YAMAHA XT660Z 2012 Manual Online

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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-39
TIP
●Make sure that the slot in the
brake \faliper bra\fket is fit over the
retainer on the s\bingarm.
●Make sure that there is enough
spa\fe bet\been the brake pads
before installing the\b \bheel.
2. Install the drive \fhain onto the rear spro\fket.
3. Install the axle nut, and then lo\b- er the rear \bheel so that it is on
the ground.
4. Adjust the drive \fhain sla\fk. (See page 7-24.)
5. Apply the rear brake several times, and then tighten the axle
nut to the spe\fified\b torque.
Tightening torque:
Axle nut:105 Nm (10.5 m·kgf, 75 ft·lbf)
EAU25871
Troubleshooting
Although Yamaha motor\fy\fles re\feive
a thorough inspe\ftion before shipment
from the fa\ftory, trouble may o\f\fur
during operation. Any problem in the
fuel, \fompression, or ignition systems,
for example, \fan \fause poor starting
and loss of po\ber.
The follo\bing troubleshooting \fharts
represent qui\fk and easy pro\fedures
for \fhe\fking these vital systems your-
self. Ho\bever, should your motor\fy\fle
require any repair, take it to a Yamaha
dealer, \bhose skilled te\fhni\fians have
the ne\fessary tools, experien\fe, and
kno\b-ho\b to servi\fe the motor\fy\fle
properly.
Use only genuine Yamaha repla\fe-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter servi\fe life and
\fan lead to expensive repair bills.
EWA15141
W\fRNING0
When checking the fuel system, do
not smoke, and make sure there
are no open flames or sparks in the
area, including pilot lights from wa-
ter heaters or furnaces. Gasoline or
gasoline vapors can ignite or ex-
plode, causing severe injury or
property damage.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-39

PERIODIC MAINTENANCE AND ADJUSTMENT
7-40
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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

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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

MOTORCYCLE CARE AND STORAGE
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EAU26004
Care
While the ope\f desig\f o\b a motorcycle
reveals the attractive\fess o\b the tech-
\fology, it also makes it more vul\fera-
ble. Rust a\fd corrosio\f ca\f develop
eve\f i\b high-quality compo\fe\fts are
used. A rusty exhaust pipe may go u\f-
\foticed o\f a car, however, it detracts
\brom the overall appeara\fce o\b a mo-
torcycle. Freque\ft a\fd proper care
does \fot o\fly comply with the terms o\b
the warra\fty, but it will also keep your
motorcycle looki\fg good, exte\fd its
li\be a\fd optimize its per\borma\fce.
Before cleaning 1. Cover the mu\b\bler outlet with a plastic bag a\bter the e\fgi\fe has
cooled dow\f.
2. Make sure that all caps a\fd cov- ers as well as all electrical cou-
plers a\fd co\f\fectors, i\fcludi\fg
the spark plug cap, are tightly i\f-
stalled. 3. Remove extremely stubbor\f dirt,
like oil bur\ft o\fto the cra\fkcase,
with a degreasi\fg age\ft a\fd a
brush, but \fever apply such prod-
ucts o\fto seals, gaskets, sprockets,
the drive chai\f a\fd wheel axles. Al-
ways ri\fse the dirt a\fd degreaser
o\b\b with water.
Cleaning
ECA10772
NOTICE
●Avoid using strong acidic
wheel cleaners, especially on
spoked wheels. If such prod-
ucts are used on hard-to-re-
move dirt, do not leave the
cleaner on the affected area
any longer than instructed. Al-
so, thoroughly rinse the area
off with water, immediately dry
it, and then apply a corrosion
protection spray.
●Improper cleaning can damage
plastic parts (such as cowlings,
panels, windshields, headlight
lenses, meter lenses, etc.) and
the mufflers. Use only a soft,
clean cloth or sponge with wa- ter to clean plastic. However, if
the plastic parts cannot be
thoroughly cleaned with water,
diluted mild detergent with wa-
ter may be used. Be sure to
rinse off any detergent residue
using plenty of water, as it is
harmful to plastic p\5arts.
●Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.
●Do not use high-pressure
washers or steam-jet cleaners
since they cause water seep-
age and deterioration in the fol-
lowing areas: seals (of wheel
and swingarm bearings, fork
and brakes), electric compo-
nents (couplers, connectors,
instruments, switches and
lights), breather hoses and
vents.
XT660Z 08-10 ING-AUS:MY03 07-10 ING 11-05-2009 10:10 Pagina 2

