2015 YAMAHA XT660Z brake pads

TABLE OF CONTENTSSAFETY INFORMATION.................. 1-1
DESCRIPTION.................................. 2-1
Left view ......................................... 2-1
Right view ....................................... 2-3
Controls and instruments ............... 2-5
INSTRUMENT AND CONTROL
FUNCTIONS...................................... 3-1
Immobilizer system......................... 3-1
Main switch/steering lock............... 3-2
Indicator lights and warning
lights............................................ 3-4
Multi-function display ..................... 3-6
Handlebar switches ........................ 3-9
Clutch lever .................................. 3-10
Shift pedal .................................... 3-11
Brake lever.................................... 3-11
Brake pedal .................................. 3-11
ABS (for ABS models) .................. 3-12
Fuel tank cap ................................ 3-13
Fuel ............................................... 3-13
Fuel tank breather/overflow
hose .......................................... 3-15
Catalytic converter ....................... 3-15
Seat .............................................. 3-16
Adjusting the front fork ................. 3-16
Adjusting the shock absorber
assembly ................................... 3-18
Sidestand ..................................... 3-19
Ignition circuit cut-off system ....... 3-19FOR YOUR SAFETY –
PRE-OPERATION CHECKS............. 4-1
OPERATION AND IMPORTANT
RIDING POINTS................................ 5-1
Starting the engine .......................... 5-1
Shifting ............................................ 5-2
Tips for reducing fuel
consumption ................................ 5-3
Engine break-in ............................... 5-3
Parking ............................................ 5-4
PERIODIC MAINTENANCE AND
ADJUSTMENT................................... 6-1
Owner’s tool kit ............................... 6-2
Periodic maintenance chart for the
emission control system .............. 6-3
General maintenance and
lubrication chart ........................... 6-4
Removing and installing panels ...... 6-8
Checking the spark plug ................. 6-9
Engine oil and oil filter element ..... 6-10
Coolant.......................................... 6-13
Replacing the air filter element
and cleaning the check hose..... 6-14
Adjusting the engine idling
speed ......................................... 6-16
Checking the throttle grip free
play ............................................ 6-16
Valve clearance ............................. 6-17
Tires .............................................. 6-17Spoke wheels ............................... 6-19
Adjusting the clutch lever free
play ............................................ 6-20
Checking the front and rear brake
pads .......................................... 6-21
Checking the brake fluid level ...... 6-21
Changing the brake fluid .............. 6-23
Drive chain slack........................... 6-23
Cleaning and lubricating the drive
chain.......................................... 6-24
Checking and lubricating the
cables ........................................ 6-25
Checking and lubricating the
throttle grip and cable ............... 6-25
Checking and lubricating the
brake and clutch levers ............. 6-26
Checking and lubricating the
brake pedal ............................... 6-26
Checking and lubricating the
sidestand................................... 6-27
Lubricating the rear suspension ... 6-27
Lubricating the swingarm
pivots......................................... 6-27
Checking the front fork ................. 6-28
Checking the steering................... 6-28
Checking the wheel bearings ....... 6-29
Battery .......................................... 6-29
Replacing the fuses ...................... 6-31
Replacing a headlight bulb ........... 6-32
Replacing an auxiliary light bulb ... 6-34
Tail/brake light .............................. 6-34U2BDE1E0.book Page 1 Tuesday, December 16, 2014 5:38 PM

FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-1
4
EAU15599
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner’s Manual.
WARNING
EWA11152
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in
this manual, have the vehicle inspected by a Yamaha dealer.Before using this vehicle, check the following points:
ITEM CHECKS PAGE
Fuel• Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.
• Check fuel tank breather hose and overflow hose for obstructions, cracks or
damage, and check hose connections.3-13, 3-15
Engine oil• Check oil level in oil tank.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage.6-10
Coolant• Check coolant level in reservoir.
• If necessary, add recommended coolant to specified level.
• Check cooling system for leakage.6-13
Front brake• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check lever free play.
• Adjust if necessary.
• 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
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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
6-21
6
EAU22393
Checking the front and rear
brake padsThe front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU22421
Front brake pads
Each front brake pad is provided with a
wear indicator groove, which allows
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator groove. If a brake
pad has worn to the point that the wearindicator groove has almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
EAU22501
Rear brake pads
Check each rear brake pad for damage
and measure the lining thickness. If a
brake pad is damaged or if the lining
thickness is less than 3.8 mm, have a
Yamaha dealer replace the brake pads
as a set.
EAUM3570
Checking the brake fluid levelBefore riding, check that the brake fluid
is above the minimum level mark.
