Yamaha MT-03 (2006) manual

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Bulldog 01-03 ITA 22-06-2004 8:15 Pagina 3.23[...]

E N G L I S H MY03 01-03 ING 6-10-2005 13:52 Pagina 1[...]

DECLARA TION of CONFORMITY We Company: MORIC CO., L TD. Address: 1450-6 Mori Mori-Machi Shuchi-gun Shizuoka 437-0292 Japan Hereby declare that the pr oduct: Kind of equipment: IMMOBILIZER T ype-designation: 5SL-00 is in compliance with following norm(s) or documents: R&TTE Directive(1999/5/EC) EN300 330-2 v1.1.1(2001-6), EN60950(2000) T wo or T[...]

INTRODUCTION EAU10100 Welcome to the Y amaha world of motorcycling! As the owner of the MT -03, you are benefiting from Y amaha’ s vast experience and newest technology regarding the de- sign and manufacture of high-quality products, which have earned Y amaha a reputation for dependability . Please take the time to read this manual thoroughly , s[...]

IMPOR T ANT MANUAL INFORMA TION Particularly important information is distinguished in this manual by the following notations: WARNING 0 NOTE: CAUTION: The Safety Alert Symbol means A TTENTION! BECOME ALERT! YOUR SAFETY IS INVOL VED! Failure to follow W ARNING instructions could result in sever e injury or death to the motorcycle operator , a bysta[...]

IMPOR T ANT MANUAL INFORMA TION MT -03 OWNER'S MANUAL ©2006 by Y amaha Motor Italia S.P .A. 2 nd edition, september 2006 All rights reserved. Any reprinting or unauthorized use without the written permission of Y amaha Motor Italia S.P .A. is expressly pr ohibited. Printed in the Italy . EAUB101 1[...]

T ABLE OF CONTENTS SAFETY INFORMA TION .....................1-1 Safe riding .........................................1-1 Protective apparel .............................1-2 Modifications .....................................1-2 Loading and accessories ..................1-2 Gasoline and exhaust gas ................1-4 DESCRIPTION ...................[...]

T ABLE OF CONTENTS Checking the front fork....................6-27 Checking the steering .....................6-28 Checking the wheel bearings..........6-29 Battery .............................................6-29 Replacing the fuses ........................6-31 Replacing the headlight bulb ..........6-33 Replacing an auxiliary light bulb .....6-3[...]

1-1 1 2 3 4 5 6 7 8 9 10 SAFETY INFORMA TION EAU10281 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERA TION ARE DEPEN- DENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERA- TOR. EVER Y OPERA TOR SHOULD KNOW THE FOLLOWING REQUIRE- MENTS BEFORE RIDING THIS MO- TORCYCLE. HE OR SHE SHOULD: ● OBT AIN THORO[...]

1 2 3 4 5 6 7 8 9 10 SAFETY INFORMA TION • Always obey the speed limit and never travel faster than warranted by road and traffic conditions. • Always signal before turning or changing lanes. Make sure that other motorists can see you. ● The posture of the operator and passenger is important for proper control. • The operator should keep bo[...]

SAFETY INFORMA TION Here are some general guidelines to follow if loading cargo or adding ac- cessories to your motorcycle: Loading The total weight of the operator , pas- senger , accessories and cargo must not exceed the maximum load limit. ● Never attach any large or heavy items to the handlebar , front fork, or front fender . These items, in-[...]

1 2 3 4 5 6 7 8 9 10 SAFETY INFORMA TION • Certain accessories can dis- place the operator from his or her normal riding position. This improper position limits the freedom of movement of the operator and may limit control ability , therefore, such acces- sories are not recommended. ● Use caution when adding electri- cal accessories. If electri[...]

DESCRIPTION EAU10410 Left view 1. Main fuse (page 6-31) 2. Battery (page 6-29) 3. Idle adjusting screw (page 6-14) 4. Air filter element (page 6-13) 5. Owner ’s tool kit (page 6-1) 6. Seat lock (page 3-14) 7. Shift pedal (page 3-10) 8. Engine oil drain bolt (crankcase) (page 6-9) 9. Engine oil drain bolt (oil tank) (page 6-9) 2-1 1 2 3 4 5 6 7 8 [...]

