YAMAHA MT-03 2016 Service Manual

For your safety – pre-operation checks
4-3
4
Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary. —
Instruments, li ghts, si gnals
an d switches • Check operation.
• Correct if necessary.
—
Si destan d switch • Check operation of ignition circuit cut-off system.
• If system is not working correctly, have Yamaha dealer check vehicle. 3-21
ITEM CHECKS PAGE
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Operation and important rid ing points
5-1
5
EAU15952
Read the Owner’s Manual carefully to
become familiar with all controls. If
there is a control or function you do not
understand, ask your Yamaha dealer.
WARNING
EWA10272
Failure to familiarize yourself with
the controls can lead to loss of con-
trol, which coul d cause an acci dent
or injury.
EAU62513
TIPThis model is equipped with:  a lean angle sensor to stop the en-
gine in case of a turnover. In this
case, the display will indicate error
code 30, but this is not a malfunc-
tion. Turn the key to “ ” and then
to “ ” to clear the error code.
Failing to do so will prevent the en-
gine from starting even though the
engine will crank when pushing
the start switch.
 an engine auto-stop system. The
engine stops automatically if left
idling for 20 minutes. If the engine
stops, simply push the start
switch to restart the engine.
EAU67610
Startin g the en gineIn 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.
See page 3-22 for more informa-
tion.
1. Turn the key to “ ” and make sure that the engine stop switch is
set to “ ”.
The engine trouble warning light
should come on for a few sec-
onds, then go off. NOTICE: If the
warnin g lig ht does not go off,
have a Yamaha dealer check its
electrical circuit.
[ECAT1121]
The ABS warning light should
come on when the main switch is
turned to “ON” and then go off af-
ter traveling at a speed 10 km/h (6
mi/h) or higher.
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Operation and important ri din g points
5-2
5
NOTICE
ECA17682
If the ABS warnin g li ght does not
come on an d then go off as ex-
plaine d a bove, see pa ge 3-2 for the
warnin g li ght circuit check.2. Shift the transmission into the
neutral position. The neutral indi-
cator light should come on. If not,
ask a Yamaha dealer to check the
electrical circuit.
3. Start the engine by pushing the start switch.
If the engine fails to start, release
the start switch, wait a few sec-
onds, and then try again. Each
starting attempt should be as
short as possible to preserve the
battery. Do not crank the engine
more than 10 seconds on any one
attempt.NOTICE
ECA11043
For maximum en gine life, never ac-
celerate har d when the en gine is
col d!
EAU16673
Shiftin gShifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the il-
lustration.TIPTo shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.
NOTICE
ECA10261
Even with the transmission in
the neutral position, d o not
coast for lon g period s of time
with the en gine off, an d d o not
tow the motorcycle for lon g d is-
tances. The transmission is
properly lu bricated only when
the en gine is runnin g. Ina de-
quate lu brication may d amage
the transmission.
 Always use the clutch while
chan gin g g ears to avoi d d am-
a g in g the en gine, transmission,
an d d rive train, which are not
d esi gne d to withstan d the
shock of force d shiftin g.
EAU16682
To start out an d accelerate
1. Pull the clutch lever to disengage the clutch.
2. Shift the transmission into first gear. The neutral indicator light
should go out.
3. Open the throttle gradually, and at the same time, release the clutch
lever slowly.
1. Shift pedal
2. Neutral position
1
1 2
2 3 4 5 6N
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Operation and important rid ing points
5-3
5 4. At the recommended shift points
shown in the following table, close
the throttle, and at the same time,
quickly pull the clutch lever in.
5. Shift the transmission into second gear. (Make sure not to shift the
transmission into the neutral posi-
tion.)
6. Open the throttle part way and gradually release the clutch lever.
7. Follow the same procedure when shifting to the next higher gear.
TIPWhen shifting gears in normal operat-
ing conditions, use the recommended
shift points.
EAU58270
To decelerate
1. Release the throttle and apply both the front and the rear brakes
smoothly to slow the motorcycle.
2. At the recommended shift points shown in the following table, shift
to a lower gear.
3. When the motorcycle reaches 25 km/h (16 mi/h), the engine is about
to stall or runs roughly, pull the clutch lever in, use the brakes to
slow the motorcycle, and continue
to downshift as necessary.
4. Once the motorcycle has stopped, the transmission can be
shifted into the neutral position.
The neutral indicator light should
come on and then the clutch lever
can be released.
