clutch YAMAHA MT-03 2020 Owners Manual

Table of contents
Safety information............................1-1
Description........................................2-1
Left view ..........................................2-1
Right view........................................2-2
Controls and instruments ................2-3
Instrument and control functions....3-1
Main switch/steering lock ...............3-1
Indicator lights and warning
lights ............................................3-2
Multi-function meter unit .................3-4
Handlebar switches.......................3-10
Clutch lever ...................................3-11
Shift pedal .....................................3-12
Brake lever ....................................3-12
Brake pedal ...................................3-13
ABS ...............................................3-13
Fuel tank cap.................................3-14
Fuel................................................3-15
Fuel tank overflow hose ................3-16
Catalytic converter ........................3-17
Seats .............................................3-17
Helmet holders ..............................3-19
Storage compartment ...................3-20
Adjusting the shock absorber
assembly....................................3-20
Luggage strap holders ..................3-21
Sidestand ......................................3-22
Ignition circuit cut-off system........3-22
For your safety – pre-operation
checks...............................................4-1
Operation and important riding
points.................................................5-1
Engine break-in ...............................5-1
Starting the engine ..........................5-2
Shifting ............................................5-3
Tips for reducing fuel
consumption ................................5-4
Parking ............................................5-5
Periodic maintenance and
adjustment........................................6-1
Tool kit.............................................6-2Periodic maintenance charts .......... 6-3
Periodic maintenance chart for
the emission control system........ 6-3
General maintenance and
lubrication chart........................... 6-4
Checking the spark plugs ............... 6-7
Canister........................................... 6-8
Engine oil and oil filter cartridge ..... 6-8
Why Yamalube .............................. 6-11
Coolant ......................................... 6-12
Replacing the air filter element
and cleaning the check hose..... 6-13
Checking the throttle grip
free play ..................................... 6-15
Valve clearance ............................. 6-15
Tires .............................................. 6-16
Cast wheels .................................. 6-18
Adjusting the clutch lever
free play ..................................... 6-18
Checking the brake lever
free play ..................................... 6-19
Brake light switches ...................... 6-20
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 shift pedals ............... 6-26
Checking and lubricating the
brake and clutch levers ............. 6-26
Checking and lubricating the
sidestand ................................... 6-27
Lubricating the swingarm pivots... 6-27
Checking the front fork ................. 6-28
Checking the steering ................... 6-28
Checking the wheel bearings ....... 6-29
Battery .......................................... 6-29
Replacing the fuses ...................... 6-31
Vehicle lights ................................. 6-33
UB6WE0E0.book Page 1 Friday, March 27, 2020 11:37 AM

Description
2-3
2
EAU63401
Controls and instruments
12 456783
1. Clutch lever (page 3-11)
2. Left handlebar switches (page 3-10)
3. Multi-function meter unit (page 3-4)
4. Main switch/steering lock (page 3-1)
5. Front brake fluid reservoir (page 6-21)
6. Right handlebar switches (page 3-10)
7. Throttle grip (page 6-15)
8. Brake lever (page 3-12)
UB6WE0E0.book Page 3 Friday, March 27, 2020 11:37 AM

Instrument and control functions
3-11
3
NOTICE
ECA10062
Do not use the hazard lights for an
extended length of time with the en-
gine not running, otherwise the bat-
tery may discharge.
EAU12823
Clutch lever
To disengage the drivetrain from the
engine, such as when shifting gears,
pull the clutch lever toward to the han-
dlebar. Release the lever to engage the
clutch and transmit power to the rear
wheel.
TIP
The lever should be pulled rapidly and
released slowly for smooth shifting.
(See page 5-3.)
1. Clutch lever
1
UB6WE0E0.book Page 11 Friday, March 27, 2020 11:37 AM

