Yamaha MT-03 Owner'S Manual Download Page 63 | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

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 tires may run
the danger of bursting at super
high speeds.

●

Brand-new tires can have a rel-
atively poor grip on certain
road surfaces until they have
been "broken in". Therefore, it
is advisable before doing any
high-speed riding to ride con-
servatively for approximately
100 km (60 mi) after installing a
new tire.

●

The tires must be warmed up
before a high-speed run.

●

Always adjust the tire air pres-
sure according to the operating
conditions.

EAU21960

Cast wheels

To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points regard-
ing the specified wheels.

●

The wheel rims should be
checked for cracks, bends or
warpage before each ride. If any
damage is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair
to the wheel. A deformed or
cracked wheel must be replaced.

●

The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced.
An unbalanced wheel can result
in poor performance, adverse
handling characteristics, and a
shortened tire life.

●

Ride at moderate speeds after
changing a tire since the tire sur-
face must first be "broken in" for it
to develop its optimal characteris-
tics.

EAU22041

Adjusting the clutch lever
free play

1. Locknut
2. Adjusting bolt
3. Clutch lever free play

The clutch lever free play should mea-
sure 10.0-15.0 mm (0.39-0.59 in) as
shown. Periodically check the clutch
lever free play and, if necessary, ad-
just it as follows.

1. Loosen the locknut at the clutch

lever.

2. To increase the clutch lever free

play, turn the adjusting bolt in di-
rection (a). To decrease the clutch
lever free play, turn the adjusting
bolt in direction (b).

6-19

MY03 04-06 ING 6-10-2005 9:25 Pagina 6-19

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Summary of Contents for MT-03

Page 1: ......

Page 2: ...Bulldog 01 03 ITA 22 06 2004 8 15 Pagina 3 23 ...

Page 3: ...E N G L I S H MY03 01 03 ING 6 10 2005 13 52 Pagina 1 ...

Page 4: ...6 EN60950 2000 Two or Three Wheel Motor Vehicles Directive 97 24 EC Chapter 8 EMC Place of issue Shizuoka Japan Date of issue 1 Aug 2002 Revolution record No Contents Date To change contact person and integrate type designation 9 Jun 2005 General manager of quality assurance div representative name and signature MORIC CO LTD 1450 6 Mori machi Shuchi gun Shizuoka 437 0292 JAPAN Telephone 81 538 85 ...

Page 5: ... so as to enjoy all advantages of your MT 03 The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and others from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha...

Page 6: ...ke procedures easier or clearer NOTE This manual should be considered a permanent part of this motorcycle and should remain with it even if the motor cycle is subsequently sold Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product information available at the time of printing there may be minor discrepancies between your m...

Page 7: ...R S MANUAL 2006 by Yamaha Motor Italia S P A 2nd edition september 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Italia S P A is expressly prohibited Printed in the Italy EAUB1011 ...

Page 8: ...ON AND IMPORTANT RIDING POINTS 5 1 Starting the engine 5 1 Shifting 5 2 Tips for reducing fuel consumption 5 3 Engine break in 5 3 Parking 5 4 PERIODIC MAINTENANCE AND MINOR REPAIR 6 1 Owner s tool kit 6 1 Periodic maintenance and lubrication chart 6 2 Removing and installing panels 6 6 Checking the spark plug 6 6 Engine oil and oil filter element 6 8 Coolant 6 12 Replacing the air filter element ...

Page 9: ...ulb 6 34 Replacing the tail brake light bulb 6 34 Replacing a turn signal light bulb 6 35 Replacing the license plate light bulb 6 36 Supporting the motorcycle 6 36 Front wheel 6 37 Rear wheel 6 38 Troubleshooting 6 39 Troubleshooting charts 6 40 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 MY03 01 03 ING 6 10 2005 13 5...

Page 10: ...an automobile driver who did not see the motorcycle Making yourself conspicuous ap pears to be very effective in re ducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when you are approaching and passing through intersections since in tersections are the most likely places for motorcycle accidents to occur Ride where other motorists can see you Av...

