lock YAMAHA XT660Z 2013 User Guide

aligned with the “ ” mark on the
brake lever.EAU12941
Brake pedal
1. Brake pedal
The brake pedal is on the right side of
the motorcycle. To apply the rear bra-
ke, press down on the brake pedal.
EAU26794
ABS (for ABS models)
The Yamaha ABS (Anti-lock Brake
System) features a dual electronic
control system, which acts on the
front and rear brakes independently.
The ABS is monitored by an ECU,
which will have recourse to manual
braking if a malfunction occurs.
EWA10090
The ABS performs best on long
braking distances.
On certain (rough or gravel)
roads, the braking distance
may be longer with than wit-
hout the ABS. Therefore,
always keep a sufficient distan-
ce to the vehicle ahead to
match the riding speed.
TIP
When the ABS is activated, the
brakes are operated in the usual
way. A pulsating action may be
felt at the brake lever or brake
pedal, but this does not indicate
a malfunction.
WARNING
INSTRUMENT AND CONTROL FUNCTIONS
3-12
3

This ABS has a test mode which
allows the owner to experience
the pulsating at the brake lever or
brake pedal when the ABS is
operating. However, special tools
are required, so please consult
your Yamaha dealer when perfor-
ming this test.
ECA16120
Keep any type of magnets (inclu-
ding magnetic pick-up tools, mag-
netic screwdrivers, etc.) away from
the front and rear wheel hubs,
otherwise the magnetic rotors
equipped in the wheel hubs may be
damaged, resulting in improper
performance of the ABS system.
1. Front wheel hub
1. Rear wheel hub
EAU13074
Fuel tank cap
1. Lock cover
2. Open
To open the fuel tank cap
Open the fuel tank cap lock cover,
insert the key into the lock, and then
turn it 1/4 turn clockwise. The lock will
be released and the fuel tank cap can
be opened.
To close the fuel tank cap
1. Push the fuel tank cap into posi-
tion with the key inserted in the
lock.
2. Turn the key counterclockwise to
the original position, remove it,
and then close the lock cover.
NOTICE
INSTRUMENT AND CONTROL FUNCTIONS
3-13
3

TIP
The fuel tank cap cannot be closed
unless the key is in the lock. In addi-
tion, the key cannot be removed if the
cap is not properly closed and loc-
ked.
EWA11091
Make sure that the fuel tank cap is
properly closed after filling fuel.
Leaking fuel is a fire hazard.
EAU13212
Fuel
Make sure there is sufficient gasoline
in the tank.
EWA10881
Gasoline and gasoline vapors are
extremely flammable. To avoid fires
and explosions and to reduce the
risk of injury when refueling, follow
these instructions.
1. Before refueling, turn off the engi-
ne and be sure that no one is sit-
ting on the vehicle. Never refuel
while smoking, or while in the
vicinity of sparks, open flames, or
other sources of ignition such as
the pilot lights of water heaters
and clothes dryers.
2. Do not overfill the fuel tank. Stop
filling when the fuel reaches the
bottom of the filler tube. Because
fuel expands when it heats up,
heat from the engine or the sun
can cause fuel to spill out of the
fuel tank.
1. Fuel tank filler tube
2. Maximum fuel level
3. Wipe up any spilled fuel imme-
diately. NOTICE: Immediately
wipe off spilled fuel with a cle-
an, dry, soft cloth, since fuel
may deteriorate painted surfa-
ces or plastic parts.
[ECA10071]
4. Be sure to securely close the fuel
tank cap.
EWA15151
Gasoline is poisonous and can cau-
se injury or death. Handle gasoline
with care. Never siphon gasoline by
mouth. If you should swallow some
gasoline or inhale a lot of gasoline
WARNING
WARNING
WARNING
INSTRUMENT AND CONTROL FUNCTIONS
3-14
3