Check the brake fluid level with the top
of the reservoir level. Replenish the
brake fluid if necessary.
Front brake
1. Wear indicator groove
1. Lining thickness
1
ZAUM1253
1. Minimum level mark
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-22
6Rear brake (for XT660Z)
Rear brake (for XT660ZA)
TIPThe rear brake fluid reservoir is located
under the seat. (See page 3-16.)
WARNING
EWA16011
Improper maintenance can result in
loss of braking ability. Observe
these precautions:
Insufficient brake fluid may al-
low air to enter the brake sys-
tem, reducing braking
performance.
Clean the filler cap before re-
moving. Use only DOT 4 brake
fluid from a sealed container.
Use only the specified brake flu-
id; otherwise, the rubber seals
may deteriorate, causing leak-
age.
Refill with the same type of
brake fluid. Adding a brake fluid
other than DOT 4 may result in a
harmful chemical reaction.
Be careful that water or dust
does not enter the brake fluid
reservoir when refilling. Water
will significantly lower the boil-
ing point of the fluid and may re-sult in vapor lock, and
dirt may
clog the ABS hydraulic unit
valves.
NOTICE
ECA17641
Brake fluid may damage painted
surfaces or plastic parts. Always
clean up spilled fluid immediately.As the brake pads wear, it is normal for
the brake fluid level to gradually go
down. A low brake fluid level may indi-
cate worn brake pads and/or brake
system leakage; therefore, be sure to
check the brake pads for wear and the
brake system for leakage. If the brake
fluid level goes down suddenly, have a
Yamaha dealer check the cause before
further riding.
1. Minimum level mark
1. Minimum level mark
Specified brake fluid:
DOT 4
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-36
6
EAU44792
Front wheel (for non-ABS
models)
WARNING
EWA14841
For the ABS model, have a Yamaha
dealer remove and install the wheel.
EAU56480
To remove the front wheel
WARNING
EWA10822
To avoid injury, securely support the
vehicle so there is no danger of it
falling over.1. Loosen the front wheel axle pinch
bolts, the wheel axle and the
brake caliper bolts.2. Lift the front wheel off the ground
according to the procedure in the
previous section “Supporting the
motorcycle”.
3. Remove the brake caliper on each
side by removing the bolts.
NOTICE: Do not apply the brake
after the brake calipers have
been removed, otherwise the
brake pads will be forced shut.
[ECA11052]
4. Pull the wheel axle out, and then
remove the wheel.To install the front wheel
1. Lift the wheel up between the fork
legs.
2. Insert the wheel axle.
3. Install the brake calipers by install-
ing the bolts.
TIPMake sure that there is enough space
between the brake pads before install-
ing the brake calipers onto the brake
discs.4. Lower the front wheel so that it is
on the ground.
5. Tighten the wheel axle and the
brake caliper bolts to the specified
torques.NOTICE
ECAB0062
Be sure the right brake disc is posi-
tioned exactly between the brake
pads to prevent any brake drag. Tap
the side of the right fork leg to posi-
tion the disc correctly.6. Tighten wheel axle pinch bolt A,
and then pinch bolt B to their
specified torque.
1. Wheel axle
2. Brake caliper bolt
3. Front wheel axle pinch boltZAUM1266
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-38
6
6. Remove the drive chain from the
rear sprocket.
TIPIf the drive chain is difficult to re-
move, remove the wheel axle first,
and then lift the wheel upward
enough to remove the drive chain
from the rear sprocket.
The drive chain cannot be disas-
sembled.7. While supporting the brake caliper
bracket, pull the wheel axle out,
and then remove the wheel.
NOTICE: Do not apply the brakeafter the wheel and brake disc
have been removed, otherwise
the brake pads will be forced
shut.
[ECA11073]
To install the rear wheel
1. Install the wheel and the brake cal-
iper bracket by inserting the wheel
axle from the left-hand side.TIPMake sure that the slot in the
brake caliper bracket is fit over the
retainer on the swingarm.
Make sure that there is enough
space between the brake pads
before installing the wheel.2. Install the drive chain onto the rear
sprocket.
3. Install the axle nut, and then lower
the rear wheel so that it is on the
ground.
4. Adjust the drive chain slack. (See
page 6-23.)
5. Apply the rear brake several times,
and then tighten the axle nut to the
specified torque.
1. Wheel axle
2. Drive chain slack adjusting bolt
3. Locknut
4. Brake caliperZAUM1268
Tightening torque:
Axle nut:
104 Nm
U2BDE1E0.book Page 38 Tuesday, December 16, 2014 5:38 PM