light YAMAHA XT660Z 2012 User Guide

ECA10260CAUTION:
Even with the tran\fmi\f\fion in
the neutra\b po\fition, do not
coa\ft for \bong period\f of time
with the engine off, and do not
tow the motorcyc\be for \bong
di\ftance\f. The tran\fmi\f\fion i\f
proper\by \bubricated on\by when
the engine i\f running. Inade-
quate \bubrication may damage
the tran\fmi\f\fion.
A\bway\f u\fe the c\butch whi\be
changing gear\f to avoid dam-
aging the engine, tran\fmi\f\fion,
and drive train, which are not
de\figned to with\ftand the
\fhock of forced \fhifting.
EAU16810
Tip\f for reducing fue\b
con\fumption
Fuel consum\ftion de\fends l\brgely on
your riding style. Consider the follow-
ing ti\fs to reduce f\muel consum\ftion:
Shift u\f swiftly, \bnd \bvoid high en-
gine s\feeds during \bc\mceler\btion.
Do not rev the engine while shift-
ing down, \bnd \bvoid high engine
s\feeds with no lo\bd on the en-
gine.
Turn the engine off inste\bd of let-
ting it idle for \bn extended length
of time (e.g., in tr\bffic j\bms, \bt tr\bf-
fic lights or \bt r\bil\mro\bd crossings).
EAU16841
Engine break-in
There is never \b more im\fort\bnt \feri-
od in the life of your engine th\bn the
\feriod between 0 \bnd 1600 km (1000
mi). For this re\bson, you should re\bd
the following m\bteri\m\bl c\brefully.
Since the engine is br\bnd new, do not
\fut \bn excessive lo\bd on it for the first
1600 km (1000 mi). The v\brious \f\brts
in the engine we\br \bnd \folish them-
selves to the correct o\fer\bting cle\br-
\bnces. During this \feriod, \frolonged
full-throttle o\fer\btion or \bny condition
th\bt might result in engine overhe\bting
must be \bvoided.
OPERATION AND IMPORTANT RIDING POINTS
6-3
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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-57-5
EAUM1890
TIP
●Replace t\fe air filte\tr ele\bent \bore frequen\ttly if you are riding in unusually wet or dusty areas.
●Hydraulic brake service
●Regularly c\feck and, if necessary, correct t\fe brake fluid level.
●Every two years replace t\fe inter\tnal co\bponents of t\fe \tbrake \baster cylinder, and c\fange t\fe brake fluid.
●Replace t\fe brake \foses every four years and if cracked or da\baged.
NO. ITEMCHECK OR M\fINTEN\fNCE\M JOB
ODOMETER RE\fDING
1000 km 10000 km 20000 km 30000 km 40000 km(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
\fNN\b\fL
CHECK
√ √ √
√ √ √ √ √
√ √ √ √ √ √ √ √ √ √ √
√ √ √ √ √
√ √ √ √ √ √ Replace.
 C\feck coolant level and ve\ficle for coolant leakage.
 C\fange.
 C\feck operation.
 Lubricate.
 C\feck operation and free play.
 Adjust t\fe t\frottle cab\tle free play if necessary.
 Lubricate t\fe t\frottle grip \fousing
and cable.
 C\feck operation.
 Adjust \feadlig\ft bea\b.\t
Engine oil filter
element
Cooling system
Front and rear brake
switches
Moving parts and
cables
Throttle grip housing
and cable
Lights, signals and
switches
Every 3 years
19
22 20
✻
21✻
24✻
23✻
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-5

PERIODIC MAINTENANCE AND ADJUSTMENT
EAU18722
Remov\fng an\b \fnstall\fng the
cowl\fng an\b panels
The cowling an\f panels shown nee\f
to \be remove\f to perform some of the
maintenance jo\bs \fescri\be\f in this
chapter. Refer to this section each
time the cowling or a panel nee\fs to
\be remove\f an\f installe\f.
EAUB1540
Panel A an\b B
1. Panel mounting \bolt
A. Right panel
B. Left panel
To remove one of the panels
Remove the \bolts, an\f then pull the
panel off at the area\as shown.
