2015 YAMAHA XT660Z Owners Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
6-5
6
9*Swingarm• Check operation and for exces-
sive play.√√√√
• Lubricate with lithium-soap-
based grease.Every 50000 km (30000 mi)
10 Drive chain• Check chain slack, alignment and
condition.
• Adjust and lubricate chain with a
special O-ring chain lubricant
thoroughly.Every 500 km (300 mi) and after washing the motorcycle, riding in the rain or
riding in wet areas
11*Steering bearings• Check bearing play and steering
for roughness.√√√√√
• Lubricate with lithium-soap-
based grease.Every 20000 km (12000 mi)
12*Chassis fasteners• Make sure that all nuts, bolts and
screws are properly tightened.√√√√√
13Brake lever pivot
shaft• Lubricate with silicone grease.√√√√√
14Brake pedal pivot
shaft• Lubricate with silicone grease.√√√√√
15Clutch lever pivot
shaft• Lubricate with lithium-soap-
based grease.√√√√√
16 Sidestand• Check operation.
• Lubricate with lithium-soap-
based grease.√√√√√
17*Sidestand switch• Check operation.√√√√√√
18*Front fork• Check operation and for oil leak-
age.√√√√ NO. 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)
U2BDE1E0.book Page 5 Tuesday, December 16, 2014 5:38 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-6
6
19*Shock absorber as-
sembly• Check operation and shock ab-
sorber for oil leakage.√√√√
20*Rear suspension re-
lay arm and con-
necting arm
pivoting points• Check operation.√√√√
• Lubricate with lithium-soap-
based grease.√√
21 Engine oil• Change.
• Check oil level and vehicle for oil
leakage.√√√√√√
22Engine oil filter ele-
ment• Replace.√√√
23*Cooling system• Check coolant level and vehicle
for coolant leakage.√√√√√
• Change coolant. Every 3 years
24*Front and rear
brake switches• Check operation.√√√√√√
25Moving parts and
cables• Lubricate.√√√√√
26*Throttle grip• Check operation.
• Check throttle grip free play, and
adjust if necessary.
• Lubricate cable and grip housing.√√√√√
27*Lights, signals and
switches• Check operation.
• Adjust headlight beam.√√√√√√ NO. 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)
U2BDE1E0.book Page 6 Tuesday, December 16, 2014 5:38 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-7
6
EAUM1891
TIPReplace the air filter element more frequently if you are riding in unusually wet or dusty areas.
Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinder, and change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
U2BDE1E0.book Page 7 Tuesday, December 16, 2014 5:38 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-8
6
EAU18773
Removing and installing pan-
elsThe panels shown need to be removed
to perform some of the maintenance
jobs described in this chapter. Refer to
this section each time a panel needs to
be removed and installed.
EAUM3580
Panel A
To remove the panelRemove the bolts and the quick fas-
tener, and then take the panel off.To install the panel
Place the panel in the original position,
and then install the bolts and the quick
fastener.
Panel B
To remove the panelRemove the bolts, and then take the
panel off.
1. Panel AZAUM1242
1
1. Panel BZAUM1243
1
1. Panel mounting bolt
2. Quick fastener
3. Panel A
3
ZAUM1239
U2BDE1E0.book Page 8 Tuesday, December 16, 2014 5:38 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-9
6 To install the panel
Place the panel in the original position,
and then install the bolts.
EAU19605
Checking the spark plugThe spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic main-
tenance and lubrication chart. In addi-
tion, the condition of the spark plug
can reveal the condition of the engine.
To remove the spark plug
1. Remove the spark plug cap.
2. Remove the spark plug as shown,
with the spark plug wrench includ-
ed in the owner’s tool kit.To check the spark plug
1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light
tan (the ideal color when the vehi-
cle is ridden normally).
TIPIf the spark plug shows a distinctly dif-
ferent color, the engine could be oper-
ating improperly. Do not attempt to
diagnose such problems yourself. In-
stead, have a Yamaha dealer check
the vehicle.2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if
necessary.
3. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifi-
cation.
1. Bolt
2. Panel B
1. Panel B
2. Center pin
2
ZAUM1240ZAUM1241
1. Spark plug cap
2. Spark plug wrench
Specified spark plug:
NGK/CR7E
U2BDE1E0.book Page 9 Tuesday, December 16, 2014 5:38 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-10
6
To install the spark plug
1. Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
2. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
TIPIf a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is 1/4…
1/2 turn past finger tight. However, the
spark plug should be tightened to the
specified torque as soon as possible.3. Install the spark plug cap.
EAUB1567
Engine oil and oil filter ele-
mentThe engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart.
To check the engine oil level
1. Place the vehicle on a level sur-
face and hold it in an upright posi-
tion.TIPMake sure that the vehicle is posi-
tioned straight up when checking the
oil level. A slight tilt to the side can re-
sult in a false reading.2. Start the engine, warm it up for
10…15 minutes, and then turn it off.
3. Remove the oil filler cap, wipe the
dipstick clean, insert it back into
the oil filler hole (without screwing
it in), and then remove it again to
check the oil level. WARNING!
Never remove the engine oil fill-
er cap after high-speed opera-
1. Spark plug gapSpark plug gap:
0.7–0.8 mm (0.028–0.031 in)
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf, 9.04 ft·lbf)
1
ZAUM0037
U2BDE1E0.book Page 10 Tuesday, December 16, 2014 5:38 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-11
6 tion, otherwise hot engine oil
could spout out and cause dam-
age or injury. Always let the en-
gine oil cool down sufficiently
before removing the oil filler
cap.
[EWA17640]
TIPThe engine oil tank is located in-
side of the frame.
The engine oil should be between
the minimum and maximum level
marks.4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raiseit to the correct level. NOTICE: Do
not operate the vehicle until you
know that the engine oil level is
sufficient.
[ECA10012]
5. Install the oil filler cap.
To change the engine oil (with or
without oil filter element replace-
ment)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Remove the engine guard by re-
moving the screws.
3. Place an oil pan under the engine
to collect the used oil.4. Remove the engine oil filler cap
and the drain bolt to drain the oil
from the crankcase.
5. Remove the drain bolt to drain the
oil from the oil tank.
1. Engine oil filler cap
2. Maximum level mark
3. Minimum level mark
1. Screw
2. Engine guard
1. Engine oil drain bolt (crankcase)
1. Engine oil drain bolt (oil tank)ZAUM1262ZAUM1263
U2BDE1E0.book Page 11 Tuesday, December 16, 2014 5:38 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-12
66. Remove the oil filter element drain
bolt to drain the oil from the oil fil-
ter element.
TIPSkip steps 7…9 if the oil filter element is
not being replaced.7. Remove the oil filter element cover
by removing the bolts.
8. Remove and replace the oil filter
element and O-rings.TIPMake sure that the O-rings are properly
seated.
9. Install the oil filter element cover
by installing the bolts.
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.
12. Install the engine oil drain bolts,
and then tighten them to their
specified torques.13. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.
NOTICE
ECAM1063
The engine oil tank must be filled in
2 steps. First, fill the engine oil tank
with 1.90 L (2.0 US qt, 1.67 Imp.qt) of
the recommended engine oil. Then,
start the engine, race it 5 or 6 times,
turn it off, and then add the remain-
der of the engine oil.
1. Oil filter element drain bolt
2. Oil filter element cover bolt
1. Oil filter element
2. O-ringTightening torques:
Oil filter element cover bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil filter element drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Tightening torques:
Engine oil drain bolt (crankcase):
30 Nm
Engine oil drain bolt (oil tank):
18 Nm
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element replace-
ment:
2.50 L (2.64 US qt, 2.20 Imp.qt)
With oil filter element replacement:
2.60 L (2.75 US qt, 2.29 Imp.qt)
U2BDE1E0.book Page 12 Tuesday, December 16, 2014 5:38 PM