engine YAMAHA XT660Z 2009 Owner's Manual

PRE-OPERATION CHECKS
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ITEM
Fuel
Engine oil
Coolant
Front brake
Rear brake
EAU15605
Pre-operation check list
CHECKS
• Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.
• Check oil level in oil tank.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage.
• Check coolant level in reservoir.
• If necessary, add recommended coolant to specified level.
• Check cooling system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage. PAGE
3-12
6-9
6-12
3-11, 6-21, 6-22, 6-26
3-11, 6-21, 6-22, 6-27

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OPERATION AND IMPORTANT RIDING POINTS
EAU15950
EWA10270
WARNING0
●Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.
●Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
●Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.

EAUB1570
Starting the engine
In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
●The transmission is in the neutral
position.
●The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EWA10290
WARNING0
●Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure de-
scribed on page 3-18.
●Never ride with the sidestand
down.
1. Turn the key to “ON” and make sure that the engine stop switch is
set to “
I”.

ECAB0070CAUTION:
The following warning lights and in-
dicator 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
If a warning or indicator light does
not go off, see page 3-3 for the cor-
responding warning and indicator
light circuit check.
2. Shift the transmission into the neutral position.
NOTE:
When the transmission is in the neu-
tral position, the neutral indicator light
should be on, otherwise have a Yama-
ha dealer check the electrical circuit.
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OPERATION AND IMPORTANT RIDING POINTS
3. Start the engine by pushing thestart switch.
NOTE:
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 en-
gine more than 10 seconds on any one
attempt.
ECA11040CAUTION:
For maximum engine life, never ac-
celerate hard when the engine is
cold!
NOTE:
The engine is warm when it quickly re-
sponds to the throttle.
EAU16671
Shifting
1. Shift pedal
N. 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 il-
lustration.
NOTE:
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 raise it.

ECA10260CAUTION:
●Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long
distances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.
●Always use the clutch while
changing gears to avoid dam-
aging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
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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.
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OPERATION AND IMPORTANT RIDING POINTS
ECA10310CAUTION:
●Keep the engine speed out of
the tachometer red zone.
●If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the
vehicle.
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EAU17212
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EWA10310
WARNING0
●Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.
●Do not park on a slope or on
soft ground, otherwise the ve-
hicle may overturn.
ECA10380CAUTION:
Never park in an area where there
are fire hazards such as grass or
other flammable materials.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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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
√√√√
√√√√
√√√√
√√
√√√√√ √
√√√√√ √
√√√
√√√√ √
√√√√√ √ √√√√ √
√√√√ √18✻
19✻
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NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUAL
CHECK
Every 3 years

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PERIODIC MAINTENANCE AND MINOR REPAIR
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2. Remove the spark plug as shown, with the spark plug wrench includ-
ed in the owner’s tool kit.
To check the spark plug 1. Check that the porcelain insulator around the center electrode of the
spark plug is a medium-to-light
tan (the ideal color when the vehi-
cle is ridden normally).
NOTE:
If the spark plug shows a distinctly dif-
ferent color, the engine could be oper-
ating improperly. Do not attempt to di-
agnose such problems yourself.
Instead, have a Yamaha dealer check
the vehicle.
2. Check the spark plug for elec- trode erosion and excessive car-
bon or other deposits, and re-
place it if necessary.
Specified spark plug:CR7E (NGK)
Spark plug gap:0.7-0.8 mm (0.028-0.032 in)
To install the spark plug
1. Measure the spark plug gap with a wire thickness gauge and, if
necessary, adjust the gap to
specification.
1. Spark plug gap

2. Clean the surface of the sparkplug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the spark plug wrench, and then tight-
en it to the specified torque.
EAU19603
Checking the spark plug
The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause
any spark plug to slowly erode, the
spark plug should be removed and
checked in accordance with the peri-
odic maintenance and lubrication
chart. In addition, the condition of the
spark plug can reveal the condition of
the engine.
To remove the spark plug
1. Spark plug cap
2. Spark plug wrench
1. Remove the spark plug cap.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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EAUB1560
Engine oil and oil filter
element
The engine oil level should be checked
before each ride. In addition, the oil must
be changed and the oil filter element re-
placed at the intervals specified in the
periodic maintenance and lubrication
chart.
To check the engine oil level1. Place the vehicle on a level surface and hold it in an upright position.
NOTE:
Make sure that the vehicle is posi-
tioned straight up when checking the
oil level. A slight tilt to the side can re-
sult 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 screwing
it in), and then remove it again to
check the oil level.
1. Engine oil filler cap
2. Maximum level mark
3. Minimum level mark
NOTE:
●The engine oil tank is located in-
side of the frame.
●The engine oil should be between
the minimum and maximum level
marks.

Tightening torque:Spark plug:12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)
NOTE:
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is 1/4-
1/2 turn past finger tight. However, the
spark plug should be tightened to the
specified torque as soon as possible.
4. Install the spark plug cap.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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To change the engine oil
(with or without oil filter element
replacement)
1. Mounting screw
2. Engine guard
1. Start the engine, warm it up for sev- eral minutes, and then turn it off.
2. To reach the drain bolt of the crankcase and the drain bolt of
the oil tank, remove the engine
guard by removing the screws.
3. Place an oil pan under the engine to collect the used oil.
4. Remove the engine oil filler cap and the drain bolt to drain the oil
from the crankcase.
5. Remove the drain bolt to drain the oil from the oil tank.

1. Engine oil crankcase drain bolt
1. Engine oil tank drain bolt
6. Remove the oil filter elementdrain bolt to drain the oil from the
oil filter element.

1

ECA10010CAUTION:
Do not operate the vehicle until you
know that the engine oil level is suf-
ficient.
EWA10360
WARNING0
Never remove the engine oil tank
cap after high-speed operation,
otherwise hot engine oil could
spout out and cause damage or in-
jury. 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 raise
it to the correct level.
5. Install the oil filler cap.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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Tightening torques:Oil filter element cover bolt:10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil filter element drain bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Tightening torques:Engine oil drain bolt (crankcase):30 Nm (3.0 m·kgf, 22 ft·lbf)
Engine oil drain bolt (oil tank): 18 Nm (1.8 m·kgf, 12.9 ft·lbf)
13. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filter
cap.
10. Install the oil filter element drain
bolt.
11. Tighten the oil filter element cover bolts and the oil filter element
drain bolt to their specified
torques.1. Engine oil filter element
2. O-rings

12. Install the engine oil drain bolts,and then tighten them to their
specified torques.
NOTE:
Skip steps 7-9 if the oil filter element is
not being replaced.
7. Remove the oil filter element cov- er by removing the bolts.
8. Remove and replace the oil filter element and O-rings.
9. Install the oil filter element cover by installing the bolts.
NOTE:
Make sure that the O-rings are proper-
ly seated.
1. Engine oil filter element drain bolt
2. Oil filter element cover bolts

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