2008 YAMAHA XT660Z maintenance

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

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SAFETY INFORMATION

EAU10311
MOTORCYCLES ARE SINGLE
TRACK VEHICLES. THEIR SAFE
USE AND OPERATION ARE DEPEN-
DENT UPON THE USE OF PROPER
RIDING TECHNIQUES AS WELL AS
THE EXPERTISE OF THE OPERA-
TOR. EVERY OPERATOR SHOULD
KNOW THE FOLLOWING REQUIRE-
MENTS BEFORE RIDING THIS MO-
TORCYCLE.
HE OR SHE SHOULD:
●OBTAIN THOROUGH INSTRUC-
TIONS FROM A COMPETENT
SOURCE ON ALL ASPECTS OF
MOTORCYCLE OPERATION.
●OBSERVE THE WARNINGS
AND MAINTENANCE REQUIRE-
MENTS IN THE OWNER'S MAN-
UAL.
●OBTAIN QUALIFIED TRAINING
IN SAFE AND PROPER RIDING
TECHNIQUES.
●OBTAIN PROFESSIONAL TECH-
NICAL SERVICE AS INDICATED
BY THE OWNER'S MANUAL
AND/OR WHEN MADE NECES-
SARY BY MECHANICAL CONDI-
TIONS. Safe riding
●Always make pre-operation
checks. Careful checks may help
prevent an accident.
●This motorcycle is designed to
carry the operator and a passen-
ger.
●The failure of motorists to detect
and recognize motorcycles in traf-
fic is the predominating cause of
automobile/motorcycle accidents.
Many accidents have been
caused by an automobile driver
who did not see the motorcycle.
Making yourself conspicuous ap-
pears to be very effective in re-
ducing the chance of this type of
accident.
Therefore: • Wear a brightly colored jacket.
• Use extra caution when you areapproaching and passing
through intersections, since in-
tersections are the most likely
places for motorcycle accidents
to occur. • Ride where other motorists can
see you. Avoid riding in another
motorist's blind spot.
●Many accidents involve inexperi-
enced operators. In fact, many op-
erators who have been involved in
accidents do not even have a cur-
rent motorcycle license.
• Make sure that you are quali-fied and that you only lend your
motorcycle to other qualified
operators.
• Know your skills and limits. Staying within your limits may
help you to avoid an accident.
• We recommend that you prac- tice riding your motorcycle
where there is no traffic until
you have become thoroughly
familiar with the motorcycle and
all of its controls.
●Many accidents have been
caused by error of the motorcycle
operator. A typical error made by
the operator is veering wide on a
turn due to EXCESSIVE SPEED
or undercornering (insufficient
lean angle for the speed).

XT660Z 01-03 ING 10-03-2008 16:11 Pagina 8

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INSTRUMENT AND CONTROL FUNCTIONS
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EAU13412
Fuel tank breather hose
1. Fuel tank breather hose
2. Clamp
Before operating the motorcycle:
●Check the fuel tank breather hose
connection.
●Check the fuel tank breather hose
for cracks or damage, and replace
it if damaged.
●Make sure that the fuel tank
breather hose is not blocked, and
clean it if necessary.

ECA11400CAUTION:
Use only unleaded gasoline. The
use of leaded gasoline will cause
severe damage to internal engine
parts, such as the valves and piston
rings, as well as to the exhaust sys-
tem.
Your Yamaha engine has been de-
signed to use premium unleaded
gasoline with a research octane num-
ber of 95 or higher. If knocking (or
pinging) occurs, use a gasoline of a
different brand. Use of unleaded fuel
will extend spark plug life and reduce
maintenance costs.
EAU13431
Catalytic converter
This model is equipped with a catalyt-
ic converter in the exhaust system.
EWA10860
WARNING0
The exhaust system is hot after op-
eration. Make sure that the exhaust
system has cooled down before
doing any maintenance work.

XT660Z 01-03 ING 10-03-2008 16:11 Pagina 3-13

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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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XT660Z 04-06 ING 11-03-2008 8:30 Pagina 6-1

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
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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

XT660Z 04-06 ING 11-03-2008 8:30 Pagina 6-3

PERIODIC MAINTENANCE AND MINOR REPAIR
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• Check operation and for oil leakage.
• Check operation and shock absorber for oil
leakage.
• Check operation.
• Lubricate with lithium-soap-based grease.
• Adjust engine idling speed.
• Change.
• Check oil level and vehicle for oil leakage.
• Replace.
• Check coolant level and vehicle for coolant leakage.
• Change.
• Check operation.
• Lubricate.
• Check operation and free play.
• Adjust the throttle cable free play if necessary.
• Lubricate the throttle grip housing and cable.
Front fork
Shock absorber
assembly
Rear suspension
relay arm and
connecting arm
pivoting points
Fuel injection
Engine oil
Engine oil filter
element
Cooling system
Front and rear brake
switches
Moving parts and
cables
Throttle grip housing
and cable
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NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUAL
CHECK
Every 3 years

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PERIODIC MAINTENANCE AND MINOR REPAIR
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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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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