fuel 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
XT660Z 01-03 ING-AUS:AUSTRALIA 11-05-2009 9:57 Pagina 6

DESCRIPTION
3-3
1
2
3
4
5
6
7
8
9
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
XT660Z 01-03 ING-AUS:AUSTRALIA 11-05-2009 9:57 Pagina 16

1
2
3
4
5
6
7
8
9
10
INSTRUMENT \fND CONTRO\b FUNCTIONS
4-5
EAUB1501
Multi-function display
1. Tachomete\f
2. Spee\bomete\f
3. O\bomete\f
4. T\fipmete\fs/Fuel \fese\fve t\fipmete\f
5. Clock
6. Fuel mete\f
7. “RESET” button
8. “SELECT” button
EWA12311
W\fRNING0
Be sure to stop the vehicle before
making any setting changes to the
multi-function displ\ ay.
The multi-function \bisplay is equippe\b
with the following:
●a spee\bomete\f (which shows the
\fi\bing spee\b)
●a \bigital tachomete\f (which shows
engine \f/min)
●an o\bomete\f (which shows the to-
tal \bistance t\favele\b)
●two t\fipmete\fs (which show the
\bistance t\favele\b since they we\fe
last set to ze\fo)
●a fuel \fese\fve t\fipmete\f (which
shows the \bistance t\favele\b since
the bottom segment of the fuel
mete\f sta\fte\b flashing)
●a clock
●a fuel mete\f
●a self-\biagnosis \bevice
TIP
●Be su\fe to tu\fn the key to "ON"
befo\fe using the "SELECT" an\b
"RESET" buttons.
●Fo\f the U.K. only: To switch the
spee\bomete\f an\b o\bome-
te\f/t\fipmete\f \bisplays between
kilomete\fs an\b miles, push the
"SELECT" an\b "RESET" buttons
togethe\f an\b tu\fn the key to "ON".
When the \bigits sta\ft flashing,
push the "SELECT" button to
choose kilomete\fs o\f \tmiles.
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-5

INSTRUMENT AND CONTROL FUNCTIONS
4-6
1
2
3
4
\f
6
7
8
\b
10
Tachometer
1. Tachometer
2. Red zo\fe
The tachometer allows the r\bder to
mo\f\btor the e\fg\b\fe speed a\fd keep \bt
w\bth\b\f the \bdeal power ra\fge.
Whe\f the key \bs tur\fed to "ON", the
tachometer \feedle w\bll sweep o\fce
across the r/m\b\f ra\fge a\fd the\f retur\f
to zero r/m\b\f \b\f order to test the elec-
tr\bcal c\brcu\bt.
ECA10030
NOTICE
Do not operate the engine in the
tachometer red zone.
Red zone: 7,\f00 r/m\4in and above.
Tripmeter and tachometer modes
1. “SELECT” butto\f
2. “RESET” butto\f
Push\b\fg the "SELECT" butto\f sw\btch-
es the d\bsplay betwee\f the tr\bpmeter
modes "TRIP 1" a\fd "TRIP 2" \b\f the
follow\b\fg order:
TRIP 1
6TRIP 2 6TRIP 1
Whe\f the fuel amou\ft \b\f the fuel ta\fk
decreases to 6.7 L (1.77 US gal) (1.47
Imp.gal), the bottom segme\ft of the
fuel meter w\bll start flash\b\fg, a\fd the
tr\bpmeter d\bsplay w\bll automat\bcally
cha\fge to the fuel reserve tr\bpmeter
mode “F-TRIP” a\fd start cou\ft\b\fg the
d\bsta\fce traveled from that po\b\ft. I\f
that case, push\b\fg the "SELECT" but-
to\f sw\btches the d\bsplay betwee\f the
var\bous tr\bpmeter modes \b\f the follow-
\b\fg order:
F-TRIP
6TRIP 1 6TRIP 2 6F-TRIP
To reset a tr\bpmeter, select \bt by push-
\b\fg the "SELECT" butto\f, a\fd the\f
push the "RESET" butto\f for at least
four seco\fds. If you do \fot reset the
fuel reserve tr\bpmeter ma\fually, \bt w\bll
reset \btself automat\bcally a\fd the d\bs-
play w\bll retur\f to the pr\bor mode after
refuel\b\fg a\fd travel\b\fg 5 km (3 m\b).
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-6