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MOTORCYCLE C\fRE \fND STOR\f\bE
8-2
●For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the wind-
shield. Test the product on a
small hidden part of the wind-
shield to make sure that it does
not leave any marks. If the
windshield is scratched, use a
quality plastic polishing com-
pound after washing\ .After normal use
Remove d\frt w\fth warm water, a m\fld
deter\bent, and a soft, clean spon\be,
and then r\fnse thorou\bhly w\fth clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn d\frt
and \fnsects w\fll come off more eas\fly \ff
the area \fs covered w\fth a wet cloth for
a few m\fnutes before clean\fn\b.
After r\fd\fn\b \fn the ra\fn, near the sea
or on salt-sprayed roads
S\fnce sea salt or salt sprayed on roads
dur\fn\b w\fnter are extremely corros\fve
\fn comb\fnat\fon w\fth water, carry out
the follow\fn\b steps after each r\fde \fn
the ra\fn, near the sea or on salt-
sprayed roads.
TIP
Salt sprayed on roads \fn the w\fnter
may rema\fn well \fnto spr\fn\b.
1. Clean the motorcycle w\fth cold water and a m\fld deter\bent, after
the en\b\fne has cooled down. NO-
TICE: Do not use warm water
since it increases the corrosive
action of the salt. 2. Apply a corros\fon protect\fon
spray on all metal, \fnclud\fn\b
chrome- and n\fckel-plated, sur-
faces to prevent corros\fon.
\ffter cleaning 1. Dr y the motorcycle w\fth a chamo\fs or an absor\db\fn\b cloth.
2. Immed\fately dry the dr\fve cha\fn and lubr\fcate \ft to prevent \ft from
rust\fn\b.
3. Use a chrome pol\fsh to sh\fne chrome, alum\fnum and sta\fnless-
steel parts, \fnclud\fn\b the exhaust
system. (Even the thermally \fn-
duced d\fscolor\fn\b of sta\fnless-
steel exhaust systems can be re-
moved throu\bh pol\fsh\fn\b.)\d
4. To prevent corros\fon, \ft \fs recom- mended to apply a corros\fon pro-
tect\fon spray on all metal, \fnclud-
\fn\b chrome- and n\fckel-plated,
surfaces.
5. Use spray o\fl as a un\fversal clean- er to remove any rema\fn\fn\b d\frt.
6. Touch up m\fnor pa\fnt dama\be caused by stones, etc.
7. Wax all pa\fnted surfaces.
XT660Z 08-10 ING-AUS:MY03 07-10 ING 11-05-2009 10:10 Pagina 3

MOTORCYCLE CARE AND STORAGE
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8. Let the motorcycle dry completely before \ftoring or co\bering it.
EWA11131
WARNING0
Contaminants on the brakes or
tires can cause loss \5of control.
●Make sure that there is no oil or
wax on the brakes \5or tires.
●If necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or
acetone, and wash the tires
with warm water and a mild de-
tergent. Before riding at higher
speeds, test the motorcycle's
braking performance and cor-
nering behavior.
ECA10800
NOTICE
●Apply spray oil and wax spar-
ingly and make sure to wipe off
any excess
●Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
●Avoid using abrasive polishing
compounds as they will wear
away the paint.
TIP
●Con\fult a Yamaha dealer for ad-
\bice on what product\f\f to u\fe.
●Wa\fhing, rainy weather or humid
climate\f can cau\fe the headlight
len\f to fog. Turning the headlight
on for a \fhort period of time will
help remo\be the moi\fture from
the len\f.
EAUM1901
Storage
Short-term
Alway\f \ftore your motorcycle in a cool,
dry place and, if nece\f\fary, protect it
again\ft du\ft with a porou\f co\ber.
ECA10810
NOTICE
●Storing the motorcycle in a
poorly ventilated room or cov-
ering it with a tarp, while it is
still wet, will allow water and
humidity to seep in and cause
rust.
●To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.
XT660Z 08-10 ING-AUS:MY03 07-10 ING 11-05-2009 10:10 Pagina 4

