warning YAMAHA XT660Z 2013 Owner's Manual

ECAS0040
The following warning lights and
indicator lights should come on for
a few seconds, then go off.
Neutral indicator light
Turn signal indicator light
High beam indicator light
Engine trouble warning light
Coolant temperature warning
light
Immobilizer system indicator
light
ABS warning light (for ABS
model)
If a warning or indicator light does
not go off, see page 3-4 for the
corresponding warning and indica-
tor light circuit check.
2. Shift the transmission into the
neutral position.
TIP
When the transmission is in the neu-
tral position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical
circuit.
3. Start the engine by pushing the
start switch. NOTICE: For maxi-
mum engine life, never accele-
rate hard when the engine is
cold!
[ECA11041]
TIP
If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the
engine more than 10 seconds on any
one attempt.
TIP
The engine is warm when it quickly
responds to the throttle.
EAU16671
Shifting
1. Shift pedal
2. Neutral position
Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing
hills, etc.
The gear positions are shown in the
illustration.
TIP
To shift the transmission into the neu-
tral position, press the shift pedal
down repeatedly until it reaches the
end of its travel, and then slightly rai-
se it.
NOTICE
OPERATION AND IMPORTANT RIDING POINTS
5-2
5

1600 km (1000 mi) and beyond
The vehicle can now be operated
normally.
ECA10310
Keep the engine speed out of
the tachometer red zone.
If any engine trouble should
occur during the engine break-
in period, immediately have a
Yamaha dealer check the vehi-
cle.
EAU17213
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EWA10311
Since the engine and exhaust
system can become very hot,
park in a place where pedes-
trians or children are not likely
to touch them and be burned.
Do not park on a slope or on
soft ground, otherwise the
vehicle may overturn, increa-
sing the risk of a fuel leak and
fire.
Do not park near grass or other
flammable materials which
might catch fire.
WARNING
NOTICE
OPERATION AND IMPORTANT RIDING POINTS
5-4
5

PERIODIC MAINTENANCE AND ADJUSTMENT
6-1
6
EAU17243
Periodic inspection, adjustment, and
lubrication will keep your vehicle in
the safest and most efficient condi-
tion possible. Safety is an obligation
of the vehicle owner/operator. The
most important points of vehicle ins-
pection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance charts should be simply
considered as a general guide under
normal riding conditions. However,
depending on the weather, terrain,
geographical location, and individual
use, the maintenance intervals may
need to be shortened.
EWA10321
Failure to properly maintain the
vehicle 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.
EWA15121
Turn off the engine when perfor-
ming maintenance unless otherwi-
se specified.
A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.
Running the engine while servi-
cing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 1-1 for more
information about carbon
monoxide.
EWA15460
Brake discs, calipers, drums, and
linings can become very hot during
use. To avoid possible burns, let
brake components cool before tou-
ching them.
EAU17381
Owner’s tool kit
1. Owner’s tool kit
The owner’s tool kit is located under
the seat. (See page 3-16).
The service information included in
this manual and the tools provided in
the owner’s tool kit are intended to
assist you in the performance of pre-
ventive maintenance and minor
repairs. However, additional tools
such as a torque wrench may be
necessary to perform certain mainte-
nance work correctly.
WARNING
WARNING
WARNING

EAUB1561
Engine oil and oil filter
element
The engine oil level should be chec-
ked before each ride. In addition, the
oil must be changed and the oil filter
element replaced at the intervals spe-
cified in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the vehicle on a level surfa-
ce and hold it in an upright posi-
tion.
TIP
Make sure that the vehicle is positio-
ned straight up when checking the oil
level. A slight tilt to the side can result
in a false reading.
2. Start the engine, warm it up for
10–15 minutes, and then turn it
off.
3. Remove the oil filler cap, wipe the
dipstick clean, insert it back into
the oil filler hole (without scre-
wing it in), and then remove it
again to check the oil level.
TIP
The engine oil tank is located
inside of the frame.
The engine oil should be between
the minimum and maximum level
marks.
1. Engine oil filler cap
2. Maximum level mark
3. Minimum level mark
EWA10361
Never remove the engine oil tank
cap after high-speed operation,
otherwise hot engine oil could
spout out and cause damage or
injury. Always let the engine oil cool
down sufficiently before removing
the oil tank cap.
4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to rai-
se it to the correct level. NOTICE:
Do not operate the vehicle until
you know that the engine oil
level is sufficient.
[ECA10011]
5. Install the oil filler cap.
To change the engine oil (with or
without oil filter element
replacement)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Remove the engine guard by
removing the screws.
1. Screw
2. Engine guard
WARNING
PERIODIC MAINTENANCE AND ADJUSTMENT
6-11
6

