2010 YAMAHA XT660Z service

INSTRUMENT AND CONTROL FUNCTIONS
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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).
TIP
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.
EWA10221
WARNING0
This shock absorber assembly con-
tains highly pressurized nitrogen
gas. Read and understand the fol-
lowing information before handling
the shock absorber assembly.
●Do not tamper with or attempt
to open the cylinder assembly.
●Do not subject the shock ab-
sorber assembly to an open
flame or other high heat
source. This may cause the unit
to explode due to excessive
gas pressure.
●Do not deform or damage the
cylinder in any way. Cylinder
damage will result in poor
damping performance.
●Do not dispose of a damaged
or worn-out shock absorber
assembly yourself. Take the
shock absorber assembly to a
Yamaha dealer for any service.
EAUB1461
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.
ECA10100
NOTICE
Never attempt to turn an adjusting
mechanism beyond the maximum
or minimum settings.
Spring preload setting:
Minimum (soft):
1
Standard:
2
Maximum (hard):
9
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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
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
7-25
EAU23023
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.
ECA10581
NOTICE
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. NOTICE:
To prevent damaging the O-
rings, do not clean the drive
chain with steam cleaners,
high-pressure washers or inap-
propriate solvents.2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant. NOTICE:Do not use
engine oil or any other lubri-
cants for the drive chain, as
they may contain substances
that could damage the O-rings.
EAU23101
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.
WARNING! Damage to the outer
sheath may interfere with proper
cable operation and will cause the
inner cable to rust. Replace a dam-
aged cable as soon as possible to
prevent unsafe conditions.
Recommended lubricant:
Engine oil
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PERIODIC MAINTENANCE AND ADJUSTMENT
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To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a mo-
torcycle stand is not available, by plac-
ing a jack either under each side of the
frame in front of the rear wheel or un-
der each side of the swingarm.EAU24360
Front wheelEAUB1440To remove the front wheel
EWA10820
WARNING0
●It is advisable to have a Yama-
ha dealer service the wheel.
●Securely support the motorcy-
cle so that there is no danger of
it falling over.
1. Wheel axle
2. Brake caliper bolts
A. Front wheel axle pinch bolt
B. Front wheel axle pinch bolt
A
2
B
1
EAU24350
Supporting the motorcycle
Since this model is not equipped with
a centerstand, follow these precau-
tions when removing the front and rear
wheel or performing other mainte-
nance requiring the motorcycle to
stand upright. Check that the motorcy-
cle is in a stable and level position be-
fore starting any maintenance. A
strong wooden box can be placed un-
der the engine for added stability.
To service the front wheel
1. Stabilize the rear of the motorcy-
cle by using a motorcycle stand
or, if an additional motorcycle
stand is not available, by placing a
jack under the frame in front of the
rear wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
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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.
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SPECIFICATIONS
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Engine oil:Type:
SAE10W30 or SAE10W40 or SAE15W40
or SAE20W40 or SAE20W50
Recommended engine oil grade:
API service SE, SF, SG type or higher
Engine 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)
Total amount (dry engine):
2.90 L (3.07 US qt) (2.55 Imp.qt)
Cooling system:Radiator capacity (including all routes):
1.2 L (1.26 US qt) (1.05 Imp.qt) (Radiator) +
0.5 L (0.52 US qt) (0.44 Imp.qt)
(Coolant reservoir)
Coolant reservoir capacity (up to the
maximum level mark):
0.50 L (0.52 US qt) (0.44 Imp.qt)
From low to full level:
0.30 L (0.32 US qt) (0.26 Imp.qt)
Air filter:Air filter element:
Paper
Fuel:Recommended fuel:
Premium unleaded gasoline only
Fuel tank capacity:
23.0 L (6.07 US gal) (5.06 Imp.gal)
Fuel reserve amount:
6.7 L (1.76 US gal) (1.46 Imp.gal)
Fuel injection:Manufacturer:
DENSO
Model:
297500-0390
Spark plug:Manufacturer/model:NGK/CR7EGap:
0.7-0.8 mm (0.028-0.032 in)
Clutch:Clutch type:
Wet, multiple-disc
Transmission:Primary reduction system:
Spur gear
Primary reduction ratio:
75/36 (2.083)
Secondary reduction system:
Chain drive
Secondary reduction ratio:
45/15 (3.00)
Transmission type:
Constant mesh 5-speed
Dimensions:Overall length:
2246 mm (88.42 in)
Overall width:
864 mm (34.01 in)
Overall height:
1477 mm (58.14 in)
Seat height:
896 mm (35.27 in)
Wheelbase:
1500 mm (59.05 in)
Ground clearance:
260 mm (10.23 in)
Minimum turning radius:
1958 mm (77.08 in)
Basic weight:With oil and fuel:
208.5 kg (459 lb)
Engine:Engine type:
Liquid cooled 4-stroke, SOHC
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
660.0 cm
3(40.27 cu.in)
Bore x stroke:
100.0 x 84.0 mm (3.94 x 3.31 in)
Compression ratio:
10.00 : 1
Starting system:
Electric starter
Lubrication system:
Dry sump
-20-10 0 1020304050°C
SAE 10W-30
SAE 10W-40
SAE 20W-40
SAE 20W-50
SAE 15W-40
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