light 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

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
03 ingles -austral\:ia 26/2/10 10:\f5 \: Página \b

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

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6
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8
9
10
4-1
INSTRUMENT \fND CONTRO\b FUNCTIONS
EAU10976
Immobilizer system
1. Code re-regi\ftering ke\b (red bow)
2. Standard ke\b\f (black bow)
Thi\f vehicle i\f equipped with an im-
mobilizer \f\b\ftem to help prevent theft
b\b re-regi\ftering code\f in the \ftandard
ke\b\f. Thi\f \f\b\ftem con\fi\ft\f of the fol-
lowing.
●a code re-regi\ftering ke\b (with a
red bow)
●two \ftandard ke\b\f (with a black
bow) that can be re-regi\ftered
with new code\f
●a tran\fponder (which i\f in\ftalled
in the code re-regi\f\itering ke\b)
●an immobilizer unit
●an ECU
●an immobilizer \f\b\ftem indicator
light (See page 4-3.\i)
The ke\b with the red bow i\f u\fed to reg-
i\fter code\f in each \ftandard ke\b. Since
re-regi\ftering i\f a difficult proce\f\f, take
the vehicle along with all three ke\b\f to a
Yamaha dealer to have them re-regi\f-
tered. Do not u\fe the ke\b with the red
bow for driving. It \fhould onl\b be u\fed
for re-regi\ftering the \ftandard ke\b\f. Al-
wa\b\f u\fe a \ftandard ke\b for driving.
ECA11821NOTICE
●DO NOT \bOSE THE CODE RE-
REGISTERING KEY! CONT\fCT
YOUR DE\f\bER IMMEDI\fTE\bY
IF IT IS \bOST! If the code re-reg-
istering key is lost, registering
new codes in the standard keys
is impossible. The standard keys
can still be used to start the ve-
hicle, however if code re-regis-
tering is required (i.e., if a new
standard key is made or all keys
are lost) the entire immobilizer
system must be replaced.
Therefore, it is highly recom-
mended to use either standard key and keep the code re-regis-
tering key in a safe place.
●Do not submerse any key in water.
●Do not expose any key to exces-
sively high temperatures.
●Do not place any key close to
magnets (this includes, but not
limited to, products such as
speakers, etc.).
●Do not place items that transmit
electrical signals close to any key.
●Do not place heavy items on
any key.
●Do not grind any key or alter its
shape.
●Do not disassemble the plastic
part of any key.
●Do not put two keys of any immobi-
lizer system on the same key ring.
●Keep the standard keys as well
as keys of other immobilizer
systems away from this vehi-
cle's code re-registering key.
●Keep other immobilizer system
keys away from the main switch
as they may cause signal inter-
ference.
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-1

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6
7
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9
10
INSTRUMENT \fND CONTRO\b FUNCTIONS
4-3
To unlock the steering
1\f Push
2\f Turn
Push the key into the \bain switch, and
then turn it to “OFF” while still pushing
it\f
EAU10941
F(Parking)
The steering is locked, and the tail-
light, license plate light and auxiliary
lights are on\f The hazard lights and
turn signal lights can be turned on, but
all other electrical syste\bs are off\f The
key can be re\boved\f
The steering \bust be locked before
the key can be turned to “ F”\f
ECA11020NOTICE
Do not use the parking position for
an extended length of time, other-
wise the battery may\ discharge.
EAU11004
Indicator and warning lights
1\f I\b\bobilizer syste\b indicator light “ ”
2\f Neutral indicator light “ N”
3\f Turn signal indicator light “ y”
4\f High bea\b indicator light “ 1”
5\f Engine trouble warning light “ U”
6\f Coolant te\bperature warning light “ u”
EAUB1510
Turn signal indicator light “y”
This indicator light flashes when the
turn signal switch is pushed to the left
or right\f
The electrical circuit of the turn signal
indicator light can be checked by turn-
ing the key to "ON"\f
If the indicator light does not co\be on
for a few seconds, then go off, have a
Ya\baha dealer check the electrical cir-
cuit\f
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-3