WARNING
EWA17380
Improper brakin g can cause
loss of control or traction. Al-
ways use b oth brakes an d apply
them smoothly.
 Make sure that the motorcycle
and the en gine have sufficiently
slowe d b efore shiftin g to a low-
er gear. En gag in g a lower gear
when the vehicle or en gine
speed is too hi gh coul d make
the rear wheel lose traction or
the en gine to over-rev. This
coul d cause loss of control, an
acci dent an d injury. It coul d also
cause en gine or drive train dam-
a g e.
EAU58280
Recommen ded shift points
The recommended shift points during
acceleration and deceleration are
shown in the table below.Shift up points: 1st → 2nd: 20 km/h (12 mi/h)
2nd → 3rd: 30 km/h (19 mi/h)
3rd → 4th: 40 km/h (25 mi/h)
4th → 5th: 50 km/h (31 mi/h)
5th → 6th: 60 km/h (37 mi/h)
Shift down points:
6th → 5th: 45 km/h (28 mi/h)
5th → 4th: 35 km/h (22 mi/h)
4th → 3rd: 25 km/h (16 mi/h)
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Operation and important ri din g points
5-4
5
EAU16842
En gine break-inThere is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the fol-
lowing 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 themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that
might result in engine overheating
must be avoided.
EAU17094
0–1000 km (0–600 mi)
Avoid prolonged operation above 7000
r/min. NOTICE: After 1000 km (600
mi) of operation, the en gine oil must
b e chan ged an d the oil filter car-
tri dge or element replace d.
[ECA10303]
1000–1600 km (600–1000 mi)
Avoid prolonged operation above 8400
r/min. 1600 km (1000 mi) an
d b eyon d
The vehicle can now be operated nor-
mally.
NOTICE
ECA10311
 Keep the en gine spee d out of
the tachometer re d zone.
 If any en gine trou ble shoul d oc-
cur durin g the en gine break-in
period , imme diately have a
Yamaha dealer check the vehi-
cle.
EAU17214
Parkin gWhen parking, stop the engine, and
then remove the key from the main
switch.
WARNING
EWA10312
Since the en gine an d exhaust
system can become very hot,
park in a place where pe destri-
ans or chil dren are not likely to
touch them and b e burne d.
 Do not park on a slope or on soft
groun d, otherwise the vehicle
may overturn, increasin g the
risk of a fuel leak an d fire.
 Do not park near grass or other
flammab le materials which
mi ght catch fire.
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Periodic maintenance an d a djustment
6-1
6
EAU17246
Periodic inspection, adjustment, and
lubrication will keep your vehicle in the
safest and most efficient condition
possible. Safety is an obligation of the
vehicle owner/operator. The most im-
portant points of vehicle inspection,
adjustment, and lubrication are ex-
plained on the following pages.
The intervals given in the periodic
maintenance charts should be simply
considered as a general guide under
normal riding conditions. However, de-
pending on the weather, terrain, geo-
graphical location, and individual use,
the maintenance intervals may need to
be shortened.
WARNING
EWA10322
Failure to properly maintain the vehi-
cle or performin g maintenance ac-
tivities incorrectly may increase
your risk of injury or death durin g
service or while usin g the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha d ealer perform
service.
WARNING
EWA15123
Turn off the en gine when performin g
maintenance unless otherwise
specified .
 A runnin g en gine has movin g
parts that can catch on body
parts or clothin g an d electrical
parts that can cause shocks or
fires.
 Runnin g the en gine while ser-
vicin g can lead to eye injury,
b urns, fire, or car bon monoxi de
poisonin g – possi bly lea din g to
d eath. See pag e 1-3 for more in-
formation a bout car bon monox-
i d e.
WARNING
EWA15461
Brake discs, calipers, drums, and
linin gs can b ecome very hot d uring
use. To avoi d possi ble burns, let
b rake components cool before
touchin g them.
EAU17303
Emission controls not only function to
ensure cleaner air, but are also vital to
proper engine operation and maximum
performance. In the following periodic
maintenance charts, the services relat-
ed to emissions control are grouped
separately. These services require
specialized data, knowledge, and
equipment. Maintenance, replace-
ment, or repair of the emission control
devices and systems may be per-
formed by any repair establishment or
individual that is certified (if applicable).
Yamaha dealers are trained and equipped to perform these particular
services.
