2010 YAMAHA XT660Z check oil

TABLE OF CONTENTS
LOCATION OF IMPORTANT LABELS...1-1
SAFETY INFORMATION.....................2-1
Be a Responsible Owner ..................2-1
Safe riding .........................................2-1
Protective apparel .............................2-2
Avoid Carbon Monoxide Poisoning ...2-2
Loading .............................................2-3
Genuine Yamaha Accessories ..........2-3
Aftermarket Parts, Accessories,
and Modifications .......................2-4
Aftermarket Tires and Rims ..............2-4
DESCRIPTION.....................................3-1
Left view ............................................3-1
Right view .........................................3-2
Controls and instruments ..................3-3
INSTRUMENT AND CONTROL
FUNCTIONS........................................4-1
Immobilizer system ...........................4-1
Main switch/steering lock ..................4-2
Indicator and warning lights ..............4-3
Multi-function display ........................4-5
Tachometer .......................................4-6
Tripmeter and tachometer modes .....4-6
Clock mode .......................................4-7
Fuel meter .........................................4-7
Self-diagnosis devices ......................4-7Handlebar switches ...........................4-9
Clutch lever .....................................4-10
Shift pedal .......................................4-10
Brake lever ......................................4-11
Brake pedal .....................................4-11
Fuel tank cap ..................................4-11
Fuel .................................................4-12
Fuel tank breather hose ..................4-13
Catalytic converter ..........................4-13
Seat .................................................4-14
Adjusting the front fork ....................4-15
Adjusting the shock absorber
assembly ..................................4-16
Sidestand ........................................4-17
Ignition circuit cut-off system ..........4-17
FOR YOUR SAFETY -
PRE-OPERATION CHECKS...............5-1
Pre-operation check list ....................5-2
OPERATION AND IMPORTANT
RIDING POINTS..................................6-1
Starting the engine............................6-1
Shifting ..............................................6-2
Tips for reducing fuel consumption ...6-3
Engine break-in .................................6-3
Parking ..............................................6-4PERIODIC MAINTENANCE AND
ADJUSTMENT.....................................7-1
Owner’s tool kit .................................7-1
Periodic maintenance chart for
the emission control system.......7-2
General maintenance
and lubrication chart ..................7-3
Removing and installing
the cowling and panels ..............7-8
Checking the spark plug ...................7-8
Engine oil and oil filter element.........7-9
Coolant ............................................7-12
Replacing the air filter element
and cleaning the check hose ...7-14
Checking the engine idling speed ...7-15
Checking the throttle cable
free play ...................................7-16
Valve clearance ...............................7-16
Tires ................................................7-16
Spoke wheels..................................7-19
Adjusting the clutch lever free play...7-20
Checking the front and rear
brake pads ...............................7-21
Checking the brake fluid level .........7-22
Changing the brake fluid .................7-23
Drive chain slack .............................7-23
Cleaning and lubricating
the drive chain ..........................7-25
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FOR YOUR SAFETY – PRE-OPERATION CHECKS
5-2
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10
ITEM
Fuel
Engine oil
Coolant
Front brake
Rear brake
EAU15605
Before using this vehicle, check the following points:
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
4-12
7-9
7-12
4-11, 7-21, 7-22, 7-26
4-11, 7-21, 7-22, 7-27
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EAU17101
0-1000 km (0-600 mi)
Avoid prolonged operation above
4500 r/min. NOTICE: After 1000 km
(600 mi) of operation, the engine oil
must be changed, and the oil filter
element replaced.
1000-1600 km (600-1000 mi)
Avoid prolonged operation above
6000 r/min.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.
ECA10310NOTICE
Keep the engine speed out of
the tachometer red zone.
If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the
vehicle.
EAU17213
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EWA10311
WARNING0
Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them and be burned.
Do not park on a slope or on
soft ground, otherwise the ve-
hicle may overturn, increasing
the risk of a fuel leak and fire.
Do not park near grass or other
flammable materials which
might catch fire.
OPERATION AND IMPORTANT RIDING POINTS
6-4
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-4
1
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10
NO. ITEM CHECK OR MAINTENANCE JOB
ODOMETER READING
1000 km 10000 km 20000 km 30000 km 40000 km(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
ANNUAL
CHECK
√√ √√
√√√ √√
√√
√√
√
√√ √√ √
√√√ √√ √
√√ √√
√√ √√
√√ √√
√√
√√√ √√ √
13
14
✻
15✻
16✻
18
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.
