2008 YAMAHA XT660Z brake fluid

TABLE OF CONTENTS
SAFETY INFORMATION.....................1-1
Safe riding .........................................1-1
Protective apparel .............................1-2
Modifications .....................................1-2
Loading and accessories ..................1-2
Gasoline and exhaust gas ................1-4
DESCRIPTION .....................................2-1
Left view ............................................2-1
Right view .........................................2-2
Controls and instruments ..................2-3
INSTRUMENT AND CONTROL
FUNCTIONS ........................................3-1
Immobilizer system ...........................3-1
Main switch/steering lock ..................3-2
Indicator and warning lights ..............3-3
Multi-function display ........................3-5
Tachometer .......................................3-6
Tripmeter and tachometer modes .....3-6
Clock mode .......................................3-7
Fuel meter .........................................3-7
Self-diagnosis devices ......................3-7
Anti-theft alarm (optional) .................3-8
Handlebar switches ...........................3-9
Clutch lever .....................................3-10
Shift pedal .......................................3-10
Brake lever ......................................3-11
Brake pedal .....................................3-11 Fuel tank cap ..................................3-11
Fuel .................................................3-12
Fuel tank breather hose ..................3-13
Catalytic converter ..........................3-13
Seat .................................................3-14
Adjusting the front fork ....................3-15
Adjusting the shock absorber
assembly ..................................3-16
Sidestand ........................................3-17
Ignition circuit cut-off system ..........3-17
PRE-OPERATION CHECKS ...............4-1
Pre-operation check list ....................4-2
OPERATION AND IMPORTANT
RIDING POINTS ..................................5-1
Starting the engine............................5-1
Shifting ..............................................5-2
Tips for reducing fuel consumption ...5-3
Engine break-in .................................5-3
Parking ..............................................5-4
PERIODIC MAINTENANCE
AND MINOR REPAIR .........................6-1
Owner’s tool kit .................................6-1
Periodic maintenance and lubrication chart..........................6-2
Removing and installing the cowling and panels..................................6-8 Checking the spark plug ...................6-8
Engine oil and oil filter element.........6-9
Coolant ............................................6-12
Replacing the air filter element
and cleaning the check hose ..... 6-14
Checking the engine idling speed ...6-15
Checking the throttle cable free play ...................................6-16
Valve clearance ...............................6-16
Tires ................................................6-16
Spoke wheels..................................6-19
Adjusting the clutch lever free play ...................................6-20
Checking the front and rear brake pads ...............................6-21
Checking the brake fluid level .........6-22
Changing the brake fluid .................6-23
Drive chain slack .............................6-23
Cleaning and lubricating the drive chain ................................6-25
Checking and lubricating the cables .......................................6-25
Checking and lubricating the throttle grip and cable ..............6-26
Checking and lubricating the brake and clutch levers ............6-26
Lubricating the brake pedal ............6-27
Checking and lubricating the sidestand ..................................6-27

XT660Z 01-03 ING 10-03-2008 16:11 Pagina 6

10. Grab bar
11. Main fuse (page 6-31)
12. Battery (page 6-30)
13. Rear brake fluid reservoir (page 6-22)14. Coolant reservoir (page 6-12) 15. Front brake fluid reservoir (page 6-22)
16. Coolant drain bolt (page 6-12)
17. Engine oil filter element (page 6-10)
18. Brake pedal (page 3-11)
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DESCRIPTION
EAU10420Right view
2-2

XT660Z 01-03 ING 10-03-2008 16:11 Pagina 13

PRE-OPERATION CHECKS
4-2
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ITEM
Fuel
Engine oil
Coolant
Front brake
Rear brake
EAU15605
Pre-operation check list
CHECKS
• Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.
• Check oil level in oil tank.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage.
• Check coolant level in reservoir.
• If necessary, add recommended coolant to specified level.
• Check cooling system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage. PAGE
3-12
6-9
6-12
3-11, 6-21, 6-22, 6-26
3-11, 6-21, 6-22, 6-27

