2011 YAMAHA XT660Z brake pads

SAFETY INFORMATION .....................1-1
DESCRIPTION.....................................2-1
Left view ...........................................2-1
Right view .........................................2-3
Controls and instruments .................2-5
INSTRUMENT AND CONTROL
FUNCTIONS ........................................3-1
Immobilizer system ...........................3-1
Main switch/steering lock .................3-2
Indicator and warning lights .............3-4
Multi-function display .......................3-6
Anti-theft alarm (optional) .................3-9
Handlebar switches ..........................3-9
Pass switch ....................................3-10
Dimmer switch ...............................3-10
Horn switch ...................................3-10
Turn signal switch ..........................3-10
Hazard switch ................................3-10
Engine stop switch ........................3-10
Start switch ....................................3-10
Clutch lever .....................................3-11
Shift pedal.......................................3-11
Brake lever ......................................3-11
Brake pedal.....................................3-12
ABS (for ABS models) ....................3-12
Fuel tank cap ..................................3-13
Fuel .................................................3-14
Fuel tank breather/overflow
hose .............................................3-15
Catalytic converters ........................3-16Seat.................................................3-16
Adjusting the front fork ...................3-17
Adjusting the shock absorber
assembly .....................................3-18
Sidestand ........................................3-19
Ignition circuit cut-off system .........3-20
FOR YOUR SAFETY – PRE-
OPERATION CHECKS ........................4-1
OPERATION AND IMPORTANT
RIDING POINTS ..................................5-1
Starting the engine ...........................5-1
Shifting ..............................................5-2
Tips for reducing fuel
consumption..................................5-3
Engine break-in.................................5-3
Parking ..............................................5-4
PERIODIC MAINTENANCE AND
ADJUSTMENT ....................................6-1
Owner’s tool kit .................................6-1
Periodic maintenance chart for
the emission control system .........6-3
General maintenance and
lubrication chart ............................6-4
Removing and installing panels........6-8
Checking the spark plug ..................6-9
Engine oil and oil filter element ......6-11
Coolant ...........................................6-14Replacing the air filter element
and cleaning the check hose ......6-15
Checking the engine idling speed ..6-16
Checking the throttle cable free
play ..............................................6-17
Valve clearance ...............................6-17
Tires ................................................6-17
Spoke wheels .................................6-19
Adjusting the clutch lever free
play ..............................................6-20
Checking the front and rear brake
pads.............................................6-21
Checking the brake fluid level ........6-21
Drive chain slack.............................6-23
Cleaning and lubricating the
drive chain ...................................6-24
Checking and lubricating the
cables ..........................................6-25
Checking and lubricating the
brake and clutch levers ...............6-25
Checking and lubricating the
brake pedal .................................6-26
Checking and lubricating the
sidestand .....................................6-26
Lubricating the rear suspension .....6-27
Lubricating the swingarm pivots ....6-27
Checking the front fork ...................6-27
Checking the steering.....................6-28
Checking the wheel bearings .........6-29
Battery ............................................6-29
Replacing the fuses ........................6-31
Replacing a headlight bulb .............6-32
TABLE OF CONTENTS
56P-F8199-E0 30/6/10 09:24 Página 7

FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-1
4
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the ins-
pection and maintenance procedures and schedules described in the Owner’s Manual.
EWA11151
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment dama-
ge. Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures pro-
vided in this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
WARNING
ITEM CHECKS PAGE
• Check fuel level in fuel tank.
• Refuel if necessary.
Fuel• Check fuel line for leakage. 3-14
• Check the fuel tank breather/overflow hose for obstructions, cracks or
damage, and check the hose connection.
• Check oil level in oil tank.
Engine oil• If necessary, add recommended oil to specified level. 6-11
• Check vehicle for oil leakage.
• Check coolant level in reservoir.
Coolant• If necessary, add recommended coolant to specified level. 6-14
• Check cooling system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check lever free play.
• Adjust if necessary.
Front brake• Check brake pads for wear. 6-21
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
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ITEM CHECKS PAGE
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
Rear brake• Replace if necessary. 6-21
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Check operation.
Clutch• Lubricate cable if necessary.
6-20
• Check lever free play.
• Adjust if necessary.
• Make sure that operation is smooth.
Throttle grip• Check cable free play.
6-17, 6-25
• If necessary, have Yamaha dealer adjust cable free play and lubricate cable
and grip housing.
Control cables• Make sure that operation is smooth.
• Lubricate if necessary.6-25
• Check chain slack.
Drive chain• Adjust if necessary.
6-23, 6-24
• Check chain condition.
• Lubricate if necessary.
• Check for damage.
Wheels and tires• Check tire condition and tread depth.
6-17, 6-19
• Check air pressure.
• Correct if necessary.
Brake pedal• Make sure that operation is smooth.
• Lubricate pedal pivoting point if necessary.6-26
Brake and clutch levers• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.6-25
Sidestand• Make sure that operation is smooth.
• Lubricate pivot if necessary.6-26
Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.—
Instruments, lights, signals • Check operation.
and switches• Correct if necessary.—
FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-2
4
56P-F8199-E0 30/6/10 09:24 Página 41

PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
6
EAU1770C
General maintenance and lubrication chart
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)
1Air filter element• Replace.√√
2Clutch• Check operation.
• Adjust.√√ √ √ √
3*Front brake• Check operation, fluid level and
vehicle for fluid leakage.√√ √ √ √ √
• Replace brake pads. Whenever worn to the limit
4*Rear brake• Check operation, fluid level and
vehicle for fluid leakage.√√ √ √ √ √
• Replace brake pads. Whenever worn to the limit
5*Brake hoses• Check for cracks or damage.√√√ √√• Replace. Every 4 years
• Check runout, spoke tightness
6*Wheelsand for damage.√√ √ √ √
• Tighten spokes if necessary.
• Check tread depth and for
damage.
7*Tires• Replace if necessary.√√√ √√
• Check air pressure.
• Correct if necessary.
8*Wheel bearings• Check bearing for looseness or
damage.√√√ √
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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
6-21
6
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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
6-22
6
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EAU44790
Front wheelEWA14840
For the ABS model, have a Yamaha
dealer remove and install the whe-
el.
EAUB1441
To remove the front wheelEWA10821
To avoid injury, securely support
the vehicle so there is no danger of
it falling over.
1. Loosen the front wheel axle pinch
bolts, the wheel axle and the bra-
ke caliper bolts.
1. Wheel axle
2. Brake caliper bolt
3. Front wheel axle pinch bolt
4. Front wheel axle pinch bolt
2. Lift the front wheel off the ground
according to the procedure on
page 6-35.
3. Remove the brake caliper on
each side by removing the bolts.
NOTICE: Do not apply the bra-
ke after the brake calipers have
been removed, otherwise the
brake pads will be forced shut.
[ECA11051]
4. Pull the wheel axle out, and then
remove the wheel.
EAUB1472
To install the front wheel
1. Lift the wheel up between the
fork legs.
2. Insert the wheel axle.
3. Install the brake calipers by insta-
lling the bolts.
TIP
Make sure that there is enough space
between the brake pads before insta-
lling the brake calipers onto the brake
discs.
4. Lower the front wheel so that it is
on the ground.
5. Tighten the wheel axle and the
brake caliper bolts to the speci-
fied torques.
ECAB0061
Be sure the right brake disc is posi-
tioned exactly between the brake
pads to prevent any brake drag.
Tap the side of the right fork leg to
position the disc correctly.
6. Tighten wheel axle pinch bolt A,
and then pinch bolt B to their
specified torque.
NOTICE
WARNING
WARNING
PERIODIC MAINTENANCE AND ADJUSTMENT
6-36
6
56P-F8199-E0 30/6/10 09:24 Página 82

first, and then lift the wheel upward
enough to remove the drive chain
from the rear sprocket.
The drive chain cannot be disas-
sembled.
7. While supporting the brake cali-
per bracket, pull the wheel axle
out, and then remove the wheel.
NOTICE: Do not apply the bra-
ke after the wheel has been
removed together with the bra-
ke disc, otherwise the brake
pads will be forced shut.
[ECA11071]
EAUB1450
To install the rear wheel
1. Install the wheel and the brake
caliper bracket by inserting the
wheel axle from the left-hand
side.
TIP
Make sure that the slot in the bra-
ke 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
lower the rear wheel so that it is
on the ground.
4. Adjust the drive chain slack. (See
page 6-23).
5. Apply the rear brake several
times, and then tighten the axle
nut to the specified torque.EAU25871
Troubleshooting
Although Yamaha motorcycles recei-
ve a thorough inspection before ship-
ment 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 motorcy-
cle require any repair, take it to a
Yamaha dealer, whose skilled techni-
cians have the necessary tools, expe-
rience, 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
When checking the fuel system, do
not smoke, and make sure there
are no open flames or sparks in the
WARNING
Tightening torque:
Axle nut:
105 Nm (10.5 m·kgf, 75 ft·lbf)
PERIODIC MAINTENANCE AND ADJUSTMENT
6-38
6
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