Yamaha Mt-03 Mt03 2006 – 2012 Service Repair Workshop Manual – PDF DOWNLOAD

Description

Yamaha Mt-03 Mt03 2006 – 2012 Service Repair Workshop Manual

FILE DETAILS:

LANGUAGE:ENGLISH
PAGES:400
DOWNLOADABLE:YES
FILE TYPE:PDF
YAMAHA MT-03 MT03 2006 – 2012 SERVICE REPAIR WORKSHOP MANUAL – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Yamaha Mt-03 Mt03 2006 – 2012 Service Repair Workshop Manual

This manual was produced by the Yamaha Motor Italia S.p.A. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. Yamaha Motor Italia S.p.A. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.

HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title “1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disassembly step.
• Symbols “5” indicate parts to be lubricated or replaced. Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequentially.

TABLE OF CONTENTS:

Yamaha Mt-03 Mt03 2006 – 2012 Service Repair Workshop Manual

IDENTIFICATION 1-1
VEHICLE IDENTIFICATION NUMBER 1-1
MODEL LABEL 1-1
FEATURES 1-2
OUTLINE OF THE FI SYSTEM 1-2
FI SYSTEM 1-3
INSTRUMENT FUNCTIONS 1-4
IMPORTANT INFORMATION 1-7
PREPARATION FOR REMOVAL AND DISASSEMBLY 1-7
REPLACEMENT PARTS 1-7
GASKETS, OIL SEALS AND O-RINGS 1-7
LOCK WASHERS/PLATES AND COTTER PINS 1-7
BEARINGS AND OIL SEALS 1-8
CIRCLIPS 1-8
CHECKING THE CONNECTIONS 1-9
SPECIAL TOOLS 1-10
GENERAL SPECIFICATIONS 2-1
ENGINE SPECIFICATIONS 2-2
CHASSIS SPECIFICATIONS 2-10
ELECTRICAL SPECIFICATIONS 2-13
TIGHTENING TORQUES2-16
GENERAL TIGHTENING TORQUE SPECIFICATIONS 2-16
ENGINE TIGHTENING TORQUES2-17
CHASSIS TIGHTENING TORQUES2-20
LUBRICATION POINTS AND LUBRICANT TYPES 2-23
ENGINE2-23
CHASSIS2-25
COOLING SYSTEM DIAGRAMS2-26
LUBRICATION CHART2-30
LUBRICATION DIAGRAMS 2-32
CABLE ROUTING 2-40
2
PERIODIC MAINTENANCE 3-1
INTRODUCTION 3-1
PERIODIC MAINTENANCE AND LUBRICATION CHART 3-1
ENGINE 3-3
ADJUSTING THE VALVE CLEARANCE 3-3
ADJUSTING THE ENGINE IDLING SPEED 3-5
ADJUSTING THE THROTTLE CABLE FREE PLAY 3-5
CHECKING THE SPARK PLUG 3-6
CHECKING THE IGNITION TIMING 3-7
MEASURING THE COMPRESSION PRESSURE 3-8
CHECKING THE ENGINE OIL LEVEL 3-9
CHANGING THE ENGINE OIL 3-10
ADJUSTING THE CLUTCH CABLE FREE PLAY3-11
CHECKING THE AIR FILTER ELEMENT 3-12
CHECKING THE THROTTLE BODY JOINT3-13
CHECKING THE FUEL HOSE 3-13
CHECKING THE FUEL TANK BREATHER/OVERFLOW HOSES 3-13
CHECKING THE CRANKCASE BREATHER HOSES3-13
CHECKING THE EXHAUST SYSTEM3-14
CHECKING THE COOLANT LEVEL3-14
CHECKING THE COOLING SYSTEM3-15
CHANGING THE COOLANT3-16
CHASSIS 3-18
ADJUSTING THE FRONT BRAKE3-18
ADJUSTING THE REAR BRAKE PEDAL3-18
CHECKING THE BRAKE FLUID LEVEL3-19
CHECKING THE FRONT AND REAR BRAKE PADS
AND BRAKE PAD PINS 3-20
CHECKING THE FRONT AND REAR BRAKE HOSES3-20
BLEEDING THE HYDRAULIC BRAKE SYSTEM 3-21
ADJUSTING THE SHIFT PEDAL3-22
ADJUSTING THE DRIVE CHAIN SLACK3-22
LUBRICATING THE DRIVE CHAIN 3-23
CHECKING AND ADJUSTING THE STEERING HEAD 3-23
CHECKING THE FRONT FORK 3-25
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3-25
