tires YAMAHA XT660Z 2009 Owners Manual

TABLE OF CONTENTS
SAFETY INFORMATION.....................1-1
Safe riding .........................................1-1
Protective apparel .............................1-2
Modifications .....................................1-2
Loading and accessories ..................1-2
Gasoline and exhaust gas ................1-4
DESCRIPTION .....................................2-1
Left view ............................................2-1
Right view .........................................2-2
Controls and instruments ..................2-3
INSTRUMENT AND CONTROL
FUNCTIONS ........................................3-1
Immobilizer system ...........................3-1
Main switch/steering lock ..................3-2
Indicator and warning lights ..............3-3
Multi-function display ........................3-5
Tachometer .......................................3-6
Tripmeter and tachometer modes .....3-6
Clock mode .......................................3-7
Fuel meter .........................................3-7
Self-diagnosis devices ......................3-7
Anti-theft alarm (optional) .................3-8
Handlebar switches ...........................3-9
Clutch lever .....................................3-10
Shift pedal .......................................3-10
Brake lever ......................................3-11
Brake pedal .....................................3-11 Fuel tank cap ..................................3-11
Fuel .................................................3-12
Fuel tank breather hose ..................3-13
Catalytic converter ..........................3-13
Seat .................................................3-14
Adjusting the front fork ....................3-15
Adjusting the shock absorber
assembly ..................................3-16
Sidestand ........................................3-17
Ignition circuit cut-off system ..........3-17
PRE-OPERATION CHECKS ...............4-1
Pre-operation check list ....................4-2
OPERATION AND IMPORTANT
RIDING POINTS ..................................5-1
Starting the engine............................5-1
Shifting ..............................................5-2
Tips for reducing fuel consumption ...5-3
Engine break-in .................................5-3
Parking ..............................................5-4
PERIODIC MAINTENANCE
AND MINOR REPAIR .........................6-1
Owner’s tool kit .................................6-1
Periodic maintenance and lubrication chart..........................6-2
Removing and installing the cowling and panels..................................6-8 Checking the spark plug ...................6-8
Engine oil and oil filter element.........6-9
Coolant ............................................6-12
Replacing the air filter element
and cleaning the check hose ..... 6-14
Checking the engine idling speed ...6-15
Checking the throttle cable free play ...................................6-16
Valve clearance ...............................6-16
Tires ................................................6-16
Spoke wheels..................................6-19
Adjusting the clutch lever free play ...................................6-20
Checking the front and rear brake pads ...............................6-21
Checking the brake fluid level .........6-22
Changing the brake fluid .................6-23
Drive chain slack .............................6-23
Cleaning and lubricating the drive chain ................................6-25
Checking and lubricating the cables .......................................6-25
Checking and lubricating the throttle grip and cable ..............6-26
Checking and lubricating the brake and clutch levers ............6-26
Lubricating the brake pedal ............6-27
Checking and lubricating the sidestand ..................................6-27

XT660Z 01-03 ING 10-03-2008 16:11 Pagina 6

1
2
3
4
5
6
7
8
9
10
PRE-OPERATION CHECKS
4-3
ITEM
Clutch
Throttle grip
Control cables
Drive chain
Wheels and tires
Brake pedal
Brake and
clutch levers
Sidestand
Chassis fasteners CHECKS
• Check operation.
• Lubricate cable if necessary.
• Check lever free play.
• Adjust if necessary.
• Make sure that operation is smooth.
• Check cable free play.
• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing.
• Make sure that operation is smooth.
• Lubricate if necessary.
• Check chain slack.
• Adjust if necessary.
• Check chain condition.
• Lubricate if necessary.
• Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary.
• Make sure that operation is smooth.
• Lubricate pedal pivoting point if necessary.
• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.
• Make sure that operation is smooth.
• Lubricate pivot if necessary.
• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary. PAGE
3-10, 6-20, 6-26
6-16, 6-266-25
6-23, 6-24, 6-25
6-16, 6-196-27
6-26
6-27–

