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MT-03 2006
Yamaha MT-03 2006 Manuals
Manuals and User Guides for Yamaha MT-03 2006. We have
1
Yamaha MT-03 2006 manual available for free PDF download: Service Manual
Yamaha MT-03 2006 Service Manual (400 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 15.92 MB
Table of Contents
Table of Contents
6
How to Use this Manual
4
Symbols
5
General Information
8
Identification
10
Vehicle Identification Number
10
Model Label
10
Features
11
Outline of the Fi System
11
Fi System
12
Instrument Functions
13
Important Information
16
Preparation for Removal and Disassembly
16
Replacement Parts
16
Gaskets, Oil Seals and O-Rings
16
Lock Washers/Plates and Cotter Pins
16
Bearings and Oil Seals
17
Circlips
17
Checking the Connections
18
Special Tools
19
Special Tools
22
Specifications
24
General Specifications
26
Engine Specifications
27
Chassis Specifications
35
Electrical Specifications
38
Tightening Torques
41
General Tightening Torque Specifications
41
Engine Tightening Torques
42
Chassis Tightening Torques
45
Lubrication Points and Lubricant Types
48
Engine
48
Chassis
50
Cooling System Diagrams
51
Lubrication Chart
55
Lubrication Diagrams
57
Cable Routing
65
Periodic Checks and Adjustments
88
Periodic Maintenance
90
Introduction
90
Periodic Maintenance and Lubrication Chart
90
Engine
92
Adjusting the Valve Clearance
92
Thickness Gauge
93
Adjusting the Engine Idling Speed
94
Adjusting the Throttle Cable Free Play
94
Checking the Spark Plug
95
Checking the Ignition Timing
96
Measuring the Compression Pressure
97
Checking the Engine Oil Level
98
Changing the Engine Oil
99
Adjusting the Clutch Cable Free Play
100
Checking the Air Filter Element
101
Checking the Throttle Body Joint
102
Checking the Fuel Hose
102
Checking the Fuel Tank Breather/Overflow Hoses
102
Checking the Crankcase Breather Hoses
102
Checking the Exhaust System
103
Checking the Coolant Level
103
Checking the Cooling System
104
Changing the Coolant
105
Chassis
107
Adjusting the Front Brake
107
Adjusting the Rear Brake Pedal
107
Checking the Brake Fluid Level
108
Checking the Front and Rear Brake Pads and Brake Pad Pins
109
Checking the Front and Rear Brake Hoses
109
Bleeding the Hydraulic Brake System
110
Adjusting the Shift Pedal
111
Adjusting the Drive Chain Slack
111
Lubricating the Drive Chain
112
Checking and Adjusting the Steering Head
112
Checking the Front Fork
114
Adjusting the Rear Shock Absorber Assembly
114
Checking the Tires
115
Checking the Wheels
116
Checking and Lubricating the Cables
117
Lubricating the Levers and Brake Pedal
117
Lubricating the Sidestand
117
Lubricating the Side Suspension
117
Chassis
122
General Chassis
124
Removing the Seats
124
Removing the Cowling
125
Removing the Rear Fender Cover, License Bracket and Tail/Brake Light Assembly
126
Removing the Air Filter Case and Crankcase Breather Chamber
127
Installing the Air Filter Case Joint Clamp
128
Front Wheel
129
Removing the Front Wheel
131
Disassembling the Front Wheel
131
Checking the Front Wheel
131
Assembling the Front Wheel
132
Adjusting the Front Wheel Static Balance
132
Checking the Front Brake Discs
133
Installing the Front Wheel (Front Brake Discs)
133
Rear Wheel
135
Removing the Rear Wheel
138
Disassembling the Rear Wheel
138
Checking the Rear Wheel
138
Checking the Rear Wheel Drive Hub
139
Checking and Replacing the Rear Wheel Sprocket
139
Assembling the Rear Wheel
139
Adjusting the Rear Wheel Static Balance
139
Checking the Rear Brake Disc
139
Installing the Rear Wheel (Rear Brake Disc)
139
Front Brake
141
Introduction
146
Checking the Front Brake Discs
146
Replacing the Front Brake Pads
147
Removing the Front Brake Calipers
148
Disassembling the Front Brake Calipers
148
Checking the Front Brake Calipers
149
Assembling the Front Brake Calipers
149
Installing the Front Brake Calipers
149
Removing the Front Brake Master Cylinder
150
Checking the Front Brake Master Cylinder
151
Assembling the Front Brake Master Cylinder
151
Installing the Front Brake Master Cylinder
151
Rear Brake
153
Introduction
158
Checking the Rear Brake Disc
158
Replacing the Rear Brake Pads
158
Removing the Rear Brake Caliper
159
Disassembling the Rear Brake Caliper
159
Checking the Rear Brake Caliper
160
Assembling the Rear Brake Caliper
160
Installing the Rear Brake Caliper
160
Removing the Rear Brake Master Cylinder
161
Checking the Rear Brake Master Cylinder
162
Assembling the Rear Brake Master Cylinder
162
Installing the Rear Brake Master Cylinder
162
Handlebar
164
Removing the Handlebar
166
Checking the Handlebar
166
Installing the Handlebar
166
Front Fork
169
Removing the Front Fork Legs
172
Disassembling the Front Fork Legs
172
Checking the Front Fork Legs
173
Assembling the Front Fork Legs
174
Installing the Front Fork Legs
176
Steering Head
178
Removing the Lower Bracket
180
Checking the Steering Head