EAU20070
Coolant
The coolant level should be checked
before each ride. In addition, the coo-
lant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAU20253
To check the coolant level
1. Place the vehicle on a level surface
and hold it in an upright position.
TIP
The coolant level must be chec-
ked on a cold engine since the
level varies with engine tempera-
ture.
Make sure that the vehicle is
positioned straight up when
checking the coolant level. A
slight tilt to the side can result in
a false reading.
2. Check the coolant level in the
coolant reservoir.
TIP
The coolant should be between the
minimum and maximum level marks.
1. Coolant reservoir
2. Maximum level mark
3. Minimum level mark
4. Coolant reservoir cap
3. If the coolant is at or below the
minimum level mark, remove
panel E (See page 6-8). , remove
the reservoir cap, add coolant to
the maximum level mark, and
then install the reservoir cap and
the panel. WARNING! Remove
only the coolant reservoir cap.
Never attempt to remove the
radiator cap when the engine is
hot.
[EWA15161]
NOTICE: If coolant is not avai-
lable, use distilled water or soft
tap water instead. Do not use
hard water or salt water since it
is harmful to the engine. If
water has been used instead of
coolant, replace it with coolant
as soon as possible, otherwise
the cooling system will not be
protected against frost and
corrosion. If water has been
added to the coolant, have a
Yamaha dealer check the anti-
freeze content of the coolant
as soon as possible, otherwise
the effectiveness of the coolant
will be reduced.
[ECA10472]
Coolant reservoir capacity (up to
the maximum level mark):
0.50 L (0.53 US qt, 0.44 Imp.qt)
PERIODIC MAINTENANCE AND ADJUSTMENT
6-14
6

EAU33031
Changing the coolant
The coolant must be changed at the
intervals specified in the periodic
maintenance and lubrication chart.
Have a Yamaha dealer change the
coolant. WARNING! Never attempt
to remove the radiator cap when
the engine is hot.
[EWA10381]EAUB1481
Replacing the air filter
element and cleaning the
check hose
The air filter element should be repla-
ced at the intervals specified in the
periodic maintenance and lubrication
chart. Replace the air filter element
more frequently if you are riding in
unusually wet or dusty areas. In addi-
tion, the air filter check hose must be
frequently checked and cleaned if
necessary.
To replace the air filter element
1. Remove the seat. (See page
3-16).
2. Remove the air filter case cover
by removing the screws.
1. Air filter case cover
2. Screw
3. Pull the air filter element out.
4. Insert a new air filter element into
the air filter case as shown.
NOTICE: Make sure that the air
filter element is properly sea-
ted in the air filter case. The
engine should never be opera-
ted without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s)
may become excessively worn.
[ECA10481]
PERIODIC MAINTENANCE AND ADJUSTMENT
6-15
6

EAU21383
Checking the throttle cable
free play
1. Throttle grip free play
The throttle cable free play should
measure 3.0–5.0 mm (0.12–0.20 in) at
the inner edge of the throttle grip.
Periodically check the throttle cable
free play and, if necessary, have a
Yamaha dealer adjust it.
EAU21401
Valve clearance
The valve clearance changes with
use, resulting in improper air-fuel mix-
ture and/or engine noise. To prevent
this from occurring, the valve clearan-
ce must be adjusted by a Yamaha
dealer at the intervals specified in the
periodic maintenance and lubrication
chart.
EAU21642
Tires
To maximize the performance, durabi-
lity, and safe operation of your
motorcycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be chec-
ked and, if necessary, adjusted befo-
re each ride.
EWA10503
Operation of this vehicle with
improper tire pressure may
cause severe injury or death
from loss of control.
The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperatu-
re of the tires equals the
ambient temperature).
The tire air pressure must be
adjusted in accordance with
the riding speed and with the
total weight of rider, passenger,
cargo, and accessories appro-
ved for this model.
WARNING
PERIODIC MAINTENANCE AND ADJUSTMENT
6-17
6

