YAMAHA XT660Z 2015 Service Manual

OPERATION AND IMPORTANT RIDING POINTS
5-1
5
EAU15952
Read the Owner’s Manual carefully to
become familiar with all controls. If
there is a control or function you do not
understand, ask your Yamaha dealer.
WARNING
EWA10272
Failure to familiarize yourself with
the controls can lead to loss of con-
trol, which could cause an accident
or injury.
EAU48021
TIPThis model is equipped with a lean an-
gle sensor to stop the engine in case of
a turnover. In this case, the multi-func-
tion display indicates error code 30,
but this is not a malfunction. Turn the

the error code. Failing to do so will pre-
vent the engine from starting even
though the engine will crank when
pushing the start switch.
EAUS1952
Starting the engineIn order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
The transmission is in the neutral
position.
The transmission is in gear with
the clutch lever pulled and the
sidestand up.
WARNING
EWA10291
Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-19.
Never ride with the sidestand
down.1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “ ”.NOTICE
ECAS0041
The following warning lights and in-
dicator lights should come on for a
few seconds, then go off.
Neutral indicator light
Turn signal indicator light
U2BDE1E0.book Page 1 Tuesday, December 16, 2014 5:38 PM

OPERATION AND IMPORTANT RIDING POINTS
5-2
5High beam indicator light
Engine trouble warning light
Coolant temperature warning
light
Immobilizer system indicator
light
ABS warning light (for ABS
model)
If a warning or indicator light does
not go off, see page 3-4 for the cor-
responding warning and indicator
light circuit check.
2. Shift the transmission into the
neutral position.TIPWhen the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical cir-
cuit.3. Start the engine by pushing the
start switch.TIPIf the engine fails to start, release the
start switch, wait a few seconds, 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.
TIPThe engine is warm when it quickly re-
sponds to the throttle.NOTICE
ECA11043
For maximum engine life, never ac-
celerate hard when the engine is
cold!
EAU16673
ShiftingShifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the il-
lustration.TIPTo shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.1. Shift pedal
2. Neutral positionZAUM12612
U2BDE1E0.book Page 2 Tuesday, December 16, 2014 5:38 PM

OPERATION AND IMPORTANT RIDING POINTS
5-3
5
NOTICE
ECA10261
Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long dis-
tances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.
Always use the clutch while
changing gears to avoid dam-
aging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
EAU16811
Tips for reducing fuel con-
sumptionFuel consumption depends largely on
your riding style. Consider the follow-
ing tips to reduce fuel consumption:
Shift up swiftly, and avoid high en-
gine speeds during acceleration.
Do not rev the engine while shift-
ing down, and avoid high engine
speeds with no load on the en-
gine.
Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at traf-
fic lights or at railroad crossings).
EAU16842
Engine break-inThere is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the fol-
lowing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that
might result in engine overheating
must be avoided.
EAU17103
0–1000 km (0–600 mi)
Avoid prolonged operation above 4500
r/min. NOTICE: After 1000 km (600
mi) of operation, the engine oil must
be changed, and the oil filter ele-
ment replaced.
[ECA11152]
1000–1600 km (600–1000 mi)
Avoid prolonged operation above 6000
r/min.
U2BDE1E0.book Page 3 Tuesday, December 16, 2014 5:38 PM

