fuel 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
XT660Z 01-03 ING-AUS:AUSTRALIA 11-05-2009 9:57 Pagina 6

DESCRIPTION
3-3
1
2
3
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

1
2
3
4
5
6
7
8
9
10
INSTRUMENT AND CONTROL FUNCTIONS
4-5
EAUB1501
Multi-function display
1. Tachometer
2. Speedometer
3. Odometer
4. Tripmeters/Fuel reserve tripmeter
5. Clock
6. Fuel meter
7. “RESET” button
8. “SELECT” button
EWA12311
WARNING0
Be sure to stop the vehicle before
making any setting changes to the
multi-function display.
The multi-function display is equipped
with the following:
●a speedometer (which shows the
riding speed)
●a digital tachometer (which shows
engine r/min)
●an odometer (which shows the to-
tal distance traveled)
●two tripmeters (which show the
distance traveled since they were
last set to zero)
●a fuel reserve tripmeter (which
shows the distance traveled since
the bottom segment of the fuel
meter started flashing)
●a clock
●a fuel meter
●a self-diagnosis device
TIP
●Be sure to turn the key to "ON"
before using the "SELECT" and
"RESET" buttons.
●For the U.K. only: To switch the
speedometer and odome-
ter/tripmeter displays between
kilometers and miles, push the
"SELECT" and "RESET" buttons
together and turn the key to "ON".
When the digits start flashing,
push the "SELECT" button to
choose kilometers or miles.
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-5

INSTRUMENT AND CONTROL FUNCTIONS
4-6
1
2
3
4
5
6
7
8
9
10
Tachometer
1. Tachometer
2. Red zone
The tachometer allows the rider to
monitor the engine speed and keep it
within the ideal power range.
When the key is turned to "ON", the
tachometer needle will sweep once
across the r/min range and then return
to zero r/min in order to test the elec-
trical circuit.
ECA10030
NOTICE
Do not operate the engine in the
tachometer red zone.
Red zone: 7,500 r/min and above.
Tripmeter and tachometer modes
1. “SELECT” button
2. “RESET” button
Pushing the "SELECT" button switch-
es the display between the tripmeter
modes "TRIP 1" and "TRIP 2" in the
following order:
TRIP 1
6TRIP 2 6TRIP 1
When the fuel amount in the fuel tank
decreases to 6.7 L (1.77 US gal) (1.47
Imp.gal), the bottom segment of the
fuel meter will start flashing, and the
tripmeter display will automatically
change to the fuel reserve tripmeter
mode “F-TRIP” and start counting the
distance traveled from that point. In
that case, pushing the "SELECT" but-
ton switches the display between the
various tripmeter modes in the follow-
ing order:
F-TRIP
6TRIP 1 6TRIP 2 6F-TRIP
To reset a tripmeter, select it by push-
ing the "SELECT" button, and then
push the "RESET" button for at least
four seconds. If you do not reset the
fuel reserve tripmeter manually, it will
reset itself automatically and the dis-
play will return to the prior mode after
refueling and traveling 5 km (3 mi).
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-6

1
2
3
4
5
6
7
8
9
10
INSTRUMENT AND CONTROL FUNCTIONS
4-7
Clock mode
1. Clock
2. “SELECT” button
3. “RESET” button
TIP
The clock is displayed even when the
key is turned to "OFF".
To set the clock:
1. Push the "SELECT" button for at
least four seconds.
2. When the hour digits start flash-
ing, push the "RESET" button to
set the hours.
3. Push the "SELECT" button, and
the minute digits will start flashing.
4. Push the "RESET" button to set
the minutes.
5. Push the "SELECT" button and
then release it to start the clock.
Fuel meter
1. Fuel meter
With the key in the "ON" position, the
fuel meter indicates the amount of fuel
in the fuel tank. When the key is turned
to "ON", all of the display segments of
the fuel meter will appear one after the
other and then disappear in order to
test the electrical circuit. The display
segments of the fuel meter disappear
towards "E" (Empty) as the fuel level
decreases. When only one segment is
left near "E" (Empty), refuel as soon
as possible.
TIP
This fuel meter is equipped with a self-
diagnosis system. If the electrical cir-
cuit is defective, all the segments will
start flashing. If this occurs, have a
Yamaha dealer check the electrical cir-
cuit.
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-7

1
2
3
4
5
6
7
8
9
10
INSTRUMENT AND CONTROL FUNCTIONS
4-11
EAU26823
Brake lever
1. Brake lever
2. Position adjusting dial
3. Arrow mark
4. Distance
The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the han-
dlebar grip.
The brake lever is equipped with a po-
sition adjusting dial. To adjust the dis-
tance between the brake lever and the
handlebar grip, turn the adjusting dial
while holding the lever pushed away
from the handlebar grip. Make sure
that the appropriate setting on the ad-
justing dial is aligned with the “˙”
mark on the brake lever.
EAU12941
Brake pedal
1. Brake pedal
The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
1
EAU13074
Fuel tank cap
1. Lock cover
2. Open
To open the fuel tank cap
Open the fuel tank cap lock cover, in-
sert the key into the lock, and then turn
it 1/4 turn clockwise. The lock will be re-
leased and the fuel tank cap can be
opened.
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-11

