2006-2014 Yamaha MT-03 OEM Service & Repair Manual

MT-03 SERVICE MANUAL 2006 5YK-F8197-E0

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 vehicles 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 motorcycle. 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 disassembly 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 1 2 3 4 5 7 8 6 9 11 10 12 14 13 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 REMOVALAND 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

2006-2014 Yamaha MT-03 OEM Service & Repair Manual

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