oil level 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

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

PERIODIC MAINTENANCE AND ADJUSTMENT
7-4
1
2
3
4
\f
6
7
8
\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
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-4

1
2
3
4
5
6
7
8
9
10
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✻
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-5

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5
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7
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9
10
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

PERIODIC MAINTENANCE AND ADJUSTMENT
7-10
1
2
3
4
\f
6
7
8
\b
10
To change the engine oil
(with or without oil filter element
replacement)
1. Mounting screw
2. \fngine guard
1. Start t\be engine, warm it up for sev- eral minutes, and t\ben turn it off.
2. To reac\b t\be drain bolt of t\be crankcase and t\be drain bolt of
t\be oil tank, remove t\be engine
guard by removing t\be screws.
3. Place an oil pan under t\be engine to collect t\be used\2 oil.
4. Remove t\be engine oil filler cap and t\be drain bolt to drain t\be oil
from t\be crankcase.
5. Remove t\be drain bolt to drain t\be oil from t\be oil ta\2nk.
1. \fngine oil crankcase drain bolt
1. \fngine oil tank drain bolt
6. Remove t\be oil filter elementdrain bolt to drain t\be oil from t\be
oil filter element\2.
1
\fCA10010
NOTICE
Do not operate the vehicle until you
know that the engine oil level is suf-
ficient.
\fWA10360
WARNING0
Never remove the engine oil tank
cap after high-speed operation,
otherwise hot engine oil could
spout out and cause damage or in-
jury. Always let the engine oil cool
down sufficiently before removing
the oil tank cap.
4. If t\be engine oil is below t\be mini- mum level mark, add sufficient oil
of t\be recommended type to raise
it to t\be correct l\2evel.
5. Install t\be oil fil\2ler cap.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-10

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
7
03 ingles -austral\:ia 3/5/10 06:00 \:\fágina 54

PERIODIC MAINTENANCE AND ADJUSTMENT
7-22
1
2
3
4
\f
6
7
8
\b
10
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
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-22

PERIODIC MAINTENANCE AND ADJUSTMENT
7-28
1
2
3
4
\f
6
7
8
\b
10
EAU23272
Checking the front fork
The condition and o\feration of the
front fork \bust be checked as follows
at the inter vals s\fecified in the
\feriodic \baintenance and lubrication
chart.
To check the condition
Check the inner tubes for scratches,
da\bage and excessive oil leakage.
To check the operation 1. Place the \botorcycle on a level surface and hold it in an u\fright
\fosition. WARNING! To avoid in-
jury, securely support the vehi-
cle so there is no danger of it
falling over.
2. While a\f\flying the front brake, \fush down hard on the handle-
bars several ti\bes to check if the
front fork co\b\fresses and re-
bounds s\boothly.
ECA10590
NOTICE
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAUM1650
Lubricating the swingarm
pivots
The swingar\b \fivots \bust be lubricat-
ed at the intervals s\fecified in the \fe-
riodic \baintenance and lubrication
chart.
Recommended lubric\4ant: Lithiu\b-soa\f-based g\arease
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-28

SPECIFICATIONS
9-1
1
2
3
4
5
6
7
8
9
1\f
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