2015 YAMAHA XT660Z wheel

INSTRUMENT AND CONTROL FUNCTIONS
3-12
3
EAU51802
ABS (for ABS models)The Yamaha ABS (Anti-lock Brake
System) features a dual electronic con-
trol system, which acts on the front and
rear brakes independently.
Operate the brakes with ABS as you
would conventional brakes. If the ABS
is activated, a pulsating sensation may
be felt at the brake lever or brake ped-
al. In this situation, continue to apply
the brakes and let the ABS work; do
not “pump” the brakes as this will re-
duce braking effectiveness.
WARNING
EWA16051
Always keep a sufficient distance
from the vehicle ahead to match the
riding speed even with ABS.
The ABS performs best with
long braking distances.
On certain surfaces, such as
rough or gravel roads, the brak-
ing distance may be longer with
the ABS than without.The ABS is monitored by an ECU,
which will revert the system to conven-
tional braking if a malfunction occurs.
TIPThe ABS performs a self-diagno-
sis test each time the vehicle first
starts off after the key is turned to
“ON” and the vehicle has traveled
at a speed of 10 km/h (6 mi/h) or
higher. During this test, a “click-
ing” noise can be heard from un-
der the seat, and if the brake lever
or brake pedal is even slightly ap-
plied, a vibration can be felt at the
lever and pedal, but these do not
indicate a malfunction.
This ABS has a test mode which
allows the owner to experience
the pulsation at the brake lever or
brake pedal when the ABS is op-
erating. However, special tools are
required, so please consult your
Yamaha dealer.NOTICE
ECA16121
Keep any type of magnets (including
magnetic pick-up tools, magnetic
screwdrivers, etc.) away from the
front and rear wheel hubs, otherwise
the magnetic rotors equipped in thewheel hubs may be damaged, re-
sulting in improper performance of
the ABS system.
1. Front wheel hub
1. Rear wheel hub
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FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-2
4
Rear brake• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add specified brake fluid to specified level.
• Check hydraulic system for leakage.6-21, 6-21
Clutch• Check operation.
• Lubricate cable if necessary.
• Check lever free play.
• Adjust if necessary.6-20
Throttle grip• Make sure that operation is smooth.
• Check throttle grip free play.
• If necessary, have Yamaha dealer adjust throttle grip free play and lubricate ca-
ble and grip housing.6-16, 6-25
Control cables• Make sure that operation is smooth.
• Lubricate if necessary.6-25
Drive chain• Check chain slack.
• Adjust if necessary.
• Check chain condition.
• Lubricate if necessary.6-23, 6-24
Wheels and tires• Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary.6-17, 6-19
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.6-26
Sidestand• Make sure that operation is smooth.
• Lubricate pivot if necessary.6-27 ITEM CHECKS PAGE
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
6
EAU1770M
General maintenance and lubrication chartNO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
1 Air 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.
• Check for correct routing and
clamping.√√√√√
• Replace. Every 4 years
6*Wheels• Check runout, spoke tightness
and for damage.
• Tighten spokes if necessary.√√√√√
7*Tires• Check tread depth and for dam-
age.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.√√√√√
8*Wheel bearings• Check bearings for looseness or
damage.√√√√
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-19
6
WARNING
EWA10572
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the mo-torcycle with excessively worn
tires decreases riding stability
and can lead to loss of control.
The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.
It is not recommended to patch
a punctured tube. If unavoid-
able, however, patch the tube
very carefully and replace it as
soon as possible with a high-
quality product.
Ride at moderate speeds after
changing a tire since the tire
surface must first be “
broken
in” for it to develop its optimal
characteristics.
EAU21944
Spoke wheels
WARNING
EWA10611
The wheels on this model are not
designed for use with tubeless tires.
Do not attempt to use tubeless tires
on this model.To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified wheels.
The wheel rims should be
checked for cracks, bends, warp-
age or other damage, and the
spokes for looseness or damage
before each ride. If any damage is
found, have a Yamaha dealer re-
place the wheel. Do not attempt
even the smallest repair to the
wheel. A deformed or cracked
wheel must be replaced.
