service YAMAHA MT-03 2020 Owners Manual

Periodic maintenance and adjustment
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 performing maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha dealer perform
service.
WARNING
EWA15123
Turn off the engine when performing
maintenance unless otherwise
specified.
A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.
Running the engine while ser-
vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading todeath. See page 1-3 for more in-
formation about carbon monox-
ide.
WARNING
EWA15461
Brake discs, calipers, drums, and
linings can become very hot during
use. To avoid possible burns, let
brake components cool before
touching them.
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Periodic maintenance and adjustment
6-6
6
EAU72710
TIP
Air filter
• This model’s air intake system is equipped with a disposable oil-coated pa-
per element. The air filter element cannot be cleaned with compressed air,
it must be replaced.
• The air filter element needs to be replaced more frequently when riding in
unusually wet or dusty areas.
Hydraulic brake service
• After disassembling the brake master cylinder and caliper, always change
the fluid. Regularly check the brake fluid level and fill the reservoir as re-
quired.
• Every two years replace the internal components of the brake master cyl-
inder and caliper, and change the brake fluid.
• Replace the brake hose every four years and if cracked or damaged.
28*Moving parts and
cables• Lubricate.√√√√√
29*Throttle grip hous-
ing and cable• Check operation and free play.
• Adjust the throttle cable free
play if necessary.
• Lubricate the throttle grip hous-
ing and cable.√√√√√
30*Lights, signals and
switches• Check operation.
• Adjust headlight beam.√√√√√√ NO. ITEM
X 1000 km CHECK OR
MAINTENANCE JOB
X 1000 miODOMETER
READINGS
ANNUAL CHECK
110203040
0.6 6 12 18 24
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Periodic maintenance and adjustment
6-15
6
EAU21386
Checking the throttle grip free
play
Measure the throttle grip free play as
shown.
Periodically check the throttle grip free
play and, if necessary, have a Yamaha
dealer adjust it.
EAU21403
Valve clearance
The valves are an important engine
component, and since valve clearance
changes with use, they must be
checked and adjusted at the intervals
specified in the periodic maintenance
chart. Unadjusted valves can result in
improper air-fuel mixture, engine
noise, and eventually engine damage.
To prevent this from occurring, have
your Yamaha dealer check and adjust
the valve clearance at regular intervals.
TIP
This service must be performed when
the engine is cold.1. Throttle grip free play
Throttle grip free play:
3.0–5.0 mm (0.12–0.20 in)
1
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Periodic maintenance and adjustment
6-20
6
EAU36505
Brake light switches
The brake light should come on just
before braking takes effect. The brake
light is activated by switches connect-
ed to the brake lever and brake pedal.
Since the brake light switches are
components of the anti-lock brake sys-
tem, they should only be serviced by a
Yamaha dealer.
EAU22393
Checking the front and rear
brake pads
The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU22433Front brake pads
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wear
indicator grooves have almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
1. Brake pad wear indicator groove
1
1
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Periodic maintenance and adjustment
6-24
6
TIP
Using the alignment marks on each
side of the swingarm, make sure that
both drive chain pullers are in the same
position for proper wheel alignment.
3. Tighten the axle nut, then the lock-
nuts to their specified torques.
4. Make sure that the drive chain
pullers are in the same position,
the drive chain slack is correct,
and the drive chain moves
smoothly.
5. Install the drive chain puller caps.
EAU23026
Cleaning and lubricating the
drive chain
The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.
NOTICE
ECA10584
The drive chain must be lubricated
after washing the motorcycle, riding
in the rain or riding in wet areas.
1. Clean the drive chain with kero-
sene and a small soft brush.
NOTICE: To prevent damaging
the O-rings, do not clean the
drive chain with steam cleaners,
high-pressure washers or inap-
propriate solvents.
[ECA11122]
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant. NOTICE: Do not use
engine oil or any other lubri-
cants for the drive chain, as they
may contain substances that
could damage the O-rings.
[ECA11112]
1. Alignment marks
2. Drive chain puller
Tightening torques:
Axle nut:
57 N·m (5.7 kgf·m, 42 lb·ft)
Locknut:
16 N·m (1.6 kgf·m, 12 lb·ft)
1 2
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Periodic maintenance and adjustment
6-34
65. Insert a new bulb into the socket.
6. Install the socket (together with
the bulb) by pushing it in.
7. Install the rear fender lower panel
by installing the bolts and screws.
8. Install the mudguard by installing
the quick fasteners.
