brake YAMAHA XT660Z 2011 Owner's Manual

Rear brake (for XT660ZA)
1. Minimum level mark
Insufficient brake fluid may allow air
to enter the brake system, possibly
causing it to become ineffective.
Before riding, check that the brake
fluid is above the minimum level mark
and replenish if necessary. A low bra-
ke 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 leakage.
TIP
For XT660ZA, the rear brake fluid
reservoir is located under the seat.
(See page 3-16).
Observe these precautions:
When checking the fluid level,
make sure that the top of the bra-
ke fluid reservoir is level.
Use only the recommended qua-
lity brake fluid, otherwise the rub-
ber seals may deteriorate, cau-
sing 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 performan-
ce.
Be careful that water or dust
does not enter the brake fluid
reservoir when refilling. Water will
significantly lower the boiling
point of the fluid and may result
in vapor lock, and dirt may clog
the ABS hydraulic unit valves.
Brake fluid may deteriorate pain-
ted surfaces or plastic parts.
Always clean up spilled fluid
immediately.
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.
EAU22731
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the TIP after the periodic maintenan-
ce and lubrication chart. In addition,
have the oil seals of the master cylin-
ders 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.
Recommended brake fluid:
DOT 4
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EAU23093
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 cables and cable ends should
be lubricated if necessary. If a cable is
damaged or does not move smoothly,
have a Yamaha dealer check or repla-
ce it.
EWA10711
Damage to the outer housing of
cables may result in internal rusting
and cause interference with cable
movement. Replace damaged
cables as soon as possible to pre-
vent unsafe conditions.
EAU23142
Checking and lubricating the
brake and clutch levers
Brake lever
Clutch lever
The operation of the brake and clutch
levers should be checked before eachride, and the lever pivots should be
lubricated if necessary.Recommended lubricants:
Brake lever:
Silicone grease
Clutch lever:
Lithium-soap-based grease
Recommended lubricant:
Yamaha Chain and Cable Lube or
engine oil
WARNING
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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 lubrica-
ted if necessary.
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.
EWA10731
If the sidestand does not move up
and down smoothly, have a Yama-
ha dealer check or repair it. Other-
wise, the sidestand could contact
the ground and distract the opera-
tor, resulting in a possible loss of
control.
Recommended lubricant:
Lithium-soap-based grease
WARNINGRecommended lubricant:
Silicone grease
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EAU23251
Lubricating the rear
suspension
The pivoting points of the rear sus-
pension must be lubricated by a
Yamaha dealer at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
EAUM1651
Lubricating the swingarm
pivots
The swingarm pivots must be lubrica-
ted by a Yamaha dealer at the inter-
vals specified in the periodic mainte-
nance and lubrication chart.
EAU23272
Checking the front fork
The condition and operation of the
front fork must be checked as follows
at the intervals specified in the perio-
dic maintenance and lubrication
chart.
To check the condition
1. Check the inner tubes for scrat-
ches, damage and excessive oil
leakage.
To check the operation
1. Place the vehicle on a level surfa-
ce and hold it in an upright posi-
tion. WARNING! To avoid injury,
securely support the vehicle so
there is no danger of it falling
over.
[EWA10751]
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and
rebounds smoothly.
Recommended lubricant:
Lithium-soap-based grease
Recommended lubricant:
Lithium-soap-based grease
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6
1. Headlight bulb holder
2. Headlight bulb
2. Unhook the headlight bulb hol-
der, and then remove the defecti-
ve bulb.
1. Do not touch the glass part of the bulb.
EWA10790
Headlight bulbs get very hot. The-
refore, 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.
4. Connect the coupler, and then
install the headlight bulb cover.
5. Have a Yamaha dealer adjust the
headlight beam if necessary.
EAU24181
Tail/brake light
This model is equipped with an LED-
type tail/brake light.
If the tail/brake light does not come
on, have a Yamaha dealer check it.WARNING
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EAU44790
Front wheelEWA14840
For the ABS model, have a Yamaha
dealer remove and install the whe-
el.
EAUB1441
To remove the front wheelEWA10821
To avoid injury, securely support
the vehicle so there is no danger of
it falling over.
1. Loosen the front wheel axle pinch
bolts, the wheel axle and the bra-
ke caliper bolts.
1. Wheel axle
2. Brake caliper bolt
3. Front wheel axle pinch bolt
4. Front wheel axle pinch bolt
2. Lift the front wheel off the ground
according to the procedure on
page 6-35.
3. Remove the brake caliper on
each side by removing the bolts.
NOTICE: Do not apply the bra-
ke after the brake calipers have
been removed, otherwise the
brake pads will be forced shut.
[ECA11051]
4. Pull the wheel axle out, and then
remove the wheel.
EAUB1472
To install the front wheel
1. Lift the wheel up between the
fork legs.
2. Insert the wheel axle.
3. Install the brake calipers by insta-
lling the bolts.
TIP
Make sure that there is enough space
between the brake pads before insta-
lling the brake calipers onto the brake
discs.
4. Lower the front wheel so that it is
on the ground.
5. Tighten the wheel axle and the
brake caliper bolts to the speci-
fied torques.
ECAB0061
Be sure the right brake disc is posi-
tioned exactly between the brake
pads to prevent any brake drag.
Tap the side of the right fork leg to
position the disc correctly.
6. Tighten wheel axle pinch bolt A,
and then pinch bolt B to their
specified torque.
NOTICE
WARNING
WARNING
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7. Retighten pinch bolt A to the spe-
cified torque.
8. Apply the brake lever several
times, and then while holding the
brake lever in, push down hard
on the handlebar several times to
check for proper fork operation.EAU44800
Rear wheelEWA14840
For the ABS model, have a Yamaha
dealer remove and install the wheel.
