brake YAMAHA XT660Z 2012 Owners Manual

TABLE OF CONTENTS
LOCATION OF IMPORTANT LABELS...1-1
SAFETY INFORMATION ..................\r...2-1
Be a Responsible Owner ..................\r2-1
\fafe riding ..................\r..................\r.....2-1
\brotective apparel ..................\r...........2-2
Avoid Carbon Monoxide \boisoning ...2-2
Loading ..................\r..................\r.........2-3
Genuine Yamaha Accessories ..........2-3
Aftermarket \barts, Accessories, and Modifications ..................\r.....2-4
Aftermarket Tires and Rims ..............2-4
DESCRIPTION ..................\r..................\r.3-1
Left view ..................\r..................\r........3-1
Right view ..................\r..................\r.....3-2
Controls and instruments ..................\r3-3
INSTRUMENT AND CONTROL
FUNCTIONS ..................\r..................\r....4-1
Immobilizer system ..................\r.........4-1
Main switch/steering lock ..................\r4-2
Indicator and warning lights ..............4-3
Multi-function display ..................\r......4-5
Tachometer ..................\r..................\r...4-6
Tripmeter and tachometer modes .....4-6
Clock mode ..................\r..................\r...4-7
Fuel meter ..................\r..................\r.....4-7
\felf-diagnosis devices ..................\r....4-7 Handlebar switches ..................\r.........4-9
Clutch lever ..................\r..................\r.4-10
\fhift pedal ..................\r..................\r...4-10
Brake lever ..................\r..................\r..4-11
Brake pedal ..................\r..................\r.4-11
Fuel tank cap ..................\r................4-\r11
Fuel ..................\r..................\r.............4-12
Fuel tank breather hose ..................\r4-13
Catalytic converter ..................\r........4-13
\feat ..................\r..................\r.............4-14
Adjusting the front fork ..................\r..4-15
Adjusting the shock absorber
assembly ..................\r................4-\r16
\fidestand ..................\r..................\r....4-17
Ignition circuit cut-off system ..........4-17
FOR YOUR SAFETY -
PRE-OPERATION C\fECKS ...............5-1\r
\bre-operation check list ..................\r..5-2
OPERATION AND IMPORTANT
RIDING POINTS ..................\r................6-\r1
\ftarting the engine..................\r..........6-1
\fhifting ..................\r..................\r..........6-2
Tips for reducing fuel consumption ...6-3
Engine break-in ..................\r...............6-3\r
\barking ..................\r..................\r..........6-4 PERIODIC MAINTENANCE AND
ADJUSTMENT
..................\r..................\r.7-1
Owner’s tool kit ..................\r...............7-1\r
\beriodic maintenance chart for the emission control system.......7-2
General maintenance and lubrication chart ..................\r7-3
Removing and installing the cowling and panels ..............7-8
Checking the spark plug ..................\r.7-8
Engine oil and oil filter element.........7-9
Coolant ..................\r..................\r........7-12
Replacing the air filter element and cleaning the check hose ...7-14
Checking the engine idling speed ...7-15
Checking the throttle cable free play ..................\r.................7\r-16
Valve clearance ..................\r.............7-16
Tires ..................\r..................\r............7-16
\fpoke wheels..................\r................7-\r19
Adjusting the clutch lever free play ...7-20
Checking the front and rear brake pads ..................\r.............7-21
Checking the brake fluid level .........7-22
Changing the brake fluid .................7\r-23
Drive chain slack ..................\r...........7-23
Cleaning and lubricating the drive chain ..................\r........7-25
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Checking and lubricating the cables ..................\7...............7\f25
Checking and lubricating the throttle gri\b and cable ........7\f26
Checking and lubricating the brake and clutch levers ..................\7....7\f26
Lubricating the brake \bedal ............7\f27
Checking and lubricating the sidestand ..................\7..........7\f27
Lubricating the rear sus\bension......7\f27
Lubricating the swingarm \bivots .....7\f28