1 2 3 4 5 6 7 8 9 10 DESCRIPTION EAU10420 Right view 2-2 10. Grab bar 1 1. Fuse box (page 6-32) 12. Rear brake fluid reservoir (page 6-21) 13. Front brake fluid reservoir (page 6-21) 14. Coolant reservoir (page 6-12) 15. Engine oil filler cap/dipstick (page 6-8) 16. Coolant drain bolt (page 6-12) 17. Engine oil filter element (page 6-10) 18. Shock [...]

DESCRIPTION EAU10430 Controls and instruments 1. Clutch lever (page 3-10) 2. Left handlebar switches (page 3-9) 3. Multi-function meter unit and warning lights (page 3-3, 3-5) 4. Main switch and steering lock (page 3-2) 5. Right handlebar switches (page 3-9) 6. Throttle grip (page 6-15) 7. Brake lever (page 3-1 1) 8. Fuel tank cap (page 3-1 1) 2-3 [...]

1 2 3 4 5 6 7 8 9 10 3-1 INSTRUMENT AND CONTROL FUNCTIONS EAU10972 Immobilizer system 1. Code re-registering key (red bow) 2. Standard keys (black bow) This vehicle is equipped with an im- mobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the fol- lowing. ● a code re-registering key (with[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-2 1 2 3 4 5 6 7 8 9 10 EAU10471 Main switch/steering lock The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. NOTE: Be sure to use the standard key (black bow) for regular use of the vehicle. T o minimize the risk of losing the code re- registering key (red b[...]

1 2 3 4 5 6 7 8 9 10 INSTRUMENT AND CONTROL FUNCTIONS 3-3 T o unlock the steering 1. Push 2. Turn Push the key in, and then turn it to “OFF” while still pushing it. EWA10060 WARNING 0 Never turn the key to “OFF” or “LOCK” while the vehicle is moving, otherwise the electrical systems will be switched off, which may r e- sult in loss of c[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-4 1 2 3 4 5 6 7 8 9 10 When the key is turned to “OFF” and 30 seconds have passed, the indicator light will start flashing indicating the immobilizer system is enabled. After 24 hours have passed, the indicator light will stop flashing, however the im- mobilizer system is still enabled. This model is also equi[...]

1 2 3 4 5 6 7 8 9 10 INSTRUMENT AND CONTROL FUNCTIONS 3-5 The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, and then go off, have a Y amaha dealer check the elec- trical circuit. NOTE: This model is also equipped with a self-diagnosis device for the fu[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-6 1 2 3 4 5 6 7 8 9 10 T achometer 1. T achometer 2. Red zone The electric tachometer allows the rid- er to monitor the engine speed and keep it within the ideal power range. ECA10031 CAUTION: Do not operate the engine in the tachometer red zone. Red zone: 7,500 r/min and above. Odometer , tripmeter modes 1. “SE[...]

1 2 3 4 5 6 7 8 9 10 INSTRUMENT AND CONTROL FUNCTIONS 3-7 Clock mode 1. Clock 2. “SELECT” button 3. “RESET” button T urn the key to “ON”. T o set the clock 1. Push the “SELECT” button for at least two seconds. 2. When the hour digits start flash- ing, push the “RESET” button to set the hours. 3. Push the “SELECT” button, and[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-8 1 2 3 4 5 6 7 8 9 10 If the immobilizer system indicator light flashes any error codes, have a Y amaha dealer check the vehicle. ECA1 1590 CAUTION: If the display indicates an error code, the vehicle should be checked as soon as possible in or- der to avoid engine damage. Indicator lights brightness control mode[...]

1 2 3 4 5 6 7 8 9 10 INSTRUMENT AND CONTROL FUNCTIONS 3-9 EAU12343 Handlebar switches Left 1. Pass switch “ 1 ” 2. Dimmer switch “ 2 / 1 ” 3. Horn switch “ o ” 4. Turn signal switch “ y ” 5. Hazard switch “ r ” Right 1. Engine stop switch “ I / B ” 2. Start switch “ J ” EAU12350 Pass switch “ 1 ” Press this switch to[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-10 1 2 3 4 5 6 7 8 9 10 EAU12733 Hazard switch “ r ” With the key in the “ON” or F position, use this switch to turn on the hazard lights (simultaneous flashing of all turn signal lights). The hazard lights are used in case of an emergency or to warn other drivers when your vehicle is stopped where it migh[...]