EAU25314
To remove the rear wheelEWA10821
To avoid injury, securely support
the vehicle so there is no danger of
it falling over.
1. Loosen the axle nut.
1. Wheel axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Drive chain
2. Lift the rear wheel off the ground
according to the procedure on
page 6-35.
3. Remove the axle nut.
1. Wheel axle
2. Drive chain slack adjusting bolt
3. Locknut
4. Brake caliper
4. Fully loosen the locknut on each
side of the swingarm.
5. Turn the drive chain slack adjus-
ting bolts fully in direction (a) and
push the wheel forward.
6. Remove the drive chain from the
rear sprocket.
TIP
If the drive chain is difficult to
remove, remove the wheel axle
WARNING
WARNING
Tightening torques:
Wheel axle:
60 Nm (6.0 m·kgf, 44 ft·lbf)
Front wheel axle pinch bolt:
18 Nm (1.8 m·kgf, 13 ft·lbf)
Brake caliper bolt:
40 Nm (4.0 m·kgf, 29 ft·lbf)
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first, and then lift the wheel upward
enough to remove the drive chain
from the rear sprocket.
The drive chain cannot be disas-
sembled.
7. While supporting the brake cali-
per bracket, pull the wheel axle
out, and then remove the wheel.
NOTICE: Do not apply the bra-
ke after the wheel has been
removed together with the bra-
ke disc, otherwise the brake
pads will be forced shut.
[ECA11071]
EAUB1450
To install the rear wheel
1. Install the wheel and the brake
caliper bracket by inserting the
wheel axle from the left-hand
side.
TIP
Make sure that the slot in the bra-
ke caliper bracket is fit over the
retainer on the swingarm.
Make sure that there is enough
space between the brake pads
before installing the wheel.
2. Install the drive chain onto the
rear sprocket.
3. Install the axle nut, and then
lower the rear wheel so that it is
on the ground.
4. Adjust the drive chain slack. (See
page 6-23).
5. Apply the rear brake several
times, and then tighten the axle
nut to the specified torque.EAU25871
Troubleshooting
Although Yamaha motorcycles recei-
ve a thorough inspection before ship-
ment from the factory, trouble may
occur during operation. Any problem
in the fuel, compression, or ignition
systems, for example, can cause poor
starting and loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcy-
cle require any repair, take it to a
Yamaha dealer, whose skilled techni-
cians have the necessary tools, expe-
rience, and know-how to service the
motorcycle properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.
EWA15141
When checking the fuel system, do
not smoke, and make sure there
are no open flames or sparks in the
WARNING
Tightening torque:
Axle nut:
105 Nm (10.5 m·kgf, 75 ft·lbf)
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water, diluted mild detergent
with water may be used. Be
sure to rinse off any detergent
residue using plenty of water,
as it is harmful to plastic parts.
Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust
removers or inhibitors, brake
fluid, antifreeze or electrolyte.
Do not use high-pressure was-
hers or steam-jet cleaners sin-
ce they cause water seepage
and deterioration in the follo-
wing areas: seals (of wheel and
swingarm bearings, fork and
brakes), electric components
(couplers, connectors, instru-
ments, switches and lights),
breather hoses and vents.
For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or scrat-
ching. Some cleaning com-pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid-
den part of the windshield to
make sure that it does not lea-
ve any marks. If the windshield
is scratched, use a quality
plastic polishing compound
after washing.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge, and
then rinse thoroughly with clean water.
Use a toothbrush or bottlebrush for
hard-to-reach areas. Stubborn dirt and
insects will come off more easily if the
area is covered with a wet cloth for a few
minutes before cleaning.
After riding in the rain, near the sea or
on salt-sprayed roads
Since sea salt or salt sprayed on
roads during winter are extremely
corrosive in combination with water,
carry out the following steps after
each ride in the rain, near the sea or
on salt-sprayed roads.
TIP
Salt sprayed on roads in the winter
may remain well into spring.
1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.
NOTICE: Do not use warm
water since it increases the
corrosive action of the salt.
[ECA10791]
2. Apply a corrosion protection
spray on all metal, including
chrome- and nickel-plated, surfa-
ces to prevent corrosion.
After cleaning
1. Dry the motorcycle with a cha-
mois or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally indu-
ced discoloring of stainless-steel
exhaust systems can be removed
through polishing.)
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4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal, inclu-
ding chrome- and nickel-plated,
surfaces.
5. Use spray oil as a universal clea-
ner to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry comple-
tely before storing or covering it.
EWA11131
Contaminants on the brakes or
tires can cause loss of control.
Make sure that there is no oil or
wax on the brakes or tires.
If necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or
acetone, and wash the tires
with warm water and a mild
detergent. Before riding at hig-
her speeds, test the motorcy-
cle’s braking performance and
cornering behavior.
ECA10800
Apply spray oil and wax spa-
ringly and make sure to wipe
off any excess.
Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
Avoid using abrasive polishing
compounds as they will wear
away the paint.
TIP
Consult a Yamaha dealer for
advice on what products to use.
Washing, rainy weather or humid
climates can cause the headlight
lens to fog. Turning the headlight
on for a short period of time will
help remove the moisture from
the lens.
EAUM1902
Storage
Short-term
Always store your motorcycle in a
cool, dry place and, if necessary, pro-
tect it against dust with a porous
cover. Be sure the engine and the
exhaust system are cool before cove-
ring the motorcycle.
ECA10810
Storing the motorcycle in a
poorly ventilated room or cove-
ring it with a tarp, while it is still
wet, will allow water and humi-
dity to seep in and cause rust.
To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.
Long-term
Before storing your motorcycle for
several months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. Fill up the fuel tank and add fuel
NOTICE
NOTICE
WARNING
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