check engine YAMAHA XT660Z 2012 User Guide

PERIODIC MAINTENANCE AND ADJUSTMENT
EAU46861
TIP● The ann\fal check\b m\f\bt be performed every year, except if a kilometer-ba\bed maintenance, or for the UK, a
mileage-ba\bed mainte\nnance, i\b performed i\nn\btead.
●From 50000 km (3000\)0 mi)\f repea\b \bhe main\)\benance in\bervals s\bar\bing from 10000 km (\)6000 mi).
●I\bems marked wi\bh an as\berisk should be performed by a Yamaha dealer as \bhey require special \bools\f da\ba and \bech-
nical skills.
EAU46910Periodic maintenance chart for the emi\b\bion control \by\btem
7-2
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10
NO. ITEM CHECK OR MAINTENAN\nCE 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 condi\bion.
 Clean and regap.
 Replace.
 Check valve clearance.
 Adjus\b.
 Adjus\b engine idlin\)g speed.
 Check \bhe screw clamp(s) for
looseness.
 Check \bhe air cu\b-off valve\f reed valve\f and hose for damage.
 Replace any damaged par\bs if necessary.
F\fel line
Spark pl\fg
Valve\b
F\fel injection
M\fffler and exha\f\bt
pipe
Air ind\fction \by\btem
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-2

PERIODIC MAINTENANCE AND ADJUSTMENT
7-4
1
2
3
4
\f
6
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8
\b
10
NO. ITEM CHECK OR MAINTENAN\4CE 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
✻
1\f✻
16✻
18
 Check operation and for e\fcessive pla\b.
 Lubricate with lithium-\fsoap-based grease.
 Check chain slack, alignment and condition.
 Adjust and lubricate chain with a\f special
O-ring chain lubricant thoroughl\b.
 Check bearing pla\b and steering
for roughness.
 Lubricate with lithium-\fsoap-based grease.
 Make sure that all nuts, bolts and screws
are properl\b 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-\fsoap-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
Ever\b 50000 km (30000 mi)
Ever\b 50000 km (30000 mi)
Ever\b 500 km (300 mi) and after washing the motorc\bcle or riding in the rain
\b✻
11✻
17✻
12✻
10
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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-57-5
EAUM1890
TIP
●Replace t\fe air filte\tr ele\bent \bore frequen\ttly if you are riding in unusually wet or dusty areas.
●Hydraulic brake service
●Regularly c\feck and, if necessary, correct t\fe brake fluid level.
●Every two years replace t\fe inter\tnal co\bponents of t\fe \tbrake \baster cylinder, and c\fange t\fe brake fluid.
●Replace t\fe brake \foses every four years and if cracked or da\baged.
NO. ITEMCHECK OR M\fINTEN\fNCE\M JOB
ODOMETER RE\fDING
1000 km 10000 km 20000 km 30000 km 40000 km(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
\fNN\b\fL
CHECK
√ √ √
√ √ √ √ √
√ √ √ √ √ √ √ √ √ √ √
√ √ √ √ √
√ √ √ √ √ √ Replace.
 C\feck coolant level and ve\ficle for coolant leakage.
 C\fange.
 C\feck operation.
 Lubricate.
 C\feck operation and free play.
 Adjust t\fe t\frottle cab\tle free play if necessary.
 Lubricate t\fe t\frottle grip \fousing
and cable.
 C\feck operation.
 Adjust \feadlig\ft bea\b.\t
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✻
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-5

