clutch YAMAHA XT660Z 2010 Owners Manual

TABLE OF CONTENTS
LOCATION OF IMPORTANT LABELS...1-1
SAFETY INFORMATION.....................2-1
Be a Responsible Owner ..................2-1
Safe riding .........................................2-1
Protective apparel .............................2-2
Avoid Carbon Monoxide Poisoning ...2-2
Loading .............................................2-3
Genuine Yamaha Accessories ..........2-3
Aftermarket Parts, Accessories,
and Modifications .......................2-4
Aftermarket Tires and Rims ..............2-4
DESCRIPTION.....................................3-1
Left view ............................................3-1
Right view .........................................3-2
Controls and instruments ..................3-3
INSTRUMENT AND CONTROL
FUNCTIONS........................................4-1
Immobilizer system ...........................4-1
Main switch/steering lock ..................4-2
Indicator and warning lights ..............4-3
Multi-function display ........................4-5
Tachometer .......................................4-6
Tripmeter and tachometer modes .....4-6
Clock mode .......................................4-7
Fuel meter .........................................4-7
Self-diagnosis devices ......................4-7Handlebar switches ...........................4-9
Clutch lever .....................................4-10
Shift pedal .......................................4-10
Brake lever ......................................4-11
Brake pedal .....................................4-11
Fuel tank cap ..................................4-11
Fuel .................................................4-12
Fuel tank breather hose ..................4-13
Catalytic converter ..........................4-13
Seat .................................................4-14
Adjusting the front fork ....................4-15
Adjusting the shock absorber
assembly ..................................4-16
Sidestand ........................................4-17
Ignition circuit cut-off system ..........4-17
FOR YOUR SAFETY -
PRE-OPERATION CHECKS...............5-1
Pre-operation check list ....................5-2
OPERATION AND IMPORTANT
RIDING POINTS..................................6-1
Starting the engine............................6-1
Shifting ..............................................6-2
Tips for reducing fuel consumption ...6-3
Engine break-in .................................6-3
Parking ..............................................6-4PERIODIC MAINTENANCE AND
ADJUSTMENT.....................................7-1
Owner’s tool kit .................................7-1
Periodic maintenance chart for
the emission control system.......7-2
General maintenance
and lubrication chart ..................7-3
Removing and installing
the cowling and panels ..............7-8
Checking the spark plug ...................7-8
Engine oil and oil filter element.........7-9
Coolant ............................................7-12
Replacing the air filter element
and cleaning the check hose ...7-14
Checking the engine idling speed ...7-15
Checking the throttle cable
free play ...................................7-16
Valve clearance ...............................7-16
Tires ................................................7-16
Spoke wheels..................................7-19
Adjusting the clutch lever free play...7-20
Checking the front and rear
brake pads ...............................7-21
Checking the brake fluid level .........7-22
Changing the brake fluid .................7-23
Drive chain slack .............................7-23
Cleaning and lubricating
the drive chain ..........................7-25
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Checking and lubricating the cables .................................7-25
Checking and lubricating the throttle grip and cable ........7-26
Checking and lubricating the brake and clutch levers ......................7-26
Lubricating the brake pedal ............7-27
Checking and lubricating the sidestand ............................7-27
Lubricating the rear suspension......7-27
Lubricating the swingarm pivots .....7-28
Checking the front fork....................7-28
Checking the steering .....................7-29
Checking the wheel bearings..........7-29
Battery .............................................7-30
Replacing the fuses ........................7-31
Replacing a headlight bulb .............7-33
Replacing a turn signal light bulb....7-34
Replacing the license plate light bulb ...................................7-35
Replacing an auxiliary light bulb .....7-35
Supporting the motorcycle ..............7-36
Front wheel .....................................7-36
Rear wheel ......................................7-38
Troubleshooting ..............................7-39
Troubleshooting charts....................7-40 MOTORCYCLE CARE
AND STORAGE
...................................8-1
Care ..................................................8-1
Storage .............................................8-3
SPECIFICATIONS ...............................9-1
CONSUMER INFORMATION ............10-1
Identification numbers .....................10-1
Motorcycle noise regulation (for Australia) ............................10-2
TABLE OF CONTENTS
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DESCRIPTION
3-3
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4
5
6
7
8
9
10
EAU10430
Controls and instruments
1. Clutch lever (page 4-10)
2. Left handlebar switches (page 4-9)
3. Multi-function meter unit and warning lights (page 4-3, 4-5)
4. Right handlebar switches (page 4-9)
5. Throttle grip (page 7-16)6. Brake lever (page 4-11)
7. Engine oil filler cap/dipstick (page 7-9)
8. Fuel tank cap (page 4-11)
9. Main switch and steering lock (page 4-2)
XT660Z 01-03 ING-AUS:AUSTRALIA 11-05-2009 9:57 Pagina 16