180
Ring Nut Wrench
180
Installing the Steering Head
181
Rear Shock Absorber Assembly
184
Handling the Rear Shock Absorber
184
Disposing of a Rear Shock Absorber
184
Removing the Rear Shock Absorber Assembly
184
Checking the Rear Shock Absorber Assembly
184
Installing the Rear Shock Absorber Assembly
184
Swingarm
186
Removing the Swingarm
188
Checking the Swingarm
188
Installing the Swingarm
189
Chain Drive
190
Removing the Drive Chain
191
Checking the Drive Chain
191
Removing the Drive Sprocket
192
Checking the Drive Sprocket
192
Checking the Rear Wheel Sprocket
192
Checking the Rear Wheel Drive Hub
192
Installing the Drive Chain
192
Engine
194
Engine Removal
202
Engine Alignment Tool
202
Installing the Engine
202
Cylinder Head
204
Removing the Cylinder Head
205
Checking the Cylinder Head
205
Checking the Tappet Covers and Camshaft Sprocket Cover
206
Checking the Timing Chain Tensioner
206
Checking the Camshaft Sprocket
207
Installing the Cylinder Head
207
Rocker Arms and Camshaft
211
Removing the Rocker Arms and Camshaft
211
Checking the Camshaft
211
Checking the Decompression System
212
Checking the Rocker Arms and Rocker Arm Shafts
212
Installing the Camshaft and Rocker Arms
213
Valves and Valve Springs
216
Removing the Valves
216
Checking the Valves and Valve Guides
216
Valve Guide Remover (Ø 6)
217
Checking the Valve Seats
218
Checking the Valve Springs
219
Installing the Valves
220
Cylinder and Piston
223
Removing the Cylinder and Piston
223
Checking the Cylinder and Piston
223
Piston Pin Puller Set
223
Checking the Piston Rings
224
Checking the Piston Pin
225
Installing the Piston and Cylinder
225
Clutch
228
Clutch Cover
228
Clutch
229
Removing the Clutch
231
Checking the Friction Plates
231
Checking the Clutch Plates
231
Checking the Clutch Springs
232
Checking the Clutch Housing
232
Checking the Clutch Boss
232
Checking the Pressure Plate
233
Checking the Pull Lever Shaft and Pull Rod
233
Checking the Primary Driven Gear
233
Installing the Clutch
233
Oil Pump
239
Checking the Oil Pump
239
Checking the Oil Delivery Pipes and Hoses
239
Assembling the Oil Pump
240
Installing the Oil Pump
240
Balancer Driven Gear
241
Removing the Balancer Driven Gear and Balancer Drive Gear
242
Checking the Balancer Driven Gear, Water Pump Drive Gear, Primary Drive Gear, and Balancer Drive Gear
242
Installing the Balancer Driven Gear and Balancer Drive Gear
242
Shift Shaft
244
Shift Shaft and Stopper Lever
244
Checking the Shift Shaft
246
Checking the Stopper Lever
246
Installing the Shift Shaft
246
Starter Clutch and A.C. Magneto
249
Removing the A.C. Magneto Rotor
249
Checking the Stator Coil and Crankshaft Position Sensor
249
Flywheel Puller
249
Checking the Starter Clutch
250
Checking the Torque Limiter
250
Installing the A.C. Magneto Rotor
250
Electric Starter
253
Checking the Starter Motor
254
Assembling the Starter Motor
255
Crankcase
258
Separating the Crankcase
259
Checking the Oil Strainer and Oil Delivery Pipe 3
259
Checking the Timing Chain and Timing Chain Guides
259
Checking the Bearings and Oil Seals
260
Checking the Crankcase
260
Assembling the Crankcase
260
Crankshaft
262
Crankshaft and Balancer
262
Removing the Crankshaft Assembly
263
Checking the Crankshaft
263
Crankcase Separating Tool
263
Installing the Crankshaft
264
Crankshaft Installer Pot
264
Transmission
265
Checking the Shift Forks
268
Checking the Shift Drum Assembly
268
Checking the Transmission
268
Assembling the Main Axle and Drive Axle
269
Installing the Transmission
269
Cooling System
272
Radiator
274
Checking the Radiator
275
Installing the Radiator
275
Radiator Cap Tester Adaptor
275
Thermostat
277
Checking the Thermostat
278
Installing the Thermostat
278
Water Pump
280
Disassembling the Water Pump
282
Checking the Water Pump
282
Assembling the Water Pump
283
Middle Driven Shaft Bearing Driver
283
Installing the Water Pump
284
Fuel Injection System
286
Fuel Tank
289
Removing the Fuel Tank
289
Removing the Fuel Pump
289
Installing the Fuel Pump
290
Installing the Fuel Hose
290
Checking the Fuel Sender
290
Throttle Body Assembly
292
Checking the Fuel Injector
294
Checking the Throttle Body
294
Installing the Throttle Body Assembly
294
Checking the Fuel Pump
295
Pressure Gauge
295
Checking and Adjusting the Throttle Position
296
Sensor
296
Air Induction System
298
Air Injection
298
Air Cut-Off Valve
298
Air Induction System Diagrams
299
Air Cut-Off Valve Assembly
300
Checking the Air Induction System
302
Fuel Injection System
303
Wiring Diagram
304
Ecu's Self-Diagnostic Function
306
Self-Diagnostic Function Table
307
Fail-Safe Action Table
307
Troubleshooting Chart
309
Diagnostic Mode
310
Troubleshooting Details
315
Electrical System
326
General Information
326
Electric Starting System
332
Signaling System
346
Immobilizer System
356
Troubleshooting
390
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