engine YAMAHA XT660Z 2012 Owner's Guide

PERIODIC MAINTENANCE AND ADJUSTMENT
7-14
1
2
3
4
\f
6
7
8
\b
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
7
Australia 4/8/10 \n 18:04 Página \f7

PERIODIC MAINTENANCE AND ADJUSTMENT
7-24
1
2
3
4
\f
6
7
8
\b
10
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

1
2
3
4
5
6
7
8
9
10
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
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-25

PERIODIC MAINTENANCE AND ADJUSTMENT
7-40
1
2
3
4
\f
6
7
8
\b
10
EAU42131Troubleshooting charts
Starting problems or poor engine performance
1. Fuel
2. Compression
3. Ignition
4. Battery
Check the fue\f \feve\f in the
fue\f t\bnk.
Oper\bte the e\fectric
st\brter.
Remove the sp\brk p\fug
\bnd check the e\fectrodes.
Oper\bte the e\fectric
st\brter.
There is enough
fue\f.
There is
compression.
Wet.
The engine turns
over quick\fy.
There is no fue\f.
There is no
compression.
Dry.
The engine turns
over s\fow\fy.
Check the
compression.
Check the ignition.
Wipe off with \b dry c\foth \bnd correct
the sp\brk p\fug g\bp, or rep\f\bce the
sp\brk p\fug.
The b\bttery is good.
H\bve \b Y\bm\bh\b de\b\fer check the
vehic\fe.
Check the b\bttery \fe\bd connections,
\bnd ch\brge the b\bttery if necess\bry.
Oper\bte the e\fectric st\brter.
The engine does not st\brt.
Check the b\bttery.
The engine does
not st\brt. H\bve \b
Y\bm\bh\b de\b\fer
check the vehic\fe.
Supp\fy fue\f.
H\bve \b Y\bm\bh\b de\b\fer check
the vehic\fe.
The engine does not st\brt.
Check the compression.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-40

1
2
3
4
5
6
7
8
9
10
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

1
2
3
4
5
6
7
8
9
10
MOTORCYCLE C\fRE \fND STOR\f\bE
8-4
Long-term
Before storing your motorcycle for se\f-
eral months:\b. Follow all the instructions in the “Care” section of this ch\lapter.
2. Fill up the fuel tank and add fuel stabilizer (if a\failable) to pre\fent
the fuel tank from rusting and the
fuel from deteriorating.
3. Perform the following steps to protect the cylinder, piston rings,
etc. from corrosion.a. Remo\fe the spark plug cap and spark plug.
b. Pour a teaspoonful of engine oil into the spark plug bore.
c. Install the spark plug cap onto the spark plug, and then place
the spark plug on the cylinder
head so that the electrodes
are grounded. (This will limit
sparking during the next step.)
d. Turn the engine o\fer se\feral times with the starter. (This will
coat the cylinder wall with oil.)
e. Remo\fe the spark plug cap from the spark plug, and then
install the spark plug and the
spark plug cap. W\fRNIN\b! To prevent damage or injury
from sparking, make sure to
ground the spark plug elec-
trodes while turning the en-
gine over.
4. Lubricate all control cables and the pi\foting points of all le\fers
and pedals as well as of the side-
stand/centerstand.\l
5. Check and, if necessary, correct the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alter-
nati\fely, turn the wheels a little
e\fery month in order to pre\fent
the tires from becoming degraded
in one spot.
6. Co\fer the muffler outlets with plastic bags to pre\fent moisture
from entering them. 7. Remo\fe the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex-
cessi\fely cold or warm place [less
than 0 °C (30 °F) or more than 30
°C (90 °F)]. For more information
on storing the batter y, see
page 7-3\b.
TIP
Make any necessary repairs before
storing the motorcycle.
XT660Z 08-10 ING-AUS:MY03 07-10 ING 11-05-2009 10:10 Pagina 5

SPECIFICATIONS
9-3
1
2
3
4
5
6
7
8
9
1\f
Rea\b suspension:
Type: Swingarm (lin\f suspension\b
Spring/damper type: Coil spring/gas-oil damper, spring
preload adjustable
Wheel travel: 200 mm (7.87 in\b
Elect\bical system:
Ignition system:Transistorized coil ignition (digital\b
Charging system: A.C. magneto
Batte\by:
Model:GT9B-4
Voltage, capacity: 12 V, 8 Ah
Headlight:
Bulb type:Halogen bulb
Bulb voltage, wattage x quantity:Headlight:12 V, 55 W x 2
Auxiliary light: 12 V, 5 W x 2
Tail/bra\fe light: LED
Front turn signal light: 12 V, 10 W x 2
Rear turn signal light: 12 V, 10 W x 2
Meter lighting: LED (bac\flight\b Neutral indicator light:
LED
Turn signal indicator light: LED
High beam indicator light: LED
Coolant temperature warning light: LED
Engine trouble warning light: LED
Immobilizer system indicator light: LED
Fuses:Main fuse:
30 A
Headlight fuse: 20 A
Signaling system fuse: 10 A
Ignition fuse: 10 A
Par\fing lighting fuse: 10 A
Radiator fan fuse: 7.5 A
Fuel injection system fuse: 10 A
Bac\fup fuse (for odometer, cloc\f and immobilizer\b:
10 A
XT660Z 08-10 ING-AUS:MY03 07-10 ING 11-05-2009 10:10 Pagina 8

1
2
3
4
5
6
7
8
9
10
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
Australia 5/8/10 \á 16:21 Pá\fina 94