YAMAHA MT03 PARTS CATALOGUE 08

MT03 (5YK5) EUROPE MT03 (5YK6) EUROPE (25kW)

A2

1G5YK-300E1

2G5YK-300E1

()

MT-03

PARTS CATALOGUE

1st edition, September 2007

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Italia S.p.a.

is expressly prohibited.

Printed in Italy.

A3

MT-03: COLOR A

MT-03: COLOR B MT-03: COLOR C

A4

FOREWORD

This Parts Catalogue is related to the parts for the model(s) on the cover page. When you are ordering replacement parts, please refer to this Parts Catalogue and quote both part numbers and part names correctly.

1. Modifications or additions which have been made after the issue of the Parts Catalogue will be announced in the Parts News. It is advisable that you make the necessary corrections to the Parts Catalogue according to the Parts News.

2. Abbreviations The following abbreviations are used in this Parts Catalogue.

“UR” Use specified parts number. “UN” Use as many as needed. “AP” Alternate Parts “LM” Locally Made (Parts need to be ordered locally) “F#” Frame No. (Applicable machine No.) “O/S” Over Size

3. The number of components for assembly

• Parts, which are to be supplied in an assembly, are listed with a dot (.) in front of the part name as shown below.

• The numeral appearing to the right of each component part indicates the quantity of parts for each assembly unit.

PART NO. DESCRIPTION Q’TY REMARKS

2F5–83310–60 FRONT FLASHER LIGHT ASSY 2

115–83311–60 .BULB (6V–18W) 1

6. The asterisk (*) before a reference number indicates modified items after the first edition.

4. Applicable colours of graphics are represented in the “REMARKS” as shown below.

PART NO. DESCRIPTION Q’TY REMARKS

2N4–24110–00–X5 FUEL TANK COMP. 2 MXR

3J1–24240–10 .GRAPHIC, FUEL TANK 1 FOR MXR

5. Note that the illustrations for reference in finding parts numbers are not to be used for assembling. When assembling, please use the applicable service manual.

A5

FOREWORD

7. Applicable Serial No.

Engine Serial No. Frame Serial No.

8. Applicable Colour Code (The (*) mark shows Model colour.)

Abbreviation Colour Name Colour Code

CIS CIRCUIT SILVER 00WN

LBNM5(*) LIGHT BLUISH GRAY METALLISH 5 0989

MBL2 MAT BLACK 2 0582

SM1 SILVER METALLIC 1 0660

SMX(*) BLACK METALLIC X 0903

VRC1(*) VIVID RED COCKTAIL 1 0121

Column No. Name Of Q’ty Column Destination

5 6020

5YK6 : PRODUCT DESTINA-

TION 020

9. Quantity Column Information

Column No. Name Of Q’ty Column Destination

1 5010

2 5020

3 5030

4 6010

5YK5 : PRODUCT DESTINA-

TION 010

5YK5 : PRODUCT DESTINA-

TION 020

5YK5 : PRODUCT DESTINA-

TION 030

5YK6 : PRODUCT DESTINA-

TION 010

A6

MODEL LABEL

(1) A label called “Model Label” is affixed in the location as indicated in (3) below.

When using this parts catalogue, please be sure to cross–reference the “model code – production code No.” in the catalogue with the “model code – production code No.” indicated on the Model Label affixed onto the product concerned.

(2) “Model Label” Indication

(3) Model Label Affixing Location

(4) Colouring Information

Model Code

5YK5

5YK6

Colouring

Type Code

A 0903

B 0989

C 0121

A 0903

B 0989

C 0121

Colour

Code

Colour Name

BLACK METALLIC X SMX

LIGHT BLUISH GRAY METALLISH 5 LBNM5

VIVID RED COCKTAIL 1 VRC1

BLACK METALLIC X SMX

LIGHT BLUISH GRAY METALLISH 5 LBNM5

VIVID RED COCKTAIL 1 VRC1

Abbrevia-

tion

(5) Model Code – Production Code Number of Model Listed in This Parts Catalogue

Model

Code

5YK5

5YK6

Production

Code No.

