check engine YAMAHA XT660Z 2010 User Guide

EAU17101
0-1000 km (0-600 mi)
Avoid prolonged operation above
4500 r/min. NOTICE: After 1000 km
(600 mi) of operation, the engine oil
must be changed, and the oil filter
element replaced.
1000-1600 km (600-1000 mi)
Avoid prolonged operation above
6000 r/min.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.
ECA10310NOTICE
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.
EAU17213
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EWA10311
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 and be burned.
Do not park on a slope or on
soft ground, otherwise the ve-
hicle may overturn, increasing
the risk of a fuel leak and fire.
Do not park near grass or other
flammable materials which
might catch fire.
OPERATION AND IMPORTANT RIDING POINTS
6-4
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PERIODIC MAINTENANCE AND ADJUSTMENT
EAU46861
TIP
●The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.
●From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
●Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and tech-
nical skills.
EAU46910Periodic maintenance chart for the emission control system
7-2
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7
8
9
10
NO. ITEM CHECK OR MAINTENANCE JOB
ODOMETER READING
1000 km 10000 km 20000 km 30000 km 40000 km(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
ANNUAL
CHECK
√√ √√ √
√√
√√
√√
√√√ √√ √
√√√ √√
√√ √√ √1✻
2
3
✻
4✻
5✻
6✻
Check fuel hoses for cracks or damage.
Check condition.
Clean and regap.
Replace.
Check valve clearance.
Adjust.
Adjust engine idling speed.
Check the screw clamp(s) for
looseness.
Check the air cut-off valve, reed valve,
and hose for damage.
Replace any damaged parts if necessary. Fuel line
Spark plug
Valves
Fuel injection
Muffler and exhaust
pipe
Air induction system
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-4
1
2
3
4
5
6
7
8
9
10
NO. ITEM CHECK OR MAINTENANCE JOB
ODOMETER READING
1000 km 10000 km 20000 km 30000 km 40000 km(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
ANNUAL
CHECK
√√ √√
√√√ √√
√√
√√
√
√√ √√ √
√√√ √√ √
√√ √√
√√ √√
√√ √√
√√
√√√ √√ √
13
14
✻
15✻
16✻
18
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.
Check operation and for oil leakage.
Check operation and shock absorber
for oil leakage.
Check operation.
Lubricate with lithium-soap-based grease.
Change.
Check oil level and vehicle for oil leakage. Swingarm
Drive chain
Steering bearings
Chassis fasteners
Sidestand
Sidestand switch
Front fork
Shock absorber
assembly
Rear suspension
relay arm and
connecting arm
pivoting points
Engine oil
Every 50000 km (30000 mi) Every 50000 km (30000 mi)
Every 500 km (300 mi) and after
washing the motorcycle or riding
in the rain
9✻
11✻
17✻
12✻
10
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-57-5
EAUM1890
TIP
●Replace the air filter element more frequently if you are riding in unusually wet or dusty areas.
●Hydraulic brake service
●Regularly check and, if necessary, correct the brake fluid level.
●Every two years replace the internal components of the brake master cylinder, and change the brake fluid.
●Replace the brake hoses every four years and if cracked or damaged.
NO. ITEM CHECK OR MAINTENANCE JOB
ODOMETER READING
1000 km 10000 km 20000 km 30000 km 40000 km(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
ANNUAL
CHECK
√√ √
√√ √√ √
√√√ √√ √
√√ √√ √
√√ √√ √
√√√ √√ √ 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.
Check operation.
Adjust headlight beam. Engine oil filter
element
Cooling system
Front and rear brake
switches
Moving parts and
cables
Throttle grip housing
and cable
Lights, signals and
switches
Every 3 years
19
22 20
✻
21✻
24✻
23✻
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-8
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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).
TIP
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 spark
plug 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 ADJUSTMENT
7-9
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 level
1. Place the vehicle on a level surface
and hold it in an upright position.
