fuel YAMAHA MT-03 2012 User Guide

PRE-OPERATION CHECKS
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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

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 “ ”.
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.
OPERATION AND IMPORTANT RIDING POINTS
5-1
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OPERATION AND IMPORTANT RIDING POINTS
ECA10260CAUTION:
●Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long
distances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.
●Always use the clutch while
changing gears to avoid dam-
aging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
EAU16810
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the follow-
ing tips to reduce fuel consumption:
●Shift up swiftly, and avoid high en-
gine speeds during acceleration.
●Do not rev the engine while shift-
ing down, and avoid high engine
speeds with no load on the en-
gine.
●Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at traf-
fic lights or at railroad crossings).
EAU16841
Engine break-in
There is never a more important peri-
od in the life of your engine than the
period between 0 and 1600 km (1000
mi). For this reason, you should read
the following material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts
in the engine wear and polish them-
selves to the correct operating clear-
ances. During this period, prolonged
full-throttle operation or any condition
that might result in engine overheating
must be avoided.
5-3

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.
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NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUAL
CHECK
√√√√ √
√√
√√
√√
√√
√√√√√
√√√√√ √
√√√√√ √1✻
2
3
✻
4
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6
✻
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

PERIODIC MAINTENANCE AND MINOR REPAIR
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• 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
√√√√
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√√√√
√√
√√√√√ √
√√√√√ √
√√√
√√√√ √
√√√√√ √
√√√√ √
√√√√ √18✻
19✻
20✻
21✻
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✻
25✻
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27
✻
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUAL
CHECK
Every 3 years

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-56-5
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUAL
CHECK
• Check the air cut-off valve, reed valve, and hose
for damage.
• Check fuel hoses for cracks or damage.
• Check the screw clamp for looseness.
• Check operation.
• Adjust headlight beam. Air induction system
Muffler and exhaust
pipe
Lights, signals and
switches 28
✻
29✻
30✻
EAU18670
NOTE:
●The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
●Hydraulic brake service
●Regularly check and, if necessary, correct the brake fluid level.
●Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.
●Replace the brake hoses every four years and if cracked or damaged.√√√√ √
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PERIODIC MAINTENANCE AND MINOR REPAIR
Check the engine idling speed and, if
necessary, adjust it to specification by
turning the idle adjusting screw. To in-
crease the engine idling speed, turn
the screw in direction (a). To decrease
the engine idling speed, turn the screw
in direction (b).
NOTE:
If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment.
EAU21381
Checking the throttle cable
free play
1. Throttle cable free play
The throttle cable free play should
measure 3.0-5.0 mm (0.12-0.20 in) at
the throttle grip. Periodically check the
throttle cable free play and, if neces-
sary, have a Yamaha dealer adjust it.
6-15
Engine idling speed:
1300-1500 r/min
1400-1600 r/min (EU3 version)
EAU21401
Valve clearance
The valve clearance changes with
use, resulting in improper air-fuel mix-
ture and/or engine noise. To prevent
this from occurring, the valve clear-
ance must be adjusted by a Yamaha
dealer at the intervals specified in the
periodic maintenance and lubrication
chart.

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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)

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.
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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.
6-32
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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