YAMAHA XT660Z 2012 Service Manual

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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03 ingles -austral\:ia 3/5/10 06:00 \:\fágina 41

EAU17101
0-1000 km (0-600 mi)
Avoid prolonged operation a\fove
4500 r/\bin. NOTICE: After 1000 km
(600 mi) of operation, t\fe engine oil
mu\bt be c\fanged, and t\fe oil filter
element replaced.
1000-1600 km (600-1000 mi)
Avoid prolonged operation a\fove
6000 r/\bin.
1600 km (1000 mi) and beyond
The vehicle can now \fe operated nor-
\bally.
ECA10310NOTICE
Keep \fhe engine speed o\b\f of
\fhe \fachome\fer red zone.
If any engine \fro\bble sho\bld oc-
c\br d\bring \fhe engine break-in
period, immedia\fely have a
Yamaha dealer check \fhe
vehicle.
EAU17213
Parking
When parking, stop the engine, and
then re\bove the key fro\b the \bain
switch.
EWA10311
WARNING0
Since \fhe engine and exha\bs\f
sys\fem can become very ho\f,
park in a place where pedes\fri-
ans or children are no\f likely \fo
\fo\bch \fhem and be b\b\prned.
Do no\f park on a slope or on
sof\f gro\bnd, o\fherwise \fhe ve-
hicle may over\f\brn, increasing
\fhe risk of a f\bel l\peak and fire.
Do no\f park near grass or o\fher
flammable ma\ferials which
migh\f ca\fch fire.
OPERATION AND IMPORTANT RIDING POINTS
6-4
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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
EAU17241
Periodic inspection\f adjust\bent\f and
lubrication will keep your vehicle in the
safest and \bost efficient condition
possible. Safety is an obligation of the
vehicle owner/operator. The \bost i\b-
portant points of vehicle inspection\f
adjust\bent\f and lubrication are ex-
plained on the following pages.
The intervals given in the periodic
\baintenance and lubrication char t
should be si\bply considered as a gen-
eral guide under nor\bal riding condi-
tions. However\f depending on the
weather\f terrain\f geographical loca-
tion\f and individual use\f the \bainte-
nance intervals \bay need to be short-
ened.
EWA10321
W\fRNING0
Failure to properly maintain the ve-
hicle or performing maintenance
activities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle
service, have a Yamaha dealer per-
form service.
EAU17391
Owner’s tool kit
1. Owner’s tool kit
The owner’s tool kit is located under
the seat. (See page 4-14).
The service infor\bation included in this
\banual and the tools provided in the
owner’s tool kit are intended to assist
you in the perfor\bance of preventive
\baintenance and \binor repairs. How-
ever\f additional tools such as a torque
wrench \bay be necessary to perfor\b
certain \baintenance work correctly.
TIP
If you do not have the tools or experi-
ence required for a particular job\f have
a Ya\baha dealer perfor\b it for you.
7-1
EWA15121
W\fRNING0
Turn off the engine when perform-
ing maintenance unless otherwise
specified.
\f running engine has moving parts
that can catch on body parts or
clothing and electrical parts that
can cause shocks or\M fires.
Running the engine while servicing
can lead to eye injury, burns, fire, or
carbon monoxide poisoning - pos-
sibly leading to death. See page 2-2
for more information about carbon
monoxide.
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PERIODIC MAINTENANCE AND ADJUSTMENT
EAU46861
TIP● The ann\fal check\b m\f\bt be performed every year, except if a kilometer-ba\bed maintenance, or for the UK, a
mileage-ba\bed mainte\nnance, i\b performed i\nn\btead.
●From 50000 km (3000\)0 mi)\f repea\b \bhe main\)\benance in\bervals s\bar\bing from 10000 km (\)6000 mi).
●I\bems marked wi\bh an as\berisk should be performed by a Yamaha dealer as \bhey require special \bools\f da\ba and \bech-
nical skills.
EAU46910Periodic maintenance chart for the emi\b\bion control \by\btem
7-2
1
2
3
4
5
6
7
8
9
10
NO. ITEM CHECK OR MAINTENAN\nCE JOB
ODOMETER READING
1000 km 10000 km 20000 km 30000 km 40000 km(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
ANNUAL
CHECK
√ √ √ √ √
√ √
√ √
√ √
√ √ √ √ √ √
√ √ √ √ √
√ √ √ √ √1✻
2
3
✻
4✻
5✻
6✻
 Check fuel hoses for cracks or damage.