TIP
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
TIP
●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)
TIP
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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ECAM1060CAUTION:
The engine oil tank must be filled in
2 steps. First, fill the engine oil tank
with 1.90 L (2.0 US qt) (1.67 Imp.qt)
of the recommended engine oil.
Then, start the engine, race it 5 or 6
times, turn it off, and then add the
remainder of the engine oil.
NOTE:
Be sure to wipe off spilled oil on any
parts after the engine and exhaust
system have cooled down.
ECA11620CAUTION:  In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a
higher quality than specified. In
addition, do not use oils la-
beled “ENERGY CONSERVING
II” or higher.
 Make sure that no foreign ma-
terial enters the crankcase.
14. Start the engine, and then let it idle for several minutes while
checking it for oil leakage. If oil is
leaking, immediately turn the en-
gine off and check for the cause.
15. Turn the engine off, and then check the oil level and correct it if
necessary.
16. Install the engine guard by in- stalling the screws.
EAU20070
Coolant
The coolant level should be checked
before each ride. In addition, the
coolant must be changed at the inter-
vals specified in the periodic mainte-
nance and lubrication chart.
EAU20253
To check the coolant level1. Place the vehicle on a level sur- face and hold it in an upright posi-
tion.
NOTE:
The coolant level must be
checked on a cold engine since
the level varies with engine tem-
perature.
Make sure that the vehicle is posi-
tioned 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.
Recommended engine oil:See page 8-1.
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)
PERIODIC MAINTENANCE AND ADJUSTMENT
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-13
TIP
The coolant should be between the
minimum and maximum level marks.
1. Coolant reservoir
2. Maximum level mark
3. Minimum level mark
4. Reservoir cap
3. If the coolant is at or below the
minimum level mark, remove pan-
el E (See page 7-7.), remove the
reservoir cap, add coolant to the
maximum level mark, and then in-
stall the reservoir cap and the
panel. WARNING! Remove only
the coolant reservoir cap. Nev-
er attempt to remove the radia-
tor cap when the engine is hot.
NOTICE:If coolant is not avail-
able, use distilled water or soft
tap water instead. Do not use
hard water or salt water since it
is harmful to the engine. If wa-
ter 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 an-
tifreeze content of the coolant
as soon as possible, otherwise
the effectiveness of the coolant
will be reduced.
Coolant reservoir capacity
(up to the maximum level mark):
0.50 L (0.52 US qt) (0.44 Imp.
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.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-14
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1. Air filter element
ECA10480
NOTICE
●Make sure that the air filter ele-
ment is properly seated in the
air filter case.
●The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
5. Install the air filter case cover by
installing the screws.
6. Install the seat.
1
EAUB1480
Replacing the air filter
element and cleaning the
check hose
The air filter element should be re-
placed at the intervals specified in the
periodic maintenance and lubrication
chart. Replace the air filter element
more frequently if you are riding in un-
usually wet or dusty areas. In addition,
the air filter check hose must be fre-
quently checked and cleaned if neces-
sary. To replace the air filter element
1. Air filter case
2. Screws
1. Remove the seat. (See page 4-
14.)
2. Remove the air filter case cover
by removing the screws.
3. Pull the air filter element out.
4. Insert a new air filter element into
the air filter case as shown.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-15
To clean the air filter check hose
1. Air filter check hose
2. Check hose cap
1. Check the hose on the side of the
air filter case for accumulated dirt
or water.
2. If dirt or water is visible, remove
the hose, clean it, and then install
it.
EAU44730
Checking the engine idling
speed
1. Idle adjusting screw
a. Increasing the engine idling speed
b. Decreasing the engine idling speed
The engine idling speed must be
checked as follows and, if necessary,
adjusted by a Yamaha dealer at the in-
tervals specified in the periodic main-
tenance and lubrication chart.
Start the engine and warm it up for
several minutes at 1000-2000 r/min
while occasionally revving it to 4000-
5000 r/min.
Engine idling speed:
1400-1600 r/min
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