fuel YAMAHA XT660Z 2008 User Guide

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OPERATION AND IMPORTANT RIDING POINTS
EAU16810
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the follow-
ing tips to reduce fuel consumption:
●Shift up swiftly, and avoid high en-
gine speeds during acceleration.
●Do not rev the engine while shift-
ing down, and avoid high engine
speeds with no load on the en-
gine.
●Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at traf-
fic lights or at railroad crossings).
EAU16841
Engine break-in
There is never a more important peri-
od in the life of your engine than the
period between 0 and 1600 km (1000
mi). For this reason, you should read
the following material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts
in the engine wear and polish them-
selves to the correct operating clear-
ances. During this period, prolonged
full-throttle operation or any condition
that might result in engine overheating
must be avoided.
EAU17100
0-1000 km (0-600 mi)
Avoid prolonged operation above
4500 r/min.
1000-1600 km (600-1000 mi)
Avoid prolonged operation above
6000 r/min.
ECA10301CAUTION:
After 1000 km (600 mi) of operation,
the engine oil must be changed and
the oil filter cartridge or element re-
placed.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.
5-3

XT660Z 04-06 ING 11-03-2008 8:30 Pagina 5-3

PERIODIC MAINTENANCE AND MINOR REPAIR
EAU17709
Periodic maintenance and lubrication chart
NOTE:● The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-
stead.
●From 50000 km, repeat the maintenance intervals starting from 10000 km.
●Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and tech-
nical skills.
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NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUAL CHECK
√√√√ √
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√√
√√
√√
√√√√√
√√√√√ √
√√√√√ √1✻
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✻
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✻
7✻
• Check fuel hoses for cracks or damage.
• Check condition.
• Clean and regap.
• Replace.
• Check valve clearance.
• Adjust.
• Replace.
• Check operation.
• Adjust.
• Check operation, fluid level and vehicle for fluid
leakage.
• Replace brake pads.
• Check operation, fluid level and vehicle for fluid
leakage.
• Replace brake pads.
Fuel line
Spark plug
Valves
Air filter element
Clutch
Front brake
Rear brake
Whenever worn to the limit
Whenever worn to the limit

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
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• Check operation and for oil leakage.
• Check operation and shock absorber for oil
leakage.
• Check operation.
• Lubricate with lithium-soap-based grease.
• Adjust engine idling speed.
• Change.
• Check oil level and vehicle for oil leakage.
• Replace.
• Check coolant level and vehicle for coolant leakage.
• Change.
• Check operation.
• Lubricate.
• Check operation and free play.
• Adjust the throttle cable free play if necessary.
• Lubricate the throttle grip housing and cable.
Front fork
Shock absorber
assembly
Rear suspension
relay arm and
connecting arm
pivoting points
Fuel injection
Engine oil
Engine oil filter
element
Cooling system
Front and rear brake
switches
Moving parts and
cables
Throttle grip housing
and cable
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√√√√√ √
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√√√√√ √ √√√√ √
√√√√ √18✻
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NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUAL
CHECK
Every 3 years

XT660Z 04-06 ING 11-03-2008 8:31 Pagina 6-4

PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
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EAU21640
Tires
To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points regard-
ing the specified tires.
Tire air pressure
The tire air pressure should be
checked and, if necessary, adjusted
before each ride.
EWA10500
WARNING0
●The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the tempera-
ture of the tires equals the am-
bient 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 ap-
proved for this model.

EAU21382
Checking the throttle cable
free play
1. Throttle cable free play
The throttle cable free play should
measure 3.0-5.0 mm (0.12-0.20 in) at
the throttle grip. Periodically check the
throttle cable free play and, if neces-
sary, 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 clear-
ance must be adjusted by a Yamaha
dealer at the intervals specified in the
periodic maintenance and lubrication
chart.

