2007 YAMAHA MT-03 suspension

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 ..................2-3
INSTRUMENT AND CONTROL
FUNCTIONS........................................3-1
Immobilizer system ...........................3-1
Main switch/steering lock ..................3-2
Indicator and warning lights ..............3-3
Multi-function meter unit ...................3-5
Tachometer .......................................3-6
Odometer, tripmeter modes ..............3-6
Clock mode .......................................3-7
Self-diagnosis devices ......................3-7
Indicator lights brightness
control mode ..............................3-8
Anti-theft alarm (optional) .................3-8
Handlebar switches...........................3-9
Clutch lever .....................................3-10
Shift pedal .......................................3-10
Brake lever ......................................3-11Brake pedal .....................................3-11
Fuel tank cap...................................3-11
Fuel .................................................3-12
Fuel tank breather/overflow hose ...3-13
Catalytic converter ..........................3-13
Seats ...............................................3-14
Adjusting the shock absorber
assembly ..................................3-16
Sidestand ........................................3-18
Ignition circuit cut-off system ..........3-19
PRE-OPERATION CHECKS...............4-1
Pre-operation check list ....................4-2
OPERATION 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 ...................6-6Engine oil and oil filter element.........6-8
Coolant ............................................6-12
Replacing the air filter element
and cleaning the check hoses ...6-13
Adjusting the engine idling speed ...6-14
Checking the throttle cable
free play ...................................6-15
Valve clearance...............................6-15
Tires ................................................6-16
Cast wheels ....................................6-19
Adjusting the clutch lever
free play ...................................6-19
Checking the front and rear
brake pads ...............................6-20
Checking the brake fluid level .........6-21
Changing the brake fluid .................6-22
Drive chain slack .............................6-23
Cleaning and lubricating the
drive chain ................................6-24
Checking and lubricating the
cables .......................................6-25
Checking and lubricating the
throttle grip and cable ..............6-25
Checking and lubricating the
brake and clutch levers ............6-26
Lubricating the brake pedal ............6-26
Checking and lubricating the
sidestand ..................................6-27
Lubricating the side suspension .....6-27
MY03 01-03 ING 6-10-2005 13:52 Pagina 6

SAFETY INFORMATION
Here are some general guidelines to
follow if loading cargo or adding ac-
cessories to your motorcycle:
Loading
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit.
Never attach any large or heavy
items to the handlebar, front fork,
or front fender. These items, in-
cluding such cargo as sleeping
bags, duffel bags, or tents, can
create unstable handling or a
slow steering response.
Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this motorcycle. Since Yamaha cannot
test all other accessories that may be
available, you must personally be re-
sponsible for the proper selection, in-
stallation and use of non-Yamaha ac-
cessories. Use extreme caution when
selecting and installing any acces-
sories.
Keep the following guidelines in mind,
as well as those provided under "Load-
ing" when mounting accessories.
Never install accessories or carry
cargo that would impair the perfor-
mance of your motorcycle. Care-
fully inspect the accessory before
using it to make sure that it does
not in any way reduce 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 kept to a minimum.
• Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerody-
namic effects. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become
unstable in cross winds. These
accessories may also cause in-
stability when passing or being
passed by large vehicles.
1-3
1
2
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.
Make sure to distribute the weight
as evenly as possible on both
sides of the motorcycle to mini-
mize imbalance or instability.
Shifting weights can create a sud-
den imbalance. Make sure that
accessories and cargo are se-
curely attached to the motorcycle
before riding. Check accessory
mounts and cargo restraints fre-
quently.
MY03 01-03 ING 6-10-2005 13:52 Pagina 10

INSTRUMENT AND CONTROL FUNCTIONS
3-16
1
2
3
4
5
6
7
8
9
10
A. Distance (spring preload)
Adjust the spring preload as follows.
1. Loosen the locknut.
2. To increase the spring preload
and thereby harden the suspen-
sion, turn the adjusting nut in di-
rection (a). To decrease the
spring preload and thereby soften
the suspension, turn the adjusting
nut in direction (b).
NOTE:
Use the special wrench included
in the owner's tool kit to make the
adjustment.
The spring preload setting is de-
termined by measuring 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. Locknut
(a) Increasing the spring preload
(b) Decreasing the spring preload
This shock absorber assembly is
equipped with a spring preload adjust-
ing nut.
ECA10100
WARNING0
Never attempt to turn an adjusting
mechanism beyond the maximum
or minimum settings.
MY03 01-03 ING 6-10-2005 13:53 Pagina 3-16

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
1
2
3
4
5
6
7
8
9
10
• Check operation and for oil leakage.
• Check operation and shock absorber for oil
leakage.
• Check operation.
• Lubricate with lithium-soap-based grease.
• Adjust engine idling speed.
• Change.
• Check oil level and vehicle for oil leakage.
• Replace.
• Check coolant level and vehicle for coolant leakage.
• Change.
• Check operation.
• 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✻
21✻
22
23
24
✻
25✻
26
27
✻
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUAL
CHECK
Every 3 years
MY03 04-06 ING 6-10-2005 9:24 Pagina 6-4

