2008 YAMAHA XT660Z air condition

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SAFETY INFORMATION

• Always obey the speed limitand never travel faster than
warranted by road and traffic
conditions.
• Always signal before turning or changing lanes. Make sure that
other motorists can see you.
●The posture of the operator and
passenger is important for proper
control.
• The operator should keep bothhands on the handlebar and
both feet on the operator
footrests during operation to
maintain control of the motor-
cycle.
• The passenger should always hold onto the operator, the seat
strap or grab bar, if equipped,
with both hands and keep
both feet on the passenger
footrests.
• Never carry a passenger un- less he or she can firmly place
both feet on the passenger
footrests.
●Never ride under the influence of
alcohol or other drugs. Protective apparel
The majority of fatalities from motorcy-
cle accidents are the result of head in-
juries. The use of a safety helmet is the
single most critical factor in the pre-
vention or reduction of head injuries.
●Always wear an approved helmet.
●Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.
●The use of a jacket, heavy boots,
trousers, gloves, etc., is effective
in preventing or reducing abra-
sions or lacerations.
●Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or
wheels and cause injury or an ac-
cident.
●Never touch the engine or ex-
haust system during or after oper-
ation. They become very hot and
can cause burns. Always wear
protective clothing that covers
your legs, ankles, and feet.
●Passengers should also observe
the precautions mentioned above.Modifications
Modifications made to this motorcycle
not approved by Yamaha, or the re-
moval of original equipment, may ren-
der the motorcycle unsafe for use and
may cause severe personal injury.
Modifications may also make your mo-
torcycle illegal to use.
Loading and accessories
Adding accessories or cargo to your
motorcycle can adversely affect stabili-
ty and handling if the weight distribution
of the motorcycle is changed. To avoid
the possibility of an accident, use ex-
treme caution when adding cargo or
accessories to your motorcycle. Use
extra care when riding a motorcycle
that has added cargo or accessories.
Here are some general guidelines to
follow if loading cargo or adding ac-
cessories to your motorcycle:
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PRE-OPERATION CHECKS
4-1
EAU15593
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpected-
ly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage
or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough vi-
sual inspection, to check the following points before each ride.
NOTE:
Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved.
EWA11150
WARNING0
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operat-
ing the vehicle.

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PRE-OPERATION CHECKS
4-3
ITEM
Clutch
Throttle grip
Control cables
Drive chain
Wheels and tires
Brake pedal
Brake and
clutch levers
Sidestand
Chassis fasteners CHECKS
• Check operation.
• Lubricate cable if necessary.
• Check lever free play.
• Adjust if necessary.
• Make sure that operation is smooth.
• Check cable free play.
• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing.
• Make sure that operation is smooth.
• Lubricate if necessary.
• Check chain slack.
• Adjust if necessary.
• Check chain condition.
• Lubricate if necessary.
• Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary.
• Make sure that operation is smooth.
• Lubricate pedal pivoting point if necessary.
• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.
• Make sure that operation is smooth.
• Lubricate pivot if necessary.
• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary. PAGE
3-10, 6-20, 6-26
6-16, 6-266-25
6-23, 6-24, 6-25
6-16, 6-196-27
6-26
6-27–

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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17240
Safety is an obligation of the owner.
Periodic inspection, adjustment and
lubrication will keep your vehicle in the
safest and most efficient condition
possible. The most important points of
inspection, adjustment, and lubrica-
tion are explained on the following
pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.
EWA10320
WARNING0
If you are not familiar with motorcy-
cle maintenance work, have a
Yamaha dealer do it for you.

EAU17380
Owner’s tool kit
1. Owner’s tool kit
The owner’s tool kit is located under
the seat. (See page 3-14).
The service information included in
this manual and the tools provided in
the owner’s tool kit are intended to as-
sist you in the performance of preven-
tive maintenance and minor repairs.
However, additional tools such as a
torque wrench may be necessary to
perform certain maintenance work
correctly.

NOTE:
If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
EWA10350
WARNING0
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any
changes.