Checking the front fork..................\7..7\f28
Checking the steering ..................\7...7\f29
Checking the wheel bearings..........7\f29
Battery ..................\7..................\7.........7\f30
Re\blacing the fuses ..................\7......7\f31
Re\blacing a headlight bulb .............7\f33
Re\blacing a turn signal light bulb....7\f34
Re\blacing the license \blate light bulb ..................\7.................7\f\735
Re\blacing an auxiliary light bulb .....7\f35
Su\b\borting the motorcycle ..............7\f36
Front wheel ..................\7..................\7.7\f36
Rear wheel ..................\7..................\7..7\f38
Troubleshooting ..................\7............7\f39
Troubleshooting charts..................\7..7\f40 MOTORCYCLE CARE
AND STORAGE
..................\7.................8\7\f1
Care ..................\7..................\7..............8\f1
Storage ..................\7..................\7.........8\f3
SPECIFICATIONS ..................\7.............9\f1
CONSUMER INFORMATION ............10\f1
Identification numbers ..................\7...10\f1
Motorcycle noise regulation (for Australia) ..................\7..........10\f2
TABLE OF CONTENTS
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3-2
DESCRIPTIO\f
10. Grab bar
11. Main fuse (\fage 7-31)
12. \battery (\fage 7-30)
13. Rear brake fluid reservoir (\fage 7-22)14. Coolant reservoir (\fage 7-13) 15. Front brake fluid reservoir (\fage 7-22)
16. Coolant drain bolt (\fage 7-12)
17. Engine oil filter element (\fage 7-11)
18. \brake \fedal (\fage 4-11)
EAU10420Righ\b view
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DESCRIPTION
3-3
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1\f
EAU10430
Cont\bols and inst\buments
1. Clutch lever \fpage 4-10\b
2. Left handlebar switches \fpage 4-9\b
3. Multi-function meter unit and warning lights \fpage 4-3, 4-5\b
4. Right handlebar switches \fpage 4-9\b
5. Throttle grip \fpage 7-16\b 6. Brake lever \fpage 4-11\b
7. Engine oil filler cap/dipstick \fpage 7-9\b
8. Fuel tank cap \fpage 4-11\b
9. Main switch and steering lock \fpage 4-2\b
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INSTRUMENT \fND CONTRO\b FUNCTIONS
4-11
EAU26823
Brake lever
1. Brake lever
2. \fosi\bion adjus\bing dial
3. Arrow mark
4. Dis\bance
The brake lever is loca\bed a\b \bhe righ\b
handlebar grip. To apply \bhe fron\b
brake, pull \bhe lever \boward \bhe han-
dlebar grip.
The brake lever is equipped wi\bh a po-
si\bion adjus\bing dial. To adjus\b \bhe dis-
\bance be\bween \bhe brake lever and \bhe
handlebar grip, \burn \bhe adjus\bing dial
while holding \bhe lever pushed away
from \bhe handlebar grip. Make sure
\bha\b \bhe appropria\be se\b\bing on \bhe ad-
jus\bing dial is aligned wi\bh \bhe “˙”
mark on \bhe brake lever.
EAU12941
Brake pedal
1. Brake pedal
The brake pedal is on \bhe righ\b side of
\bhe mo\borcycle. To apply \bhe rear
brake, press down on \bhe brake pedal.
1
EAU13074
Fuel tank cap
1. Lock cover
2. Open
To open the fuel tank cap
Open \bhe fuel \bank cap lock cover, in-
ser\b \bhe key in\bo \bhe lock, and \bhen \burn
i\b 1/4 \burn clockwise. The lock will be re-
leased and \bhe fuel \bank cap can be
opened.
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EAU15605
Before using t\fis ve\ficle\b c\feck t\fe following points:
ITEMCHECKS PAGE
 C\feck fuel level in fuel tank.
 Refuel if necessary.
Fuel  C\feck fuel line for leakage. 4-12\b 4-13
 C\feck t\fe fuel tank breat\fer/overflow \fose for obstructions\b cracks or
damage\b and c\feck t\fe \fose connection.
 C\feck oil level in oil tank.
Engine \fil  If necessary\b add recommended oil to specified level. 7-9
 C\feck ve\ficle for oil leakage.
 C\feck coolant level in reservoir.
C\f\flant  If necessary\b add recommended coolant to specified level. 7-12
 C\feck cooling system for leakage.
 C\feck operation.
 If soft or spongy\b \fave Yama\fa dealer bleed \fydraulic system.
 C\feck brake pads for wear.
Fr\fnt \brake  Replace if necessary. 4-11\b 7\b21\b 7-22\b 7-26
 C\feck fluid level in reservoir.
 If necessary\b add recommended brake fluid to specified level.
 C\feck \fydraulic system for leakage.
 C\feck operation.
 If soft or spongy\b \fave Yama\fa dealer bleed \fydraulic system.
 C\feck brake pads for wear.
Rear \brake  Replace if necessary. 4-11\b 7\b21\b 7-22\b 7-27
 C\feck fluid level in reservoir.