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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
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Engin\b oil:Type: SAE10W30 or SAE10W40 or SAE15W40
or SAE\f0W40 or SAE\f0W50
Recomme\bded e\bgi\be oil grade: API service SE, SF, SG type or higher
E\bgi\be oil qua\btity: Without oil filter eleme\bt replaceme\bt:\f.50 L (\f.64 US qt) (\f.19 Imp.qt)
With oil filter eleme\bt replaceme\bt: \f.60 L (\f.73 US qt) (\f.\f6 Imp.qt)
Total amou\bt (dry e\bgi\be): \f.90 L (3.07 US qt) (\f.55 Imp.qt)
Cooling syst\bm:Radiator capacity (i\bcludi\bg all routes): 1.\f L (1.\f6 US qt) (1.05 Imp.qt) (Radiator) +
0.5 L (0.5\f US qt) (0.44 Imp.qt)
(Coola\bt reservoir)
Coola\bt reservoir capacity (up to the
maximum level mark): 0.50 L (0.5\f US qt) (0.44 Imp.qt)
From low to full level: 0.30 L (0.3\f US qt) (0.\f6 Imp.qt)
Air filt\br:Air filter eleme\bt:Paper
Fu\bl:Recomme\bded fuel:Premium u\bleaded gasoli\be o\bly
Fuel ta\bk capacity: \f3.0 L (6.07 US gal) (5.06 Imp.gal)
Fuel reserve amou\bt: 6.7 L (1.76 US gal) (1.46 Imp.gal)
Fu\bl inj\bction:Ma\bufacturer:DENSO
Model: \f97500-0390
Spark plug:Ma\bufacturer/model:NGK/CR7EGap:0.7-0.8 mm (0.0\f8-0.03\f i\b)
Clutch:Clutch type:Wet, multiple-disc
Transmission:Primary reductio\b system:Spur gear
Primary reductio\b ratio: 75/36 (\f.083)
Seco\bdary reductio\b system: Chai\b drive
Seco\bdary reductio\b ratio: 45/15 (3.00)
Tra\bsmissio\b type: Co\bsta\bt mesh 5-speed
Dim\bnsions:Overall le\bgth:\f\f46 mm (88.4\f i\b)
Overall width: 864 mm (34.01 i\b)
Overall height: 1477 mm (58.14 i\b)
Seat height: 896 mm (35.\f7 i\b)
Wheelbase: 1500 mm (59.05 i\b)
Grou\bd cleara\bce: \f60 mm (10.\f3 i\b)
Mi\bimum tur\bi\bg radius: 1958 mm (77.08 i\b)
Basic w\bight:With oil a\bd fuel:\f08.5 kg (459 lb)
Engin\b:E\bgi\be type:Liquid cooled 4-stroke, SOHC
Cyli\bder arra\bgeme\bt: Forward-i\bcli\bed si\bgle cyli\bder
Displaceme\bt: 660.0 cm
3(40.\f7 cu.i\b)
Bore x stroke: 100.0 x 84.0 mm (3.94 x 3.31 i\b)
Compressio\b ratio: 10.00 : 1
Starti\bg system: Electric starter
Lubricatio\b system: Dry sump
-\f0 -10 0 10 \f0 30 40 50 °C
SAE 10W-30
SAE 10W-40
SAE \f0W-40
SAE \f0W-50
SAE 15W-40
XT660Z 08-10 ING-AUS:MY03 07-10 ING 11-05-2009 10:10 Pagina 6

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SPECIFICATIO\fS
9-2
Operation:Left foot operation
Gear ratio: 1
st:\f0/12 (2\b500)
2
nd:
26/16 (1\b625)
\f
rd: 2\f/20 (1\b150)
4
th: 20/22 (0\b909)
5
th: 20/26 (0\b769)
Chass\bs:
Frame type:
Diamond
Caster angle: 28°
Trail: 11\f\b0 mm (4\b44 in)
Front t\bre:
Type:With tube
Size: 90/90-21M/C 54S,
90/90-21M/C 54T
Manufacturer/model: METZELER/TOURANCE FRONT
MICHELIN/SIRAC
Rear t\bre:
Type:With tube
Size: 1\f0/80-17M/C 65S,
1\f0/80-17M/C 65T Manufacturer/model:
METZELER/TOURANCE
MICHELIN/SIRAC A
Load:
Maximum load:190 kg (419 lb)
(Total weight of rider, passenger, cargo
and accessories)
T\bre a\br pressure
(measured on cold t\bres):
Load:Up to 90 kg (0-198 lb)
Front: 210 kPa (\f0 psi) (2\b1 kgf/cm
2)
Rear: 2\f0 kPa (\f\f psi) (2\b\f kgf/cm
2)
Load: 90-190 kg (198-419 lb)
Front: 2\f0 kPa (\f\f psi) (2\b\f kgf/cm
2)
Rear: 250 kPa (\f6 psi) (2\b5 kgf/cm
2)
Off-road riding:
Front: 200 kPa (29 psi) (2\b0 kgf/cm
2)
Rear: 200 kPa (29 psi) (2\b0 kgf/cm
2)
High-speed riding:
Front: 210 kPa (\f0 psi) (2\b1 kgf/cm
2)
Rear: 2\f0 kPa (\f\f psi) (2\b\f kgf/cm
2)
Front wheel:
Type:
Spoke wheel
Rim size: 21 x 1\b85
Rear wheel:
Type:Spoke wheel
Rim size: 17M/C x MT2\b75
Front brake:
Type:Dual disc brake
Operation: Right hand
Fluid: DOT 4
Rear brake:
Type:Single disc brake
Operation: Right foot
Fluid: DOT 4
Front suspens\bon:
Type:Telescopic fork
Spring/damper type: Coil spring/oil damper
Wheel travel: 210 mm (8\b26 in)
XT660Z 08-10 ING-AUS:MY03 07-10 ING 11-05-2009 10:10 Pagina 7

SPECIFICATIONS
9-3
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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
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