coolant level YAMAHA MT-03 2006 Owners Manual

TABLE OF CONTENTS
SAFETY INFORMATION.....................1-1
Safe riding .........................................1-1
Protective apparel .............................1-2
Modifications .....................................1-2
Loading and accessories ..................1-2
Gasoline and exhaust gas ................1-4
DESCRIPTION.....................................2-1
Left view ............................................2-1
Right view .........................................2-2
Controls and instruments ..................2-3
INSTRUMENT AND CONTROL
FUNCTIONS........................................3-1
Immobilizer system ...........................3-1
Main switch/steering lock ..................3-2
Indicator and warning lights ..............3-3
Multi-function meter unit ...................3-5
Tachometer .......................................3-6
Odometer, tripmeter modes ..............3-6
Clock mode .......................................3-7
Self-diagnosis devices ......................3-7
Indicator lights brightness
control mode ..............................3-8
Anti-theft alarm (optional) .................3-8
Handlebar switches...........................3-9
Clutch lever .....................................3-10
Shift pedal .......................................3-10
Brake lever ......................................3-11Brake pedal .....................................3-11
Fuel tank cap...................................3-11
Fuel .................................................3-12
Fuel tank breather/overflow hose ...3-13
Catalytic converter ..........................3-13
Seats ...............................................3-14
Adjusting the shock absorber
assembly ..................................3-16
Sidestand ........................................3-18
Ignition circuit cut-off system ..........3-19
PRE-OPERATION CHECKS...............4-1
Pre-operation check list ....................4-2
OPERATION AND IMPORTANT
RIDING POINTS..................................5-1
Starting the engine ............................5-1
Shifting ..............................................5-2
Tips for reducing fuel consumption ...5-3
Engine break-in .................................5-3
Parking ..............................................5-4
PERIODIC MAINTENANCE
AND MINOR REPAIR.........................6-1
Owner’s tool kit .................................6-1
Periodic maintenance and
lubrication chart ..........................6-2
Removing and installing panels ........6-6
Checking the spark plug ...................6-6Engine oil and oil filter element.........6-8
Coolant ............................................6-12
Replacing the air filter element
and cleaning the check hoses ...6-13
Adjusting the engine idling speed ...6-14
Checking the throttle cable
free play ...................................6-15
Valve clearance...............................6-15
Tires ................................................6-16
Cast wheels ....................................6-19
Adjusting the clutch lever
free play ...................................6-19
Checking the front and rear
brake pads ...............................6-20
Checking the brake fluid level .........6-21
Changing the brake fluid .................6-22
Drive chain slack .............................6-23
Cleaning and lubricating the
drive chain ................................6-24
Checking and lubricating the
cables .......................................6-25
Checking and lubricating the
throttle grip and cable ..............6-25
Checking and lubricating the
brake and clutch levers ............6-26
Lubricating the brake pedal ............6-26
Checking and lubricating the
sidestand ..................................6-27
Lubricating the side suspension .....6-27
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INSTRUMENT AND CONTROL FUNCTIONS
3-3
To unlock the steering
1. Push
2. Turn
Push the key in, and then turn it to
“OFF” while still pushing it.
EWA10060
WARNING0
Never turn the key to “OFF” or
“LOCK” while the vehicle is moving,
otherwise the electrical systems
will be switched off, which may re-
sult in loss of control or an acci-
dent. Make sure that the vehicle is
stopped before turning the key to
“OFF” or “LOCK”.
EAU10941
F(Parking)
The steering is locked, and the tail-
light, license plate light and auxiliary
lights are on. The hazard lights and
turn signal lights can be turned on, but
all other electrical systems are off. The
key can be removed.
The steering must be locked before
the key can be turned to “F”.
ECA11020CAUTION:
Do not use the parking position for
an extended length of time, other-
wise the battery may discharge.
EAU11003
Indicator and warning lights
1. Immobilizer system indicator light “ ”
2. Neutral indicator light “N”
3. Turn signal indicator light “y”
4. High beam indicator light “1”
5. Engine trouble warning light “U”
6. Coolant temperature warning light “u”
7. Fuel level warning light “K”
EAU26873
Immobilizer system indicator
light “ ”
The electrical circuit of the indicator
light can be checked by turning the
key to “ON”.
If the indicator light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical
circuit.
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INSTRUMENT AND CONTROL FUNCTIONS
3-4
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When the key is turned to “OFF” and
30 seconds have passed, the indicator
light will start flashing indicating the
immobilizer system is enabled. After
24 hours have passed, the indicator
light will stop flashing, however the im-
mobilizer system is still enabled.
This model is also equipped with a
self-diagnosis device for the immobi-
lizer system. (See page 3-7 for an ex-
planation of the self-diagnosis device.)
EAU11060
Neutral indicator light “N”
This indicator light comes on when the
transmission is in the neutral position.
EAU11020
Turn signal indicator light “y”
This indicator light flashes when the
turn signal switch is pushed to the left
or right.
EAU11080
High beam indicator light “1”
This indicator light comes on when the
high beam of the headlight is switched
on.
EWA10060
WARNING0
Never turn the key to “OFF” or
“LOCK” while the vehicle is moving,
otherwise the electrical systems
will be switched off, which may re-
sult in loss of control or an acci-
dent. Make sure that the vehicle is
stopped before turning the key to
“OFF” or “LOCK”.
EAU11530
Engine trouble warning light “U”
This warning light comes on or flashes
when an electrical circuit monitoring
the engine is defective. When this oc-
curs, have a Yamaha dealer check the
self-diagnosis system. (See page 3-7
for an explanation of the self-diagno-
sis device.)
The electrical circuit of the warning
light can be checked by turning the
key to “ON”. If the warning light does
not come on for a few seconds, then
go off, have a Yamaha dealer check
the electrical circuit.
EAU11440
Coolant temperature warning
light “u”
This warning light comes on when the
engine overheats. When this occurs,
stop the engine immediately and allow
the engine to cool.
The electrical circuit of the warning
light can be checked by turning the
key to “ON”.
If the warning light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical
circuit.
ECA10020
CAUTION:
Do not operate the engine if it is
overheated.
EAU11361
Fuel level warning light “K”
This warning light comes on when the
fuel level drops below approximately
4.25 L (1.12 US gal) (0.93 Imp.gal).
When this occurs, refuel as soon as
possible.
MY03 01-03 ING 6-10-2005 13:52 Pagina 3-4

