YAMAHA XT660Z 2008 Owners Manual

XT660Z

11D -F 8199-E 0

O W NER ’S M ANUA L

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DECLARATION of CONFORMITY
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General manager of quality assurance div.
1Version up the norm of EN60950 to EN60950-1
To change company name27 Feb. 2006
1 Mar. 20072
3
Revision record
No. Contents Date
To change contact person and integrate type-designation. 9 Jun. 2005
Date of issue: 1 Aug. 2002
Place of issue: Shizuoka, Japan
R&TTE Directive(1999/5/EC)
EN300 330-2 v1.1.1(2001-6), EN60950-1(2001)
Two or Three-Wheel Motor Vehicles Directive(97/24/EC: Chapter 8, EMC) is in compliance with following norm(s) or documents:
Kind of equipment: IMMOBILIZER
Type-designation: 5SL-00 Hereby declare that the product:
Company: YAMAHA MOTOR ELECTRONICS CO., LTD.
Address: 1450-6, Mori, Mori-Machi, Shuchi-gun, Shizuoka-Ken, 437-0292 JapanWe

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INTRODUCTION
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Welcome to the Yamaha world of motorcycling!
As the owner of the XT660Z Ténéré, you are benefiting from Yamaha’s vast experience and newest technology regarding
the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability.
Please take the time to read this manual thoroughly, so as to enjoy all advantages of your XT660Z Ténéré.
The owner’s manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how
to safeguard yourself and others from trouble and injury.
In addition, the many tips given in this manual will help keep your motorcycle in the best possible condition. If you have
any further questions, do not hesitate to contact your Yamaha dealer.
The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!

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IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations:
WARNING0

NOTE:
CAUTION:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to the
motorcycle operator, a bystander, or a person inspecting or repairing the motorcycle.
A CAUTION indicates special precautions that must be taken to avoid damage to
the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
NOTE:
●This manual should be considered a permanent part of this motorcycle and should remain with it even if the motor-
cycle is subsequently sold.
●Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the
most current product information available at the time of printing, there may be minor discrepancies between your mo-
torcycle and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer..
EWA10030
WARNING0
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
* Product and specifications are subject to change without notice.

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IMPORTANT MANUAL INFORMATION
XT660Z
OWNER'S MANUAL
©2008 by Yamaha Motor Italia S.P.A. 1
stedition, march 2008
All rights reserved.
Any reprinting or unauthorized use without the written permission of Yamaha Motor Italia S.P.A.is expressly prohibited. Printed in the Italy.
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TABLE OF CONTENTS
SAFETY INFORMATION.....................1-1
Safe riding .........................................1-1
Protective apparel .............................1-2
Modifications .....................................1-2
Loading and accessories ..................1-2
Gasoline and exhaust gas ................1-4
DESCRIPTION .....................................2-1
Left view ............................................2-1
Right view .........................................2-2
Controls and instruments ..................2-3
INSTRUMENT AND CONTROL
FUNCTIONS ........................................3-1
Immobilizer system ...........................3-1
Main switch/steering lock ..................3-2
Indicator and warning lights ..............3-3
Multi-function display ........................3-5
Tachometer .......................................3-6
Tripmeter and tachometer modes .....3-6
Clock mode .......................................3-7
Fuel meter .........................................3-7
Self-diagnosis devices ......................3-7
Anti-theft alarm (optional) .................3-8
Handlebar switches ...........................3-9
Clutch lever .....................................3-10
Shift pedal .......................................3-10
Brake lever ......................................3-11
Brake pedal .....................................3-11 Fuel tank cap ..................................3-11
Fuel .................................................3-12
Fuel tank breather hose ..................3-13
Catalytic converter ..........................3-13
Seat .................................................3-14
Adjusting the front fork ....................3-15
Adjusting the shock absorber
assembly ..................................3-16
Sidestand ........................................3-17
Ignition circuit cut-off system ..........3-17
PRE-OPERATION CHECKS ...............4-1
Pre-operation check list ....................4-2
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 MINOR REPAIR .........................6-1
Owner’s tool kit .................................6-1
Periodic maintenance and lubrication chart..........................6-2
Removing and installing the cowling and panels..................................6-8 Checking the spark plug ...................6-8
Engine oil and oil filter element.........6-9
Coolant ............................................6-12
Replacing the air filter element
and cleaning the check hose ..... 6-14
Checking the engine idling speed ...6-15
Checking the throttle cable free play ...................................6-16
Valve clearance ...............................6-16
Tires ................................................6-16
Spoke 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 .........6-22
Changing the brake fluid .................6-23
Drive chain slack .............................6-23
Cleaning and lubricating the drive chain ................................6-25
Checking and lubricating the cables .......................................6-25
Checking and lubricating the throttle grip and cable ..............6-26
Checking and lubricating the brake and clutch levers ............6-26
Lubricating the brake pedal ............6-27
Checking and lubricating the sidestand ..................................6-27

