2020 YAMAHA MT-03 brake

For your safety – pre-operation checks
4-1
4
EAU63441
Inspect your vehicle each time you use it to make sure the vehicle is in safe oper-
ating condition. Always follow the inspection and maintenance procedures and
schedules described in the Owner’s Manual.
WARNING
EWA11152
Failure to inspect or maintain the vehicle properly increases the possibility
of an accident or equipment damage. Do not operate the vehicle if you find
any problem. If a problem cannot be corrected by the procedures provided
in this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
ITEM CHECKS PAGE
Fuel• Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.
• Check fuel tank breather hose and overflow hose for
obstructions, cracks or damage, and check hose con-
nections.3-15,
3-16
Engine oil• Check oil level in engine.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage.6-8
Coolant• Check coolant level in reservoir.
• If necessary, add recommended coolant to specified
level.
• Check cooling system for leakage.6-12
Front brake• 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 specified brake fluid to specified level.
• Check hydraulic system for leakage.6-20,
6-21
Rear brake• 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 specified brake fluid to specified level.
• Check hydraulic system for leakage.6-20,
6-21
Clutch• Check operation.
• Lubricate cable if necessary.
• Check lever free play.
• Adjust if necessary.6-18
UB6WE0E0.book Page 1 Friday, March 27, 2020 11:37 AM

For your safety – pre-operation checks
4-2
4
Throttle grip• Make sure that operation is smooth.
• Check throttle grip free play.
• If necessary, have Yamaha dealer adjust throttle grip
free play and lubricate cable and grip housing.6-15,
6-25
Control cables• Make sure that operation is smooth.
• Lubricate if necessary.6-25
Drive chain• Check chain slack.
• Adjust if necessary.
• Check chain condition.
• Lubricate if necessary.6-23,
6-24
Wheels and tires•Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary.6-16,
6-18
Brake and shift pedals• Make sure that operation is smooth.
• Lubricate pedal pivoting points if necessary.6-26
Brake and clutch le-
vers• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.6-26
Sidestand• Make sure that operation is smooth.
• Lubricate pivot if necessary.6-27
Chassis fasteners• Make sure that all nuts, bolts and screws are properly
tightened.
• Tighten if necessary.—
Instruments, lights,
signals and switches• Check operation.
• Correct if necessary.—
Sidestand switch • Check operation of ignition circuit cut-off system.
• If system is not working correctly, have Yamaha dealer
check vehicle.3-22 ITEM CHECKS PAGE
UB6WE0E0.book Page 2 Friday, March 27, 2020 11:37 AM

Periodic maintenance and adjustment
6-1
6
EAU17246
Periodic inspection, adjustment, and
lubrication will keep your vehicle in the
safest and most efficient condition
possible. Safety is an obligation of the
vehicle owner/operator. The most im-
portant points of vehicle inspection,
adjustment, and lubrication are ex-
plained on the following pages.
The intervals given in the periodic
maintenance charts should be simply
considered as a general guide under
normal riding conditions. However, de-
pending on the weather, terrain, geo-
graphical location, and individual use,
the maintenance intervals may need to
be shortened.
WARNING
EWA10322
Failure to properly maintain the vehi-
cle or performing maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha dealer perform
service.
WARNING
EWA15123
Turn off the engine when performing
maintenance unless otherwise
specified.
A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.
Running the engine while ser-
vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading todeath. See page 1-3 for more in-
formation about carbon monox-
ide.
WARNING
EWA15461
Brake discs, calipers, drums, and
linings can become very hot during
use. To avoid possible burns, let
brake components cool before
touching them.
UB6WE0E0.book Page 1 Friday, March 27, 2020 11:37 AM

Periodic maintenance and adjustment
6-4
6
EAU71372
General maintenance and lubrication chart
NO. ITEM
1*Diagnostic system
check• Perform dynamic inspection
using Yamaha diagnostic tool.
• Check the error codes.√√√√√√
2*Air filter element• Replace.√√
3Air filter case
check hose• Clean.√√√√√
4Clutch• Check operation.
•Adjust.√√√√√
5*Front brake• Check operation, fluid level,
and for fluid leakage.
• Replace brake pads if neces-
sary.√√√√√√
6*Rear brake• Check operation, fluid level,
and for fluid leakage.
• Replace brake pads if neces-
sary.√√√√√√
7*Brake hoses• Check for cracks or damage.√√√√√
• Replace. Every 4 years
8*Brake fluid• Change. Every 2 years
9*Wheels• Check runout and for damage.
• Replace if necessary.√√√√
10*Tires• Check tread depth and for
damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.√√√√√
11*Wheel bearings• Check bearing for looseness or
damage.√√√√
12*Swingarm pivot
bearings• Check operation and for exces-
sive play.√√√√
13 Drive chain• Check chain slack, alignment
and condition.
• Adjust and lubricate chain with
a special O-ring chain lubricant
thoroughly.Every 800 km (500 mi) and after
washing the motorcycle, riding
in the rain or riding in wet areasX 1000 km CHECK OR
MAINTENANCE JOB
X 1000 miODOMETER
READINGSANNUAL CHECK
1 10203040
0.6 6 12 18 24
UB6WE0E0.book Page 4 Friday, March 27, 2020 11:37 AM

