YAMAHA XT660Z 2011 Owner's Guide

This ABS has a test mode which
allows the owner to experience
the pulsating at the brake lever or
brake pedal when the ABS is
operating. However, special tools
are required, so please consult
your Yamaha dealer when perfor-
ming this test.
ECA16120
Keep any type of magnets (inclu-
ding magnetic pick-up tools, mag-
netic screwdrivers, etc.) away from
the front and rear wheel hubs,
otherwise the magnetic rotors
equipped in the wheel hubs may be
damaged, resulting in improper
performance of the ABS system.
1. Front wheel hub
1. Rear wheel hub
EAU13074
Fuel tank cap
1. Lock cover
2. Open
To open the fuel tank cap
Open the fuel tank cap lock cover,
insert the key into the lock, and then
turn it 1/4 turn clockwise. The lock will
be released and the fuel tank cap can
be opened.
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.
NOTICE
INSTRUMENT AND CONTROL FUNCTIONS
3-13
3
56P-F8199-E0 30/6/10 09:24 Página 31

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 loc-
ked.
EWA11091
Make sure that the fuel tank cap is
properly closed after filling fuel.
Leaking fuel is a fire hazard.
EAU13212
Fuel
Make sure there is sufficient gasoline
in the tank.
EWA10881
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 engi-
ne and be sure that no one is sit-
ting 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. Stop
filling when the fuel 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. Maximum fuel level
3. Wipe up any spilled fuel imme-
diately. NOTICE: Immediately
wipe off spilled fuel with a cle-
an, dry, soft cloth, since fuel
may deteriorate painted surfa-
ces or plastic parts.
[ECA10071]
4. Be sure to securely close the fuel
tank cap.
EWA15151
Gasoline is poisonous and can cau-
se injury or death. Handle gasoline
with care. Never siphon gasoline by
mouth. If you should swallow some
gasoline or inhale a lot of gasoline
WARNING
WARNING
WARNING
INSTRUMENT AND CONTROL FUNCTIONS
3-14
3
56P-F8199-E0 30/6/10 09:24 Página 32

vapor, or get some gasoline in your
eyes, see your doctor immediately.
If gasoline spills on your skin, wash
with soap and water. If gasoline
spills on your clothing, change your
clothes.
EAU49460
ECA11400
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 sys-
tem.
Your Yamaha engine has been desig-
ned to use premium unleaded gasoli-ne with a research octane number 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.
EAUB1300
Fuel tank breather/overflow
hose
1. Fuel tank breather/overflow hose
2. Hose clamp
Before operating the motorcycle:
Check the fuel tank breather/over-
flow hose connection.
Check the fuel tank
breather/overflow hose for
cracks or damage, and replace it
if damaged.
Make sure that the end of the fuel
tank breather/overflow hose is
not blocked, and clean it if
necessary.
Make sure that the end of the fuel
tank breather/overflow hose is
positioned inside of the clamp.
NOTICE
Recommended fuel:
PREMIUM UNLEADED
GASOLINE ONLY
Fuel tank capacity:
23.0 L (6.08 US gal, 5.06 Imp.gal)
Fuel reserve amount:
XT660Z 6.7 L (1.76 US gal,
1.46 Imp.gal)
XT660ZA 5.8 L (1.53 US gal,
1.28 Imp.gal)
INSTRUMENT AND CONTROL FUNCTIONS
3-15
3
56P-F8199-E0 30/6/10 09:24 Página 33

EAU13445
Catalytic converters
This vehicle is equipped with catalytic
converters in the exhaust system.
EWA10862
The exhaust system is hot after
operation. 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 befo-
re 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.
ECA10701
Use only unleaded gasoline. The
use of leaded gasoline will cause
unrepairable damage to the cataly-
tic converter.
EAU13861
Seat
To remove the seat
1. Insert the key into the seat lock,
turn it counterclockwise, and
then pull the seat off.
1. Seat lock
2. Unlock
To install the seat
Insert the projections on the front of
the seat into the seat holders, push
the rear of the seat down to lock it in
place, and then remove the key.
NOTICE
WARNING
INSTRUMENT AND CONTROL FUNCTIONS
3-16
3
56P-F8199-E0 30/6/10 09:24 Página 34

