2010 YAMAHA XT660Z brake

1
2
3
4
5
6
7
8
9
10
PERIODIC MAINTENANCE AND ADJUSTMENT
7-37
1. Loosen the front wheel axle pinch
bolts, the wheel axle and the
brake caliper bolts.
2. Lift the front wheel off the ground
according to the procedure on
page 7-36.
3. Remove the brake caliper on
each side by removing the bolts.
ECA11050
NOTICE
Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will be
forced shut.
4. Pull the wheel axle out, and then
remove the wheel.
EAUB1470
To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Insert the wheel axle.
3. Install the brake calipers by in-
stalling the bolts.
TIP
Make sure that there is enough space
between the brake pads before in-
stalling the brake calipers onto the
brake discs.
4. Lower the front wheel so that it is
on the ground.
5. Tighten the wheel axle and the
brake caliper bolts to the specified
torques.
ECAB0060
NOTICE
Be sure the right brake disc is posi-
tioned exactly in the middle of the
caliper pads to prevent any brake
drag. Tap the side of the right fork
leg to position the disc correctly.
Tightening torques:
Wheel axle:
60 Nm (6.0 m·kgf, 44 ft·lbf)
Front wheel axle pinch bolt:
18 Nm (1.8 m·kgf, 13 ft·lbf)
Brake caliper bolt:
40 Nm (4.0 m·kgf, 29 ft·lbf)
6. Tighten wheel axle pinch bolt A,
and then pinch bolt B to the spec-
ified torque.
7. Retighten pinch bolt A to the
specified torque.
8. Apply the front brake several
times, and then while holding the
brake lever in, push down hard on
the handlebar several times to
check for proper fork operation.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-37

PERIODIC MAINTENANCE AND ADJUSTMENT
7-38
1
2
3
4
5
6
7
8
9
10
TIP
●If the drive chain is difficult to re-
move, remove the wheel axle first,
and then lift the wheel upward
enough to remove the drive chain
from the rear sprocket.
●The drive chain cannot be disas-
sembled.
7. While supporting the brake
caliper bracket, pull the wheel
axle out, and then remove the
wheel. NOTICE: Do not apply
the brake after the wheel has
been removed together with
the brake disc, otherwise the
brake pads will be forced shut.
EAUB1450
To install the rear wheel
1. Install the wheel and the brake
caliper bracket by inserting the
wheel axle from the right-hand
side.
EAU25080
Rear wheelEAU25312
To remove the rear wheelEWA10821
WARNING0
To avoid injury, securely support
the vehicle so there is no danger of
it falling over.
1. Wheel axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Drive chain
3
4
1
1. Wheel axle
2. Drive chain slack adjusting bolt
3. Locknut
4. Brake caliper
1. Loosen the axle nut.
2. Lift the rear wheel off the ground
according to the procedure on
page 7-36.
3. Remove the axle nut.
4. Loosen the locknut on each side
of the swingarm.
5. Turn the drive chain slack adjust-
ing bolts fully in direction (a) and
push the wheel forward.
6. Remove the drive chain from the
rear sprocket.
4
3
1
2
a
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-38

1
2
3
4
5
6
7
8
9
10
PERIODIC MAINTENANCE AND ADJUSTMENT
7-39
TIP
●Make sure that the slot in the
brake caliper bracket is fit over the
retainer on the swingarm.
●Make sure that there is enough
space between the brake pads
before installing the wheel.
2. Install the drive chain onto the
rear sprocket.
3. Install the axle nut, and then low-
er the rear wheel so that it is on
the ground.
4. Adjust the drive chain slack. (See
page 7-24.)
5. Apply the rear brake several
times, and then tighten the axle
nut to the specified torque.
Tightening torque:
Axle nut:
105 Nm (10.5 m·kgf, 75 ft·lbf)
EAU25871
Troubleshooting
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur
during operation. Any problem in the
fuel, compression, or ignition systems,
for example, can cause poor starting
and loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.
EWA15141
WARNING0
When checking the fuel system, do
not smoke, and make sure there
are no open flames or sparks in the
area, including pilot lights from wa-
ter heaters or furnaces. Gasoline or
gasoline vapors can ignite or ex-
plode, causing severe injury or
property damage.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-39

