2011 YAMAHA XT660Z oil

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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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)
PERIODIC MAINTENANCE AND ADJUSTMENT
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13. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil
filler cap.
ECAM1061
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.
TIP
Be sure to wipe off spilled oil on any
parts after the engine and exhaust
system have cooled down.
ECA11620
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 hig-
her quality than specified. In
addition, do not use oils labe-
led “ENERGY CONSERVING II”
or higher.
Make sure that no foreign
material 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
engine off and check for the cau-
se.
15. Turn the engine off, and then
check the oil level and correct it if
necessary.16. Install the engine guard by insta-
lling the screws.
NOTICE
Recommended engine oil:
See page 8-1
Without oil filter element
replacement:
2.50 L (2.64 US qt, 2.20 Imp.qt)
With oil filter element
replacement:
2.60 L (2.75 US qt, 2.29 Imp.qt
NOTICE
Tightening torques:
Engine oil drain bolt (crankcase):
30 Nm (3.0 m·kgf, 22 ft·lbf)
Engine oil drain bolt (oil tank):
18 Nm (1.8 m·kgf, 12.9 ft·lbf)
PERIODIC MAINTENANCE AND ADJUSTMENT
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Rear brake (for XT660ZA)
1. Minimum level mark
Insufficient brake fluid may allow air
to enter the brake system, possibly
causing it to become ineffective.
Before riding, check that the brake
fluid is above the minimum level mark
and replenish if necessary. A low bra-
ke 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 leakage.
TIP
For XT660ZA, the rear brake fluid
reservoir is located under the seat.
(See page 3-16).
Observe these precautions:
When checking the fluid level,
make sure that the top of the bra-
ke fluid reservoir is level.
Use only the recommended qua-
lity brake fluid, otherwise the rub-
ber seals may deteriorate, cau-
sing 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 performan-
ce.
Be careful that water or dust
does not enter the brake fluid
reservoir when refilling. Water will
significantly lower the boiling
point of the fluid and may result
in vapor lock, and dirt may clog
the ABS hydraulic unit valves.
Brake fluid may deteriorate pain-
ted surfaces or plastic parts.
Always clean up spilled fluid
immediately.
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.
EAU22731
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the TIP after the periodic maintenan-
ce and lubrication chart. In addition,
have the oil seals of the master cylin-
ders and calipers as well as the brake
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.
Oil seals: Replace every two
years.
Brake hoses: Replace every four
years.
Recommended brake fluid:
DOT 4
PERIODIC MAINTENANCE AND ADJUSTMENT
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TIP
Using the alignment marks on each
side of the swingarm, make sure that
both drive chain pullers are in the
same position for proper wheel align-
ment.
3. Tighten the axle nut, then the
locknuts to their specified tor-
ques.
EAU23025
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.
ECA10583
The drive chain must be lubricated
after washing the motorcycle,
riding in the rain or riding in wet
areas.
1. Clean the drive chain with kero-
sene and a small soft brush.
NOTICE: To prevent damaging
the O-rings, do not clean the
drive chain with steam clea-
ners, high-pressure washers or
inappropriate solvents.
[ECA11121]
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.
[ECA11111]
NOTICETightening torques:
Axle nut:
16 Nm (1.6 m·kgf, 11 ft·lbf)
Locknut:
105 Nm (10.5 m·kgf, 75 ft·lbf)
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EAU23093
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 cables and cable ends should
be lubricated if necessary. If a cable is
damaged or does not move smoothly,
have a Yamaha dealer check or repla-
ce it.
EWA10711
Damage to the outer housing of
cables may result in internal rusting
and cause interference with cable
movement. Replace damaged
cables as soon as possible to pre-
vent unsafe conditions.
EAU23142
Checking and lubricating the
brake and clutch levers
Brake lever
Clutch lever
The operation of the brake and clutch
levers should be checked before eachride, and the lever pivots should be
lubricated if necessary.Recommended lubricants:
Brake lever:
Silicone grease
Clutch lever:
Lithium-soap-based grease
Recommended lubricant:
Yamaha Chain and Cable Lube or
engine oil
WARNING
PERIODIC MAINTENANCE AND ADJUSTMENT
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PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU23251
Lubricating the rear
suspension
The pivoting points of the rear sus-
pension must be lubricated by a
Yamaha dealer at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
EAUM1651
Lubricating the swingarm
pivots
The swingarm pivots must be lubrica-
ted by a Yamaha dealer at the inter-
vals specified in the periodic mainte-
nance and lubrication chart.
EAU23272
Checking the front fork
The condition and operation of the
front fork must be checked as follows
at the intervals specified in the perio-
dic maintenance and lubrication
chart.
To check the condition
1. Check the inner tubes for scrat-
ches, damage and excessive oil
leakage.
To check the operation
1. Place the vehicle on a level surfa-
ce and hold it in an upright posi-
tion. WARNING! To avoid injury,
securely support the vehicle so
there is no danger of it falling
over.
[EWA10751]
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and
rebounds smoothly.
Recommended lubricant:
Lithium-soap-based grease
Recommended lubricant:
Lithium-soap-based grease
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