wheel 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

1
2
3
4
5
6
7
8
9
10
FOR YOUR SAFE\fY – PRE-OPERA\f\bON CHECKS
5-3
\b\fEM
Clutch
\fhrottle grip
Control cables
Drive chain
Wheels and tires
Brake and shift pedals
Brake and
clutch levers
Sidestand
Chassis fasteners CHECKS
 Check operation.
 L\fbricate cable if nece\b\bary.
 Check lever free play.
 Adj\f\bt if nece\b\bary.
 Make \b\fre that operation i\b \bmooth.
 Check cable free play.
 If nece\b\bary, have Yamaha dealer adj\f\bt \Lcable free play and l\fbricate cable and grip ho\f\bing.
 Make \b\fre that operation i\b \bmooth.
 L\fbricate if nece\b\bary.
 Check chain \black.
 Adj\f\bt if nece\b\bary.
 Check chain condition.\L
 L\fbricate if nece\b\bary.
 Check for damage.
 Check tire condition a\Lnd tread depth.
 Check air pre\b\b\fre.
 Correct if nece\b\bary.
 Make \b\fre that operation i\b \bmooth.
 L\fbricate pedal pivoting point\b if nec\Le\b\bary.
 Make \b\fre that operation i\b \bmooth.
 L\fbricate lever pivoting point\b if nec\Le\b\bary.
 Make \b\fre that operation i\b \bmooth.
 L\fbricate pivot if nece\b\bary.
 Make \b\fre that all n\ft\b, bolt\b and \bcrew\b are properly tightened.
 Tighten if nece\b\bary. PAGE
4-10, 7-20, 7-26
7-16, 7-267-25
7-23, 7-24, 7-25
7-16, 7-197-27
7-26
7-27–
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 3

1
2
3
4
5
6
7
8
9
10
PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-3
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
√ √
√ √ √ √ √
√ √ √
√√
√
√ √ √ √ √ √
√ √ √ √ √
√ √ √ √
√ √ √ √ √
√ √ √ √1
2
3
✻
4✻
5✻
6✻
7✻
8✻
 Replace.
 Check operatio\f.
 Adj\bst.
 Check operatio\f, fl\bid level a\fd vehicle
for fl\bid leakage.
 Replace brake pads.
 Check operatio\f, fl\bid level a\fd vehicle
for fl\bid leakage.
 Replace brake pads.
 Check for cracks or damage.
 Replace.
 Check r\b\fo\bt, spoke tight\fess a\fd for damage.
 Tighte\f spokes if \fecessary.
 Check tread depth a\fd for damage.
 Replace if \fecessar\iy.
 Check air press\bre.
 Correct if \fecessar\iy.
 Check beari\fg for loose\fess or dam\iage.
\fir filter element
Clutch
Front brake
Rear brake
Brake hoses
Wheels
Tires
Wheel bearings
EAU1770C
Ge\feral mai\fte\fa\fce a\fd l\bb\iricatio\f chart
Whe\fever wor\f to the limit
Whe\fever wor\f to the limit Every 4 years
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-3

1
2
3
4
5
6
7
8
9
10
PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-19
EAU21940
Spoke wheels
To maximize \fhe per\bormance, durabil-
i\fy, and sa\be opera\fion o\b your mo\for-
cycle, no\fe \fhe \bollowing poin\fs regard-
ing \fhe speci\bied whee\els.
●The wheel rims should bechecked \bor cracks, bends or
war page, and \fhe spokes \bor
looseness or damage be\bore
each ride. I\b any damage is \bound,
have a Yamaha dealer replace \fhe
wheel. Do no\f a\f\femp\f even \fhe
smalles\f repair \fo \fhe wheel. A de-
\bormed or cracked wheel mus\f be
replaced.●The wheel should be balancedwhenever ei\fher \fhe \fire or wheel
has been changed or replaced.
An unbalanced wheel can resul\f
in poor per\bormance, adverse
handling charac\feris\fics, and a
shor\fened \fire li\be.
●Ride a\f modera\fe speeds a\b\ferchanging a \fire since \fhe \fire sur-
\bace mus\f \birs\f be "broken in" \bor i\f
\fo develop i\fs op\fimal charac\feris-
\fics.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-19

1
2
3
4
5
6
7
8
9
10
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)
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-23

PERIODIC MAINTENANCE AND ADJUSTMENT
7-24
1
2
3
4
\f
6
7
8
\b
10
1. Wheel axle
2. Drive chain \flack adj\b\fting bolt
3. Lockn\bt
4. Alignment mark\f
TIP
U\fing the alignment mark\f on each
\fide of the \fwingarm, make \f\bre that
both chain p\bller\f are in the \fame po-
\fition for proper wheel al\nignment.
3. Tighten the axle n\bt, then the lock- n\bt\f to their \fpecified torq\be\f.
Tightening torques:
Axle n\bt:105 Nm (10.5 m·kgf, 75 ft·lbf)
Lockn\bt: 16 Nm (1.6 m·kgf, 11 ft·lbf)
EAU34314
To adjust the drive chain slack1. Loo\fen the axle n\bt and the lock- n\bt on each \fide of the \fwingarm.
2. To tighten the drive chain, t\brn the drive chain \flack adj\b\fting bolt on
each \fide of the \fwingarm in di-
rection (a). To loo\fen the drive
chain, t\brn the adj\b\fting bolt on
each \fide of the \fwingarm in di-
rection (b), and then p\b\fh the rear
wheel forward. NOTICE: Improp-
er drive chain slack will over-
load the engine as well as other
vital parts of the motorcycle
and can lead to chain slippage
or breakage. To prevent this
from occurring, keep the drive
chain slack within the specified
limits.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-24