Panel C an\b D
1. Panel mounting \bolt
C. Right panel
D. Left panel
To remove one of the panels
Remove the \bolts, an\f then pull the
panel off at the area\as shown.
To install the panel
Place the panel in the original position,
an\f then install the \b\aolts.
7-6
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1. Panel
2. Turn signal light coupler
3. Pin
To install the panel
Place the panel in the original position,
an\f then install the \b\aolts.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-8
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2. Remove the spark pl\fg as shown\b with the spark pl\fg wrench incl\fd-
ed in the owner’s tool kit.
To check the spark plug 1. Check that the porcelain ins\flator aro\fnd the center electrode of the
spark pl\fg is a medi\fm-to-light
tan (the ideal color when the vehi-
cle is ridden normally).
TIP
If the spark pl\fg shows a distinctly dif-
ferent color\b the engine co\fld be oper-
ating improperly. Do not attempt to di-
agnose s\fch problems yo\frself.
Instead\b have a Yamaha dealer check
the vehicle.
2. Check the spark pl\fg for elec- trode erosion and excessive car-
bon or other deposits\b and re-
place it if necessa\lry.
Specified spark plu\4g:CR7E (NGK)
Spark plug gap:0.7-0.8 mm (0.028-0\l.032 in)
To install the spark plug
1. Meas\fre the spark pl\fg gap with a wire thickness ga\fge and\b if
necessar y\b adj\fst the gap to
specification.
1. Spark pl\fg gap
2. Clean the s\frface of the sparkpl\fg gasket and its mating s\fr-
face\b and then wipe off any grime
from the spark pl\fg threads.
3. Install the spark pl\fg with the spark pl\fg wrench\b and then tight-
en it to the specif\lied torq\fe.
EAU19603
Checking the spark plug
The spark pl\fg is an important engine
component\b which is easy to check.
Since heat and deposits will ca\fse
any spark pl\fg to slowly erode\b the
spark pl\fg sho\fld be removed and
checked in accordance with the peri-
odic maintenance and l\fbrication
chart. In addition\b the condition of the
spark pl\fg can reveal the condition of
the engine.
To remove the spark plug
1. Spark pl\fg cap
2. Spark pl\fg wrench
1. Remove the spark pl\fg cap.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-8

PERIODIC MAINTENANCE AND ADJUSTMENT
7-32
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ECA10640
NOTICE
Do not use a fuse of a higher am-
perage rating than recommended
to avoid causing extensive damage
to the electrical system and possi-
bly a fire.
3. Turn th\f k\fy to \bON” and turn on th\f \fl\fctrical circuit in qu\fstion to
ch\fck if th\f d\fvic\f op\frat\fs.
4. If th\f fus\f imm\fdiat\fly blows again, hav\f a Yamaha d\fal\fr
ch\fck th\f \fl\fctrical syst\fm.
1. Parking lighting fus\f
2. Signaling syst\fm fus\f
3. H\fadlight fus\f
4. Ignition fus\f
5. El\fctronic fu\fl inj\fction fus\f
6. Radiator fan fus\f
7. Backup fus\f
8. R\fs\frv\f fus\fs
Th\f main fus\f and fus\f box ar\f locat-
\fd und\fr th\f s\fat. (S\f\f pag\f 7-31.)
If a fus\f is blown, r\fplac\f it as follows.1. Turn th\f k\fy to \bOFF” and turn off th\f \fl\fctrical circuit in qu\fstio\hn.
2. R\fmov\f th\f blown fus\f, and th\fn install a n\fw fus\f of th\f sp\fcifi\fd
amp\frag\f.
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654321Specified fuses:
Main fus\f:30 A
Parking lighting fus\f: 10 A
Signalling syst\fm fus\h\f: 10 A
H\fadlight fus\f: 20 A
Ignition fus\f: 10 A
Fu\fl inj\fction syst\fm \hfus\f: 10 A
Radiator fan fus\f: 7.5 A
Backup fus\f (for odom\ft\fr,
clock and immobiliz\fr): 10 A
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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-33
EAUB1580
Replacing a headlight bulb
1. Headli\fht b\blb cover
1. Headli\fht co\bpler
2. Headli\fht b\blb holder
3. Headli\fht b\blb
EWA10790
W\fRNING0
Headlight bulbs get very hot. There-
fore, keep flammable products
away from a lit headlight bulb, and
do not touch the bulb until it has
cooled down.3. Place a new headli\fht b\blb into position, and then sec\bre it with
the b\blb holder.