010 EUROPE

020

030 PORTUGAL

010 EUROPE

020 BELGIUM

(destination)

BELGIUM

NETHERLANDS

Country

Model

Code

Production

Code No.

Country

(destination)

A7

ENGINE

CYLINDER HEAD ................................................................. B2

CYLINDER ............................................................................B3

CRANKSHAFT & PISTON .................................................... B4

VALVE ...................................................................................B5

CAMSHAFT & CHAIN ........................................................... B6

WATER PUMP ...................................................................... B7

RADIATOR & HOSE ............................................................. B8

OIL PUMP ............................................................................. B10

INTAKE .................................................................................B12

INTAKE 2 ..............................................................................B14

AIR INDUCTION SYSTEM .................................................... B15

EXHAUST .............................................................................C2

CRANKCASE ........................................................................C4

CRANKCASE COVER 1 .......................................................C5

STARTER ..............................................................................C7

CLUTCH ................................................................................C8

TRANSMISSION ...................................................................C10

SHIFT CAM & FORK ............................................................. C12

SHIFT SHAFT .......................................................................C13

CHASSIS

FRAME ..................................................................................C14

FENDER ................................................................................D2

OIL TANK .............................................................................. D3

REAR ARM ...........................................................................D4

REAR SUSPENSION ............................................................D5

STEERING ............................................................................D6

FRONT FORK ....................................................................... D7

FUEL TANK ........................................................................... D10

SEAT .....................................................................................D12

FRONT WHEEL ....................................................................D14

FRONT BRAKE .....................................................................D15

REAR WHEEL ....................................................................... E2

REAR BRAKE CALIPER .......................................................E3

STEERING HANDLE & CABLE ............................................ E4

FRONT MASTER CYLINDER ............................................... E5

STAND & FOOTREST ..........................................................E6

REAR MASTER CYLINDER .................................................E8

GENERATOR ........................................................................E10

FLASHER LIGHT .................................................................. E11

METER ..................................................................................E12

CONTENTS

HEADLIGHT ......................................................................... E13

TAILLIGHT ............................................................................ E14

HANDLE SWITCH & LEVER ................................................ E15

ELECTRICAL 1 ..................................................................... F2

ELECTRICAL 2 ..................................................................... F4

INDEX

NUMERICAL INDEX ............................................................. M1

FIG. 1 CYLINDER HEAD

REF. NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

PART NO. DESCRIPTION

5VK–E1101–00

4G0–11133–11

93440–10X00

95617–08618

5VK–11181–00

90105–09002

90105–09004

90105–09003

91317–06030

90201–096J9

94701–00X09

93612–16X00

5VK–E1185–00

93210–96X00

90105–06X06

CYLINDER HEAD ASSY 1 1 1 1 1

.GUIDE, VALVE 1 44444

.CIRCLIP 4 4 4 4 4

BOLT, STUD 4 4 4 4 4

GASKET, CYLINDER HEAD 1 1 1 1 1 1

BOLT, FLANGE 2 2 2 2 2

BOLT 22222

WASHER, PLATE 6 6 6 6 6

PLUG, SPARK (NGK CR7E) 1 1 1 1 1

PIN, DOWEL 2 2 2 2 2

COVER, CYLINDER HEAD SIDE 1 1 1 1 1 1

O-RING 1 1 1 1 1

BOLT, FLANGE 2 2 2 2 2

5010

5020

5030

6010

REMARKS

6020

B

2

16

90465–10044

17

5VK–E1186–00

18

93210–78X00

19

91317–06018

CLAMP 11111

COVER, CYLINDER HEAD SIDE 2 2 2 2 2 2

O-RING 2 2 2 2 2

BOLT 88888

FIG. 2 CYLINDER

REF. NO.