1
2
3
4
5
6
7
8
9
10
PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-29
EAU23283
Checking the steering
Worn or loose steerin\f bearin\fs ma\b
cause dan\fer. Therefore, the opera-
tion of the steerin\f must be checked
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.1. Place a stand under the en\fine to raise the front wheel off the
\fround. (See pa\fe 7-36 for more
information.) W\fRNING! To avoid
injury, securely support the vehi-
cle so there is no danger of it
falling over.
2. Hold the lower ends of the front fork le\fs and tr\b to move them for-
ward and backward. If an\b free
pla\b can be felt, have a Yamaha
dealer check or repair the steerin\f.EAU23290
Checking the wheel bearings
The front and rear wheel bearin\fs
must be checked at the intervals spec-
ified in the periodic maintenance and
lubrication chart. If there is pla\b in the
wheel hub or if the wheel does not turn
smoothl\b, have a Yamaha dealer
check the wheel bearin\fs.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-29

PERIODIC MAINTENANCE AND ADJUSTMENT
7-36
1
2
3
4
\f
6
7
8
\b
10
To service the rear wheel
Raise the rear wheel off the grou\fd by
usi\fg a \botorcycle sta\fd or, if a \bo-
torcycle sta\fd is \fot available, by plac-
i\fg a jack either u\fder each side of the
fra\be i\f fro\ft of the rear wheel or u\f-
der each side of t\uhe swi\fgar\b.EAU24360
Front wheelEAUB1440To remove the front wheel
EWA10820
WARNING0
●It is advisable to have a Yama-
ha dealer service t\4he wheel.
●Securely support the motorcy-
cle so that there is no danger of
it falling over.
1. Wheel axle
2. Brake caliper bolts
A. Fro\ft wheel axle pi\fch bolt
B. Fro\ft wheel axle pi\fch bolt
A
2
B
1
EAU24350
Supporting the motorcycle
Si\fce this \bodel is \fot equipped with
a ce\ftersta\fd, follow these precau-
tio\fs whe\f re\bovi\fg the fro\ft a\fd rear
wheel or perfor\bi\fg other \bai\fte-
\fa\fce requiri\fg the \botorcycle to
sta\fd upright. Check that the \botorcy-
cle is i\f a stable a\fd level positio\f be-
fore star ti\fg a\fy \bai\fte\fa\fce. A
stro\fg woode\f box ca\f be placed u\f-
der the e\fgi\fe for added stability.
To service the front wheel 1. Stabilize the rear of the \botorcy- cle by usi\fg a \botorcycle sta\fd
or, if a\f additio\fal \botorcycle
sta\fd is \fot available, by placi\fg a
jack u\fder the fra\be i\f fro\ft of the
rear wheel.
2. Raise the fro\ft wheel off the grou\fd by usi\fg a \botorcycle
sta\fd.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-36

1
2
3
4
5
6
7
8
9
10
PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-37
1. Loosen the front wheel axle \finchbolts\b the wheel axle and the
brake cali\fer bolts.
2. Lift the front wheel off the ground according to the \frocedure on
\fage 7-36.
3. Remove the brake cali\fer on each side by removing the bolts.
ECA11050
NOTICE
Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will be
forced shut.
4. Pull the wheel axle out\b and then remove the wheel.
EAUB1470
To install the front wheel1. Lift the wheel u\f between the fork legs.
2. Insert the wheel axle.
3. Install the brake cali\fers by in- stalling the bolts.
TIP
Make sure that there is enough s\face
between the brake \fads before in-
stalling the brake cali\fers onto the
brake discs.
4. Lower the front wheel so that it is on the ground.
5. Tighten the wheel axle and the brake cali\fer bolts to the s\fecified
torques.
ECAB0060
NOTICE
Be sure the right brake disc is posi-
tioned exactly in the middle of the
caliper pads to prevent any brake
drag. Tap the side of the right fork
leg to position th\Me disc correctly.
Tightening torques: Wheel axle:60 Nm (6.0 m·kgf\b 44 ft·lbf)
Front wheel axle \fin\xch bolt: 18 Nm (1.8 m·kgf\b 13 ft·lbf)
Brake cali\fer bolt: 40 Nm (4.0 m·kgf\b 29 ft·lbf)
6. Tighten wheel axle \finch bolt A\b and then \finch bolt B to the s\fec-
ified torque.
7. Retighten \finch bolt A to the s\fecified torque.
8. A\f\fly the front brake several times\b and then while holding the
brake lever in\b \fush down hard on
the handlebar several times to
check for \fro\fer fork o\feration.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-37