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

1
2
3
4
5
6
7
8
9
10
PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUALCHECK
√√√√ √
√√√√
√√√√ √
√√√√
√√√√
√√√√√ √√√√ √
√√√√ √
√√√√√ √8✻
9✻
10✻
11✻
12✻
13
14
✻
15✻
16
17
✻
• Check for cracks or damage.
• Replace.
• Check runout, spoke tightness and for damage.
• Tighten spokes if necessary.
• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
• Check bearing for looseness
or damage.
• Check operation and for excessive play.
• Lubricate with lithium-soap-based grease.
• Check chain slack, alignment and condition.
• Adjust and lubricate chain with a special O-ring
chain lubricant thoroughly.
• Check bearing play and steering for roughness.
• Lubricate with lithium-soap-based grease.
• Make sure that all nuts, bolts and screws are
properly tightened.
• Check operation.
• Lubricate.
• Check operation.
Every 4 years
Brake hoses
Wheels
Tires
Wheel bearings
Swingarm
Drive chain
Steering bearings
Chassis fasteners
Sidestand
Sidestand switch
Every 50000 km
Every 500 km and after washing
the motorcycle or riding in the rain
Every 20000 km

XT660Z 04-06 ING 11-03-2008 8:30 Pagina 6-3

PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
1
2
3
4
5
6
7
8
9
10
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

1
2
3
4
5
6
7
8
9
10
PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
EWA11020
WARNING0
Because loading has an enormous
impact on the handling, braking,
performance and safety character-
istics of your motorcycle, you
should keep the following precau-
tions in mind.
●NEVER OVERLOAD THE MO-
TORCYCLE! Operation of an
overloaded motorcycle may re-
sult in tire damage, loss of con-
trol, or severe injury. Make sure
that the total weight of rider,
passenger, cargo, and acces-
sories does not exceed the
specified maximum load for the
vehicle.
●Do not carry along loosely
packed items, which can shift
during a ride.
●Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.

Tire air pressure
(measured on cold tires):Up to 90 kg (198 lb):
Front:210 kPa (30 psi) (2.1 kgf/cm
2)
Rear: 230 kPa (33 psi) (2.3 kgf/cm
2)
90 kg (198 lb) to maximum load:
Front: 230 kPa (33 psi) (2.3 kgf/cm
2)
Rear: 250 kPa (36 psi) (2.5 kgf/cm
2)
Off-road riding:
Front: 200 kPa (29 psi) (2.0 kgf/cm
2)
Rear: 200 kPa (29 psi) (2.0 kgf/cm
2)
High-speed riding:
Front: 210 kPa (30 psi) (2.1 kgf/cm
2)
Rear: 230 kPa (33 psi) (2.3 kgf/cm
2)
Maximum load*: 190 kg (419 lb)
* Total weight of rider, passenger, cargo and accessories
●Adjust the suspension and tire
air pressure with regard to the
load.
●Check the tire condition and air
pressure before each ride.

XT660Z 04-06 ING 11-03-2008 8:31 Pagina 6-17

PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
1
2
3
4
5
6
7
8
9
10
Tire information
This motorcycle is equipped with tube
tires.
EWA10460
WARNING0
●The front and rear tires should
be of the same make and de-
sign, otherwise the handling
characteristics of the vehicle
cannot be guaranteed.
●After extensive tests, only the
tires listed below have been
approved for this model by
Yamaha Motor Co., Ltd.

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 Yama-
ha dealer replace the tire immediately.

NOTE:
The tire tread depth limits may differ
from country to country. Always com-
ply with the local regulations.
Minimum tire tread depth
(front and rear): 1.6 mm (0.06 in)

XT660Z 04-06 ING 11-03-2008 8:31 Pagina 6-18

1
2
3
4
5
6
7
8
9
10
PERIODIC MAINTENANCE AND MINOR REPAIR
6-19
Front tire:Size:90/90-21M/C 54S
90/90-21M/C 54T
Manufacturer/model: METZELER/TOURANCE
FRONT MICHELIN/SIRAC
Rear tire: Size:130/80-17M/C 65S
130/80-17M/C 65T
Manufacturer/model: METZELER/TOURANCE
MICHELIN/SIRAC A
EWA10570
WARNING0
●Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the mo-
torcycle with excessively worn
tires decreases riding stability
and can lead to loss of control.
●The replacement of all wheel-
and brake-related parts, in-
cluding the tires, should be left
to a Yamaha dealer, who has
the necessary professional
knowledge and experience.
●It is not recommended to patch
a punctured tube. If unavoid-
able, however, patch the tube
very carefully and replace it as
soon as possible with a high-
quality product.

