YAMAHA MT-03 2006 Manual PDF

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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23200
Checking and lubricating
the sidestand
The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated
if necessary.
EWA10730
WARNING0
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it.
EAUB1240
Lubricating the side
suspension
The pivoting points of the side suspen-
sion must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Swingarm pivots:
Bearing grease
Other pivoting points:
Lithium-soap-based grease
EAU23271
Checking the front fork
The condition and operation of the
front fork must be checked as follows
at the intervals specified in the period-
ic maintenance and lubrication chart.
To check the condition
EWA10750
WARNING0
Securely support the motorcycle so
that there is no danger of it falling
over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
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PERIODIC MAINTENANCE AND MINOR REPAIR
ECA10590CAUTION:
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU23280
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the opera-
tion of the steering must be checked
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
6-28
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EWA10750
WARNING0
Securely support the motorcycle so
that there is no danger of it falling
over.
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23290
Checking the wheel bearings
The front and rear wheel bearings
must be checked at the intervals spec-
ified in the periodic maintenance and
lubrication chart. If there is play in the
wheel hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.
EAUB1270
Battery
This model is equipped with a sealed-
type (MF) battery, which does not re-
quire any maintenance. There is no
need to check the electrolyte or to add
distilled water.
ECA10620CAUTION:
Never attempt to remove the bat-
tery cell seals, as this would perma-
nently damage the battery.
To access the battery
1. Remove the passenger seat and
rider seat. (See page 3-14.)
2. Remove panels A and B. (See
page 6-6.)
6-29
1. Fuel tank rear bolt
1. Fuel tank front bolt (RH)
2. Fuel tank front bolt (LH)
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PERIODIC MAINTENANCE AND MINOR REPAIR
1. Fuel tank couplers
2. Fuel hose
3. Fuel tank breather/overflow hoses
4. Clamps
3. Remove the fuel tank, by remov-
ing the bolt and the washer at the
rear of the fuel tank, and the two
bolts at the front of the fuel tank.
4. Remove the clamp shown, and
then remove the fuel hoses.
5. Remove the fuel tank by pulling it
upward.
6. Remove the battery cover by
pulling it upward.
1. Positive battery terminal
2. Negative battery terminal
To charge the battery
Have a Yamaha dealer charge the bat-
tery as soon as possible if it seems to
have discharged. Keep in mind that
the battery tends to discharge more
quickly if the vehicle is equipped with
optional electrical accessories.
EWA10760
WARNING0
Electrolyte is poisonous and
dangerous since it contains
sulfuric acid, which causes se-
vere burns. Avoid any contact
with skin, eyes or clothing and
always shield your eyes when
working near batteries. In case
of contact, administer the fol-
lowing FIRST AID.
•EXTERNAL: Flush with plenty
of water.
•INTERNAL: Drink large quan-
tities of water or milk and im-
mediately call a physician.
•EYES: Flush with water for 15
minutes and seek prompt
medical attention.
Batteries produce explosive hy-
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro-
vide sufficient ventilation when
charging it in an enclosed space.
KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
6-30
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PERIODIC MAINTENANCE AND MINOR REPAIR
To store the battery
1. If the vehicle will not be used for
more than one month, remove the
battery, fully charge it, and then
place it in a cool, dry place.
2. If the battery will be stored for
more than two months, check it at
least once a month and fully
charge it if necessary.
3. Fully charge the battery before in-
stallation.
4. After installation, make sure that
the battery leads are properly
connected to the battery termi-
nals.ECA10630CAUTION:
Always keep the battery
charged. Storing a discharged
battery can cause permanent
battery damage.
To charge a sealed-type (MF)
battery, a special (constant-
voltage) battery charger is re-
quired. Using a conventional
battery charger will damage
the battery. If you do not have
access to a sealed-type (MF)
battery charger, have a Yamaha
dealer charge your battery.