Page 11: ...elmet Wear a face shield or goggles Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abra sions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an ac cident Never...

Page 12: ...educe ground clearance or cornering clearance limit suspension travel steering travel or control operation or ob scure lights or reflectors Accessories fitted to the han dlebar or the front fork area can create instability due to improp er weight distribution or aerody namic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be k...

Page 13: ...ness and death within a short time Always operate your motorcycle in an area that has ad equate ventilation Always turn the engine off before leaving the motorcycle unattend ed and remove the key from the main switch When parking the motorcycle note the following The engine and exhaust sys tem may be hot therefore park the motorcycle in a place where pedestrians or children are not likely to touch...

Page 14: ...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 9 10 MY03 01 03 ING 6 10 2005 13 54 Pagina 12 ...

Page 15: ...e 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 absorber assembly spring preload adjusting ring page 3 16 19 Brake pedal page 3 11 MY03 01 03 ING 6 10 2005 13 56 Pagina 13 ...

Page 16: ...tches 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 11 8 Fuel tank cap page 3 11 2 3 1 2 3 4 5 6 7 8 9 10 MY03 01 03 ING 6 10 2005 13 52 Pagina 14 ...

Page 17: ...OT LOSE THE CODE RE REGISTERING KEY CONTACT YOUR DEALER IMMEDIATELY IF IT IS LOST If the code re reg istering key is lost registering new codes in the standard keys is impossible The standard keys can still be used to start the ve hicle however if code re regis tering is required i e if a new standard key is made or all keys are lost the entire immobilizer system must be replaced Therefore it is h...

Page 18: ...r the meter lighting taillight li cense plate light and auxiliary lights come on and the engine can be start ed The key cannot be removed NOTE The headlight comes on automatically when the engine is started and stays on until the key is turned to OFF even if the engine stalls EAU10660 OFF All electrical systems are off The key can be removed EAU10680 LOCK The steering is locked and all electri cal...

Page 19: ...all other electrical systems are off The key can be removed The steering must be locked before the key can be turned to F ECA11020 CAUTION Do not use the parking position for an extended length of time other wise the battery may discharge EAU11003 Indicator and warning lights 1 Immobilizer system indicator light 2 Neutral indicator light N 3 Turn signal indicator light y 4 High beam indicator ligh...

Page 20: ...e sure that the vehicle is stopped before turning the key to OFF or LOCK EAU11530 Engine trouble warning light U This warning light comes on or flashes when an electrical circuit monitoring the engine is defective When this oc curs have a Yamaha dealer check the self diagnosis system See page 3 7 for an explanation of the self diagno sis device The electrical circuit of the warning light can be ch...

Page 21: ... 6 RESET button EWA12421 WARNING 0 Be sure to stop the vehicle before making any setting changes to the multi function meter unit The multi function meter unit is equip ped with the following a speedometer which shows the riding speed a tachometer which shows en gine speed an odometer which shows the to tal distance traveled two tripmeters which show the distance traveled since they were last set ...

Page 22: ...6 TRIP 2 6 ODO If the fuel level warning light comes on see page 3 4 the odometer display will automatically change to the fuel reserve tripmeter mode F TRIP and start counting the distance traveled from that point In that case push the SELECT button to switch the display between the various tripmeter odometer modes in the following or der F TRIP 6 ODO 6 TRIP 1 6 TRIP 2 6 F TRIP To reset a tripmet...

Page 23: ...immobi lizer system Turn the key to ON If any of the im mobilizer system circuits are defec tive the immobilizer system indicator light will flash and it will indicate an er ror code If this occurs have a Yamaha dealer check the vehicle However if the indi cator light slowly flashes five times and then quickly flashes two times re peatedly this error could be caused by signal interference If this ...

Page 24: ...ws you to adjust the brightness of the indicator lights to suit the outside lighting conditions To adjust the brightness of the indicator lights 1 Turn the key to ON 2 Push the SELECT button to se lect ODO meter mode and then push the RESET button for at least five seconds 3 Release the RESET button and then select the desired lighting brightness level by pushing the RESET button EAU12331 Anti the...