1 2 3 4 5 6 7 8 9 10 INSTRUMENT AND CONTROL FUNCTIONS 3-11 EAU26822 Brake lever 1. Brake lever 2. Position adjusting dial 3. Arrow mark 4. Distance The brake lever is located at the right handlebar grip. T o apply the front brake, pull the lever toward the han- dlebar grip. The brake lever is equipped with a po- sition adjusting dial. T o adjust th[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-12 1 2 3 4 5 6 7 8 9 10 T o close the fuel tank cap 1. Push the fuel tank cap into posi- tion with the key inserted in the lock. 2. T urn the key counterclockwise to the original position, remove it, and then close the lock cover . NOTE: The fuel tank cap cannot be closed unless the key is in the lock. In addi- ti[...]

1 2 3 4 5 6 7 8 9 10 INSTRUMENT AND CONTROL FUNCTIONS 3-13 EAUB1300 Fuel tank breather/overflow hose 1. Fuel tank breather/overflow hose 2. Clamp Before operating the motorcycle: ● Check the fuel tank breather/ overflow hose connection. ● Check the fuel tank breather/ overflow hose for cracks or dam- age, and replace it if damaged. ● Make sur[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-14 1 2 3 4 5 6 7 8 9 10 T o install the passenger seat 1. Projection 2. Seat holder 1. Insert the projection on the front of the passenger seat into the seat holder as shown, and then push the back of the seat down to lock it in place. 2. Remove the key . EAUB131 1 Seats Passenger seat 1. Open T o remove the passe[...]

1 2 3 4 5 6 7 8 9 10 INSTRUMENT AND CONTROL FUNCTIONS 3-15 1. Y amaha U-LOCK (optional) 2. Fastening strap 3. Owner ’s tool kit The passenger seat is designed to fasten a genuine Y amaha U-LOCK to the bottom of the seat. (Other locks may not fit.) When fastening a U- LOCK to the seat, securely fasten it with the straps. When the U-LOCK is not fas[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-16 1 2 3 4 5 6 7 8 9 10 A. Distance (spring preload) Adjust the spring preload as follows. 1. Loosen the locknut. 2. T o increase the spring preload and thereby harden the suspen- sion, turn the adjusting nut in di- rection (a). T o decrease the spring preload and thereby soften the suspension, turn the adjusting [...]

1 2 3 4 5 6 7 8 9 10 INSTRUMENT AND CONTROL FUNCTIONS 3-17 Spring preload: Minimum (soft): Distance A = 174.5 mm (6.87 in) Standard: Distance A = 170 mm (6.69 in) Maximum (hard): Distance A = 165.5 mm (6.49 in) Spring preload Distance A SOFT 174.5 mm (6.87 in) For light operators and primarily use without passenger ST ANDARD 170 mm (6.69 in) HARD 1[...]

EAU15301 Sidestand 1. Sidestand The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the motorcycle upright. NOTE: The built-in sidestand switch is part of the ignition circuit cut-off system, which cuts the ignition in certain situa- tions. (See further down for an expla- nation of th[...]

1 2 3 4 5 6 7 8 9 10 INSTRUMENT AND CONTROL FUNCTIONS EWA10240 WARNING 0 The vehicle must not be ridden with the sidestand down, or if the sidestand cannot be properly moved up (or does not stay up), otherwise the sidestand could con- tact the ground and distract the operator , resulting in a possible loss of control. Y amaha’ s ignition circuit [...]

INSTRUMENT AND CONTROL FUNCTIONS 3-20 1 2 3 4 5 6 7 8 9 10 With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is turned on. 3. T urn the key on. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? With the engine still running: 6. Move the sidestand up. [...]

1 2 3 4 5 6 7 8 9 10 PRE-OPERA TION CHECKS 4-1 EAU15591 The condition of a vehicle is the owner ’ s responsibility . Vital components can start to deteriorate quickly and unexpected- ly , even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have ser[...]

