YAMAHA XT660Z 2010 Service Manual

ECA10260CAUTION:
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
distances. 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.
EAU16810
Tips for reducing fuel
consumption
Fuel 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).
EAU16841
Engine break-in
There is never a more important peri-
od in the life of your engine than the
period between 0 and 1600 km (1000
mi). For this reason, you should read
the following 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 them-
selves to the correct operating clear-
ances. During this period, prolonged
full-throttle operation or any condition
that might result in engine overheating
must be avoided.
OPERATION AND IMPORTANT RIDING POINTS
6-3
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EAU17101
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
element replaced.
1000-1600 km (600-1000 mi)
Avoid prolonged operation above
6000 r/min.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.
ECA10310NOTICE
Keep the engine speed out of
the tachometer red zone.
If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the
vehicle.
EAU17213
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EWA10311
WARNING0
Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them and be burned.
Do not park on a slope or on
soft ground, otherwise the ve-
hicle may overturn, increasing
the risk of a fuel leak and fire.
Do not park near grass or other
flammable materials which
might catch fire.
OPERATION AND IMPORTANT RIDING POINTS
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PERIODIC MAINTENANCE AND ADJUSTMENT
EAU17241
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 and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, depending on the
weather, terrain, geographical loca-
tion, and individual use, the mainte-
nance intervals may need to be short-
ened.
EWA10321
WARNING0
Failure to properly maintain the ve-
hicle or performing maintenance
activities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle
service, have a Yamaha dealer per-
form service.
EAU17391
Owner’s tool kit
1. Owner’s tool kit
The owner’s tool kit is located under
the seat. (See page 4-14).
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.
TIP
If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
7-1
EWA15121
WARNING0
Turn off the engine when perform-
ing 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 servicing
can lead to eye injury, burns, fire, or
carbon monoxide poisoning - pos-
sibly leading to death. See page 2-2
for more information about carbon
monoxide.
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PERIODIC MAINTENANCE AND ADJUSTMENT
EAU46861
TIP
●The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.
●From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
●Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and tech-
nical skills.
EAU46910Periodic maintenance chart for the emission control system
7-2
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10
NO. ITEM CHECK OR MAINTENANCE JOB
ODOMETER READING
1000 km 10000 km 20000 km 30000 km 40000 km(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
ANNUAL
CHECK
√√ √√ √
√√
√√
√√
√√√ √√ √
√√√ √√
√√ √√ √1✻
2
3
✻
4✻
5✻
6✻
Check fuel hoses for cracks or damage.
Check condition.
Clean and regap.
Replace.
Check valve clearance.
Adjust.
Adjust engine idling speed.
Check the screw clamp(s) for
looseness.
Check the air cut-off valve, reed valve,
and hose for damage.
Replace any damaged parts if necessary. Fuel line
Spark plug
Valves
Fuel injection
Muffler and exhaust
pipe
Air induction system
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-3
NO. ITEM CHECK OR MAINTENANCE JOB
ODOMETER READING
1000 km 10000 km 20000 km 30000 km 40000 km(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
ANNUAL
CHECK
√√
√√√ √√
√√√
√√
√
√√√ √√ √
√√ √√ √
√√ √√
√√ √√ √
√√ √√1
2
3
✻
4✻
5✻
6✻
7✻
8✻
Replace.
Check operation.
Adjust.
Check operation, fluid level and vehicle
for fluid leakage.
Replace brake pads.
Check operation, fluid level and vehicle
for fluid leakage.
Replace brake pads.
Check for cracks or damage.
Replace.
Check runout, spoke tightness and
for damage.
Tighten spokes if necessary.
Check tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.
Check bearing for looseness or damage. Air filter element
Clutch
Front brake
Rear brake
Brake hoses
Wheels
Tires
Wheel bearings
EAU1770C
General maintenance and lubrication chart
Whenever worn to the limit
Whenever worn to the limit
Every 4 years
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-4
1
2
3
4
5
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7
8
9
10
NO. ITEM CHECK OR MAINTENANCE JOB
ODOMETER READING
1000 km 10000 km 20000 km 30000 km 40000 km(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
ANNUAL
CHECK
√√ √√
√√√ √√
√√
√√
√
√√ √√ √
√√√ √√ √
√√ √√
√√ √√
√√ √√
√√
√√√ √√ √
13
14
✻
15✻
16✻
18
Check operation and for excessive play.