MOTORCYCLE CARE AND STORAGE
8-1
1
2
3
4
5
6
7
8
9
10
EAU26004
Care
While the open design of a motorcycle
reveals the attractiveness of the tech-
nology, it also makes it more vulnera-
ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go un-
noticed on a car, however, it detracts
from the overall appearance of a mo-
torcycle. Frequent and proper care
does not only comply with the terms of
the warranty, but it will also keep your
motorcycle looking good, extend its
life and optimize its performance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and cov-
ers as well as all electrical cou-
plers and connectors, including
the spark plug cap, are tightly in-
stalled.3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-
ucts onto seals, gaskets, sprockets,
the drive chain and wheel axles. Al-
ways rinse the dirt and degreaser
off with water.
Cleaning
ECA10772
NOTICE
●Avoid using strong acidic
wheel cleaners, especially on
spoked wheels. If such prod-
ucts are used on hard-to-re-
move dirt, do not leave the
cleaner on the affected area
any longer than instructed. Al-
so, thoroughly rinse the area
off with water, immediately dry
it, and then apply a corrosion
protection spray.
●Improper cleaning can damage
plastic parts (such as cowlings,
panels, windshields, headlight
lenses, meter lenses, etc.) and
the mufflers. Use only a soft,
clean cloth or sponge with wa-ter to clean plastic. However, if
the plastic parts cannot be
thoroughly cleaned with water,
diluted mild detergent with wa-
ter may be used. Be sure to
rinse off any detergent residue
using plenty of water, as it is
harmful to plastic parts.
●Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.
●Do not use high-pressure
washers or steam-jet cleaners
since they cause water seep-
age and deterioration in the fol-
lowing areas: seals (of wheel
and swingarm bearings, fork
and brakes), electric compo-
nents (couplers, connectors,
instruments, switches and
lights), breather hoses and
vents.
XT660Z 08-10 ING-AUS:MY03 07-10 ING 11-05-2009 10:10 Pagina 2

MOTORCYCLE CARE AND STORAGE
8-3
1
2
3
4
5
6
7
8
9
10
8. Let the motorcycle dry completely
before storing or covering it.
EWA11131
WARNING0
Contaminants on the brakes or
tires can cause loss of control.
●Make sure that there is no oil or
wax on the brakes or tires.
●If necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or
acetone, and wash the tires
with warm water and a mild de-
tergent. Before riding at higher
speeds, test the motorcycle's
braking performance and cor-
nering behavior.
ECA10800
NOTICE
●Apply spray oil and wax spar-
ingly and make sure to wipe off
any excess
●Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
●Avoid using abrasive polishing
compounds as they will wear
away the paint.
TIP
●Consult a Yamaha dealer for ad-
vice on what products to use.
●Washing, rainy weather or humid
climates can cause the headlight
lens to fog. Turning the headlight
on for a short period of time will
help remove the moisture from
the lens.
EAUM1901
Storage
Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
ECA10810
NOTICE
●Storing the motorcycle in a
poorly ventilated room or cov-
ering it with a tarp, while it is
still wet, will allow water and
humidity to seep in and cause
rust.
●To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.
XT660Z 08-10 ING-AUS:MY03 07-10 ING 11-05-2009 10:10 Pagina 4

1
2
3
4
5
6
7
8
9
10
SPECIFICATIONS
9-2
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 65TManufacturer/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 08-10 ING-AUS:MY03 07-10 ING 11-05-2009 10:10 Pagina 7

