2011 YAMAHA XT660Z maintenance

EAU22392
Checking the front and rear
brake pads
The front and rear brake pads must
be checked for wear at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU22420
Front brake pads
1. Wear indicator groove
Each front brake pad is provided with
a wear indicator groove, which allows
you to check the brake pad wear wit-
hout having to disassemble the brake.
To check the brake pad wear, check
the wear indicator groove. If a brake
pad has worn to the point that the
wear indicator groove has almostdisappeared, have a Yamaha dealer
replace the brake pads as a set.
EAU22500
Rear brake pads
1. Lining thickness
Check each rear brake pad for dama-
ge and measure the lining thickness.
If a brake pad is damaged or if the
lining thickness is less than 10 mm
(0.04 in), have a Yamaha dealer repla-
ce the brake pads as a set.
EAU38640
Checking the brake fluid
level
Front brake
1. Minimum level mark
Rear brake (for XT660Z)
1. Minimum level mark
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
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EAU22760
Drive chain slack
The drive chain slack should be chec-
ked before each ride and adjusted if
necessary.
EAU22783
To check the drive chain slack
1. Drive chain slack
1. Place the motorcycle on the
sidestand.
TIP
When checking and adjusting the dri-
ve chain slack, there should be no
weight on the motorcycle.
2. Shift the transmission into the
neutral position.3. Move the rear wheel by pushing
the motorcycle to locate the tigh-
test portion of the drive chain,
and then measure the drive chain
slack as shown.
4. If the drive chain slack is inco-
rrect, adjust it as follows.
TIP
When checking the drive chain slack,
the chain tensioner should not be tou-
ching the drive chain.
EAU34316
To adjust the drive chain slack
1. Loosen the axle nut and the lock-
nut on each side of the swin-
garm.
1. Wheel axle
2. Drive chain slack adjusting bolt
3. Locknut
4. Alignment marks
2. To tighten the drive chain, turn
the drive chain slack adjusting
bolt on each side of the swin-
garm in direction (a). To loosen
the drive chain, turn the adjusting
bolt on each side of the swin-
garm in direction (b), and then
push the rear wheel forward.
NOTICE: Improper drive chain
slack will overload the engine
as well as other vital parts of
the motorcycle and can lead to
chain slippage or breakage. To
prevent this from occurring,
keep the drive chain slack wit-
hin the specified limits.
[ECA10571]
Drive chain slack:
XT660Z 50.0-60.0 mm
(1.96-2.36 in)
XT660ZA 40.0-55.0 mm
(1.57-2.17 in)
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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
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EAU23182
Checking and lubricating the
brake pedal
The operation of the brake pedal
should be checked before each ride,
and the pedal pivot should be lubrica-
ted if necessary.
EAU23202
Checking and lubricating the
sidestand
The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated
if necessary.
EWA10731
If the sidestand does not move up
and down smoothly, have a Yama-
ha dealer check or repair it. Other-
wise, the sidestand could contact
the ground and distract the opera-
tor, resulting in a possible loss of
control.
Recommended lubricant:
Lithium-soap-based grease
WARNINGRecommended lubricant:
Silicone grease
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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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ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
EAU23283
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the opera-
tion of the steering must be checked
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
1. Place a stand under the engine to
raise the front wheel off the
ground. (See page 6-35 for more
information.) WARNING! To
avoid injury, securely support
the vehicle so there is no dan-
ger of it falling over.
[EWA10751]
2. Hold the lower ends of the front
fork legs and try to move them
forward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the stee-
ring.
NOTICE
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