2012 YAMAHA XT660Z brake

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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-57-5
EAUM1890
TIP
●Replace t\fe air filte\tr ele\bent \bore frequen\ttly if you are riding in unusually wet or dusty areas.
●Hydraulic brake service
●Regularly c\feck and, if necessary, correct t\fe brake fluid level.
●Every two years replace t\fe inter\tnal co\bponents of t\fe \tbrake \baster cylinder, and c\fange t\fe brake fluid.
●Replace t\fe brake \foses every four years and if cracked or da\baged.
NO. ITEMCHECK OR M\fINTEN\fNCE\M JOB
ODOMETER RE\fDING
1000 km 10000 km 20000 km 30000 km 40000 km(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
\fNN\b\fL
CHECK
√ √ √
√ √ √ √ √
√ √ √ √ √ √ √ √ √ √ √
√ √ √ √ √
√ √ √ √ √ √ Replace.
 C\feck coolant level and ve\ficle for coolant leakage.
 C\fange.
 C\feck operation.
 Lubricate.
 C\feck operation and free play.
 Adjust t\fe t\frottle cab\tle free play if necessary.
 Lubricate t\fe t\frottle grip \fousing
and cable.
 C\feck operation.
 Adjust \feadlig\ft bea\b.\t
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✻
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-5

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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-21
EAU22390
Checking the front and rear
brake pads
The front \fnd re\fr br\fke \b\fds must be
checked for we\fr \ft the interv\fls s\bec-
ified in the \beriodic m\finten\fnce \fnd
lubric\ftion ch\frt.
EAU22420
Front brake pads
1. Front br\fke \b\fd we\fr indic\ftor groove
E\fch front br\fke \b\fd is \brovided with
\f we\fr indic\ftor groove, which \fllows
you to check the br\fke \b\fd we\fr with-
out h\fving to dis\fssemble the br\fke.
To check the br\fke \b\fd we\fr, check
the we\fr indic\ftor groove. If \f br\fke
\b\fd h\fs worn to the \boint th\ft the
we\fr indic\ftor groove h\fs \flmost dis-
\f\b\be\fred, h\fve \f Y\fm\fh\f de\fler re-
\bl\fce the br\fke \b\fds \fs \f set.
EAU22500
Rear brake pads
1. Re\fr br\fke \b\fd lining thickness
Check e\fch re\fr br\fke \b\fd for d\fm-
\fge \fnd me\fsure the lining thickness.
If \f br\fke \b\fd is d\fm\fged or if the lin-
ing thickness is less th\fn 1.0 mm
(0.04 in), h\fve \f Y\fm\fh\f de\fler re-
\bl\fce the br\fke \b\fds \fs \f set.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-21

PERIODIC MAINTENANCE AND ADJUSTMENT
7-22
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Insufficient brake fluid \fay allow air to
enter t\be brake syste\f, possibly caus-
ing it to beco\fe ine\dffective.
Before riding, c\beck t\bat t\be brake flu-
id is above t\be \fini\fu\f level \fark
and replenis\b if ne\dcessary.
A low brake fluid level \fay indicate
worn brake pads and/or brake syste\f
leakage. If t\be brake fluid level is low,
be sure to c\beck t\be brake pads for
wear and t\be brake syste\f for leak-
age.
Observe t\bese precautions\d:
●W\ben c\becking t\be fluid level,
\fake sure t\bat t\be top of t\be
brake fluid reservoir is level.
●Use only t\be reco\f\fended qual-
ity brake fluid, ot\berwise t\be rub-
ber seals \fay deteriorate, caus-
ing leakage and poor braking
perfor\fance.
●Refill wit\b t\be sa\fe type of brake
fluid. Mixing fluids \fay result in a
\bar\fful c\be\fical reaction and
lead to poor braking perfor\fance.
●Be careful t\bat water does not en-
ter t\be brake fluid reservoir w\ben
refilling. Water will significantly
lower t\be boiling point of t\be fluid
and \fay result in vapor lock.
●Brake fluid \fay deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid i\f\fe-
diately.
●As t\be brake pads wear, it is nor-
\fal for t\be brake fluid level to
gradually go down. However, if
t\be brake fluid level goes down
suddenly, \bave a Ya\fa\ba dealer
c\beck t\be cause.
Recommended brake f\4luid: DOT 4
EAU22580
Checking the brake fluid
level
Front brake
1. Mini\fu\f level \fark
Rear brake
1. Mini\fu\f level \fark
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-22

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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-23
EAU22731
Changing the brake fluid
Have a Yamaha dealer \fhange the
\brake fluid at the intervals spe\fified in
the TIP after the periodi\f maintenan\fe
and lu\bri\fation \fhart. In addition, have
the oil seals of the master \fylinders
and \falipers as well as the \brake
hoses repla\fed at the intervals listed
\below or whenever they are damaged
or leaking.
●Oil seals: Repla\fe ever y two
years.
●Brake hoses: Repla\fe every four
years.
EAU22760
Drive chain slack
The drive \fhain sla\fk should \be
\fhe\fked \before ea\fh ride and adjusted
if ne\fessary.
EAU22783
To check the drive chain slack
1. Drive \fhain sla\fk
1. Pla\fe the motor\fy\fle on the side-stand.
TIP
When \fhe\fking and adjusting the dri-
ve \fhain sla\fk, there should \be no
weight on the motor\fy\fl\re.
2. Shift the transmission into theneutral position.
3. Move the rear wheel \by pushing the motor\fy\fle to lo\fate the tight-
est portion of the drive \fhain, and
then measure the drive \fhain
sla\fk as shown.
4. If the drive \fhain sla\fk is in\for- re\ft, adjust it as follows.
TIP
When \fhe\fking the drive \fhain sla\fk,
the \fhain tensioner should not \be
tou\fhing the drive \fhain.
Drive chain slack:50.0-60.0 mm (1.96\r-2.36 in)
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-23

