2010 YAMAHA XT660Z maintenance

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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INSTRUMENT AND CONTROL FUNCTIONS
4-13
your skin, wash with soap and wa-
ter. If gasoline spills on your cloth-
ing, change your clothes.
EAU13390EAU13412
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.
ECA11400
NOTICE
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 system.
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.
Recommended fuel:
PREMIUM UNLEADED
GASOLINE ONLY
Fuel tank capacity:
23.0 L (6.07 US gal) (5.05 Imp.gal)
Fuel reserve amount (when the fuel
level warning light comes on):
6.7 L (1.77 US gal) (1.47 Imp.gal)
EAU13433
Catalytic converter
This model is equipped with a catalyt-
ic converter in the exhaust system.
EWA10862
WARNING0
The exhaust system is hot after op-
eration. To prevent a fire hazard or
burns:
●Do not park the vehicle near
possible fire hazards such as
grass or other materials that
easily burn.
●Park the vehicle in a place
where pedestrians or children
are not likely to touch the hot
exhaust system.
●Make sure that the exhaust
system has cooled down be-
fore doing any maintenance
work.
●Do not allow the engine to idle
more than a few minutes. Long
idling can cause a build-up of
heat.
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EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the in-
spection and maintenance procedures and schedules described in the Owner's Manual.
EWA11151
WARNING0
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided
in this manual, have the vehicle inspected by a Yamaha dealer.
5-1
FOR YOUR SAFETY – PRE-OPERATION CHECKS
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PERIODIC MAINTENANCE AND ADJUSTMENT
EAU17241
Periodic inspection, adjustment, and
lubrication will keep your vehicle in the
safest and most efficient condition
possible. Safety is an obligation of the
vehicle owner/operator. The most im-
portant points of vehicle inspection,
adjustment, and lubrication are ex-
plained 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, geographical loca-
tion, and individual use, the mainte-
nance intervals may need to be short-
ened.
EWA10321
WARNING0
Failure to properly maintain the ve-
hicle or performing maintenance
activities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle
service, have a Yamaha dealer per-
form service.
EAU17391
Owner’s tool kit
1. Owner’s tool kit
The owner’s tool kit is located under
the seat. (See page 4-14).
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
TIP
If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
7-1
EWA15121
WARNING0
Turn off the engine when perform-
ing maintenance unless otherwise
specified.
A running engine has moving parts
that can catch on body parts or
clothing and electrical parts that
can cause shocks or fires.
Running the engine while servicing
can lead to eye injury, burns, fire, or
carbon monoxide poisoning - pos-
sibly leading to death. See page 2-2
for more information about carbon
monoxide.
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PERIODIC MAINTENANCE AND ADJUSTMENT
EAU46861
TIP
●The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.
●From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
●Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and tech-
nical skills.
EAU46910Periodic maintenance chart for the emission control system
7-2
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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
√√ √√ √
√√
√√
√√
√√√ √√ √
√√√ √√
√√ √√ √1✻
2
3
✻
4✻
5✻
6✻
Check fuel hoses for cracks or damage.
Check condition.
Clean and regap.
Replace.
Check valve clearance.
Adjust.
Adjust engine idling speed.
Check the screw clamp(s) for
looseness.
Check the air cut-off valve, reed valve,
and hose for damage.
Replace any damaged parts if necessary. Fuel line
Spark plug
Valves
Fuel injection
Muffler and exhaust
pipe
Air induction system
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-3
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
√√
√√√ √√
√√√
√√
√
√√√ √√ √
√√ √√ √
√√ √√
√√ √√ √
√√ √√1
2
3
✻
4✻
5✻
6✻
7✻
8✻
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.
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. Air filter element
Clutch
Front brake
Rear brake
Brake hoses
Wheels
Tires
Wheel bearings
EAU1770C
General maintenance and lubrication chart
Whenever worn to the limit
Whenever worn to the limit
Every 4 years
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-4
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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✻
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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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