mt03

MT-03SERVICEMANUAL20065YK-F8197-E0MT-03(2006)SERVICEMANUAL©2006byYamahaMotorItaliaS.p.A.Firstedition,February2006Allrightsreserved.AnyreproductionorunauthorizedusewithoutthewrittenpermissionofYamahaMotorItaliaS.p.A.isexpresslyprohibited.PrintedinItalyEAS00020NOTICEThismanualwasproducedbytheYamahaMotorItaliaS.p.A.primarilyforusebyYamahadealersandtheirqualifiedmechanics.Itisnotpossibletoincludealltheknowledgeofamechanicinonemanual.Therefore,anyonewhousesthisbooktoperformmaintenanceandrepairsonYamahave-hiclesshouldhaveabasicunderstandingofmechanicsandthetechniquestorepairthesetypesofvehicles.Repairandmaintenanceworkattemptedbyanyonewithoutthisknowledgeislikelytoren-derthevehicleunsafeandunfitforuse.YamahaMotorItaliaS.p.A.iscontinuallystrivingtoimproveallofitsmodels.Modificationsandsig-nificantchangesinspecificationsorprocedureswillbeforwardedtoallauthorizedYamahadealersandwillappearinfutureeditionsofthismanualwhereapplicable.NOTE:Designsandspecificationsaresubjecttochangewithoutnotice.EAS00040IMPORTANTMANUALINFORMATIONParticularlyimportantinformationisdistinguishedinthismanualbythefollowing.TheSafetyAlertSymbolmeansATTENTION!BECOMEALERT!YOURSAFE-TYISINVOLVED!FailuretofollowWARNINGinstructionscouldresultinsevereinjuryordeathtothemotorcycleoperator,abystanderorapersoncheckingorrepairingthemo-torcycle.ACAUTIONindicatesspecialprecautionsthatmustbetakentoavoiddamagetothemotorcycle.NOTE:ANOTEprovideskeyinformationtomakeprocedureseasierorclearer.WARNINGCAUTION:EAS20090HOWTOUSETHISMANUALThismanualisintendedasahandy,easy-to-readreferencebookforthemechanic.Comprehensiveexplanationsofallinstallation,removal,disassembly,assembly,repairandcheckproceduresarelaidoutwiththeindividualstepsinsequentialorder.•Themanualisdividedintochaptersandeachchapterisdividedintosections.Thecurrentsectiontitle“1”isshownatthetopofeachpage.•Sub-sectiontitles“2”appearinsmallerprintthanthesectiontitle.•Tohelpidentifypartsandclarifyproceduresteps,thereareexplodeddiagrams“3”atthestartofeachremovalanddisassemblysection.•Numbers“4”aregivenintheorderofthejobsintheexplodeddiagram.Anumberindicatesadis-assemblystep.•Symbols“5”indicatepartstobelubricatedorreplaced.Referto“SYMBOLS”.•Ajobinstructionchart“6”accompaniestheexplodeddiagram,providingtheorderofjobs,namesofparts,notesinjobs,etc.•Jobs“7”requiringmoreinformation(suchasspecialtoolsandtechnicaldata)aredescribedsequentially.EAS20100SYMBOLSThefollowingsymbolsareusedinthismanualforeasierunderstanding.NOTE:Thefollowingsymbolsarenotrelevanttoeveryvehicle.1.Serviceablewithenginemounted2.Fillingfluid3.Lubricant4.Specialtool5.Tighteningtorque6.Wearlimit,clearance7.Enginespeed8.Electricaldata9.Engineoil10.Gearoil11.Molybdenumdisulfideoil12.Wheelbearinggrease13.Lithium-soap-basedgrease14.Molybdenumdisulfidegrease15.Applylockingagent(LOCTITE®)16.Replacethepartwithanewone.New12345786911101214131516GENERALINFORMATIONTABLEOFCONTENTS1SPECIFICATIONS2PERIODICCHECKSANDADJUSTMENTS3CHASSIS4ENGINE5COOLINGSYSTEM6FUELINJECTIONSYSTEM7ELECTRICALSYSTEM8TROUBLESHOOTING9GENERALINFORMATIONIDENTIFICATION............................................................................................1-1VEHICLEIDENTIFICATIONNUMBER....................................................1-1MODELLABEL.........................................................................................1-1FEATURES....................................................................................................1-2OUTLINEOFTHEFISYSTEM................................................................1-2FISYSTEM...............................................................................................1-3INSTRUMENTFUNCTIONS....................................................................1-4IMPORTANTINFORMATION.......................................................................1-7PREPARATIONFORREMOVALANDDISASSEMBLY...........................1-7REPLACEMENTPARTS..........................................................................1-7GASKETS,OILSEALSANDO-RINGS...................................................1-7LOCKWASHERS/PLATESANDCOTTERPINS....................................1-7BEARINGSANDOILSEALS...................................................................1-8CIRCLIPS.................................................................................................1-8CHECKINGTHECONNECTIONS................................................................1-9SPECIALTOOLS...........................................................................................1-1011-1IDENTIFICATIONIDENTIFICATIONEAS00170VEHICLEIDENTIFICATIONNUMBERThevehicleidentificationnumber“1”isstampedintotherightsideofthesteeringheadpipe.EAS00180MODELLABELThemodellabel“1”isaffixedtotheframeun-derthepassengerseat.Thisinformationwillbeneededtoorderspareparts.111-2FEATURESEAS00019FEATURESEAS00896OUTLINEOFTHEFISYSTEMThemainfunctionofafuelsupplysystemistoprovidefueltothecombustionchamberattheopti-mumair-fuelratioinaccordancewiththeengineoperatingconditionsandtheatmospherictemper-ature.I