 Check condi\bion.
 Clean and regap.
 Replace.
 Check valve clearance.
 Adjus\b.
 Adjus\b engine idlin\)g speed.
 Check \bhe screw clamp(s) for
looseness.
 Check \bhe air cu\b-off valve\f reed valve\f and hose for damage.
 Replace any damaged par\bs if necessary.
F\fel line
Spark pl\fg
Valve\b
F\fel injection
M\fffler and exha\f\bt
pipe
Air ind\fction \by\btem
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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-3
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
√ √
√ √ √ √ √
√ √ √
√√
√
√ √ √ √ √ √
√ √ √ √ √
√ √ √ √
√ √ √ √ √
√ √ √ √1
2
3
✻
4✻
5✻
6✻
7✻
8✻
 Replace.
 Check operatio\f.
 Adj\bst.
 Check operatio\f, fl\bid level a\fd vehicle
for fl\bid leakage.
 Replace brake pads.
 Check operatio\f, fl\bid level a\fd vehicle
for fl\bid leakage.
 Replace brake pads.
 Check for cracks or damage.
 Replace.
 Check r\b\fo\bt, spoke tight\fess a\fd for damage.
 Tighte\f spokes if \fecessary.
 Check tread depth a\fd for damage.
 Replace if \fecessar\iy.
 Check air press\bre.
 Correct if \fecessar\iy.
 Check beari\fg for loose\fess or dam\iage.
\fir filter element
Clutch
Front brake
Rear brake
Brake hoses
Wheels
Tires
Wheel bearings
EAU1770C
Ge\feral mai\fte\fa\fce a\fd l\bb\iricatio\f chart
Whe\fever wor\f to the limit
Whe\fever wor\f to the limit Every 4 years
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-4
1
2
3
4
\f
6
7
8
\b
10
NO. ITEM CHECK OR MAINTENAN\4CE JOB
ODOMETER READING
1000 km 10000 km 20000 km 30000 km 40000 km(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
ANNUAL
CHECK
√ √ √ √
√ √ √ √ √ √ √
√√
√
√ √ √ √ √
√ √ √ √ √ √ √ √ √ √
√ √ √ √
√ √ √ √
√ √
√ √ √ √ √ √
13
14
✻
1\f✻
16✻
18
 Check operation and for e\fcessive pla\b.
 Lubricate with lithium-\fsoap-based grease.
 Check chain slack, alignment and condition.
 Adjust and lubricate chain with a\f special
O-ring chain lubricant thoroughl\b.
 Check bearing pla\b and steering
for roughness.
 Lubricate with lithium-\fsoap-based grease.
 Make sure that all nuts, bolts and screws
are properl\b tightened.
 Check operation.
 Lubricate.
 Check operation.
 Check operation and for oil leakage.
 Check operation and shock absorber
for oil leakage.
 Check operation.
 Lubricate with lithium-\fsoap-based grease.
 Change.
 Check oil level and vehicle for oil leakage.
Swingarm
Drive chain
Steering bearings
Chassis fasteners
Sidestand
Sidestand switch
Front fork
Shock absorber
assembly
Rear suspension
relay arm and
connecting arm
pivoting points
Engine oil
Ever\b 50000 km (30000 mi)
Ever\b 50000 km (30000 mi)
Ever\b 500 km (300 mi) and after washing the motorc\bcle or riding in the rain
\b✻
11✻
17✻
12✻
10
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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✻
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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
1
2
3
4
5
6
7
8
9
10
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 M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-7
Panel E and F
1. Panel mounting bolt
2. Qui\fk fastene\b
E. Right panel
F. Left panel
To \bemove one of the panels
1. Remove the bolts.
2. Remove the qui\fk fastene\b and thenpull the panel off at the a\beas
shown.
To install the panel
1. Pla\fe the panel in the o\biginal posi- tion.
2. Install the qui\fk fastene\b and the bolts.
11
2E-F
Panel G
1. Panel mounting bolt
G. Panel
To \bemove the panel
Remove the bolts, and then pull the
panel off at the a\be\Qas shown.
1. Panel
2. Pin
To install the panel
Pla\fe the panel in the o\biginal position,
and then install th\Qe bolts.
2
2
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-8
1
2
3
4
\f
6
7
8
\b
10
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.
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