PERIODIC MAINTENANCE AND ADJUSTMENT
7-8
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2. Remove the spark pl\fg as shown\b with the spark pl\fg wrench incl\fd-
ed in the owner’s tool kit.
To check the spark plug 1. Check that the porcelain ins\flator aro\fnd the center electrode of the
spark pl\fg is a medi\fm-to-light
tan (the ideal color when the vehi-
cle is ridden normally).
TIP
If the spark pl\fg shows a distinctly dif-
ferent color\b the engine co\fld be oper-
ating improperly. Do not attempt to di-
agnose s\fch problems yo\frself.
Instead\b have a Yamaha dealer check
the vehicle.
2. Check the spark pl\fg for elec- trode erosion and excessive car-
bon or other deposits\b and re-
place it if necessa\lry.
Specified spark plu\4g:CR7E (NGK)
Spark plug gap:0.7-0.8 mm (0.028-0\l.032 in)
To install the spark plug
1. Meas\fre the spark pl\fg gap with a wire thickness ga\fge and\b if
necessar y\b adj\fst the gap to
specification.
1. Spark pl\fg gap
2. Clean the s\frface of the sparkpl\fg gasket and its mating s\fr-
face\b and then wipe off any grime
from the spark pl\fg threads.
3. Install the spark pl\fg with the spark pl\fg wrench\b and then tight-
en it to the specif\lied torq\fe.
EAU19603
Checking the spark plug
The spark pl\fg is an important engine
component\b which is easy to check.
Since heat and deposits will ca\fse
any spark pl\fg to slowly erode\b the
spark pl\fg sho\fld be removed and
checked in accordance with the peri-
odic maintenance and l\fbrication
chart. In addition\b the condition of the
spark pl\fg can reveal the condition of
the engine.
To remove the spark plug
1. Spark pl\fg cap
2. Spark pl\fg wrench
1. Remove the spark pl\fg cap.
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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-9
EAUB1560
Engine oil and oil filter
element
The engine oi\f \feve\f shou\f\b be checke\b
before each ri\be. In a\b\bition, the oi\f must
be change\b an\b the oi\f fi\fter e\fement re-
p\face\b at the interva\fs specifie\b in the
perio\bic maintenance an\b \fubrication
chart.
To check the engine oil level1. P\face the vehic\fe on a \feve\f surface an\b ho\f\b it in an upright position.
TIP
Make sure that the vehic\fe is posi-
tione\b straight up when checking the
oi\f \feve\f. A s\fight ti\ft to the si\be can re-
su\ft in a fa\fse rea\bing.
2. Start the engine, warm it up for 10-15 minutes an\b then turn it off.
3. Remove the oi\f fi\f\fer cap, wipe the \bipstick c\fean, insert it back into
the oi\f fi\f\fer ho\fe (without screwing
it in), an\b then remove it again to
check the oi\f \feve\f.
1. Engine oi\f fi\f\fer cap
2. Maximum \feve\f mark
3. Minimum \feve\f mark
TIP
●The engine oi\f tank is \focate\b in-
si\be of the frame.
●The engine oi\f shou\f\b be between
the minimum an\b maximum \feve\f
marks.
Tightening torque:Spark p\fug:12.5 Nm (1.25 m·kg\of, 9.0 ft·\fbf)
TIP
If a torque wrench is not avai\fab\fe
when insta\f\fing a spark p\fug, a goo\b
estimate of the correct torque is 1/4-
1/2 turn past finger tight. However, the
spark p\fug shou\f\b be tightene\b to the
specifie\b torque as s\ooon as possib\fe.
4. Insta\f\f the spark p\fug cap.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-9

ECAM1060CAUTION:
The engine oil tank \fust be \billed in
2 steps. First, \bill the engine oil tank
with 1.90 L (2.0 US qt) (1.67 I\fp.qt)
o\b the reco\f\fended engine oil.
Then, start the engine, race it 5 or 6
ti\fes, turn it o\b\b, and then add the
re\fainder o\b the eng\kine oil.
NOTE:
Be sure to wipe off spi\f\fed oi\f on an\b
parts after the engine and exhaust
s\bstem have coo\fed d\fown.
ECA11620CAUTION: In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
\fix any che\fical additives. Do
not use oils with a diesel speci-
\bication o\b “CD” or oils o\b a
higher quality than speci\bied. In
addition, do not use oils la-
beled “ENERGY CONSERVING
II” or higher.
Make sure that no \boreign \fa-
terial enters the c\krankcase.
14. Start the engine, and then \fet it id\fe for severa\f minutes whi\fe
checking it for oi\f \feakage. If oi\f is
\feaking, immediate\f\b turn the en-
gine off and check for the \fcause.
15. Turn the engine off, and then check the oi\f \feve\f and correct it if
necessar\b.
16. Insta\f\f the engine guard b\b in- sta\f\fing the screws.\f
EAU20070
Coolant
The coo\fant \feve\f sho\fu\fd be checked
before each ride. In addition, the
coo\fant must be changed at the inter-
va\fs specified in the periodic mainte-
nance and \fubrication \fchart.
EAU20253
To check the coolant level1. P\face the vehic\fe on a \feve\f sur- face and ho\fd it in an upright posi-
tion.
NOTE:
The coo\fant \feve\f must be
checked on a co\fd engine since
the \feve\f varies with engine tem-
perature.
Make sure that the vehic\fe is posi-
tioned straight up when checking
the coo\fant \feve\f. A s\fight ti\ft to the
side can resu\ft in a \ffa\fse reading.
2. Check the coo\fant \feve\f in the coo\fant reservoir.
Reco\f\fended engine \koil:See page 8-1.
Oil quantity: Without oi\f fi\fter e\f\fement
rep\facement:2.50 L (2.64 US qt) (2.19 I\fmp.qt)
With oi\f fi\fter e\fem\fent rep\facement: 2.60 L (2.73 US qt) (2.26 Im\fp.qt)
PERIODIC MAINTENANCE AND ADJUSTMENT
7-12
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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-13
TIP
The coolant should be between the
\fini\fu\f and \faxi\fu\f level \fa\bks.
1. Coolant \bese\bvoi\b
2. Maxi\fu\f level \fa\bk
3. Mini\fu\f level \fa\bk
4. Rese\bvoi\b cap
3. If the coolant is at o\b below the\fini\fu\f level \fa\bk, \be\fove pan-
el E (See page 7-7.), \be\fove the
\bese\bvoi\b cap, add coolant to the
\faxi\fu\f level \fa\bk, and then in-
stall the \bese\bvoi\b cap and the
panel. W\fRNING! 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\M level mark): 0.50 L (0.52 US qt\w) (0.44 I\fp.
EAU33031
Changing the coolant
The coolant \fust be changed at the
inte\bvals specified in the pe\biodic
\faintenance and lub\bication cha\bt.
Have a Ya\faha deale\b change the
coolant. W\fRNING! Never attempt
to remove the radiator cap when
the engine is hot.\M
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-13

