clutch YAMAHA XT660Z 2008 User Guide

PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
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NOTE:
If the specified clutch lever free play
could be obtained as described above,
tighten the locknut and skip the rest of
the procedure, otherwise proceed as
follows. 3. Fully turn the adjusting bolt at the clutch lever in direction (a) to
loosen the clutch cable.
4. Loosen the locknut at the crankcase.
1. Locknut
2. Clutch lever free play adjusting nut(crankcase)
5. To increase the clutch lever free
play, turn the adjusting nut in di-
rection (a). To decrease the clutch
lever free play, turn the adjusting
nut in direction (b).
6. Tighten the locknut at the clutch lever and the crankcase.

1
b
a
2

EAU22041
Adjusting the clutch lever
free play
1. Locknut
2. Adjusting bolt
3. Clutch lever free play
The clutch lever free play should mea-
sure 10.0-15.0 mm (0.39-0.59 in) as
shown. Periodically check the clutch
lever free play and, if necessary, ad-
just it as follows.1. Loosen the locknut at the clutch lever.
2. To increase the clutch lever free play, turn the adjusting bolt in di-
rection (a). To decrease the clutch
lever free play, turn the adjusting
bolt in direction (b).

31
2
b
a

XT660Z 04-06 ING 11-03-2008 8:31 Pagina 6-20

PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
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The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
Recommended lubricants: Brake lever:Silicone grease
Clutch lever: Lithium-soap-based grease
(all-purpose grease)
EAU23111
Checking and lubricating
the throttle grip and cable
The operation of the throttle grip
should be checked before each ride. In
addition, the cable should be lubricat-
ed at the intervals specified in the pe-
riodic maintenance chart.
EAU23141
Checking and lubricating
the brake and clutch levers
Brake lever
Clutch lever

XT660Z 04-06 ING 11-03-2008 8:31 Pagina 6-26

SPECIFICATIONS
8-1
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Engine oil:Type: SAE10W30 or SAE10W40 or SAE15W40
or SAE20W40 or SAE20W50
Recommended engine oil grade: API service SE, SF, SG type or higher
Engine oil quantity: Without oil filter element replacement:2.50 L (2.64 US qt) (2.19 Imp.qt)
With oil filter element replacement: 2.60 L (2.73 US qt) (2.26 Imp.qt)
Total amount (dry engine): 2.90 L (3.07 US qt) (2.55 Imp.qt)
Cooling system:Radiator capacity (including all routes): 1.2 L (1.26 US qt) (1.05 Imp.qt) (Radiator) +
0.5 L (0.52 US qt) (0.44 Imp.qt)
(Coolant reservoir)
Coolant reservoir capacity (up to the
maximum level mark): 0.50 L (0.52 US qt) (0.44 Imp.qt)
From low to full level: 0.30 L (0.32 US qt) (0.26 Imp.qt)
Air filter:Air filter element:Paper
Fuel:Recommended fuel:Premium unleaded gasoline only
Fuel tank capacity: 23.0 L (6.07 US gal) (5.06 Imp.gal)
Fuel reserve amount: 6.7 L (1.76 US gal) (1.46 Imp.gal)
Fuel injection:Manufacturer:DENSO
Model: 297500-0390
Spark plug:Manufacturer/model:NGK/CR7EGap:0.7-0.8 mm (0.028-0.032 in)
Clutch:Clutch type:Wet, multiple-disc
Transmission:Primary reduction system:Spur gear
Primary reduction ratio: 75/36 (2.083)
Secondary reduction system: Chain drive
Secondary reduction ratio: 45/15 (3.00)
Transmission type: Constant mesh 5-speed
Dimensions:Overall length:2246 mm (88.42 in)
Overall width: 864 mm (34.01 in)
Overall height: 1477 mm (58.14 in)
Seat height: 896 mm (35.27 in)
Wheelbase: 1500 mm (59.05 in)
Ground clearance: 260 mm (10.23 in)
Minimum turning radius: 1958 mm (77.08 in)
Basic weight:With oil and fuel:208.5 kg (459 lb)
Engine:Engine type:Liquid cooled 4-stroke, SOHC
Cylinder arrangement: Forward-inclined single cylinder
Displacement: 660.0 cm
3(40.27 cu.in)
Bore x stroke: 100.0 x 84.0 mm (3.94 x 3.31 in)
Compression ratio: 10.00 : 1
Starting system: Electric starter
Lubrication system: Dry sump
-20 -10 0 10 20 30 40 50 °C
SAE 10W-30
SAE 10W-40
SAE 20W-40
SAE 20W-50
SAE 15W-40

