2012 YAMAHA MT-03 brake fluid

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

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DESCRIPTION
EAU10420
Right view
2-2
10. Grab bar
11. Fuse box (page 6-32)
12. Rear brake fluid reservoir (page 6-21)
13. Front brake fluid reservoir (page 6-21)
14. Coolant reservoir (page 6-12)15. Engine oil filler cap/dipstick (page 6-8)
16. Coolant drain bolt (page 6-12)
17. Engine oil filter element (page 6-10)
18. Shock absorber assembly spring preload adjusting ring (page 3-16)
19. Brake pedal (page 3-11)

PRE-OPERATION CHECKS
4-2
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3
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9
10
ITEM
Fuel
Engine oil
Coolant
Front brake
Rear brake
EAU15603
Pre-operation check list
CHECKS
• Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.
• Check oil level in oil tank.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage.
• Check coolant level in reservoir.
• If necessary, add recommended coolant to specified level.
• Check cooling system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.PAGE
3-12
6-8
6-12
3-11, 6-20, 6-21, 6-26
3-11, 6-20, 6-21, 6-26

PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17705
Periodic maintenance and lubrication chart
NOTE:
●The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.
●From 50000 km, repeat the maintenance intervals starting from 10000 km.
●Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and tech-
nical skills.
6-2
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10
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUAL
CHECK
√√√√ √
√√
√√
√√
√√
√√√√√
√√√√√ √
√√√√√ √1✻
2
3
✻
4
5
6
✻
7✻
• Check fuel hoses for cracks or damage.
• Check condition.
• Clean and regap.
• Replace.
• Check valve clearance.
• Adjust.
• Replace.
• Check operation.
• Adjust.
• Check operation, fluid level and vehicle for fluid
leakage.
• Replace brake pads.
• Check operation, fluid level and vehicle for fluid
leakage.
• Replace brake pads. Fuel line
Spark plug
Valves
Air filter element
Clutch
Front brake
Rear brakeWhenever worn to the limit
Whenever worn to the limit

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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
✻
29✻
30✻
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
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.

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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)