CHECKING THE TIRES3-26
CHECKING THE WHEELS 3-27
CHECKING AND LUBRICATING THE CABLES3-28
LUBRICATING THE LEVERS AND BRAKE PEDAL3-28
LUBRICATING THE SIDESTAND 3-28
LUBRICATING THE SIDE SUSPENSION3-28
3
GENERAL CHASSIS 4-1
REMOVING THE SEATS 4-1
REMOVING THE COWLING 4-2
REMOVING THE REAR FENDER COVER, LICENSE BRACKET
AND TAIL/BRAKE LIGHT ASSEMBLY 4-3
REMOVING THE AIR FILTER CASE AND CRANKCASE
BREATHER CHAMBER 4-4
INSTALLING THE AIR FILTER CASE JOINT CLAMP 4-5
FRONT WHEEL 4-6
REMOVING THE FRONT WHEEL 4-8
DISASSEMBLING THE FRONT WHEEL 4-8
CHECKING THE FRONT WHEEL 4-8
ASSEMBLING THE FRONT WHEEL 4-9
ADJUSTING THE FRONT WHEEL STATIC BALANCE 4-9
CHECKING THE FRONT BRAKE DISCS4-10
INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS) 4-10
REAR WHEEL 4-12
REMOVING THE REAR WHEEL4-15
DISASSEMBLING THE REAR WHEEL4-15
CHECKING THE REAR WHEEL 4-15
CHECKING THE REAR WHEEL DRIVE HUB4-16
CHECKING AND REPLACING THE REAR WHEEL SPROCKET 4-16
ASSEMBLING THE REAR WHEEL4-16
ADJUSTING THE REAR WHEEL STATIC BALANCE4-16
CHECKING THE REAR BRAKE DISC 4-16
INSTALLING THE REAR WHEEL (REAR BRAKE DISC) 4-16
FRONT BRAKE4-18
INTRODUCTION4-23
CHECKING THE FRONT BRAKE DISCS4-23
REPLACING THE FRONT BRAKE PADS 4-24
REMOVING THE FRONT BRAKE CALIPERS 4-25
DISASSEMBLING THE FRONT BRAKE CALIPERS 4-25
CHECKING THE FRONT BRAKE CALIPERS4-26
ASSEMBLING THE FRONT BRAKE CALIPERS 4-26
INSTALLING THE FRONT BRAKE CALIPERS4-26
REMOVING THE FRONT BRAKE MASTER CYLINDER4-27
CHECKING THE FRONT BRAKE MASTER CYLINDER 4-28
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER4-28
INSTALLING THE FRONT BRAKE MASTER CYLINDER 4-28
REAR BRAKE 4-30
INTRODUCTION4-35
CHECKING THE REAR BRAKE DISC 4-35
REPLACING THE REAR BRAKE PADS4-35
REMOVING THE REAR BRAKE CALIPER4-36
DISASSEMBLING THE REAR BRAKE CALIPER 4-36
CHECKING THE REAR BRAKE CALIPER 4-37
ENGINE REMOVAL 5-1
INSTALLING THE ENGINE 5-7
CYLINDER HEAD 5-9
REMOVING THE CYLINDER HEAD5-10
CHECKING THE CYLINDER HEAD 5-10
CHECKING THE TAPPET COVERS AND CAMSHAFT
SPROCKET COVER 5-11
CHECKING THE TIMING CHAIN TENSIONER5-11
CHECKING THE CAMSHAFT SPROCKET5-12
INSTALLING THE CYLINDER HEAD5-12
ROCKER ARMS AND CAMSHAFT5-15
REMOVING THE ROCKER ARMS AND CAMSHAFT5-16
CHECKING THE CAMSHAFT5-16
CHECKING THE DECOMPRESSION SYSTEM5-17
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS5-17
INSTALLING THE CAMSHAFT AND ROCKER ARMS5-18
VALVES AND VALVE SPRINGS5-20
REMOVING THE VALVES 5-21
CHECKING THE VALVES AND VALVE GUIDES5-21
CHECKING THE VALVE SEATS5-23
CHECKING THE VALVE SPRINGS 5-24
INSTALLING THE VALVES 5-25
CYLINDER AND PISTON 5-27
REMOVING THE CYLINDER AND PISTON5-28
CHECKING THE CYLINDER AND PISTON 5-28
CHECKING THE PISTON RINGS5-29
CHECKING THE PISTON PIN 5-30
INSTALLING THE PISTON AND CYLINDER5-30
CLUTCH 5-33
CLUTCH COVER 5-33
PULL LEVER SHAFT 5-34
CLUTCH 5-35
REMOVING THE CLUTCH 5-36
CHECKING THE FRICTION PLATES5-36
CHECKING THE CLUTCH PLATES 5-36
CHECKING THE CLUTCH SPRINGS5-37
CHECKING THE CLUTCH HOUSING 5-37
