YAMAHA XT660Z 2013 Manual PDF

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
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6

EAU23182
Checking and lubricating the
brake pedal
The operation of the brake pedal
should be checked before each ride,
and the pedal pivot should be lubrica-
ted if necessary.
EAU23202
Checking and lubricating the
sidestand
The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated
if necessary.
EWA10731
If the sidestand does not move up
and down smoothly, have a Yama-
ha dealer check or repair it. Other-
wise, the sidestand could contact
the ground and distract the opera-
tor, resulting in a possible loss of
control.
Recommended lubricant:
Lithium-soap-based grease
WARNINGRecommended lubricant:
Silicone grease
PERIODIC MAINTENANCE AND ADJUSTMENT
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6

PERIODIC MAINTENANCE AND ADJUSTMENT
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6
EAU23251
Lubricating the rear
suspension
The pivoting points of the rear sus-
pension must be lubricated by a
Yamaha dealer at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
EAUM1651
Lubricating the swingarm
pivots
The swingarm pivots must be lubrica-
ted by a Yamaha dealer at the inter-
vals specified in the periodic mainte-
nance and lubrication chart.
EAU23272
Checking the front fork
The condition and operation of the
front fork must be checked as follows
at the intervals specified in the perio-
dic maintenance and lubrication
chart.
To check the condition
1. Check the inner tubes for scrat-
ches, damage and excessive oil
leakage.
To check the operation
1. Place the vehicle on a level surfa-
ce and hold it in an upright posi-
tion. WARNING! To avoid injury,
securely support the vehicle so
there is no danger of it falling
over.
[EWA10751]
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and
rebounds smoothly.
Recommended lubricant:
Lithium-soap-based grease
Recommended lubricant:
Lithium-soap-based grease

PERIODIC MAINTENANCE AND ADJUSTMENT
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6
ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or
repair it.
EAU23283
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the opera-
tion of the steering must be checked
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.
1. Place a stand under the engine to
raise the front wheel off the
ground. (See page 6-35 for more
information.) WARNING! To
avoid injury, securely support
the vehicle so there is no dan-
ger of it falling over.
[EWA10751]
2. Hold the lower ends of the front
fork legs and try to move them
forward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the stee-
ring.
NOTICE

EAU23291
Checking the wheel bearings
The front and rear wheel bearings
must be checked at the intervals spe-
cified in the periodic maintenance and
lubrication chart. If there is play in the
wheel hub or if the wheel does not
turn smoothly, have a Yamaha dealer
check the wheel bearings.
EAUS1910
Battery
To access the battery (XT660Z):
The battery is located under the seat.
(See page 3-16).
Remove the battery holder bracket by
removing the bolts.
1. Positive battery terminal
2. Holder
3. Bolt
4. Negative battery terminal
Battery (XT660ZA):
The battery is located under the fuel
tank.
1. Battery
Have a Yamaha dealer access the
battery.
These models are equipped with a
VRLA (Valve Regulated Lead Acid)
battery. There is no need to check the
electrolyte or to add distilled water.
However, the battery lead connec-
tions need to be checked and, if
necessary, tightened.
ECA10620
Never attempt to remove the bat-
tery cell seals, as this would per-
manently damage the battery.
NOTICE
PERIODIC MAINTENANCE AND ADJUSTMENT
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6

EWA10760
Electrolyte is poisonous and
dangerous since it contains
sulfuric acid, which causes
severe burns. Avoid any con-
tact with skin, eyes or clothing
and always shield your eyes
when working near batteries.
In case of contact, administer
the following FIRST AID.
•EXTERNAL: Flush with plenty
of water.
•INTERNAL: Drink large quan-
tities of water or milk and
immediately call a physician.
•EYES: Flush with water for 15
minutes and seek prompt
medical attention.
•Batteries produce explosive
hydrogen gas. Therefore,
keep sparks, flames, cigaret-
tes, etc., away from the bat-
tery and provide sufficient
ventilation when charging it
in an enclosed space.
KEEP THIS AND ALL BATTE-
RIES OUT OF THE REACH OF
CHILDREN.
To charge the battery:
Have a Yamaha dealer charge the
battery as soon as possible if it seems
to have discharged. Keep in mind that
the battery tends to discharge more
quickly if the vehicle is equipped with
optional electrical accessories.
ECA16521
To charge a VRLA (Valve Regulated
Lead Acid) battery, a special (cons-
tant-voltage) battery charger is
required. Using a conventional bat-
tery charger will damage the bat-
tery.
To store the battery:
1. If the vehicle will not be used for
more than one month, remove
the battery, fully charge it, and
then place it in a cool, dry place.
NOTICE: When removing the
battery, be sure the key is tur-
ned to “OFF”, then disconnect
the negative lead before dis-
connecting the positive lead.
[ECA16302]
2. If the battery will be stored for
more than two months, check it
at least once a month and fully
charge it if necessary.
3. Fully charge the battery before
installation. NOTICE: When ins-
talling the battery, be sure the
key is turned to “OFF”, then
connect the positive lead befo-
re connecting the negative
lead.
[ECA16840]
4. After installation, make sure that
the battery leads are properly
connected to the battery termi-
nals.
ECA16530
Always keep the battery charged.
Storing a discharged battery can
cause permanent battery damage.
NOTICE
NOTICE
WARNING
PERIODIC MAINTENANCE AND ADJUSTMENT
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6