1

2

3

4

5

6

7

PART NO. DESCRIPTION

5VK–11311–00

5VK–11351–00

90105–10078

90105–10077

90201–101A4

91317–06040

90465–10045

CYLINDER 1 1 1 1 1 1

GASKET, CYLINDER 1 1 1 1 1

BOLT, FLANGE 2 2 2 2 2

WASHER, PLATE 4 4 4 4 4

BOLT 22222

CLAMP 11111

5010

5020

5030

6010

REMARKS

6020

B

3

FIG. 3 CRANKSHAFT & PISTON

REF. NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

PART NO. DESCRIPTION

5VK–11400–00

5VK–11401–09

5VK–11422–00

5VK–11681–00

93310–84010

5VK–11651–00

90280–05001

90201–16013

90179–16448

93306–308Y0

5VK–11631–00

5VK–11603–00

5VK–11633–00

93450–24824

90201–30X00

CRANKSHAFT ASSY 1 1 1 1 1

.CRANK SUB ASSY 1 1 1 1 1 1

.CRANK 2 11111

.PIN, CRANK 1 1 1 1 1 1

.BEARING 11111

.ROD, CONNECTING 1 1 1 1 1

KEY, WOODRUFF 11111

WASHER, PLATE 1 1 1 1 1

NUT 11111

BEARING 1 1 1 1 1

PISTON (STD) 1 1 1 1 1

PISTON RING SET (STD) 1 1 1 1 1

PIN, PISTON 1 1 1 1 1

CIRCLIP 22222

WASHER, PLATE 1 1 1 1 1

5010

5020

5030

6010

REMARKS

6020

B

4

16

5VK–E1536–00

17

5VK–E1531–00

18

5VK–E1454–00

19

93306–305YA

20

93306–305X4

21

93101–25106

22

90282–05058

23

90170–18003

24

90215–18X00

GEAR, DRIVE 1 1 1 1 1

GEAR, BALANCE WEIGHT 1 1 1 1 1

WEIGHT 1 11111

BEARING 1 1 1 1 1

OIL SEAL 11111

KEY, STRAIGHT 1 1 1 1 1

NUT 11111

WASHER, LOCK 1 1 1 1 1

FIG. 4 VALVE

REF. NO.

