OWNER’S MANUAL MT-03 2BF-F8199-E0
EAU26942 DECLARATION of CONFORMITY We Company: YAMAHA MOTOR ELECTRONICS CO., LTD. Address: 1450-6, Mori, Mori-Machi, Shuchi-gun, Shizuoka-Ken, 437-0292 Japan Hereby declare that the product: Kind of equipment: IMMOBILIZER Type-designation: 5SL-00 is in compliance with following norm(s) or documents: R&TTE Directive(1999/5/EC) EN300 330-2 v1.3.1(2006-01), EN300 330-2 v1.5.
INTRODUCTION EAU10100 Welcome to the Yamaha world of motorcycling! As the owner of the MT-03, you are benefiting from Yamaha’s vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your MT-03.
IMPORTANT MANUAL INFORMATION EAU10151 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING 0 Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander, or a person inspecting or repairing the motorcycle. CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle.
IMPORTANT MANUAL INFORMATION EAUB1011 MT-03 OWNER'S MANUAL 2012 by MBK industrie 1st edition, March 2012 All rights reserved. Any reprinting or unauthorized use without the written permission of MBK industrie is expressly prohibited.
TABLE OF CONTENTS SAFETY INFORMATION .....................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.....................................2-1 Left view............................................2-1 Right view .........................................2-2 Controls and instruments ......
TABLE 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 .....6-34 Replacing the tail/brake light bulb...6-34 Replacing a turn signal light bulb....6-35 Replacing the license plate light bulb...................................
SAFETY INFORMATION EAU10281 1 2 3 4 5 6 7 8 9 10 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: ● OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION. ● OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER'S MANUAL.
SAFETY INFORMATION ● ● • 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 both hands on the handlebar and both feet on the operator footrests during operation to maintain control of the motorcycle.
SAFETY INFORMATION Here are some general guidelines to follow if loading cargo or adding accessories to your motorcycle: 1 2 Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit. 3 4 5 6 7 8 9 10 Maximum load: 186 kg (410 lb) When loading within this weight limit, keep the following in mind: ● Cargo and accessory weight should be kept as low and close to the motorcycle as possible.
SAFETY INFORMATION ● • Certain accessories can displace 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 accessories are not recommended. Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the motorcycle's electrical system, an electric failure could result, which could cause a dangerous loss of lights or engine power.
DESCRIPTION EAU10410 Left view 1 2 3 4 5 6 7 8 9 10 1. 2. 3. 4. 5. Main fuse (page 6-31) Battery (page 6-29) Idle adjusting screw (page 6-14) Air filter element (page 6-13) Owner’s tool kit (page 6-1) 6. 7. 8. 9.
DESCRIPTION EAU10420 Right view 1 2 3 4 5 6 7 8 9 10. 11. 12. 13. 14. Grab bar Fuse box (page 6-32) Rear brake fluid reservoir (page 6-21) Front brake fluid reservoir (page 6-21) Coolant reservoir (page 6-12) 15. 16. 17. 18. 19.
DESCRIPTION EAU10430 Controls and instruments 1 2 3 4 5 6 7 8 9 10 1. 2. 3. 4. Clutch lever (page 3-10) Left handlebar switches (page 3-9) Multi-function meter unit and warning lights (page 3-3, 3-5) Main switch and steering lock (page 3-2) 5. 6. 7. 8.
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 immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following.
INSTRUMENT AND CONTROL FUNCTIONS EAU10471 Main switch/steering lock 1 2 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. 3 4 5 6 7 8 9 10 EAU36870 ON All electrical circuits are supplied with power, the meter lighting, taillight, license plate light and auxiliary lights come on, and the engine can be started. The key cannot be removed.
INSTRUMENT AND CONTROL FUNCTIONS To unlock the steering EAU10941 F (Parking) The steering is locked, and the taillight, license plate light and auxiliary lights are on. The hazard lights and turn signal lights can be turned on, but all other electrical systems are off. The key can be removed. The steering must be locked before the key can be turned to “F”. EAU11003 Indicator and warning lights 1 2 3 4 ECA11020 1. Push 2.
INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 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 immobilizer system is still enabled. This model is also equipped with a self-diagnosis device for the immobilizer system. (See page 3-7 for an explanation of the self-diagnosis device.
