Yamaha MT-03 User manual

MT-03

SERVICE MANUAL

2006

5YK-F8197-E0

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ou=MTOC,

email=admin@mt

oc.org.uk, c=GB

MT-03 (2006)

SERVICE MANUAL

First edition, February 2006

unauthorized use without the written

permission of Yamaha Motor Italia S.p.A.

is expressly prohibited.

Printed in Italy

EAS00020

NOTICE

This manual was produced by the Yamaha Motor Italia S.p.A. primarily for use by Yamaha dealers

and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one

manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha ve-

hicles should have a basic understanding of mechanics and the techniques to repair these types of

vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to ren-

der the vehicle unsafe and unfit for use.

Yamaha Motor Italia S.p.A. is continually striving to improve all of its models. Modifications and sig-

nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers

and will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

EAS00040

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFE-

TY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to

the motorcycle operator, a bystander or a person checking or repairing the mo-

torcycle.

A CAUTION indicates special precautions that must be taken to avoid damage

to the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

EAS20090

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are

laid out with the individual steps in sequential order.

• The manual is divided into chapters and each chapter is divided into sections. The current section

title “1” is shown at the top of each page.

• Sub-section titles “2” appear in smaller print than the section title.

• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of

each removal and disassembly section.

• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a dis-

assembly step.

• Symbols “5” indicate parts to be lubricated or replaced. Refer to “SYMBOLS”.

• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names

of parts, notes in jobs, etc.

• Jobs “7” requiring more information (such as special tools and technical data) are described

sequentially.

EAS20100

SYMBOLS

The following symbols are used in this manual

for easier understanding.

NOTE:

The following symbols are not relevant to every

vehicle.

1. Serviceable with engine mounted

2. Filling fluid

3. Lubricant

4. Special tool

5. Tightening torque

6. Wear limit, clearance

7. Engine speed

8. Electrical data

9. Engine oil

10.Gear oil

11. Molybdenum disulfide oil

12.Wheel bearing grease

13.Lithium-soap-based grease

14.Molybdenum disulfide grease

15.Apply locking agent (LOCTITE®)

16.Replace the part with a new one.

New

123

91110

12 1413

15 16

GENERAL INFORMATION 
TABLE OF CONTENTS
1
SPECIFICATIONS 2
PERIODIC CHECKS AND 
ADJUSTMENTS 3
CHASSIS 4
ENGINE 5
COOLING SYSTEM 6
FUEL INJECTION SYSTEM 7
ELECTRICAL SYSTEM 8
TROUBLESHOOTING 9

GENERAL INFORMATION
IDENTIFICATION............................................................................................ 1-1
VEHICLE IDENTIFICATION NUMBER .................................................... 1-1
MODEL LABEL......................................................................................... 1-1
FEATURES .................................................................................................... 1-2
OUTLINE OF THE FI SYSTEM................................................................ 1-2
FI SYSTEM............................................................................................... 1-3
INSTRUMENT FUNCTIONS .................................................................... 1-4
IMPORTANT INFORMATION ....................................................................... 1-7
PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-7
REPLACEMENT PARTS .......................................................................... 1-7
GASKETS, OIL SEALS AND O-RINGS ................................................... 1-7
LOCK WASHERS/PLATES AND COTTER PINS .................................... 1-7
BEARINGS AND OIL SEALS ................................................................... 1-8
CIRCLIPS ................................................................................................. 1-8
CHECKING THE CONNECTIONS ................................................................ 1-9
SPECIAL TOOLS ...........................................................................................1-10
1