lock YAMAHA XT660Z 2012 User Guide

PERIODIC MAINTENANCE AND ADJUSTMENT
7-20
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3. To increase the cl\ftch lever free pla\b, t\frn the adj\fsting bolt in di-
rection (a). To decrease the cl\ftch
lever free pla\b, t\frn the adj\fsting
bolt in direction (\lb).
TIP
If the specified cl\ftch lever free pla\b
co\fld be obtained as described above,
skip steps 4-7.
4. F\fll\b t\frn the adj\fsting bolt at the cl\ftch lever in direction (a) to
loosen the cl\ftch ca\lble.
5. Loosen the lockn\ft at the crankcase.1. Lockn\ft
2. Cl\ftch lever free pla\b adj\fsting n\ft(crankcase)
6. To increase the cl\ftch lever free
pla\b, t\frn the adj\fsting n\ft in di-
rection (a). To decrease the cl\ftch
lever free pla\b, t\frn the adj\fsting
n\ft in direction (b)\l.
7. Tighten the lockn\ft at the crankcase.
8. Tighten the lockn\ft at the cl\ftch lever and then slide the r\fbber
cover to its original position.
1
b
a
2
EAU22043
Adjusting the clutch lever
free play
1. Lockn\ft
2. Adj\fsting bolt
3. Cl\ftch lever free pla\b
The cl\ftch lever free pla\b sho\fld mea-
s\fre 10.0-15.0 mm (0.39-0.59 in) as
shown. Periodicall\b check the cl\ftch
lever free pla\b and, if necessar\b, ad-
j\fst it as follows.
1. Slide the r\fbber cover back at the cl\ftch lever.
2. Loosen the lockn\ft.
31
2
b
a
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-20

PERIODIC MAINTENANCE AND ADJUSTMENT
7-22
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Insufficient brake fluid \fay allow air to
enter t\be brake syste\f, possibly caus-
ing it to beco\fe ine\dffective.
Before riding, c\beck t\bat t\be brake flu-
id is above t\be \fini\fu\f level \fark
and replenis\b if ne\dcessary.
A low brake fluid level \fay indicate
worn brake pads and/or brake syste\f
leakage. If t\be brake fluid level is low,
be sure to c\beck t\be brake pads for
wear and t\be brake syste\f for leak-
age.
Observe t\bese precautions\d:
●W\ben c\becking t\be fluid level,
\fake sure t\bat t\be top of t\be
brake fluid reservoir is level.
●Use only t\be reco\f\fended qual-
ity brake fluid, ot\berwise t\be rub-
ber seals \fay deteriorate, caus-
ing leakage and poor braking
perfor\fance.
●Refill wit\b t\be sa\fe type of brake
fluid. Mixing fluids \fay result in a
\bar\fful c\be\fical reaction and
lead to poor braking perfor\fance.
●Be careful t\bat water does not en-
ter t\be brake fluid reservoir w\ben
refilling. Water will significantly
lower t\be boiling point of t\be fluid
and \fay result in vapor lock.
●Brake fluid \fay deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid i\f\fe-
diately.
●As t\be brake pads wear, it is nor-
\fal for t\be brake fluid level to
gradually go down. However, if
t\be brake fluid level goes down
suddenly, \bave a Ya\fa\ba dealer
c\beck t\be cause.
Recommended brake f\4luid: DOT 4
EAU22580
Checking the brake fluid
level
Front brake
1. Mini\fu\f level \fark
Rear brake
1. Mini\fu\f level \fark
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-22

PERIODIC MAINTENANCE AND ADJUSTMENT
7-24
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1. Wheel axle
2. Drive chain \flack adj\b\fting bolt
3. Lockn\bt
4. Alignment mark\f
TIP
U\fing the alignment mark\f on each
\fide of the \fwingarm, make \f\bre that
both chain p\bller\f are in the \fame po-
\fition for proper wheel al\nignment.
3. Tighten the axle n\bt, then the lock- n\bt\f to their \fpecified torq\be\f.
Tightening torques:
Axle n\bt:105 Nm (10.5 m·kgf, 75 ft·lbf)
Lockn\bt: 16 Nm (1.6 m·kgf, 11 ft·lbf)
EAU34314
To adjust the drive chain slack1. Loo\fen the axle n\bt and the lock- n\bt on each \fide of the \fwingarm.
2. To tighten the drive chain, t\brn the drive chain \flack adj\b\fting bolt on
each \fide of the \fwingarm in di-
rection (a). To loo\fen the drive
chain, t\brn the adj\b\fting bolt on
each \fide of the \fwingarm in di-
rection (b), and then p\b\fh the rear
wheel forward. NOTICE: Improp-
er drive chain slack will over-
load the engine as well as other
vital parts of the motorcycle
and can lead to chain slippage
or breakage. To prevent this
from occurring, keep the drive
chain slack within the specified
limits.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-24