Page 25: ...y To signal a right hand turn push this switch to To signal a left hand turn push this switch to Ÿ When re leased the switch returns to the cen ter position To cancel the turn signal lights push the switch in after it has returned to the center position EAU12660 Engine stop switch I B Set this switch to I before starting the engine Set this switch to B to stop the engine in case of an emergency su...

Page 26: ...ischarge EAU12820 Clutch lever 1 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the han dlebar grip To engage the clutch re lease the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of the igni tion circuit cut off system See pa...

Page 27: ... the adjusting dial while holding the lever pushed away from the handlebar grip Make sure that the appropriate setting on the ad justing dial is aligned with the mark on the brake lever EAU12941 Brake pedal 1 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal EAU13070 Fuel tank cap 1 Lock cover 2 Open To open the fuel tank cap O...

Page 28: ...AU13210 Fuel 1 Fuel tank filler tube 2 Fuel level Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bot tom of the filler tube as shown EWA10880 WARNING 0 Do not overfill the fuel tank otherwise it may overflow when the fuel warms up and expands Avoid spilling fuel on the hot engine ECA10070 CAUTION Immediately wipe off spilled fuel with a clean dry soft cloth since fue...

Page 29: ...AUTION Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust sys tem Your Yamaha engine has been de signed to use premium unleaded gasoline with a research octane num ber of 95 or higher If knocking or pinging occurs use a gasoline of a different brand Use of unleaded fuel will extend sp...

Page 30: ...remove the passenger seat 1 Insert the key into the seat lock and then turn it counterclockwise 2 Pull the passenger seat off ECA10700 CAUTION The following precautions must be observed to prevent a fire hazard or other damages Use only unleaded gasoline The use of leaded gasoline will cause unrepairable damage to the catalytic converter Never park the vehicle near possible fire hazards such as gr...

Page 31: ...e seat be sure to se cure the straps to prevent losing them Rider seat 1 Rider seat mounting bolts To remove the rider seat 1 Remove the passenger seat 2 Remove the bolts and then pull the rider seat off To install the rider seat 1 Projection 2 Seat holder 1 Insert the projection on the front of the rider seat into the seat hold er as shown place the seat in the original position and then tighten ...

Page 32: ... distance A shown in the illustration The longer distance A is the lower the spring preload the shorter dis tance A is the higher the spring preload With each complete turn of the adjusting nut distance A changes by 1 5 mm 0 059 in When measuring distance A the rear wheel must be raised off the ground See page 6 36 EAUB1330 Adjusting the shock absorber assembly 1 Spring preload adjusting nut 2 Loc...

Page 33: ...tance 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 STANDARD 170 mm 6 69 in HARD 165 5 mm 6 49 in For use with heavy operator and passenger and accessories trunk bags etc MY03 01 03 ING 6 10 2005 13 53 Pagina 3 17 ...

Page 34: ...knut to the specified torque EWA10220 WARNING 0 This shock absorber contains high ly pressurized nitrogen gas For proper handling read and under stand the following information be fore handling the shock absorber The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling Do not tamper with or attempt to open the gas cylinder Do not sub...

Page 35: ...does not function properly 3 19 EAU15311 Ignition circuit cut off system The ignition circuit cut off system comprising the sidestand switch clutch switch and neutral switch has the following functions It prevents starting when the transmission is in gear and the sidestand is up but the clutch lever is not pulled It prevents starting when the transmission is in gear and the clutch lever is pulled ...

Page 36: ...gine stall NOTE This check is most reliable if performed with a warmed up engine The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer Aft...

Page 37: ...e serious consequences Therefore it is very important in addition to a thorough vi sual inspection to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved EWA11150 WARNING 0 If any item in the Pre operation ch...

Page 38: ... cooling system for leakage Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary ...

