engine YAMAHA XT660Z 2010 Service Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU42131Troubleshooting charts
Starting problems or poor engine performance
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.
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.
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-41
Engine overheatingEWA10400
WARNING0
●Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
●After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hiss-
ing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
TIP
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended
coolant as soon as possible.
Wait until the
engine has cooled.Check the coolant level
in the reservoir and radiator.
The coolant level is low.
Check the cooling
system for leakage.
The coolant level
is OK.
There is
leakage.
There is no
leakage.
Have a Yamaha dealer check
and repair the cooling system.
Start the engine. If the engine overheats again, have
a Yamaha dealer check and repair the cooling system.
Add coolant. (See TIP.)
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MOTORCYCLE CARE AND STORAGE
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EAU26004
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, sprockets,
the drive chain and wheel axles. Al-
ways rinse the dirt and degreaser
off with water.
Cleaning
ECA10772
NOTICE
●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
plastic parts (such as cowlings,
panels, windshields, headlight
lenses, meter lenses, etc.) and
the mufflers. Use only a soft,
clean cloth or sponge with wa-ter to clean plastic. However, if
the plastic parts cannot be
thoroughly cleaned with water,
diluted mild detergent with wa-
ter may be used. Be sure to
rinse off any detergent residue
using plenty of water, as it is
harmful to plastic parts.
●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
8-2
●For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the wind-
shield. Test the product on a
small hidden part of the wind-
shield to make sure that it does
not leave any marks. If the
windshield is scratched, use a
quality plastic polishing com-
pound after washing.After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain, near the sea
or on salt-sprayed roads
Since sea salt or salt sprayed on roads
during winter are extremely corrosive
in combination with water, carry out
the following steps after each ride in
the rain, near the sea or on salt-
sprayed roads.
TIP
Salt sprayed on roads in the winter
may remain well into spring.
1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.NO-
TICE: Do not use warm water
since it increases the corrosive
action of the salt.2. Apply a corrosion protection
spray on all metal, including
chrome- and nickel-plated, sur-
faces to prevent corrosion.
After cleaning
1. Dry the motorcycle with a
chamois or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally in-
duced discoloring of stainless-
steel exhaust systems can be re-
moved through polishing.)
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all metal, includ-
ing chrome- and nickel-plated,
surfaces.
5. Use spray oil as a universal clean-
er to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
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MOTORCYCLE CARE AND STORAGE
8-4
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. WARNING! Toprevent damage or injury
from sparking, make sure to
ground the spark plug elec-
trodes while turning the en-
gine 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 fully
charge 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 7-31.
TIP
Make any necessary repairs before
storing the motorcycle.
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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 1020304050°C
SAE 10W-30
SAE 10W-40
SAE 20W-40
SAE 20W-50
SAE 15W-40
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SPECIFICATIONS
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Rear suspension:
Type:
Swingarm (link suspension)
Spring/damper type:
Coil spring/gas-oil damper, spring
preload adjustable
Wheel travel:
200 mm (7.87 in)
Electrical system:
Ignition system:
Transistorized coil ignition (digital)
Charging system:
A.C. magneto
Battery:
Model:
GT9B-4
Voltage, capacity:
12 V, 8 Ah
Headlight:
Bulb type:
Halogen bulb
Bulb voltage, wattage x quantity:Headlight:
12 V, 55 W x 2
Auxiliary light:
12 V, 5 W x 2
Tail/brake light:
LED
Front turn signal light:
12 V, 10 W x 2
Rear turn signal light:
12 V, 10 W x 2
Meter lighting:
LED (backlight)Neutral indicator light:
LED
Turn signal indicator light:
LED
High beam indicator light:
LED
Coolant temperature warning light:
LED
Engine trouble warning light:
LED
Immobilizer system indicator light:
LED
Fuses:Main fuse:
30 A
Headlight fuse:
20 A
Signaling system fuse:
10 A
Ignition fuse:
10 A
Parking lighting fuse:
10 A
Radiator fan fuse:
7.5 A
Fuel injection system fuse:
10 A
Backup fuse (for odometer, clock and
immobilizer):
10 A
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INDEX
A
Aftermarket Parts, Accessories, and
Modifications ...................................2-4
Aftermarket Tires and Rims ...............2-4
Air filter element, cleaning the check
hose ..............................................7-14
Air filter element, replacing ..............7-14
Auxiliary light bulb, replacing............7-35
Avoid Carbon Monoxide poisoning ....2-2
B
Battery ..............................................7-30
To access the battery ...................7-30
To charge the battery....................7-30
To store the battery.......................7-31
Be a Responsible Owner ...................2-1
Brake and clutch levers, checking
and lubricating ..............................7-26
Brake fluid ........................................7-22
Changing ......................................7-23
Checking fluid level .......................7-22
Brake lever .......................................4-11
Brake pads, checking .......................7-21
Brake pedal ......................................4-11
Checking .......................................7-27
Lubricating ....................................7-27
C
Cables, checking and lubricating .....7-25
Carbon Monoxide (avoid Carbon
Monoxide poisoning).......................2-2
Care and storage ...............................8-1Catalytic converter ...........................4-13
Checking and lubricating the brake
and clutch levers ...........................7-26
Checking and lubricating the brake
pedal .............................................7-27
Checking and lubricating the cables..7-25
Checking and lubricating the
sidestand ......................................7-27
Checking and lubricating the throttle
grip and cable ...............................7-26
Checking the brake pedal ................7-27
Checking the sidestand switch .........4-18
Clock mode ........................................4-7
Clutch lever ......................................4-10
Clutch lever free play, adjusting .......7-20
Consumer information ......................10-1
Controls and instruments ...................3-3
Function ..........................................4-1
Coolant .............................................7-12
Coolant temperature warning light .....4-4
D
Description .........................................3-1