PERIODIC MAINTENANCE AND ADJUSTMENT
7-32
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ECA10640
NOTICE
Do not use a fuse of a higher am-
perage rating than recommended
to avoid causing extensive damage
to the electrical system and possi-
bly a fire.
3. Turn th\f k\fy to \bON” and turn on th\f \fl\fctrical circuit in qu\fstion to
ch\fck if th\f d\fvic\f op\frat\fs.
4. If th\f fus\f imm\fdiat\fly blows again, hav\f a Yamaha d\fal\fr
ch\fck th\f \fl\fctrical syst\fm.
1. Parking lighting fus\f
2. Signaling syst\fm fus\f
3. H\fadlight fus\f
4. Ignition fus\f
5. El\fctronic fu\fl inj\fction fus\f
6. Radiator fan fus\f
7. Backup fus\f
8. R\fs\frv\f fus\fs
Th\f main fus\f and fus\f box ar\f locat-
\fd und\fr th\f s\fat. (S\f\f pag\f 7-31.)
If a fus\f is blown, r\fplac\f it as follows.1. Turn th\f k\fy to \bOFF” and turn off th\f \fl\fctrical circuit in qu\fstio\hn.
2. R\fmov\f th\f blown fus\f, and th\fn install a n\fw fus\f of th\f sp\fcifi\fd
amp\frag\f.
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8
654321Specified fuses:
Main fus\f:30 A
Parking lighting fus\f: 10 A
Signalling syst\fm fus\h\f: 10 A
H\fadlight fus\f: 20 A
Ignition fus\f: 10 A
Fu\fl inj\fction syst\fm \hfus\f: 10 A
Radiator fan fus\f: 7.5 A
Backup fus\f (for odom\ft\fr,
clock and immobiliz\fr): 10 A
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-32

PERIODIC MAINTENANCE AND ADJUSTMENT
7-34
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ECA10650
NOTICE
Take care not to damage the fol-
lowing parts:
●Headlight bulb  Do not touch the glass part
of the headlight bulb to keep
it free from oil, otherwise the
transparency of the glass,
the luminosity of the bulb,
and the bulb life will be ad-
versely affected. Thoroughly
clean off any dirt and finger-
prints on the headlight bulb
using a cloth moistened with
alcohol or thinner.
●Headlight lens
 Do not affix any type of tinted
film or stickers to the head-
light lens.
 Do not use a headlight bulb
of a wattage higher than
specified. 4. Connect t\fe couple\b, and t\fen in-
stall t\fe \feadlig\ft bulb cove\b.
5. Have a Yama\fa deale\b adjust t\fe \feadlig\ft beam if nec\ essa\by.
EAU24204
Replacing a turn signal
light bulb
1. Sc\bew
2. Tu\bn signal lig\ft lens
3. Tu\bn signal lig\ft bulb
1. Remove t\fe tu\bn signal lig\ft lensby \bemoving t\fe sc\bew.
2. Remove t\fe bu\bnt-out bulb by pus\fing it in and tu\bning it coun-
te\bclockwise.
3. Inse\bt a new bulb into t\fe socket, pus\f it in, and t\fen tu\bn it clock-
wise until it stops.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-34

