warning YAMAHA XT660Z 2008 Owner's Manual

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
EWA11020
WARNING0
Because loading has an enormous
impact on the handling, braking,
performance and safety character-
istics of your motorcycle, you
should keep the following precau-
tions in mind.
●NEVER OVERLOAD THE MO-
TORCYCLE! Operation of an
overloaded motorcycle may re-
sult in tire damage, loss of con-
trol, or severe injury. Make sure
that the total weight of rider,
passenger, cargo, and acces-
sories does not exceed the
specified maximum load for the
vehicle.
●Do not carry along loosely
packed items, which can shift
during a ride.
●Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.

Tire air pressure
(measured on cold tires):Up to 90 kg (198 lb):
Front:210 kPa (30 psi) (2.1 kgf/cm
2)
Rear: 230 kPa (33 psi) (2.3 kgf/cm
2)
90 kg (198 lb) to maximum load:
Front: 230 kPa (33 psi) (2.3 kgf/cm
2)
Rear: 250 kPa (36 psi) (2.5 kgf/cm
2)
Off-road riding:
Front: 200 kPa (29 psi) (2.0 kgf/cm
2)
Rear: 200 kPa (29 psi) (2.0 kgf/cm
2)
High-speed riding:
Front: 210 kPa (30 psi) (2.1 kgf/cm
2)
Rear: 230 kPa (33 psi) (2.3 kgf/cm
2)
Maximum load*: 190 kg (419 lb)
* Total weight of rider, passenger, cargo and accessories
●Adjust the suspension and tire
air pressure with regard to the
load.
●Check the tire condition and air
pressure before each ride.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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Tire information
This motorcycle is equipped with tube
tires.
EWA10460
WARNING0
●The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the vehicle
cannot be guaranteed.
●After extensive tests, only the
tires listed below have been
approved for this model by
Yamaha Motor Co., Ltd.

Tire inspection
1. Tire sidewall
2. Tire tread depth
The tires must be checked before
each ride. If the center tread depth
reaches the specified limit, if the tire
has a nail or glass fragments in it, or if
the sidewall is cracked, have a Yama-
ha dealer replace the tire immediately.

NOTE:
The tire tread depth limits may differ
from country to country. Always com-
ply with the local regulations.
Minimum tire tread depth
(front and rear): 1.6 mm (0.06 in)

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PERIODIC MAINTENANCE AND MINOR REPAIR
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Front tire:Size:90/90-21M/C 54S
90/90-21M/C 54T
Manufacturer/model: METZELER/TOURANCE
FRONT MICHELIN/SIRAC
Rear tire: Size:130/80-17M/C 65S
130/80-17M/C 65T
Manufacturer/model: METZELER/TOURANCE
MICHELIN/SIRAC A
EWA10570
WARNING0
●Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the mo-
torcycle with excessively worn
tires decreases riding stability
and can lead to loss of control.
●The replacement of all wheel-
and brake-related parts, in-
cluding the tires, should be left
to a Yamaha dealer, who has
the necessary professional
knowledge and experience.
●It is not recommended to patch
a punctured tube. If unavoid-
able, however, patch the tube
very carefully and replace it as
soon as possible with a high-
quality product.

EAU21940
Spoke wheels
To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points regard-
ing the specified wheels.
●The wheel rims should be
checked for cracks, bends or
warpage, and the spokes for
looseness or damage before
each ride. If any damage is found,
have a Yamaha dealer replace the
wheel. Do not attempt even the
smallest repair to the wheel. A de-
formed or cracked wheel must be
replaced.
●The wheel should be balancedwhenever either the tire or wheel
has been changed or replaced.
An unbalanced wheel can result
in poor performance, adverse
handling characteristics, and a
shortened tire life.
●Ride at moderate speeds afterchanging a tire since the tire sur-
face must first be "broken in" for it
to develop its optimal characteris-
tics.

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
EAU23022
Cleaning and lubricating
the drive chain
The 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.
ECA10581CAUTION:
The drive chain must be lubricated
after washing the motorcycle and
riding in the rain.
1. Clean the drive chain with kerosene and a small soft brush.
ECA11120CAUTION:
To prevent damaging the O-rings,
do not clean the drive chain with
steam cleaners, high-pressure
washers or inappropriate solvents. 2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
ECA11110CAUTION:
Do not use engine oil or any other
lubricants for the drive chain, as
they may contain substances that
could damage the O-rings.
EAU23100
Checking and lubricating
the cables
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubri-
cated if necessary. If a cable is dam-
aged or does not move smoothly, have
a Yamaha dealer check or replace it.
Recommended lubricant: Engine oil
EWA10720
WARNING0
Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions.

