2009 YAMAHA XT660Z maintenance

PERIODIC MAINTENANCE AND MINOR REPAIR
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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

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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
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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
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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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