PRE-OPERA TION CHECKS 4-2 1 2 3 4 5 6 7 8 9 10 ITEM Fuel Engine oil Coolant Front brake Rear brake EAU15603 Pre-operation check list CHECKS • Check fuel level in fuel tank. • Refuel if necessary . • Check fuel line for leakage. • Check oil level in oil tank. • If necessary , add recommended oil to specified level. • Check vehicle for oi[...]

1 2 3 4 5 6 7 8 9 10 PRE-OPERA TION CHECKS 4-3 ITEM Clutch Throttle grip Control cables Drive chain Wheels and tires Brake pedal Brake and clutch levers Sidestand Chassis fasteners CHECKS • Check operation. • Lubricate cable if necessary . • Check lever free play . • Adjust if necessary . • Make sure that operation is smooth. • Check ca[...]

PRE-OPERA TION CHECKS 4-4 1 2 3 4 5 6 7 8 9 10 ITEM Instruments, lights, signals and switches Sidestand switch CHECKS • Check operation. • Correct if necessary . • Check operation of ignition circuit cut-off system. • If system is defective, have Y amaha dealer check vehicle. P AGE 3-3, 3-9 3-20 MY03 04-06 ING 6-10-2005 9:24 Pagina 4[...]

1 2 3 4 5 6 7 8 9 10 OPERA TION AND IMPORT ANT RIDING POINTS EAU15950 EWA10270 WARNING 0 ● Become thoroughly familiar with all operating controls and their functions before riding. Consult a Y amaha dealer re- garding any contr ol or function that you do not thoroughly un- derstand. ● Never start the engine or oper- ate it in a closed area for [...]

OPERA TION AND IMPORT ANT RIDING POINTS NOTE: When the transmission is in the neu- tral position, the neutral indicator light should be on, otherwise have a Y ama- ha dealer check the electrical circuit. 3. Start the engine by pushing the start switch. NOTE: If the engine fails to start, release the start switch, wait a few seconds, and then try ag[...]

1 2 3 4 5 6 7 8 9 10 OPERA TION AND IMPORT ANT RIDING POINTS ECA10260 CAUTION: ● 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 distances. The transmission is properly lubricated only when the engine is running. Inade- quate lubrication may dama[...]

OPERA TION AND IMPORT ANT RIDING POINTS EAU17100 0-1000 km (0-600 mi) Avoid prolonged operation above 4500 r/min. 1000-1600 km (600-1000 mi) Avoid prolonged operation above 6000 r/min. ECA11150 CAUTION: After 1000 km (600 mi) of operation, the engine oil must be changed, and the oil filter element replaced. 1600 km (1000 mi) and beyond The vehicle [...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND MINOR REP AIR EAU17240 Safety is an obligation of the owner . Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of inspection, adjustment, and lubrica- tion are explained on the following pages. The inter[...]

PERIODIC MAINTENANCE AND MINOR REP AIR EAU17705 Periodic maintenance and lubrication chart NOTE: ● The annual checks must be performed every year , except if a kilometer -based maintenance is performed in- stead. ● From 50000 km, repeat the maintenance intervals starting from 10000 km. ● Items marked with an asterisk should be performed by a [...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND MINOR REP AIR 6-3 NO. ITEM CHECK OR MAINTENANCE JOB ODOMETER READING (x 1,000 km) 11 0 2 0 3 0 4 0 ANNUAL CHECK √√√√ √ √√√√ √√√√ √ √√√√ √√√√ √√√ √√ √√√√ √ √√√√ √ √√√ √√ √ 8 ✻ 9 ✻ 10 ✻ 11 ✻ 12 ✻ 13 14 ✻ 15 ?[...]

PERIODIC MAINTENANCE AND MINOR REP AIR 6-4 1 2 3 4 5 6 7 8 9 10 • Check operation and for oil leakage. • Check operation and shock absorber for oil leakage. • Check operation. • Lubricate with lithium-soap-based grease. • Adjust engine idling speed. • Change. • Check oil level and vehicle for oil leakage. • Replace. • Check coolan[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND MINOR REP AIR 6-5 6-5 NO. ITEM CHECK OR MAINTENANCE JOB ODOMETER READING (x 1,000 km) 11 0 2 0 3 0 4 0 ANNUAL CHECK • Check the air cut-off valve, reed valve, and hose for damage. • Check fuel hoses for cracks or damage. • Check the screw clamp for looseness. • Check operation. • Adjust headli[...]