Page 39: ...t operation is smooth Lubricate if necessary Check chain slack Adjust if necessary Check chain condition Lubricate if necessary Check for damage Check tire condition and tread depth Check air pressure Correct if necessary Make sure that operation is smooth Lubricate pedal pivoting point if necessary Make sure that operation is smooth Lubricate lever pivoting points if necessary Make sure that oper...

Page 40: ...ments 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 Yamaha dealer check vehicle PAGE 3 3 3 9 3 20 MY03 04 06 ING 6 10 2005 9 24 Pagina 4 ...

Page 41: ...to enable starting one of the following conditions must be met The transmission is in the neutral position The transmission is in gear with the clutch lever pulled and the sidestand up EWA10290 WARNING 0 Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure de scribed on page 3 20 Never ride with the sidestand down 1 Turn the key to ON an...

Page 42: ...e more than 10 seconds on any one attempt ECA11040 CAUTION For maximum engine life never ac celerate hard when the engine is cold NOTE The engine is warm when it quickly re sponds to the throttle EAU16671 Shifting 1 Shift pedal N Neutral position Shifting gears lets you control the amount of engine power available for starting off accelerating climbing hills etc The gear positions are shown in the...

Page 43: ...on Shift up swiftly and avoid high en gine speeds during acceleration Do not rev the engine while shift ing down and avoid high engine speeds with no load on the en gine Turn the engine off instead of let ting it idle for an extended length of time e g in traffic jams at traf fic lights or at railroad crossings EAU16841 Engine break in There is never a more important peri od in the life of your en...

Page 44: ...eed out of the tachometer red zone If any engine trouble should oc cur during the engine break in period immediately have a Yamaha dealer check the vehicle EAU17212 Parking When parking stop the engine and then remove the key from the main switch EWA10310 WARNING 0 Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them Do...

Page 45: ...e maintenance work have a Yamaha dealer do it for you EAUB1400 Owner s tool kit 1 Owner s tool kit 2 Fastening strap The owner s tool kit is located on the bottom of the passenger seat See page 3 14 and it held in place with an O ring The service information included in this manual and the tools provided in the owner s tool kit are intended to as sist you in the performance of preven tive maintena...

Page 46: ...kills 6 2 1 2 3 4 5 6 7 8 9 10 NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READING x 1 000 km 1 10 20 30 40 ANNUAL CHECK 1 2 3 4 5 6 7 Check fuel hoses for cracks or damage Check condition Clean and regap Replace Check valve clearance Adjust Replace Check operation Adjust Check operation fluid level and vehicle for fluid leakage Replace brake pads Check operation fluid level and vehicle for fluid le...

Page 47: ...te with lithium soap based grease Check chain slack alignment and condition Adjust and lubricate chain with a special O ring chain lubricant thoroughly Check bearing play and steering for roughness Lubricate with lithium soap based grease Make sure that all nuts bolts and screws are properly tightened Check operation Lubricate Check operation Every 4 years Brake hoses Wheels Tires Wheel bearings S...

Page 48: ...ration Lubricate Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable Front fork Shock absorber assembly Side suspension relay arm and connecting arm pivoting points Fuel injection Engine oil Engine oil filter element Cooling system Front and rear brake switches Moving parts and cables Throttle grip housing and cable 18 19 20 ...

Page 49: ...adlight beam Air induction system Muffler and exhaust pipe Lights signals and switches 28 29 30 EAU18670 NOTE The air filter needs more frequent service if you are riding in unusually wet or dusty areas Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinders and calipers and change the brak...

Page 50: ...To install a panel 1 Insert the panel on the hook and slide the panel downward to the original position 2 Install the bolts EAU19602 Checking the spark plug The spark plug is an important engine component which is easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checked in accordance with the peri odic maintenance and lubrication ...

Page 51: ...e it if necessary 6 7 Specified spark plug CR7E NGK Spark plug gap 0 7 0 8 mm 0 028 0 032 in Tightening torque Spark plug 12 5 Nm 1 25 m kgf 9 0 ft lbf To install the spark plug 1 Measure the spark plug gap with a wire thickness gauge and if necessary adjust the gap to specification 1 Spark plug gap 1 2 Clean the surface of the spark plug gasket and its mating sur face and then wipe off any grime ...