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TABLE OF CONTENTS
Lubricating the rear suspension......6-27
Lubricating the swingarm pivots .....6-28
Checking the front fork ....................6-28
Checking the steering .....................6-29
Checking the wheel bearings..........6-29
Battery.............................................6-30
Replacing the fuses ........................6-31
Replacing a headlight bulb .............6-33
Tail/brake light .................................6-34
Replacing a turn signal light bulb....6-34
Replacing the license plate light bulb ...................................6-35
Replacing an auxiliary light bulb .....6-35
Supporting the motorcycle ..............6-36
Front wheel .....................................6-36
Rear wheel ......................................6-38
Troubleshooting ...............................6-39
Troubleshooting charts ....................6-40
MOTORCYCLE CARE
AND STORAGE ...................................7-1
Care ..................................................7-1
Storage..............................................7-3 SPECIFICATIONS
...............................8-1
CONSUMER INFORMATION ..............9-1
Identification numbers .......................9-1

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1-1
1
2
3
4
5
6
7
8
9
10
SAFETY INFORMATION

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MOTORCYCLES ARE SINGLE
TRACK VEHICLES. THEIR SAFE
USE AND OPERATION ARE DEPEN-
DENT UPON THE USE OF PROPER
RIDING TECHNIQUES AS WELL AS
THE EXPERTISE OF THE OPERA-
TOR. EVERY OPERATOR SHOULD
KNOW THE FOLLOWING REQUIRE-
MENTS BEFORE RIDING THIS MO-
TORCYCLE.
HE OR SHE SHOULD:
●OBTAIN THOROUGH INSTRUC-
TIONS FROM A COMPETENT
SOURCE ON ALL ASPECTS OF
MOTORCYCLE OPERATION.
●OBSERVE THE WARNINGS
AND MAINTENANCE REQUIRE-
MENTS IN THE OWNER'S MAN-
UAL.
●OBTAIN QUALIFIED TRAINING
IN SAFE AND PROPER RIDING
TECHNIQUES.
●OBTAIN PROFESSIONAL TECH-
NICAL SERVICE AS INDICATED
BY THE OWNER'S MANUAL
AND/OR WHEN MADE NECES-
SARY BY MECHANICAL CONDI-
TIONS. Safe riding
●Always make pre-operation
checks. Careful checks may help
prevent an accident.
●This motorcycle is designed to
carry the operator and a passen-
ger.
●The failure of motorists to detect
and recognize motorcycles in traf-
fic is the predominating cause of
automobile/motorcycle accidents.
Many accidents have been
caused by an automobile driver
who did not see the motorcycle.
Making yourself conspicuous ap-
pears to be very effective in re-
ducing the chance of this type of
accident.
Therefore: • Wear a brightly colored jacket.
• Use extra caution when you areapproaching and passing
through intersections, since in-
tersections are the most likely
places for motorcycle accidents
to occur. • Ride where other motorists can
see you. Avoid riding in another
motorist's blind spot.
●Many accidents involve inexperi-
enced operators. In fact, many op-
erators who have been involved in
accidents do not even have a cur-
rent motorcycle license.
• Make sure that you are quali-fied and that you only lend your
motorcycle to other qualified
operators.
• Know your skills and limits. Staying within your limits may
help you to avoid an accident.
• We recommend that you prac- tice riding your motorcycle
where there is no traffic until
you have become thoroughly
familiar with the motorcycle and
all of its controls.
●Many accidents have been
caused by error of the motorcycle
operator. A typical error made by
the operator is veering wide on a
turn due to EXCESSIVE SPEED
or undercornering (insufficient
lean angle for the speed).

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