SPECIFICATIONS
9-3
1
2
3
4
5
6
7
8
9
10
Rear suspension:
Type:
Swingarm (link suspension)
Spring/damper type:
Coil spring/gas-oil damper, spring
preload adjustable
Wheel travel:
200 mm (7.87 in)
Electrical system:
Ignition system:
Transistorized coil ignition (digital)
Charging system:
A.C. magneto
Battery:
Model:
GT9B-4
Voltage, capacity:
12 V, 8 Ah
Headlight:
Bulb type:
Halogen bulb
Bulb voltage, wattage x quantity:Headlight:
12 V, 55 W x 2
Auxiliary light:
12 V, 5 W x 2
Tail/brake light:
LED
Front turn signal light:
12 V, 10 W x 2
Rear turn signal light:
12 V, 10 W x 2
Meter lighting:
LED (backlight)Neutral indicator light:
LED
Turn signal indicator light:
LED
High beam indicator light:
LED
Coolant temperature warning light:
LED
Engine trouble warning light:
LED
Immobilizer system indicator light:
LED
Fuses:Main fuse:
30 A
Headlight fuse:
20 A
Signaling system fuse:
10 A
Ignition fuse:
10 A
Parking lighting fuse:
10 A
Radiator fan fuse:
7.5 A
Fuel injection system fuse:
10 A
Backup fuse (for odometer, clock and
immobilizer):
10 A
XT660Z 08-10 ING-AUS:MY03 07-10 ING 11-05-2009 10:10 Pagina 8

1
2
3
4
5
6
7
8
9
10
INDEX
A
Aftermarket Parts, Accessories, and
Modifications ...................................2-4
Aftermarket Tires and Rims ...............2-4
Air filter element, cleaning the check
hose ..............................................7-14
Air filter element, replacing ..............7-14
Auxiliary light bulb, replacing............7-35
Avoid Carbon Monoxide poisoning ....2-2
B
Battery ..............................................7-30
To access the battery ...................7-30
To charge the battery....................7-30
To store the battery.......................7-31
Be a Responsible Owner ...................2-1
Brake and clutch levers, checking
and lubricating ..............................7-26
Brake fluid ........................................7-22
Changing ......................................7-23
Checking fluid level .......................7-22
Brake lever .......................................4-11
Brake pads, checking .......................7-21
Brake pedal ......................................4-11
Checking .......................................7-27
Lubricating ....................................7-27
C
Cables, checking and lubricating .....7-25
Carbon Monoxide (avoid Carbon
Monoxide poisoning).......................2-2
Care and storage ...............................8-1Catalytic converter ...........................4-13
Checking and lubricating the brake
and clutch levers ...........................7-26
Checking and lubricating the brake
pedal .............................................7-27
Checking and lubricating the cables..7-25
Checking and lubricating the
sidestand ......................................7-27
Checking and lubricating the throttle
grip and cable ...............................7-26
Checking the brake pedal ................7-27
Checking the sidestand switch .........4-18
Clock mode ........................................4-7
Clutch lever ......................................4-10
Clutch lever free play, adjusting .......7-20
Consumer information ......................10-1
Controls and instruments ...................3-3
Function ..........................................4-1
Coolant .............................................7-12
Coolant temperature warning light .....4-4
D
Description .........................................3-1
Controls and instrument .................3-3
Left view..........................................3-1
Right view .......................................3-2
Dimmer switch....................................4-9
Drive chain, cleaning
and lubricating ..............................7-25
Drive chain slack ..............................7-23
Adjusting .......................................7-23
Checking .......................................7-23Cleaning and lubricating ...............7-25
E
Emission control system (periodic
maintenance chart) .........................7-2
Engine break-in ..................................6-3
Engine idling speed, adjusting .........7-15
Engine oil and oil filter element ..........7-9
Engine oil filter element....................7-10
Engine stop switch .............................4-9
Engine trouble warning light...............4-4
F
For your safety - Pre-operation
checks .............................................5-1
Front fork ..........................................4-15
Adjusting .......................................4-15
Checking .......................................7-28
Front wheel ......................................7-36
Installing........................................7-37
Removing......................................7-36
Fuel ..................................................4-12
Fuel consumption, tips for reducing ...6-3
Fuel meter ..........................................4-7
Fuel tank breather hose ...................4-13
Fuel tank cap ...................................4-11
Fuses, replacing ...............................7-31
G
Genuine Yamaha Accessories ...........2-3
H
Handlebar switches ............................4-9
XT660Z 08-10 ING-AUS:MY03 07-10 ING 11-05-2009 10:10 Pagina 1