PERIODIC MAINTENANCE AND ADJUSTMENT
7-38
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TIP
●If the drive chain is difficu\ft to re-
move, remove the \bhee\f ax\fe first,
and then \fift the \bhee\f up\bard
enough to remove the drive chain
from the rear sprocket.
●The drive chain cannot be disas-
semb\fed.
7. Whi\fe suppor ting the brake ca\fiper bracket, pu\f\f the \bhee\f
ax\fe out, and then remove the
\bhee\f. NOTICE: Do not apply
the brake after the wheel has
been removed together with
the brake disc, otherwise the
brake pads will be\4 forced shut.
EAUB1450
To install the rear wheel 1. Insta\f\f the \bhee\f and the brake ca\fiper bracket by inserting the
\bhee\f ax\fe from the right-hand
side.
EAU25080
Rear wheelEAU25312
To remove the rear wheelEWA10821
WARNING0
To avoid injury, securely support
the vehicle so there is no danger of
it falling over.
1. Whee\f ax\fe nut
2. Drive chain s\fack adjusting bo\ft
3. Locknut
4. Drive chain
3
4
1
1. Whee\f ax\fe
2. Drive chain s\fack adjusting bo\ft
3. Locknut
4. Brake ca\fiper
1. Loosen the ax\fe nut.
2. Lift the rear \bhee\f off the groundaccording to the procedure on
page 7-36.
3. Remove the ax\fe nut.
4. Loosen the \focknut on each side of the s\bingarm.
5. Turn the drive chain s\fack adjust- ing bo\fts fu\f\fy in direction (a) and
push the \bhee\f for\bard.
6. Remove the drive chain from the rear sprocket.
4
3
1
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a
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-38

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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-41
Engine overheatingEWA10400
W\fRNING0
●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 cau\Mse serious injury. Be sure to wait until th\Me engine has coole\Md.
●\ffter 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 a\failable, ta\b water can be tem\borarily used instead, \bro\fided that it is changed to the recommended
coolant as soon as \b\sossible.
Wait until the
engine has cooled.Check the coolant le\fel
in the reser\foir and radiator.
The coolant le\fel is low.
Check the cooling
system for leakage.
The coolant le\fel
is OK.
There is
leakage.
There is no
leakage.
Ha\fe a Yamaha dealer check
and re\bair the cooling system.
Start the engine. If the engine o\ferheats again, ha\fe
a Yamaha dealer check and re\bair the coo\sling system.
Add coolant. (See TIP.)
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-41

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INDEX
AAftermarket Parts, Accessories, and Modifications ...................................\f\.-4
Aftermarket Tires and \bims ...............\f-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 ....\f-\f
B Battery ....................................\...........7-30 To access the battery ...................7-30
To charge the battery....................7-30
To store the battery.......................7-31
Be a \besponsible Owner ...................\f-1
Brake and clutch levers, checking and lubricating ..............................7-\f6\.
Brake fluid ....................................\.....7-\f\f Changing ....................................\...7-\f3
Checking fluid level .......................7-\f\f
Brake lever ....................................\....4-11
Brake pads, checking .......................7-\f1
Brake pedal ....................................\...4-11 Checking ....................................\....7-\f7
Lubricating ....................................\.7-\f7
C Cables, checking and lubricating .....7-\f5
Carbon Monoxide (avoid Carbon Monoxide poisoning).......................\f-\f
Care and storage ...............................8-1\. Catalytic converter ...........................4-13
Checking and lubricating the brake
and clutch levers ...........................7-\f6
Checking and lubricating the brake pedal ....................................\..........7-\f7
Checking and lubricating the cables..7-\f5
Checking and lubricating the sidestand ....................................\...7-\f7
Checking and lubricating the throttle grip and cable ...............................7-\f\.6
Checking the brake pedal ................7-\f7
Checking the sidestand switch .........4-18
Clock mode ....................................\.....4-7
Clutch lever ....................................\...4-10
Clutch lever free play, adjusting .......7-\f0
Consumer information ......................10-1
Controls and instruments ...................3-3 Function ....................................\.......4-1
Coolant ....................................\..........7-1\f
Coolant temperature warning light .....4-4
D Description ....................................\......3-1 Controls and instrument .................3-3
Left view....................................\.......3-1
\bight view ....................................\....3-\f
Dimmer switch....................................\.4-9
Drive chain, cleaning and lubricating ..............................7-\f5\.
Drive chain slack ..............................7-\f3\. Adjusting ....................................\....7-\f3
Checking ....................................\....7-\f3 Cleaning and lubricating ...............7-\f5
E Emission control system (periodic maintenance chart) .........................7-\f
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-\f8
Front wheel ....................................\...7-36 Installing....................................\.....7-37
\bemoving....................................\...7-36
Fuel ....................................\...............4-1\f
Fuel consumption, tips for reducing ...6-3
Fuel meter ....................................\.......4-7
Fuel tank breather hose ...................4-13
Fuel tank cap ...................................4\.-11
Fuses, replacing ...............................7-3\.1
\f Genuine Yamaha Accessories ...........\f-3
H Handlebar switches ............................4-9
XT660Z 08-10 ING-AUS:MY03 07-10 ING 11-05-2009 10:10 Pagina 1

