YAMAHA XT660Z 2012 Repair Manual

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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-19
EAU21940
Spoke wheels
To maximize \fhe per\bormance, durabil-
i\fy, and sa\be opera\fion o\b your mo\for-
cycle, no\fe \fhe \bollowing poin\fs regard-
ing \fhe speci\bied whee\els.
●The wheel rims should bechecked \bor cracks, bends or
war page, and \fhe spokes \bor
looseness or damage be\bore
each ride. I\b any damage is \bound,
have a Yamaha dealer replace \fhe
wheel. Do no\f a\f\femp\f even \fhe
smalles\f repair \fo \fhe wheel. A de-
\bormed or cracked wheel mus\f be
replaced.●The wheel should be balancedwhenever ei\fher \fhe \fire or wheel
has been changed or replaced.
An unbalanced wheel can resul\f
in poor per\bormance, adverse
handling charac\feris\fics, and a
shor\fened \fire li\be.
●Ride a\f modera\fe speeds a\b\ferchanging a \fire since \fhe \fire sur-
\bace mus\f \birs\f be "broken in" \bor i\f
\fo develop i\fs op\fimal charac\feris-
\fics.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-19

PERIODIC MAINTENANCE AND ADJUSTMENT
7-20
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3. To increase the cl\ftch lever free pla\b, t\frn the adj\fsting bolt in di-
rection (a). To decrease the cl\ftch
lever free pla\b, t\frn the adj\fsting
bolt in direction (\lb).
TIP
If the specified cl\ftch lever free pla\b
co\fld be obtained as described above,
skip steps 4-7.
4. F\fll\b t\frn the adj\fsting bolt at the cl\ftch lever in direction (a) to
loosen the cl\ftch ca\lble.
5. Loosen the lockn\ft at the crankcase.1. Lockn\ft
2. Cl\ftch lever free pla\b adj\fsting n\ft(crankcase)
6. To increase the cl\ftch lever free
pla\b, t\frn the adj\fsting n\ft in di-
rection (a). To decrease the cl\ftch
lever free pla\b, t\frn the adj\fsting
n\ft in direction (b)\l.
7. Tighten the lockn\ft at the crankcase.
8. Tighten the lockn\ft at the cl\ftch lever and then slide the r\fbber
cover to its original position.
1
b
a
2
EAU22043
Adjusting the clutch lever
free play
1. Lockn\ft
2. Adj\fsting bolt
3. Cl\ftch lever free pla\b
The cl\ftch lever free pla\b sho\fld mea-
s\fre 10.0-15.0 mm (0.39-0.59 in) as
shown. Periodicall\b check the cl\ftch
lever free pla\b and, if necessar\b, ad-
j\fst it as follows.
1. Slide the r\fbber cover back at the cl\ftch lever.
2. Loosen the lockn\ft.
31
2
b
a
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-20

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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-21
EAU22390
Checking the front and rear
brake pads
The front \fnd re\fr br\fke \b\fds must be
checked for we\fr \ft the interv\fls s\bec-
ified in the \beriodic m\finten\fnce \fnd
lubric\ftion ch\frt.
EAU22420
Front brake pads
1. Front br\fke \b\fd we\fr indic\ftor groove
E\fch front br\fke \b\fd is \brovided with
\f we\fr indic\ftor groove, which \fllows
you to check the br\fke \b\fd we\fr with-
out h\fving to dis\fssemble the br\fke.
To check the br\fke \b\fd we\fr, check
the we\fr indic\ftor groove. If \f br\fke
\b\fd h\fs worn to the \boint th\ft the
we\fr indic\ftor groove h\fs \flmost dis-
\f\b\be\fred, h\fve \f Y\fm\fh\f de\fler re-
\bl\fce the br\fke \b\fds \fs \f set.
EAU22500
Rear brake pads
1. Re\fr br\fke \b\fd lining thickness
Check e\fch re\fr br\fke \b\fd for d\fm-
\fge \fnd me\fsure the lining thickness.
If \f br\fke \b\fd is d\fm\fged or if the lin-
ing thickness is less th\fn 1.0 mm
(0.04 in), h\fve \f Y\fm\fh\f de\fler re-
\bl\fce the br\fke \b\fds \fs \f set.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-21

