Yamaha MT-03 2006 Manuals

Manuals and User Guides for Yamaha MT-03 2006. We have 1 Yamaha MT-03 2006 manual available for free PDF download: Service Manual

Yamaha MT-03 2006 Service Manual

Yamaha MT-03 2006 Service Manual (400 pages)

Brand: Yamaha | Category: Motorcycle | Size: 15.92 MB

Table of Contents

Table of Contents

6
- How to Use this Manual
  4
- Symbols
  5
- General Information
  8
  - Identification
    10
    
    Vehicle Identification Number
    10
    
    Model Label
    10
  - Features
    11
    
    Outline of the Fi System
    11
    
    Fi System
    12
    
    Instrument Functions
    13
  - Important Information
    16
    
    Preparation for Removal and Disassembly
    16
    
    Replacement Parts
    16
    
    Gaskets, Oil Seals and O-Rings
    16
    
    Lock Washers/Plates and Cotter Pins
    16
    
    Bearings and Oil Seals
    17
    
    Circlips
    17
  - Checking the Connections
    18
  - Special Tools
    19
Special Tools

22
- Specifications
  24
  - General Specifications
    26
  - Engine Specifications
    27
  - Chassis Specifications
    35
  - Electrical Specifications
    38
  - Tightening Torques
    41
    
    General Tightening Torque Specifications
    41
    
    Engine Tightening Torques
    42
    
    Chassis Tightening Torques
    45
  - Lubrication Points and Lubricant Types
    48
    
    Engine
    48
    
    Chassis
    50
  - Cooling System Diagrams
    51
  - Lubrication Chart
    55
    
    Lubrication Diagrams
    57
  - Cable Routing
    65
Periodic Checks and Adjustments

88
- Periodic Maintenance
  
  90
  - Introduction
    90
  - Periodic Maintenance and Lubrication Chart
    90
- Engine
  
  92
  - Adjusting the Valve Clearance
    92
  - Thickness Gauge
    93
  - Adjusting the Engine Idling Speed
    94
  - Adjusting the Throttle Cable Free Play
    94
  - Checking the Spark Plug
    95
  - Checking the Ignition Timing
    96
  - Measuring the Compression Pressure
    97
  - Checking the Engine Oil Level
    98
  - Changing the Engine Oil
    99
  - Adjusting the Clutch Cable Free Play
    100
  - Checking the Air Filter Element
    101
  - Checking the Throttle Body Joint
    102
  - Checking the Fuel Hose
    102
  - Checking the Fuel Tank Breather/Overflow Hoses
    102
  - Checking the Crankcase Breather Hoses
    102
  - Checking the Exhaust System
    103
  - Checking the Coolant Level
    103
  - Checking the Cooling System
    104
  - Changing the Coolant
    105
- Chassis
  
  107
  - Adjusting the Front Brake
    107
    
    Adjusting the Rear Brake Pedal
    107
    
    Checking the Brake Fluid Level
    108
    
    Checking the Front and Rear Brake Pads and Brake Pad Pins
    109
    
    Checking the Front and Rear Brake Hoses
    109
    
    Bleeding the Hydraulic Brake System
    110
    
    Adjusting the Shift Pedal
    111
    
    Adjusting the Drive Chain Slack
    111
    
    Lubricating the Drive Chain
    112
    
    Checking and Adjusting the Steering Head
    112
    
    Checking the Front Fork
    114
    
    Adjusting the Rear Shock Absorber Assembly
    114
    
    Checking the Tires
    115
    
    Checking the Wheels
    116
    
    Checking and Lubricating the Cables
    117
    
    Lubricating the Levers and Brake Pedal
    117
    
    Lubricating the Sidestand
    117
    
    Lubricating the Side Suspension
    117
Chassis

122
- General Chassis
  
  124
- Front Wheel
  
  129
  - Removing the Front Wheel
    131
  - Disassembling the Front Wheel
    131
  - Checking the Front Wheel
    131
  - Assembling the Front Wheel
    132
  - Adjusting the Front Wheel Static Balance
    132
  - Checking the Front Brake Discs
    133
  - Installing the Front Wheel (Front Brake Discs)
    133
- Rear Wheel
  
  135
  - Removing the Rear Wheel
    138
  - Disassembling the Rear Wheel
    138
  - Checking the Rear Wheel
    138
  - Checking the Rear Wheel Drive Hub
    139
  - Checking and Replacing the Rear Wheel Sprocket
    139
  - Assembling the Rear Wheel
    139
  - Adjusting the Rear Wheel Static Balance
    139
  - Checking the Rear Brake Disc
    139
  - Installing the Rear Wheel (Rear Brake Disc)
    139
- Front Brake
  
  141
- Rear Brake
  
  153
  - Introduction
    158
  - Checking the Rear Brake Disc
    158
  - Replacing the Rear Brake Pads
    158
  - Removing the Rear Brake Caliper
    159
  - Disassembling the Rear Brake Caliper
    159
  - Checking the Rear Brake Caliper
    160
  - Assembling the Rear Brake Caliper
    160
  - Installing the Rear Brake Caliper
    160
  - Removing the Rear Brake Master Cylinder
    161
  - Checking the Rear Brake Master Cylinder
    162
  - Assembling the Rear Brake Master Cylinder
    162
  - Installing the Rear Brake Master Cylinder
    162
- Handlebar
  
  164
  - Removing the Handlebar
    166
  - Checking the Handlebar
    166
  - Installing the Handlebar
    166
- Front Fork
  