1
2
3
4
5
6
7
8
9
10
INSTRUMENT \fND CONTRO\b FUNCTIONS
4-7
Clock mode
1. Clock
2. “SELECT” b\ftton
3. “\bESET” b\ftton
TIP
The clock is displayed even when the
key is t\frned to "OFF".
To set the clock:
1. P\fsh the "SELECT" b\ftton for atleast fo\fr seconds.
2. When the ho\fr digits start flash- ing, p\fsh the "\bESET" b\ftton to
set the ho\frs.
3. P\fsh the "SELECT" b\ftton, and the min\fte digits will start flashing.
4. P\fsh the "\bESET" b\ftton to set the min\ftes.
5. P\fsh the "SELECT" b\ftton and then release it to \bstart the clock.
Fuel meter
1. F\fel meter
With the key in the "ON" position, the
f\fel meter indicates the amo\fnt of f\fel
in the f\fel tank. When the key is t\frned
to "ON", all of the display segments of
the f\fel meter will appear one after the
other and then disappear in order to
test the electrical circ\fit. The display
segments of the f\fel meter disappear
towards "E" (Empty) as the f\fel level
decreases. When only one segment is
left near "E" (Empty), ref\fel as soon
as possible.
TIP
This f\fel meter is eq\fipped with a self-
diagnosis system. If the electrical cir-
c\fit is defective, all the segments will
start flashing. If this occ\frs, have a
Yamaha dealer check the electrical cir-
c\fit.
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-7

1
2
3
4
5
6
7
8
9
10
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.
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-11

INSTRUMENT AND CONTROL FUNCTIONS
4-12
1
2
3
4
\f
6
7
8
\b
10
To close the fuel tank cap 1. Push the fuel tank cap \fnto pos\f- t\fon w\fth the key \fnse\bted \fn the
lock.
2. Tu\bn the key counte\bclockw\fse to the o\b\fg\fnal pos\ft\fon, \bemove \ft,
and then close the\p lock cove\b.
TIP
The fuel tank cap cannot be closed
unless the key \fs \fn the lock. In add\f-
t\fon, the key cannot be \bemoved \ff the
cap \fs not p\bope\bly closed and locked.
EWA11091
WARNING0
Make sure that the fuel tank cap is
properly closed after filling fuel.
Leaking fuel is a \4fire hazard.
EAU13221
Fuel
Make su\be the\be \fs suff\fc\fent gasol\fne
\fn the tank.
EWA10881
WARNING0
Gasoline and gasoline vapors are
extremely flammable. To avoid fires
and explosions and to reduce the
risk of injury when refueling, follow
these instructions.\4
1. Befo\be \befuel\fng, tu\bn off the en- g\fne and be su\be that no one \fs
s\ftt\fng on the veh\fcle. Neve\b \befuel
wh\fle smok\fng, o\b wh\fle \fn the
v\fc\fn\fty of spa\bks, open flames, o\b
othe\b sou\bces of \fgn\ft\fon such as
the p\flot l\fghts of wate\b heate\bs
and clothes d\bye\bs.
2. Do not ove\bf\fll the fuel tank. When \befuel\fng, be su\be to \fnse\bt the
pump nozzle \fnto the fuel tank
f\flle\b hole. Stop f\fll\fng when the fu-
el \beaches the bottom of the f\flle\b
tube. Because fuel expands when
\ft heats up, heat f\bom the eng\fne
o\b the sun can cause fuel to sp\fll
out of the fuel ta\pnk.
1. Fuel tank f\flle\b tube
2. Fuel level
3. W\fpe up any sp\flled fuel \fmmed\f-ately. NOTICE: Immediately wipe
off spilled fuel with a clean, dry,
soft cloth, since fuel may deteri-
orate painted surfaces or plas-
tic parts.
4. Be su\be to secu\bely close the fuel tank cap.
EWA15151
WARNING0
Gasoline is poisonous and can
cause injury or death. Handle gaso-
line with care. Never siphon gaso-
line by mouth. If you should swal-
low some gasoline or inhale a lot of
gasoline vapor, or get some gaso-
line in your eyes, see your doctor
immediately. If gasoline spills on
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-12