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Periodic maintenance an d a djustment
6-2
6
EAUB1402
Owner’s tool kitThe owner’s tool kit is located on the
bottom of the passenger seat (see
page 3-18) and is 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 assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
TIPIf you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
1. Owner’s tool kit
2. O-ring
1
2
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Periodic maintenance an d a djustment
6-3
6
EAU46862
TIP The annual checks must b e performed every year, except if a kilometer- based maintenance, or for the UK, a
milea ge- base d maintenance, is performe d instead .
 From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
 Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and tech-
nical skills.
EAU46911
Perio dic maintenance chart for the emission control systemNO. ITEM CHECK OR MAINTENANCE JOB ODOMETER READING
ANNUAL
CHECK
1000 km
(600 mi) 10000 km
(6000 mi) 20000 km
(12000 mi) 30000 km
(18000 mi) 40000 km
(24000 mi)
1 *Fuel line • Check fuel hoses for cracks or
damage. √√√√√
2 *Spark plu gs • Check condition.
• Clean and regap.
√√
• Replace. √√
3 *Va l ve s • Check valve clearance.
•Adjust.
Every 40000 km (24000 mi)
4 *Fuel injection sys-
tem • Adjust synchronization.
√√√√√
5 *Muffler an
d ex-
haust pipe • Check the screw clamp(s) for
looseness. √√√√√
6 *Air in
duction sys-
tem • Check the air cut-off valve, reed
valve, and hose for damage.
• Replace any damaged parts if necessary. √√√√√
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Periodic maintenance an d a djustment
6-4
6
EAU1770M
General maintenance an d lu brication chartNO. ITEM CHECK OR MAINTENANCE JOB ODOMETER READING
ANNUAL
CHECK
1000 km
(600 mi) 10000 km
(6000 mi) 20000 km
(12000 mi) 30000 km
(18000 mi) 40000 km
(24000 mi)
1 Air filter element •Replace. √√
2 Air filter check hose • Clean. √√√√√
3Clutch • Check operation.
•Adjust. √√√√√
4 *Front brake • Check operation, fluid level and
vehicle for fluid leakage. √√√√√√
• Replace brake pads. Whenever worn to the limit
5 *Rear brake • Check operation, fluid level and
vehicle for fluid leakage. √√√√√√
• Replace brake pads. Whenever worn to the limit
6 *Brake hoses • Check for cracks or damage.
• Check for correct routing and
clamping. √√√√√
• Replace. Every 4 years
7 *Brake flui d • Change. Every 2 years
8 *Wheels • Check runout and for damage. √√√√
9 *Tires • Check tread depth and for dam-
age.
• Replace if necessary.
• Check air pressure.
• Correct if necessary. √√√√√
10 *Wheel bearin gs • Check bearings for looseness or
damage. √√√√
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Periodic maintenance an d a djustment
6-5
6
11 *Swin garm • Check operation and for exces-
sive play. √√√√
• Lubricate with lithium-soap- based grease. Every 50000 km (30000 mi)
12 Drive chain • Check chain slack, alignment and
condition.
• Adjust and lubricate chain with a special O-ring chain lubricant
thoroughly. Every 800 km (500 mi) and after washing the motorcycle, riding in the rain or
riding in wet areas
13 *Steerin g b earin gs • Check bearing play and steering
for roughness. √√√√√
• Lubricate with lithium-soap- based grease. Every 20000 km (12000 mi)
14 *Chassis fasteners • Make sure that all nuts, bolts and
screws are properly tightened. √√√√√
15 Brake lever pivot
shaft • Lubricate with silicone grease.
√√√√√
16 Brake ped
al pivot
shaft • Lubricate with lithium-soap-
based grease. √√√√√
17 Clutch lever pivot
shaft • Lubricate with lithium-soap-
based grease. √√√√√
18 Shift pe
dal pivot
shaft • Lubricate with lithium-soap-
based grease. √√√√√
19 Si destan d • Check operation.
• Lubricate with lithium-soap-
based grease. √√√√√
20 *Sidestan d switch • Check operation. √√√√√√
NO. ITEM CHECK OR MAINTENANCE JOB
ODOMETER READING
ANNUAL
CHECK
1000 km
(600 mi) 10000 km
(6000 mi) 20000 km
(12000 mi) 30000 km
(18000 mi) 40000 km
(24000 mi)UB08E1E0.book Page 5 Friday, October 2, 2015 9:33 AM