XT660Z 04-06 ING 11-03-2008 8:31 Pagina 6-16

PERIODIC MAINTENANCE AND MINOR REPAIR
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ECA10640CAUTION:
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 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.
1. Parking lighting fuse
2. Signaling system fuse
3. Headlight fuse
4. Ignition fuse
5. Electronic fuel injection fuse
6. Radiator fan fuse
7. Backup fuse
8. Reserve fuses
The main fuse and fuse box are locat-
ed under the seat. (See page 6-31.)
If a fuse is blown, replace it as follows.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.

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654321
Specified fuses:
Main fuse:30 A
Parking lighting fuse: 10 A
Signalling system fuse: 10 A
Headlight fuse: 20 A
Ignition fuse: 10 A
Fuel injection system fuse: 10 A
Radiator fan fuse: 7.5 A
Backup fuse (for odometer,
clock and immobilizer): 10 A

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-39
EAUB1450
To install the rear wheel1. Install the wheel and the brake caliper bracket by inserting the
wheel axle from the right-hand
side.
NOTE:
●Make sure that the slot in the
brake caliper bracket is fit over the
retainer on the swingarm.
●Make sure that there is enough
space between the brake pads
before installing the wheel.
2. Install the drive chain onto the rear sprocket.
3. Install the axle nut, and then low- er the rear wheel so that it is on
the ground.
4. Adjust the drive chain slack. (See page 6-24.)
5. Apply the rear brake several times, and then tighten the axle
nut to the specified torque.
Tightening torque:
Axle nut:105 Nm (10.5 m·kgf, 75 ft·lbf)
EAU25870
Troubleshooting
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur
during operation. Any problem in the
fuel, compression, or ignition systems,
for example, can cause poor starting
and loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.

XT660Z 04-06 ING 11-03-2008 8:31 Pagina 6-39

PERIODIC MAINTENANCE AND MINOR REPAIR
6-40
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EAU42130Troubleshooting charts
Starting problems or poor engine performanceEWA10840
WARNING0
Keep away open flames and do not smoke while checking or working on the \
fuel system.

1. Fuel
2. Compression
3. Ignition
4. Battery
Check the fuel level in the
fuel tank.
Operate the electric
starter.
Remove the spark plug
and check the electrodes.
Operate the electric
starter.
There is enough
fuel.
There is
compression.
Wet.
The engine turns
over quickly.
There is no fuel.
There is no
compression.
Dry.
The engine turns
over slowly.
Check the
compression.
Check the ignition.
Wipe off with a dry cloth and correct
the spark plug gap, or replace the
spark plug.
The battery is good.
Have a Yamaha dealer check the
vehicle.
Check the battery lead connections,
and charge the battery if necessary.
Open the throttle halfway and
operate the electric starter.
The engine does not start.
Check the battery.
The engine does
not start. Have a
Yamaha dealer
check the vehicle.
Supply fuel.
Have a Yamaha dealer check
the vehicle.
The engine does not start.
Check the compression.

XT660Z 04-06 ING 11-03-2008 8:31 Pagina 6-40

MOTORCYCLE CARE AND STORAGE
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EAU26000
Care
While the open design of a motorcycle
reveals the attractiveness of the tech-
nology, it also makes it more vulnera-
ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go un-
noticed on a car, however, it detracts
from the overall appearance of a mo-
torcycle. Frequent and proper care
does not only comply with the terms of
the warranty, but it will also keep your
motorcycle looking good, extend its
life and optimize its performance.
Before cleaning 1. Cover the muffler outlet with a plastic bag after the engine has
cooled down.
2. Make sure that all caps and cov- ers as well as all electrical cou-
plers and connectors, including
the spark plug cap, are tightly in-
stalled. 3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-
ucts onto seals, gaskets, sprock-
ets, the drive chain and wheel
axles. Always rinse the dirt and
degreaser off with water.
Cleaning
ECA10770CAUTION:
●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
windshields, cowlings, panels
and other plastic parts. Use on-
ly a soft, clean cloth or sponge
with mild detergent and water
to clean plastic.
●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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MOTORCYCLE CARE AND STORAGE
7-4
Long-term
Before storing your motorcycle for sev-
eral months:1. Follow all the instructions in the “Care” section of this chapter.
2. Fill up the fuel tank and add fuel stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
3. Perform the following steps to protect the cylinder, piston rings,
etc. from corrosion.a. Remove the spark plug cap and spark plug.
b. Pour a teaspoonful of engine oil into the spark plug bore.
c. Install the spark plug cap onto the spark plug, and then place
the spark plug on the cylinder
head so that the electrodes
are grounded. (This will limit
sparking during the next step.)
d. Turn the engine over several times with the starter. (This will
coat the cylinder wall with oil.)
e. Remove the spark plug cap from the spark plug, and then
install the spark plug and the
spark plug cap.EWA10950
WARNING0
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.
4. Lubricate all control cables and the pivoting points of all levers
and pedals as well as of the side-
stand/centerstand.
5. Check and, if necessary, correct the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alter-
natively, turn the wheels a little
every month in order to prevent
the tires from becoming degraded
in one spot.
6. Cover the muffler outlets with plastic bags to prevent moisture
from entering them.