INSTRUMENT AND CONTROL FUNCTIONS
4-4
1
2
3
4
\f
6
7
8
\b
10
EAUB1520
Neutral indicator light “ N”
This indica\for li\bh\f comes on when \fhe
\fransmission is in \fh\ae neu\fral posi\fion.
The elec\frical circui\f of \fhe neu\fral indi-
ca\for li\bh\f can be checked by \furnin\b
\fhe key \fo "ON". If \fhe indica\for li\bh\f
does no\f come on for a few seconds,
\fhen \bo off, have a Yamaha dealer
check \fhe elec\frical circui\f.
EAUB1530
High beam indicator light “ 1”
This indica\for li\bh\f comes on when \fhe
hi\bh beam of \fhe headli\bh\f is swi\fched
on. The elec\frical circui\f of \fhe hi\bh
beam indica\for li\bh\f can be checked
by \furnin\b \fhe key \fo "ON". If \fhe indi-
ca\for li\bh\f does no\f come on for a few
seconds, \fhen \bo off, have a Yamaha
dealer check \fhe elec\frical circui\f.
EAU11444
Coolant temperature warning
light “u”
This warnin\b li\bh\f comes on if \fhe en-
\bine overhea\fs. If \fhis occurs, s\fop \fhe
en\bine immedia\fely and allow \fhe en-
\bine \fo cool. The elec\frical circui\f of \fhe
warnin\b li\bh\f can be checked by \furn-
in\b \fhe key \fo "ON". The warnin\b li\bh\f
should come on for a few seconds, and \fhen \bo off. If \fhe warnin\b li\bh\f
does no\f come on ini\fially when \fhe
key is \furned \fo "ON", or if \fhe warnin\b
li\bh\f remains on, have a Yamaha deal-
er check \fhe elec\frical circui\f.
ECA10021
NOTICE
Do not continue to operate the en-
gine if it is overhea\4ting.
TIP
●For radia\for-fan-equipped vehi- cles, \fhe radia\for fan(s) au\foma\fi-
cally swi\fch on or off accordin\b \fo
\fhe coolan\f \fempera\fure in \fhe ra-
dia\for.
●If \fhe en\bine overhea\fs, see pa\be
7-41 for fur\fher ins\fruc\fions.
EAU11534
Engine trouble warning light “ U”
This warnin\b li\bh\f comes on or flashes
if a problem is de\fec\fed in \fhe elec\fri-
cal circui\f moni\forin\b \fhe en\bine. If \fhis
occurs, have a Yamaha dealer check
\fhe self-dia\bnosis sys\fem. (See pa\be
4-8 for an explana\fion of \fhe self-dia\b-
nosis device.) The elec\frical circui\f of
\fhe warnin\b li\bh\f can be checked by \furnin\b \fhe key \fo "ON". The warnin\b
li\bh\f should come on for a few seconds,
and \fhen \bo off. If \fhe warnin\b li\bh\f does
no\f come on ini\fially when \fhe key is
\furned \fo "ON", or if \fhe warnin\b li\bh\f re-
mains on, have a Yamaha dealer check
\fhe elec\frical circui\f.
EAU26876
Immobilizer system indicator
light “ ”
The elec\frical circui\f of \fhe indica\for
li\bh\f can be checked by \furnin\b \fhe
key \fo "ON". The indica\for li\bh\f should
come on for a few seconds, and \fhen
\bo off. If \fhe indica\for li\bh\f does no\f
come on ini\fially when \fhe key is
\furned \fo "ON", or if \fhe indica\for li\bh\f
remains on, have a Yamaha dealer
check \fhe elec\frical circui\f.
When \fhe key is \furned \fo "OFF" and
30 seconds have passed, \fhe indica\for
li\bh\f will s\far\f flashin\b indica\fin\b \fhe
immobilizer sys\fem is enabled. Af\fer
24 hours have passed, \fhe indica\for
li\bh\f will s\fop flashin\b, however \fhe im-
mobilizer sys\fem is s\fill en\aabled.
This model is also equipped wi\fh a
self-dia\bnosis device for \fhe immobi-
lizer sys\fem. (See pa\be 4-8 for an ex-
plana\fion of \fhe self-dia\bnosis device.)
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-4

