air condition YAMAHA MT-03 2006 Owners Manual

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SAFETY INFORMATION
• Always obey the speed limit
and never travel faster than
warranted by road and traffic
conditions.
• Always signal before turning or
changing lanes. Make sure that
other motorists can see you.
The posture of the operator and
passenger is important for proper
control.
• The operator should keep both
hands on the handlebar and
both feet on the operator
footrests during operation to
maintain control of the motor-
cycle.
• The passenger should always
hold onto the operator, the seat
strap or grab bar, if equipped,
with both hands and keep
both feet on the passenger
footrests.
• Never carry a passenger un-
less he or she can firmly place
both feet on the passenger
footrests.
Never ride under the influence of
alcohol or other drugs.
This motorcycle is designed for
on-road use only. It is not suitable
for off-road use.
Protective apparel
The majority of fatalities from motorcy-
cle accidents are the result of head in-
juries. The use of a safety helmet is
the single most critical factor in the
prevention or reduction of head in-
juries.
Always wear an approved helmet.
Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.
The use of a jacket, heavy boots,
trousers, gloves, etc., is effective
in preventing or reducing abra-
sions or lacerations.
Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or
wheels and cause injury or an ac-
cident.
Never touch the engine or ex-
haust system during or after oper-
ation. They become very hot and
can cause burns. Always wear
protective clothing that covers
your legs, ankles, and feet.
A passenger should also observe
the above precautions.
Modifications
Modifications made to this motorcycle
not approved by Yamaha, or the re-
moval of original equipment, may ren-
der the motorcycle unsafe for use and
may cause severe personal injury.
Modifications may also make your mo-
torcycle illegal to use.
Loading and accessories
Adding accessories or cargo to your
motorcycle can adversely affect stabili-
ty and handling if the weight distribution
of the motorcycle is changed. To avoid
the possibility of an accident, use ex-
treme caution when adding cargo or
accessories to your motorcycle. Use
extra care when riding a motorcycle
that has added cargo or accessories.
1-2
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PRE-OPERATION CHECKS
4-1
EAU15591
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpected-
ly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage
or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough vi-
sual inspection, to check the following points before each ride.
NOTE:
Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved.
EWA11150
WARNING0
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operat-
ing the vehicle.
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PRE-OPERATION CHECKS
4-3
ITEM
Clutch
Throttle grip
Control cables
Drive chain
Wheels and tires
Brake pedal
Brake and
clutch levers
Sidestand
Chassis fastenersCHECKS
• Check operation.
• Lubricate cable if necessary.
• Check lever free play.
• Adjust if necessary.
• Make sure that operation is smooth.
• Check cable free play.
• If necessary, have Yamaha dealer adjust cable free play and lubricate
cable and grip housing.
• Make sure that operation is smooth.
• Lubricate if necessary.
• Check chain slack.
• Adjust if necessary.
• Check chain condition.
• Lubricate if necessary.
• Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary.
• Make sure that operation is smooth.
• Lubricate pedal pivoting point if necessary.
• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.
• Make sure that operation is smooth.
• Lubricate pivot if necessary.
• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.PAGE
3-10, 6-19, 6-26
6-15, 6-25
6-25
6-23, 6-24
6-16, 6-19
6-26
6-26
6-27
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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.
6-1
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17705
Periodic maintenance and lubrication chart
NOTE:
The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.
From 50000 km, repeat the maintenance intervals starting from 10000 km.
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and tech-
nical skills.
6-2
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NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUAL
CHECK
√√√√ √
√√
√√
√√
√√
√√√√√
√√√√√ √
√√√√√ √1✻
2
3
✻
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✻
7✻
• Check fuel hoses for cracks or damage.
• Check condition.
• Clean and regap.
• Replace.
• Check valve clearance.
• Adjust.
• Replace.
• Check operation.
• Adjust.
• Check operation, fluid level and vehicle for fluid
leakage.
• Replace brake pads.
• Check operation, fluid level and vehicle for fluid
leakage.