The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.
Front tire:
Size:
XT660Z 90/90-21 M/C 54S(MET-
ZELER)-54T(MICHELIN)
XT660ZA 90/90-21 M/C
54S(PIRELLI)
Manufacturer/model:
XT660Z METZELER/TOURANCE
FRONT
XT660ZA PIRELLI/SCORPION
TRAIL
XT660Z MICHELIN/SIRAC
Rear tire:
Size:
XT660Z 130/80-17 M/C
65S(METZELER)-65T(MICHELIN)
XT660ZA 130/80-17 M/C
65S(PIRELLI)
Manufacturer/model:
XT660Z METZELER/TOURANCE
FRONT
XT660ZA PIRELLI/SCORPION
TRAIL
XT660Z MICHELIN/SIRAC
U2BDE1E0.book Page 19 Tuesday, December 16, 2014 5:38 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-23
6
EAU22733
Changing the brake fluidHave a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrica-
tion chart. In addition, have the oil seals
of the master cylinders 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.
EAU22762
Drive chain slackThe drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22786
To check the drive chain slack
1. Place the motorcycle on the side-
stand.TIPWhen checking and adjusting the drive
chain slack, there should be no weight
on the motorcycle.2. Shift the transmission into the
neutral position.
3. Measure the drive chain slack as
shown.4. If the drive chain slack is incorrect,
adjust it as follows.
TIPWhen checking the drive chain slack,
the chain tensioner should not be
touching the drive chain.
EAU34318
To adjust the drive chain slack
Consult a Yamaha dealer before ad-
justing the drive chain slack.
1. Loosen the axle nut and the lock-
nut on each side of the swingarm.
2. To tighten the drive chain, turn the
drive chain slack adjusting bolt on
each side of the swingarm in di-
rection (a). To loosen the drive
chain, turn the adjusting bolt on
each side of the swingarm in di-
rection (b), and then push 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
1. Drive chain slack
Drive chain slack:
50.0–60.0 mm (1.97–2.36 in)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-24
6occurring, keep the drive chain
slack within the specified limits.
[ECA10572]
TIPUsing the alignment marks on each
side of the swingarm, make sure that
both drive chain pullers are in the same
position for proper wheel alignment.3. Tighten the axle nut, then the lock-
nuts to their specified torques.4. Make sure that the drive chain
pullers are in the same position,
the drive chain slack is correct,
and the drive chain moves
smoothly.
EAU23026
Cleaning and lubricating the
drive chainThe 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.NOTICE
ECA10584
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 cleaners,
high-pressure washers or inap-
propriate solvents.
[ECA11122]
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
1. Axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Alignment marks
Tightening torques:
Axle nut:
104 Nm
Locknut:
16 Nm
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-28
6
EAU23273
Checking the front forkThe condition and operation of the
front fork must be checked as follows
at the intervals specified in the periodic
maintenance and lubrication chart.
To check the condition
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation
1. Place the vehicle on a level sur-
face 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.
[EWA10752]
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
NOTICE
ECA10591
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU23285
Checking the steeringWorn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the
periodic maintenance and lubrication
chart.
1. Raise the front wheel off the
ground. (See page 6-35.)
WARNING! To avoid injury, se-
curely support the vehicle so
there is no danger of it falling
over.
[EWA10752]
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steer-
ing.
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-29
6
EAU23292
Checking the wheel bearingsThe front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.
EAUS1913
BatteryTo access the battery (XTZ660Z):
The battery is located under the seat.
(See page 3-16.)
Remove the battery bracket by remov-
ing the bolts.
Battery (XTZ660ZA):
The battery is located under the fuel
tank.Have a Yamaha dealer access the bat-
tery.
These models are equipped with a
VRLA (Valve Regulated Lead Acid) bat-
tery. There is no need to check the
electrolyte or to add distilled water.
However, the battery lead connections
need to be checked and, if necessary,
tightened.
WARNING
EWA10761
Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al-
ways shield your eyes when
1. Positive battery terminal
2. Holder
3. Bolt
4. Negative battery terminal
1. Battery
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