2008 YAMAHA XT660Z Owners Manual

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
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.
EAU22760
Drive chain slack
The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22783
To check the drive chain slack
1. Drive chain slack
1. Place the motorcycle on the side-stand.
NOTE:
When checking and adjusting the dri-
ve chain slack, there should be no
weight on the motorcycle.
2. Shift the transmission into theneutral position.
3. Move the rear wheel by pushing the motorcycle to locate the tight-
est portion of the drive chain, and
then measure the drive chain
slack as shown.
4. If the drive chain slack is incor- rect, adjust it as follows.
NOTE:
When checking the drive chain slack,
the chain tensioner should not be
touching the drive chain.
Drive chain slack:50.0-60.0 mm (1.96-2.36 in)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-24
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1. Wheel axle
2. Drive chain slack adjusting bolt
3. Locknut
4. Alignment marks
ECA10570
CAUTION:
Improper drive chain slack will
overload the engine as well as oth-
er vital parts of the motorcycle and
can lead to chain slippage or break-
age. To prevent this from occurring,
keep the drive chain slack within
the specified limits.
3. Tighten the locknuts, then the axle nut to their specified torques.
Tightening torques:
Locknut:16 Nm (1.6 m·kgf, 11 ft·lbf)
Axle nut: 105 Nm (10.5 m·kgf, 75 ft·lbf)
EAU34311
To adjust the drive chain slack1. Loosen the axle nut and the lock- nut on each side of the swingarm.
2. To tighten the drive chain, turn the adjusting bolt on each side of the
swingarm in direction (a). To
loosen the drive chain, turn the
adjusting bolt on each side of the
swingarm in direction (b), and
then push the rear wheel forward.
NOTE:
Using the alignment marks on each
side of the swingarm, make sure that
both chain pullers are in the same po-
sition for proper wheel alignment.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
EAU23022
Cleaning and lubricating
the drive chain
The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly
wear out, especially when riding in
dusty or wet areas. Service the drive
chain as follows.
ECA10581CAUTION:
The drive chain must be lubricated
after washing the motorcycle and
riding in the rain.
1. Clean the drive chain with kerosene and a small soft brush.
ECA11120CAUTION:
To prevent damaging the O-rings,
do not clean the drive chain with
steam cleaners, high-pressure
washers or inappropriate solvents. 2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
ECA11110CAUTION:
Do not use engine oil or any other
lubricants for the drive chain, as
they may contain substances that
could damage the O-rings.
EAU23100
Checking and lubricating
the cables
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubri-
cated if necessary. If a cable is dam-
aged or does not move smoothly, have
a Yamaha dealer check or replace it.
Recommended lubricant: Engine oil
EWA10720
WARNING0
Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
Recommended lubricants: Brake lever:Silicone grease
Clutch lever: Lithium-soap-based grease
(all-purpose grease)
EAU23111
Checking and lubricating
the throttle grip and cable
The operation of the throttle grip
should be checked before each ride. In
addition, the cable should be lubricat-
ed at the intervals specified in the pe-
riodic maintenance chart.
EAU23141
Checking and lubricating
the brake and clutch levers
Brake lever
Clutch lever

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
EAU23181
Lubricating the brake
pedal
The operation of the brake pedal
should be checked before each ride,
and the pedal pivot should be lubricat-
ed if necessary.
Recommended lubricant:Silicone grease
EAU23200
Checking and lubricating
the sidestand
The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated
if necessary.
EWA10730
WARNING0
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it.
Recommended lubricant:Lithium-soap-based grease
(all-purpose grease)
EAU23250
Lubricating the rear
suspension
The pivoting points of the rear suspen-
sion must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.
Recommended lubricant:Lithium-soap-based grease
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PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU23271
Checking the front fork
The condition and operation of the
front fork must be checked as follows
at the intervals specified in the period-
ic maintenance and lubrication chart.
To check the condition
EWA10750
WARNING0
Securely support the motorcycle so
that there is no danger of it falling
over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation 1. Place the motorcycle on a level surface and hold it in an upright
position.
2. While applying the front brake, push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.

ECA10590CAUTION:
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.

EAUM1650
Lubricating the swingarm
pivots
The swingarm pivots must be lubricat-
ed at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
Recommended lubricant: Lithium-soap-based grease

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
EAU23280
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the opera-
tion of the steering must be checked
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.1. Place a stand under the engine to raise the front wheel off the
ground.
EWA10750
WARNING0
Securely support the motorcycle so
that there is no danger of it falling
over.

2. Hold the lower ends of the frontfork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.EAU23290
Checking the wheel bearings
The front and rear wheel bearings
must be checked at the intervals spec-
ified in the periodic maintenance and
lubrication chart. If there is play in the
wheel hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
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EWA10760
WARNING0
●Electrolyte is poisonous and
dangerous since it contains
sulfuric acid, which causes se-
vere burns. Avoid any contact
with skin, eyes or clothing and
always shield your eyes when
working near batteries. In case
of contact, administer the fol-
lowing FIRST AID.
• EXTERNAL: Flush with plenty
of water.
• INTERNAL: Drink large quan-
tities of water or milk and im-
mediately call a physician.
• EYES: Flush with water for 15
minutes and seek prompt
medical attention.
●Batteries produce explosive hy-
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro-
vide sufficient ventilation when
charging it in an enclosed space.
●KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
EAUB1430
Battery
This model is equipped with a sealed-
type (MF) battery, which does not re-
quire any maintenance. There is no
need to check the electrolyte or to add
distilled water.
ECA10620CAUTION:
Never attempt to remove the bat-
tery cell seals, as this would perma-
nently damage the battery.
To access the battery
Remove the battery holder bracket by
removing the bolts.
1. Positive battery terminal
2. Negative battery terminal
To charge the battery
Have a Yamaha dealer charge the bat-
tery as soon as possible if it seems to
have discharged. Keep in mind that
the battery tends to discharge more
quickly if the vehicle is equipped with
optional electrical accessories.
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