XT660Z 07-10 ING 11-03-2008 8:33 Pagina 6

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INDEX
AAir filter element, cleaning the check hose....................................6-14
Air filter element, replacing ..............6-14
Anti-theft alarm (optional)...................3-8
Auxiliary light bulb, replacing............6-35
B Battery ..............................................6-30 To access the battery ...................6-30
To charge the battery....................6-30
To store the battery.......................6-31
Brake and clutch levers, checking and lubricating ...............6-26
Brake fluid ........................................6-22 Changing ......................................6-23
Checking fluid level .......................6-22
Brake lever .......................................3-11
Brake pads, checking .......................6-21
Brake pedal ......................................3-11 Lubricating ....................................6-27
C Cables, checking and lubricating .....6-25
Care and storage ...............................7-1
Catalytic converter ...........................3-13
Checking and lubricating the brake and clutch levers .................6-26
Checking and lubricating the brake pedal ...................................6-27
Checking and lubricating the cables ...........................................6-25 Checking and lubricating the
sidestand ......................................6-27
Checking and lubricating the throttle grip and cable ...................6-26
Checking the sidestand switch .........3-18
Clock mode ........................................3-7
Clutch lever ......................................3-10
Clutch lever free play, adjusting .......6-20
Consumer information ........................9-1
Controls and instruments ...................2-3
Function ..........................................3-1
Coolant .............................................6-12
Coolant temperature warning light .....3-4
D Description .........................................2-1 Controls and instrument .................2-3
Left view..........................................2-1
Right view .......................................2-2
Dimmer switch....................................3-9
Drive chain, cleaning and lubricating .....................................6-25
Drive chain slack ..............................6-23 Adjusting .......................................6-23
Checking .......................................6-23
Cleaning and lubricating ...............6-25
E Engine break-in ..................................5-3
Engine idling speed, adjusting .........6-15
Engine oil and oil filter element ..........6-9
Engine oil filter element....................6-10 Engine stop switch .............................3-9
Engine trouble warning light...............3-4
F Front fork ..........................................3-15 Adjusting .......................................3-15
Checking .......................................6-28
Front wheel ......................................6-36 Installing........................................6-37
Removing......................................6-36
Fuel ..................................................3-12
Fuel consumption, tips for reducing ...5-3
Fuel meter ..........................................3-7
Fuel tank breather hose ...................3-13
Fuel tank cap ...................................3-11
Fuses, replacing ...............................6-31
H Handlebar switches ............................3-9 Dimmer switch ................................3-9
Engine stop switch ..........................3-9
Hazard switch ...............................3-10
Horn switch .....................................3-9
Pass switch .....................................3-9
Start switch .....................................3-9
Turn signal switch ...........................3-9
Headlight bulb, replacing..................6-33
High beam indicator light ...................3-4
Horn switch ........................................3-9
I Identification numbers ........................9-1
Idling speed, checking .....................6-15

XT660Z 07-10 ING 11-03-2008 8:33 Pagina 1

INDEX
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Ignition circuit cut-off system............3-17 Checking operation procedure......3-18
Immobilizer system ............................3-1
Immobilizer system indicator light ......3-4
Indicator and warning lights ...............3-3 Coolant temperature warning
light .................................................3-4
Engine trouble warning light ...........3-4
High beam indicator light ................3-4
Immobilizer system indicator light...3-4
Neutral indicator light ......................3-4
Turn signal indicator light ................3-3
Instruments ........................................2-3
Instrument and control functions........3-1
K Key identification number ...................9-1
Keys ...................................................3-1
L License plate light bulb, replacing ....6-35
Lubricating the brake and clutch levers ..................................6-26
Lubricating the brake pedal..............6-27
Lubricating the cables ......................6-25
Lubricating the drive chain ...............6-25
Lubricating the sidestand .................6-27
Lubricating the throttle grip and cable .............................................6-26
Lubricating the swingarm pivots.......6-28
M Main switch/steering lock ...................3-2 Model label .........................................9-2
Multi-function display..........................3-5
Clock mode .....................................3-7
Self-diagnosis devices ....................3-7
Tachometer .....................................3-6
Tripmeter and tachometer modes ...3-6
N Neutral indicator light .........................3-4
O Oil filter element ...............................6-10
Operation and important riding points ..............................................5-1
Owner’s tool kit...................................6-1
P Panels, removing and installing .........6-6
Parking ...............................................5-4
Pass switch ........................................3-9
Periodic maintenance and lubrication chart ..............................6-2
Periodic maintenance and minor repair...............................................6-1
Pre-operation check list......................4-2
Pre-operation checks .........................4-1
R Rear suspension, lubricating............6-27
Rear wheel .......................................6-38 Installing........................................6-39
Removing......................................6-38
Record the identification numbers .....9-1 S
Safety information ..............................1-1
Seat ..................................................3-14
Self-diagnosis devices .......................3-7
Shift pedal ........................................3-10
Shifting ...............................................5-2
Shock absorber assembly (adjusting) .....................................3-16
Sidestand .........................................3-17
Sidestand, checking and lubricating .....................................6-27
Sidestand switch, checking ..............3-18
Spark plug, checking..........................6-8
Specifications .....................................8-1
Spoke wheels ...................................6-19
Start switch ........................................3-9
Starting the engine.............................5-1
Steering, checking............................6-29
Steering lock ......................................3-2
Storage...............................................7-3
Supporting the motorcycle ...............6-36
Swingarm, lubricating the pivots ......6-28
T Tachometer ........................................3-6
Tail/brake light ..................................6-34
Throttle cable free play, checking.....6-16
Throttle grip and cable, checking and lubricating ..............................6-26
Tips for reducing fuel consumption ....5-3
Tires .................................................6-16 Air pressure ..................................6-16

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