vapor, or get some gasoline in your
eyes, see your doctor immediately.
If gasoline spills on your skin, wash
with soap and water. If gasoline
spills on your clothing, change your
clothes.
EAU49460
ECA11400
Use only unleaded gasoline. The
use of leaded gasoline will cause
severe damage to internal engine
parts, such as the valves and piston
rings, as well as to the exhaust sys-
tem.
Your Yamaha engine has been desig-
ned to use premium unleaded gasoli-ne with a research octane number of
95 or higher. If knocking (or pinging)
occurs, use a gasoline of a different
brand. Use of unleaded fuel will
extend spark plug life and reduce
maintenance costs.
EAUB1300
Fuel tank breather/overflow
hose
1. Fuel tank breather/overflow hose
2. Hose clamp
Before operating the motorcycle:
Check the fuel tank breather/over-
flow hose connection.
Check the fuel tank
breather/overflow hose for
cracks or damage, and replace it
if damaged.
Make sure that the end of the fuel
tank breather/overflow hose is
not blocked, and clean it if
necessary.
Make sure that the end of the fuel
tank breather/overflow hose is
positioned inside of the clamp.
NOTICE
Recommended fuel:
PREMIUM UNLEADED
GASOLINE ONLY
Fuel tank capacity:
23.0 L (6.08 US gal, 5.06 Imp.gal)
Fuel reserve amount:
XT660Z 6.7 L (1.76 US gal,
1.46 Imp.gal)
XT660ZA 5.8 L (1.53 US gal,
1.28 Imp.gal)
INSTRUMENT AND CONTROL FUNCTIONS
3-15
3

EAU13445
Catalytic converters
This vehicle is equipped with catalytic
converters in the exhaust system.
EWA10862
The exhaust system is hot after
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 befo-
re doing any maintenance
work.
Do not allow the engine to idle
more than a few minutes. Long
idling can cause a build-up of
heat.
ECA10701
Use only unleaded gasoline. The
use of leaded gasoline will cause
unrepairable damage to the cataly-
tic converter.
EAU13861
Seat
To remove the seat
1. Insert the key into the seat lock,
turn it counterclockwise, and
then pull the seat off.
1. Seat lock
2. Unlock
To install the seat
Insert the projections on the front of
the seat into the seat holders, push
the rear of the seat down to lock it in
place, and then remove the key.
NOTICE
WARNING
INSTRUMENT AND CONTROL FUNCTIONS
3-16
3

EAU22043
Adjusting the clutch lever
free play
The clutch lever free play should mea-
sure 10.0–15.0 mm (0.39–0.59 in) as
shown. Periodically check the clutch
lever free play and, if necessary,
adjust it as follows.
1. Slide the rubber cover back at
the clutch lever.
2. Loosen the locknut.
3. To increase the clutch lever free
play, turn the adjusting bolt in
direction (a). To decrease the
clutch lever free play, turn the
adjusting bolt in direction (b).
1. Locknut (clutch lever)
2. Clutch lever free play adjusting bolt
3. Clutch lever free play
TIP
If the specified clutch lever free play
could be obtained as described abo-
ve, skip steps 4–7.
4. Fully turn the adjusting bolt at the
clutch lever in direction (a) to loo-
sen the clutch cable.
5. Loosen the locknut at the crank-
case.
6. To increase the clutch lever free
play, turn the adjusting nut in
direction (a). To decrease the
clutch lever free play, turn the
adjusting nut in direction (b).
1. Locknut (crankcase)
2. Clutch lever free play adjusting nut (crank-
case)
7. Tighten the locknut at the crank-
case.
8. Tighten the locknut at the clutch
lever and then slide the rubber
cover to its original position.
PERIODIC MAINTENANCE AND ADJUSTMENT
6-20
6

Rear brake (for XT660ZA)
1. Minimum level mark
Insufficient brake fluid may allow air
to enter the brake system, possibly
causing it to become ineffective.
Before riding, check that the brake
fluid is above the minimum level mark
and replenish if necessary. A low bra-
ke fluid level may indicate worn brake
pads and/or brake system leakage. If
the brake fluid level is low, be sure to
check the brake pads for wear and
the brake system for leakage.
TIP
For XT660ZA, the rear brake fluid
reservoir is located under the seat.
(See page 3-16).
Observe these precautions:
When checking the fluid level,
make sure that the top of the bra-
ke fluid reservoir is level.
Use only the recommended qua-
lity brake fluid, otherwise the rub-
ber seals may deteriorate, cau-
sing leakage and poor braking
performance.
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performan-
ce.
Be careful that water or dust
does not enter the brake fluid
reservoir when refilling. Water will
significantly lower the boiling
point of the fluid and may result
in vapor lock, and dirt may clog
the ABS hydraulic unit valves.
Brake fluid may deteriorate pain-
ted surfaces or plastic parts.
Always clean up spilled fluid
immediately.
As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if
the brake fluid level goes down
suddenly, have a Yamaha dealer
check the cause.
EAU22731
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the TIP after the periodic maintenan-
ce and lubrication chart. In addition,
have the oil seals of the master cylin-
ders and calipers as well as the brake
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.
Oil seals: Replace every two
years.
Brake hoses: Replace every four
years.
Recommended brake fluid:
DOT 4
PERIODIC MAINTENANCE AND ADJUSTMENT
6-22
6