PRE-OPERATION CHECKS
4-2
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ITEM
Fuel
Engine oil
Coolant
Front brake
Rear brake
EAU15603
Pre-operation check list
CHECKS
• Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.
• Check oil level in oil tank.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage.
• Check coolant level in reservoir.
• If necessary, add recommended coolant to specified level.
• Check cooling system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.PAGE
3-12
6-8
6-12
3-11, 6-20, 6-21, 6-26
3-11, 6-20, 6-21, 6-26
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OPERATION AND IMPORTANT RIDING POINTS
EAU15950
EWA10270
WARNING0
Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.
Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
EAUB1340
Starting the engine
In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
The transmission is in the neutral
position.
The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EWA10290
WARNING0
Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure de-
scribed on page 3-20.
Never ride with the sidestand
down.
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “
I”.
ECAB0040CAUTION:
The following warning lights and in-
dicator lights should come on for a
few seconds, then go off.
Neutral indicator light
Turn signal indicator light
High beam indicator light
Engine trouble warning light
Coolant temperature warning
light
Fuel level warning light
Immobilizer system indicator
light
If a warning or indicator light does
not go off, see page 3-3 for the cor-
responding warning and indicator
light circuit check.
2. Shift the transmission into the
neutral position.
5-1
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
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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
EAU20070
Coolant
The coolant level should be checked
before each ride. In addition, the
coolant must be changed at the inter-
vals specified in the periodic mainte-
nance and lubrication chart.
EAU20090
To check the coolant level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
NOTE:
The coolant level must be
checked on a cold engine since
the level varies with engine tem-
perature.
Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.
2. Check the coolant level in the
coolant reservoir.
NOTE:
The coolant should be between the
minimum and maximum level marks.
1. Coolant reservoir
2. Maximum level mark
3. Minimum level mark
4. Reservoir cap
3. If the coolant is at or below the
minimum level mark, open the
reservoir cap, add coolant to the
maximum level mark, and then
close the reservoir cap.
ECA10470CAUTION:
If coolant is not available, use
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.
If water has been used instead
of coolant, replace it with
coolant as soon as possible,
otherwise the engine may not
be sufficiently cooled and the
cooling system will not be pro-
tected against frost and corro-
sion.
If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possi-
ble, otherwise the effective-
ness of the coolant will be re-
duced.
6-12
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Coolant reservoir capacity:
0.25 L (0.26 US qt) (0.22 Imp.qt)
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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

SPECIFICATIONS
8-1
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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

SPECIFICATIONS
8-3
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Electrical system:
Ignition system:
Transistorized coil ignition (digital)
Charging system:
A.C. magneto
Battery:
Model:
GT9B-4
Voltage, capacity:
12 V, 8 Ah
Headlight:
Bulb type:
Halogen bulb
Bulb voltage, wattage x quantity:
Headlight:
12 V, 55 W/60 W x 1
Auxiliary light:
12 V, 3 W x 1
Tail/brake light:
12 V, 5 W/21 W x 1
Front turn signal light:
12 V, 10 W x 2
Rear turn signal light:
12 V, 10 W x 2
Meter lighting:
LED (backlight)
Neutral indicator light:
LED
Turn signal indicator light:
LED
High beam indicator light:
LED
Fuel level warning light:
LEDCoolant temperature warning light:
LED
Engine trouble warning light:
LED
Immobilizer system indicator light:
LED
Fuses:Main fuse:
30 A
Headlight fuse:
20 A
Signaling system fuse:
10 A
Ignition fuse:
10 A
Parking lighting fuse:
10 A
Radiator fan fuse:
7.5 A
Fuel injection system fuse:
10 A
Backup fuse (for odometer, clock and
immobilizer):
10 A
MY03 07-10 ING 5-10-2005 17:09 Pagina 8