EAU24351
Supporting the motorcycle
Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other mainte-
nance requiring the motorcycle to
stand upright. Check that the motorcy-
cle is in a stable and level position be-
fore starting any maintenance. A
strong wooden box can be placed un-
der the engine for added stability.
To service the front wheel
1. Stabilize the rear of the motorcy-
cle by using a motorcycle stand
or, if an additional motorcycle
stand is not available, by placing a
jack under the frame in front of the
rear wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor-
cycle stand is not available, by placing
a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
1. License plate light bulb
2. License plate light bulb socket
2
1
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Periodic maintenance and adjustment
6-35
6
EAU25872
Troubleshooting
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur
during operation. Any problem in the
fuel, compression, or ignition systems,
for example, can cause poor starting
and loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.
WARNING
EWA15142
When checking the fuel system, do
not smoke, and make sure there are
no open flames or sparks in the ar-
ea, including pilot lights from water
heaters or furnaces. Gasoline or
gasoline vapors can ignite or ex-
plode, causing severe injury or prop-
erty damage.
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Specifications
8-1
8
*Dimensions:
Overall length:
2090 mm (82.3 in)
Overall width:
755 mm (29.7 in)
Overall height:
1070 mm (42.1 in)
Seat height:
780 mm (30.7 in)
Wheelbase:
1380 mm (54.3 in)
Ground clearance:
160 mm (6.30 in)
Minimum turning radius:
2.9 m (9.51 ft)
*Weight:
Curb weight:
169 kg (373 lb)
*Engine:
Combustion cycle:
4-stroke
Cooling system:
Liquid cooled
Valve train:
DOHC
Cylinder arrangement:
Inline
Number of cylinders:
2-cylinder
Displacement:
321 cm3
Bore × stroke:
68.0 × 44.1 mm (2.68 × 1.74 in)
Starting system:
Electric starter
*Engine oil:
Recommended brand:
SAE viscosity grades:
10W-40
Recommended engine oil grade:
API service SG type or higher, JASO
standard MA
*Engine oil quantity:
Oil change:
1.80 L (1.90 US qt, 1.58 Imp.qt)With oil filter removal:
2.10 L (2.22 US qt, 1.85 Imp.qt)
*Coolant quantity:
Coolant reservoir (up to the maximum level
mark):
0.25 L (0.26 US qt, 0.22 Imp.qt)
Radiator (including all routes):
0.81 L (0.86 US qt, 0.72 Imp.qt)
*Fuel:
Recommended fuel:
Unleaded gasoline (E10 acceptable)
Octane number (RON):
90
Fuel tank capacity:
14 L (3.7 US gal, 3.1 Imp.gal)
Fuel reserve amount:
3.0 L (0.79 US gal, 0.66 Imp.gal)
*Fuel injection:
*Throttle body:
ID mark:
BR51
*Drivetrain:
*Gear ratio:
1st:
2.500 (35/14)
2nd:
1.824 (31/17)
3rd:
1.348 (31/23)
4th:
1.087 (25/23)
5th:
0.920 (23/25)
6th:
0.800 (24/30)
*Front tire:
Type:
Tubeless
Size:
110/70R-17M/C 54H
Manufacturer/model:
DUNLOP/GPR-300F
*Rear tire:
Type:
Tubeless
Size:
140/70R-17M/C 66H
Manufacturer/model:
DUNLOP/GPR-300
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Consumer information
9-2
9
EAU69910
Diagnostic connector
The diagnostic connector is located as
shown.
EAU85300
Vehicle data recording
This model’s ECU stores certain vehi-
cle data to assist in the diagnosis of
malfunctions and for research, statisti-
cal analysis and development purpos-
es.
Although the sensors and recorded
data will vary by model, the main data
points are:
Vehicle status and engine perfor-
mance data
Fuel-injection and emission-relat-
ed data
This data will be uploaded only when a
special Yamaha diagnostic tool is at-
tached to the vehicle, such as when
maintenance checks or service proce-
dures are performed.
Vehicle data uploaded will be handled
appropriately according to the follow-
ing Privacy Policy.
Privacy Policy
Yamaha will not disclose this data to a
third party except in the following cas-
es. In addition, Yamaha may provide
vehicle data to a contractor in order to
outsource services related to the han-
dling of vehicle data. Even in this case,
Yamaha will require the contractor to
properly handle the vehicle data we
provided and Yamaha will appropriate-
ly manage the data.
With the consent of the vehicle
owner
Where obligated by law
For use by Yamaha in litigation
When the data is not related to an
individual vehicle nor owner
1. FI diagnostic connector
1
https://www.yamaha-motor.eu/eu/
privacy/privacy-policy.aspx
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