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
© 2006 by Yamaha Motor Italia S.p.A.
First edition, February 2006
All rights reserved. Any reproduction or
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
45
78
6
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

1-1
IDENTIFICATION
IDENTIFICATION
EAS00170
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is stamped
into the right side of the steering head pipe.
EAS00180
MODEL LABEL
The model label “1” is affixed to the frame un-
der the passenger seat. This information will be
needed to order spare parts.
1
1