INSTRUMENT AND CONTROL FUNCTIONS 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 Yamaha dealer check the electrical circuit. NOTE: This model is also equipped with a self-diagnosis device for the fuel level detection circuit.
INSTRUMENT AND CONTROL FUNCTIONS Tachometer Odometer, tripmeter modes between the various tripmeter, odometer modes in the following order: 1 F-TRIP 6 ODO 6 TRIP 1 6 TRIP 2 6 F-TRIP 2 3 4 1. Tachometer 2. Red zone 1. “SELECT” button 2. “RESET” button 6 The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range.
INSTRUMENT AND CONTROL FUNCTIONS Clock mode If this occurs, have a Yamaha dealer check the vehicle. However, if the indicator light slowly flashes five times, and then quickly flashes two times repeatedly, this error could be caused by signal interference. If this occurs, try the following. Self-diagnosis devices 1. Use the code re-registering key to start the engine. 1. Clock 2. “SELECT” button 3. “RESET” button Turn the key to “ON”. To set the clock 1.
INSTRUMENT AND CONTROL FUNCTIONS If the immobilizer system indicator light flashes any error codes, have a Yamaha dealer check the vehicle. 1 ECA11590 CAUTION: 2 3 4 5 6 7 If the display indicates an error code, the vehicle should be checked as soon as possible in order to avoid engine damage. Indicator lights brightness control mode ● Indicator lights brightness: This function allows you to adjust the brightness of the indicator lights to suit the outside lighting conditions.
INSTRUMENT AND CONTROL FUNCTIONS EAU12343 Handlebar switches Right EAU12460 Turn signal switch “ ” To signal a right-hand turn, push this switch to “ ”. To signal a left-hand turn, push this switch to “ ”. When released, the switch returns to the center position. To cancel the turn signal lights, push the switch in after it has returned to the center position. Left EAU12660 1. Engine stop switch “ 2. Start switch “ ” 1. Pass switch “ ” 2. Dimmer switch “ / 3. Horn switch “ ” 4.
INSTRUMENT AND CONTROL FUNCTIONS EAU12733 1 2 3 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 might be a traffic hazard. 4 6 7 8 9 10 EAU12870 Shift pedal 1. Clutch lever 1. Shift pedal The clutch lever is located at the left handlebar grip.
INSTRUMENT AND CONTROL FUNCTIONS EAU26822 Brake lever EAU12941 Brake pedal EAU13070 Fuel tank cap 1 2 3 4 1. Brake lever 2. Position adjusting dial 3. Arrow mark 4. Distance The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip. The brake lever is equipped with a position adjusting dial.
INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 To close the fuel tank cap 1. Push the fuel tank cap into position with the key inserted in the lock. 2. Turn 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 addition, the key cannot be removed if the cap is not properly closed and locked. EWA11090 6 7 WARNING 0 Make sure that the fuel tank cap is properly closed before riding.
INSTRUMENT AND CONTROL FUNCTIONS ECA11400 CAUTION: 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 system. Your Yamaha engine has been designed to use premium unleaded gasoline with a research octane number of 95 or higher. If knocking (or pinging) occurs, use a gasoline of a different brand. Use of unleaded fuel will extend spark plug life and reduce maintenance costs.
INSTRUMENT AND CONTROL FUNCTIONS ECA10700 1 2 Seats The following precautions must be observed to prevent a fire hazard or other damages. Passenger seat ● 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 grass or other materials that easily burn. 3 4 5 6 7 EAUB1311 CAUTION: ● Do not allow the engine to idle too long. To install the passenger seat 1. Projection 2.
INSTRUMENT AND CONTROL FUNCTIONS To install the rider seat Rider seat 1 2 3 1. Yamaha U-LOCK (optional) 2. Fastening strap 3. Owner’s tool kit The passenger seat is designed to fasten a genuine Yamaha U-LOCK to the bottom of the seat. (Other locks may not fit.) When fastening a ULOCK to the seat, securely fasten it with the straps. When the U-LOCK is not fastened to the seat, be sure to secure the straps to prevent losing them. 4 1. Rider seat mounting bolts To remove the rider seat 1.