INSTRUMENT AND CONTROL FUNCTIONS
4-12
1
2
3
4
5
6
7
8
9
10
To close the fuel tank cap
1. Push the fuel tank cap into posi-
tion with the key inserted in the
lock.
2. Turn the key counterclockwise to
the original position, remove it,
and then close the lock cover.
TIP
The fuel tank cap cannot be closed
unless the key is in the lock. In addi-
tion, the key cannot be removed if the
cap is not properly closed and locked.
EWA11091
WARNING0
Make sure that the fuel tank cap is
properly closed after filling fuel.
Leaking fuel is a fire hazard.
EAU13221
Fuel
Make sure there is sufficient gasoline
in the tank.
EWA10881
WARNING0
Gasoline and gasoline vapors are
extremely flammable. To avoid fires
and explosions and to reduce the
risk of injury when refueling, follow
these instructions.
1. Before refueling, turn off the en-
gine and be sure that no one is
sitting on the vehicle. Never refuel
while smoking, or while in the
vicinity of sparks, open flames, or
other sources of ignition such as
the pilot lights of water heaters
and clothes dryers.
2. Do not overfill the fuel tank. When
refueling, be sure to insert the
pump nozzle into the fuel tank
filler hole. Stop filling when the fu-
el reaches the bottom of the filler
tube. Because fuel expands when
it heats up, heat from the engine
or the sun can cause fuel to spill
out of the fuel tank.
1. Fuel tank filler tube
2. Fuel level
3. Wipe up any spilled fuel immedi-
ately. NOTICE:Immediately wipe
off spilled fuel with a clean, dry,
soft cloth, since fuel may deteri-
orate painted surfaces or plas-
tic parts.
4. Be sure to securely close the fuel
tank cap.
EWA15151
WARNING0
Gasoline is poisonous and can
cause injury or death. Handle gaso-
line with care. Never siphon gaso-
line by mouth. If you should swal-
low some gasoline or inhale a lot of
gasoline vapor, or get some gaso-
line in your eyes, see your doctor
immediately. If gasoline spills on
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-12

1
2
3
4
5
6
7
8
9
10
INSTRUMENT AND CONTROL FUNCTIONS
4-13
your skin, wash with soap and wa-
ter. If gasoline spills on your cloth-
ing, change your clothes.
EAU13390EAU13412
Fuel tank breather hose
1. Fuel tank breather hose
2. Clamp
Before operating the motorcycle:
●Check the fuel tank breather hose
connection.
●Check the fuel tank breather hose
for cracks or damage, and replace
it if damaged.
●Make sure that the fuel tank
breather hose is not blocked, and
clean it if necessary.
ECA11400
NOTICE
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,
as well as to the exhaust system.
Your Yamaha engine has been de-
signed to use premium unleaded
gasoline with a research octane num-
ber of 95 or higher. If knocking (or
pinging) occurs, use a gasoline of a
different brand. Use of unleaded fuel
will extend spark plug life and reduce
maintenance costs.
Recommended fuel:
PREMIUM UNLEADED
GASOLINE ONLY
Fuel tank capacity:
23.0 L (6.07 US gal) (5.05 Imp.gal)
Fuel reserve amount (when the fuel
level warning light comes on):
6.7 L (1.77 US gal) (1.47 Imp.gal)
EAU13433
Catalytic converter
This model is equipped with a catalyt-
ic converter in the exhaust system.
EWA10862
WARNING0
The exhaust system is hot after op-
eration. To prevent a fire hazard or
burns:
●Do not park the vehicle near
possible fire hazards such as
grass or other materials that
easily burn.
●Park the vehicle in a place
where pedestrians or children
are not likely to touch the hot
exhaust system.
●Make sure that the exhaust
system has cooled down be-
fore doing any maintenance
work.
●Do not allow the engine to idle
more than a few minutes. Long
idling can cause a build-up of
heat.
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-13

FOR YOUR SAFETY – PRE-OPERATION CHECKS
5-2
1
2
3
4
5
6
7
8
9
10
ITEM
Fuel
Engine oil
Coolant
Front brake
Rear brake
EAU15605
Before using this vehicle, check the following points:
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
4-12
7-9
7-12
4-11, 7-21, 7-22, 7-26
4-11, 7-21, 7-22, 7-27
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 2

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
03 ingles -australia 3/5/10 06:00 Página 41