2006 YAMAHA MT-03 engine

PERIODIC MAINTENANCE AND MINOR REPAIR
EAU18771
Removing and installing
panels
The panels shown need to be re-
moved to perform some of the mainte-
nance jobs described in this chapter.
Refer to this section each time a panel
needs to be removed and installed.
EAUB1290
Panels A and B
1. Panel mounting bolts
A. Right panel
B. Left panel
To remove a panel
1. Remove the bolts.
2. Unhook the panel from the hook
by sliding the panel upward to re-
lease it.
T
o 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
chart. In addition, the condition of the
spark plug can reveal the condition of
the engine.
To remove the spark plug
1. Spark plug cap
2. Spark plug wrench
1. Remove the spark plug cap.
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PERIODIC MAINTENANCE AND MINOR REPAIR
2. Remove the spark plug as shown,
with the spark plug wrench includ-
ed 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 vehi-
cle is ridden normally).
NOTE:
If the spark plug shows a distinctly dif-
ferent color, the engine could be defec-
tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the vehicle.
2. Check the spark plug for elec-
trode erosion and excessive car-
bon or other deposits, and re-
place 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


2. Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
NOTE:
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is 1/4-
1/2 turn past finger tight. However, the
spark plug should be tightened to the
specified torque as soon as possible.
4. Install the spark plug cap.
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAUB1350
Engine oil and oil filter
element
The engine oil level should be checked
before each ride. In addition, the oil must
be changed and the oil filter element re-
placed at the intervals specified in the pe-
riodic maintenance and lubrication chart.To check the engine oil level
1. Place the vehicle on a level surface
and hold it in an upright position.NOTE:
Make sure that the vehicle is posi-
tioned straight up when checking the
oil level. A slight tilt to the side can re-
sult in a false reading.
2. Start 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
WARNING0
The exhaust pipes are very hot dur-
ing and following operation. To pre-
vent burns when removing the oil
filler cap, use extra care not to
touch the exhaust pipes.
NOTE:
The engine oil tank is located in
front of the frame.
The engine oil should be between
the minimum and maximum level
marks.
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PERIODIC MAINTENANCE AND MINOR REPAIR
ECA10010CAUTION:
Do not operate the vehicle until you
know that the engine oil level is suf-
ficient.
EWA10360
WARNING0
Never remove the engine oil tank
cap after high-speed operation,
otherwise hot engine oil could
spout out and cause damage or in-
jury. Always let the engine oil cool
down sufficiently before removing
the oil tank cap.
4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type 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 drain the oil
from the crankcase.
4. Remove the drain bolt to drain the
oil from the oil tank.
1. Engine oil crankcase drain bolt
2. Engine oil tank drain bolt
5. Remove the oil filter element
drain bolt to drain the oil from the
oil filter element.
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NOTE:
Make sure that the O-rings are proper-
ly seated.
9. Install the oil drain bolts, and then
tighten them to the specified
torques.
PERIODIC MAINTENANCE AND MINOR REPAIR
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 cov-
er by removing the bolts.
7. Remove and replace the oil filter
element and O-rings.
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
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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 Nm (3.0 m·kgf, 22 ft·lbf)
Engine oil drain bolt (oil tank):
30 Nm (3.0 m·kgf, 22 ft·lbf)
10. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element
replacement:
3.0 L (3.17 US qt) (2.64 Imp.qt)
With oil filter element replacement:
3.1 L (3.28 US qt) (2.72 Imp.qt)
ECA11620CAUTION:
In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a
higher quality than specified. 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.
ECAB0030CAUTION:
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.
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU20070
Coolant
The coolant level should be checked
before each ride. In addition, the
coolant must be changed at the inter-
vals specified in the periodic mainte-
nance and lubrication chart.
EAU20090
To check the coolant level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.
NOTE:
The coolant level must be
checked on a cold engine since
the level varies with engine tem-
perature.
Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.
2. Check the coolant level in the
coolant reservoir.
NOTE:
The coolant should be between the
minimum and maximum level marks.
1. 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.
ECA10470CAUTION:
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 been used instead
of coolant, replace it with
coolant as soon as possible,
otherwise the engine may not
be sufficiently cooled and the
cooling system will not be pro-
tected against frost and corro-
sion.
If water has been added to the
coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possi-
ble, otherwise the effective-
ness of the coolant will be re-
duced.
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Coolant reservoir capacity:
0.25 L (0.26 US qt) (0.22 Imp.qt)
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PERIODIC MAINTENANCE AND MINOR REPAIR
EWA10380
WARNING0
Never attempt to remove the radia-
tor cap when the engine is hot.
NOTE:
The radiator fan is automatically
switched on or off according to
the coolant temperature in the ra-
diator.
If the engine overheats, see page
3-4 for further instructions.
EAU33030
Changing the coolant
EWA10380
WARNING0
Never attempt to remove the radia-
tor cap when the engine is hot.
The coolant must be changed at the
intervals specified in the periodic
maintenance 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 fre-
quently checked and cleaned if neces-
sary. To replace the air filter element
1. Air filter case
2. Screws
1. Remove the air filter case cover
by removing the screws.
2. Pull the air filter element out.
3. Insert a new air filter element into
the air filter case as shown.
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