PERIODIC MAINTENANCE AND MINOR REP AIR EAU18771 Removing and installing panels The panels shown need to be re- moved to perform some of the mainte- nance jobs described in this chapter . Refer to this section each time a panel needs to be removed and installed. EAUB1290 Panels A and B 1. Panel mounting bolts A. Right panel B. Left panel T o remove [...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND MINOR REP AIR 2. Remove the spark plug as shown, with the spark plug wrench includ- ed in the owner ’ s tool kit. T o check the spark plug 1. Check that the porcelain insulator around the center electrode of the spark plug is a medium-to-light tan (the ideal color when the vehi- cle is ridden normally[...]

PERIODIC MAINTENANCE AND MINOR REP AIR EAUB1350 Engine oil and oil filter element The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter element re- placed at the intervals specified in the pe- riodic maintenance and lubrication chart. T o check the engine oil level 1. Place the vehicle on a[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND MINOR REP AIR ECA10010 CAUTION: Do not operate the vehicle until you know that the engine oil level is suf- ficient. EWA10360 WARNING 0 Never remove the engine oil tank cap after high-speed operation, otherwise hot engine oil could spout out and cause damage or in- jury . Always let the engine oil cool [...]

NOTE: Make sure that the O-rings are proper- ly seated. 9. Install the oil drain bolts, and then tighten them to the specified torques. PERIODIC MAINTENANCE AND MINOR REP AIR 1. Engine oil filter element drain bolt 2. Oil filter element cover bolts NOTE: Skip steps 6-8 if the oil filter element is not being replaced. 6. Remove the oil filter elemen[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND MINOR REP AIR 6-11 Recommended engine oil: See page 8-1. Oil quantity: Without oil filter element replacement: 3.0 L (3.17 US qt) (2.64 Imp.qt) With oil filter element replacement: 3.1 L (3.28 US qt) (2.72 Imp.qt) ECA11620 CAUTION: ● In order to pr event clutch slip- page (since the engine oil also lu[...]

PERIODIC MAINTENANCE AND MINOR REP AIR EAU20070 Coolant The coolant level should be checked before each ride. In addition, the coolant must be changed at the inter- vals specified in the periodic mainte- nance and lubrication chart. EAU20090 T o check the coolant level 1. Place the vehicle on a level sur- face and hold it in an upright posi- tion. [...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND MINOR REP AIR EWA10380 WARNING 0 Never attempt to remove the radia- tor cap when the engine is hot. NOTE: ● The radiator fan is automatically switched on or off according to the coolant temperature in the ra- diator . ● If the engine overheats, see page 3-4 for further instructions. EAU33030 Changin[...]

PERIODIC MAINTENANCE AND MINOR REP AIR 1. Air filter element ECA10480 CAUTION: ● Make sure that the air filter ele- ment is properly seated in the air filter case. ● The engine should never be op- erated without the air filter ele- ment installed, otherwise the piston(s) and/or cylinder(s) may become excessively worn. 4. Install the air filter [...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND MINOR REP AIR Check the engine idling speed and, if necessary , adjust it to specification by turning the idle adjusting screw . T o in- crease the engine idling speed, turn the screw in direction (a). T o decrease the engine idling speed, turn the screw in direction (b). NOTE: If the specified idling s[...]

PERIODIC MAINTENANCE AND MINOR REP AIR EAU21660 Tires T o maximize the performance, durabil- ity , and safe operation of your motor- cycle, note the following points regard- ing the specified tires. Tire air pr essure The tire air pressure should be checked and, if necessary , adjusted before each ride. EWA10500 WARNING 0 ● The tire air pr essure[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND MINOR REP AIR ● Adjust the suspension and tire air pressur e with regar d to the load. ● Check the tire condition and air pressur e before each ride. Tire inspection 1. Tire sidewall 2. Tire tread depth The tires must be checked before each ride. If the center tread depth reaches the specified limit[...]