INSTRUMENT AND CONTROL FUNCTIONS EAUB1330 Adjusting the shock absorber assembly 1 2 3 A. Distance (spring preload) 4 5 6 7 8 1. Spring preload adjusting nut 2. Locknut (a) Increasing the spring preload (b) Decreasing the spring preload This shock absorber assembly is equipped with a spring preload adjusting nut. Adjust the spring preload as follows. 1. Loosen the locknut. 2. To increase the spring preload and thereby harden the suspension, turn the adjusting nut in direction (a).
INSTRUMENT AND CONTROL FUNCTIONS 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) 1 2 For light operators and primarily use without passenger 3 STANDARD 170 mm (6.69 in) HARD 4 5 165.5 mm (6.49 in) 6 For use with heavy operator and passenger and accessories (trunk, bags, etc.
INSTRUMENT AND CONTROL FUNCTIONS 3. Tighten the locknut to the specified torque. 1 2 Tightening torque: Locknut: 45 Nm (4.5 m·kgf, 32.5 ft·lbf) 3 ECA11240 CAUTION: 4 5 6 7 8 9 10 Always tighten the locknut against the adjusting nut, and then tighten the locknut to the specified torque. EWA10220 WARNING 0 EAU15301 Sidestand This shock absorber contains highly pressurized nitrogen gas. For proper handling, read and understand the following information before handling the shock absorber.
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 contact the ground and distract the operator, resulting in a possible loss of control. Yamaha’s ignition circuit cut-off system has been designed to assist the operator in fulfilling the responsibility of raising the sidestand before starting off.
INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 NOTE: This check is most reliable if performed with a warmed-up engine. With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is turned on. 3. Turn the key on. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? YES NO The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. NO The sidestand switch may be defective.
PRE-OPERATION CHECKS EAU15591 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, 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 serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.
PRE-OPERATION CHECKS EAU15603 Pre-operation check list ITEM 1 2 3 PAGE Fuel • Check fuel level in fuel tank. • Refuel if necessary. • Check fuel line for leakage. 3-12 Engine oil • Check oil level in oil tank. • If necessary, add recommended oil to specified level. • Check vehicle for oil leakage. 6-8 Coolant • Check coolant level in reservoir. • If necessary, add recommended coolant to specified level. • Check cooling system for leakage. 6-12 Front brake • • • • • • • Check operation.
PRE-OPERATION CHECKS ITEM CHECKS Clutch • • • • Check operation. Lubricate cable if necessary. Check lever free play. Adjust if necessary. Throttle grip • Make sure that operation is smooth. • Check cable free play. • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. PAGE 3-10, 6-19, 6-26 1 2 6-15, 6-25 3 Control cables • Make sure that operation is smooth. • Lubricate if necessary. Drive chain • • • • Check chain slack. Adjust if necessary.
PRE-OPERATION CHECKS ITEM 1 2 CHECKS Instruments, lights, signals and switches • Check operation. • Correct if necessary. Sidestand switch • Check operation of ignition circuit cut-off system. • If system is defective, have Yamaha dealer check vehicle.
OPERATION AND IMPORTANT RIDING POINTS EAU15950 WARNING 0 G G G EWA10270 Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. Never start the engine or operate it in a closed area for any length of time. Exhaust fumes are poisonous, and inhaling them can cause loss of consciousness and death within a short time. Always make sure that there is adequate ventilation.
OPERATION AND IMPORTANT RIDING POINTS 1 2 NOTE: When the transmission is in the neutral position, the neutral indicator light should be on, otherwise have a Yamaha dealer check the electrical circuit. 3. Start the engine by pushing the start switch. 3 4 5 6 NOTE: If the engine fails to start, release the start switch, wait a few seconds, and then try again. Each starting attempt should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one attempt.
OPERATION AND IMPORTANT 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. Inadequate lubrication may damage the transmission.
OPERATION AND IMPORTANT RIDING POINTS EAU17100 1 2 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. 3 ECA11150 CAUTION: 4 5 6 ECA10310 CAUTION: ● ● EAU17212 Parking Keep the engine speed out of the tachometer red zone. If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the vehicle.
