2008 YAMAHA XT660Z suspension

TABLE OF CONTENTS
Lubricating the rear suspension......6-27
Lubricating the swingarm pivots .....6-28
Checking the front fork ....................6-28
Checking the steering .....................6-29
Checking the wheel bearings..........6-29
Battery.............................................6-30
Replacing the fuses ........................6-31
Replacing a headlight bulb .............6-33
Tail/brake light .................................6-34
Replacing a turn signal light bulb....6-34
Replacing the license plate light bulb ...................................6-35
Replacing an auxiliary light bulb .....6-35
Supporting the motorcycle ..............6-36
Front wheel .....................................6-36
Rear wheel ......................................6-38
Troubleshooting ...............................6-39
Troubleshooting charts ....................6-40
MOTORCYCLE CARE
AND STORAGE ...................................7-1
Care ..................................................7-1
Storage..............................................7-3 SPECIFICATIONS
...............................8-1
CONSUMER INFORMATION ..............9-1
Identification numbers .......................9-1

XT660Z 01-03 ING 10-03-2008 16:11 Pagina 7

SAFETY INFORMATION

Loading
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit.
●Never attach any large or heavy
items to the handlebar, front fork,
or front fender. These items, in-
cluding such cargo as sleeping
bags, duffel bags, or tents, can
create unstable handling or a
slow steering response.
Accessor
ies
Genuine Yamaha accessories have
been specifically designed for use on
this motorcycle. Since Yamaha cannot
test all other accessories that may be
available, you must personally be re-
sponsible for the proper selection, in-
stallation and use of non-Yamaha ac-
cessories. Use extreme caution when
selecting and installing any acces-
sories.
Keep the following guidelines in mind,
as well as those provided under "Load-
ing" when mounting accessories.
●Never install accessories or carry
cargo that would impair the perfor-
mance of your motorcycle. Care-
fully inspect the accessory before
using it to make sure that it does
not in any way reduce ground
clearance or cornering clearance,
limit suspension travel, steering
travel or control operation, or ob-
scure lights or reflectors.
• Accessories fitted to the han- dlebar or the front fork area can
create instability due to improp-
er weight distribution or aerody-
namic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.
• Bulky or large accessories may seriously affect the stability of
the motorcycle due to aerody-
namic effects. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become
unstable in cross winds. These
accessories may also cause in-
stability when passing or being
passed by large vehicles.
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Maximum load: 190 kg (419 lb)
When loading within this weight limit,
keep the following in mind:
●Cargo and accessory weight
should be kept as low and close
to the motorcycle as possible.
Make sure to distribute the weight
as evenly as possible on both
sides of the motorcycle to mini-
mize imbalance or instability.
●Shifting weights can create a sud-
den imbalance. Make sure that
accessories and cargo are se-
curely attached to the motorcycle
before riding. Check accessory
mounts and cargo restraints fre-
quently.

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

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INSTRUMENT AND CONTROL FUNCTIONS
3-15
EAUB1550
Adjusting the front fork
1. Spring preload adjusting bolt
(a) Increasing the spring preload
(b) Decreasing the spring preload
This front fork is equipped with spring
preload adjusting bolt.

EWA10180
WARNING0
Always adjust both fork legs equal-
ly, otherwise poor handling and
loss of stability may result.
Adjust the spring preload as follows.
To increase the spring preload and
thereby harden the suspension, turn
the adjusting bolts on each fork leg in
direction (a). To decrease the spring
preload and thereby soften the sus-
pension, turn the adjusting bolts on
each fork leg in direction (b).

Maximum (hard):0 complete turns in direction (b)*
Standard: 22 complete turns in direction (b)*
Minimum (soft): 27 complete turns in direction (b)*
* With the adjusting bolt fully turned in
direction (a)
NOTE:
Use the 10 mm hexagon wrench in-
cluded in the owner’s tool kit to turn
the adjusting bolts.

XT660Z 01-03 ING 10-03-2008 16:11 Pagina 3-15

INSTRUMENT AND CONTROL FUNCTIONS
3-16
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Adjust the spring preload as follows.
To increase the spring preload and
thereby harden the suspension, turn
the adjusting ring in direction (a).
To decrease the spring preload and
thereby soften the suspension, turn
the adjusting ring in direction (b).
NOTE:
Align the appropriate notch in the ad-
justing ring with the position indicator
on the shock absorber.
EWAB0020
WARNING0
Never adjust the spring preload un-
til the exhaust system has cooled
down.

EWA10220
WARNING0
This shock absorber contains high-
ly pressurized nitrogen gas. For
proper handling, read and under-
stand the following information be-
fore handling the shock absorber.
The manufacturer cannot be held
responsible for property damage or
personal injury that may result from
improper handling.
●Do not tamper with or attempt
to open the gas cylinder.
●Do not subject the shock ab-
sorber to an open flame or oth-
er high heat sources, otherwise
it may explode due to exces-
sive gas pressure.
●Do not deform or damage the
gas cylinder in any way, as this
will result in poor damping per-
formance.
●Always have a Yamaha dealer
service the shock absorber.

EAUB1460
Adjusting the shock
absorber assembly
1. Spring preload adjusting ring
2. Position indicator
(a) Increasing the spring preload
(b) Decreasing the spring preload
This shock absorber assembly is
equipped with a spring preload adjust-
ing ring.
ECA10100CAUTION:
Never attempt to turn an adjusting
mechanism beyond the maximum
or minimum settings.

Spring preload setting: Minimum (soft):1
Standard: 2
Maximum (hard): 9

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

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
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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
√√√√
√√√√
√√√√
√√
√√√√√ √
√√√√√ √
√√√
√√√√ √
√√√√√ √ √√√√ √
√√√√ √18✻
19✻
20✻
21✻
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✻
25✻
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✻
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUAL
CHECK
Every 3 years

XT660Z 04-06 ING 11-03-2008 8:31 Pagina 6-4

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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.

XT660Z 04-06 ING 11-03-2008 8:31 Pagina 6-17

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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
XT660Z 04-06 ING 31-03-2008 14:05 Pagina 6-27

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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