warning YAMAHA XT660Z 2012 Owners Manual

INTRODUCTION
EAU10102
Welcome to the Yamaha worl\f of motorcycli\bg!
As the ow\ber of the XT660Z Té\béré, you are be\befiti\bg from Yamaha's vast experie\bce a\b\f \bewest tech\bology regar\fi\bg
the \fesig\b a\b\f ma\bufacture of high-qual\rity pro\fucts, which have ear\be\f Yamaha a reputatio\b f\ror \fepe\b\fability.
Please take the time to rea\f this ma\bual thoroughly, so as to e\bjoy all a\fva\btages of your XT660Z Té\béré. The Ow\ber's
Ma\bual \foes \bot o\bly i\bstruct you i\b how to operate, i\bspect a\b\f mai\btai\b your motorcycle, but also i\b how to safeguar\f
yourself a\b\f others f\rrom trouble a\b\f i\bjury.
I\b a\f\fitio\b, the ma\by tips give\b i\b this ma\bual will help keep your motorcycle i\b the best possible co\b\fitio\b. If you have
a\by further questio\bs, \fo \bot hesitate to\r co\btact your Yamaha \fealer.
The Yamaha team wishes y\rou ma\by safe a\b\f pleasa\bt ri\fes. So, remember to put s\rafety first!
Yamaha co\bti\bually seeks a\fva\bceme\bts i\b pro\fuct \fesig\b a\b\f quality. Therefore, while this ma\bual co\btai\bs the most
curre\bt pro\fuct i\bformatio\b available at the time of pri\bti\bg, there may be mi\bor \fiscrepa\bcies betwee\b your motorcycle
a\b\f this ma\bual. If there is a\by questio\b co\bcer\bi\bg this ma\bual, please co\bsult\r a Yamaha \fealer.
EWA10031
WARNING0
Please read \fhis ma\bual carefully a\bd comple\fel\dy before opera\fi\bg \fhis mo\forcycle.
XT660Z 01-03 ING-AUS:AUSTRALIA 11-05-2009 9:57 Pagina 3

IMPORTANT MANUAL INFORMATION
Particularly important information is distingu\hish\fd in this manual by th\f following notations:
WARNING\b
TIP
This is the s\ffety \fle\bt symbol. It is used to \fle\bt you to potenti\fl pe\bson\fl inju\by h\fz-
\f\bds. Obey \fll s\ffety mess\fges th\ft follow this symbol to \fvoid possible inju\by o\b
de\fth.
A WARNING indic\ftes \f h\fz\f\bdous situ\ftion which, if not \fvoided, could \besult in
de\fth o\b se\bious inju\by.
A NOTICE indic\ftes speci\fl p\bec\futions th\ft must be t\fken to \fvoid d\fm\fge to the
vehicle o\b othe\b p\bope\bty.
A TIP provid\fs k\fy information to mak\f proc\fdur\fs \fasi\fr o\hr cl\far\fr.
EAU1\b132
NOTICE
XT660Z 01-03 ING-AUS:AUSTRALIA 11-05-2009 9:57 Pagina 4

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

INSTRUMENT AND CONTROL FUNCTIONS
4-2
1
2
3
4
\f
6
7
8
\b
10
EAU10471
Main switch/steering lock
The main swi\fch/s\feerin\b lock con\frols
\fhe i\bni\fion and li\bh\fin\b sys\fems, and
is used \fo lock \fhe s\feerin\b.
TIP
Be sure \fo use \fhe s\fandard key (black
bow) for re\bular use of \fhe vehicle. To
minimize \fhe risk of losin\b \fhe code re-
re\bis\ferin\b key (red bow), keep i\f in a
safe place and only use i\f for code re-
re\bis\ferin\b.
EAU10550
ON
All elec\frical circui\fs are supplied wi\fh
power, \fhe me\fer li\bh\fin\b, \failli\bh\f, li-
cense pla\fe li\bh\f and auxiliary li\bh\fs
come on, and \fhe en\bine can be s\far\f-
ed. The key canno\f be removed.
TIP
The headli\bh\fs comes on au\foma\fical-
ly when \fhe en\bine is s\far\fed and s\fay
on un\fil \fhe key is \furned \fo “OFF”,
even if \fhe en\bine s\fa\wlls.
EAU10661
OFF
All elec\frical sys\fems are off. The key
can be removed.
EWA10061
WARNING0
Never turn the key to "OFF" or
"LOCK" while the vehicle is moving.
Otherwise the electrical systems
will be switched off, which may re-
sult in loss of control or an acci-
dent.
EAU10691
LOCK
The s\feerin\b is locked, and all elec\fri-
cal sys\fems are off. The key can be re-
moved.
To lock \fhe s\feerin\b
1. Push
2. Turn
1. Turn \fhe handlebars all \fhe way \fo \fhe lef\f or ri\bh\f.
2. Push \fhe key in from \fhe “OFF” posi\fion, and \fhen \furn i\f \fo
“LOCK” while s\fill pushin\w\b i\f.
3. Remove \fhe key.
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-2

1
2
3
4
5
6
7
8
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
4-8
1
2
3
4
\f
6
7
8
\b
10
Self-diagnosis devices
1. Engine trouble warning lig\ft “ U”
2. \bmmobilizer system indicator lig\ft “ ”
T\fis model is equipped wit\f a self-di-
agnosis device for various electrical
circuits.
\bf any of t\fose circuits are defective,
t\fe engine trouble warning lig\ft will
start flas\fing. \bf t\fis occurs, \fave a
Yama\fa dealer c\feck t\fe ve\ficle.
T\fis model is also equipped wit\f a
self-diagnosis device for t\fe immobi-
lizer system.
\bf any of t\fe immobilizer system cir-
cuits are defective, t\fe immobilizer
system indicator lig\ft will start flas\f-
ing.
\bf t\fis occurs, \fave a Yama\fa dealer
c\feck t\fe ve\ficle.
TIP
\bf t\fe indicator lig\ft slowly flas\fes five
times, and t\fen quickly flas\fes two
times repeatedly, t\fis error could be
caused by transponder interference. \bf
t\fis occurs, try t\fe following.
1. Use t\fe code re-registering key to start t\fe engine.
TIP
Make sure t\fere are no ot\fer immobi-
lizer keys close to t\fe main switc\f, and
do not keep more t\fan one immobiliz-
er key on t\fe same key ring! \bmmobi-
lizer system keys may cause signal in-
terference, w\fic\f may prevent t\fe
engine from starting. 2. \bf t\fe engine starts, turn it off, and
try starting t\fe engine wit\f t\fe
standard keys.
3. \bf one or bot\f of t\fe standard keys do not start t\fe engine, take t\fe
ve\ficle, t\fe code re-registering
key and bot\f standard keys to a
Yama\fa dealer and \fave t\fe
standard keys re-registered.
\bf t\fe immobilizer system indicator
lig\ft continues to flas\f, \fave a Yama-
\fa dealer c\feck t\fe ve\ficle.
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-8

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