YAMAHA XT660Z 2010 Repair Manual

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PERIODIC MAINTENANCE AND ADJUSTMENT
7-19
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 balanced
whenever 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 after
changing 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 ADJUSTMENT
7-20
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3. 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).
TIP
If the specified clutch lever free play
could be obtained as described above,
skip steps 4-7.
4. Fully turn the adjusting bolt at the
clutch lever in direction (a) to
loosen the clutch cable.
5. Loosen the locknut at the
crankcase.1. Locknut
2. Clutch lever free play adjusting nut
(crankcase)
6. 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).
7. Tighten the locknut at the
crankcase.
8. Tighten the locknut at the clutch
lever and then slide the rubber
cover to its original position.
1
b
a
2
EAU22043
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. Slide the rubber cover back at the
clutch lever.
2. Loosen the locknut.
31
2
b
a
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-21
EAU22390
Checking the front and rear
brake pads
The front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU22420
Front brake pads
1. Front brake pad wear indicator groove
Each front brake pad is provided with
a wear indicator groove, which allows
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator groove. If a brake
pad has worn to the point that the
wear indicator groove has almost dis-
appeared, have a Yamaha dealer re-
place the brake pads as a set.
EAU22500
Rear brake pads
1. Rear brake pad lining thickness
Check each rear brake pad for dam-
age and measure the lining thickness.
If a brake pad is damaged or if the lin-
ing thickness is less than 1.0 mm
(0.04 in), have a Yamaha dealer re-
place the brake pads as a set.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-22
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Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake flu-
id is above the minimum level mark
and replenish if necessary.
A low brake fluid level may indicate
worn brake pads and/or brake system
leakage. If the brake fluid level is low,
be sure to check the brake pads for
wear and the brake system for leak-
age.
Observe these precautions:
●When checking the fluid level,
make sure that the top of the
brake fluid reservoir is level.
●Use only the recommended qual-
ity brake fluid, otherwise the rub-
ber seals may deteriorate, caus-
ing leakage and poor braking
performance.
●Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
●Be careful that water does not en-
ter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.
●Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid imme-
diately.
●As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if
the brake fluid level goes down
suddenly, have a Yamaha dealer
check the cause.
Recommended brake fluid:
DOT 4
EAU22580
Checking the brake fluid
level
Front brake
1. Minimum level mark
Rear brake
1. Minimum level mark
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-23
EAU22731
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the TIP after the periodic maintenance
and lubrication chart. In addition, have
the oil seals of the master cylinders
and calipers as well as the brake
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.
●Oil seals: Replace every two
years.
●Brake hoses: Replace every four
years.
EAU22760
Drive chain slack
The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22783
To check the drive chain slack
1. Drive chain slack
1. Place the motorcycle on the side-
stand.
TIP
When checking and adjusting the dri-
ve chain slack, there should be no
weight on the motorcycle.
2. Shift the transmission into the
neutral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain, and
then measure the drive chain
slack as shown.
4. If the drive chain slack is incor-
rect, adjust it as follows.
TIP
When checking the drive chain slack,
the chain tensioner should not be
touching the drive chain.
Drive chain slack:
50.0-60.0 mm (1.96-2.36 in)
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PERIODIC MAINTENANCE AND ADJUSTMENT
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1. Wheel axle
2. Drive chain slack adjusting bolt
3. Locknut
4. Alignment marks
TIP
Using the alignment marks on each
side of the swingarm, make sure that
both chain pullers are in the same po-
sition for proper wheel alignment.
3. Tighten the axle nut, then the lock-
nuts to their specified torques.
Tightening torques:
Axle nut:
105 Nm (10.5 m·kgf, 75 ft·lbf)
Locknut:
16 Nm (1.6 m·kgf, 11 ft·lbf)
EAU34314
To adjust the drive chain slack
1. Loosen the axle nut and the lock-
nut on each side of the swingarm.
2. To tighten the drive chain, turn the
drive chain slack adjusting bolt on
each side of the swingarm in di-
rection (a). To loosen the drive
chain, turn the adjusting bolt on
each side of the swingarm in di-
rection (b), and then push the rear
wheel forward. NOTICE: Improp-
er drive chain slack will over-
load the engine as well as other
vital parts of the motorcycle
and can lead to chain slippage
or breakage. To prevent this
from occurring, keep the drive
chain slack within the specified
limits.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-25
EAU23023
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.
ECA10581
NOTICE
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. NOTICE:
To prevent damaging the O-
rings, do not clean the drive
chain with steam cleaners,
high-pressure washers or inap-
propriate solvents.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 may contain substances
that could damage the O-rings.
EAU23101
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.
WARNING! Damage to the outer
sheath may interfere with proper
cable operation and will cause the
inner cable to rust. Replace a dam-
aged cable as soon as possible to
prevent unsafe conditions.
Recommended lubricant:
Engine oil
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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 lubri-
cated at the intervals specified in the
periodic maintenance chart.
EAU23142
Checking and lubricating
the brake and clutch levers
Brake lever
Clutch leverThe 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
PERIODIC MAINTENANCE AND ADJUSTMENT
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PERIODIC MAINTENANCE AND ADJUSTMENT
EAU23182
Checking and 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:
Lithium-soap-based grease
EAU23202
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. Otherwise,
the sidestand could contact the
ground and distract the operator, re-
sulting in a possible loss of control.
Recommended lubricant:
Lithium-soap-based 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
7-27
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PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU23272
Checking the front fork
The condition and operation of the
front fork must be checked as follows
at the intervals specified in the
periodic maintenance and lubrication
chart.
To check the condition
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. WARNING! To avoid in-
jury, securely support the vehi-
cle so there is no danger of it
falling over.
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.
ECA10590
NOTICE
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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