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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17709
Periodic maintenance and lubrication chart
NOTE:● The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.
●From 50000 km, repeat the maintenance intervals starting from 10000 km.
●Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and tech-
nical skills.
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NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUAL CHECK
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• Check fuel hoses for cracks or damage.
• Check condition.
• Clean and regap.
• Replace.
• Check valve clearance.
• Adjust.
• Replace.
• Check operation.
• Adjust.
• Check operation, fluid level and vehicle for fluid
leakage.
• Replace brake pads.
• Check operation, fluid level and vehicle for fluid
leakage.
• Replace brake pads.
Fuel line
Spark plug
Valves
Air filter element
Clutch
Front brake
Rear brake
Whenever worn to the limit
Whenever worn to the limit

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUALCHECK
√√√√ √
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• Check for cracks or damage.
• Replace.
• Check runout, spoke tightness and for damage.
• Tighten spokes if necessary.
• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
• Check bearing for looseness
or damage.
• Check operation and for excessive play.
• Lubricate with lithium-soap-based grease.
• Check chain slack, alignment and condition.
• Adjust and lubricate chain with a special O-ring
chain lubricant thoroughly.
• Check bearing play and steering for roughness.
• Lubricate with lithium-soap-based grease.
• Make sure that all nuts, bolts and screws are
properly tightened.
• Check operation.
• Lubricate.
• Check operation.
Every 4 years
Brake hoses
Wheels
Tires
Wheel bearings
Swingarm
Drive chain
Steering bearings
Chassis fasteners
Sidestand
Sidestand switch
Every 50000 km
Every 500 km and after washing
the motorcycle or riding in the rain
Every 20000 km

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
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2. Remove the spark plug as shown, with the spark plug wrench includ-
ed in the owner’s tool kit.
To check the spark plug 1. Check that the porcelain insulator around the center electrode of the
spark plug is a medium-to-light
tan (the ideal color when the vehi-
cle is ridden normally).
NOTE:
If the spark plug shows a distinctly dif-
ferent color, the engine could be oper-
ating improperly. Do not attempt to di-
agnose such problems yourself.
Instead, have a Yamaha dealer check
the vehicle.
2. Check the spark plug for elec- trode erosion and excessive car-
bon or other deposits, and re-
place it if necessary.
Specified spark plug:CR7E (NGK)
Spark plug gap:0.7-0.8 mm (0.028-0.032 in)
To install the spark plug
1. Measure the spark plug gap with a wire thickness gauge and, if
necessary, adjust the gap to
specification.
1. Spark plug gap

2. Clean the surface of the sparkplug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the spark plug wrench, and then tight-
en it to the specified torque.
EAU19603
Checking the spark plug
The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause
any spark plug to slowly erode, the
spark plug should be removed and
checked in accordance with the peri-
odic maintenance and lubrication
chart. In addition, the condition of the
spark plug can reveal the condition of
the engine.
To remove the spark plug
1. Spark plug cap
2. Spark plug wrench
1. Remove the spark plug cap.

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
EWA11020
WARNING0
Because loading has an enormous
impact on the handling, braking,
performance and safety character-
istics of your motorcycle, you
should keep the following precau-
tions in mind.
●NEVER OVERLOAD THE MO-
TORCYCLE! Operation of an
overloaded motorcycle may re-
sult in tire damage, loss of con-
trol, or severe injury. Make sure
that the total weight of rider,
passenger, cargo, and acces-
sories does not exceed the
specified maximum load for the
vehicle.
●Do not carry along loosely
packed items, which can shift
during a ride.
●Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.

Tire air pressure
(measured on cold tires):Up to 90 kg (198 lb):
Front:210 kPa (30 psi) (2.1 kgf/cm
2)
Rear: 230 kPa (33 psi) (2.3 kgf/cm
2)
90 kg (198 lb) to maximum load:
Front: 230 kPa (33 psi) (2.3 kgf/cm
2)
Rear: 250 kPa (36 psi) (2.5 kgf/cm
2)
Off-road riding:
Front: 200 kPa (29 psi) (2.0 kgf/cm
2)
Rear: 200 kPa (29 psi) (2.0 kgf/cm
2)
High-speed riding:
Front: 210 kPa (30 psi) (2.1 kgf/cm
2)
Rear: 230 kPa (33 psi) (2.3 kgf/cm
2)
Maximum load*: 190 kg (419 lb)
* Total weight of rider, passenger, cargo and accessories
●Adjust the suspension and tire
air pressure with regard to the
load.
●Check the tire condition and air
pressure before each ride.

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