CHECKING THE CLUTCH BOSS5-37
CHECKING THE PRESSURE PLATE5-38
CHECKING THE PULL LEVER SHAFT AND PULL ROD 5-38
CHECKING THE PRIMARY DRIVEN GEAR 5-38
INSTALLING THE CLUTCH 5-38
RADIATOR 6-1
CHECKING THE RADIATOR 6-2
INSTALLING THE RADIATOR 6-2
THERMOSTAT 6-4
CHECKING THE THERMOSTAT 6-5
INSTALLING THE THERMOSTAT 6-5
WATER PUMP 6-7
DISASSEMBLING THE WATER PUMP 6-9
CHECKING THE WATER PUMP 6-9
ASSEMBLING THE WATER PUMP6-10
INSTALLING THE WATER PUMP 6-11
FUEL TANK 7-1
REMOVING THE FUEL TANK 7-2
REMOVING THE FUEL PUMP 7-2
INSTALLING THE FUEL PUMP 7-3
INSTALLING THE FUEL HOSE 7-3
CHECKING THE FUEL SENDER 7-3
THROTTLE BODY ASSEMBLY 7-4
CHECKING THE FUEL INJECTOR 7-7
CHECKING THE THROTTLE BODY 7-7
INSTALLING THE THROTTLE BODY ASSEMBLY 7-7
CHECKING THE FUEL PUMP 7-8
CHECKING AND ADJUSTING THE THROTTLE POSITION
SENSOR 7-9
AIR INDUCTION SYSTEM 7-11
AIR INJECTION7-11
AIR CUT-OFF VALVE7-11
AIR INDUCTION SYSTEM DIAGRAMS7-12
AIR CUT-OFF VALVE ASSEMBLY7-13
CHECKING THE AIR INDUCTION SYSTEM7-15
FUEL INJECTION SYSTEM7-16
WIRING DIAGRAM7-17
ECU’S SELF-DIAGNOSTIC FUNCTION7-19
SELF-DIAGNOSTIC FUNCTION TABLE 7-20
FAIL-SAFE ACTION TABLE 7-20
TROUBLESHOOTING CHART 7-22
DIAGNOSTIC MODE7-23
TROUBLESHOOTING DETAILS7-28
IGNITION SYSTEM 8-1
CIRCUIT DIAGRAM 8-1
TROUBLESHOOTING 8-3
ELECTRIC STARTING SYSTEM 8-5
CIRCUIT DIAGRAM 8-5
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION 8-7
TROUBLESHOOTING 8-9
CHARGING SYSTEM 8-11
CIRCUIT DIAGRAM 8-11
TROUBLESHOOTING 8-13
LIGHTING SYSTEM8-15
CIRCUIT DIAGRAM 8-15
TROUBLESHOOTING 8-17
SIGNALING SYSTEM 8-19
CIRCUIT DIAGRAM 8-19
TROUBLESHOOTING 8-21
COOLING SYSTEM 8-25
CIRCUIT DIAGRAM 8-25
TROUBLESHOOTING 8-27
IMMOBILIZER SYSTEM8-29
CIRCUIT DIAGRAM 8-29
GENERAL INFORMATION 8-31
PART REPLACEMENT AND KEY CODE REGISTRATION
REQUIREMENTS8-31
TROUBLESHOOTING 8-35
SELF-DIAGNOSIS FAULT CODE INDICATION 8-36
ELECTRICAL COMPONENTS 8-39
CHECKING THE SWITCHES 8-43
CHECKING THE BULBS AND BULB SOCKETS 8-46
CHECKING THE LEDS8-47
CHECKING THE FUSES 8-48
CHECKING AND CHARGING THE BATTERY8-49
CHECKING THE RELAYS 8-51
CHECKING THE TURN SIGNAL/HAZARD RELAY8-53
CHECKING THE RELAY UNIT (DIODE) 8-53
CHECKING THE SPARK PLUG CAP8-54
CHECKING THE IGNITION COIL8-54
CHECKING THE IGNITION SPARK GAP8-55
CHECKING THE CRANKSHAFT POSITION SENSOR 8-55
CHECKING THE LEAN ANGLE CUT-OFF SWITCH8-56
CHECKING THE STATOR COIL8-56
CHECKING THE HORN8-57
TROUBLESHOOTING 9-1
GENERAL INFORMATION 9-1
STARTING FAILURES 9-1
INCORRECT ENGINE IDLING SPEED 9-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE 9-2
FAULTY GEAR SHIFTING 9-2
FAULTY CLUTCH 9-2
OVERHEATING 9-3
OVERCOOLING 9-3
POOR BRAKING PERFORMANCE 9-3
FAULTY FRONT FORK LEGS 9-3
UNSTABLE HANDLING 9-3
FAULTY LIGHTING OR SIGNALING SYSTEM 9-4
9

PLEASE NOTE:

• This is the SAME MANUAL used by the dealerships to diagnose your vehicle
• No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
• Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
• So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com