tires 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
MY03 01-03 ING 6-10-2005 13:52 Pagina 6

1
2
3
4
5
6
7
8
9
10
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
–
MY03 04-06 ING 6-10-2005 9:24 Pagina 3

1
2
3
4
5
6
7
8
9
10
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✻
13
14
✻
15✻
16
17
✻
• 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
MY03 04-06 ING 6-10-2005 9:24 Pagina 6-3

PERIODIC MAINTENANCE AND MINOR REPAIR
EAU21660
Tires
To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points regard-
ing the specified tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
EWA10500
WARNING0
The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the tempera-
ture of the tires equals the am-
bient temperature).
The tire air pressure must be
adjusted in accordance with
the riding speed and with the
total weight of rider, passenger,
cargo, and accessories ap-
proved for this model.
EWA11020
WARNING0
Because loading has an enormous
impact on the handling, braking,
performance and safety character-
istics of your motorcycle, you
should keep the following precau-
tions in mind.
NEVER OVERLOAD THE MO-
TORCYCLE! Operation of an
overloaded motorcycle may re-
sult in tire damage, loss of con-
trol, or severe injury. Make sure
that the total weight of rider,
passenger, cargo, and acces-
sories does not exceed the
specified maximum load for the
vehicle.
Do not carry along loosely
packed items, which can shift
during a ride.
Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.
6-16
1
2
3
4
5
6
7
8
9
10
Tire air pressure
(measured on cold tires):
Up to 90 kg (198 lb):
Front:
210 kPa (30 psi) (2.1 kgf/cm
2)
Rear:
230 kPa (33 psi) (2.3 kgf/cm
2)
90 kg (198 lb) to maximum load:
Front:
230 kPa (33 psi) (2.3 kgf/cm
2)
Rear:
250 kPa (36 psi) (2.5 kgf/cm
2)
High-speed riding:
Front:
210 kPa (30 psi) (2.1 kgf/cm
2)
Rear:
230 kPa (33 psi) (2.3 kgf/cm
2)
Maximum load*:
186 kg (410 lb)
* Total weight of rider, passenger,
cargo and accessories
MY03 04-06 ING 6-10-2005 9:25 Pagina 6-16

1
2
3
4
5
6
7
8
9
10
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)
MY03 04-06 ING 6-10-2005 9:25 Pagina 6-17

PERIODIC MAINTENANCE AND MINOR REPAIR
Tire information
1. Tire air valve
2. Valve core
3. Valve cap
This motorcycle is equipped with cast
wheels and tubeless tires with valves.
EWA10900
WARNING0
The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the motorcy-
cle cannot be guaranteed.
After extensive tests, only the
tires listed below have been
approved for this model by
Yamaha Motor Italia S.P.A.
Always make sure that the
valve caps are securely in-
stalled to prevent air pressure
leakage.
Use only the tire valves and
valve cores listed below to
avoid tire deflation during a
ride.
6-18
1
2
3
4
5
6
7
8
9
10
Front tire:
Size:
120/70-ZR17 M/C (58W)
120/70-R17 M/C (58H)
Manufacturer/model:
DUNLOP D270F
PIRELLI SCORPION SYNC
Tire air valve:
TR412
Valve core:
#9000A (standard)
Rear tire:
Size:
160/60-ZR17 M/C (69W)
160/60-R17 M/C (69H)
Manufacturer/model:
DUNLOP D270
PIRELLI SCORPION SYNC
Tire air valve:
TR412
Valve core:
#9000A (standard)
MY03 04-06 ING 6-10-2005 9:25 Pagina 6-18

1
2
3
4
5
6
7
8
9
10
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).
6-19
MY03 04-06 ING 6-10-2005 9:25 Pagina 6-19

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

1
2
3
4
5
6
7
8
9
10
SPECIFICATIONS
8-2
Operation:
Left foot operation
Gear ratio:
1
st:
30/12 (2.500)
2
nd:
26/16 (1.625)
3
rd:
23/20 (1.150)
4
th:
20/22 (0.909)
5
th:
20/26 (0.769)
Chassis:
Frame type:
Truss diamond
Caster angle:
26°
Trail:
97.0 mm (3.81 in)
Front tire:
Type:
Tubeless
Size:
120/70-ZR17M/C (58W),
120/70-R17M/C (58H)
Manufacturer/model:
DUNLOP D270F
PIRELLI SCORPION SYNC
Rear tire:
Type:
Tubeless
Size:
160/60-ZR17M/C (69W),
160/60-R17M/C (69H)Manufacturer/model:
DUNLOP D270
PIRELLI SCORPION SYNC
Load:
Maximum load:
186 kg (410 lb)
(Total weight of rider, passenger, cargo
and accessories)
Tire air pressure
(measured on cold tires):
Load:
Up to 90 kg (0-198 lb)
Front:
210 kPa (30 psi) (2.1 kgf/cm
3)
Rear:
230 kPa (33 psi) (2.3 kgf/cm
3)
Load:
90-186 kg (198-410 lb)
Front:
230 kPa (33 psi) (2.3 kgf/cm
3)
Rear:
250 kPa (36 psi) (2.5 kgf/cm
3)
High-speed riding:
Front:
210 kPa (30 psi) (2.1 kgf/cm
3)
Rear:
230 kPa (33 psi) (2.3 kgf/cm
3)
Front wheel:
Type:
Cast wheel
Rim size:
17M/C x MT3.50
Rear wheel:
Type:
Cast wheel
Rim size:
17M/C x MT5.00
Front brake:
Type:
Dual disc brake
Operation:
Right hand
Fluid:
DOT 4
Rear brake:
Type:
Single disc brake
Operation:
Right foot
Fluid:
DOT 4
Front suspension:
Type:
Telescopic fork
Spring/damper type:
Coil spring/oil damper
Wheel travel:
130 mm (5.12 in)
Rear suspension:
Type:
Swingarm
Spring/damper type:
Coil spring/gas-oil damper,
spring preload adjustable
Wheel travel:
120.0 mm (4.72 in)
MY03 07-10 ING 5-10-2005 17:09 Pagina 7