your skin, wash with soap and
water. I\f gasoline spills on your
clothing, change your clothes.
EAU13390
ECA11400
\bse only unleaded gasoline. The use
o\f leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,
as well as to the exhaust system.
Your Yamaha en\fine has been \besi\f-
ne\b to use premium unlea\be\b \fasoli-
ne with a research octane number of
95 or hi\fher. If knockin\f (or pin\fin\f)
occurs, use a \fasoline of a \bifferent
bran\b. Use of unlea\be\b fuel will
exten\b spark plu\f life an\b re\buce
maintenance costs.
EAUB1300
Fuel tank breather/over\flow
hose
1. Fuel tank breather/hose
2. Hose clamp
Before operatin\f the motorcycle:
Check the fuel tank breather/over-
flow hose connection.
Check the fuel tank
breather/overflow hose for
cracks or \bama\fe, an\b replace it
if \bama\fe\b.
Make sure that the en\b of the fuel
tank breather/overflow hose is
not blocke\b, an\b clean it if
necessary.
Make sure that the en\b of the fuel
tank breather/overflow hose is
positione\b insi\be of the clamp.
EAU13433
Catalytic converters
This vehicle is equippe\b with catalytic
converters in the exhaust system.
EWA10862
The exhaust system is hot a\fter
operation. To prevent a \fire hazard
or burns:
Do not park the vehicle near
possible \fire hazards such as
grass or other materials that
easily burn.
Park the vehicle in a place
where pedestrians or children
are not likely to touch the hot
exhaust system.
Make sure that the exhaust
system has cooled down be\fo-
re doing any maintenance
work.
Do not allow the engine to idle
more than a \few minutes. Long
idling can cause a build-up o\f
heat.
WARNING
NOTICE
Recommended \fuel:PREMIUM UNLEADED
GASOLINE ONLY
Fuel tank capacity: 23.0 L (6.07 US \fal) (5.05 Imp.\fal)
Fuel reserve amount (when the
\fuel level warning light comes on): 6.7 L (1.77 US \fal) (1.47 Imp.\fal)
INSTR\bMENT AND CONTROL F\bNCTIONS
4-13
4
Australia 5/8/10 \g 16:16 Pági\fa 29

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
Australia 4/8/10 \n 18:04 Página \f6

ECA10260CAUTION:
Even with the tran\fmi\f\fion in
the neutra\b po\fition, do not
coa\ft for \bong period\f of time
with the engine off, and do not
tow the motorcyc\be for \bong
di\ftance\f. The tran\fmi\f\fion i\f
proper\by \bubricated on\by when
the engine i\f running. Inade-
quate \bubrication may damage
the tran\fmi\f\fion.
A\bway\f u\fe the c\butch whi\be
changing gear\f to avoid dam-
aging the engine, tran\fmi\f\fion,
and drive train, which are not
de\figned to with\ftand the
\fhock of forced \fhifting.
EAU16810
Tip\f for reducing fue\b
con\fumption
Fuel consum\ftion de\fends l\brgely on
your riding style. Consider the follow-
ing ti\fs to reduce f\muel consum\ftion:
Shift u\f swiftly, \bnd \bvoid high en-
gine s\feeds during \bc\mceler\btion.
Do not rev the engine while shift-
ing down, \bnd \bvoid high engine
s\feeds with no lo\bd on the en-
gine.
Turn the engine off inste\bd of let-
ting it idle for \bn extended length
of time (e.g., in tr\bffic j\bms, \bt tr\bf-
fic lights or \bt r\bil\mro\bd crossings).
EAU16841
Engine break-in
There is never \b more im\fort\bnt \feri-
od in the life of your engine th\bn the
\feriod between 0 \bnd 1600 km (1000
mi). For this re\bson, you should re\bd
the following m\bteri\m\bl c\brefully.
Since the engine is br\bnd new, do not
\fut \bn excessive lo\bd on it for the first
1600 km (1000 mi). The v\brious \f\brts
in the engine we\br \bnd \folish them-
selves to the correct o\fer\bting cle\br-
\bnces. During this \feriod, \frolonged
full-throttle o\fer\btion or \bny condition
th\bt might result in engine overhe\bting
must be \bvoided.
OPERATION AND IMPORTANT RIDING POINTS
6-3
6
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