Page 52: ... the engine warm it up for 10 15 minutes let it continue to idle for 20 30 seconds and then turn it off 3 Wait a few minutes until the oil settles remove the oil filler cap wipe the dipstick clean insert it back into the oil filler hole without screwing it in and then remove it again to check the oil level 1 Engine oil filler cap 2 Maximum level mark 3 Minimum level mark EWAB0010 WARNING 0 The exh...

Page 53: ...pe to raise it to the correct level 5 Install the oil filler cap To change the engine oil with or without oil filter element replacement 1 Start the engine warm it up for several minutes and then turn it off 2 Place the motorcycle on its side stand then place an oil pan under the oil tank and another under the engine to collect the used oil 3 Remove the engine oil filler cap and the drain bolt to ...

Page 54: ... 8 Install the oil filter element cover by installing the bolts and the oil filter element drain bolt then tightening them to the specified torques 1 Engine oil filter element 2 O rings 6 10 1 2 3 4 5 6 7 8 9 10 Tightening torques Oil filter element cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf Oil filter element drain bolt 10 Nm 1 0 m kgf 7 2 ft lbf Tightening torques Engine oil drain bolt crankcase 30 N...

Page 55: ...d In addition do not use oils la beled ENERGY CONSERVING II or higher Make sure that no foreign ma terial enters the crankcase 11 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the en gine off and check for the cause 12 Turn the engine off and then check the oil level and correct it if necessary ECAB0030 CAUTION The en...

Page 56: ... Coolant reservoir 2 Maximum level mark 3 Minimum level mark 4 Reservoir cap 3 If the coolant is at or below the minimum level mark open the reservoir cap add coolant to the maximum level mark and then close the reservoir cap ECA10470 CAUTION If coolant is not available use distilled water or soft tap water instead Do not use hard water or salt water since it is harmful to the engine If water has ...

Page 57: ...e and lubrication chart Have a Yamaha dealer change the coolant EAUB1280 Replacing the air filter element and cleaning the check hoses The air filter element should be re placed at the intervals specified in the periodic maintenance and lubrication chart Replace the air filter element more frequently if you are riding in un usually wet or dusty areas In addition the air filter check hoses must be ...

Page 58: ...ir filter check hose case cover 1 Check the hoses shown for accu mulated dirt water or oil 2 If dirt water or oil is visible re move the hose clean it and then install it in its original position EAU34300 Adjusting the engine idling speed 1 Idle adjusting screw The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lu...

Page 59: ... EAU21381 Checking the throttle cable free play 1 Throttle cable free play The throttle cable free play should measure 3 0 5 0 mm 0 12 0 20 in at the throttle grip Periodically check the throttle cable free play and if neces sary have a Yamaha dealer adjust it 6 15 Engine idling speed 1300 1500 r min 1400 1600 r min EU3 version EAU21401 Valve clearance The valve clearance changes with use resultin...

Page 60: ... you should keep the following precau tions in mind NEVER OVERLOAD THE MO TORCYCLE Operation of an overloaded motorcycle may re sult in tire damage loss of con trol or severe injury Make sure that the total weight of rider passenger cargo and acces sories does not exceed the specified maximum load for the vehicle Do not carry along loosely packed items which can shift during a ride Securely pack t...

Page 61: ...a ha dealer replace the tire immediately NOTE The tire tread depth limits may differ from country to country Always com ply with the local regulations EWA10470 WARNING 0 Have a Yamaha dealer replace excessively worn tires Besides being illegal operating the ve hicle with excessively worn tires decreases riding stability and can lead to loss of control The replacement of all wheel and brake related...