EWA10511
Never overload your vehicle. Ope-
ration of an overloaded vehicle
could cause an accident.
Tire inspection
1. Tire sidewall
2. Tire tread depth
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer replace
the tire immediately.
TIPThe tire tread depth limits may differ
from country to country. Always comply
with the local regulations.
Tire information
This motorcycle is equipped with tube
tires.
EWA10461
The front and rear tires should be of
the same make and design, other-
wise the handling characteristics of
the vehicle may be different, which
could lead to an accident.
After extensive tests, only the tires lis-
ted below have been approved for
this model by Yamaha Motor Co., Ltd.
WARNING
Minimum tire tread depth (front
and rear):
1.6 mm (0.06 in)
WARNINGTire air pressure (measured on
cold tires):
0–90 kg (0–198 lb):
Front:
210 kPa (2.10 kgf/cm
2,
30 psi, 2.10 bar)
Rear:
230 kPa (2.30 kgf/cm
2,
33 psi, 2.30 bar)
XT660Z 90–190 kg (198–419 lb)
XT660ZA 90–188 kg (198–414 lb):
Front:
230 kPa (2.30 kgf/cm
2,
33 psi, 2.30 bar)
Rear:
250 kPa (2.50 kgf/cm
2,
36 psi, 2.50 bar)
Off-road riding:
Front:
200 kPa (2.00 kgf/cm
2,
29 psi, 2.00 bar)
Rear:
200 kPa (2.00 kgf/cm
2,
29 psi, 2.00 bar)
High-speed riding:
Front:
210 kPa (2.10 kgf/cm
2,
30 psi, 2.10 bar)
Rear:
230 kPa (2.30 kgf/cm
2,
33 psi, 2.30 bar)
Maximum load*:
XT660Z: 190 kg (419 lb)
XT660ZA: 188 kg (414 lb)
* Total weight of rider, passenger,
cargo and accessories
PERIODIC MAINTENANCE AND ADJUSTMENT
6-18
6

PERIODIC MAINTENANCE AND ADJUSTMENT
6-19
6
EWA10570
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding
stability and can lead to loss of
control.
The replacement of all wheel-
and brake-related parts, inclu-ding the tires, should be left to
a Yamaha dealer, who has the
necessary professional know-
ledge and experience.
It is not recommended to patch
a punctured tube. If unavoida-
ble, however, patch the tube
very carefully and replace it as
soon as possible with a high-
quality product.
EAU21942
Spoke wheelsEWA10610
The wheels on this model are not
designed for use with tubeless
tires. Do not attempt to use tube-
less tires on this model.
To maximize the performance, durabi-
lity, and safe operation of your
motorcycle, note the following points
regarding the specified wheels.
The wheel rims should be chec-
ked for cracks, bends or warpa-
ge, and the spokes for looseness
or damage before each ride. If
any damage is found, have a
Yamaha dealer replace the whe-
el. Do not attempt even the sma-
llest repair to the wheel. A defor-
med or cracked wheel must be
replaced.
The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced.
An unbalanced wheel can result
in poor performance, adverse
handling characteristics, and a
shortened tire life.
WARNING
WARNING
Front tire:
Size:
XT660Z 90/90-21M/C 54S
XT660Z 90/90-21M/C 54T
XT660ZA 90/90-21M/C 54S
Manufacturer/model:
XT660Z METZELER/ TOURANCE
XT660Z MICHELIN/SIRAC
XT660ZA PIRELLI/SCORPION
TRAIL
Rear tire:
Size:
XT660Z 130/80-17M/C 65S
XT660Z 130/80-17M/C 65T
XT660ZA 130/80-17M/C 65S
Manufacturer/model:
XT660Z METZELER/ TOURANCE
XT660Z MICHELIN/SIRAC
XT660ZA PIRELLI/SCORPION
TRAIL

EAU23093
Checking and lubricating the
cables
The operation of all control cables
and the condition of the cables
should be checked before each ride,
and the cables and cable ends should
be lubricated if necessary. If a cable is
damaged or does not move smoothly,
have a Yamaha dealer check or repla-
ce it.
EWA10711
Damage to the outer housing of
cables may result in internal rusting
and cause interference with cable
movement. Replace damaged
cables as soon as possible to pre-
vent unsafe conditions.
EAU23142
Checking and lubricating the
brake and clutch levers
Brake lever
Clutch lever
The operation of the brake and clutch
levers should be checked before eachride, and the lever pivots should be
lubricated if necessary.Recommended lubricants:
Brake lever:
Silicone grease
Clutch lever:
Lithium-soap-based grease
Recommended lubricant:
Yamaha Chain and Cable Lube or
engine oil
WARNING
PERIODIC MAINTENANCE AND ADJUSTMENT
6-25
6