2012 YAMAHA XT660Z torque

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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
EAU17241
Periodic inspection\f adjust\bent\f and
lubrication will keep your vehicle in the
safest and \bost efficient condition
possible. Safety is an obligation of the
vehicle owner/operator. The \bost i\b-
portant points of vehicle inspection\f
adjust\bent\f and lubrication are ex-
plained on the following pages.
The intervals given in the periodic
\baintenance and lubrication char t
should be si\bply considered as a gen-
eral guide under nor\bal riding condi-
tions. However\f depending on the
weather\f terrain\f geographical loca-
tion\f and individual use\f the \bainte-
nance intervals \bay need to be short-
ened.
EWA10321
W\fRNING0
Failure to properly maintain the ve-
hicle or performing maintenance
activities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle
service, have a Yamaha dealer per-
form service.
EAU17391
Owner’s tool kit
1. Owner’s tool kit
The owner’s tool kit is located under
the seat. (See page 4-14).
The service infor\bation included in this
\banual and the tools provided in the
owner’s tool kit are intended to assist
you in the perfor\bance of preventive
\baintenance and \binor repairs. How-
ever\f additional tools such as a torque
wrench \bay be necessary to perfor\b
certain \baintenance work correctly.
TIP
If you do not have the tools or experi-
ence required for a particular job\f have
a Ya\baha dealer perfor\b it for you.
7-1
EWA15121
W\fRNING0
Turn off the engine when perform-
ing maintenance unless otherwise
specified.
\f running engine has moving parts
that can catch on body parts or
clothing and electrical parts that
can cause shocks or\M fires.
Running the engine while servicing
can lead to eye injury, burns, fire, or
carbon monoxide poisoning - pos-
sibly leading to death. See page 2-2
for more information about carbon
monoxide.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-1

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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-9
EAUB1560
Engine oil and oil filter
element
The engine oi\f \feve\f shou\f\b be checke\b
before each ri\be. In a\b\bition, the oi\f must
be change\b an\b the oi\f fi\fter e\fement re-
p\face\b at the interva\fs specifie\b in the
perio\bic maintenance an\b \fubrication
chart.
To check the engine oil level1. P\face the vehic\fe on a \feve\f surface an\b ho\f\b it in an upright position.
TIP
Make sure that the vehic\fe is posi-
tione\b straight up when checking the
oi\f \feve\f. A s\fight ti\ft to the si\be can re-
su\ft in a fa\fse rea\bing.
2. Start the engine, warm it up for 10-15 minutes an\b then turn it off.
3. Remove the oi\f fi\f\fer cap, wipe the \bipstick c\fean, insert it back into
the oi\f fi\f\fer ho\fe (without screwing
it in), an\b then remove it again to
check the oi\f \feve\f.
1. Engine oi\f fi\f\fer cap
2. Maximum \feve\f mark
3. Minimum \feve\f mark
TIP
●The engine oi\f tank is \focate\b in-
si\be of the frame.
●The engine oi\f shou\f\b be between
the minimum an\b maximum \feve\f
marks.
Tightening torque:Spark p\fug:12.5 Nm (1.25 m·kg\of, 9.0 ft·\fbf)
TIP
If a torque wrench is not avai\fab\fe
when insta\f\fing a spark p\fug, a goo\b
estimate of the correct torque is 1/4-
1/2 turn past finger tight. However, the
spark p\fug shou\f\b be tightene\b to the
specifie\b torque as s\ooon as possib\fe.
4. Insta\f\f the spark p\fug cap.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-9

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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-11
Tightening torques:Oil filter element\0 cover bolt:10 \fm (1.0 m·\bgf, 7.2 ft·lbf)
Oil filter element\0 drain bolt: 10 \fm (1.0 m·\bgf, 7.2 ft·lbf)
Tightening torques:Engine oil drain bolt (cran\bcase):30 \fm (3.0 m·\bgf, 22 ft·lbf)
Engine oil drain bolt (oil tan\b)\0: 18 \fm (1.8 m·\bgf, 12.9 ft·lbf)
13. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filter
cap.
10. Install the oil filter element drain
bolt.
11. Tighten the oil filter element cover bolts and the oil filter element
drain bolt to their specified
torques.1. Engine oil filter element
2. O-rings
12. Install the engine oil drain bolts,and then tighten them to their
specified torques.
TIP
S\bip steps 7-9 if the oil filter element is
not being replaced\0.
7. Remove the oil filter element cov- er by removing the bolts.
8. Remove and replace the oil filter element and O-rings.
9. Install the oil filter element cover by installing the bo\0lts.
TIP
Ma\be sure that the O-rings are proper-
ly seated.
1. Engine oil filter element drain bolt
2. Oil filter element cover bolts
2
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XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-11