Lubricate with lithium-soap-based grease.
Check chain slack, alignment and condition.
Adjust and lubricate chain with a special
O-ring chain lubricant thoroughly.
Check bearing play and steering
for roughness.
Lubricate with lithium-soap-based grease.
Make sure that all nuts, bolts and screws
are properly tightened.
Check operation.
Lubricate.
Check operation.
Check operation and for oil leakage.
Check operation and shock absorber
for oil leakage.
Check operation.
Lubricate with lithium-soap-based grease.
Change.
Check oil level and vehicle for oil leakage. Swingarm
Drive chain
Steering bearings
Chassis fasteners
Sidestand
Sidestand switch
Front fork
Shock absorber
assembly
Rear suspension
relay arm and
connecting arm
pivoting points
Engine oil
Every 50000 km (30000 mi) Every 50000 km (30000 mi)
Every 500 km (300 mi) and after
washing the motorcycle or riding
in the rain
9✻
11✻
17✻
12✻
10
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-57-5
EAUM1890
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.
NO. ITEM CHECK OR MAINTENANCE JOB
ODOMETER READING
1000 km 10000 km 20000 km 30000 km 40000 km(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
ANNUAL
CHECK
√√ √
√√ √√ √
√√√ √√ √
√√ √√ √
√√ √√ √
√√√ √√ √ Replace.
Check coolant level and vehicle for coolant leakage.
Change.
Check operation.
Lubricate.
Check operation and free play.
Adjust the throttle cable free play
if necessary.
Lubricate the throttle grip housing
and cable.
Check operation.
Adjust headlight beam. Engine oil filter
element
Cooling system
Front and rear brake
switches
Moving parts and
cables
Throttle grip housing
and cable
Lights, signals and
switches
Every 3 years
19
22 20
✻
21✻
24✻
23✻
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PERIODIC MAINTENANCE AND ADJUSTMENT
EAU18722
Removing and installing the
cowling and panels
The cowling and panels shown need
to be removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each
time the cowling or a panel needs to
be removed and installed.
EAUB1540
Panel A and B
1. Panel mounting bolt
A. Right panel
B. Left panel
To remove one of the panels
Remove the bolts, and then pull the
panel off at the areas shown.
Panel C and D
1. Panel mounting bolt
C. Right panel
D. Left panel
To remove one of the panels
Remove the bolts, and then pull the
panel off at the areas shown.
To install the panel
Place the panel in the original position,
and then install the bolts.
7-6
1
2
3
4
5
6
7
8
9
10
1. Panel
2. Turn signal light coupler
3. Pin
To install the panel
Place the panel in the original position,
and then install the bolts.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-7
Panel E and F
1. Panel mounting bolt
2. Quick fastener
E. Right panel
F. Left panel
To remove one of the panels
1. Remove the bolts.
2. Remove the quick fastener and then
pull the panel off at the areas
shown.
To install the panel
1. Place the panel in the original posi-
tion.
2. Install the quick fastener and the
bolts.
11
2E-F
Panel G
1. Panel mounting bolt
G. Panel
To remove the panel
Remove the bolts, and then pull the
panel off at the areas shown.
1. Panel
2. Pin
To install the panel
Place the panel in the original position,
and then install the bolts.
2
2
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-8
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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).
TIP
If the spark plug shows a distinctly dif-
ferent color, the engine could be oper-
ating improperly. Do not attempt to di-
agnose such problems yourself.
Instead, have a Yamaha dealer check
the vehicle.
2. Check the spark plug for elec-
trode erosion and excessive car-
bon or other deposits, and re-
place it if necessary.
Specified spark plug:
CR7E (NGK)
Spark plug gap:
0.7-0.8 mm (0.028-0.032 in)
To install the spark plug
1. Measure the spark plug gap with
a wire thickness gauge and, if
necessary, adjust the gap to
specification.
1. Spark plug gap
2. Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
EAU19603
Checking the spark plug
The 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 peri-
odic maintenance and lubrication
chart. In addition, the condition of the
spark plug can reveal the condition of
the engine.
To remove the spark plug
1. Spark plug cap
2. Spark plug wrench
1. Remove the spark plug cap.
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