2012 YAMAHA XT660Z maintenance

PERIODIC MAINTENANCE AND ADJUSTMENT
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To change the engine oil
(with or without oil filter element
replacement)
1. Mounting screw
2. \fngine guard
1. Start t\be engine, warm it up for sev- eral minutes, and t\ben turn it off.
2. To reac\b t\be drain bolt of t\be crankcase and t\be drain bolt of
t\be oil tank, remove t\be engine
guard by removing t\be screws.
3. Place an oil pan under t\be engine to collect t\be used\2 oil.
4. Remove t\be engine oil filler cap and t\be drain bolt to drain t\be oil
from t\be crankcase.
5. Remove t\be drain bolt to drain t\be oil from t\be oil ta\2nk.
1. \fngine oil crankcase drain bolt
1. \fngine oil tank drain bolt
6. Remove t\be oil filter elementdrain bolt to drain t\be oil from t\be
oil filter element\2.
1
\fCA10010
NOTICE
Do not operate the vehicle until you
know that the engine oil level is suf-
ficient.
\fWA10360
WARNING0
Never remove the engine oil tank
cap after high-speed operation,
otherwise hot engine oil could
spout out and cause damage or in-
jury. Always let the engine oil cool
down sufficiently before removing
the oil tank cap.
4. If t\be engine oil is below t\be mini- mum level mark, add sufficient oil
of t\be recommended type to raise
it to t\be correct l\2evel.
5. Install t\be oil fil\2ler cap.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-10

ECAM1060CAUTION:
The engine oil tank \fust be \billed in
2 steps. First, \bill the engine oil tank
with 1.90 L (2.0 US qt) (1.67 I\fp.qt)
o\b the reco\f\fended engine oil.
Then, start the engine, race it 5 or 6
ti\fes, turn it o\b\b, and then add the
re\fainder o\b the eng\kine oil.
NOTE:
Be sure to wipe off spi\f\fed oi\f on an\b
parts after the engine and exhaust
s\bstem have coo\fed d\fown.
ECA11620CAUTION: In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
\fix any che\fical additives. Do
not use oils with a diesel speci-
\bication o\b “CD” or oils o\b a
higher quality than speci\bied. In
addition, do not use oils la-
beled “ENERGY CONSERVING
II” or higher.
Make sure that no \boreign \fa-
terial enters the c\krankcase.
14. Start the engine, and then \fet it id\fe for severa\f minutes whi\fe
checking it for oi\f \feakage. If oi\f is
\feaking, immediate\f\b turn the en-
gine off and check for the \fcause.
15. Turn the engine off, and then check the oi\f \feve\f and correct it if
necessar\b.
16. Insta\f\f the engine guard b\b in- sta\f\fing the screws.\f
EAU20070
Coolant
The coo\fant \feve\f sho\fu\fd be checked
before each ride. In addition, the
coo\fant must be changed at the inter-
va\fs specified in the periodic mainte-
nance and \fubrication \fchart.
EAU20253
To check the coolant level1. P\face the vehic\fe on a \feve\f sur- face and ho\fd it in an upright posi-
tion.
NOTE:
The coo\fant \feve\f must be
checked on a co\fd engine since
the \feve\f varies with engine tem-
perature.
Make sure that the vehic\fe is posi-
tioned straight up when checking
the coo\fant \feve\f. A s\fight ti\ft to the
side can resu\ft in a \ffa\fse reading.
2. Check the coo\fant \feve\f in the coo\fant reservoir.
Reco\f\fended engine \koil:See page 8-1.
Oil quantity: Without oi\f fi\fter e\f\fement
rep\facement:2.50 L (2.64 US qt) (2.19 I\fmp.qt)
With oi\f fi\fter e\fem\fent rep\facement: 2.60 L (2.73 US qt) (2.26 Im\fp.qt)
PERIODIC MAINTENANCE AND ADJUSTMENT
7-12
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03 ingles -austral\:ia 3/5/10 06:00 \:\fágina 54

PERIODIC MAINTENANCE AND ADJUSTMENT
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1. Air filter element
ECA10480
NOTICE ● Make sure that the air filter ele-
ment is properly seated in the
air filter case.
● The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively\4 worn.
\f. Install t\be air filter case cover by installing t\be screws.
6. Install t\be seat.
1
EAUB1480
Replacing the air filter
element and cleaning the
check hose
T\be air filter element s\bould be re-
placed at t\be intervals specified in t\be
periodic maintenance and lubrication
c\bart. Replace t\be air filter element
more frequently if you are riding in un-
usually wet or dusty areas. In addition,
t\be air filter c\beck \bose must be fre-
quently c\becked and cleaned if neces-
sary. To replace the air filter element
1. Air filter case
2. Screws
1. Remove t\be seat. (See page 4-
14.)
2. Remove t\be air filter case cover by removing t\be screws.
3. Pull t\be air filter\8 element out.
4. Insert a new air filter element into t\be air filter case \8as s\bown.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-14

PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU21631
Tires
To maximize t\fe performa\bce, durabil-
ity, a\bd safe operatio\b of your motor-
cycle, \bote t\fe followi\bg poi\bts regard-
i\bg t\fe specified tire\ts.
Tire air pressure
T\fe tire air pressure s\fould be
c\fecked a\bd, if \becessary, adjusted
before eac\f ride.
EWA10501
WARNING0
Operation of this vehicle with im-
proper tire pressure may cause se-
vere injury or death from loss of
control.
●The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the tempera-
ture of the tires equals the am-
bient temperature).
●The tire air pressure must be
adjusted in accordance with
the riding speed and with the
total weight of rider, passenger,
cargo, and accessories ap-
proved for this mode\4l.
EAU21382
Checking the throttle cable
free play
1. T\frottle cable free play
T\fe t\frottle cable free play s\fould
measure 3.0-5.0 mm (0.12-0.20 i\b) at
t\fe t\frottle grip. Periodically c\feck t\fe
t\frottle cable free play a\bd, if \beces-
sary, \fave a Yama\fa dealer adjust i\tt.
EAU21401
Valve clearance
T\fe valve cleara\bce c\fa\bges wit\f
use, resulti\bg i\b improper air-fuel mix-
ture a\bd/or e\bgi\be \boise. To preve\bt
t\fis from occurri\bg, t\fe valve clear-
a\bce must be adjusted by a Yama\fa
dealer at t\fe i\btervals specified i\b t\fe
periodic mai\bte\ba\bce a\bd lubricatio\b
c\fart.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-16

PERIODIC MAINTENANCE AND ADJUSTMENT
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Tire information
This motorcycle is equi\f\fed with tube
tires\b
Front tire: Size:90/90-21M/C 54S
90/90-21M/C 54T
Manufacturer/model: METZELER/TOURANCE
FRONT MICHELIN/SIRAC
Rear tire: Size:130/80-17M/C 65S
130/80-17M/C 65T
Manufacturer/model: METZELER/TOURANCE
MICHELIN/SIRAC A
Tire inspection
1\b Tire sidewall
2\b Tire tread de\fth
The tires must be checked before
each ride\b If the center tread de\fth
reaches the s\fecified limit, if the tire
has a nail or glass fragments in it, or if
the sidewall is cracked, have a Yama-
ha dealer re\flace the tire immediately\b
TIP
The tire tread de\fth limits may differ
from country to country\b Always com-
\fly with the local \uregulations\b
Minimum tire tread depth
(front and rear):1\b0 mm (0\b04 in)
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-18

PERIODIC MAINTENANCE AND ADJUSTMENT
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3. To increase the cl\ftch lever free pla\b, t\frn the adj\fsting bolt in di-
rection (a). To decrease the cl\ftch
lever free pla\b, t\frn the adj\fsting
bolt in direction (\lb).
TIP
If the specified cl\ftch lever free pla\b
co\fld be obtained as described above,
skip steps 4-7.
4. F\fll\b t\frn the adj\fsting bolt at the cl\ftch lever in direction (a) to
loosen the cl\ftch ca\lble.
5. Loosen the lockn\ft at the crankcase.1. Lockn\ft
2. Cl\ftch lever free pla\b adj\fsting n\ft(crankcase)
6. To increase the cl\ftch lever free
pla\b, t\frn the adj\fsting n\ft in di-
rection (a). To decrease the cl\ftch
lever free pla\b, t\frn the adj\fsting
n\ft in direction (b)\l.
7. Tighten the lockn\ft at the crankcase.
8. Tighten the lockn\ft at the cl\ftch lever and then slide the r\fbber
cover to its original position.
1
b
a
2
EAU22043
Adjusting the clutch lever
free play
1. Lockn\ft
2. Adj\fsting bolt
3. Cl\ftch lever free pla\b
The cl\ftch lever free pla\b sho\fld mea-
s\fre 10.0-15.0 mm (0.39-0.59 in) as
shown. Periodicall\b check the cl\ftch
lever free pla\b and, if necessar\b, ad-
j\fst it as follows.
1. Slide the r\fbber cover back at the cl\ftch lever.
2. Loosen the lockn\ft.
31
2
b
a
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-20

PERIODIC MAINTENANCE AND ADJUSTMENT
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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

PERIODIC MAINTENANCE AND ADJUSTMENT
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1. Wheel axle
2. Drive chain \flack adj\b\fting bolt
3. Lockn\bt
4. Alignment mark\f
TIP
U\fing the alignment mark\f on each
\fide of the \fwingarm, make \f\bre that
both chain p\bller\f are in the \fame po-
\fition for proper wheel al\nignment.
3. Tighten the axle n\bt, then the lock- n\bt\f to their \fpecified torq\be\f.
Tightening torques:
Axle n\bt:105 Nm (10.5 m·kgf, 75 ft·lbf)
Lockn\bt: 16 Nm (1.6 m·kgf, 11 ft·lbf)
EAU34314
To adjust the drive chain slack1. Loo\fen the axle n\bt and the lock- n\bt on each \fide of the \fwingarm.
2. To tighten the drive chain, t\brn the drive chain \flack adj\b\fting bolt on
each \fide of the \fwingarm in di-
rection (a). To loo\fen the drive
chain, t\brn the adj\b\fting bolt on
each \fide of the \fwingarm in di-
rection (b), and then p\b\fh the rear
wheel forward. NOTICE: Improp-
er drive chain slack will over-
load 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 within the specified
limits.
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