User manual YAMAHA XT660Z SERVICE MANUAL

[. . . ] 2008 SERVICE MANUAL XT660Z 11D-F8197-E0 XT660Z (2008) SERVICE MANUAL © 2008 by Yamaha Motor Italia S. p. A. First edition, May 2008 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Italia S. p. A. Printed in Italy EAS00020 NOTICE This manual was produced by the Yamaha Motor Italia S. p. A. [. . . ] Install: · Washers New · Cylinder bolts NOTE: · Lubricate the cylinder bolt threads and muting surface with engine oil. · Install the washers with their blunt surface facing up. 5-30 CYLINDER AND PISTON 8. Tighten: · Cylinder bolts Cylinder bolts "1" L = 116 mm (4. 57 in) 1st 15 Nm (1. 5 m·kg, 11 ft·lb) 2nd 50 Nm (5. 0 m·kg, 36 ft·lb) Cylinder bolts "2" L = 109 mm (4. 29 in) 1st 15 Nm (1. 5 m·kg, 11 ft·lb) 2nd 50 Nm (5. 0 m·kg, 36 ft·lb) Cylinder bolts (timing chain side) "3" 10 Nm (1. 0 m·kg, 7. 2 ft·lb) NOTE: Tighten the cylinder bolts in the proper tightening sequence as shown and torque them in two stages. 5-31 CLUTCH EAS00273 CLUTCH Removing the clutch cover Order Engine oil Job/Parts to remove Q'ty Remarks Drain. Refer to "CHANGING THE ENGINE OIL" on page 3-10. 1 2 3 4 5 Clutch cable Clutch cable holder Clutch cover Gasket Dowel pin 1 1 1 1 2 For installation, reverse the removal procedure. 5-32 CLUTCH Removing the pull lever shaft 1 New 3 E 7 New 8 8 6 E 5 4 3 2 New Order 1 2 3 4 5 6 7 8 Circlip Circlip Washer Pull lever Job/Parts to remove Q'ty 1 1 2 1 1 1 1 2 Remarks Pull lever spring Pull lever shaft Oil seal Bearing For installation, reverse the removal procedure. 5-33 CLUTCH Removing the clutch Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Clutch spring Job/Parts to remove Q'ty 5 1 1 4 6 2 1 1 1 1 1 1 1 1 Remarks Pressure plate Pull rod Friction plate 1 Clutch plate Friction plate 2 Friction plate 3 Clutch damper spring Clutch damper spring seat Clutch boss nut Lock washer Clutch boss Thrust washer Clutch housing Inside diameter (plate with notched tabs) = 119 mm (4. 69 in) Inside diameter (plate with no notched tabs) = 119 mm (4. 69 in) Inside diameter (plate with notched tabs) = 128 mm (5. 04 in) For installation, reverse the removal procedure. 5-34 CLUTCH EAS00275 EAS00280 REMOVING THE CLUTCH 1. Remove: · Clutch cover "1" NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates. Check: · Friction plate "1" · Friction plate "2" · Friction plate "3" Damage/wear Replace the friction plates as a set. Measure: · Friction plate 1 thickness · Friction plate 2 thickness · Friction plate 3 thickness Out of specification Replace the friction plates as a set. NOTE: Measure the friction plate at four places. 1 2. Loosen: · Clutch boss nut "1" NOTE: While holding the clutch boss "2" with the universal clutch holder "3", loosen the clutch boss nut. Friction plate 1 thickness 2. 90-3. 10 mm (0. 114-0. 122 in) <Limit>: 2. 80 mm (0. 110 in) Friction plate 2 thickness 2. 92-3. 08 mm (0. 115-0. 121 in) <Limit>: 2. 80 mm (0. 110 in) Friction plate 3 thickness 2. 90-3. 10 mm (0. 114-0. 122 in) <Limit>: 2. 80 mm (0. 110 in) Universal clutch holder 90890-04086 3 2 1 EAS00281 4. Remove: · Clutch boss nut · Lock washer · Clutch boss CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. Check: · Clutch plate Damage Replace the clutch plates as a set. 5-35 CLUTCH 2. Measure: · Clutch plate warpage (with a surface plate and thickness gauge "1") Out of specification Replace the clutch plates as a set. Clutch plate warpage limit 0. 20 mm (0. 0079 in) EAS00284 CHECKING THE CLUTCH HOUSING 1. Check: · Clutch housing dogs Damage/pitting/wear Deburr the clutch housing dogs or replace the clutch housing. NOTE: Pitting on the clutch housing dogs will cause erratic clutch operation. EAS00282 EAS00285 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. Check: · Clutch spring Damage Replace the clutch springs as a set. Measure: · Clutch spring free length "a" Out of specification Replace the clutch springs as a set. Clutch spring free length 55. 60 mm (2. 19 in) <Limit>: 52. 82 mm (2. 08 in) CHECKING THE CLUTCH BOSS The following procedure applies to all of the clutch springs. Check: · Clutch boss splines Damage/pitting/wear Replace the clutch boss. NOTE: Pitting on the clutch boss splines will cause erratic clutch operation. 5-36 CLUTCH EAS00286 CHECKING THE PRESSURE PLATE 1. Check: · Pressure plate "1" Cracks/damage Replace. [. . . ] Clutch · Unevenly tensioned clutch springs · Warped pressure plate · Bent clutch plate · Swollen friction plate · Bent clutch push rod · Damaged clutch boss · Burnt primary driven gear bushing · Damaged clutch release cylinder · Match marks not aligned 2. Engine oil · Incorrect oil level · Incorrect oil viscosity (high) · Deteriorated oil POOR MEDIUM AND HIGH-SPEED PERFORMANCE Refer to "STARTING FAILURES" on page 9-1. Air filter · Clogged air filter element Fuel system 1. Fuel pump · Faulty fuel pump EAS28530 FAULTY GEAR SHIFTING Shifting is difficult Refer to "Clutch drags". EAS28540 SHIFT PEDAL DOES NOT MOVE Shift shaft · Improperly adjusted shift rod · Bent shift shaft Shift drum and shift forks · Foreign object in a shift drum groove · Seized shift fork · Bent shift fork guide bar Transmission · Seized transmission gear · Foreign object between transmission gears · Improperly assembled transmission 9-2 TROUBLESHOOTING EAS28590 EAS28620 OVERHEATING Engine 1. [. . . ]