PERIODIC MAINTENANCE AND MINOR REP AIR Tire information 1. Tire air valve 2. V alve core 3. V alve cap This motorcycle is equipped with cast wheels and tubeless tires with valves. EWA10900 WARNING 0 ● The front and r ear tires should be of the same make and de- sign, otherwise the handling characteristics of the motorcy- cle cannot be guaranteed.[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND MINOR REP AIR EWA10600 WARNING 0 This motorcycle is fitted with super - high-speed tires. Note the following points in order to make the most ef- ficient use of these tires. ● Use only the specified replace- ment tires. Other tir es may run the danger of bursting at super high speeds. ● Brand-new ti[...]

PERIODIC MAINTENANCE AND MINOR REP AIR NOTE: If the specified clutch lever free play could be obtained as described above, tighten the locknut and skip the rest of the procedure, otherwise pro- ceed as follows. 3. Fully turn the adjusting bolt at the clutch lever in direction (a) to loosen the clutch cable. 4. Loosen the locknut at the crankcase. 1[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND MINOR REP AIR EAU22420 Front brake pads 1. Front brake pad wear indicator groove Each front brake pad is provided with a wear indicator groove, which allows you to check the brake pad wear with- out having to disassemble the brake. T o check the brake pad wear , check the wear indicator groove. If a bra[...]

PERIODIC MAINTENANCE AND MINOR REP AIR Insufficient brake fluid may allow air to enter the brake system, possibly caus- ing it to become ineffective. Before riding, check that the brake flu- id is above the minimum level mark and replenish if necessary . A low brake fluid level may indicate worn brake pads and/or brake system leak- age. If the brak[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND MINOR REP AIR 6-23 EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary . EAU22771 T o check the drive chain slack 1. Drive chain slack 1. Place the motorcycle on the side- stand. NOTE: When checking and adjusting the dri- ve chain slack, there sh[...]

PERIODIC MAINTENANCE AND MINOR REP AIR 6-24 1 2 3 4 5 6 7 8 9 10 1. Axle nut 2. Drive chain slack adjusting bolt 3. Locknut 4. Alignment marks ECA10570 CAUTION: Improper drive chain slack will overload the engine as well as oth- er vital parts of the motorcycle and can lead to chain slippage or break- age. T o pr event this from occurring, keep the[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND MINOR REP AIR 6-25 2. Wipe the drive chain dry . 3. Thoroughly lubricate the drive chain with a special O-ring chain lubricant. ECA11110 CAUTION: Do not use engine oil or any other lubricants for the drive chain, as they may contain substances that could damage the O-rings. EAU23100 Checking and lubrica[...]

PERIODIC MAINTENANCE AND MINOR REP AIR 6-26 1 2 3 4 5 6 7 8 9 10 EAU23140 Checking and lubricating the brake and clutch levers Brake lever Clutch lever The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lu- bricated if necessary . Recommended lubricant: Lithium-soap-based grease (all-purp[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND MINOR REP AIR EAU23200 Checking and lubricating the sidestand The operation of the sidestand should be checked before each ride, and the sidestand pivot and metal-to-metal contact surfaces should be lubricated if necessary . EWA10730 WARNING 0 If the sidestand does not move up and down smoothly , have a[...]

PERIODIC MAINTENANCE AND MINOR REP AIR ECA10590 CAUTION: If any damage is found or the front fork does not operate smoothly , have a Y amaha dealer check or re- pair it. EAU23280 Checking the steering Worn or loose steering bearings may cause danger . Therefore, the opera- tion of the steering must be checked as follows at the intervals specified i[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND MINOR REP AIR EAU23290 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals spec- ified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly , have a Y amaha dealer check the wheel bearings. [...]

PERIODIC MAINTENANCE AND MINOR REP AIR 1. Fuel tank couplers 2. Fuel hose 3. Fuel tank breather/overflow hoses 4. Clamps 3. Remove the fuel tank, by remov- ing the bolt and the washer at the rear of the fuel tank, and the two bolts at the front of the fuel tank. 4. Remove the clamp shown, and then remove the fuel hoses. 5. Remove the fuel tank by p[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND MINOR REP AIR T o stor e the battery 1. If the vehicle will not be used for more than one month, remove the battery , fully charge it, and then place it in a cool, dry place. 2. If the battery will be stored for more than two months, check it at least once a month and fully charge it if necessary . 3. F[...]