1

2

3

4

5

6

7

8

9

10

11

12

PART NO. DESCRIPTION

5VK–12111–00

5VK–12121–00

5VK–12113–00

3YF–12116–00

5H0–12119–00

3YF–12117–01

4G0–12118–00

5VK–E2151–00

5VK–E2161–00

5VK–12146–00

5BP–12159–01

90170–06128

VALVE, INTAKE 2 2 2 2 2

VALVE, EXHAUST 2 2 2 2 2

SPRING, VALVE INNER 4 4 4 4 4

SEAT, VALVE SPRING 4 4 4 4 4

SEAL, VALVE STEM 4 4 4 4 4

RETAINER, VALVE SPRING 4 4 4 4 4

COTTER, VALVE 8 8 8 8 8

ARM, VALVE ROCKER 1 1 1 1 1

ARM, VALVE ROCKER 2 1 1 1 1 1

SHAFT, ROCKER 2 2 2 2 2

SCREW, VALVE ADJUSTING 4 4 4 4 4

NUT 44444

5010

5020

5030

6010

REMARKS

6020

B

5

FIG. 5 CAMSHAFT & CHAIN

REF. NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

PART NO. DESCRIPTION

5VK–E2170–10

93306–07209

5VK–12284–00

5VK–12290–00

5VK–12280–01

5VK–E111F–00

95027–06012

90105–07004

94591–57126

5VK–12231–00

5VK–12241–00

90119–06X05

3TB–12210–00

91317–06025

4DW–12213–00

CAMSHAFT ASSY 1 1 1 1 1 1

.BEARING 11111

PIN, DECOMPRESSION LEVER 1 1 1 1 1

LEVER, DECOMPRESSION SPRING 1 1 1 1 1

DECOMPRESSION ASSY 1 1 1 1 1

PLATE 11111

BOLT, FLANGE 2 2 2 2 2

CHAIN (98XRH2010-126M) 1 1 1 1 1

GUIDE, STOPPER 1 1 1 1 1 1

GUIDE, STOPPER 2 1 1 1 1 1

BOLT, WITH WASHER 2 2 2 2 2

TENSIONER ASSY, CAM CHAIN 1 1 1 1 1

BOLT 22222

GASKET, TENSIONER CASE 1 1 1 1 1

5010

5020

5030

6010

REMARKS

6020

B

6

FIG. 6 WATER PUMP

REF. NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

PART NO. DESCRIPTION

5VK–12436–00

5VK–12450–00

5VK–12422–00

93210–61750

93306–00106

5VK–12421–00

95027–06025

93101–12173

11H–12438–10

90201–12541

5VK–12428–00

90430–06014

93603–16219

5VK–12459–00

99009–12400

GEAR, DRIVE 1 1 1 1 1

IMPELLER SHAFT ASSY 1 1 1 1 1

COVER, HOUSING 1 1 1 1 1

O-RING 1 1 1 1 1

BEARING 1 1 1 1 1

HOUSING, WATER PUMP 1 1 1 1 1

BOLT, FLANGE 2 2 2 2 2

OIL SEAL 11111

SEAL, MECHANICAL 1 1 1 1 1

WASHER, PLATE 1 1 1 1 1

GASKET, HOUSING COVER 2 1 1 1 1 1

GASKET 11111

PIN, DOWEL 1 1 1 1 1

GEAR, IMPELLER SHAFT 1 1 1 1 1

CIRCLIP 11111

5010

5020

5030

6010

REMARKS

6020

B

7

16

5VK–E2469–00

17

91317–06020

18

93210–33X00

19

5VK–12481–00

20

93210–21X00

21

91317–06012

22

5VK–E2577–00

23

90450–32X03

24

91317–06050

JOINT 1 11111

BOLT 22222

O-RING 1 1 1 1 1

PIPE 1 1 1 1 1 1

O-RING 1 1 1 1 1

BOLT 11111

HOSE 2 11111

HOSE CLAMP ASSY 2 2 2 2 2

BOLT 33333

FIG. 7 RADIATOR & HOSE

REF. NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

PART NO. DESCRIPTION

5VK–12410–00

5VK–E2413–00

90105–06X06

93210–41X00

5YK–E2578–00

90450–32X03

5YK–E2461–00

5VK–E2405–00

5VK–E2462–00

90169–05801

90169–05802

5YK–E240J–00

92014–06016

9290L–06600

90387–06X30

THERMOSTAT ASSY 1 1 1 1 1

COVER, THERMOSTAT 1 1 1 1 1

BOLT, FLANGE 2 2 2 2 2

O-RING 1 1 1 1 1

HOSE 3 11111

HOSE CLAMP ASSY 4 4 4 4 4

RADIATOR ASSY 1 1 1 1 1

BLOWER ASSY 1 1 1 1 1

CAP, RADIATOR 1 1 1 1 1

TAPPING SCREW 22222

TAPPING SCREW 11111

RADIATOR COVER ASSY1 1 1 1 1 1

BOLT, BUTTON HEAD 2 2 2 2 2

WASHER 2 2 2 2 2

COLLAR 22222

5010

5020

5030

6010

REMARKS

6020

B

8

16

5YK–E240K–00

17

92014–06020

18

9290L–06600

19

90387–06X29

20

5YK–E2579–00

21

90480–18276

22

90387–068R3

23

92907–06600

24

97007–06020

25

90480–15363

26

5YK–F1871–00

27

5VK–21875–00

RADIATOR COVER ASSY 2 1 1 1 1 1

BOLT, BUTTON HEAD 2 2 2 2 2

WASHER 2 2 2 2 2

COLLAR 22222

HOSE 4 11111

GROMMET 22222

COLLAR 22222

WASHER, PLATE 2 2 2 2 2

BOLT 22222

GROMMET 11111

TANK, RECOVERY 1 1 1 1 1

CAP 11111

FIG. 7 RADIATOR & HOSE

REF. NO.