  169
  - Removing the Front Fork Legs
    172
  - Disassembling the Front Fork Legs
    172
  - Checking the Front Fork Legs
    173
  - Assembling the Front Fork Legs
    174
  - Installing the Front Fork Legs
    176
- Steering Head
  
  178
  - Removing the Lower Bracket
    180
  - Checking the Steering Head
    180
  - Ring Nut Wrench
    180
    
    Installing the Steering Head
    181
- Rear Shock Absorber Assembly
  
  184
- Swingarm
  
  186
  - Removing the Swingarm
    188
  - Checking the Swingarm
    188
  - Installing the Swingarm
    189
- Chain Drive
  
  190
  - Removing the Drive Chain
    191
  - Checking the Drive Chain
    191
  - Removing the Drive Sprocket
    192
  - Checking the Drive Sprocket
    192
  - Checking the Rear Wheel Sprocket
    192
  - Checking the Rear Wheel Drive Hub
    192
  - Installing the Drive Chain
    192
Engine

194
- Engine Removal
  
  202
  - Engine Alignment Tool
    202
  - Installing the Engine
    202
- Cylinder Head
  
  204
- Rocker Arms and Camshaft
  
  211
- Valves and Valve Springs
  
  216
  - Removing the Valves
    216
  - Checking the Valves and Valve Guides
    216
  - Valve Guide Remover (Ø 6)
    217
  - Checking the Valve Seats
    218
  - Checking the Valve Springs
    219
  - Installing the Valves
    220
- Cylinder and Piston
  
  223
  - Removing the Cylinder and Piston
    223
  - Checking the Cylinder and Piston
    223
  - Piston Pin Puller Set
    223
  - Checking the Piston Rings
    224
  - Checking the Piston Pin
    225
  - Installing the Piston and Cylinder
    225
- Clutch
  
  228
  - Clutch Cover
    228
  - Clutch
    229
  - Removing the Clutch
    231
  - Checking the Friction Plates
    231
  - Checking the Clutch Plates
    231
  - Checking the Clutch Springs
    232
  - Checking the Clutch Housing
    232
  - Checking the Clutch Boss
    232
  - Checking the Pressure Plate
    233
  - Checking the Pull Lever Shaft and Pull Rod
    233
  - Checking the Primary Driven Gear
    233
  - Installing the Clutch
    233
- Oil Pump
  
  239
  - Checking the Oil Pump
    239
  - Checking the Oil Delivery Pipes and Hoses
    239
  - Assembling the Oil Pump
    240
  - Installing the Oil Pump
    240
- Balancer Driven Gear
  
  241
- Shift Shaft
  
  244
  - Shift Shaft and Stopper Lever
    244
  - Checking the Shift Shaft
    246
  - Checking the Stopper Lever
    246
  - Installing the Shift Shaft
    246
- Starter Clutch and A.C. Magneto
  
  249
  - Removing the A.C. Magneto Rotor
    249
  - Checking the Stator Coil and Crankshaft Position Sensor
    249
  - Flywheel Puller
    249
  - Checking the Starter Clutch
    250
  - Checking the Torque Limiter
    250
  - Installing the A.C. Magneto Rotor
    250
- Electric Starter
  
  253
  - Checking the Starter Motor
    254
  - Assembling the Starter Motor
    255
- Crankcase
  
  258
- Crankshaft
  
  262
  - Crankshaft and Balancer
    262
  - Removing the Crankshaft Assembly
    263
  - Checking the Crankshaft
    263
  - Crankcase Separating Tool
    263
    
    Installing the Crankshaft
    264
  - Crankshaft Installer Pot
    264
- Transmission
  
  265
  - Checking the Shift Forks
    268
  - Checking the Shift Drum Assembly
    268
  - Checking the Transmission
    268
  - Assembling the Main Axle and Drive Axle
    269
  - Installing the Transmission
    269
Cooling System

272
- Radiator
  
  274
  - Checking the Radiator
    275
  - Installing the Radiator
    275
  - Radiator Cap Tester Adaptor
    275
- Thermostat
  
  277
  - Checking the Thermostat
    278
  - Installing the Thermostat
    278
- Water Pump
  
  280
  - Disassembling the Water Pump
    282
  - Checking the Water Pump
    282
  - Assembling the Water Pump
    283
  - Middle Driven Shaft Bearing Driver
    283
    
    Installing the Water Pump
    284
Fuel Injection System

286
- Fuel Tank
  
  289
  - Removing the Fuel Tank
    289
  - Removing the Fuel Pump
    289
  - Installing the Fuel Pump
    290
  - Installing the Fuel Hose
    290
  - Checking the Fuel Sender
    290
- Throttle Body Assembly
  
  292
  - Checking the Fuel Injector
    294
  - Checking the Throttle Body
    294
  - Installing the Throttle Body Assembly
    294
  - Checking the Fuel Pump
    295
  - Pressure Gauge
    295
  - Checking and Adjusting the Throttle Position
    296
  - Sensor
    296
- Air Induction System
  
  298
  - Air Injection
    298
  - Air Cut-Off Valve
    298
  - Air Induction System Diagrams
    299
  - Air Cut-Off Valve Assembly
    300
  - Checking the Air Induction System
    302
- Fuel Injection System
  
  303
  - Wiring Diagram
    304
  - Ecu's Self-Diagnostic Function
    306
  - Self-Diagnostic Function Table
    307
  - Fail-Safe Action Table
    307
  - Troubleshooting Chart
    309
  - Diagnostic Mode
    310
  - Troubleshooting Details
    315
  - Electrical System
    326
    
    General Information
    326
    
    Electric Starting System
    332
    
    Signaling System
    346
    
    Immobilizer System
    356
  - Troubleshooting
    390

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