 If necessary\b add recommended brake fluid to specified level.
 C\feck \fydraulic system for leakage.
FOR YOUR SAFETY - PRE-OPERATION CHECKS
5-2
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FOR YOUR SAFE\fY – PRE-OPERA\f\bON CHECKS
5-3
\b\fEM
Clutch
\fhrottle grip
Control cables
Drive chain
Wheels and tires
Brake and shift pedals
Brake and
clutch levers
Sidestand
Chassis fasteners CHECKS
 Check operation.
 L\fbricate cable if nece\b\bary.
 Check lever free play.
 Adj\f\bt if nece\b\bary.
 Make \b\fre that operation i\b \bmooth.
 Check cable free play.
 If nece\b\bary, have Yamaha dealer adj\f\bt \Lcable free play and l\fbricate cable and grip ho\f\bing.
 Make \b\fre that operation i\b \bmooth.
 L\fbricate if nece\b\bary.
 Check chain \black.
 Adj\f\bt if nece\b\bary.
 Check chain condition.\L
 L\fbricate if nece\b\bary.
 Check for damage.
 Check tire condition a\Lnd tread depth.
 Check air pre\b\b\fre.
 Correct if nece\b\bary.
 Make \b\fre that operation i\b \bmooth.
 L\fbricate pedal pivoting point\b if nec\Le\b\bary.
 Make \b\fre that operation i\b \bmooth.
 L\fbricate lever pivoting point\b if nec\Le\b\bary.
 Make \b\fre that operation i\b \bmooth.
 L\fbricate pivot if nece\b\bary.
 Make \b\fre that all n\ft\b, bolt\b and \bcrew\b are properly tightened.
 Tighten if nece\b\bary. PAGE
4-10, 7-20, 7-26
7-16, 7-267-25
7-23, 7-24, 7-25
7-16, 7-197-27
7-26
7-27–
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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-3
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
√ √
√ √ √ √ √
√ √ √
√√
√
√ √ √ √ √ √
√ √ √ √ √
√ √ √ √
√ √ √ √ √
√ √ √ √1
2
3
✻
4✻
5✻
6✻
7✻
8✻
 Replace.
 Check operatio\f.
 Adj\bst.
 Check operatio\f, fl\bid level a\fd vehicle
for fl\bid leakage.
 Replace brake pads.
 Check operatio\f, fl\bid level a\fd vehicle
for fl\bid leakage.
 Replace brake pads.
 Check for cracks or damage.
 Replace.
 Check r\b\fo\bt, spoke tight\fess a\fd for damage.
 Tighte\f spokes if \fecessary.
 Check tread depth a\fd for damage.
 Replace if \fecessar\iy.
 Check air press\bre.
 Correct if \fecessar\iy.
 Check beari\fg for loose\fess or dam\iage.
\fir filter element
Clutch
Front brake
Rear brake
Brake hoses
Wheels
Tires
Wheel bearings
EAU1770C
Ge\feral mai\fte\fa\fce a\fd l\bb\iricatio\f chart
Whe\fever wor\f to the limit
Whe\fever wor\f to the limit Every 4 years
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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✻
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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-21
EAU22390
Checking the front and rear
brake pads
The front \fnd re\fr br\fke \b\fds must be
checked for we\fr \ft the interv\fls s\bec-
ified in the \beriodic m\finten\fnce \fnd
lubric\ftion ch\frt.
EAU22420
Front brake pads
1. Front br\fke \b\fd we\fr indic\ftor groove
E\fch front br\fke \b\fd is \brovided with
\f we\fr indic\ftor groove, which \fllows
you to check the br\fke \b\fd we\fr with-
out h\fving to dis\fssemble the br\fke.
To check the br\fke \b\fd we\fr, check
the we\fr indic\ftor groove. If \f br\fke
\b\fd h\fs worn to the \boint th\ft the
we\fr indic\ftor groove h\fs \flmost dis-
\f\b\be\fred, h\fve \f Y\fm\fh\f de\fler re-
\bl\fce the br\fke \b\fds \fs \f set.
EAU22500
Rear brake pads
1. Re\fr br\fke \b\fd lining thickness
Check e\fch re\fr br\fke \b\fd for d\fm-
\fge \fnd me\fsure the lining thickness.
If \f br\fke \b\fd is d\fm\fged or if the lin-
ing thickness is less th\fn 1.0 mm
(0.04 in), h\fve \f Y\fm\fh\f de\fler re-
\bl\fce the br\fke \b\fds \fs \f set.
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