EAUB1260
Replacing the fuses
1. Main fuse
2. Reserve fuse
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PERIODIC MAINTENANCE AND MINOR REPAIR
1. Parking lighting fuse
2. Signaling system fuse
3. Headlight fuse
4. Ignition fuse
5. Electronic fuel injection fuse
6. Radiator fan fuse
7. Backup fuse
8. Reserve fuses
The main fuse is located under the fu-
el tank. (See page 6-31.)
The fuse box which contains the fuses
for the individual circuits is located un-
der the rider seat. (See page 3-15.)
If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off
the electrical circuit in question.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
ECA10640CAUTION:
Do not use a fuse of a higher am-
perage rating than recommended
to avoid causing extensive damage
to the electrical system and possi-
bly a fire.
3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
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Specified fuses:
Main fuse:
30 A
Fuse box:
Parking lighting fuse:
10 A
Signaling system fuse:
10 A
Headlight fuse:
20 A
Ignition fuse:
10 A
Electronic fuel injection fuse:
10 A
Radiator fan fuse:
7.5 A
Fuel injection system fuse:
10 A
Backup fuse (for odometer,
clock and immobilizer):
10 A
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAUB1360
Replacing the headlight bulb
1. Headlight coupler
2. Headlight bulb cover
1. Headlight bulb holder
2. Headlight bulb
This model is equipped with a quartz
bulb headlight. If the headlight bulb
burns out, replace it as follows.
1. Turn the handlebar to the left side
to access the headlight coupler.
2. Disconnect the headlight coupler,
and then remove the bulb cover.
3. Unhook the headlight bulb holder,
and then remove the defective
bulb.
EWA10790
WARNING0
Headlight bulbs get very hot. There-
fore, keep flammable products
away from a lit headlight bulb, and
do not touch the bulb until it has
cooled down.
4. Place a new headlight bulb into
position, and then secure it with
the bulb holder.
1. Do not touch this areaECA10650CAUTION:
Take care not to damage the fol-
lowing parts:
Headlight bulb
•Do not touch the glass part
of the headlight bulb to keep
it free from oil, otherwise the
transparency of the glass,
the luminosity of the bulb,
and the bulb life will be ad-
versely affected. Thoroughly
clean off any dirt and finger-
prints on the headlight bulb
using a cloth moistened with
alcohol or thinner.
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PERIODIC MAINTENANCE AND MINOR REPAIR
Headlight lens
•Do not affix any type of tinted
film or stickers to the head-
light lens.
•Do not use a headlight bulb
of a wattage higher than
specified.
5. Install the headlight bulb cover,
and then connect the coupler.
6. Have a Yamaha dealer adjust the
headlight beam if necessary.
EAUB1380
Replacing an auxiliary
light bulb
1. Auxiliary light socket
2. Auxiliary light bulb
If the auxiliary light bulb burns out, re-
place it as follows.
1. Turn the handlebar to the right or
left side to access the auxiliary
light socket.
2. Remove the auxiliary light socket
(together with the bulb) by pulling it.
3. Remove the defective bulb by
pulling it out.
4. Insert a new bulb into the socket.
5. Install the auxiliary light socket
(together with the bulb) by push-
ing it in.
EAUB1370
Replacing the tail/brake
light bulb
1. Tail/brake light bulb cover
2. Cover bolts
1. Tail/brake light socket
2. Tail/brake light bulb
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PERIODIC MAINTENANCE AND MINOR REPAIR
1. Remove the tail/brake light bulb
cover by removing the bolts.
2. Remove the socket (together with
the bulb) by turning it counter-
clockwise.
3. Remove the defective bulb by
pushing it in and turning it coun-
terclockwise.
4. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
5. Install the socket (together with
the bulb) by turning it clockwise.
6. Place the tail/brake light bulb
cover in its original position, insert
the bolts and then tighten them to
the specified torque.EAU24202
Replacing a turn signal
light bulb
1. Screw
2. Turn signal light lens
3. Turn signal light bulb
1. Remove the turn signal light lens
by removing the screw.
2. Remove the defective bulb by
pushing it in and turning it coun-
terclockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screw.
ECA11190CAUTION:
Do not overtighten the screw, oth-
erwise the lens may break.
6-35
Tightening torque:
Tail/brake light bulb cover bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
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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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