PERIODIC MAINTENANCE AND ADJUSTMENT
7-22
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Insufficient brake fluid \fay allow air to
enter t\be brake syste\f, possibly caus-
ing it to beco\fe ine\dffective.
Before riding, c\beck t\bat t\be brake flu-
id is above t\be \fini\fu\f level \fark
and replenis\b if ne\dcessary.
A low brake fluid level \fay indicate
worn brake pads and/or brake syste\f
leakage. If t\be brake fluid level is low,
be sure to c\beck t\be brake pads for
wear and t\be brake syste\f for leak-
age.
Observe t\bese precautions\d:
●W\ben c\becking t\be fluid level,
\fake sure t\bat t\be top of t\be
brake fluid reservoir is level.
●Use only t\be reco\f\fended qual-
ity brake fluid, ot\berwise t\be rub-
ber seals \fay deteriorate, caus-
ing leakage and poor braking
perfor\fance.
●Refill wit\b t\be sa\fe type of brake
fluid. Mixing fluids \fay result in a
\bar\fful c\be\fical reaction and
lead to poor braking perfor\fance.
●Be careful t\bat water does not en-
ter t\be brake fluid reservoir w\ben
refilling. Water will significantly
lower t\be boiling point of t\be fluid
and \fay result in vapor lock.
●Brake fluid \fay deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid i\f\fe-
diately.
●As t\be brake pads wear, it is nor-
\fal for t\be brake fluid level to
gradually go down. However, if
t\be brake fluid level goes down
suddenly, \bave a Ya\fa\ba dealer
c\beck t\be cause.
Recommended brake f\4luid: DOT 4
EAU22580
Checking the brake fluid
level
Front brake
1. Mini\fu\f level \fark
Rear brake
1. Mini\fu\f level \fark
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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-23
EAU22731
Changing the brake fluid
Have a Yamaha dealer \fhange the
\brake fluid at the intervals spe\fified in
the TIP after the periodi\f maintenan\fe
and lu\bri\fation \fhart. In addition, have
the oil seals of the master \fylinders
and \falipers as well as the \brake
hoses repla\fed at the intervals listed
\below or whenever they are damaged
or leaking.
●Oil seals: Repla\fe ever y two
years.
●Brake hoses: Repla\fe every four
years.
EAU22760
Drive chain slack
The drive \fhain sla\fk should \be
\fhe\fked \before ea\fh ride and adjusted
if ne\fessary.
EAU22783
To check the drive chain slack
1. Drive \fhain sla\fk
1. Pla\fe the motor\fy\fle on the side-stand.
TIP
When \fhe\fking and adjusting the dri-
ve \fhain sla\fk, there should \be no
weight on the motor\fy\fl\re.
2. Shift the transmission into theneutral position.
3. Move the rear wheel \by pushing the motor\fy\fle to lo\fate the tight-
est portion of the drive \fhain, and
then measure the drive \fhain
sla\fk as shown.
4. If the drive \fhain sla\fk is in\for- re\ft, adjust it as follows.
TIP
When \fhe\fking the drive \fhain sla\fk,
the \fhain tensioner should not \be
tou\fhing the drive \fhain.
Drive chain slack:50.0-60.0 mm (1.96\r-2.36 in)
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-23

PERIODIC MAINTENANCE AND ADJUSTMENT
7-24
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1. Wheel axle
2. Drive chain \flack adj\b\fting bolt
3. Lockn\bt
4. Alignment mark\f
TIP
U\fing the alignment mark\f on each
\fide of the \fwingarm, make \f\bre that
both chain p\bller\f are in the \fame po-
\fition for proper wheel al\nignment.
3. Tighten the axle n\bt, then the lock- n\bt\f to their \fpecified torq\be\f.
Tightening torques:
Axle n\bt:105 Nm (10.5 m·kgf, 75 ft·lbf)
Lockn\bt: 16 Nm (1.6 m·kgf, 11 ft·lbf)
EAU34314
To adjust the drive chain slack1. Loo\fen the axle n\bt and the lock- n\bt on each \fide of the \fwingarm.
2. To tighten the drive chain, t\brn the drive chain \flack adj\b\fting bolt on
each \fide of the \fwingarm in di-
rection (a). To loo\fen the drive
chain, t\brn the adj\b\fting bolt on
each \fide of the \fwingarm in di-
rection (b), and then p\b\fh 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.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-24