PERIODIC MAINTENANCE AND MINOR REP AIR 1. Parking lighting fuse 2. Signaling system fuse 3. Headlight fuse 4. Ignition fuse 5. Electronic fuel injection fuse 6. Radiator fan fuse 7. Backup fuse 8. Reserve fuses The main fuse is located under the fu- el tank. (See page 6-31.) The fuse box which contains the fuses for the individual circuits is locat[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND MINOR REP AIR EAUB1360 Replacing the headlight bulb 1. Headlight coupler 2. Headlight bulb cover 1. Headlight bulb holder 2. Headlight bulb This model is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows. 1. T urn the handlebar to the left side to access the h[...]

PERIODIC MAINTENANCE AND MINOR REP AIR ● Headlight lens • Do not affix any type of tinted film or stickers to the head- light lens. • Do not use a headlight bulb of a wattage higher than specified. 5. Install the headlight bulb cover , and then connect the coupler . 6. Have a Y amaha dealer adjust the headlight beam if necessary . EAUB1380 Re[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND MINOR REP AIR 1. Remove the tail/brake light bulb cover by removing the bolts. 2. Remove the socket (together with the bulb) by turning it counter- clockwise. 3. Remove the defective bulb by pushing it in and turning it coun- terclockwise. 4. Insert a new bulb into the socket, push it in, and then turn [...]

PERIODIC MAINTENANCE AND MINOR REP AIR EAUB1410 Replacing the license plate light bulb 1. Reinforcement plate 2. Bulb socket 3. License plate light bulb 1. Remove the reinforcement plate by removing the bolts and nuts. 2. Remove the license plate light bulb socket by pulling it out. NOTE: When removing the license plate light bulb socket, be carefu[...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND MINOR REP AIR 6-37 T o service the r ear wheel Raise the rear wheel off the ground by using a motorcycle stand or , if a mo- torcycle stand is not available, by plac- ing a jack either under each side of the frame in front of the rear wheel or un- der each side of the swingarm. EAU24360 Front wheel EAU3[...]

PERIODIC MAINTENANCE AND MINOR REP AIR 6-38 1 2 3 4 5 6 7 8 9 10 EAU25080 Rear wheel EAU25311 T o r emove the rear wheel EWA10820 WARNING 0 ● It is advisable to have a Y ama- ha dealer service the wheel. ● Securely support the motor cy- cle so that there is no danger of it falling over . 1. Wheel axle nut 2. Drive chain slack adjusting bolt 3. [...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND MINOR REP AIR 6-39 NOTE: ● If the drive chain is difficult to re- move, remove the wheel axle first, and then lift the wheel upward enough to remove the drive chain from the rear sprocket. ● The drive chain cannot be disas- sembled. 7. While supporting the brake caliper bracket, pull the wheel axle [...]

PERIODIC MAINTENANCE AND MINOR REP AIR 1 2 3 4 5 6 7 8 9 10 EAU25921 T r oubleshooting charts Starting problems or poor engine performance WARNING 0 Keep away open flames and do not smoke while checking or working on the fuel system. 1. Fuel 2. Compression 3. Ignition 4. Battery Check the fuel level in the fuel tank. Operate the electric starter . [...]

1 2 3 4 5 6 7 8 9 10 PERIODIC MAINTENANCE AND MINOR REP AIR 6-41 Engine overheating EWA10400 WARNING 0 ● Do not remove the radiator cap when the engine and radiator ar e hot. Scalding hot fluid and steam may be blown out under pressur e, which could cause serious injury . Be sure to wait until the engine has cooled. ● After removing the radiato[...]

MOTORCYCLE CARE AND STORAGE 7-1 1 2 3 4 5 6 7 8 9 10 EAU26000 Care While the open design of a motorcycle reveals the attractiveness of the tech- nology , it also makes it more vulnera- ble. Rust and corrosion can develop even if high-quality components are used. A rusty exhaust pipe may go un- noticed on a car , however , it detracts from the overa[...]

1 2 3 4 5 6 7 8 9 10 MOTORCYCLE CARE AND STORAGE 7-2 ● For motorcycles equipped with a windshield: Do not use strong cleaners or hard sponges as they will cause dulling or scratching. Some cleaning compounds for plastic may leave scratches on the wind- shield. T est the pr oduct on a small hidden part of the wind- shield to make sure that it does[...]