EAUS1930
Replacing the fuses
To replace the fuses (XT660Z):
The main fuse and fuse box 1 (for
individual circuits) are located under
the seat. (See page 3-16).
1. Main fuse
2. Spare main fuse1. Fuse box 1
2. Parking lighting fuse
3. Signaling system fuse
4. Headlight fuse
5. Ignition fuse
6. ECU fuse
7. Radiator fan fuse
8. Backup fuse
9. Spare fuseTo replace the fuses (XT660ZA):
The main fuse and fuse box 1 (for
ABS model only),which are in a diffe-
rent and hard-to-reach location, must
be replaced by a Yamaha dealer.
Fuse box 2 (for ABS model only) and
fuse box 3 (for individual circuits) are
located under the seat. (See page
3-16).
To access fuse box 2, pull it upward
and then open it.
1. Fuse box 2
2. ABS control unit fuse
3. Spare fuse
4. Fuse box 3
5. Parking lighting fuse
6. Signaling system fuse
7. Headlight fuse
8. Ignition fuse
9. ECU fuse
10. Radiator fan fuse
11. Backup fuse
12. Spare fuse
1. Turn the key to “OFF” and turn off
the electrical circuit in question.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage. WARNING! Do not
use a fuse of a higher ampera-
ge rating than recommended
to avoid causing extensive
damage to the electrical sys-
tem and possibly a fire.
[EWA15131]
PERIODIC MAINTENANCE AND ADJUSTMENT
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6

3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
EAUB1581
Replacing a headlight bulb
This model is equipped with quartz
bulb headlights. If a headlight bulb
burns out, replace it as follows.
ECA10650
Take care not to damage the follo-
wing 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 adversely affec-
ted. Thoroughly clean off any
dirt and fingerprints on the
headlight bulb using a cloth
moistened with alcohol or thin-
ner.
Headlight lens
Do not affix any type of tinted
film or stickers to the headlight
lens.
Do not use a headlight bulb of a
wattage higher than specified.
1. Headlight bulb cover
1. Remove the headlight bulb cover,
and then disconnect the head-
light coupler.
1. Headlight coupler
2. Headlight bulb holder
3. Headlight bulb
NOTICE
Specified fuses:
Main fuse:
30.0 A
Parking lighting fuse:
10.0 A
Signaling system fuse:
10.0 A
Headlight fuse:
20.0 A
Ignition fuse:
10.0 A
Fuel injection system fuse:
10.0 A
Radiator fan fuse:
7.5 A
Backup fuse:
10.0 A
ABS motor fuse (for ABS model):
30.0 A
ABS solenoid fuse (for ABS
model):
20.0 A
ABS control unit fuse (for ABS
model):
5.0 A
PERIODIC MAINTENANCE AND ADJUSTMENT
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PERIODIC MAINTENANCE AND ADJUSTMENT
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6
1. Headlight bulb holder
2. Headlight bulb
2. Unhook the headlight bulb hol-
der, and then remove the defecti-
ve bulb.
1. Do not touch the glass part of the bulb.
EWA10790
Headlight bulbs get very hot. The-
refore, keep flammable products
away from a lit headlight bulb, and
do not touch the bulb until it has
cooled down.
3. Place a new headlight bulb into
position, and then secure it with
the bulb holder.
4. Connect the coupler, and then
install the headlight bulb cover.
5. Have a Yamaha dealer adjust the
headlight beam if necessary.
EAU24181
Tail/brake light
This model is equipped with an LED-
type tail/brake light.
If the tail/brake light does not come
on, have a Yamaha dealer check it.WARNING

PERIODIC MAINTENANCE AND ADJUSTMENT
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6
EAU24204
Replacing a turn signal light
bulb
1. Remove the turn signal light lens
by removing the screw.
1. Screw
2. Turn signal light lens
3. Turn signal light bulb
2. Remove the burnt-out bulb by
pushing it in and turning it coun-
terclockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screw. NOTICE: Do not over-
tighten the screw, otherwise
the lens may break.
[ECA11191]EAUM2202
Replacing the license plate
light bulb
1. Remove the socket (together
with the bulb) by pulling it out.
1. License plate light bulb socket
2. License plate light bulb
2. Remove the burnt-out bulb by
pulling it out.
3. Insert a new bulb into the socket.
4. Install the socket (together with
the bulb) by pushing it in.
EAU42652
Replacing an auxiliary light
bulb
This model is equipped with two auxi-
liary lights. If an auxiliary light bulb
burns out, replace it as follows.
1. Remove panel G. (See page 6-8).
2. Remove the auxiliary light socket
(together with the bulb) by pulling
it out.
1. Auxiliary light bulb socket
2. Auxiliary light bulb
3. Remove the burnt-out bulb by
pulling it out.
4. Insert a new bulb into the socket.