1. Do not to\bch this area
1. Headli\fht b\blb holder
2. Headli\fht b\blb
This model is eq\bipped with q\bartz
b\blb headli\fhts. If a headli\fht b\blb
b\brns o\bt, replace it a\is follows.1. Remove the headli\fht b\blb cover, and then disconnect the headli\fht
co\bpler.
2. Unhook the headli\fht b\blb holder, and then remove the defective
b\blb.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-33

PERIODIC MAINTENANCE AND ADJUSTMENT
7-34
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ECA10650
NOTICE
Take care not to damage the fol-
lowing parts:
●Headlight bulb  Do not touch the glass part
of the headlight bulb to keep
it free from oil, otherwise the
transparency of the glass,
the luminosity of the bulb,
and the bulb life will be ad-
versely affected. Thoroughly
clean off any dirt and finger-
prints on the headlight bulb
using a cloth moistened with
alcohol or thinner.
●Headlight lens
 Do not affix any type of tinted
film or stickers to the head-
light lens.
 Do not use a headlight bulb
of a wattage higher than
specified. 4. Connect t\fe couple\b, and t\fen in-
stall t\fe \feadlig\ft bulb cove\b.
5. Have a Yama\fa deale\b adjust t\fe \feadlig\ft beam if nec\ essa\by.
EAU24204
Replacing a turn signal
light bulb
1. Sc\bew
2. Tu\bn signal lig\ft lens
3. Tu\bn signal lig\ft bulb
1. Remove t\fe tu\bn signal lig\ft lensby \bemoving t\fe sc\bew.
2. Remove t\fe bu\bnt-out bulb by pus\fing it in and tu\bning it coun-
te\bclockwise.
3. Inse\bt a new bulb into t\fe socket, pus\f it in, and t\fen tu\bn it clock-
wise until it stops.
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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-35
EAU42652
Replacing an auxiliary light
bulb
1. Auxiliary\flight\f\bocket
2. Auxiliary\flight\fbulb
Thi\b\fmodel\fi\b\fequipped\fwith\ftwo\fauxil-
iary\f light\b.\f If\f an\f auxiliary\f light\f bulb
burn\b\fout,\freplace\fit\fa\b\ff\yollow\b.1. Remove\fpanel\fG.\f(See\fpage\f7-7.)
2. Remove\fthe\fauxiliary\flight\f\bocket\f(to- gether\fwith\fthe\fbulb)\fby\fpulling\fit\fout.
3. Remove\f the\f burnt-out\f bulb\f by pulling\fit\fout.
4. In\bert\fa\fnew\fbulb\finto\fthe\f\bocket.
5. In\btall\f the\f auxiliary\f light\f \bocket (together\f with\f the\f bulb)\f by\f pu\bh-
ing\fit\fin.
6. In\btall\fthe\fpanel.
EAUM2202
Replacing the license plate
light bulb
1. Bulb\f\bocket
2. Licen\be\fplate\flight\fbulb
1. Remove\fthe\f\bocket\f(together\fwith the\fbulb)\fby\fpulling\fit\fout.
2. Remove\f the\f burnt-out\f bulb\f by pulling\fit\fout.
3. In\bert\fa\fnew\fbulb\finto\fthe\f\bocket.
4. In\btall\f the\f \bocket\f (together\f with the\fbulb)\fby\fpu\bhing\fit\fin.
4. In\btall\f the\f len\b\f by\f in\btalling\f the\bcrew.\f NOTICE: Do not over-
tighten the screw, otherwise
the lens may break.
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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-39
TIP
●Make sure that the slot in the
brake \faliper bra\fket is fit over the
retainer on the s\bingarm.
●Make sure that there is enough
spa\fe bet\been the brake pads
before installing the\b \bheel.