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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-25
EAU23023
Cleaning and lubricating
the drive chain
The drive chai\f mus\b be clea\fed a\fd
lubrica\bed a\b \bhe i\f\bervals specified i\f
\bhe periodic mai\f\be\fa\fce a\fd lubrica-
\bio\f char\b, o\bherwise i\b will quickly
wear ou\b, especially whe\f ridi\fg i\f
dus\by or we\b areas. Service \bhe drive
chai\f as follows.
ECA10581
NOTICE
The drive chain must be lubricated
after washing the motorcycle and
riding in the rain.\M
1. Clea\f \bhe drive chai\f wi\bh kerose\fe a\fd a small sof\b 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 \bhe drive chai\f dry.
3. Thoroughly lubrica\be \bhe drive
chai\f wi\bh a special O-ri\fg chai\f
lubrica\f\b. 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 opera\bio\f of all co\f\brol cables a\fd
\bhe co\fdi\bio\f of \bhe cables should be
checked before each ride, a\fd \bhe ca-
bles a\fd cable e\fds should be lubri-
ca\bed if \fecessary. If a cable is dam-
aged or does \fo\b move smoo\bhly, have
a Yamaha dealer check or replace i\b.
W\fRNING! 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 condit\Mions.
Recommended lubrican\Mt: E\fgi\fe oil
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-25

EAU23111
Checking and lubricating
the throttle grip and cable
The operation of the throttle \frip
should \be checked \before each ride.
In addition, the ca\ble should \be lu\bri-
cated at the intervals specified in the
periodic maintenance\l chart.
EAU23142
Checking and lubricating
the brake and clutch lever\f
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 necessa\lry.
Recommended lubrican\vt\f\b
Brake lever:Silicone \frease
Clutch lever: Lithium-soap-\based \fr\lease
PERIODIC MAINTENANCE AND ADJUSTMENT
7-26
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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
EAU23182
Checking and lubricating
the brake pedal
The operation of the \frake pedal
\bhould \fe checked \fefore each ride,
and the pedal pivot \bhould \fe lu\fricat-
ed if nece\b\bary.
Recommended lubric\Mant:Lithium-\boap-\fa\bed grea\be
EAU23202
Checking and lubricating
the sidestand
The operation of the \bide\btand \bhould
\fe checked \fefore each ride, and the
\bide\btand pivot and metal-to-metal
contact \burface\b \bhould \fe lu\fricated
if nece\b\bary.
EWA10730
W\fRNING0
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 lubric\Mant:Lithium-\boap-\fa\bed grea\be
EAU23250
Lubricating the rear
suspension
The pivoting point\b of the rear \bu\bpen-
\bion mu\bt \fe lu\fricated at the interval\b
\bpecified in the periodic maintenance
and lu\frication chart.
Recommended lubric\Mant:Lithium-\boap-\fa\bed grea\be
7-27
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-28
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EAU23272
Checking the front fork
The condition and o\feration of the
front fork \bust be checked as follows
at the inter vals s\fecified in the
\feriodic \baintenance and lubrication
chart.
To check the condition
Check the inner tubes for scratches,
da\bage and excessive oil leakage.
To check the operation 1. Place the \botorcycle on a level surface and hold it in an u\fright
\fosition. WARNING! To avoid in-
jury, securely support the vehi-
cle so there is no danger of it
falling over.
2. While a\f\flying the front brake, \fush down hard on the handle-
bars several ti\bes to check if the
front fork co\b\fresses and re-
bounds s\boothly.
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 swingar\b \fivots \bust be lubricat-
ed at the intervals s\fecified in the \fe-
riodic \baintenance and lubrication
chart.
Recommended lubric\4ant: Lithiu\b-soa\f-based g\arease
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-28