check oil 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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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
5
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EAU17101
0-1000 km (0-600 mi)
Avoid prolonged operation a\fove
4500 r/\bin. NOTICE: After 1000 km
(600 mi) of operation, t\fe engine oil
mu\bt be c\fanged, and t\fe oil filter
element replaced.
1000-1600 km (600-1000 mi)
Avoid prolonged operation a\fove
6000 r/\bin.
1600 km (1000 mi) and beyond
The vehicle can now \fe operated nor-
\bally.
ECA10310NOTICE
Keep \fhe engine speed o\b\f of
\fhe \fachome\fer red zone.
If any engine \fro\bble sho\bld oc-
c\br d\bring \fhe engine break-in
period, immedia\fely have a
Yamaha dealer check \fhe
vehicle.
EAU17213
Parking
When parking, stop the engine, and
then re\bove the key fro\b the \bain
switch.
EWA10311
WARNING0
Since \fhe engine and exha\bs\f
sys\fem can become very ho\f,
park in a place where pedes\fri-
ans or children are no\f likely \fo
\fo\bch \fhem and be b\b\prned.
Do no\f park on a slope or on
sof\f gro\bnd, o\fherwise \fhe ve-
hicle may over\f\brn, increasing
\fhe risk of a f\bel l\peak and fire.
Do no\f park near grass or o\fher
flammable ma\ferials which
migh\f ca\fch fire.
OPERATION AND IMPORTANT RIDING POINTS
6-4
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-4
1
2
3
4
\f
6
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\b
10
NO. ITEM CHECK OR MAINTENAN\4CE JOB
ODOMETER READING
1000 km 10000 km 20000 km 30000 km 40000 km(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
ANNUAL
CHECK
√ √ √ √
√ √ √ √ √ √ √
√√
√
√ √ √ √ √
√ √ √ √ √ √ √ √ √ √
√ √ √ √
√ √ √ √
√ √
√ √ √ √ √ √
13
14
✻
1\f✻
16✻
18
 Check operation and for e\fcessive pla\b.
 Lubricate with lithium-\fsoap-based grease.
 Check chain slack, alignment and condition.
 Adjust and lubricate chain with a\f special
O-ring chain lubricant thoroughl\b.
 Check bearing pla\b and steering
for roughness.
 Lubricate with lithium-\fsoap-based grease.
 Make sure that all nuts, bolts and screws
are properl\b tightened.
 Check operation.
 Lubricate.
 Check operation.
 Check operation and for oil leakage.
 Check operation and shock absorber
for oil leakage.
 Check operation.
 Lubricate with lithium-\fsoap-based grease.
 Change.
 Check oil level and vehicle for oil leakage.
Swingarm
Drive chain
Steering bearings
Chassis fasteners
Sidestand
Sidestand switch
Front fork
Shock absorber
assembly
Rear suspension
relay arm and
connecting arm
pivoting points
Engine oil
Ever\b 50000 km (30000 mi)
Ever\b 50000 km (30000 mi)
Ever\b 500 km (300 mi) and after washing the motorc\bcle or riding in the rain
\b✻
11✻
17✻
12✻
10
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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
7-9
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

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
7-12
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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
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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-23
EAU22731
Changing the brake fluid
Have a Yamaha dealer \fhange the
\brake fluid at the intervals spe\fified in
the TIP after the periodi\f maintenan\fe
and lu\bri\fation \fhart. In addition, have
the oil seals of the master \fylinders
and \falipers as well as the \brake
hoses repla\fed at the intervals listed
\below or whenever they are damaged
or leaking.
●Oil seals: Repla\fe ever y two
years.
●Brake hoses: Repla\fe every four
years.
EAU22760
Drive chain slack
The drive \fhain sla\fk should \be
\fhe\fked \before ea\fh ride and adjusted
if ne\fessary.
EAU22783
To check the drive chain slack
1. Drive \fhain sla\fk
1. Pla\fe the motor\fy\fle on the side-stand.
TIP
When \fhe\fking and adjusting the dri-
ve \fhain sla\fk, there should \be no
weight on the motor\fy\fl\re.
2. Shift the transmission into theneutral position.
3. Move the rear wheel \by pushing the motor\fy\fle to lo\fate the tight-
est portion of the drive \fhain, and
then measure the drive \fhain
sla\fk as shown.
4. If the drive \fhain sla\fk is in\for- re\ft, adjust it as follows.
TIP
When \fhe\fking the drive \fhain sla\fk,
the \fhain tensioner should not \be
tou\fhing the drive \fhain.
Drive chain slack:50.0-60.0 mm (1.96\r-2.36 in)
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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
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