2007 YAMAHA MT-03 wheel bolts

1
2
3
4
5
6
7
8
9
10
PRE-OPERATION CHECKS
4-3
ITEM
Clutch
Throttle grip
Control cables
Drive chain
Wheels and tires
Brake pedal
Brake and
clutch levers
Sidestand
Chassis fastenersCHECKS
• Check operation.
• Lubricate cable if necessary.
• Check lever free play.
• Adjust if necessary.
• Make sure that operation is smooth.
• Check cable free play.
• If necessary, have Yamaha dealer adjust cable free play and lubricate
cable and grip housing.
• Make sure that operation is smooth.
• Lubricate if necessary.
• Check chain slack.
• Adjust if necessary.
• Check chain condition.
• Lubricate if necessary.
• Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary.
• Make sure that operation is smooth.
• Lubricate pedal pivoting point if necessary.
• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.
• Make sure that operation is smooth.
• Lubricate pivot if necessary.
• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.PAGE
3-10, 6-19, 6-26
6-15, 6-25
6-25
6-23, 6-24
6-16, 6-19
6-26
6-26
6-27
–
MY03 04-06 ING 6-10-2005 9:24 Pagina 3

1
2
3
4
5
6
7
8
9
10
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUAL
CHECK
√√√√ √
√√√√
√√√√ √
√√√√
√√√√
√√√√√
√√√√ √
√√√√ √
√√√√√ √8✻
9✻
10✻
11✻
12✻
13
14
✻
15✻
16
17
✻
• Check for cracks or damage.
• Replace.
• Check runout and for damage.
• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
• Check bearing for looseness
or damage.
• Check operation and for excessive play.
• Lubricate with lithium-soap-based grease.
• Check chain slack, alignment and condition.
• Adjust and lubricate chain with a special O-ring
chain lubricant thoroughly.
• Check bearing play and steering for roughness.
• Lubricate with lithium-soap-based grease.
• Make sure that all nuts, bolts and screws are
properly tightened.
• Check operation.
• Lubricate.
• Check operation.
Every 4 years Brake hoses
Wheels
Tires
Wheel bearings
Swingarm
Drive chain
Steering bearings
Chassis fasteners
Sidestand
Sidestand switch
Every 800 km and after washing
the motorcycle or riding in the rain
Every 20000 km
Every 50000 km
MY03 04-06 ING 6-10-2005 9:24 Pagina 6-3

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

1
2
3
4
5
6
7
8
9
10
PERIODIC MAINTENANCE AND MINOR REPAIR
6-37
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a mo-
torcycle stand is not available, by plac-
ing a jack either under each side of the
frame in front of the rear wheel or un-
der each side of the swingarm.EAU24360
Front wheelEAU34390
To remove the front wheel
EWA10820
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. Front wheel axle pinch bolt
2. Wheel axle bolt
3. Brake caliper bolts
4. Brake hose holder bolt
1. Lift the front wheel off the ground
according to the procedure on
page 6-36.
2. Loosen the front wheel axle pinch
bolt, then the wheel axle and the
brake caliper bolts.
3. Remove the brake hose holder on
each side by removing the bolts.
4. Remove the brake caliper on
each side by removing the bolts.
ECA11050CAUTION:
Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will be
forced shut.
5. Pull the wheel axle out, and then
remove the wheel.
EAU24860
To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Insert the wheel axle.
3. Lower the front wheel so that it is
on the ground.
MY03 04-06 ING 6-10-2005 9:26 Pagina 6-37

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