2011 YAMAHA XT660Z maintenance

PERIODIC MAINTENANCE AND ADJUSTMENT
6-5
6
ODOMETER READING
NO. ITEM CHECK OR MAINTENANCE JOBANNUAL
1000 km 10000 km 20000 km 30000 km 40000 kmCHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
9*Swingarm• Check operation and for
excessive play.√√√ √
• Lubricate with lithium-soap-
based grease.Every 50000 km (30000 mi)
• Check chain slack, alignment
and condition.
Every 500 km (300 mi) and after washing the motorcycle,
10Drive chain• Adjust and lubricate chain with a
special O-ring chain lubricant riding in the rain or riding in wet areas
thoroughly.
• Check bearing play and steering
11 *Steering bearingsfor roughness.√√ √ √ √
• Lubricate with lithium-soap-
based grease.Every 20000 km (12000 mi)
12 *Chassis fasteners• Make sure that all nuts, bolts and
screws are properly tightened.√√√ √√
13Brake lever pivot
shaft• Lubricate with silicone grease.√√√ √√
14Brake pedal pivot
shaft• Lubricate with silicone grease.√√√ √√
15Clutch lever pivot • Lubricate with lithium-soap-
shaftbased grease.√√√ √√
• Check operation.
16Sidestand• Lubricate with lithium-soap-√√√ √√
based grease.
17 *Sidestand switch• Check operation.√√ √ √ √ √
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-6
6
ODOMETER READING
NO. ITEM CHECK OR MAINTENANCE JOBANNUAL
1000 km 10000 km 20000 km 30000 km 40000 kmCHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
18 *Front fork• Check operation and for oil
leakage.√√√ √
19 *Shock absorber • Check operation and shock
assemblyabsorber for oil leakage.√√√ √
Rear suspension• Check operation.√√√ √
20 *relay arm and
• Lubricate with lithium-soap-
connecting arm
√√
pivoting pointsbased grease.
• Change.
21Engine oil• Check oil level and vehicle for √√ √ √ √ √
oil leakage.
22Engine oil filter
element• Replace.√√ √
• Check coolant level and vehicle
23 *Cooling systemfor coolant leakage.√√√ √√
• Change. Every 3 years
24 *Front and rear brake
switches• Check operation.√√ √ √ √ √
25Moving parts and
cables• Lubricate.√√√ √√
• Check operation and free play.
Throttle grip • Adjust the throttle cable free
26 *housingplay if necessary.√√√ √√
and cable• Lubricate the throttle grip housing
and cable.
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PERIODIC MAINTENANCE AND ADJUSTMENT
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6
ODOMETER READING
NO. ITEM CHECK OR MAINTENANCE JOBANNUAL
1000 km 10000 km 20000 km 30000 km 40000 kmCHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
27 *Lights, signals and • Check operation.
switches• Adjust headlight beam.√√ √ √ √ √
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.
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EAU18771
Removing and installing
panels
The panels shown need to be remo-
ved to perform some of the mainte-
nance jobs described in this chapter.
Refer to this section each time a
panel needs to be removed and insta-
lled.
EAUB1541
Panels A and B
T
o remove one of the panels
Remove the bolts, and then pull the
panel off at the areas shown.
1. Panel mounting bolt
A. Right panel
B. Left panel
To install the panel
Place the panel in the original posi-
tion, and then install the bolts.
1. Panel
2. Turn signal light coupler
3. Pin
Panels C and D
T
o remove one of the panels
Remove the bolts, and then pull the
panel off at the areas shown.
1. Panel mounting bolt
C. Right panel
D. Left panel
To install the panel
Place the panel in the original position
as shown, and then install the bolts.
Panels E and F
T
o remove one of the panels
1. Remove the bolts.
2. Remove the quick fastener and
then pull the panel off at the are-
as shown.
PERIODIC MAINTENANCE AND ADJUSTMENT
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1. Panel mountign bolt
2. Quick fastener
E. Right panel
F. Left panel
To install the panel
1. Place the panel in the original
position.
2. Install the quick fastener and the
bolts.
Panel G
T
o remove the panel
Remove the bolts, and then pull the
panel off at the areas shown.
