YAMAHA XT660Z 2012 Workshop Manual

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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
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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

PERIODIC MAINTENANCE AND ADJUSTMENT
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To change the engine oil
(with or without oil filter element
replacement)
1. Mounting screw
2. \fngine guard
1. Start t\be engine, warm it up for sev- eral minutes, and t\ben turn it off.
2. To reac\b t\be drain bolt of t\be crankcase and t\be drain bolt of
t\be oil tank, remove t\be engine
guard by removing t\be screws.
3. Place an oil pan under t\be engine to collect t\be used\2 oil.
4. Remove t\be engine oil filler cap and t\be drain bolt to drain t\be oil
from t\be crankcase.
5. Remove t\be drain bolt to drain t\be oil from t\be oil ta\2nk.
1. \fngine oil crankcase drain bolt
1. \fngine oil tank drain bolt
6. Remove t\be oil filter elementdrain bolt to drain t\be oil from t\be
oil filter element\2.
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\fCA10010
NOTICE
Do not operate the vehicle until you
know that the engine oil level is suf-
ficient.
\fWA10360
WARNING0
Never remove the engine oil tank
cap after high-speed operation,
otherwise hot engine oil could
spout out and cause damage or in-
jury. Always let the engine oil cool
down sufficiently before removing
the oil tank cap.
4. If t\be engine oil is below t\be mini- mum level mark, add sufficient oil
of t\be recommended type to raise
it to t\be correct l\2evel.
5. Install t\be oil fil\2ler cap.
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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
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Tightening torques:Oil filter element\0 cover bolt:10 \fm (1.0 m·\bgf, 7.2 ft·lbf)
Oil filter element\0 drain bolt: 10 \fm (1.0 m·\bgf, 7.2 ft·lbf)
Tightening torques:Engine oil drain bolt (cran\bcase):30 \fm (3.0 m·\bgf, 22 ft·lbf)
Engine oil drain bolt (oil tan\b)\0: 18 \fm (1.8 m·\bgf, 12.9 ft·lbf)
13. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filter
cap.
10. Install the oil filter element drain
bolt.
11. Tighten the oil filter element cover bolts and the oil filter element
drain bolt to their specified
torques.1. Engine oil filter element
2. O-rings
12. Install the engine oil drain bolts,and then tighten them to their
specified torques.
TIP
S\bip steps 7-9 if the oil filter element is
not being replaced\0.
7. Remove the oil filter element cov- er by removing the bolts.
8. Remove and replace the oil filter element and O-rings.
9. Install the oil filter element cover by installing the bo\0lts.
TIP
Ma\be sure that the O-rings are proper-
ly seated.
1. Engine oil filter element drain bolt
2. Oil filter element cover bolts
2
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XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-11

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
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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
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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
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PERIODIC MAINTENANCE AND ADJUSTMENT
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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
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PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU21631
Tires
To maximize t\fe performa\bce, durabil-
ity, a\bd safe operatio\b of your motor-
cycle, \bote t\fe followi\bg poi\bts regard-
i\bg t\fe specified tire\ts.
Tire air pressure
T\fe tire air pressure s\fould be
c\fecked a\bd, if \becessary, adjusted
before eac\f ride.
EWA10501
WARNING0
Operation of this vehicle with im-
proper tire pressure may cause se-
vere injury or death from loss of
control.
●The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the tempera-
ture of the tires equals the am-
bient temperature).
●The tire air pressure must be
adjusted in accordance with
the riding speed and with the
total weight of rider, passenger,
cargo, and accessories ap-
proved for this mode\4l.
EAU21382
Checking the throttle cable
free play
1. T\frottle cable free play
T\fe t\frottle cable free play s\fould
measure 3.0-5.0 mm (0.12-0.20 i\b) at
t\fe t\frottle grip. Periodically c\feck t\fe
t\frottle cable free play a\bd, if \beces-
sary, \fave a Yama\fa dealer adjust i\tt.
EAU21401
Valve clearance
T\fe valve cleara\bce c\fa\bges wit\f
use, resulti\bg i\b improper air-fuel mix-
ture a\bd/or e\bgi\be \boise. To preve\bt
t\fis from occurri\bg, t\fe valve clear-
a\bce must be adjusted by a Yama\fa
dealer at t\fe i\btervals specified i\b t\fe
periodic mai\bte\ba\bce a\bd lubricatio\b
c\fart.
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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
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EWA10511
W\fRNING0
Never overload your vehicle. Oper-
ation of an overloaded vehicle
could cause an acci\Mdent.
Tire air pressure
(measured on cold tires):\bp to 90 kg (198 lb):
Front:210 kPa \f30 ps\b) \f2.1 kgf/cm
2)
Rear: 230 kPa \f33 ps\b) \f2.3 kgf/cm
2)
90 kg (198 lb) to maximum load:
Front: 230 kPa \f33 ps\b) \f2.3 kgf/cm
2)
Rear: 250 kPa \f36 ps\b) \f2.5 kgf/cm
2)
Off-road riding:
Front: 200 kPa \f29 ps\b) \f2.0 kgf/cm
2)
Rear: 200 kPa \f29 ps\b) \f2.0 kgf/cm
2)
High-speed riding:
Front: 210 kPa \f30 ps\b) \f2.1 kgf/cm
2)
Rear: 230 kPa \f33 ps\b) \f2.3 kgf/cm
2)
Maximum load*: 190 kg \f419 lb)
* Total we\bght of r\bder, passenger, cargo and accessor\bes
EWA10461
W\fRNING0
The front and rear tires should be of
the same make and design, other-
wise the handling characteristics of
the vehicle may be different, which
could lead to an acc\Mident.
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Tire information
This motorcycle is equi\f\fed with tube
tires\b
Front tire: Size:90/90-21M/C 54S
90/90-21M/C 54T
Manufacturer/model: METZELER/TOURANCE
FRONT MICHELIN/SIRAC
Rear tire: Size:130/80-17M/C 65S
130/80-17M/C 65T
Manufacturer/model: METZELER/TOURANCE
MICHELIN/SIRAC A
Tire inspection
1\b Tire sidewall
2\b Tire tread de\fth
The tires must be checked before
each ride\b If the center tread de\fth
reaches the s\fecified limit, if the tire
has a nail or glass fragments in it, or if
the sidewall is cracked, have a Yama-
ha dealer re\flace the tire immediately\b
TIP
The tire tread de\fth limits may differ
from country to country\b Always com-
\fly with the local \uregulations\b
Minimum tire tread depth
(front and rear):1\b0 mm (0\b04 in)
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