2015 YAMAHA XT660Z service

INSTRUMENT AND CONTROL FUNCTIONS
3-18
3
EAUB1463
Adjusting the shock absorber
assemblyThis shock absorber assembly is
equipped with a spring preload adjust-
ing ring.NOTICE
ECA10102
To avoid damaging the mechanism,
do not attempt to turn beyond the
maximum or minimum settings.Adjust the spring preload as follows.
To increase the spring preload and
thereby harden the suspension, turn
the adjusting ring in direction (a). To
decrease the spring preload and there-
by soften the suspension, turn the ad-
justing ring in direction (b).TIPAlign the appropriate notch in the ad-
justing ring with the position indicator
on the shock absorber.
WARNING
EWAB0021
Never adjust the spring preload until
the exhaust system has cooled
down.
WARNING
EWA10222
This shock absorber assembly con-
tains highly pressurized nitrogen
gas. Read and understand the fol-
lowing information before handling
the shock absorber assembly.
Do not tamper with or attempt
to open the cylinder assembly.
Do not subject the shock ab-
sorber assembly to an open
flame or other high heat source.
This may cause the unit to ex-
plode due to excessive gas
pressure.
Do not deform or damage the
cylinder in any way. Cylinder
damage will result in poor
damping performance.
Do not dispose of a damaged or
worn-out shock ab
sorber as-
sembly yourself. Take the shock
absorber assembly to a Yamaha
dealer for any service.
1. Spring preload adjusting ring
2. Position indicator
Spring preload setting:
Minimum (soft):
1
Standard:
2
Maximum (hard):
9
U2BDE1E0.book Page 18 Tuesday, December 16, 2014 5:38 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-1
6
EAU17245
Periodic inspection, adjustment, and
lubrication will keep your vehicle in the
safest and most efficient condition
possible. Safety is an obligation of the
vehicle owner/operator. The most im-
portant points of vehicle inspection,
adjustment, and lubrication are ex-
plained on the following pages.
The intervals given in the periodic
maintenance charts should be simply
considered as a general guide under
normal riding conditions. However, de-
pending on the weather, terrain, geo-
graphical location, and individual use,
the maintenance intervals may need to
be shortened.
WARNING
EWA10322
Failure to properly maintain the vehi-
cle or performing maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha dealer perform
service.
WARNING
EWA15123
Turn off the engine when performing
maintenance unless otherwise
specified.
A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.
Running the engine while ser-
vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 1-2 for more in-
formation about carbon monox-
ide.
WARNING
EWA15461
Brake discs, calipers, drums, and
linings can become very hot during
use. To avoid possible burns, let
brake components cool before
touching them.
EAU17303
Emission controls not only function to
ensure cleaner air, but are also vital to
proper engine operation and maximum
performance. In the following periodic
maintenance charts, the services relat-
ed to emissions control are grouped
separately. These services require
specialized data, knowledge, and
equipment. Maintenance, replace-
ment, or repair of the emission control
devices and systems may be per-
formed by any repair establishment or
individual that is certified (if applicable).
Yamaha dealers are trained and
equipped to perform these particular
services.
U2BDE1E0.book Page 1 Tuesday, December 16, 2014 5:38 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-2
6
EAU17382
Owner’s tool kitThe owner’s tool kit is located under
the seat. (See page 3-16.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.TIPIf you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.1. U2BDE1E0.book Page 2 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
6-24
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
U2BDE1E0.book Page 24 Tuesday, December 16, 2014 5:38 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-35
6
EAUM2203
Replacing the license plate
light bulb1. Remove the socket (together with
the bulb) by pulling it out.
2. Remove the burnt-out bulb by
pulling it out.
3. Insert a new bulb into the socket.
4. Install the socket (together with
the bulb) by pushing it in.
EAU24351
Supporting the motorcycleSince this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other mainte-
nance requiring the motorcycle to
stand upright. Check that the motorcy-
cle is in a stable and level position be-
fore starting any maintenance. A
strong wooden box can be placed un-
der the engine for added stability.
To service the front wheel
1. Stabilize the rear of the motorcy-
cle by using a motorcycle stand
or, if an additional motorcycle
stand is not available, by placing a
jack under the frame in front of the
rear wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor-
cycle stand is not available, by placinga jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
1. License plate light bulb socket
2. License plate light bulb
U2BDE1E0.book Page 35 Tuesday, December 16, 2014 5:38 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-39
6
EAU25872
TroubleshootingAlthough Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur
during operation. Any problem in the
fuel, compression, or ignition systems,
for example, can cause poor starting
and loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.
WARNING
EWA15142
When checking the fuel system, do
not smoke, and make sure there are
no open flames or sparks in the ar-
ea, including pilot lights from waterheaters or furnaces. Gasoline or
gasoline vapors can ignite or ex-
plode, causing severe injury or prop-
erty damage.
U2BDE1E0.book Page 39 Tuesday, December 16, 2014 5:38 PM

SPECIFICATIONS
8-1
8
Dimensions:Overall length:
2246 mm (88.4 in)
Overall width:
896 mm (35.3 in)
Overall height:
XT660Z 1477 mm (58.1 in)
XT660ZA 1450 mm (57.1 in)
Seat height:
XT660Z 896 mm (35.3 in)
XT660ZA 865 mm (34.1 in)
Wheelbase:
XT660Z 1500 mm (59.1 in)
XT660ZA 1505 mm (59.3 in)
Ground clearance:
XT660Z 260 mm (10.24 in)
XT660ZA 205 mm (8.07 in)
Minimum turning radius:
XT660Z 1958 mm (77.1 in)
XT660ZA 1980 mm (78.0 in)Weight:Curb weight:
XT660Z 206 kg (454 lb)
XT660ZA 215 kg (474 lb)Engine:Engine type:
Liquid cooled 4-stroke, SOHC
Cylinder arrangement:
Single cylinder
Displacement:
660 cm³
Bore × stroke:
100.0 × 84.0 mm (3.94 × 3.31 in)Compression ratio:
10.0 : 1
Starting system:
Electric starter
Lubrication system:
Dry sump
Engine oil:Recommended brand:
YAMALUBE
Type:
SAE 10W-30, 10W-40, 15W-40, 20W-40 or
20W-50
Recommended engine oil grade:
API service SE type or higher, JASO
standard MA
Engine oil quantity:
Without oil filter element replacement:
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)
Coolant quantity:Coolant reservoir (up to the maximum level
mark):
0.50 L (0.53 US qt, 0.44 Imp.qt)
Radiator (including all routes):
1.70 L (1.80 US qt, 1.50 Imp.qt)Air filter:Air filter element:
Dry elementFuel:Recommended fuel:
Premium unleaded gasoline only
Fuel tank capacity:
23.0 L (6.07 US gal, 5.06 Imp.gal)
Fuel reserve amount:
XT660Z 6.7 L (1.77 US gal, 1.47 Imp.gal)
XT660ZA 5.8 L (1.53 US gal, 1.28 Imp.gal)Fuel injection:Throttle body:
ID mark:
5YK2 11Spark plug(s):Manufacturer/model:
NGK/CR7E
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)Clutch:Clutch type:
Wet, multiple-discTransmission:Primary reduction ratio:
75/36 (2.083)
Final drive:
Chain
–20 –10 0
1020 30 40 50 C 10 30 50 70 90 110 0 130 F
SAE 10W-30
SAE 15W-40SAE 20W-40SAE 20W-50
SAE 10W-40SAE 10W-50
U2BDE1E0.book Page 1 Tuesday, December 16, 2014 5:38 PM