28

29

30

31

PART NO. DESCRIPTION

26H–21828–00

90445–08X02

90467–08003

90464–13M34

ELBOW 1 1 1 1 1

HOSE 22222

CLIP 33333

CLAMP 11111

5010

5020

5030

6010

REMARKS

6020

B

9

FIG. 8 OIL PUMP

REF. NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

PART NO. DESCRIPTION

5LP–13300–00

5LP–13329–00

93210–13X00

92017–06035

3AJ–13325–00

99009–11400

5VK–E3356–00

5VK–E3327–00

91317–05008

5VK–WE343–00

5VK–E3415–00

91317–06020

90340–14132

214–11198–01

5VK–E3181–00

OIL PUMP ASSY 1 1 1 1 1

GASKET, PUMP COVER 1 1 1 1 1

O-RING 2 2 2 2 2

BOLT, BUTTON HEAD 3 3 3 3 3

GEAR, PUMP DRIVEN 1 1 1 1 1

CIRCLIP 11111

COVER, PUMP 2 1 1 1 1 1

COVER, PUMP GEAR 1 1 1 1 1

BOLT 22222

STRAINER COMP. 1 1 1 1 1

SEAL, OIL STRAINER 1 1 1 1 1

BOLT 33333

PLUG, STRAIGHT SCREW 1 1 1 1 1

GASKET 11111

PIPE, DELIVERY 3 1 1 1 1 1

5010

5020

5030

6010

REMARKS

6020

B

10

16

93210–11X00

17

4X7–13440–01

18

2WK–13447–00

19

93210–64X01

20

93210–07X01

21

90109–06419

22

91317–06095

23

90149–05110

24

90430–05X00

25

5VK–13161–00

26

90401–08133

27

90430–08X01

O-RING 2 2 2 2 2

ELEMENT ASSY, OIL CLEANER 1 1 1 1 1

COVER, OIL ELEMENT 1 1 1 1 1

O-RING 1 1 1 1 1

BOLT 11111

BOLT 22222

SCREW 11111

GASKET 11111

PIPE, DELIVERY 1 1 1 1 1 1

BOLT, UNION 22222

GASKET 44444

FIG. 8 OIL PUMP

REF. NO.