Instrument and control functions
3-22
3
EAU15306
Sidestand
The sidestand is located on the left
side of the frame. Raise the sidestand
or lower it with your foot while holding
the vehicle upright.
TIP
The built-in sidestand switch is part of
the ignition circuit cut-off system,
which cuts the ignition in certain situa-
tions. (See the following section for an
explanation of the ignition circuit cut-
off system.)
WARNING
EWA10242
The vehicle must not be ridden with
the sidestand down, or if the side-
stand cannot be properly moved up
(or does not stay up), otherwise the
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control.
Yamaha’s ignition circuit cut-off
system has been designed to assist
the operator in fulfilling the respon-
sibility of raising the sidestand be-
fore starting off. Therefore, check
this system regularly and have a
Yamaha dealer repair it if it does not
function properly.
EAU64051
Ignition circuit cut-off system
This system prevents in-gear engine
starts unless the clutch lever is pulled
and the sidestand is up. Also, it will
stop the running engine should the
sidestand be lowered while the trans-
mission is in gear.
Periodically check the system via the
following procedure.
TIP
This check is most reliable if per-
formed with a warmed-up engine.
See pages 3-1 for switch opera-
tion information.
UB6WE0E0.book Page 22 Friday, March 27, 2020 11:37 AM

Instrument and control functions
3-23
3
With the engine turned off:
1. Move the sidestand down.
2.Set engine stop switch to run position.
3. Turn main switch to on position.
4.Shift transmission into neutral.
5. Push the start switch.
Does the engine start?
With the engine still running:
6. Move the sidestand up.
7. Pull the clutch lever.
8.Shift transmission into gear.
9. Move the sidestand down.
Does the engine stall?
After the engine has stalled:
10. Move the sidestand up.
11. Pull the clutch lever.
12. Push the start switch.
Does the engine start?
The system is OK. The motorcycle can
be ridden.
The neutral switch may not be working.
The motorcycle should not be ridden
until checked by a Yamaha dealer.
The sidestand switch may not be
working.
The motorcycle should not be ridden
until checked by a Yamaha dealer.
The clutch switch may not be working.
The motorcycle should not be ridden
until checked by a Yamaha dealer.
WARNING
If a malfunction is found, have the
vehicle inspected before riding.
YES NO
YES NO
YES NO
UB6WE0E0.book Page 23 Friday, March 27, 2020 11:37 AM

For your safety – pre-operation checks
4-1
4
EAU63441
Inspect your vehicle each time you use it to make sure the vehicle is in safe oper-
ating condition. Always follow the inspection and maintenance procedures and
schedules described in the Owner’s Manual.
WARNING
EWA11152
Failure to inspect or maintain the vehicle properly increases the possibility
of an accident or equipment damage. Do not operate the vehicle if you find
any problem. If a problem cannot be corrected by the procedures provided
in this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
ITEM CHECKS PAGE
Fuel• Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.
• Check fuel tank breather hose and overflow hose for
obstructions, cracks or damage, and check hose con-
nections.3-15,
3-16
Engine oil• Check oil level in engine.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage.6-8
Coolant• Check coolant level in reservoir.
• If necessary, add recommended coolant to specified
level.
• Check cooling system for leakage.6-12
Front brake• 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 specified brake fluid to specified level.
• Check hydraulic system for leakage.6-20,
6-21
Rear brake• 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 specified brake fluid to specified level.
• Check hydraulic system for leakage.6-20,
6-21
Clutch• Check operation.
• Lubricate cable if necessary.
• Check lever free play.
• Adjust if necessary.6-18
UB6WE0E0.book Page 1 Friday, March 27, 2020 11:37 AM

