brake YAMAHA XT660Z 2015 Owner's Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
6-26
6
EAU23144
Checking and lubricating the
brake and clutch leversThe operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
Brake lever
Clutch lever
EAU23185
Checking and lubricating the
brake pedalThe operation of the brake pedal
should be checked before each ride,
and the pedal pivot should be lubricat-
ed if necessary.
Recommended lubricants:
Brake lever:
Silicone grease
Clutch lever:
Lithium-soap-based grease
Recommended lubricant:
Lithium-soap-based grease
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-28
6
EAU23273
Checking the front forkThe 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 vehicle on a level sur-
face 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.
[EWA10752]
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.
NOTICE
ECA10591
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU23285
Checking the steeringWorn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the
periodic maintenance and lubrication
chart.
1. Raise the front wheel off the
ground. (See page 6-35.)
WARNING! To avoid injury, se-
curely support the vehicle so
there is no danger of it falling
over.
[EWA10752]
2. Hold the lower ends of the front
fork 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 steer-
ing.
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-34
6
EAU42653
Replacing an auxiliary light
bulbThis model is equipped with two auxil-
iary lights. If an auxiliary light bulb
burns out, replace it as follows.
1. Remove panel B. (See page 6-8.)
2. Remove the auxiliary light socket
(together with the bulb) by pulling
it out.
3. Remove the burnt-out bulb by
pulling it out.
4. Insert a new bulb into the socket.
5. Install the auxiliary light socket (to-
gether with the bulb) by pushing it
in.
6. Install the panel.
EAU24182
Tail/brake lightThis 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.
EAU24205
Replacing a turn signal light
bulb1. Remove the turn signal light lens
by removing the screw.
2. Remove the burnt-out bulb by
pushing it in and turning it coun-
terclockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screw. NOTICE: Do not over-
tighten the screw, otherwise the
lens may break.
[ECA11192]
1. Auxiliary light bulb socket
2. Auxiliary light bulbZAUM1238
1. Screw
2. Turn signal light lens
3. Turn signal light bulb
1ZAUM1265
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-36
6
EAU44792
Front wheel (for non-ABS
models)
WARNING
EWA14841
For the ABS model, have a Yamaha
dealer remove and install the wheel.
EAU56480
To remove the front wheel
WARNING
EWA10822
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
brake caliper bolts.2. Lift the front wheel off the ground
according to the procedure in the
previous section “Supporting the
motorcycle”.
3. Remove the brake caliper on each
side by removing the bolts.
NOTICE: Do not apply the brake
after the brake calipers have
been removed, otherwise the
brake pads will be forced shut.
[ECA11052]
4. Pull the wheel axle out, and then
remove the wheel.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 install-
ing the bolts.
TIPMake sure that there is enough space
between the brake pads before install-
ing 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 specified
torques.NOTICE
ECAB0062
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 posi-
tion the disc correctly.6. Tighten wheel axle pinch bolt A,
and then pinch bolt B to their
specified torque.
1. Wheel axle
2. Brake caliper bolt
3. Front wheel axle pinch boltZAUM1266
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-37
6 7. Retighten pinch bolt A to the
specified 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.
EAU44802
Rear wheel (for non-ABS
models)
WARNING
EWA14841
For the ABS model, have a Yamaha
dealer remove and install the wheel.
EAU56711
To remove the rear wheel
WARNING
EWA10822
To avoid injury, securely support the
vehicle so there is no danger of it
falling over.1. Loosen the axle nut.2. Lift the rear wheel off the ground
according to the procedure on
page 6-35.
3. Remove the axle nut.
4. Fully loosen the locknut on each
side of the swingarm.
5. Turn the drive chain slack adjust-
ing bolts fully in direction (a) and
push the wheel forward.
Tightening torques:
Wheel axle:
59 Nm
Front wheel axle pinch bolt:
18 Nm
Brake caliper bolt:
40 Nm
1. Wheel axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Drive chainZAUM1267
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-38
6
6. Remove the drive chain from the
rear sprocket.
TIPIf the drive chain is difficult to re-
move, remove the wheel axle 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 caliper
bracket, pull the wheel axle out,
and then remove the wheel.
NOTICE: Do not apply the brakeafter the wheel and brake disc
have been removed, otherwise
the brake pads will be forced
shut.
[ECA11073]
To install the rear wheel
1. Install the wheel and the brake cal-
iper bracket by inserting the wheel
axle from the left-hand side.TIPMake sure that the slot in the
brake 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.
1. Wheel axle
2. Drive chain slack adjusting bolt
3. Locknut
4. Brake caliperZAUM1268
Tightening torque:
Axle nut:
104 Nm
U2BDE1E0.book Page 38 Tuesday, December 16, 2014 5:38 PM

MOTORCYCLE CARE AND STORAGE7-2
7 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 re-
movers or inhibitors, brake fluid,
antifreeze or electrolyte.
Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
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
scratching. Some cleaning
compounds for plastic may
leave scratches on the wind-shield. Test the product on a
small hidden part of the wind-
shield to make sure that it does
not leave any marks. If the wind-
shield is scratched, use a quality
plastic polishing compound af-
ter washing.
After normal useRemove 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 oron salt-sprayed roadsSince 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.
TIPSalt 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 wa-
ter since it increases the corro-
sive action of the salt.
[ECA10792]
2. Apply a corrosion protection spray
on all metal, including chrome-
and nickel-plated, surfaces to pre-
vent corrosion.
After cleaning
1. Dry the motorcycle with a chamois
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 in-
duced discoloring of stainless-
steel exhaust systems can be re-
moved through polishing.)