PERIODIC MAINTENANCE AND ADJUSTMENT
7-14
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10
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\4 worn.
\f. Install t\be air filter case cover by installing t\be screws.
6. Install t\be seat.
1
EAUB1480
Replacing the air filter
element and cleaning the
check hose
T\be air filter element s\bould be re-
placed at t\be intervals specified in t\be
periodic maintenance and lubrication
c\bart. Replace t\be air filter element
more frequently if you are riding in un-
usually wet or dusty areas. In addition,
t\be air filter c\beck \bose must be fre-
quently c\becked and cleaned if neces-
sary. To replace the air filter element
1. Air filter case
2. Screws
1. Remove t\be seat. (See page 4-
14.)
2. Remove t\be air filter case cover by removing t\be screws.
3. Pull t\be air filter\8 element out.
4. Insert a new air filter element into t\be air filter case \8as s\bown.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-14

To clean the air filter check hose
1. Air filter check hose
2. Check hose cap
1. Check the hose o\f the side of theair filter case for accumulated dirt
or \bater.
2. If dirt or \bater is visible, remove the hose, clea\f it, a\fd the\f i\fstall
it.
EAU44734
Checking the engine idling
speed
1. Idle adjusting screw
a. Increasing the engine idling s\feed
b. Decreasing the engine idling s\feed
The engine idling s\feed \bust be
checked as follows and, if necessary,
adjusted by a Ya\baha dealer at the in-
tervals s\fecified in the \feriodic \bain-
tenance and lubric\hation chart.
Start the engine and war\b it u\f for
several \binutes at 1000-2000 r/\bin
while occasionally revving it to 4000-
5000 r/\bin.
\fngine idling speed:1400–1600 r/mi\f
P\fR\bOD\bC MA\bNT\fNANC\f AND ADJUSTM\fNT
7-15
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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-25
EAU23023
Cleaning and lubricating
the drive chain
The drive chai\f mus\b be clea\fed a\fd
lubrica\bed a\b \bhe i\f\bervals specified i\f
\bhe periodic mai\f\be\fa\fce a\fd lubrica-
\bio\f char\b, o\bherwise i\b will quickly
wear ou\b, especially whe\f ridi\fg i\f
dus\by or we\b areas. Service \bhe drive
chai\f as follows.
ECA10581
NOTICE
The drive chain must be lubricated
after washing the motorcycle and
riding in the rain.\M
1. Clea\f \bhe drive chai\f wi\bh kerose\fe a\fd a small sof\b brush. NOTICE:
To prevent damaging the O-
rings, do not clean the drive
chain with steam cleaners,
high-pressure washers or inap-
propriate solvents. 2. Wipe \bhe drive chai\f dry.
3. Thoroughly lubrica\be \bhe drive
chai\f wi\bh a special O-ri\fg chai\f
lubrica\f\b. NOTICE: Do not use
engine oil or any other lubri-
cants for the drive chain, as
they may contain substances
that could damage the O-rings.
EAU23101
Checking and lubricating
the cables
The opera\bio\f of all co\f\brol cables a\fd
\bhe co\fdi\bio\f of \bhe cables should be
checked before each ride, a\fd \bhe ca-
bles a\fd cable e\fds should be lubri-
ca\bed if \fecessary. If a cable is dam-
aged or does \fo\b move smoo\bhly, have
a Yamaha dealer check or replace i\b.
W\fRNING! Damage to the outer
sheath may interfere with proper
cable operation and will cause the
inner cable to rust. Replace a dam-
aged cable as soon as possible to
prevent unsafe condit\Mions.
Recommended lubrican\Mt: E\fgi\fe oil
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