bolts
NOTE:
Skip steps 6-8 if the oil filter element is
not being replaced.
6. Remove the oil filter element cov-
er by removing the bolts.
7. Remove and replace the oil filter
element and O-rings.
8. Install the oil filter element cover
by installing the bolts and the oil
filter element drain bolt, then
tightening them to the specified
torques.
1. Engine oil filter element
2. O-rings
6-10
1
2
3
4
5
6
7
8
9
10
Tightening torques:
Oil filter element cover bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil filter element drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Tightening torques:
Engine oil drain bolt (crankcase):
30 Nm (3.0 m·kgf, 22 ft·lbf)
Engine oil drain bolt (oil tank):
30 Nm (3.0 m·kgf, 22 ft·lbf)
10. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.
MY03 04-06 ING 6-10-2005 9:24 Pagina 6-10

1
2
3
4
5
6
7
8
9
10
PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element
replacement:
3.0 L (3.17 US qt) (2.64 Imp.qt)
With oil filter element replacement:
3.1 L (3.28 US qt) (2.72 Imp.qt)
ECA11620CAUTION:
In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a
higher quality than specified. In
addition, do not use oils la-
beled “ENERGY CONSERVING
II” or higher.
Make sure that no foreign ma-
terial enters the crankcase.11. Start the engine, and then let it
idle for several minutes while
checking it for oil leakage. If oil is
leaking, immediately turn the en-
gine off and check for the cause.
12. Turn the engine off, and then
check the oil level and correct it if
necessary.
ECAB0030CAUTION:
The engine oil tank must be filled in
2 steps. First, fill the engine oil tank
with 2.0 L (2.11 US qt) (1.75 Imp.qt)
of the recommended engine oil.
Then, start the engine, race it 5 or 6
times, turn it off, and then add the
remainder of the engine oil.
MY03 04-06 ING 6-10-2005 9:24 Pagina 6-11