INSTRUMENT AND CONTROL FUNCTIONS
4-10
1
2
3
4
\f
6
7
8
\b
10
EAU12733
Hazard switch “r”
With the key in the \fON” \br Fp\bsiti\bn,
use this switch t\b turn \bn the hazard
lights (simultane\bus flashing \bf all turn
signal lights).
The hazard lights are used in case \bf
an emergency \br t\b warn \bther drivers
when y\bur vehicle is st\bpped where it
might be a traffic hazard.
ECA10061
NOTICE
Do not use the hazard lights for an
extended length of time with the
engine not running, otherwise the
battery may discha\4rge.
EAU12820
Clutch lever
1. Clutch lever
The clutch lever is l\bcated at the left
handlebar grip. T\b disengage the
clutch, pull the lever t\bward the han-
dlebar grip. T\b engage the clutch, re-
lease the lever. The lever sh\buld be
pulled rapidly and released sl\bwly f\br
sm\b\bth clutch \bperati\bn.
The clutch lever is equipped with a
clutch switch, which is part \bf the igni-
ti\bn circuit cut-\bff system. (See page
4-17).
1
EAU12870
Shift pedal
1. Shift pedal
The shift pedal is l\bcated \bn the left
side \bf the engine and is used in c\bm-
binati\bn with the clutch lever when
shifting the gears \bf the 5-speed c\bn-
stant-mesh transmissi\bn equipped \bn
this m\bt\brcycle.
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-10

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

FOR YOUR SAFETY – PRE-OPERATION CHECKS
5-4
1
\f
3
4
5
\b
7
8
9
10
ITEM
Instruments, lights,
signals and switches
Sidestand
switch CHECKS
 Check operation.
 Correct if nece\f\fary.
 Check operation of ignition c\fircuit cut-off \fy\fte\b.\f
 If \fy\fte\b i\f not working correctly, have Ya\baha dealer check vehicle. PAGE
4-3, 4-9
4-17
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 4

OPERATION AND IMPORTANT RIDING POINTS
3. Start the engine by pushing thestart switch.
TIP
\ff the engine fails to start\b release the
start switch\b wait a few seconds\b and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any one
attempt.
ECA11040
NOTICE
For max\fmum en\b\fne l\ffe, never ac-
celerate hard when the en\b\fne \fs
cold!
TIP
The engine is warm when it quickly re-
sponds to the thrott\cle.
EAU16671
Sh\fft\fn\b
1. Shift pedal
N. Neutral position
Shifting gears lets you control the
amount of engine power available for
star ting off\b accelerating\b climbing
hills\b etc.
The gear positions are shown in the il-
lustration.
TIP
To shift the transmission into the neu-
tral position\b press the shift pedal down
repeatedly until it reaches the end of its
travel\b and then slightly raise it.
6-2
1
2
3
4
5
6
7
8
9
10
ECAB0070
NOTICE
The follow\fn\b warn\fn\b l\f\bhts and \fn-
d\fcator l\f\bhts should come on for a
few seconds, then \bo o\xff.
●Neutral \fnd\fcator l\f\b\xht
●Turn s\f\bnal \fnd\fcator l\f\bht\x
●H\f\bh beam \fnd\fcator l\f\b\xht
●En\b\fne trouble warn\fn\b l\f\bht
●Coolant temperature warn\fn\b
l\f\bht
●Immob\fl\fzer system \fnd\fcator
l\f\bht
If a warn\fn\b or \fnd\fcator l\f\bht does
not \bo off, see pa\be 4-3 for the cor-
respond\fn\b warn\fn\b and \fnd\fcator
l\f\bht c\frcu\ft check.
2. Shift the transmission into the neutral position.
TIP
When the transmission is in the neu-
tral position\b the neutral indicator light
should be on\b otherwise have a Yama-
ha dealer check the electrical circuit.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 6