1. Projection
2. Seat holder
TIP
Make sure that the seat is properly
secured before riding.
EAUS1920
Adjusting the front fork
For XT660Z:
This front fork is equipped with spring
preload adjusting bolts.
EWA10180
Always adjust both fork legs
equally, otherwise poor handling
and loss of stability may result.
Adjust the spring preload as follows.
To increase the spring preload and
thereby harden the suspension, turn
the adjusting bolt on each fork leg in
direction (a). To decrease the spring
preload and thereby soften the sus-
pension, turn the adjusting bolt on
each fork leg in direction (b).
1. Spring preload adjusting bolt
TIP
Use the 10 mm hexagon wrench
included in the owner’s tool kit to turn
the adjusting bolts.
Spring preload setting:
Minimum (soft):
0 complete turn(s) in direction
(b)*
Standard:
22 complete turn(s) in direction
(b)*
Maximum (hard):
27 complete turn(s) in direction
(b)*
* With the adjusting bolt fully turned
in direction (a)
WARNING
INSTRUMENT AND CONTROL FUNCTIONS
3-17
3
56P-F8199-E0 30/6/10 09:24 Página 35

For XT660ZA:
This front fork cannot be adjusted.EAUB1462
Adjusting the shock
absorber assembly
This shock absorber assembly is
equipped with a spring preload adjus-
ting ring.
ECA10101
To avoid damaging the mechanism,
do not attempt to turn beyond the
maximum or minimum settings.
Adjust the spring preload as follows.
To increase the spring preload and
thereby harden the suspension, turn
the adjusting ring in direction (a). To
decrease the spring preload and the-
reby soften the suspension, turn the
adjusting ring in direction (b).
TIP
Align the appropriate notch in the
adjusting ring with the position indica-
tor on the shock absorber.
1. Spring preload adjusting ring
2. Position indicator
EWAB0020
Never adjust the spring preload
until the exhaust system has coo-
led down.
Spring preload setting:
Minimum (soft):
1
Standard:
2
Maximum (hard):
9
WARNING
NOTICE
INSTRUMENT AND CONTROL FUNCTIONS
3-18
3
56P-F8199-E0 30/6/10 09:24 Página 36

EWA10221
This shock absorber assembly
contains highly pressurized nitro-
gen gas. Read and understand the
following information before hand-
ling the shock absorber assembly.
Do not tamper with or attempt
to open the cylinder assembly.
Do not subject the shock
absorber assembly to an open
flame or other high heat sour-
ce. This may cause the unit to
explode due to excessive gas
pressure.
Do not deform or damage the
cylinder in any way. Cylinder
damage will result in poor
damping performance.
Do not dispose of a damaged
or worn-out shock absorber
assembly yourself. Take the
shock absorber assembly to a
Yamaha dealer for any service.
EAU15303
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 vehicle upright.
TIP
The built-in sidestand switch is part of
the ignition circuit cut-off system,
which cuts the ignition in certain
situations. (See page 3-20 for an
explanation of the ignition circuit cut-
off system.)
EWA10240
The vehicle must not be ridden with
the sidestand down, or if the sides-
tand cannot be properly moved up
(or does not stay up), otherwise the
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control. Yama-
ha’s ignition circuit cut-off system
has been designed to assist the
operator in fulfilling the responsibi-
lity of raising the sidestand before
starting off. Therefore, check this
system regularly as described
below and have a Yamaha dealer
repair it if it does not function pro-
perly.
WARNINGWARNING
INSTRUMENT AND CONTROL FUNCTIONS
3-19
3
56P-F8199-E0 30/6/10 09:24 Página 37

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
sidestand 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
according to the following procedure.
TIP
This check is most reliable if perfor-
med with a warmed-up engine.
INSTRUMENT AND CONTROL FUNCTIONS
3-20
3
56P-F8199-E0 30/6/10 09:24 Página 38

With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is set to “
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?
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.The neutral switch may not be working correctly.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The sidestand switch may not be working correctly.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The clutch switch may not be working correctly.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
YES NO YES NO YES NO
If a malfunction is noted, have a Yamaha
dealer check the system before riding.
WARNING
”.
INSTRUMENT AND CONTROL FUNCTIONS
3-21
3
56P-F8199-E0 30/6/10 09:24 Página 39

FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-1
4
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the ins-
pection and maintenance procedures and schedules described in the Owner’s Manual.
EWA11151
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment dama-
ge. Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures pro-
vided in this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
WARNING
ITEM CHECKS PAGE
• Check fuel level in fuel tank.
• Refuel if necessary.
Fuel• Check fuel line for leakage. 3-14
• Check the fuel tank breather/overflow hose for obstructions, cracks or
damage, and check the hose connection.
• Check oil level in oil tank.
Engine oil• If necessary, add recommended oil to specified level. 6-11
• Check vehicle for oil leakage.
• Check coolant level in reservoir.
Coolant• If necessary, add recommended coolant to specified level. 6-14
• Check cooling system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check lever free play.
• Adjust if necessary.
Front brake• Check brake pads for wear. 6-21
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
56P-F8199-E0 30/6/10 09:24 Página 40