Periodic maintenance and adjustment
6-5
6
14*Steering bearings• Check bearing assemblies for
looseness.√√ √
• Moderately repack with lithium-
soap-based grease.√√
15*Chassis fasteners• Make sure that all nuts, bolts
and screws are properly tight-
ened.√√√√√
16Brake lever pivot
shaft• Lubricate with silicone grease.√√√√√
17Brake pedal pivot
shaft• Lubricate with lithium-soap-
based grease.√√√√√
18Clutch lever pivot
shaft• Lubricate with lithium-soap-
based grease.√√√√√
19Shift pedal pivot
shaft• Lubricate with lithium-soap-
based grease.√√√√√
20 Sidestand• Check operation.
• Lubricate with lithium-soap-
based grease.√√√√√
21*Sidestand switch• Check operation and replace if
necessary.√√√√√√
22*Front fork• Check operation and for oil
leakage.
• Replace if necessary.√√√√
23*Shock absorber
assembly• Check operation and for oil
leakage.
• Replace if necessary.√√√√
24 Engine oil• Change (warm engine before
draining).
• Check oil level and vehicle for
oil leakage.At the initial interval and
when the oil change indi-
cator flashes or comes
on.√
25En
gine oil filter
cartridge• Replace.√√√
26*Cooling system• Check coolant level and vehicle
for coolant leakage.√√√√√
• Change. Every 3 years
27*Front and rear
brake switches• Check operation.√√√√√√ NO. ITEM
X 1000 km CHECK OR
MAINTENANCE JOB
X 1000 mi
ODOMETER
READINGS
ANNUAL CHECK
110203040
0.66121824
UB6WE0E0.book Page 5 Friday, March 27, 2020 11:37 AM

Periodic maintenance and adjustment
6-6
6
EAU72710
TIP
Air filter
• This model’s air intake system is equipped with a disposable oil-coated pa-
per element. The air filter element cannot be cleaned with compressed air,
it must be replaced.
• The air filter element needs to be replaced more frequently when riding in
unusually wet or dusty areas.
Hydraulic brake service
• After disassembling the brake master cylinder and caliper, always change
the fluid. Regularly check the brake fluid level and fill the reservoir as re-
quired.
• Every two years replace the internal components of the brake master cyl-
inder and caliper, and change the brake fluid.
• Replace the brake hose every four years and if cracked or damaged.
28*Moving parts and
cables• Lubricate.√√√√√
29*Throttle grip hous-
ing and cable• Check operation and free play.
• Adjust the throttle cable free
play if necessary.
• Lubricate the throttle grip hous-
ing and cable.√√√√√
30*Lights, signals and
switches• Check operation.
• Adjust headlight beam.√√√√√√ NO. ITEM
X 1000 km CHECK OR
MAINTENANCE JOB
X 1000 miODOMETER
READINGS
ANNUAL CHECK
110203040
0.6 6 12 18 24
UB6WE0E0.book Page 6 Friday, March 27, 2020 11:37 AM

Periodic maintenance and adjustment
6-17
6
TIP
The tire tread depth limits may differ
from country to country. Always com-
ply with the local regulations.
WARNING
EWA10472
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the vehi-
cle 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 to do so.
Ride at moderate speeds after
changing a tire since the tire
surface must first be “broken
in” for it to develop its optimal
characteristics.
Tire information
This model is equipped with tubeless
tires and rubber tire air valves.
Tires age, even if they have not been
used or have only been used occasion-
ally. Cracking of the tread and sidewall
rubber, sometimes accompanied by
carcass deformation, is an evidence of
ageing. Old and aged tires shall be
checked by tire specialists to ascertain
their suitability for further use.
WARNING
EWA10462
The front and rear tires should be of
the same make and design, other-
wise the handling characteristics of
the vehicle may be different, which
could lead to an accident.
After extensive tests, only the tires list-
ed below have been approved for this
model by Yamaha.
Minimum tire tread depth (front and
rear):
1.6 mm (0.06 in)
Front tire:
Size:
110/70R-17M/C 54H
Manufacturer/model:
DUNLOP/GPR-300F
Rear tire:
Size:
140/70R-17M/C 66H
Manufacturer/model:
DUNLOP/GPR-300
UB6WE0E0.book Page 17 Friday, March 27, 2020 11:37 AM

Periodic maintenance and adjustment
6-19
6 3. To increase the clutch lever free
play, turn the clutch lever free play
adjusting nut in direction (a). To
decrease the clutch lever free
play, turn the adjusting nut in di-
rection (b).
4. Tighten the locknut.
EAU37914
Checking the brake lever free
play
There should be no free play at the
brake lever end. If there is free play,
have a Yamaha dealer inspect the
brake system.
WARNING
EWA14212
A soft or spongy feeling in the brake
lever can indicate the presence of
air in the hydraulic system. If there is
air in the hydraulic system, have a
Yamaha dealer bleed the system be-
fore operating the vehicle. Air in the
hydraulic system will diminish the
braking performance, which may re-
sult in loss of control and an acci-
dent.
1. Locknut
2. Clutch lever free play adjusting nut
2
(b)
(a) 1
1. No brake lever free play
1
UB6WE0E0.book Page 19 Friday, March 27, 2020 11:37 AM