XT660Z 04-06 ING 11-03-2008 8:30 Pagina 2

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.
6-2
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NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUAL CHECK
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√√
√√√√√
√√√√√ √
√√√√√ √1✻
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✻
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7✻
• 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

XT660Z 04-06 ING 11-03-2008 8:30 Pagina 6-2

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-56-5
NO. ITEMCHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUAL
CHECK
• Check the air cut-off valve, reed valve, and hose for damage.
• 5HSODFHDQ\damageGSDUWVLIQHFHVVDU\
• Check the screw clamp for looseness.
• Check operation.
• Adjust headlight beam.
Air induction system
Muffler and exhaust
pipe
Lights, signals and
switches
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✻
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30✻
EAUM1890
NOTE:
●Replace the air filter element more frequently if you are riding in unusually wet or dusty areas.
●Hydraulic brake service
●Regularly check and, if necessary, correct the brake fluid level.
●Every two years replace the internal components of the brake master cylinder, and change the brake fluid.
●Replace the brake hoses every four years and if cracked or damaged. √√√√ √
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XT660Z 04-06 ING 29-08-2008 15.20 Pagina 6-5

PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
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Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake flu-
id is above the minimum level mark
and replenish if necessary.
A low brake fluid level may indicate
worn brake pads and/or brake system
leakage. If the brake fluid level is low,
be sure to check the brake pads for
wear and the brake system for leak-
age.
Observe these precautions:
●When checking the fluid level,
make sure that the top of the
brake fluid reservoir is level.
●Use only the recommended qual-
ity brake fluid, otherwise the rub-
ber seals may deteriorate, caus-
ing leakage and poor braking
performance.
●Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
●Be careful that water does not en-
ter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.
●Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid imme-
diately.
●As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if
the brake fluid level goes down
suddenly, have a Yamaha dealer
check the cause.
Recommended brake fluid: DOT 4
EAU22580
Checking the brake fluid
level
Front brake
1. Minimum level mark
Rear brake
1. Minimum level mark

XT660Z 04-06 ING 11-03-2008 8:31 Pagina 6-22

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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)
XT660Z 04-06 ING 11-03-2008 10:41 Pagina 6-23

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SPECIFICATIONS
8-2
Operation:Left foot operation
Gear ratio: 1
st:30/12 (2.500)
2
nd:
26/16 (1.625)
3
rd: 23/20 (1.150)
4
th: 20/22 (0.909)
5
th: 20/26 (0.769)
Chassis:
Frame type:
Diamond
Caster angle: 28°
Trail: 113.0 mm (4.44 in)
Front tire:
Type:With tube
Size: 90/90-21M/C 54S,
90/90-21M/C 54T
Manufacturer/model: METZELER/TOURANCE FRONT
MICHELIN/SIRAC
Rear tire:
Type:With tube
Size: 130/80-17M/C 65S,
130/80-17M/C 65T Manufacturer/model:
METZELER/TOURANCE
MICHELIN/SIRAC A
Load:
Maximum load:190 kg (419 lb)
(Total weight of rider, passenger, cargo
and accessories)
Tire air pressure
(measured on cold tires):
Load:Up to 90 kg (0-198 lb)
Front: 210 kPa (30 psi) (2.1 kgf/cm
2)
Rear: 230 kPa (33 psi) (2.3 kgf/cm
2)
Load: 90-190 kg (198-419 lb)
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)
Front wheel:
Type:
Spoke wheel
Rim size: 21 x 1.85
Rear wheel:
Type:Spoke wheel
Rim size: 17M/C x MT2.75
Front brake:
Type:Dual disc brake
Operation: Right hand
Fluid: DOT 4
Rear brake:
Type:Single disc brake
Operation: Right foot
Fluid:
DOT 4
Front suspension:
Type:Telescopic fork
Spring/damper type: Coil spring/oil damper
Wheel travel: 210 mm (8.26 in)

XT660Z 07-10 ING 11-03-2008 8:33 Pagina 7