2012 YAMAHA MT-03 lock

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
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.

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
EAU22760
Drive chain slack
The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22771
To check the drive chain slack
1. Drive chain slack
1. Place the motorcycle on the side-
stand.
NOTE:
When checking and adjusting the dri-
ve chain slack, there should be no
weight on the motorcycle.
2. Shift the transmission into the
neutral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain, and
then measure the drive chain
slack as shown.
4. If the drive chain slack is incor-
rect, adjust it as follows.
Drive chain slack:
40.0-50.0 mm (1.57-1.97 in)
EAU34311
To adjust the drive chain slack
1. Loosen the axle nut and the lock-
nut on each side of the swingarm.
2. To tighten the drive chain, turn the
adjusting bolt on each side of the
swingarm in direction (a). To
loosen the drive chain, turn the
adjusting bolt on each side of the
swingarm in direction (b), and
then push the rear wheel forward.
NOTE:
Using the alignment marks on each
side of the swingarm, make sure that
both chain pullers are in the same po-
sition for proper wheel alignment.

PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
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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.

PERIODIC MAINTENANCE AND MINOR REPAIR
1. Parking lighting fuse
2. Signaling system fuse
3. Headlight fuse
4. Ignition fuse
5. Electronic fuel injection fuse
6. Radiator fan fuse
7. Backup fuse
8. Reserve fuses
The main fuse is located under the fu-
el tank. (See page 6-31.)
The fuse box which contains the fuses
for the individual circuits is located un-
der the rider seat. (See page 3-15.)
If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off
the electrical circuit in question.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
ECA10640CAUTION:
Do not use a fuse of a higher am-
perage rating than recommended
to avoid causing extensive damage
to the electrical system and possi-
bly a fire.
3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
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Specified fuses:
Main fuse:
30 A
Fuse box:
Parking lighting fuse:
10 A
Signaling system fuse:
10 A
Headlight fuse:
20 A
Ignition fuse:
10 A
Electronic fuel injection fuse:
10 A
Radiator fan fuse:
7.5 A
Fuel injection system fuse:
10 A
Backup fuse (for odometer,
clock and immobilizer):
10 A

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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)

PERIODIC MAINTENANCE AND MINOR REPAIR
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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.

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-41
Engine overheatingEWA10400
WARNING0
●Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
●After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hiss-
ing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended
coolant as soon as possible.
Wait until the
engine has cooled.Check the coolant level
in the reservoir and radiator.
The coolant level is low.
Check the cooling
system for leakage.
The coolant level
is OK.
There is
leakage.
There is no
leakage.
Have a Yamaha dealer check
and repair the cooling system.
Start the engine. If the engine overheats again, have
a Yamaha dealer check and repair the cooling system.
Add coolant. (See NOTE.)