PERIODIC MAINTENANCE AND MINOR REPAIR 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 lubrication are explained on the following pages. The intervals given in the periodic maintenance and lubrication chart should be simply considered as a general guide under normal riding conditions.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU17705 Periodic maintenance and lubrication chart 1 2 3 NOTE: ● The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. ● From 50000 km, repeat the maintenance intervals starting from 10000 km. ● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. 4 NO.
PERIODIC MAINTENANCE AND MINOR REPAIR NO. ITEM CHECK OR MAINTENANCE JOB ODOMETER READING (x 1,000 km) 1 10 20 30 40 √ • Check for cracks or damage. √ √ √ 8 ✻ Brake hoses 9 ✻ Wheels • Check runout and for damage. √ √ √ √ √ √ √ √ • Replace. 10 ✻ Tires 11 ✻ Wheel bearings • Check bearing for looseness or damage. √ √ √ √ • Check operation and for excessive play. 12 ✻ Swingarm √ √ √ √ Drive chain √ Every 4 years • Check tread depth and for damage.
PERIODIC MAINTENANCE AND MINOR REPAIR NO. 1 CHECK OR MAINTENANCE JOB ODOMETER READING (x 1,000 km) 1 10 20 30 40 ✻ Front fork • Check operation and for oil leakage. √ √ √ √ 19 ✻ Shock absorber assembly • Check operation and shock absorber for oil leakage. √ √ √ √ √ √ √ √ ✻ Side suspension relay arm and connecting arm pivoting points • Check operation. 20 • Lubricate with lithium-soap-based grease. Fuel injection • Adjust engine idling speed.
PERIODIC MAINTENANCE AND MINOR REPAIR NO. ITEM CHECK OR MAINTENANCE JOB 28 ✻ Air induction system • Check the air cut-off valve, reed valve, and hose for damage. • Check fuel hoses for cracks or damage. 29 ✻ Muffler and exhaust pipe • Check the screw clamp for looseness. 30 ✻ Lights, signals and switches • Check operation. • Adjust headlight beam.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU18771 Removing and installing panels 1 2 3 EAUB1290 Panels A and B The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. 4 5 6 7 8 9 10 EAU19602 Checking the spark plug 1. Panel mounting bolts A. Right panel B. Left panel The spark plug is an important engine component, which is easy to check.
PERIODIC MAINTENANCE AND MINOR REPAIR 2. Remove the spark plug as shown, with the spark plug wrench included in the owner’s tool kit. To 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 vehicle is ridden normally). NOTE: If the spark plug shows a distinctly different color, the engine could be defective. Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the vehicle.
PERIODIC MAINTENANCE AND MINOR REPAIR EAUB1350 1 2 3 4 5 6 7 Engine oil and oil filter element To check the engine oil level 1. Place the vehicle on a level surface and hold it in an upright position. The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter element replaced at the intervals specified in the periodic maintenance and lubrication chart. NOTE: Make sure that the vehicle is positioned straight up when checking the oil level.
PERIODIC MAINTENANCE AND MINOR REPAIR ECA10010 CAUTION: Do not operate the vehicle until you know that the engine oil level is sufficient. 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 injury. Always let the engine oil cool down sufficiently before removing the oil tank cap. To change the engine oil (with or without oil filter element replacement) 1.
PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torques: Engine oil drain bolt (crankcase): 30 Nm (3.0 m·kgf, 22 ft·lbf) Engine oil drain bolt (oil tank): 30 Nm (3.0 m·kgf, 22 ft·lbf) 1 2 3 4 5 6 7 8 9 10 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 element cover by removing the bolts. 7. Remove and replace the oil filter element and O-rings. 8.
PERIODIC MAINTENANCE AND MINOR REPAIR ECAB0030 CAUTION: The engine oil tank must be filled in 2 steps. First, fill the engine oil tank with 2.0 L (2.11 US qt) (1.75 Imp.qt) of the recommended engine oil. Then, start the engine, race it 5 or 6 times, turn it off, and then add the remainder of the engine oil. 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.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU20070 Coolant 1 2 3 4 5 6 7 8 9 10 The coolant level should be checked before each ride. In addition, the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart. NOTE: The coolant should be between the minimum and maximum level marks. EAU20090 To check the coolant level 1. Place the vehicle on a level surface and hold it in an upright position.