Controls and instrument .................3-3
Left view..........................................3-1
Right view .......................................3-2
Dimmer switch....................................4-9
Drive chain, cleaning
and lubricating ..............................7-25
Drive chain slack ..............................7-23
Adjusting .......................................7-23
Checking .......................................7-23Cleaning and lubricating ...............7-25
E
Emission control system (periodic
maintenance chart) .........................7-2
Engine break-in ..................................6-3
Engine idling speed, adjusting .........7-15
Engine oil and oil filter element ..........7-9
Engine oil filter element....................7-10
Engine stop switch .............................4-9
Engine trouble warning light...............4-4
F
For your safety - Pre-operation
checks .............................................5-1
Front fork ..........................................4-15
Adjusting .......................................4-15
Checking .......................................7-28
Front wheel ......................................7-36
Installing........................................7-37
Removing......................................7-36
Fuel ..................................................4-12
Fuel consumption, tips for reducing ...6-3
Fuel meter ..........................................4-7
Fuel tank breather hose ...................4-13
Fuel tank cap ...................................4-11
Fuses, replacing ...............................7-31
G
Genuine Yamaha Accessories ...........2-3
H
Handlebar switches ............................4-9
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INDEX
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Dimmer switch ................................4-9
Engine stop switch .........................4-9
Hazard switch ...............................4-10
Horn switch .....................................4-9
Pass switch .....................................4-9
Start switch .....................................4-9
Turn signal switch ...........................4-9
Headlight bulb, replacing..................7-33
High beam indicator light ...................4-4
Horn switch ........................................4-9
I
Identification numbers ......................10-1
Idling speed, checking .....................7-15
Ignition circuit cut-off system............4-17
Checking operation procedure......4-18
Immobilizer system ............................4-1
Immobilizer system indicator light ......4-4
Indicator and warning lights ...............4-3
Coolant temperature warning light..4-4
Engine trouble warning light ...........4-4
High beam indicator light ................4-4
Immobilizer system indicator light...4-4
Neutral indicator light ......................4-4
Turn signal indicator light ................4-3
Instruments ........................................3-3
Instrument and control functions........4-1
K
Key identification number .................10-1
Keys ...................................................4-1L
Labels (location of important labels) ..1-1
License plate light bulb, replacing ....7-35
Location of important labels ...............1-1
Loading ..............................................2-3
Lubricating the brake and clutch
levers ............................................7-26
Lubricating the brake pedal..............7-27
Lubricating the cables ......................7-25
Lubricating the drive chain ...............7-25
Lubricating the sidestand .................7-27
Lubricating the throttle grip
and cable ......................................7-26
Lubricating the swingarm pivots.......7-28
M
Main switch/steering lock ...................4-2
Model label .......................................10-2
Motorcycle noise regulation
(for Australia) ................................10-2
Multi-function display..........................4-5
Clock mode .....................................4-7
Self-diagnosis devices ....................4-7
Tachometer .....................................4-6
Tripmeter and tachometer modes ...4-6
N
Neutral indicator light .........................4-4
O
Oil filter element ..............................7-10
Operation and important riding
points ..............................................6-1Owner’s tool kit...................................7-1
P
Panels, removing and installing .........7-6
Parking ...............................................6-4
Pass switch ........................................4-9
Periodic maintenance
and adjustment ...............................7-1
Periodic maintenance chart for
the emission control system ...........7-2
Pre-operation check list......................5-2
Pre-operation checks .........................5-1
R
Rear suspension, lubricating............7-27
Rear wheel .......................................7-38
Installing........................................7-39
Removing......................................7-38
Record the identification numbers ...10-1
S
Safety information ..............................2-1
Seat ..................................................4-14
Self-diagnosis devices .......................4-7
Shift pedal ........................................4-10
Shifting ...............................................6-2
Shock absorber assembly
(adjusting) .....................................4-16
Sidestand .........................................4-17
Sidestand, checking and lubricating ..7-27
Sidestand switch, checking ..............4-18
Spark plug, checking..........................7-8
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INDEX
Specifications .....................................9-1
Spoke wheels ...................................7-19
Start switch ........................................4-9
Starting the engine.............................6-1
Steering, checking............................7-29
Steering lock ......................................4-2
Storage...............................................8-3
Supporting the motorcycle ...............7-36
Swingarm, lubricating the pivots ......7-28
T
Tachometer ........................................4-6
Throttle cable free play, checking.....7-16
Throttle grip and cable, checking
and lubricating ..............................7-26
Tips for reducing fuel consumption ....6-3
Tires .................................................7-16
Air pressure ..................................7-16
Tire information .............................7-18
Tire inspection ..............................7-18
Tool kit ................................................7-1
Tripmeter and tachometer modes ......4-6
Troubleshooting ................................7-39
Troubleshooting charts .................7-40
Engine overheating .......................7-41
Turn signal indicator light ...................4-3
Turn signal light bulb, replacing........7-34
Turn signal switch...............................4-9V
Valve clearance ................................7-16
Vehicle identification number ...........10-1
W
Warning lights ....................................4-3
Wheel bearings, checking ................7-29
Wheels, spoke..................................7-19
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