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MOTORCYCLE CARE AND STORAGE
7-3
74. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
5. Use spray oil as a universal clean-
er 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 completely
before storing or covering it.
WARNING
EWA11132
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 deter-
gent. Before riding at higher
speeds, test the motorcycle’s
braking performance and cor-
nering behavior.
NOTICE
ECA10801
Apply spray oil and wax spar-
ingly 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 ad-
vice 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.
EAUM1903
StorageShort-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover. Be
sure the engine and the exhaust sys-
tem are cool before covering the mo-
torcycle.NOTICE
ECA10811
Storing the motorcycle in a
poorly ventilated room or cover-
ing it with a tarp, while it is still
wet, will allow water and humid-
ity 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 sev-
eral months:
1. Follow all the instructions in the
“Care” section of this chapter.
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SPECIFICATIONS
8-2
8
Secondary reduction ratio:
45/15 (3.000)
Transmission type:
Constant mesh 5-speed
Operation:
Left foot operation
Gear ratio:
1st:
30/12 (2.500)
2nd:
26/16 (1.625)
3rd:
23/20 (1.150)
4th:
20/22 (0.909)
5th:
20/26 (0.769)Chassis:Frame type:
Diamond
Caster angle:
28.00 °
Trail:
XT660Z 113 mm (4.4 in)
XT660ZA 120 mm (4.7 in)Front tire:Type:
With tube
Size:
XT660Z 90/90-21 M/C 54S(METZELER)-
54T(MICHELIN)
XT660ZA 90/90-21 M/C 54S(PIRELLI)Manufacturer/model:
XT660Z METZELER/TOURANCE FRONT
XT660ZA PIRELLI/SCORPION TRAIL
Manufacturer/model:
XT660Z MICHELIN/SIRAC
Rear tire:Type:
With tube
Size:
XT660Z 130/80-17 M/C 65S(METZELER)-
65T(MICHELIN)
XT660ZA 130/80-17 M/C 65S(PIRELLI)
Manufacturer/model:
XT660Z METZELER/TOURANCE FRONT
XT660ZA PIRELLI/SCORPION TRAIL
Manufacturer/model:
XT660Z MICHELIN/SIRACLoading:Maximum load:
190 kg (419 lb)
(Total weight of rider, passenger, cargo
and accessories)Tire air pressure (measured on cold
tires):Loading condition:
0–90 kg (0–198 lb)
Front:
210 kPa (2.10 kgf/cm², 30 psi)
Rear:
230 kPa (2.30 kgf/cm², 33 psi)
Loading condition:
90–190 kg (198–419 lb)Front:
XT660Z 210 kPa (2.10 kgf/cm², 30 psi)
XT660ZA 230 kPa (2.30 kgf/cm², 33 psi)
Rear:
XT660Z 230 kPa (2.30 kgf/cm², 33 psi)
XT660ZA 250 kPa (2.50 kgf/cm², 36 psi)
Off-road riding:
Front:
XT660Z 200 kPa (2.00 kgf/cm², 29 psi)
Rear:
XT660Z 200 kPa (2.00 kgf/cm², 29 psi)
High-speed riding:
Front:
210 kPa (2.10 kgf/cm², 30 psi)
Rear:
230 kPa (2.30 kgf/cm², 33 psi)
Front wheel:Wheel type:
Spoke wheel
Rim size:
21 x 1.85Rear wheel:Wheel type:
Spoke wheel
Rim size:
17 x 2.75Front brake:Type:
Dual disc brake
Operation:
Right hand operation
Specified brake fluid:
DOT 4
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SPECIFICATIONS
8-3
8
Rear brake:Type:
Single disc brake
Operation:
Right foot operation
Specified brake fluid:
DOT 4Front suspension:Type:
Telescopic fork
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
XT660Z 210 mm (8.3 in)
XT660ZA 160 mm (6.3 in)Rear suspension:Type:
Swingarm (link suspension)
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
XT660Z 200 mm (7.9 in)
XT660ZA 145 mm (5.7 in)Electrical system:Ignition system:
TCI
Charging system:
AC magnetoBattery:Model:
XT660Z GT9B-4
XT660ZA YTZ10SVoltage, capacity:
XT660Z 12 V, 8.0 Ah
XT660ZA 12 V, 8.6 Ah
Headlight:Bulb type:
Halogen bulbBulb voltage, wattage × quantity:Headlight:
12 V, 55.0 W × 2
Tail/brake light:
LED
Front turn signal light:
12 V, 10.0 W × 2
Rear turn signal light:
12 V, 10.0 W × 2
Auxiliary light:
12 V, 3.0 W × 2
License plate light:
12 V, 5.0 W × 1
Meter lighting:
LED
Neutral indicator light:
LED
High beam indicator light:
LED
Turn signal indicator light:
LED
Coolant temperature warning light:
LED
Engine trouble warning light:
LED
ABS warning light:
XT660ZA LEDImmobilizer system indicator light:
LED
Fuses:Main fuse:
30.0 A
Headlight fuse:
20.0 A
Signaling system fuse:
10.0 A
Ignition fuse:
10.0 A
Parking lighting fuse:
10.0 A
Radiator fan motor fuse:
7.5 A
Fuel injection system fuse:
10.0 A
ABS control unit fuse:
XT660ZA 5.0 A
ABS motor fuse:
XT660ZA 30.0 A
ABS solenoid fuse:
XT660ZA 20.0 A
Backup fuse:
10.0 A
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