Page 62: ...for this model by Yamaha Motor Italia S P A Always make sure that the valve caps are securely in stalled to prevent air pressure leakage Use only the tire valves and valve cores listed below to avoid tire deflation during a ride 6 18 1 2 3 4 5 6 7 8 9 10 Front tire Size 120 70 ZR17 M C 58W 120 70 R17 M C 58H Manufacturer model DUNLOP D270F PIRELLI SCORPION SYNC Tire air valve TR412 Valve core 9000...

Page 63: ...hould be checked for cracks bends or warpage before each ride If any damage is found have a Yamaha dealer replace the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced The wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse handling characteristics an...

Page 64: ...nkcase 1 Locknut 2 Clutch lever free play adjusting nut crankcase 5 To increase the clutch lever free play turn the adjusting nut in di rection a To decrease the clutch lever free play turn the adjusting nut in direction b 6 Tighten the locknut at the clutch lever and the crankcase EAU22390 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the interva...

Page 65: ... has worn to the point that the wear indicator groove has almost dis appeared have a Yamaha dealer re place the brake pads as a set EAU22500 Rear brake pads 1 Rear brake pad lining thickness Check each rear brake pad for dam age and measure the lining thickness If a brake pad is damaged or if the lin ing thickness is less than 1 0 mm 0 04 in have a Yamaha dealer re place the brake pads as a set EA...

Page 66: ...d to poor braking performance Be careful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid imme diately As the brake pads wear it is nor mal for the brake fluid level to gradually go down However i...

Page 67: ...tion of the drive chain and then measure the drive chain slack as shown 4 If the drive chain slack is incor rect adjust it as follows Drive chain slack 40 0 50 0 mm 1 57 1 97 in EAU34311 To adjust the drive chain slack 1 Loosen the axle nut and the lock nut on each side of the swingarm 2 To tighten the drive chain turn the adjusting bolt on each side of the swingarm in direction a To loosen the dr...

Page 68: ...g 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 ECA10581 CAUTION The drive chain must be lubricated after washing the motorcycle and riding in the rain 1 Clean the drive chai...

Page 69: ...the ca bles and cable ends should be lubri cated if necessary If a cable is dam aged or does not move smoothly have a Yamaha dealer check or re place it Recommended lubricant Engine oil EWA10720 WARNING 0 Damage to the outer sheath may in terfere with proper cable operation and will cause the inner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EAU23111 Chec...

Page 70: ...ked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all purpose grease EAU23180 Lubricating the brake pedal The operation of the brake pedal should be checked before each ride and the pedal pivot should be lubricat ed if necessary Recommended lubricant Lithium soap based grease all purpose grease MY03 04 06 ING 6 10 2005 9 25...

Page 71: ... based grease all purpose grease Recommended lubricant Swingarm pivots Bearing grease Other pivoting points Lithium soap based grease EAU23271 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the period ic maintenance and lubrication chart To check the condition EWA10750 WARNING 0 Securely support the motorcycle so that ...

Page 72: ...ked as follows at the intervals specified in the periodic maintenance and lubrica tion chart 1 Place a stand under the engine to raise the front wheel off the ground 6 28 1 2 3 4 5 6 7 8 9 10 EWA10750 WARNING 0 Securely support the motorcycle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be...

Page 73: ... bearings EAUB1270 Battery This model is equipped with a sealed type MF battery which does not re quire any maintenance There is no need to check the electrolyte or to add distilled water ECA10620 CAUTION Never attempt to remove the bat tery cell seals as this would perma nently damage the battery To access the battery 1 Remove the passenger seat and rider seat See page 3 14 2 Remove panels A and ...

Page 74: ...f the vehicle is equipped with optional electrical accessories EWA10760 WARNING 0 Electrolyte is poisonous and dangerous since it contains sulfuric acid which causes se vere burns Avoid any contact with skin eyes or clothing and always shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan ti...

Page 75: ...ion 4 After installation make sure that the battery leads are properly connected to the battery termi nals ECA10630 CAUTION Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a special constant voltage battery charger is re quired Using a conventional battery charger will damage the battery If you do not have access to...