OPERATION AND IMPORTANT RIDING POINTS
5-4
51600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.
NOTICE
ECA10311
Keep the engine speed out of
the tachometer red zone.
If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the vehi-
cle.
EAU17214
ParkingWhen parking, stop the engine, and
then remove the key from the main
switch.
WARNING
EWA10312
Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them and be burned.
Do not park on a slope or on soft
ground, otherwise the vehicle
may overturn, increasing the
risk of a fuel leak and fire.
Do not park near grass or other
flammable materials which
might catch fire.
U2BDE1E0.book Page 4 Tuesday, December 16, 2014 5:38 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-1
6
EAU17245
Periodic inspection, adjustment, and
lubrication will keep your vehicle in the
safest and most efficient condition
possible. Safety is an obligation of the
vehicle owner/operator. The most im-
portant points of vehicle inspection,
adjustment, and lubrication are ex-
plained on the following pages.
The intervals given in the periodic
maintenance charts should be simply
considered as a general guide under
normal riding conditions. However, de-
pending on the weather, terrain, geo-
graphical location, and individual use,
the maintenance intervals may need to
be shortened.
WARNING
EWA10322
Failure to properly maintain the vehi-
cle or performing maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha dealer perform
service.
WARNING
EWA15123
Turn off the engine when performing
maintenance unless otherwise
specified.
A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.
Running the engine while ser-
vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 1-2 for more in-
formation about carbon monox-
ide.
WARNING
EWA15461
Brake discs, calipers, drums, and
linings can become very hot during
use. To avoid possible burns, let
brake components cool before
touching them.
EAU17303
Emission controls not only function to
ensure cleaner air, but are also vital to
proper engine operation and maximum
performance. In the following periodic
maintenance charts, the services relat-
ed to emissions control are grouped
separately. These services require
specialized data, knowledge, and
equipment. Maintenance, replace-
ment, or repair of the emission control
devices and systems may be per-
formed by any repair establishment or
individual that is certified (if applicable).
Yamaha dealers are trained and
equipped to perform these particular
services.
U2BDE1E0.book Page 1 Tuesday, December 16, 2014 5:38 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-2
6
EAU17382
Owner’s tool kitThe owner’s tool kit is located under
the seat. (See page 3-16.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.TIPIf you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.1. U2BDE1E0.book Page 2 Tuesday, December 16, 2014 5:38 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-3
6
EAU46862
TIPThe annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.
From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and tech-
nical skills.
EAU46911
Periodic maintenance chart for the emission control systemNO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
1*Fuel line• Check fuel hoses for cracks or
damage.√√√√√
2 Spark plug• Check condition.
• Clean and regap.√√
•Replace.√√
3*Valves• Check valve clearance.
•Adjust.√√
4*Fuel injection• Adjust engine idling speed.√√√√√√
5*Mufflers and ex-
haust pipes• Check the screw clamps for
looseness.√√√√√
6*Air induction sys-
tem• Check the air cut-off valve, reed
valve, and hose for damage.
• Replace any damaged parts if
necessary.√√√√√
U2BDE1E0.book Page 3 Tuesday, December 16, 2014 5:38 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
6
EAU1770M
General maintenance and lubrication chartNO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
1 Air filter element• Replace.√√
2Clutch• Check operation.
•Adjust.√√√√√
3*Front brake• Check operation, fluid level and
vehicle for fluid leakage.√√√√√√
• Replace brake pads. Whenever worn to the limit
4*Rear brake• Check operation, fluid level and
vehicle for fluid leakage.√√√√√√
• Replace brake pads. Whenever worn to the limit
5*Brake hoses• Check for cracks or damage.
• Check for correct routing and
clamping.√√√√√
• Replace. Every 4 years
6*Wheels• Check runout, spoke tightness
and for damage.
• Tighten spokes if necessary.√√√√√
7*Tires• Check tread depth and for dam-
age.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.√√√√√
8*Wheel bearings• Check bearings for looseness or
damage.√√√√
U2BDE1E0.book Page 4 Tuesday, December 16, 2014 5:38 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-5
6
9*Swingarm• Check operation and for exces-
sive play.√√√√
• Lubricate with lithium-soap-
based grease.Every 50000 km (30000 mi)
10 Drive chain• Check chain slack, alignment and
condition.
• Adjust and lubricate chain with a
special O-ring chain lubricant
thoroughly.Every 500 km (300 mi) and after washing the motorcycle, riding in the rain or
riding in wet areas
11*Steering bearings• Check bearing play and steering
for roughness.√√√√√
• Lubricate with lithium-soap-
based grease.Every 20000 km (12000 mi)
12*Chassis fasteners• Make sure that all nuts, bolts and
screws are properly tightened.√√√√√
13Brake lever pivot
shaft• Lubricate with silicone grease.√√√√√
14Brake pedal pivot
shaft• Lubricate with silicone grease.√√√√√
15Clutch lever pivot
shaft• Lubricate with lithium-soap-
based grease.√√√√√
16 Sidestand• Check operation.
• Lubricate with lithium-soap-
based grease.√√√√√
17*Sidestand switch• Check operation.√√√√√√
18*Front fork• Check operation and for oil leak-
age.√√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
U2BDE1E0.book Page 5 Tuesday, December 16, 2014 5:38 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-6
6
19*Shock absorber as-
sembly• Check operation and shock ab-
sorber for oil leakage.√√√√
20*Rear suspension re-
lay arm and con-
necting arm
pivoting points• Check operation.√√√√
• Lubricate with lithium-soap-
based grease.√√
21 Engine oil• Change.
• Check oil level and vehicle for oil
leakage.√√√√√√
22Engine oil filter ele-
ment• Replace.√√√
23*Cooling system• Check coolant level and vehicle
for coolant leakage.√√√√√
• Change coolant. Every 3 years
24*Front and rear
brake switches• Check operation.√√√√√√
25Moving parts and
cables• Lubricate.√√√√√
26*Throttle grip• Check operation.
• Check throttle grip free play, and
adjust if necessary.
• Lubricate cable and grip housing.√√√√√
27*Lights, signals and
switches• Check operation.
• Adjust headlight beam.√√√√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING
ANNUAL
CHECK 1000 km
(600 mi)10000 km
(6000 mi)20000 km
(12000 mi)30000 km
(18000 mi)40000 km
(24000 mi)
U2BDE1E0.book Page 6 Tuesday, December 16, 2014 5:38 PM