2007 YAMAHA MT-03 torque

EAU15301
Sidestand
1. Sidestand
The sidestand is located on the left
side of the frame. Raise the sidestand
or lower it with your foot while holding
the motorcycle upright.
NOTE:
The built-in sidestand switch is part of
the ignition circuit cut-off system,
which cuts the ignition in certain situa-
tions. (See further down for an expla-
nation of the ignition circuit cut-off sys-
tem.)
INSTRUMENT AND CONTROL FUNCTIONS
3-18
1
2
3
4
5
6
7
8
9
10
3. Tighten the locknut to the speci-
fied torque.
ECA11240CAUTION:
Always tighten the locknut against
the adjusting nut, and then tighten
the locknut to the specified torque.
EWA10220
WARNING0
This shock absorber contains high-
ly pressurized nitrogen gas. For
proper handling, read and under-
stand the following information be-
fore handling the shock absorber.
The manufacturer cannot be held
responsible for property damage or
personal injury that may result from
improper handling.
Do not tamper with or attempt
to open the gas cylinder.
Do not subject the shock ab-
sorber to an open flame or oth-
er high heat sources, otherwise
it may explode due to exces-
sive gas pressure.
Do not deform or damage the
gas cylinder in any way, as this
will result in poor damping per-
formance.
Always have a Yamaha dealer
service the shock absorber.
Tightening torque:
Locknut:
45 Nm (4.5 m·kgf, 32.5 ft·lbf)
MY03 01-03 ING 6-10-2005 13:53 Pagina 3-18

1
2
3
4
5
6
7
8
9
10
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 lubrica-
tion are explained on the following
pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON
THE WEATHER, TERRAIN, GEO-
GRAPHICAL LOCATION, AND INDI-
VIDUAL USE, THE MAINTENANCE
INTERVALS MAY NEED TO BE
SHORTENED.
EWA10320
WARNING0
If you are not familiar with motorcy-
cle maintenance work, have a
Yamaha dealer do it for you.
EAUB1400
Owner’s tool kit
1. Owner’s tool kit
2. Fastening strap
The owner’s tool kit is located on the
bottom of the passenger seat (See
page 3-14) and it held in place with an
O-ring.
The service information included in
this manual and the tools provided in
the owner’s tool kit are intended to as-
sist you in the performance of preven-
tive maintenance and minor repairs.
However, additional tools such as a
torque wrench may be necessary to
perform certain maintenance work
correctly.
NOTE:
If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
EWA10350
WARNING0
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any
changes.
6-1
MY03 04-06 ING 6-10-2005 9:24 Pagina 6-1

1
2
3
4
5
6
7
8
9
10
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.
MY03 04-06 ING 6-10-2005 9:24 Pagina 6-7

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
6-10
1
2
3
4
5
6
7
8
9
10
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.
MY03 04-06 ING 6-10-2005 9:24 Pagina 6-10

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
1
2
3
4
5
6
7
8
9
10
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Alignment marks
ECA10570
CAUTION:
Improper drive chain slack will
overload the engine as well as oth-
er vital parts of the motorcycle and
can lead to chain slippage or break-
age. To prevent this from occurring,
keep the drive chain slack within
the specified limits.
Tightening torques:
Locknut:
16 Nm (1.6 m·kgf, 11 ft·lbf)
Axle nut:
150 Nm (15.0 m·kgf, 108 ft·lbf)
EAU23022
Cleaning and lubricating
the drive chain
The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly
wear out, especially when riding in
dusty or wet areas. Service the drive
chain as follows.
ECA10581CAUTION:
The drive chain must be lubricated
after washing the motorcycle and
riding in the rain.
1. Clean the drive chain with
kerosene and a small soft brush.
ECA11120CAUTION:
To prevent damaging the O-rings,
do not clean the drive chain with
steam cleaners, high-pressure
washers or inappropriate solvents. 3. Tighten the locknuts, then the
axle nut to their specified torques.
MY03 04-06 ING 6-10-2005 9:25 Pagina 6-24

1
2
3
4
5
6
7
8
9
10
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 counter-
clockwise.
3. Remove the defective bulb by
pushing it in and turning it coun-
terclockwise.
4. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
5. Install the socket (together with
the bulb) by turning it clockwise.
6. Place the tail/brake light bulb
cover in its original position, insert
the bolts and then tighten them to
the specified torque.EAU24202
Replacing a turn signal
light bulb
1. Screw
2. Turn signal light lens
3. Turn signal light bulb
1. Remove the turn signal light lens
by removing the screw.
2. Remove the defective bulb by
pushing it in and turning it coun-
terclockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screw.
ECA11190CAUTION:
Do not overtighten the screw, oth-
erwise the lens may break.
6-35
Tightening torque:
Tail/brake light bulb cover bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
MY03 04-06 ING 6-10-2005 9:26 Pagina 6-35

PERIODIC MAINTENANCE AND MINOR REPAIR
EAUB1410
Replacing the license plate
light bulb
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.
NOTE:
When removing the license plate light
bulb socket, be careful not to pull too
hard.
EAU24350
Supporting the motorcycle
Since this model is not equipped with
a centerstand, follow these precau-
tions when removing the front and rear
wheel or performing other mainte-
nance requiring the motorcycle to
stand upright. Check that the motorcy-
cle is in a stable and level position be-
fore starting any maintenance. A
strong wooden box can be placed un-
der the engine for added stability.
To service the front wheel
1. Stabilize the rear of the motorcy-
cle by using a motorcycle stand
or, if an additional motorcycle
stand is not available, by placing
a jack under the frame in front of
the rear wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
6-36
1
2
3
4
5
6
7
8
9
10
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. Install the reinforcement plate in
the original position, and then
tighten bolts and nuts to the spec-
ified torque.
Tightening torque:
Reinforcement plate nut:
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Reinforcement plate bolt (centre):
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Reinforcement plate bolt (upper):
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
MY03 04-06 ING 6-10-2005 9:26 Pagina 6-36

PERIODIC MAINTENANCE AND MINOR REPAIR
6-38
1
2
3
4
5
6
7
8
9
10
EAU25080
Rear wheelEAU25311
To remove the rear wheelEWA10820
WARNING0
It is advisable to have a Yama-
ha dealer service the wheel.
Securely support the motorcy-
cle so that there is no danger of
it falling over.
1. Wheel axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Drive chain
1. Wheel axle
2. Brake caliper bracket
1. Loosen the axle nut.
2. Lift the rear wheel off the ground
according to the procedure on
page 6-36.
3. Remove the axle nut.
4. Loosen the locknut on each side
of the swingarm.
5. Turn the drive chain slack adjust-
ing bolts fully in direction (a) and
push the wheel forward.
6. Remove the drive chain from the
rear sprocket.
4. Install the brake calipers by in-
stalling the bolts.
NOTE:
Make sure that there is enough space
between the brake pads before in-
stalling the brake calipers onto the
brake discs.
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 speci-
fied torques.
Tightening torques:
Wheel axle:
72 Nm (7.2 m·kgf, 52 ft·lbf)
Front wheel axle pinch bolt:
14 Nm (1.4 m·kgf, 10 ft·lbf)
Brake caliper bolt:
40 Nm (4.0 m·kgf, 29 ft·lbf)
7. Push down hard on the handlebar
several times to check for proper
fork operation.
MY03 04-06 ING 6-10-2005 9:26 Pagina 6-38