1. Panel mountign bolt
G. Panel
To install the panel
Place the panel in the original posi-
tion, and then install the bolts.
1. Panel
2. Pin
EAU19604
Checking the spark plug
The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause
any spark plug to slowly erode, the
spark plug should be removed and
checked in accordance with the
periodic maintenance and lubrication
chart. In addition, the condition of the
spark plug can reveal the condition of
the engine.
To remove the spark plug
1. Remove the spark plug cap.
1. Spark plug cap
2. Spark plug wrench
PERIODIC MAINTENANCE AND ADJUSTMENT
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2. Remove the spark plug as
shown, with the spark plug
wrench included in the owner’s
tool kit.
To check the spark plug
1. Check that the porcelain insula-
tor around the center electrode of
the spark plug is a medium-to-
light tan (the ideal color when the
vehicle is ridden normally).
TIP
If the spark plug shows a distinctly
different color, the engine could be
operating improperly. Do not attempt
to diagnose such problems yourself.
Instead, have a Yamaha dealer check
the vehicle.
2. Check the spark plug for electro-
de erosion and excessive carbon
or other deposits, and replace it if
necessary.3. Measure the spark plug gap with
a wire thickness gauge and, if
necessary, adjust the gap to spe-
cification.
1. Spark plug gap
To install the spark plug
1. Clean the surface of the spark
plug gasket and its mating surfa-
ce, and then wipe off any grime
from the spark plug threads.
2. Install the spark plug with the
spark plug wrench, and then
tighten it to the specified torque.
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. Howe-
ver, the spark plug should be tighte-
ned to the specified torque as soon
as possible.
3. Install the spark plug cap.
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
1
ZAUM0037
Specified spark plug:
NGK/CR7E
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EAUB1561
Engine oil and oil filter
element
The engine oil level should be chec-
ked before each ride. In addition, the
oil must be changed and the oil filter
element replaced at the intervals spe-
cified in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the vehicle on a level surfa-
ce and hold it in an upright posi-
tion.
TIP
Make sure that the vehicle is positio-
ned straight up when checking the oil
level. A slight tilt to the side can result
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 scre-
wing it in), and then remove it
again to check the oil level.
TIP
The engine oil tank is located
inside of the frame.
The engine oil should be between
the minimum and maximum level
marks.
1. Engine oil filler cap
2. Maximum level mark
3. Minimum level mark
EWA10361
Never remove the engine oil tank
cap after high-speed operation,
otherwise hot engine oil could
spout out and cause damage or
injury. Always let the engine oil cool
down sufficiently before removing
the oil tank cap.
4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to rai-
se it to the correct level. NOTICE:
Do not operate the vehicle until
you know that the engine oil
level is sufficient.
[ECA10011]
5. Install the oil filler cap.
To change the engine oil (with or
without oil filter element
replacement)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Remove the engine guard by
removing the screws.
1. Screw
2. Engine guard
WARNING
PERIODIC MAINTENANCE AND ADJUSTMENT
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3. Place an oil pan under the engine
to collect the used oil.
4. Remove the engine oil filler cap
and the drain bolt to drain the oil
from the crankcase.
1. Engine oil drain bolt (crankcase)
5. Remove the drain bolt to drain
the oil from the oil tank.
1. Engine oil drain bolt (oil tank)
6. Remove the oil filter element
drain bolt to drain the oil from the
oil filter element.
TIP
Skip steps 7–9 if the oil filter element
is not being replaced.
7. Remove the oil filter element
cover by removing the bolts.
1. Oil filter element drain bolt
2. Oil filter element cover bolt
8. Remove and replace the oil filter
element and O-rings.
TIP
Make sure that the O-rings are pro-
perly seated.
1. Oil filter element
2. O-ring
9. Install the oil filter element cover
by installing the bolts.
10. Install the oil filter element drain
bolt.
11. Tighten the oil filter element
cover bolts and the oil filter ele-
ment drain bolt to their specified
torques.
12. Install the engine oil drain bolts,
and then tighten them to their
specified torques.
Tightening torques:
Oil filter element cover bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil filter element drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
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