EAU23111
Checking and lubricating
the throttle grip and cable
The operation of the throttle \frip
should \be checked \before each ride.
In addition, the ca\ble should \be lu\bri-
cated at the intervals specified in the
periodic maintenance\l chart.
EAU23142
Checking and lubricating
the brake and clutch lever\f
Brake lever
Clutch leverThe operation of the \brake and clutch
levers should \be checked \before each
ride, and the lever pivots should \be lu-
\bricated if necessa\lry.
Recommended lubrican\vt\f\b
Brake lever:Silicone \frease
Clutch lever: Lithium-soap-\based \fr\lease
PERIODIC MAINTENANCE AND ADJUSTMENT
7-26
7
03 ingles -austral\:ia 3/5/10 06:00 \:\fágina 68

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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
EAU23182
Checking and lubricating
the brake pedal
The operation of the \frake pedal
\bhould \fe checked \fefore each ride,
and the pedal pivot \bhould \fe lu\fricat-
ed if nece\b\bary.
Recommended lubric\Mant:Lithium-\boap-\fa\bed grea\be
EAU23202
Checking and lubricating
the sidestand
The operation of the \bide\btand \bhould
\fe checked \fefore each ride, and the
\bide\btand pivot and metal-to-metal
contact \burface\b \bhould \fe lu\fricated
if nece\b\bary.
EWA10730
W\fRNING0
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it. Otherwise,
the sidestand could contact the
ground and distract the operator, re-
sulting in a possible loss of control.
Recommended lubric\Mant:Lithium-\boap-\fa\bed grea\be
EAU23250
Lubricating the rear
suspension
The pivoting point\b of the rear \bu\bpen-
\bion mu\bt \fe lu\fricated at the interval\b
\bpecified in the periodic maintenance
and lu\frication chart.
Recommended lubric\Mant:Lithium-\boap-\fa\bed grea\be
7-27
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-27

PERIODIC MAINTENANCE AND ADJUSTMENT
7-28
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EAU23272
Checking the front fork
The condition and o\feration of the
front fork \bust be checked as follows
at the inter vals s\fecified in the
\feriodic \baintenance and lubrication
chart.
To check the condition
Check the inner tubes for scratches,
da\bage and excessive oil leakage.
To check the operation 1. Place the \botorcycle on a level surface and hold it in an u\fright
\fosition. WARNING! To avoid in-
jury, securely support the vehi-
cle so there is no danger of it
falling over.
2. While a\f\flying the front brake, \fush down hard on the handle-
bars several ti\bes to check if the
front fork co\b\fresses and re-
bounds s\boothly.
ECA10590
NOTICE
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAUM1650
Lubricating the swingarm
pivots
The swingar\b \fivots \bust be lubricat-
ed at the intervals s\fecified in the \fe-
riodic \baintenance and lubrication
chart.
Recommended lubric\4ant: Lithiu\b-soa\f-based g\arease
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-28

PERIODIC MAINTENANCE AND ADJUSTMENT
7-36
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To service the rear wheel
Raise the rear wheel off the grou\fd by
usi\fg a \botorcycle sta\fd or, if a \bo-
torcycle sta\fd is \fot available, by plac-
i\fg a jack either u\fder each side of the
fra\be i\f fro\ft of the rear wheel or u\f-
der each side of t\uhe swi\fgar\b.EAU24360
Front wheelEAUB1440To remove the front wheel
EWA10820
WARNING0
●It is advisable to have a Yama-
ha dealer service t\4he wheel.
●Securely support the motorcy-
cle so that there is no danger of
it falling over.
1. Wheel axle
2. Brake caliper bolts
A. Fro\ft wheel axle pi\fch bolt
B. Fro\ft wheel axle pi\fch bolt
A
2
B
1
EAU24350
Supporting the motorcycle
Si\fce this \bodel is \fot equipped with
a ce\ftersta\fd, follow these precau-
tio\fs whe\f re\bovi\fg the fro\ft a\fd rear
wheel or perfor\bi\fg other \bai\fte-
\fa\fce requiri\fg the \botorcycle to
sta\fd upright. Check that the \botorcy-
cle is i\f a stable a\fd level positio\f be-
fore star ti\fg a\fy \bai\fte\fa\fce. A
stro\fg woode\f box ca\f be placed u\f-
der the e\fgi\fe for added stability.
To service the front wheel 1. Stabilize the rear of the \botorcy- cle by usi\fg a \botorcycle sta\fd
or, if a\f additio\fal \botorcycle
sta\fd is \fot available, by placi\fg a
jack u\fder the fra\be i\f fro\ft of the
rear wheel.
2. Raise the fro\ft wheel off the grou\fd by usi\fg a \botorcycle
sta\fd.
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