EAU21940
Spoke wheels
To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points regard-
ing the specified wheels.
●The wheel rims should be
checked for cracks, bends or
warpage, and the spokes for
looseness or damage before
each ride. If any damage is found,
have a Yamaha dealer replace the
wheel. Do not attempt even the
smallest repair to the wheel. A de-
formed or cracked wheel must be
replaced.
●The wheel should be balancedwhenever 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.
●Ride at moderate speeds afterchanging a tire since the tire sur-
face must first be "broken in" for it
to develop its optimal characteris-
tics.

XT660Z 04-06 ING 11-03-2008 8:31 Pagina 6-19

MOTORCYCLE CARE AND STORAGE
7-3
1
2
3
4
5
6
7
8
9
10
EWA10930
WARNING0
●Make sure that there is no oil or
wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or
acetone, and wash the tires
with warm water and a mild de-
tergent.
●Before operating the motorcy-
cle test its braking perfor-
mance and cornering behavior.
ECA10800CAUTION:
●Apply spray oil and wax spar-
ingly and make sure to wipe off
any excess
●Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
●Avoid using abrasive polishing
compounds as they will wear
away the paint.

NOTE:
Consult a Yamaha dealer for advice on
what products to use.
EAUM1900
Storage
Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
ECA10810CAUTION:
●Storing the motorcycle in a
poorly ventilated room or cov-
ering it with a tarp, while it is
still wet, will allow water and
humidity to seep in and cause
rust.
●To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.

XT660Z 07-10 ING 11-03-2008 8:33 Pagina 4

1
2
3
4
5
6
7
8
9
10
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

1
2
3
4
5
6
7
8
9
10
SPECIFICATIONS
8-2
Operation:Left foot operation
Gear ratio: 1
st:30/12 (2.500)
2
nd:
26/16 (1.625)
3
rd: 23/20 (1.150)
4
th: 20/22 (0.909)
5
th: 20/26 (0.769)
Chassis:
Frame type:
Diamond
Caster angle: 28°
Trail: 113.0 mm (4.44 in)
Front tire:
Type:With tube
Size: 90/90-21M/C 54S,
90/90-21M/C 54T
Manufacturer/model: METZELER/TOURANCE FRONT
MICHELIN/SIRAC
Rear tire:
Type:With tube
Size: 130/80-17M/C 65S,
130/80-17M/C 65T Manufacturer/model:
METZELER/TOURANCE
MICHELIN/SIRAC A
Load:
Maximum load:190 kg (419 lb)
(Total weight of rider, passenger, cargo
and accessories)
Tire air pressure
(measured on cold tires):
Load:Up to 90 kg (0-198 lb)
Front: 210 kPa (30 psi) (2.1 kgf/cm
2)
Rear: 230 kPa (33 psi) (2.3 kgf/cm
2)
Load: 90-190 kg (198-419 lb)
Front: 230 kPa (33 psi) (2.3 kgf/cm
2)
Rear: 250 kPa (36 psi) (2.5 kgf/cm
2)
Off-road riding:
Front: 200 kPa (29 psi) (2.0 kgf/cm
2)
Rear: 200 kPa (29 psi) (2.0 kgf/cm
2)
High-speed riding:
Front: 210 kPa (30 psi) (2.1 kgf/cm
2)
Rear: 230 kPa (33 psi) (2.3 kgf/cm
2)
Front wheel:
Type:
Spoke wheel
Rim size: 21 x 1.85
Rear wheel:
Type:Spoke wheel
Rim size: 17M/C x MT2.75
Front brake:
Type:Dual disc brake
Operation: Right hand
Fluid: DOT 4
Rear brake:
Type:Single disc brake
Operation: Right foot
Fluid:
DOT 4
Front suspension:
Type:Telescopic fork
Spring/damper type: Coil spring/oil damper
Wheel travel: 210 mm (8.26 in)

XT660Z 07-10 ING 11-03-2008 8:33 Pagina 7