Dimmer switch ..................\o..............4-9
Engine sto\f switch..................\o........4-9
Hazar\b switch ..................\o.............4-10
Horn switch ..................\o..................\o.4-9
Pass switch ..................\o..................\o.4-9
Start switch ..................\o..................\o.4-9
Turn signal switch ..................\o.........4-9
Hea\blight bulb, re\flacing .................7\o-33
High beam in\bicator light ..................\o.4-4
Horn switch ..................\o..................\o....4-9
I I\bentification numbers ..................\o....10-1
I\bling s\fee\b, checking ..................\o...7-15
Ignition circuit cut-off system............4-17 Checking o\feration \froce\bure .....4-18
Immobilizer system ..................\o..........4-1
Immobilizer system in\bicator light ......4-4
In\bicator an\b warning lights ...............4-3\o Coolant tem\ferature warning light ..................\o..................\o.........4-4
Engine trouble warning light ...........4-4
High beam in\bicator light ................4-\o4
Immobilizer system in\bicator light ..................\o..................\o.........4-4
Neutral in\bicator light ..................\o....4-4
Turn signal in\bicator light................4-\o3
Instruments ..................\o..................\o....4-3
Instrument an\b control functions ........4-1
K Keys ..................\o..................\o...............4-1\o L
Labels (location of im\fortant labels) ..1-1
License \flate light bulb, re\flacing....7-35
Location of im\fortant labels ...............1-1\o
Loa\bing ..................\o..................\o..........2-3
Lubricating the brake an\b clutch levers ..................\o................7-\o26
Lubricating the brake \fe\bal..............7\o-27
Lubricating the cables ..................\o....7-25
Lubricating the \brive chain ...............7-2\o5
Lubricating the si\bestan\b .................7\o-27
Lubricating the throttle gri\f an\b cable ..................\o..................\o..7-26
Lubricating the swingarm \fivots.......7-28
M Main switch/steering lock ..................\o.4-2
Mo\bel label ..................\o..................\o...10-1
Motorcycle noise regulation (for Australia) ..................\o..............10-2\o
Multi-function \bis\flay..................\o........4-5 Clock mo\be ..................\o..................\o.4-7
Self-\biagnosis \bevices ..................\o..4-7
Tachometer ..................\o..................\o.4-6
Tri\fmeter an\b tachometer mo\bes ..4-6
N Neutral in\bicator light ..................\o.......4-4
O Oil filter element ..................\o.............7-10
O\feration an\b im\fortant ri\bing \foints ..................\o..................\o..........6-1 Owner’s tool kit ..................\o................7-\o1
P Panels, removing an\b installing .........7-6
Parking ..................\o..................\o...........6-4
Pass switch ..................\o..................\o....4-9
Perio\bic maintenance an\b a\bjustment ..................\o.............7-1
Perio\bic maintenance chart for the emission control system ...........7-2
Pre-o\feration check list ..................\o...5-2
Pre-o\feration checks ..................\o.......5-1
R Rear sus\fension, lubricating............7-27
Rear wheel ..................\o..................\o...7-38 Installing..................\o..................\o....7-39
Removing..................\o..................\o..7-38
Recor\b the i\bentification numbers ...10-1
S Safety information ..................\o............2-1
Seat ..................\o..................\o..............4-14\o
Self-\biagnosis \bevices ..................\o.....4-7
Shift \fe\bal ..................\o..................\o....4-10
Shifting ..................\o..................\o...........6-2
Shock absorber assembly (a\bjusting) ..................\o..................\o.4-16
Si\bestan\b ..................\o..................\o.....4-17
Si\bestan\b, checking an\b lubricating ..................\o..................\o.7-27
Si\bestan\b switch, checking ..............4-18\o
S\fark \flug, checking..................\o........7-8
INDEX
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