For your safety – pre-operation checks
4-2
4
Throttle grip• Make sure that operation is smooth.
• Check throttle grip free play.
• If necessary, have Yamaha dealer adjust throttle grip
free play and lubricate cable and grip housing.6-15,
6-25
Control cables• Make sure that operation is smooth.
• Lubricate if necessary.6-25
Drive chain• Check chain slack.
• Adjust if necessary.
• Check chain condition.
• Lubricate if necessary.6-23,
6-24
Wheels and tires•Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary.6-16,
6-18
Brake and shift pedals• Make sure that operation is smooth.
• Lubricate pedal pivoting points if necessary.6-26
Brake and clutch le-
vers• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.6-26
Sidestand• Make sure that operation is smooth.
• Lubricate pivot if necessary.6-27
Chassis fasteners• Make sure that all nuts, bolts and screws are properly
tightened.
• Tighten if necessary.—
Instruments, lights,
signals and switches• Check operation.
• Correct if necessary.—
Sidestand switch • Check operation of ignition circuit cut-off system.
• If system is not working correctly, have Yamaha dealer
check vehicle.3-22 ITEM CHECKS PAGE
UB6WE0E0.book Page 2 Friday, March 27, 2020 11:37 AM

Operation and important riding points
5-2
5
EAU86620
Starting the engine
The ignition circuit cut-off system will
enable starting when:
the transmission is in the neutral
position or
the transmission is in gear, the
sidestand is up, and the clutch le-
ver is pulled.
To start the engine
1. Turn the main switch on and set
the engine stop switch to the run
position.
2. Confirm the indicator and warning
light(s) come on for a few sec-
onds, and the go off. (See page
3-2.)
TIP
Do not start the engine if the en-
gine trouble warning light remains
on.
The oil pressure warning light
should come on and stay on until
the engine is started.
The ABS warning light should
come on and stay on until the ve-
hicle reaches a speed of 10 km/h
(6 mi/h).
NOTICE
ECA24110
If a warning or indicator light does
not work as described above, have a
Yamaha dealer check the vehicle.
3. Shift the transmission into the
neutral position.
4. Start the engine by pushing the
start switch.5. Release the start switch when the
engine starts, or after 5 seconds.
Wait 10 seconds before pressing
the switch again to allow battery
voltage to restore.
NOTICE
ECA11043
For maximum engine life, never ac-
celerate hard when the engine is
cold!
UB6WE0E0.book Page 2 Friday, March 27, 2020 11:37 AM

Operation and important riding points
5-3
5
EAUM3632
TIP
This model is equipped with:
a lean angle sensor. This sensor
stops the engine in case of a vehi-
cle turnover. If this happens, the
engine trouble warning light will
come on, but this is not a malfunc-
tion. Turn the vehicle power off
and then back on again to cancel
the warning light. Failing to do so
will prevent the engine from start-
ing 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.
EAU16674
Shifting
Shifting 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.
TIP
To 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, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long dis-
tances. 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,
1. Gear positions
2. Shift pedal
2
1
1 N2
3
4
5
6
UB6WE0E0.book Page 3 Friday, March 27, 2020 11:37 AM

Periodic maintenance and adjustment
6-4
6
EAU71372
General maintenance and lubrication chart
NO. ITEM
1*Diagnostic system
check• Perform dynamic inspection
using Yamaha diagnostic tool.
• Check the error codes.√√√√√√
2*Air filter element• Replace.√√
3Air filter case
check hose• Clean.√√√√√
4Clutch• Check operation.
•Adjust.√√√√√
5*Front brake• Check operation, fluid level,
and for fluid leakage.
• Replace brake pads if neces-
sary.√√√√√√
6*Rear brake• Check operation, fluid level,
and for fluid leakage.
• Replace brake pads if neces-
sary.√√√√√√
7*Brake hoses• Check for cracks or damage.√√√√√
• Replace. Every 4 years
8*Brake fluid• Change. Every 2 years
9*Wheels• Check runout and for damage.
• Replace if necessary.√√√√
10*Tires• Check tread depth and for
damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.√√√√√
11*Wheel bearings• Check bearing for looseness or
damage.√√√√
12*Swingarm pivot
bearings• Check operation and for exces-
sive play.√√√√
13 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 areasX 1000 km CHECK OR
MAINTENANCE JOB
X 1000 miODOMETER
READINGSANNUAL CHECK
1 10203040
0.6 6 12 18 24
UB6WE0E0.book Page 4 Friday, March 27, 2020 11:37 AM