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

PART NO. DESCRIPTION

5VK–13171–00

90401–10096

90430–10X00

91317–06012

583–13113–00

93503–08007

90501–04X01

5YK–13464–00

93210–10X00

91810–14X00

91317–06025

5YK–13467–00

5YK–13405–00

93210–15X00

91317–06016

PIPE, DELIVERY 2 1 1 1 1 1

BOLT, UNION 22222

GASKET 44444

BOLT 11111

SEAT, CHECK BALL 1 1 1 1 1

BALL 11111

SPRING, COMPRESSION 1 1 1 1 1

HOSE, OIL 1 1 1 1 1 1

O-RING 1 1 1 1 1

PIN, DOWEL 1 1 1 1 1

BOLT 11111

HOSE 11111

OIL PIPE COMP. 1 1 1 1 1 1

O-RING 1 1 1 1 1

BOLT 22222

5010

5020

5030

6010

REMARKS

6020

B

11

43

90445–11033

44

90467–10008

45

90450–20X01

HOSE 11111

CLIP 11111

HOSE CLAMP ASSY 1 1 1 1 1

FIG. 9 INTAKE

REF. NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

PART NO. DESCRIPTION

5VK–13586–00

90450–72001

5YK–E4411–00

5YK–E4437–00

5YK–E441E–00

5VK–E4451–00

5YK–E4452–00

90467–12800

5LW–E443E–00

9770M–50030

5YK–E4422–00

5YK–E441A–00

5YK–E4457–00

9581M–06020

90387–07037

JOINT, CARBURETOR 1 1 1 1 1 1

HOSE CLAMP ASSY 2 2 2 2 2

CASE, AIR CLEANER 1 1 1 1 1 1

DUCT 1 1 1 1 1

COVER, CLEANER CASE 2 1 1 1 1 1

ELEMENT, AIR CLEANER 1 1 1 1 1

SEAL 1 1 1 1 1

CLIP 11111

PIPE, DRAIN 1 1 1 1 1

SCREW, TAPPING 15 15 15 15 15

CAP, CLEANER CASE 2 1 1 1 1 1

COVER, CLEANER CASE 1 1 1 1 1 1

SEAL 1 1 1 1 1

BOLT, FLANGE 4 4 4 4 4

COLLAR 44444

5010

5020

5030

6010

REMARKS

6020

B

12

16

90480–18276

17

5YK–E4453–00

18

90450–59001

19

5VK–E443E–00

20

90467–12085

21

90338–08801

22

5VK–E3545–00

23

90467–17128

24

90467–170A2

25

5YK–E244G–00

26

90467–11108

27

90467–11090

GROMMET 44444

JOINT, AIR CLEANER 1 1 1 1 1 1

HOSE CLAMP ASSY 1 1 1 1 1

PIPE, DRAIN 1 1 1 1 1

CLIP 11111

PLUG 11111

HOSE 1 11111

CLIP 11111

HOSE, 4 11111

CLIP 33333

CLIP 11111

FIG. 9 INTAKE

REF. NO.

28

29

30

31

32

33

34

PART NO. DESCRIPTION

90467–17801

5YK–E1167–00

90467–14800

5YK–E5371–00

5YK–13542–00

90467–07138

5YK–E243A–00

CLIP 11111

PIPE, BREATHER 2 1 1 1 1 1

CLIP 11111

BREATHER 1 1 1 1 1

HOSE, VACUUM SENSING 1 1 1 1 1 1

CLIP 22222

HOSE 1 11111

5010

5020

5030

6010

REMARKS

6020

B

13

FIG. 10 INTAKE 2

REF. NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

PART NO. DESCRIPTION

5YK–13750–11

5VK–13160–00

90430–09002

98507–06012

8CC–14216–10

5VK–14503–00

5VK–14531–00

5VK–13761–00

558–14147–00

3P6–85885–00

5YK–E3750–10

5YK–E4D77–10

90149–05X04

THROTTLE BODY ASSY 1 1 1

.DELIVERY PIPE ASSY 1 1 1 1

.GASKET 1 1 1

.SCREW, PAN HEAD 2 2 2

.SCREW 2 2 2

.ADJUST SCREW SET 1 1 1

..SPRING, ADJUST SCREW 1 1 1

.INJECTOR 1 1 1

..O-RING 1 1 1

.THROTTLE SENSOR ASSY 1 1 1

THROTTLE BODY ASSY 1 1

.STOPPER 1 1

.SCREW 2 2

5010

5020

5030

6010

REMARKS

6020

B

14

FIG. 11 AIR INDUCTION SYSTEM

REF. NO.

1

2

3

4

5

6

7

8

9

PART NO. DESCRIPTION

5VK–14803–00

5VK–14871–02

5VK–14815–00

91380–06016

5YK–E4881–00

90467–17089

5YK–E4882–00

90467–17089

90467–170A0

AIR INDUCTION SYSTEM ASSY 1 1 1 1 1

PIPE 1 1 1 1 1 1

GASKET 11111

BOLT 22222

HOSE, BEND 1 1 1 1 1 1

CLIP 22222

HOSE, BEND 2 1 1 1 1 1

CLIP 11111

5010

5020

5030

6010

REMARKS

6020

B

15