INSTRUMENT AND CONTROL FUNCTIONS
4-10
1
2
3
4
5
6
7
8
9
10
EAU12733
Hazard switch “r”
With the key in the “ON” or Fposition,
use this switch to turn on the hazard
lights (simultaneous flashing of all turn
signal lights).
The hazard lights are used in case of
an emergency or to warn other drivers
when your vehicle is stopped where it
might be a traffic hazard.
ECA10061
NOTICE
Do not use the hazard lights for an
extended length of time with the
engine not running, otherwise the
battery may discharge.
EAU12820
Clutch lever
1. Clutch lever
The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the han-
dlebar grip. To engage the clutch, re-
lease the lever. The lever should be
pulled rapidly and released slowly for
smooth clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the igni-
tion circuit cut-off system. (See page
4-17).
1
EAU12870
Shift pedal
1. Shift pedal
The shift pedal is located on the left
side of the engine and is used in com-
bination with the clutch lever when
shifting the gears of the 5-speed con-
stant-mesh transmission equipped on
this motorcycle.
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-10

EWA10240
WARNING0
The vehicle must not be ridden
with the sidestand down, or if the
sidestand cannot be properly
moved up (or does not stay up),
otherwise the sidestand could con-
tact the ground and distract the
operator, resulting in a possible
loss of control. Yamaha’s ignition
circuit cut-off system has been de-
signed to assist the operator in ful-
filling the responsibility of raising
the sidestand before starting off.
Therefore, check this system regu-
larly as described below and have
a Yamaha dealer repair it if it does
not function properly.
EAU15301
Sidestand
1. Sidestand
The sidestand is located on the left
side of the frame. Raise the sidestand
or lower it with your foot while holding
the motorcycle upright.
TIP
The built-in sidestand switch is part of
the ignition circuit cut-off system,
which cuts the ignition in certain situa-
tions. (See further down for an expla-
nation of the ignition circuit cut-off sys-
tem.)
1
1
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3
4
5
6
7
8
9
10
INSTRUMENT AND CONTROL FUNCTIONS
4-17
EAU15314
Ignition circuit cut-off
system
The ignition circuit cut-off system
(comprising the sidestand switch,
clutch switch and neutral switch) has
the following functions.
●It prevents starting when the
transmission is in gear and the
sidestand is up, but the clutch
lever is not pulled.
●It prevents starting when the
transmission is in gear and the
clutch lever is pulled, but the side-
stand is still down.
●It cuts the running engine when
the transmission is in gear and
the sidestand is moved down.
Periodically check the operation of the
ignition circuit cut-off system accord-
ing to the following procedure.
TIP
This check is most reliable if per-
formed with a warmed-up engine.
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INSTRUMENT AND CONTROL FUNCTIONS
WARNING0
If a malfunction is noted, have a Yamaha dealer
check the system before riding.
4-18
1
2
3
4
5
6
7
8
9
10
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is set to
“I”.
3. Turn the key on.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
The neutral switch may not be working correctly.
The motorcycle should not be riddenuntil checked by a
Yamaha dealer.
The sidestand switch may not be working correctly.
The motorcycle should not be riddenuntil checked by a
Yamaha dealer.
The clutch switch may not be working correctly.
The motorcycle should not be riddenuntil checked by a
Yamaha dealer.
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
The system is OK. The motorcycle can be ridden.YES NO
NO YES
NO YES
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1
2
3
4
5
6
7
8
9
10
FOR YOUR SAFETY – PRE-OPERATION CHECKS
5-3
ITEM
Clutch
Throttle grip
Control cables
Drive chain
Wheels and tires
Brake and shift pedals
Brake and
clutch levers
Sidestand
Chassis fastenersCHECKS
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 points 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
4-10, 7-20, 7-26
7-16, 7-26
7-25
7-23, 7-24, 7-25
7-16, 7-19
7-27
7-26
7-27
–
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1
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3
4
5
6
7
8
9
10
OPERATION AND IMPORTANT RIDING POINTS
EAU15951
Read the Owner's Manual carefully to
become familiar with all controls. If
there is a control or function you do not
understand, ask your Yamaha dealer.
EWA10271
WARNING0
Failure to familiarize yourself with
the controls can lead to loss of con-
trol, which could cause an accident
or injury.
6-1
EAU48020
TIP
This model is equipped with a lean an-
gle sensor to stop the engine in case
of a turnover. In this case, the multi-
function display indicates error code
30, but this is not a malfunction. Turn
the key to "OFF" and then to "ON" to
clear the error code. Failing to do so
will prevent the engine from starting
even though the engine will crank
when pushing the start switch.
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 4-18.
●Never ride with the sidestand
down.
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “
I”.
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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.
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.
OPERATION AND IMPORTANT RIDING POINTS
6-3
6
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1
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10
PERIODIC MAINTENANCE AND ADJUSTMENT
7-3
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✻
7✻
8✻
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.
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. Air filter element
Clutch
Front brake
Rear brake
Brake hoses
Wheels
Tires
Wheel bearings
EAU1770C
General maintenance and lubrication chart
Whenever worn to the limit
Whenever worn to the limit
Every 4 years
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