EAU22760
Drive chain slack
The drive chain slack should be chec-
ked before each ride and adjusted if
necessary.
EAU22783
To check the drive chain slack
1. Drive chain slack
1. Place the motorcycle on the
sidestand.
TIP
When checking and adjusting the dri-
ve chain slack, there should be no
weight on the motorcycle.
2. Shift the transmission into the
neutral position.3. Move the rear wheel by pushing
the motorcycle to locate the tigh-
test portion of the drive chain,
and then measure the drive chain
slack as shown.
4. If the drive chain slack is inco-
rrect, adjust it as follows.
TIP
When checking the drive chain slack,
the chain tensioner should not be tou-
ching the drive chain.
EAU34316
To adjust the drive chain slack
1. Loosen the axle nut and the lock-
nut on each side of the swin-
garm.
1. Wheel axle
2. Drive chain slack adjusting bolt
3. Locknut
4. Alignment marks
2. To tighten the drive chain, turn
the drive chain slack adjusting
bolt on each side of the swin-
garm in direction (a). To loosen
the drive chain, turn the adjusting
bolt on each side of the swin-
garm in direction (b), and then
push the rear wheel forward.
NOTICE: Improper drive chain
slack will overload 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 wit-
hin the specified limits.
[ECA10571]
Drive chain slack:
XT660Z 50.0-60.0 mm
(1.96-2.36 in)
XT660ZA 40.0-55.0 mm
(1.57-2.17 in)
PERIODIC MAINTENANCE AND ADJUSTMENT
6-23
6

TIP
Using the alignment marks on each
side of the swingarm, make sure that
both drive chain pullers are in the
same position for proper wheel align-
ment.
3. Tighten the axle nut, then the
locknuts to their specified tor-
ques.
EAU23025
Cleaning and lubricating the
drive chain
The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly
wear out, especially when riding in
dusty or wet areas. Service the drive
chain as follows.
ECA10583
The drive chain must be lubricated
after washing the motorcycle,
riding in the rain or riding in wet
areas.
1. Clean the drive chain with kero-
sene and a small soft brush.
NOTICE: To prevent damaging
the O-rings, do not clean the
drive chain with steam clea-
ners, high-pressure washers or
inappropriate solvents.
[ECA11121]
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant. NOTICE: Do not use
engine oil or any other lubri-cants for the drive chain, as
they may contain substances
that could damage the O-rings.
[ECA11111]
NOTICETightening torques:
Axle nut:
16 Nm (1.6 m·kgf, 11 ft·lbf)
Locknut:
105 Nm (10.5 m·kgf, 75 ft·lbf)
PERIODIC MAINTENANCE AND ADJUSTMENT
6-24
6

PERIODIC MAINTENANCE AND ADJUSTMENT
6-34
6
EAU24204
Replacing a turn signal light
bulb
1. Remove the turn signal light lens
by removing the screw.
1. Screw
2. Turn signal light lens
3. Turn signal light bulb
2. Remove the burnt-out bulb by
pushing it in and turning it coun-
terclockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screw. NOTICE: Do not over-
tighten the screw, otherwise
the lens may break.
[ECA11191]EAUM2202
Replacing the license plate
light bulb
1. Remove the socket (together
with the bulb) by pulling it out.
1. License plate light bulb socket
2. License plate light bulb
2. Remove the burnt-out bulb by
pulling it out.
3. Insert a new bulb into the socket.
4. Install the socket (together with
the bulb) by pushing it in.
EAU42652
Replacing an auxiliary light
bulb
This model is equipped with two auxi-
liary lights. If an auxiliary light bulb
burns out, replace it as follows.
1. Remove panel G. (See page 6-8).
2. Remove the auxiliary light socket
(together with the bulb) by pulling
it out.
1. Auxiliary light bulb socket
2. Auxiliary light bulb
3. Remove the burnt-out bulb by
pulling it out.
4. Insert a new bulb into the socket.