YAMAHA XT660Z 2008 Service Manual

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OPERATION AND IMPORTANT RIDING POINTS
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.
EAU17100
0-1000 km (0-600 mi)
Avoid prolonged operation above
4500 r/min.
1000-1600 km (600-1000 mi)
Avoid prolonged operation above
6000 r/min.
ECA10301CAUTION:
After 1000 km (600 mi) of operation,
the engine oil must be changed and
the oil filter cartridge or element re-
placed.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.
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OPERATION AND IMPORTANT RIDING POINTS
ECA10310CAUTION:
●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.
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EAU17212
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EWA10310
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.
●Do not park on a slope or on
soft ground, otherwise the ve-
hicle may overturn.
ECA10380CAUTION:
Never park in an area where there
are fire hazards such as grass or
other flammable materials.

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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17240
Safety is an obligation of the owner.
Periodic inspection, adjustment and
lubrication will keep your vehicle in the
safest and most efficient condition
possible. The most important points of
inspection, adjustment, and lubrica-
tion are explained 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, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.
EWA10320
WARNING0
If you are not familiar with motorcy-
cle maintenance work, have a
Yamaha dealer do it for you.

EAU17380
Owner’s tool kit
1. Owner’s tool kit
The owner’s tool kit is located under
the seat. (See page 3-14).
The service information included in
this manual and the tools provided in
the owner’s tool kit are intended to as-
sist you in the performance of preven-
tive maintenance and minor repairs.
However, additional tools such as a
torque wrench may be necessary to
perform certain maintenance work
correctly.

NOTE:
If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
EWA10350
WARNING0
Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any
changes.

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PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17709
Periodic maintenance and lubrication chart
NOTE:● The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.
●From 50000 km, repeat the maintenance intervals starting from 10000 km.
●Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and tech-
nical skills.
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NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUAL CHECK
√√√√ √
√√
√√
√√
√√
√√√√√
√√√√√ √
√√√√√ √1✻
2
3
✻
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✻
7✻
• Check fuel hoses for cracks or damage.
• Check condition.
• Clean and regap.
• Replace.
• Check valve clearance.
• Adjust.
• 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.
Fuel line
Spark plug
Valves
Air filter element
Clutch
Front brake
Rear brake
Whenever worn to the limit
Whenever worn to the limit

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUALCHECK
√√√√ √
√√√√
√√√√ √
√√√√
√√√√
√√√√√ √√√√ √
√√√√ √
√√√√√ √8✻
9✻
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✻
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✻
• 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.
• 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.
Every 4 years
Brake hoses
Wheels
Tires
Wheel bearings
Swingarm
Drive chain
Steering bearings
Chassis fasteners
Sidestand
Sidestand switch
Every 50000 km
Every 500 km and after washing
the motorcycle or riding in the rain
Every 20000 km

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PERIODIC MAINTENANCE AND MINOR REPAIR
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• Check operation and for oil leakage.
• Check operation and shock absorber for oil
leakage.
• Check operation.
• Lubricate with lithium-soap-based grease.
• Adjust engine idling speed.
• Change.
• Check oil level and vehicle for oil leakage.
• 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.
Front fork
Shock absorber
assembly
Rear suspension
relay arm and
connecting arm
pivoting points
Fuel injection
Engine oil
Engine oil filter
element
Cooling system
Front and rear brake
switches
Moving parts and
cables
Throttle grip housing
and cable
√√√√
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√√√√
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√√√√√ √
√√√√√ √
√√√
√√√√ √
√√√√√ √ √√√√ √
√√√√ √18✻
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NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUAL
CHECK
Every 3 years

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-56-5
NO. ITEMCHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUAL
CHECK
• Check the air cut-off valve, reed valve, and hose for damage.
• 5HSODFHDQ\damageGSDUWVLIQHFHVVDU\
• Check the screw clamp for looseness.
• Check operation.
• Adjust headlight beam.
Air induction system
Muffler and exhaust
pipe
Lights, signals and
switches
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✻
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EAUM1890
NOTE:
●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. √√√√ √
√√√√√
√√√√√ √
XT660Z 04-06 ING 29-08-2008 15.20 Pagina 6-5

PERIODIC MAINTENANCE AND MINOR REPAIR
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.
T
o install the panel
Place the panel in the original position,
and then install the bolts.

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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 MINOR REPAIR
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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 thenpull the panel off at the areas
shown.
T
o install the panel
1. Place the panel in the original posi- tion.
2. Install the quick fastener and the bolts.

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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.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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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).
NOTE:
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 sparkplug 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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