2. Install the drive \fhain onto the rear spro\fket.
3. Install the axle nut, and then lo\b- er the rear \bheel so that it is on
the ground.
4. Adjust the drive \fhain sla\fk. (See page 7-24.)
5. Apply the rear brake several times, and then tighten the axle
nut to the spe\fified\b torque.
Tightening torque:
Axle nut:105 Nm (10.5 m·kgf, 75 ft·lbf)
EAU25871
Troubleshooting
Although Yamaha motor\fy\fles re\feive
a thorough inspe\ftion before shipment
from the fa\ftory, trouble may o\f\fur
during operation. Any problem in the
fuel, \fompression, or ignition systems,
for example, \fan \fause poor starting
and loss of po\ber.
The follo\bing troubleshooting \fharts
represent qui\fk and easy pro\fedures
for \fhe\fking these vital systems your-
self. Ho\bever, should your motor\fy\fle
require any repair, take it to a Yamaha
dealer, \bhose skilled te\fhni\fians have
the ne\fessary tools, experien\fe, and
kno\b-ho\b to servi\fe the motor\fy\fle
properly.
Use only genuine Yamaha repla\fe-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter servi\fe life and
\fan lead to expensive repair bills.
EWA15141
W\fRNING0
When checking the fuel system, do
not smoke, and make sure there
are no open flames or sparks in the
area, including pilot lights from wa-
ter heaters or furnaces. Gasoline or
gasoline vapors can ignite or ex-
plode, causing severe injury or
property damage.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-39

MOTORCYCLE CARE AND STORAGE
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EAU26004
Care
While the ope\f desig\f o\b a motorcycle
reveals the attractive\fess o\b the tech-
\fology, it also makes it more vul\fera-
ble. Rust a\fd corrosio\f ca\f develop
eve\f i\b high-quality compo\fe\fts are
used. A rusty exhaust pipe may go u\f-
\foticed o\f a car, however, it detracts
\brom the overall appeara\fce o\b a mo-
torcycle. Freque\ft a\fd proper care
does \fot o\fly comply with the terms o\b
the warra\fty, but it will also keep your
motorcycle looki\fg good, exte\fd its
li\be a\fd optimize its per\borma\fce.
Before cleaning 1. Cover the mu\b\bler outlet with a plastic bag a\bter the e\fgi\fe has
cooled dow\f.
2. Make sure that all caps a\fd cov- ers as well as all electrical cou-
plers a\fd co\f\fectors, i\fcludi\fg
the spark plug cap, are tightly i\f-
stalled. 3. Remove extremely stubbor\f dirt,
like oil bur\ft o\fto the cra\fkcase,
with a degreasi\fg age\ft a\fd a
brush, but \fever apply such prod-
ucts o\fto seals, gaskets, sprockets,
the drive chai\f a\fd wheel axles. Al-
ways ri\fse the dirt a\fd degreaser
o\b\b with water.
Cleaning
ECA10772
NOTICE
●Avoid using strong acidic
wheel cleaners, especially on
spoked wheels. If such prod-
ucts are used on hard-to-re-
move dirt, do not leave the
cleaner on the affected area
any longer than instructed. Al-
so, thoroughly rinse the area
off with water, immediately dry
it, and then apply a corrosion
protection spray.
●Improper cleaning can damage
plastic parts (such as cowlings,
panels, windshields, headlight
lenses, meter lenses, etc.) and
the mufflers. Use only a soft,
clean cloth or sponge with wa- ter to clean plastic. However, if
the plastic parts cannot be
thoroughly cleaned with water,
diluted mild detergent with wa-
ter may be used. Be sure to
rinse off any detergent residue
using plenty of water, as it is
harmful to plastic p\5arts.
●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 flu-
id, antifreeze or electrolyte.
●Do not use high-pressure
washers or steam-jet cleaners
since they cause water seep-
age and deterioration in the fol-
lowing areas: seals (of wheel
and swingarm bearings, fork
and brakes), electric compo-
nents (couplers, connectors,
instruments, switches and
lights), breather hoses and
vents.
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