2015 YAMAHA XT660Z oil filter

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

DESCRIPTION
2-1
2
EAU32221
Left viewXT660Z1. Idle adjusting screw (page 6-16)
2. Owner’s tool kit (page 6-2)
3. Air filter element (page 6-14)
4. Fuse box 1 (page 6-31)
5. Seat lock (page 3-16)
6. Shock absorber assembly spring preload adjusting ring (page 3-18)
7. Shift pedal (page 3-11)8. Engine oil drain bolt (crankcase) (page 6-10)
9. Engine oil drain bolt (oil tank) (page 6-10)
U2BDE1E0.book Page 1 Tuesday, December 16, 2014 5:38 PM

DESCRIPTION
2-3
2
EAU32231
Right viewXT660Z
1
2
3
4
5
6
7
8
9
1. Grab bar
2. Main fuse (page 6-31)
3. Battery (page 6-29)
4. Rear brake fluid reservoir (page 6-21)
5. Coolant reservoir (page 6-13)
6. Front brake fluid reservoir (page 6-21)
7. Coolant drain bolt (page 6-14)8. Engine oil filter element (page 6-10)
9. Brake pedal (page 3-11)
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DESCRIPTION
2-4
2XT660ZA
12 3 4 5 6
7 8 9 10
1. Rear brake fluid reservoir (page 6-21)
2. Fuse box 2 (page 6-31)
3. Owner’s tool kit (page 6-2)
4. Coolant reservoir (page 6-13)
5. Battery (page 6-29)
6. Front brake fluid reservoir (page 6-21)
7. Coolant drain bolt (page 6-14)
8. Engine oil filter element (page 6-10)
9. Brake pedal (page 3-11)10.Rear wheel hubU2BDE1E0.book Page 4 Tuesday, December 16, 2014 5:38 PM

OPERATION AND IMPORTANT RIDING POINTS
5-3
5
NOTICE
ECA10261
Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long dis-
tances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.
Always use the clutch while
changing gears to avoid dam-
aging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
EAU16811
Tips for reducing fuel con-
sumptionFuel consumption depends largely on
your riding style. Consider the follow-
ing tips to reduce fuel consumption:
Shift up swiftly, and avoid high en-
gine speeds during acceleration.
Do not rev the engine while shift-
ing down, and avoid high engine
speeds with no load on the en-
gine.
Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at traf-
fic lights or at railroad crossings).
EAU16842
Engine break-inThere is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the fol-
lowing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that
might result in engine overheating
must be avoided.
EAU17103
0–1000 km (0–600 mi)
Avoid prolonged operation above 4500
r/min. NOTICE: After 1000 km (600
mi) of operation, the engine oil must
be changed, and the oil filter ele-
ment replaced.
[ECA11152]
1000–1600 km (600–1000 mi)
Avoid prolonged operation above 6000
r/min.
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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)
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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
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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