2012 YAMAHA MT-03 brake

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUAL
CHECK
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• 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

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
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• 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
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NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUAL
CHECK
Every 3 years

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-56-5
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUAL
CHECK
• Check the air cut-off valve, reed valve, and hose
for damage.
• Check fuel hoses for cracks or damage.
• Check the screw clamp for looseness.
• Check operation.
• Adjust headlight beam. Air induction system
Muffler and exhaust
pipe
Lights, signals and
switches 28
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EAU18670
NOTE:
●The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
●Hydraulic brake service
●Regularly check and, if necessary, correct the brake fluid level.
●Every two years replace the internal components of the brake master cylinders and calipers, and change the brake
fluid.
●Replace the brake hoses every four years and if cracked or damaged.√√√√ √
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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)

PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
If the specified clutch lever free play
could be obtained as described
above, tighten the locknut and skip the
rest of the procedure, otherwise pro-
ceed as follows.
3. Fully turn the adjusting bolt at the
clutch lever in direction (a) to
loosen the clutch cable.
4. Loosen the locknut at the
crankcase.
1. Locknut
2. Clutch lever free play adjusting nut
(crankcase)
5. To increase the clutch lever free
play, turn the adjusting nut in di-
rection (a). To decrease the clutch
lever free play, turn the adjusting
nut in direction (b).
6. Tighten the locknut at the clutch
lever and the crankcase.
EAU22390
Checking the front and rear
brake pads
The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
6-20
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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU22420
Front brake pads
1. Front brake pad wear indicator groove
Each front brake pad is provided with
a wear indicator groove, which allows
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator groove. If a brake
pad has worn to the point that the
wear indicator groove has almost dis-
appeared, have a Yamaha dealer re-
place the brake pads as a set.
EAU22500
Rear brake pads
1. Rear brake pad lining thickness
Check each rear brake pad for dam-
age and measure the lining thickness.
If a brake pad is damaged or if the lin-
ing thickness is less than 1.0 mm
(0.04 in), have a Yamaha dealer re-
place the brake pads as a set.
EAU22580
Checking the brake fluid
level
Front brake
1. Minimum level mark
Rear brake
1. Minimum level mark
6-21

PERIODIC MAINTENANCE AND MINOR REPAIR
Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake flu-
id is above the minimum level mark
and replenish if necessary. A low
brake fluid level may indicate worn
brake pads and/or brake system leak-
age. If the brake fluid level is low, be
sure to check the brake pads for wear
and the brake system for leakage.
Observe these precautions:
●When checking the fluid level,
make sure that the top of the
brake fluid reservoir is level.
●Use only the recommended qual-
ity brake fluid, otherwise the rub-
ber seals may deteriorate, caus-
ing leakage and poor braking
performance.
●Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
●Be careful that water does not en-
ter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.
●Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid imme-
diately.
●As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if
the brake fluid level goes down
suddenly, have a Yamaha dealer
check the cause.
6-22
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Recommended brake fluid:
DOT 4
EAU22730
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addi-
tion, have the oil seals of the master
cylinders and calipers as well as the
brake hoses replaced at the intervals
listed below or whenever they are
damaged or leaking.
●Oil seals: Replace every two
years.
●Brake hoses: Replace every four
years.

PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
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EAU23140
Checking and lubricating
the brake and clutch levers
Brake lever
Clutch lever
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
EAU23180
Lubricating the brake
pedal
The operation of the brake pedal
should be checked before each ride,
and the pedal pivot should be lubricat-
ed if necessary.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)