1
2
3
4
5
6
7
8
9
10
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
1. Tire sidewall
2. Tire tread depth
The tires must be checked before
each ride. If the center tread depth
reaches the specified limit, if the tire
has a nail or glass fragments in it, or if
the sidewall is cracked, have a Yama-
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
WARNING0
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 parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.
6-17
Minimum tire tread depth
(front and rear):
1.6 mm (0.06 in)
MY03 04-06 ING 6-10-2005 9:25 Pagina 6-17

1
2
3
4
5
6
7
8
9
10
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU23200
Checking and lubricating
the sidestand
The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated
if necessary.
EWA10730
WARNING0
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it.
EAUB1240
Lubricating the side
suspension
The pivoting points of the side suspen-
sion must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.
Recommended lubricant:
Lithium-soap-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
WARNING0
Securely support the motorcycle so
that there is no danger of it falling
over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
6-27
MY03 04-06 ING 6-10-2005 9:25 Pagina 6-27

1
2
3
4
5
6
7
8
9
10
SPECIFICATIONS
8-2
Operation:
Left foot operation
Gear ratio:
1
st:
30/12 (2.500)
2
nd:
26/16 (1.625)
3
rd:
23/20 (1.150)
4
th:
20/22 (0.909)
5
th:
20/26 (0.769)
Chassis:
Frame type:
Truss diamond
Caster angle:
26°
Trail:
97.0 mm (3.81 in)
Front tire:
Type:
Tubeless
Size:
120/70-ZR17M/C (58W),
120/70-R17M/C (58H)
Manufacturer/model:
DUNLOP D270F
PIRELLI SCORPION SYNC
Rear tire:
Type:
Tubeless
Size:
160/60-ZR17M/C (69W),
160/60-R17M/C (69H)Manufacturer/model:
DUNLOP D270
PIRELLI SCORPION SYNC
Load:
Maximum load:
186 kg (410 lb)
(Total weight of rider, passenger, cargo
and accessories)
Tire air pressure
(measured on cold tires):
Load:
Up to 90 kg (0-198 lb)
Front:
210 kPa (30 psi) (2.1 kgf/cm
3)
Rear:
230 kPa (33 psi) (2.3 kgf/cm
3)
Load:
90-186 kg (198-410 lb)
Front:
230 kPa (33 psi) (2.3 kgf/cm
3)
Rear:
250 kPa (36 psi) (2.5 kgf/cm
3)
High-speed riding:
Front:
210 kPa (30 psi) (2.1 kgf/cm
3)
Rear:
230 kPa (33 psi) (2.3 kgf/cm
3)
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 disc brake
Operation:
Right hand
Fluid:
DOT 4
Rear brake:
Type:
Single disc brake
Operation:
Right foot
Fluid:
DOT 4
Front suspension:
Type:
Telescopic fork
Spring/damper type:
Coil spring/oil damper
Wheel travel:
130 mm (5.12 in)
Rear suspension:
Type:
Swingarm
Spring/damper type:
Coil spring/gas-oil damper,
spring preload adjustable
Wheel travel:
120.0 mm (4.72 in)
MY03 07-10 ING 5-10-2005 17:09 Pagina 7

INDEX
1
2
3
4
5
6
7
8
9
10
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 ......................3-4
Turn signal indicator light................3-4
Indicator lights brightness
control mode ...................................3-8
Instruments ........................................2-3
Instrument and control functions ........3-1
K
Key identification number...................9-1
Keys ...................................................3-1
L
License plate light bulb, replacing....6-36
Lubricating the brake and
clutch levers ..................................6-26
Lubricating the brake pedal..............6-26
Lubricating the cables ......................6-25
Lubricating the drive chain ...............6-24
Lubricating the sidestand .................6-27
Lubricating the throttle grip and
cable .............................................6-25M
Main switch/steering lock ...................3-2
Model label .........................................9-2
Multi-function meter unit.....................3-5
Clock mode .....................................3-7
Indicator lights 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
Pre-operation check list .....................4-2
Pre-operation checks .........................4-1R
Rear wheel .......................................6-38
Installing........................................6-38
Removing......................................6-38
Record the identification numbers .....9-1
S
Safety information ..............................1-1
Seats ................................................3-14
Self-diagnosis devices .......................3-7
Shift pedal ........................................3-10
Shifting ...............................................5-2
Shock absorber assembly
(adjusting) .....................................3-16
Side suspension, lubricating ............6-27
Sidestand .........................................3-18
Sidestand, checking and
lubricating .....................................6-27
Sidestand switch, checking ..............3-20
Spark plug, checking..........................6-6
Specifications .....................................8-1
Start switch.........................................3-9
Starting the engine .............................5-1
Steering, checking............................6-28
Steering lock ......................................3-2
Storage...............................................7-3
Supporting the motorcycle ...............6-36
T
Tachometer ........................................3-6
Tail/brake light bulb, replacing..........6-34
Throttle cable free play, adjusting ....6-15
MY03 07-10 ING 5-10-2005 17:09 Pagina 2