PERIODIC MAINTENANCE AND MINOR REPAIR EWA10380 WARNING 0 Never attempt to remove the radiator cap when the engine is hot. NOTE: ● The radiator fan is automatically switched on or off according to the coolant temperature in the radiator. ● If the engine overheats, see page 3-4 for further instructions. EAUB1280 Replacing the air filter element and cleaning the check hoses The air filter element should be replaced at the intervals specified in the periodic maintenance and lubrication chart.
PERIODIC MAINTENANCE AND MINOR REPAIR To clean the air filter check hoses EAU34300 Adjusting the engine idling speed 1 2 3 4 1. Air filter element ECA10480 5 6 7 8 9 10 1. Air filter check hose (case cover) CAUTION: ● Make sure that the air filter element is properly seated in the air filter case. ● The engine should never be operated without the air filter element installed, otherwise the piston(s) and/or cylinder(s) may become excessively worn. 1.
PERIODIC MAINTENANCE AND MINOR REPAIR Check the engine idling speed and, if necessary, adjust it to specification by turning the idle adjusting screw. To increase the engine idling speed, turn the screw in direction (a). To decrease the engine idling speed, turn the screw in direction (b).
PERIODIC MAINTENANCE AND MINOR REPAIR EAU21660 Tires 1 2 3 4 To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified tires. Tire air pressure The tire air pressure should be checked and, if necessary, adjusted before each ride. EWA10500 WARNING 0 5 ● 6 7 8 9 10 ● The tire air pressure must be checked and adjusted on cold tires (i.e., when the temperature of the tires equals the ambient temperature).
PERIODIC MAINTENANCE AND MINOR REPAIR ● ● Adjust the suspension and tire air pressure with regard to the load. Check the tire condition and air pressure before each ride. Tire inspection NOTE: The tire tread depth limits may differ from country to country. Always comply with the local regulations. 1 EWA10470 WARNING 0 ● 1. Tire sidewall 2. Tire tread depth The tires must be checked before each ride.
PERIODIC MAINTENANCE AND MINOR REPAIR Tire information G G 1. Tire air valve 2. Valve core 3. Valve cap 6 This motorcycle is equipped with cast wheels and tubeless tires with valves. EWA10900 WARNING 0 G G The front and rear tires should be of the same make and design, otherwise the handling characteristics of the motorcycle cannot be guaranteed. After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Co., Ltd.
PERIODIC MAINTENANCE AND MINOR REPAIR EWA10600 WARNING 0 This motorcycle is fitted with superhigh-speed tires. Note the following points in order to make the most efficient use of these tires. ● Use only the specified replacement tires. Other tires may run the danger of bursting at super high speeds. ● Brand-new tires can have a relatively poor grip on certain road surfaces until they have been "broken in".
PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 3 4 5 6 7 8 EAU22390 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 proceed 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.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU22420 Front brake pads EAU22500 Rear brake pads EAU22580 Checking the brake fluid level Front brake 1 2 3 4 1. Front brake pad wear indicator groove 1. Rear brake pad lining thickness Each front brake pad is provided with a wear indicator groove, which allows you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the wear indicator groove.
PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 3 4 5 6 7 8 9 Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become ineffective. Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. EAU22771 To check the drive chain slack 2. Shift the transmission into the neutral position. 3. Move the rear wheel by pushing the motorcycle to locate the tightest portion of the drive chain, and then measure the drive chain slack as shown. Drive chain slack: 40.0-50.0 mm (1.57-1.97 in) 4. If the drive chain slack is incorrect, adjust it as follows.
PERIODIC MAINTENANCE AND MINOR REPAIR 3. Tighten the locknuts, then the axle nut to their specified torques. 1 Tightening torques: Locknut: 16 Nm (1.6 m·kgf, 11 ft·lbf) Axle nut: 150 Nm (15.0 m·kgf, 108 ft·lbf) 2 3 4 5 6 7 8 9 1. Axle nut 2. Drive chain slack adjusting bolt 3. Locknut 4.
