brake fluid YAMAHA XT660Z 2015 Owners Manual

TABLE OF CONTENTSSAFETY INFORMATION.................. 1-1
DESCRIPTION.................................. 2-1
Left view ......................................... 2-1
Right view ....................................... 2-3
Controls and instruments ............... 2-5
INSTRUMENT AND CONTROL
FUNCTIONS...................................... 3-1
Immobilizer system......................... 3-1
Main switch/steering lock............... 3-2
Indicator lights and warning
lights............................................ 3-4
Multi-function display ..................... 3-6
Handlebar switches ........................ 3-9
Clutch lever .................................. 3-10
Shift pedal .................................... 3-11
Brake lever.................................... 3-11
Brake pedal .................................. 3-11
ABS (for ABS models) .................. 3-12
Fuel tank cap ................................ 3-13
Fuel ............................................... 3-13
Fuel tank breather/overflow
hose .......................................... 3-15
Catalytic converter ....................... 3-15
Seat .............................................. 3-16
Adjusting the front fork ................. 3-16
Adjusting the shock absorber
assembly ................................... 3-18
Sidestand ..................................... 3-19
Ignition circuit cut-off system ....... 3-19FOR YOUR SAFETY –
PRE-OPERATION CHECKS............. 4-1
OPERATION AND IMPORTANT
RIDING POINTS................................ 5-1
Starting the engine .......................... 5-1
Shifting ............................................ 5-2
Tips for reducing fuel
consumption ................................ 5-3
Engine break-in ............................... 5-3
Parking ............................................ 5-4
PERIODIC MAINTENANCE AND
ADJUSTMENT................................... 6-1
Owner’s tool kit ............................... 6-2
Periodic maintenance chart for the
emission control system .............. 6-3
General maintenance and
lubrication chart ........................... 6-4
Removing and installing panels ...... 6-8
Checking the spark plug ................. 6-9
Engine oil and oil filter element ..... 6-10
Coolant.......................................... 6-13
Replacing the air filter element
and cleaning the check hose..... 6-14
Adjusting the engine idling
speed ......................................... 6-16
Checking the throttle grip free
play ............................................ 6-16
Valve clearance ............................. 6-17
Tires .............................................. 6-17Spoke wheels ............................... 6-19
Adjusting the clutch lever free
play ............................................ 6-20
Checking the front and rear brake
pads .......................................... 6-21
Checking the brake fluid level ...... 6-21
Changing the brake fluid .............. 6-23
Drive chain slack........................... 6-23
Cleaning and lubricating the drive
chain.......................................... 6-24
Checking and lubricating the
cables ........................................ 6-25
Checking and lubricating the
throttle grip and cable ............... 6-25
Checking and lubricating the
brake and clutch levers ............. 6-26
Checking and lubricating the
brake pedal ............................... 6-26
Checking and lubricating the
sidestand................................... 6-27
Lubricating the rear suspension ... 6-27
Lubricating the swingarm
pivots......................................... 6-27
Checking the front fork ................. 6-28
Checking the steering................... 6-28
Checking the wheel bearings ....... 6-29
Battery .......................................... 6-29
Replacing the fuses ...................... 6-31
Replacing a headlight bulb ........... 6-32
Replacing an auxiliary light bulb ... 6-34
Tail/brake light .............................. 6-34U2BDE1E0.book Page 1 Tuesday, December 16, 2014 5:38 PM

DESCRIPTION
2-3
2
EAU32231
Right viewXT660Z
1
2
3
4
5
6
7
8
9
1. Grab bar
2. Main fuse (page 6-31)
3. Battery (page 6-29)
4. Rear brake fluid reservoir (page 6-21)
5. Coolant reservoir (page 6-13)
6. Front brake fluid reservoir (page 6-21)
7. Coolant drain bolt (page 6-14)8. Engine oil filter element (page 6-10)
9. Brake pedal (page 3-11)
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DESCRIPTION
2-4
2XT660ZA
12 3 4 5 6
7 8 9 10
1. Rear brake fluid reservoir (page 6-21)
2. Fuse box 2 (page 6-31)
3. Owner’s tool kit (page 6-2)
4. Coolant reservoir (page 6-13)
5. Battery (page 6-29)
6. Front brake fluid reservoir (page 6-21)
7. Coolant drain bolt (page 6-14)
8. Engine oil filter element (page 6-10)
9. Brake pedal (page 3-11)10.Rear wheel hubU2BDE1E0.book Page 4 Tuesday, December 16, 2014 5:38 PM

FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-1
4
EAU15599
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner’s Manual.
WARNING
EWA11152
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in
this manual, have the vehicle inspected by a Yamaha dealer.Before using this vehicle, check the following points:
ITEM CHECKS PAGE
Fuel• Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.
• Check fuel tank breather hose and overflow hose for obstructions, cracks or
damage, and check hose connections.3-13, 3-15
Engine oil• Check oil level in oil tank.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage.6-10
Coolant• Check coolant level in reservoir.
• If necessary, add recommended coolant to specified level.
• Check cooling system for leakage.6-13
Front brake• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check lever free play.
• Adjust if necessary.
• Check brake pads for wear.
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add specified brake fluid to specified level.
• Check hydraulic system for leakage.6-21, 6-21
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FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-2
4
Rear brake• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add specified brake fluid to specified level.
• Check hydraulic system for leakage.6-21, 6-21
Clutch• Check operation.
• Lubricate cable if necessary.
• Check lever free play.
• Adjust if necessary.6-20
Throttle grip• Make sure that operation is smooth.
• Check throttle grip free play.
• If necessary, have Yamaha dealer adjust throttle grip free play and lubricate ca-
ble and grip housing.6-16, 6-25
Control cables• Make sure that operation is smooth.
• Lubricate if necessary.6-25
Drive chain• Check chain slack.
• Adjust if necessary.
• Check chain condition.
• Lubricate if necessary.6-23, 6-24
Wheels and tires• Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary.6-17, 6-19
Brake pedal• Make sure that operation is smooth.
• Lubricate pedal pivoting point if necessary.6-26
Brake and clutch levers• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.6-26
Sidestand• Make sure that operation is smooth.
• Lubricate pivot if necessary.6-27 ITEM CHECKS PAGE
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
6
EAU1770M
General maintenance and lubrication chartNO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
1 Air filter element• Replace.√√
2Clutch• Check operation.
•Adjust.√√√√√
3*Front brake• Check operation, fluid level and
vehicle for fluid leakage.√√√√√√
• Replace brake pads. Whenever worn to the limit
4*Rear brake• Check operation, fluid level and
vehicle for fluid leakage.√√√√√√
• Replace brake pads. Whenever worn to the limit
5*Brake hoses• Check for cracks or damage.
• Check for correct routing and
clamping.√√√√√
• Replace. Every 4 years
6*Wheels• Check runout, spoke tightness
and for damage.
• Tighten spokes if necessary.√√√√√
7*Tires• Check tread depth and for dam-
age.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.√√√√√
8*Wheel bearings• Check bearings for looseness or
damage.√√√√
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-7
6
EAUM1891
TIP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.
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-21
6
EAU22393
Checking the front and rear
brake padsThe front and rear brake pads must be
checked for wear at the intervals spec-
ified in the periodic maintenance and
lubrication chart.
EAU22421
Front brake pads
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 wearindicator groove has almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
EAU22501
Rear brake pads
Check each rear brake pad for damage
and measure the lining thickness. If a
brake pad is damaged or if the lining
thickness is less than 3.8 mm, have a
Yamaha dealer replace the brake pads
as a set.
EAUM3570
Checking the brake fluid levelBefore riding, check that the brake fluid
is above the minimum level mark.
Check the brake fluid level with the top
of the reservoir level. Replenish the
brake fluid if necessary.
Front brake
1. Wear indicator groove
1. Lining thickness
1
ZAUM1253
1. Minimum level mark
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-22
6Rear brake (for XT660Z)
Rear brake (for XT660ZA)
TIPThe rear brake fluid reservoir is located
under the seat. (See page 3-16.)
WARNING
EWA16011
Improper maintenance can result in
loss of braking ability. Observe
these precautions:
Insufficient brake fluid may al-
low air to enter the brake sys-
tem, reducing braking
performance.
Clean the filler cap before re-
moving. Use only DOT 4 brake
fluid from a sealed container.
Use only the specified brake flu-
id; otherwise, the rubber seals
may deteriorate, causing leak-
age.
Refill with the same type of
brake fluid. Adding a brake fluid
other than DOT 4 may result in a
harmful chemical reaction.
Be careful that water or dust
does not enter the brake fluid
reservoir when refilling. Water
will significantly lower the boil-
ing point of the fluid and may re-sult in vapor lock, and
dirt may
clog the ABS hydraulic unit
valves.
NOTICE
ECA17641
Brake fluid may damage painted
surfaces or plastic parts. Always
clean up spilled fluid immediately.As the brake pads wear, it is normal for
the brake fluid level to gradually go
down. A low brake fluid level may indi-
cate worn brake pads and/or brake
system leakage; therefore, be sure to
check the brake pads for wear and the
brake system for leakage. If the brake
fluid level goes down suddenly, have a
Yamaha dealer check the cause before
further riding.
1. Minimum level mark
1. Minimum level mark
Specified brake fluid:
DOT 4
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-23
6
EAU22733
Changing the brake fluidHave a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrica-
tion 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.
EAU22762
Drive chain slackThe drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22786
To check the drive chain slack
1. Place the motorcycle on the side-
stand.TIPWhen checking and adjusting the drive
chain slack, there should be no weight
on the motorcycle.2. Shift the transmission into the
neutral position.
3. Measure the drive chain slack as
shown.4. If the drive chain slack is incorrect,
adjust it as follows.
TIPWhen checking the drive chain slack,
the chain tensioner should not be
touching the drive chain.
EAU34318
To adjust the drive chain slack
Consult a Yamaha dealer before ad-
justing 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
1. Drive chain slack
Drive chain slack:
50.0–60.0 mm (1.97–2.36 in)
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