Page 76: ...a new fuse of the specified amperage ECA10640 CAUTION Do not use a fuse of a higher am perage rating than recommended to avoid causing extensive damage to the electrical system and possi bly a fire 3 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system 6 32 1 2 3 4 5 ...

Page 77: ...0790 WARNING 0 Headlight bulbs get very hot There fore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down 4 Place a new headlight bulb into position and then secure it with the bulb holder 1 Do not touch this area ECA10650 CAUTION Take care not to damage the fol lowing parts Headlight bulb Do not touch the glass part of the headlight bulb to k...

Page 78: ...light bulb If the auxiliary light bulb burns out re place it as follows 1 Turn the handlebar to the right or left side to access the auxiliary light socket 2 Remove the auxiliary light socket together with the bulb by pulling it 3 Remove the defective bulb by pulling it out 4 Insert a new bulb into the socket 5 Install the auxiliary light socket together with the bulb by push ing it in EAUB1370 Re...

Page 79: ...b cover in its original position insert the bolts and then tighten them to the specified torque EAU24202 Replacing a turn signal light bulb 1 Screw 2 Turn signal light lens 3 Turn signal light bulb 1 Remove the turn signal light lens by removing the screw 2 Remove the defective bulb by pushing it in and turning it coun terclockwise 3 Insert a new bulb into the socket push it in and then turn it cl...

Page 80: ...ny 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 6 36 1 2 3 4 5 6 7 8 9 10 3 Remove t...

Page 81: ... pinch bolt 2 Wheel axle bolt 3 Brake caliper bolts 4 Brake hose holder bolt 1 Lift the front wheel off the ground according to the procedure on page 6 36 2 Loosen the front wheel axle pinch bolt then the wheel axle and the brake caliper bolts 3 Remove the brake hose holder on each side by removing the bolts 4 Remove the brake caliper on each side by removing the bolts ECA11050 CAUTION Do not appl...

Page 82: ...urn the drive chain slack adjust ing bolts fully in direction a and push the wheel forward 6 Remove the drive chain from the rear sprocket 4 Install the brake calipers by in stalling the bolts NOTE Make sure that there is enough space between the brake pads before in stalling the brake calipers onto the brake discs 5 Install the brake hose holders by installing the bolts 6 Tighten the wheel axle t...

Page 83: ... drive chain onto the rear sprocket 3 Install the axle nut and then low er the rear wheel so that it is on the ground 4 Adjust the drive chain slack See page 6 23 5 Tighten the axle nut to the speci fied torque Tightening torque Axle nut 150 Nm 15 0 m kgf 108 ft lbf EAU25870 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur...

Page 84: ...engine turns over quickly There is no fuel There is no compression Dry The engine turns over slowly Check the compression Check the ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug The battery is good Have a Yamaha dealer check the vehicle Check the battery lead connections and charge the battery if necessary Open the throttle halfway and operate the elec...

Page 85: ...scape When the hiss ing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap NOTE If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is low Check the coolin...

Page 86: ...chain and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA10770 CAUTION Avoid using strong acidic wheel cleaners especially on spoked wheels If such prod ucts are used on hard to re move dirt do not leave the cleaner on the affected area any longer than instructed Al so thoroughly rinse the area off with water immediately dry it and then apply a corrosion protection spra...

Page 87: ... in the rain near the sea or on salt sprayed roads NOTE Salt sprayed on roads in the winter may remain well into spring 1 Clean the motorcycle with cold water and a mild detergent after the engine has cooled down ECA10790 CAUTION Do not use warm water since it in creases the corrosive action of the salt 2 Apply a corrosion protection spray on all metal including chrome and nickel plated sur faces ...

Page 88: ...any rubber and plastic parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint NOTE Consult a Yamaha dealer for advice on what products to use EAUM1900 Storage Short term Always store your motorcycle in a cool dry place and if necessary protect it against dust with a porous cover ECA10810 CAUTION Storing the motorcycle in a poorly...

Page 89: ...park plug and then install the spark plug and the spark plug cap EWA10950 WARNING 0 To prevent damage or injury from sparking make sure to ground the spark plug electrodes while turning the engine over 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 5 Check and if necessary correct the tire air pressure and then lift the moto...