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
EAU23181
Lubricating the brake
pedal
The operation of the brake pedal
should be checked before each ride,
and the pedal pivot should be lubricat-
ed if necessary.
Recommended lubricant:Silicone grease
EAU23200
Checking and lubricating
the sidestand
The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated
if necessary.
EWA10730
WARNING0
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it.
Recommended lubricant:Lithium-soap-based grease
(all-purpose grease)
EAU23250
Lubricating the rear
suspension
The pivoting points of the rear suspen-
sion must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.
Recommended lubricant:Lithium-soap-based grease
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EAU23271
Checking the front fork
The condition and operation of the
front fork must be checked as follows
at the intervals specified in the period-
ic maintenance and lubrication chart.
To check the condition
EWA10750
WARNING0
Securely support the motorcycle so
that there is no danger of it falling
over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation 1. Place the motorcycle on a level surface and hold it in an upright
position.
2. While applying the front brake, push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.

ECA10590CAUTION:
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.

EAUM1650
Lubricating the swingarm
pivots
The swingarm pivots must be lubricat-
ed at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
Recommended lubricant: Lithium-soap-based grease

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PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU23280
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the opera-
tion of the steering must be checked
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.1. Place a stand under the engine to raise the front wheel off the
ground.
EWA10750
WARNING0
Securely support the motorcycle so
that there is no danger of it falling
over.

2. Hold the lower ends of the frontfork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.EAU23290
Checking the wheel bearings
The front and rear wheel bearings
must be checked at the intervals spec-
ified in the periodic maintenance and
lubrication chart. If there is play in the
wheel hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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EWA10760
WARNING0
●Electrolyte is poisonous and
dangerous since it contains
sulfuric acid, which causes se-
vere burns. Avoid any contact
with skin, eyes or clothing and
always shield your eyes when
working near batteries. In case
of contact, administer the fol-
lowing FIRST AID.
• EXTERNAL: Flush with plenty
of water.
• INTERNAL: Drink large quan-
tities of water or milk and im-
mediately call a physician.
• EYES: Flush with water for 15
minutes and seek prompt
medical attention.
●Batteries produce explosive hy-
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro-
vide sufficient ventilation when
charging it in an enclosed space.
●KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
EAUB1430
Battery
This model is equipped with a sealed-
type (MF) battery, which does not re-
quire any maintenance. There is no
need to check the electrolyte or to add
distilled water.
ECA10620CAUTION:
Never attempt to remove the bat-
tery cell seals, as this would perma-
nently damage the battery.
To access the battery
Remove the battery holder bracket by
removing the bolts.
1. Positive battery terminal
2. Negative battery terminal
To charge the battery
Have a Yamaha dealer charge the bat-
tery as soon as possible if it seems to
have discharged. Keep in mind that
the battery tends to discharge more
quickly if the vehicle is equipped with
optional electrical accessories.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
EAUB1580
Replacing a headlight bulb
1. Headlight bulb cover
1. Headlight coupler
2. Headlight bulb holder
3. Headlight bulb

EWA10790
WARNING0
Headlight bulbs get very hot. There-
fore, keep flammable products
away from a lit headlight bulb, and
do not touch the bulb until it has
cooled down.3. Place a new headlight bulb into position, and then secure it with
the bulb holder.
1. Do not touch this area

1. Headlight bulb holder
2. Headlight bulb
This model is equipped with quartz
bulb headlights. If a headlight bulb
burns out, replace it as follows.1. Remove the headlight bulb cover, and then disconnect the headlight
coupler.
2. Unhook the headlight bulb holder, and then remove the defective
bulb.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a mo-
torcycle stand is not available, by plac-
ing a jack either under each side of the
frame in front of the rear wheel or un-
der each side of the swingarm.EAU24360
Front wheelEAUB1440To remove the front wheel
EWA10820
WARNING0
●It is advisable to have a Yama-
ha dealer service the wheel.
●Securely support the motorcy-
cle so that there is no danger of
it falling over.
1. Wheel axle
2. Brake caliper bolts
A. Front wheel axle pinch bolt
B. Front wheel axle pinch bolt

A
2
B
1

EAU24350
Supporting the motorcycle
Since this model is not equipped with
a centerstand, follow these precau-
tions 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.

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