YAMAHA MT-03 2006 Manual Online

1
2
3
4
5
6
7
8
9
10
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.
MY03 04-06 ING 6-10-2005 9:26 Pagina 6-37

PERIODIC MAINTENANCE AND MINOR REPAIR
6-38
1
2
3
4
5
6
7
8
9
10
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.
MY03 04-06 ING 6-10-2005 9:26 Pagina 6-38

1
2
3
4
5
6
7
8
9
10
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

PERIODIC MAINTENANCE AND MINOR REPAIR
1
2
3
4
5
6
7
8
9
10
EAU25921Troubleshooting charts
Starting problems or poor engine performance
WARNING0
Keep away open flames and do not smoke while checking or working on the fuel system.
1. Fuel
2. Compression
3. Ignition
4. Battery
Check the fuel level in the
fuel tank.
Operate the electric
starter.
Remove the spark plug
and check the electrodes.
Operate the electric
starter.
There is enough
fuel.
There is
compression.
Wet.
The engine turns
over quickly.
There is no fuel.
There is no
compression.
Dry.
The engine turns
over slowly.
Check the
compression.
Check the ignition.
Wipe off with a dry cloth and correct
the spark plug gap, or replace the
spark plug.
The battery is good.
Have a Yamaha dealer check the
vehicle.
Check the battery lead connections,
and charge the battery if necessary.
Open the throttle halfway and
operate the electric starter.
The engine does not start.
Check the battery.
The engine does
not start. Have a
Yamaha dealer
check the vehicle.
Supply fuel.
Have a Yamaha dealer check
the vehicle.
The engine does not start.
Check the compression.
6-40
MY03 04-06 ING 6-10-2005 9:26 Pagina 6-40

1
2
3
4
5
6
7
8
9
10
PERIODIC MAINTENANCE AND MINOR REPAIR
6-41
Engine overheatingEWA10400
WARNING0
Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hiss-
ing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended
coolant as soon as possible.
Wait until the
engine has cooled.Check the coolant level
in the reservoir and radiator.
The coolant level is low.
Check the cooling
system for leakage.
The coolant level
is OK.
There is
leakage.
There is no
leakage.
Have a Yamaha dealer check
and repair the cooling system.
Start the engine. If the engine overheats again, have
a Yamaha dealer check and repair the cooling system.
Add coolant. (See NOTE.)
MY03 04-06 ING 3-11-2005 10:01 Pagina 6-41

MOTORCYCLE CARE AND STORAGE
7-1
1
2
3
4
5
6
7
8
9
10
EAU26000
Care
While the open design of a motorcycle
reveals the attractiveness of the tech-
nology, it also makes it more vulnera-
ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go un-
noticed on a car, however, it detracts
from the overall appearance of a mo-
torcycle. Frequent and proper care
does not only comply with the terms of
the warranty, but it will also keep your
motorcycle looking good, extend its
life and optimize its performance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and cov-
ers as well as all electrical cou-
plers and connectors, including
the spark plug cap, are tightly in-
stalled.3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-
ucts onto seals, gaskets, sprock-
ets, the drive chain and wheel
axles. Always rinse the dirt and
degreaser off with water.
Cleaning
ECA10770CAUTION:
Avoid using strong acidic
wheel cleaners, especially on
spoked wheels. If such prod-
ucts are used on hard-to-re-
move dirt, do not leave the
cleaner on the affected area
any longer than instructed. Al-
so, thoroughly rinse the area
off with water, immediately dry
it, and then apply a corrosion
protection spray.
Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use on-
ly a soft, clean cloth or sponge
with mild detergent and water
to clean plastic.
Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.
Do not use high-pressure
washers or steam-jet cleaners
since they cause water seep-
age and deterioration in the fol-
lowing areas: seals (of wheel
and swingarm bearings, fork
and brakes), electric compo-
nents (couplers, connectors,
instruments, switches and
lights), breather hoses and
vents.
MY03 07-10 ING 5-10-2005 17:09 Pagina 2

1
2
3
4
5
6
7
8
9
10
MOTORCYCLE CARE AND STORAGE
7-2
For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the wind-
shield. Test the product on a
small hidden part of the wind-
shield to make sure that it does
not leave any marks. If the
windshield is scratched, use a
quality plastic polishing com-
pound after washing.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.After riding in the rain, near the sea
or on salt-sprayed roads
Since sea salt or salt sprayed on
roads during winter are extremely cor-
rosive in combination with water, carry
out the following steps after each ride
in the rain, near the sea or on salt-
sprayed roads.
NOTE:
Salt sprayed on roads in the winter
may remain well into spring.
1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.
ECA10790CAUTION:
Do not use warm water since it in-
creases the corrosive action of the
salt.
2. Apply a corrosion protection
spray on all metal, including
chrome- and nickel-plated, sur-
faces to prevent corrosion.After cleaning
1. Dry the motorcycle with a
chamois or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally in-
duced discoloring of stainless-
steel exhaust systems can be re-
moved through polishing.)
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal, includ-
ing chrome- and nickel-plated,
surfaces.
5. Use spray oil as a universal
cleaner to remove any remaining
dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely
before storing or covering it.
MY03 07-10 ING 5-10-2005 17:09 Pagina 3

MOTORCYCLE CARE AND STORAGE
7-3
1
2
3
4
5
6
7
8
9
10
EWA10930
WARNING0
Make sure that there is no oil or
wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or
acetone, and wash the tires
with warm water and a mild de-
tergent.
Before operating the motorcy-
cle test its braking perfor-
mance and cornering behavior.
ECA10800CAUTION:
Apply spray oil and wax spar-
ingly and make sure to wipe off
any excess
Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
Avoid using abrasive polishing
compounds as they will wear
away the paint.
NOTE:
Consult a Yamaha dealer for advice
on what products to use.
EAUM1900
Storage
Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
ECA10810CAUTION:
Storing the motorcycle in a
poorly ventilated room or cov-
ering it with a tarp, while it is
still wet, will allow water and
humidity to seep in and cause
rust.
To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.
MY03 07-10 ING 5-10-2005 17:09 Pagina 4

1
2
3
4
5
6
7
8
9
10
MOTORCYCLE CARE AND STORAGE
7-4
Long-term
Before storing your motorcycle for
several months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
3. Perform the following steps to
protect the cylinder, piston rings,
etc. from corrosion.
a. Remove the spark plug cap
and spark plug.
b. Pour a teaspoonful of engine
oil into the spark plug bore.
c. Install the spark plug cap onto
the spark plug, and then place
the spark plug on the cylinder
head so that the electrodes
are grounded. (This will limit
sparking during the next
step.)
d. Turn the engine over several
times with the starter. (This
will coat the cylinder wall with
oil.)e. Remove the spark plug cap
from the spark plug, and then
install the spark plug and the
spark plug cap.
EWA10950
WARNING0
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.
4. Lubricate all control cables and
the pivoting points of all levers
and pedals as well as of the side-
stand/centerstand.
5. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alter-
natively, turn the wheels a little
every month in order to prevent
the tires from becoming degraded
in one spot.
6. Cover the muffler outlets with
plastic bags to prevent moisture
from entering them.
7. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex-
cessively cold or warm place [less
than 0 °C (30 °F) or more than 30
°C (90 °F)]. For more information
on storing the battery, see
page 6-31.
NOTE:
Make any necessary repairs before
storing the motorcycle.
MY03 07-10 ING 5-10-2005 17:09 Pagina 5

SPECIFICATIONS
8-1
1
2
3
4
5
6
7
8
9
10
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