Check operation and for oil leakage.
Check operation and shock absorber
for oil leakage.
Check operation.
Lubricate with lithium-soap-based grease.
Change.
Check oil level and vehicle for oil leakage. Swingarm
Drive chain
Steering bearings
Chassis fasteners
Sidestand
Sidestand switch
Front fork
Shock absorber
assembly
Rear suspension
relay arm and
connecting arm
pivoting points
Engine oil
Every 50000 km (30000 mi) Every 50000 km (30000 mi)
Every 500 km (300 mi) and after
washing the motorcycle or riding
in the rain
9✻
11✻
17✻
12✻
10
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-57-5
EAUM1890
TIP
●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.
NO. ITEM CHECK OR MAINTENANCE JOB
ODOMETER READING
1000 km 10000 km 20000 km 30000 km 40000 km(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
ANNUAL
CHECK
√√ √
√√ √√ √
√√√ √√ √
√√ √√ √
√√ √√ √
√√√ √√ √ 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.
Check operation.
Adjust headlight beam. Engine oil filter
element
Cooling system
Front and rear brake
switches
Moving parts and
cables
Throttle grip housing
and cable
Lights, signals and
switches
Every 3 years
19
22 20
✻
21✻
24✻
23✻
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-9
EAUB1560
Engine oil and oil filter
element
The engine oil level should be checked
before each ride. In addition, the oil must
be changed and the oil filter element re-
placed at the intervals specified in the
periodic maintenance and lubrication
chart.
To check the engine oil level
1. Place the vehicle on a level surface
and hold it in an upright position.
TIP
Make sure that the vehicle is posi-
tioned straight up when checking the
oil level. A slight tilt to the side can re-
sult in a false reading.
2. Start the engine, warm it up for
10-15 minutes and then turn it off.
3. Remove the oil filler cap, wipe the
dipstick clean, insert it back into
the oil filler hole (without screwing
it in), and then remove it again to
check the oil level.
1. Engine oil filler cap
2. Maximum level mark
3. Minimum level mark
TIP
●The engine oil tank is located in-
side of the frame.
●The engine oil should be between
the minimum and maximum level
marks.
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)
TIP
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is 1/4-
1/2 turn past finger tight. However, the
spark plug should be tightened to the
specified torque as soon as possible.
4. Install the spark plug cap.
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ECAM1060CAUTION:
The engine oil tank must be filled in
2 steps. First, fill the engine oil tank
with 1.90 L (2.0 US qt) (1.67 Imp.qt)
of the recommended engine oil.
Then, start the engine, race it 5 or 6
times, turn it off, and then add the
remainder of the engine oil.
NOTE:
Be sure to wipe off spilled oil on any
parts after the engine and exhaust
system have cooled down.
ECA11620CAUTION:  In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a
higher quality than specified. In
addition, do not use oils la-
beled “ENERGY CONSERVING
II” or higher.
 Make sure that no foreign ma-
terial enters the crankcase.
14. Start the engine, and then let it idle for several minutes while
checking it for oil leakage. If oil is
leaking, immediately turn the en-
gine off and check for the cause.
15. Turn the engine off, and then check the oil level and correct it if
necessary.
16. Install the engine guard by in- stalling the screws.
EAU20070
Coolant
The coolant level should be checked
before each ride. In addition, the
coolant must be changed at the inter-
vals specified in the periodic mainte-
nance and lubrication chart.
EAU20253
To check the coolant level1. Place the vehicle on a level sur- face and hold it in an upright posi-
tion.
NOTE:
The coolant level must be
checked on a cold engine since
the level varies with engine tem-
perature.
Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.
2. Check the coolant level in the coolant reservoir.
Recommended engine oil:See page 8-1.
Oil quantity: Without oil filter element
replacement:2.50 L (2.64 US qt) (2.19 Imp.qt)
With oil filter element replacement: 2.60 L (2.73 US qt) (2.26 Imp.qt)
PERIODIC MAINTENANCE AND ADJUSTMENT
7-12
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-22
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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
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