7. Remove the battery and fullycharge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex-
cessively cold or warm place [less
than 0 °C (30 °F) or more than 30
°C (90 °F)]. For more information
on storing the battery, see
page 6-31.
NOTE:
Make any necessary repairs before
storing the motorcycle.

XT660Z 07-10 ING 11-03-2008 8:33 Pagina 5

SPECIFICATIONS
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Engine oil:Type: SAE10W30 or SAE10W40 or SAE15W40
or SAE20W40 or SAE20W50
Recommended engine oil grade: API service SE, SF, SG type or higher
Engine oil quantity: Without oil filter element replacement:2.50 L (2.64 US qt) (2.19 Imp.qt)
With oil filter element replacement: 2.60 L (2.73 US qt) (2.26 Imp.qt)
Total amount (dry engine): 2.90 L (3.07 US qt) (2.55 Imp.qt)
Cooling system:Radiator capacity (including all routes): 1.2 L (1.26 US qt) (1.05 Imp.qt) (Radiator) +
0.5 L (0.52 US qt) (0.44 Imp.qt)
(Coolant reservoir)
Coolant reservoir capacity (up to the
maximum level mark): 0.50 L (0.52 US qt) (0.44 Imp.qt)
From low to full level: 0.30 L (0.32 US qt) (0.26 Imp.qt)
Air filter:Air filter element:Paper
Fuel:Recommended fuel:Premium unleaded gasoline only
Fuel tank capacity: 23.0 L (6.07 US gal) (5.06 Imp.gal)
Fuel reserve amount: 6.7 L (1.76 US gal) (1.46 Imp.gal)
Fuel injection:Manufacturer:DENSO
Model: 297500-0390
Spark plug:Manufacturer/model:NGK/CR7EGap:0.7-0.8 mm (0.028-0.032 in)
Clutch:Clutch type:Wet, multiple-disc
Transmission:Primary reduction system:Spur gear
Primary reduction ratio: 75/36 (2.083)
Secondary reduction system: Chain drive
Secondary reduction ratio: 45/15 (3.00)
Transmission type: Constant mesh 5-speed
Dimensions:Overall length:2246 mm (88.42 in)
Overall width: 864 mm (34.01 in)
Overall height: 1477 mm (58.14 in)
Seat height: 896 mm (35.27 in)
Wheelbase: 1500 mm (59.05 in)
Ground clearance: 260 mm (10.23 in)
Minimum turning radius: 1958 mm (77.08 in)
Basic weight:With oil and fuel:208.5 kg (459 lb)
Engine:Engine type:Liquid cooled 4-stroke, SOHC
Cylinder arrangement: Forward-inclined single cylinder
Displacement: 660.0 cm
3(40.27 cu.in)
Bore x stroke: 100.0 x 84.0 mm (3.94 x 3.31 in)
Compression ratio: 10.00 : 1
Starting system: Electric starter
Lubrication system: Dry sump
-20 -10 0 10 20 30 40 50 °C
SAE 10W-30
SAE 10W-40
SAE 20W-40
SAE 20W-50
SAE 15W-40

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