Page 90: ...t 4 25 L 1 12 US gal 0 93 Imp gal Fuel injection Manufacturer DENSO Model 297500 0390 Spark plug Manufacturer model NGK CR7E Gap 0 7 0 8 mm 0 028 0 032 in Clutch Clutch type Wet multiple disc Transmission Primary reduction system Spur gear Primary reduction ratio 75 36 2 083 Secondary reduction system Chain drive Secondary reduction ratio 47 15 3 133 Transmission type Constant mesh 5 speed Dimensi...

Page 91: ...old tires Load Up to 90 kg 0 198 lb Front 210 kPa 30 psi 2 1 kgf cm3 Rear 230 kPa 33 psi 2 3 kgf cm3 Load 90 186 kg 198 410 lb Front 230 kPa 33 psi 2 3 kgf cm3 Rear 250 kPa 36 psi 2 5 kgf cm3 High speed riding Front 210 kPa 30 psi 2 1 kgf cm3 Rear 230 kPa 33 psi 2 3 kgf cm3 Front wheel Type Cast wheel Rim size 17M C x MT3 50 Rear wheel Type Cast wheel Rim size 17M C x MT5 00 Front brake Type Dual ...

Page 92: ...12 V 10 W x 2 Rear turn signal light 12 V 10 W x 2 Meter lighting LED backlight Neutral indicator light LED Turn signal indicator light LED High beam indicator light LED Fuel level warning light LED Coolant temperature warning light LED Engine trouble warning light LED Immobilizer system indicator light LED Fuses Main fuse 30 A Headlight fuse 20 A Signaling system fuse 10 A Ignition fuse 10 A Park...

Page 93: ...ber 1 Key identification number 2 Code re registering key red bow 3 Standard keys black bow The key identification number is stamped into the key tag Record this number in the space pro vided and use it for reference when or dering a new key EAU26400 Vehicle identification number 1 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this nu...

Page 94: ... 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 Yamaha dealer MY03 07 10 ING 5 10 2005 17 09 Pagina 2 ...

Page 95: ...y adjusting 6 19 Consumer information 9 1 Controls and instruments 2 3 Function 3 1 Coolant 6 12 Coolant temperature warning light 3 4 D Description 2 1 Controls and instrument 2 3 Left view 2 1 Right view 2 2 Dimmer switch 3 9 Drive chain cleaning and lubricating 6 24 Drive chain slack 6 23 Adjusting 6 23 Checking 6 23 E Engine break in 5 3 Engine idling speed adjusting 6 14 Engine oil and oil fi...

Page 96: ...brightness control mode 3 8 Odometer tripmeter modes 3 6 Self diagnosis devices 3 7 Tachometer 3 6 N Neutral indicator light 3 4 O Odometer tripmeter modes 3 6 Oil filter element 6 10 Operation and important riding points 5 1 Owner s tool kit 6 1 P Panels removing and installing 6 6 Parking 5 4 Pass switch 3 9 Periodic maintenance and lubrication chart 6 2 Periodic maintenance and minor repair 6 1...

Page 97: ...6 18 Tire inspection 6 17 Tool kit 6 1 Troubleshooting 6 39 Troubleshooting charts 6 40 Engine overheating 6 41 Turn signal indicator light 3 4 Turn signal light bulb replacing 6 35 Turn signal switch 3 9 V Valve clearance 6 15 Vehicle identification number 9 1 W Warning lights 3 4 Wheel bearings checking 6 29 Wheels cast 6 19 MY03 07 10 ING 5 10 2005 17 09 Pagina 3 ...

Page 98: ...1 2 3 4 5 6 7 8 9 10 MY03 07 10 ING 5 10 2005 17 09 Pagina 4 ...

Page 99: ...PRINTED IN ITALY YAMAHA MOTOR ITALIA S P A Quarta cop GB colori 6 10 2005 11 21 Pagina 2 ...

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