MOTORCYCLE CARE AND STORAGE 7-3 1 2 3 4 5 6 7 8 9 10 EWA10930 WARNING 0 ● Make sure that ther e is no oil or wax on the brakes or tires. If necessary , clean the brake discs and brake linings with a regular brake disc cleaner or acetone, and wash the tires with warm water and a mild de- tergent. ● Before operating the motor cy- cle test its bra[...]

1 2 3 4 5 6 7 8 9 10 MOTORCYCLE CARE AND STORAGE 7-4 Long-term Before storing your motorcycle for several months: 1. Follow all the instructions in the “Care” section of this chapter . 2. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel tank from rusting and the fuel from deteriorating. 3. Perform the following s[...]

SPECIFICA TIONS 8-1 1 2 3 4 5 6 7 8 9 10 Engine oil: T ype: SAE10W30 or SAE10W40 or SAE15W40 or SAE20W40 or SAE20W50 Recommended engine oil grade: API service SE, SF , SG type or higher Engine oil quantity: Without oil filter element replacement: 3.00 L (3.17 US qt) (2.64 Imp.qt) With oil filter element replacement: 3.10 L (3.28 US qt) (2.72 Imp.qt[...]

1 2 3 4 5 6 7 8 9 10 SPECIFICA TIONS 8-2 Operation: Left foot operation Gear ratio: 1 st : 30/12 (2.500) 2 nd : 26/16 (1.625) 3 rd : 23/20 (1.150) 4 th : 20/22 (0.909) 5 th : 20/26 (0.769) Chassis: Frame type: T russ diamond Caster angle: 26° T rail: 97.0 mm (3.81 in) Front tir e: T ype: T ubeless Size: 120/70-ZR17M/C (58W), 120/70-R17M/C (58H) Ma[...]

SPECIFICA TIONS 8-3 1 2 3 4 5 6 7 8 9 10 Electrical system: Ignition system: T ransistorized coil ignition (digital) Charging system: A.C. magneto Battery: Model: GT9B-4 V oltage, capacity: 12 V , 8 Ah Headlight: Bulb type: Halogen bulb Bulb voltage, wattage x quantity: Headlight: 12 V , 55 W/60 W x 1 Auxiliary light: 12 V , 3 W x 1 T ail/brake lig[...]

1 2 3 4 5 6 7 8 9 10 CONSUMER INFORMA TION 9-1 EAU26351 Identification numbers Record the key identification number , vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Y amaha dealer or for reference in case the ve- hicle is stolen. KEY IDENTIFICA TION NUMBER: VEHI[...]

CONSUMER INFORMA TION 9-2 1 2 3 4 5 6 7 8 9 10 EAU26520 Model label 1. Model label The model label is affixed to the frame under the passenger seat. (See page 3-14.) Record the information on this label in the space provided. This infor- mation will be needed when ordering spare parts from a Y amaha dealer . MY03 07-10 ING 5-10-2005 17:09 Pagina 2[...]

1 2 3 4 5 6 7 8 9 10 INDEX A Air filter element, cleaning the check hoses ..................................6-13 Air filter element, replacing ..............6-13 Anti-theft alarm (optional) ...................3-8 Auxiliary light bulb, replacing ...........6-34 B Battery ..............................................6-29 T o access the battery......[...]

INDEX 1 2 3 4 5 6 7 8 9 10 Checking operation procedure .....3-20 Immobilizer system ............................3-1 Immobilizer system indicator light ......3-3 Indicator and warning lights ...............3-4 Coolant temperature warning light .................................................3-4 Engine trouble warning light ...........3-4 Fuel leve[...]

1 2 3 4 5 6 7 8 9 10 INDEX Throttle grip and cable, checking and lubricating ..............................6-25 T ips for reducing fuel consumption ....5-3 T ires .................................................6-16 Air pressure ..................................6-16 T ire information .............................6-18 T ire inspection ............[...]

1 2 3 4 5 6 7 8 9 10 MY03 07-10 ING 5-10-2005 17:09 Pagina 4[...]

PRINTED IN IT AL Y Y AMAHA MOT OR IT ALIA S.P .A. Quarta cop. GB colori 6-10-2005 11:21 Pagina 2[...]