PERIODIC MAINTENANCE AND MINOR REPAIR 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.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23140 Checking and lubricating the brake and clutch levers 1 Brake lever 2 The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary. EAU23180 Lubricating the brake pedal Recommended lubricant: Lithium-soap-based grease (all-purpose grease) 3 4 5 6 The operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23200 Checking and lubricating the sidestand EAUB1240 Lubricating the side suspension EAU23271 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23280 Checking the steering Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 1 2 3 4 5 6 ECA10590 CAUTION: If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or repair it. 7 8 1. Place a stand under the engine to raise the front wheel off the ground.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23290 EAUB1270 Checking the wheel bearings Battery The front and rear wheel bearings must be checked at the intervals specified 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 Yamaha dealer check the wheel bearings. This model is equipped with a sealedtype (MF) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water.
PERIODIC MAINTENANCE AND MINOR REPAIR EWA10760 WARNING 0 ● 1 2 3 4 5 6 7 8 9 1. Fuel tank couplers 2. Fuel hose 3. Fuel tank breather/overflow hoses 4. Clamps 3. Remove the fuel tank, by removing 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 pulling it upward. 6. Remove the battery cover by pulling it upward. 1. Positive battery terminal 2.
PERIODIC MAINTENANCE AND MINOR REPAIR To store 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. Fully charge the battery before installation. 4. After installation, make sure that the battery leads are properly connected to the battery terminals.
PERIODIC MAINTENANCE AND MINOR REPAIR ECA10640 1 2 3 4 5 6 7 8 9 10 1. 2. 3. 4. 5. 6. 7. 8. Parking lighting fuse Signaling system fuse Headlight fuse Ignition fuse Electronic fuel injection fuse Radiator fan fuse Backup fuse Reserve fuses The main fuse is located under the fuel tank. (See page 6-31.) The fuse box which contains the fuses for the individual circuits is located under the rider seat. (See page 3-15.) If a fuse is blown, replace it as follows. 1.
PERIODIC MAINTENANCE AND MINOR REPAIR EAUB1360 Replacing the headlight bulb 1. Turn the handlebar to the left side to access the headlight coupler. 2. Disconnect the headlight coupler, and then remove the bulb cover. 3. Unhook the headlight bulb holder, and then remove the defective bulb. 1 EWA10790 3 2 WARNING 0 1. Headlight coupler 2. Headlight bulb cover Headlight bulbs get very hot.
PERIODIC MAINTENANCE AND MINOR REPAIR ● 1 2 3 4 Headlight lens • Do not affix any type of tinted film or stickers to the headlight lens. • Do not use a headlight bulb of a wattage higher than specified. EAUB1380 EAUB1370 Replacing an auxiliary light bulb Replacing the tail/brake light bulb 1. Auxiliary light socket 2. Auxiliary light bulb 1. Tail/brake light bulb cover 2. Cover bolts 5. Install the headlight bulb cover, and then connect the coupler. 6.
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Remove the tail/brake light bulb cover by removing the bolts. 2. Remove the socket (together with the bulb) by turning it counterclockwise. 3. Remove the defective bulb by pushing it in and turning it counterclockwise. 4. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 5. Install the socket (together with the bulb) by turning it clockwise. 6.
PERIODIC MAINTENANCE AND MINOR REPAIR EAUB1410 Replacing the license plate light bulb 1 2 3 4 5 6 7 8 9 10 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. 3. Remove the defective bulb by pulling it out of the socket. 4. Insert a new bulb into the socket. 5. Install the bulb socket by pushing it in. 6.
PERIODIC MAINTENANCE AND MINOR REPAIR To service the rear wheel Raise the rear wheel off the ground by using a motorcycle stand or, if a motorcycle stand is not available, by placing a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm. EAU24360 Front wheel EAU34390 To remove the front wheel EWA10820 WARNING 0 ● ● It is advisable to have a Yamaha dealer service the wheel. Securely support the motorcycle so that there is no danger of it falling over.
PERIODIC MAINTENANCE AND MINOR REPAIR 4. Install the brake calipers by installing the bolts. EAU25080 Rear wheel EAU25311 1 2 3 4 5 6 7 8 9 NOTE: Make sure that there is enough space between the brake pads before installing the brake calipers onto the brake discs. To remove the rear wheel EWA10820 WARNING 0 ● ● 5. Install the brake hose holders by installing the bolts. 6. Tighten the wheel axle, the front wheel axle pinch bolt and the brake caliper bolts to the specified torques.
PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: ● If the drive chain is difficult to remove, 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 disassembled. 7. While supporting the brake caliper bracket, pull the wheel axle out, and then remove the wheel. EAU34430 To install the rear wheel 1. Install the wheel and the brake caliper bracket by inserting the wheel axle from the right-hand side.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU25921 Troubleshooting charts Starting problems or poor engine performance 1 WARNING 0 Keep away open flames and do not smoke while checking or working on the fuel system. 2 1. Fuel 3 Check the fuel level in the fuel tank. 4 2. Compression 5 Operate the electric starter. 6 There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression.
PERIODIC MAINTENANCE AND MINOR REPAIR Engine overheating EWA10400 WARNING 0 ● ● Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled. After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape.
MOTORCYCLE CARE AND STORAGE EAU26000 Care 1 2 3 4 5 6 7 8 9 10 While the open design of a motorcycle reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop even if high-quality components are used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts from the overall appearance of a motorcycle.
MOTORCYCLE CARE AND STORAGE ● 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 windshield. Test the product on a small hidden part of the windshield to make sure that it does not leave any marks. If the windshield is scratched, use a quality plastic polishing compound after washing.
MOTORCYCLE CARE AND STORAGE EWA10930 WARNING 0 ● 1 2 3 4 ● 5 Make sure that there 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 detergent. Before operating the motorcycle test its braking performance and cornering behavior. NOTE: Consult a Yamaha dealer for advice on what products to use.
MOTORCYCLE CARE AND STORAGE 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 steps to protect the cylinder, piston rings, etc. from corrosion. a. Remove the spark plug cap and spark plug. b. Pour a teaspoonful of engine oil into the spark plug bore. c.
SPECIFICATIONS Dimensions: 1 2 3 4 5 6 Overall length: 2070 mm (81.49 in) Overall width: 860 mm (33.85 in) Overall height: 1115 mm (43.89 in) Seat height: 805 mm (31.69 in) Wheelbase: 1420 mm (55.90 in) Ground clearance: 200 mm (7.87 in) Minimum turning radius: 2225 mm (87.59 in) Basic weight: With oil and fuel: 192 kg (423 lb) 195.2 kg (429 lb) (EU3 version) Engine: 7 8 9 10 Engine type: Liquid cooled 4-stroke, SOHC Cylinder arrangement: Forward-inclined single cylinder Displacement: 660.0 cm3 (40.
SPECIFICATIONS Operation: Left foot operation Gear ratio: 1st: 30/12 (2.500) 2nd: 26/16 (1.625) 3rd: 23/20 (1.150) 4th: 20/22 (0.909) 5th: 20/26 (0.769) Chassis: Frame type: Truss diamond Caster angle: 26° Trail: 97.0 mm (3.
SPECIFICATIONS Electrical system: 1 Ignition system: Transistorized coil ignition (digital) Charging system: A.C.
CONSUMER INFORMATION EAU26351 Identification numbers EAU26381 Key identification number EAU26400 Vehicle identification number 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 Yamaha dealer or for reference in case the vehicle is stolen. 1 2 3 KEY IDENTIFICATION NUMBER: 4 1. Key identification number 2. Code re-registering key (red bow) 3.
CONSUMER INFORMATION EAU26520 Model label 1 2 3 4 1. Model label 5 6 7 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 information will be needed when ordering spare parts from a Yamaha dealer.
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 To access the battery....................6-29 To charge the battery....................6-30 To store the battery.......................6-31 Brake and clutch levers, checking and lubricating ...............
INDEX 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 level warning light ...................3-4 High beam indicator light ................3-4 Immobilizer system indicator light...3-3 Neutral indicator light......................
INDEX Throttle grip and cable, checking and lubricating ..............................6-25 Tips for reducing fuel consumption ....5-3 Tires .................................................6-16 Air pressure ..................................6-16 Tire information.............................6-18 Tire inspection ..............................6-17 Tool kit ................................................6-1 Troubleshooting................................6-39 Troubleshooting charts .................
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MBK Industrie Z.I. de Rouvroy 02100 Saint Quentin Société Anonyme au capital de 45 000 000 e R.