• Replace brake pads. Fuel line
Spark plug
Valves
Air filter element
Clutch
Front brake
Rear brakeWhenever worn to the limit
Whenever worn to the limit
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUAL
CHECK
√√√√ √
√√√√
√√√√ √
√√√√
√√√√
√√√√√
√√√√ √
√√√√ √
√√√√√ √8✻
9✻
10✻
11✻
12✻
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✻
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✻
• Check for cracks or damage.
• Replace.
• Check runout and for damage.
• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
• Check bearing for looseness
or damage.
• Check operation and for excessive play.
• Lubricate with lithium-soap-based grease.
• Check chain slack, alignment and condition.
• Adjust and lubricate chain with a special O-ring
chain lubricant thoroughly.
• Check bearing play and steering for roughness.
• Lubricate with lithium-soap-based grease.
• Make sure that all nuts, bolts and screws are
properly tightened.
• Check operation.
• Lubricate.
• Check operation.
Every 4 years Brake hoses
Wheels
Tires
Wheel bearings
Swingarm
Drive chain
Steering bearings
Chassis fasteners
Sidestand
Sidestand switch
Every 800 km and after washing
the motorcycle or riding in the rain
Every 20000 km
Every 50000 km
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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
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PERIODIC MAINTENANCE AND MINOR REPAIR
Adjust the suspension and tire
air pressure with regard to the
load.
Check the tire condition and air
pressure before each ride.Tire inspection
1. Tire sidewall
2. Tire tread depth
The tires must be checked before
each ride. If the center tread depth
reaches the specified limit, if the tire
has a nail or glass fragments in it, or if
the sidewall is cracked, have a Yama-
ha dealer replace the tire immediately.
NOTE:
The tire tread depth limits may differ
from country to country. Always com-
ply with the local regulations.
EWA10470
WARNING0
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the ve-
hicle with excessively worn
tires decreases riding stability
and can lead to loss of control.
The replacement of all wheel
and brake related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.
6-17
Minimum tire tread depth
(front and rear):
1.6 mm (0.06 in)
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PERIODIC MAINTENANCE AND MINOR REPAIR
EWA10600
WARNING0
This motorcycle is fitted with super-
high-speed tires. Note the following
points in order to make the most ef-
ficient use of these tires.
Use only the specified replace-
ment tires. Other tires may run
the danger of bursting at super
high speeds.
Brand-new tires can have a rel-
atively poor grip on certain
road surfaces until they have
been "broken in". Therefore, it
is advisable before doing any
high-speed riding to ride con-
servatively for approximately
100 km (60 mi) after installing a
new tire.
The tires must be warmed up
before a high-speed run.
Always adjust the tire air pres-
sure according to the operating
conditions.
EAU21960
Cast wheels
To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points regard-
ing the specified wheels.
The wheel rims should be
checked for cracks, bends or
warpage before each ride. If any
damage is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair
to the wheel. A deformed or
cracked wheel must be replaced.
The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced.
An unbalanced wheel can result
in poor performance, adverse
handling characteristics, and a
shortened tire life.
Ride at moderate speeds after
changing a tire since the tire sur-
face must first be "broken in" for it
to develop its optimal characteris-
tics.
EAU22041
Adjusting the clutch lever
free play
1. Locknut
2. Adjusting bolt
3. Clutch lever free play
The clutch lever free play should mea-
sure 10.0-15.0 mm (0.39-0.59 in) as
shown. Periodically check the clutch
lever free play and, if necessary, ad-
just it as follows.
1. Loosen the locknut at the clutch
lever.
2. To increase the clutch lever free
play, turn the adjusting bolt in di-
rection (a). To decrease the clutch
lever free play, turn the adjusting
bolt in direction (b).
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
ECA11110CAUTION:
Do not use engine oil or any other
lubricants for the drive chain, as
they may contain substances that
could damage the O-rings.
EAU23100
Checking and lubricating
the cables
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubri-
cated if necessary. If a cable is dam-
aged or does not move smoothly,
have a Yamaha dealer check or re-
place it.
Recommended lubricant:
Engine oil
EWA10720
WARNING0
Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions.
EAU23111
Checking and lubricating
the throttle grip and cable
The operation of the throttle grip
should be checked before each ride.
In addition, the cable should be lubri-
cated at the intervals specified in the
periodic maintenance chart.
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