PERIODIC MAINTENANCE AND ADJUSTMENT
7-24
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\f
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\b
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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.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-24

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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-37
1. Loosen the front wheel axle \finchbolts\b the wheel axle and the
brake cali\fer bolts.
2. Lift the front wheel off the ground according to the \frocedure on
\fage 7-36.
3. Remove the brake cali\fer on each side by removing the bolts.
ECA11050
NOTICE
Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will be
forced shut.
4. Pull the wheel axle out\b and then remove the wheel.
EAUB1470
To install the front wheel1. Lift the wheel u\f between the fork legs.
2. Insert the wheel axle.
3. Install the brake cali\fers by in- stalling the bolts.
TIP
Make sure that there is enough s\face
between the brake \fads before in-
stalling the brake cali\fers onto the
brake discs.
4. Lower the front wheel so that it is on the ground.
5. Tighten the wheel axle and the brake cali\fer bolts to the s\fecified
torques.
ECAB0060
NOTICE
Be sure the right brake disc is posi-
tioned exactly in the middle of the
caliper pads to prevent any brake
drag. Tap the side of the right fork
leg to position th\Me disc correctly.
Tightening torques: Wheel axle:60 Nm (6.0 m·kgf\b 44 ft·lbf)
Front wheel axle \fin\xch bolt: 18 Nm (1.8 m·kgf\b 13 ft·lbf)
Brake cali\fer bolt: 40 Nm (4.0 m·kgf\b 29 ft·lbf)
6. Tighten wheel axle \finch bolt A\b and then \finch bolt B to the s\fec-
ified torque.
7. Retighten \finch bolt A to the s\fecified torque.
8. A\f\fly the front brake several times\b and then while holding the
brake lever in\b \fush down hard on
the handlebar several times to
check for \fro\fer fork o\feration.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-37

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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-39
TIP
●Make sure that the slot in the
brake \faliper bra\fket is fit over the
retainer on the s\bingarm.
●Make sure that there is enough
spa\fe bet\been the brake pads
before installing the\b \bheel.
2. Install the drive \fhain onto the rear spro\fket.
3. Install the axle nut, and then lo\b- er the rear \bheel so that it is on
the ground.
4. Adjust the drive \fhain sla\fk. (See page 7-24.)
5. Apply the rear brake several times, and then tighten the axle
nut to the spe\fified\b torque.
Tightening torque:
Axle nut:105 Nm (10.5 m·kgf, 75 ft·lbf)
EAU25871
Troubleshooting
Although Yamaha motor\fy\fles re\feive
a thorough inspe\ftion before shipment
from the fa\ftory, trouble may o\f\fur
during operation. Any problem in the
fuel, \fompression, or ignition systems,
for example, \fan \fause poor starting
and loss of po\ber.
The follo\bing troubleshooting \fharts
represent qui\fk and easy pro\fedures
for \fhe\fking these vital systems your-
self. Ho\bever, should your motor\fy\fle
require any repair, take it to a Yamaha
dealer, \bhose skilled te\fhni\fians have
the ne\fessary tools, experien\fe, and
kno\b-ho\b to servi\fe the motor\fy\fle
properly.
Use only genuine Yamaha repla\fe-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter servi\fe life and
\fan lead to expensive repair bills.
EWA15141
W\fRNING0
When checking the fuel system, do
not smoke, and make sure there
are no open flames or sparks in the
area, including pilot lights from wa-
ter heaters or furnaces. Gasoline or
gasoline vapors can ignite or ex-
plode, causing severe injury or
property damage.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-39