2008 YAMAHA XT660Z ECU

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3-1
INSTRUMENT AND CONTROL FUNCTIONS
EAU10973
Immobilizer system
1. Code re-registering key (red bow)
2. Standard keys (black bow)
This vehicle is equipped with an im-
mobilizer system to help prevent theft
by re-registering codes in the standard
keys. This system consists of the fol-
lowing.
●a code re-registering key (with a
red bow)
●two standard keys (with a black
bow) that can be re-registered
with new codes
●a transponder (which is installed
in the code re-registering key)
●an immobilizer unit
●an ECU

●an immobilizer system indicator
light (See page 3-3.)
The key with the red bow is used to reg-
ister codes in each standard key. Since
re-registering is a difficult process, take
the vehicle along with all three keys to a
Yamaha dealer to have them re-regis-
tered. Do not use the key with the red
bow for driving. It should only be used
for re-registering the standard keys. Al-
ways use a standard key for driving.
ECA11821CAUTION:
●DO NOT LOSE THE CODE RE-
REGISTERING KEY! CONTACT
YOUR DEALER IMMEDIATELY
IF IT IS LOST! If the code re-reg-
istering key is lost, registering
new codes in the standard keys
is impossible. The standard keys
can still be used to start the ve-
hicle, however if code re-regis-
tering is required (i.e., if a new
standard key is made or all keys
are lost) the entire immobilizer
system must be replaced.
Therefore, it is highly recom-
mended to use either standard key and keep the code re-regis-
tering key in a safe place.
●Do not submerse any key in water.
●Do not expose any key to exces-
sively high temperatures.
●Do not place any key close to
magnets (this includes, but not
limited to, products such as
speakers, etc.).
●Do not place items that transmit
electrical signals close to any key.
●Do not place heavy items on
any key.
●Do not grind any key or alter its
shape.
●Do not disassemble the plastic
part of any key.
●Do not put two keys of any immobi-
lizer system on the same key ring.
●Keep the standard keys as well
as keys of other immobilizer
systems away from this vehi-
cle's code re-registering key.
●Keep other immobilizer system
keys away from the main switch
as they may cause signal inter-
ference.

XT660Z 01-03 ING 10-03-2008 16:11 Pagina 3-1

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
EWA11020
WARNING0
Because loading has an enormous
impact on the handling, braking,
performance and safety character-
istics of your motorcycle, you
should keep the following precau-
tions in mind.
●NEVER OVERLOAD THE MO-
TORCYCLE! Operation of an
overloaded motorcycle may re-
sult in tire damage, loss of con-
trol, or severe injury. Make sure
that the total weight of rider,
passenger, cargo, and acces-
sories does not exceed the
specified maximum load for the
vehicle.
●Do not carry along loosely
packed items, which can shift
during a ride.
●Securely pack the heaviest
items close to the center of the
motorcycle and distribute the
weight evenly on both sides.

Tire air pressure
(measured on cold tires):Up to 90 kg (198 lb):
Front:210 kPa (30 psi) (2.1 kgf/cm
2)
Rear: 230 kPa (33 psi) (2.3 kgf/cm
2)
90 kg (198 lb) to maximum load:
Front: 230 kPa (33 psi) (2.3 kgf/cm
2)
Rear: 250 kPa (36 psi) (2.5 kgf/cm
2)
Off-road riding:
Front: 200 kPa (29 psi) (2.0 kgf/cm
2)
Rear: 200 kPa (29 psi) (2.0 kgf/cm
2)
High-speed riding:
Front: 210 kPa (30 psi) (2.1 kgf/cm
2)
Rear: 230 kPa (33 psi) (2.3 kgf/cm
2)
Maximum load*: 190 kg (419 lb)
* Total weight of rider, passenger, cargo and accessories
●Adjust the suspension and tire
air pressure with regard to the
load.
●Check the tire condition and air
pressure before each ride.

XT660Z 04-06 ING 11-03-2008 8:31 Pagina 6-17

PERIODIC MAINTENANCE AND MINOR REPAIR
6-28
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EAU23271
Checking the front fork
The condition and operation of the
front fork must be checked as follows
at the intervals specified in the period-
ic maintenance and lubrication chart.
To check the condition
EWA10750
WARNING0
Securely support the motorcycle so
that there is no danger of it falling
over.
Check the inner tubes for scratches,
damage and excessive oil leakage.
To check the operation 1. Place the motorcycle on a level surface and hold it in an upright
position.
2. While applying the front brake, push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.

ECA10590CAUTION:
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 swingarm pivots must be lubricat-
ed at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
Recommended lubricant: Lithium-soap-based grease

XT660Z 04-06 ING 11-03-2008 8:31 Pagina 6-28

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
EAU23280
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the opera-
tion of the steering must be checked
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.1. Place a stand under the engine to raise the front wheel off the
ground.
EWA10750
WARNING0
Securely support the motorcycle so
that there is no danger of it falling
over.

2. Hold the lower ends of the frontfork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.EAU23290
Checking the wheel bearings
The front and rear wheel bearings
must be checked at the intervals spec-
ified in the periodic maintenance and
lubrication chart. If there is play in the
wheel hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.

XT660Z 04-06 ING 11-03-2008 8:31 Pagina 6-29

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
EAUB1580
Replacing a headlight bulb
1. Headlight bulb cover
1. Headlight coupler
2. Headlight bulb holder
3. Headlight bulb

EWA10790
WARNING0
Headlight bulbs get very hot. There-
fore, keep flammable products
away from a lit headlight bulb, and
do not touch the bulb until it has
cooled down.3. Place a new headlight bulb into position, and then secure it with
the bulb holder.
1. Do not touch this area

1. Headlight bulb holder
2. Headlight bulb
This model is equipped with quartz
bulb headlights. If a headlight bulb
burns out, replace it as follows.1. Remove the headlight bulb cover, and then disconnect the headlight
coupler.
2. Unhook the headlight bulb holder, and then remove the defective
bulb.

XT660Z 04-06 ING 11-03-2008 8:31 Pagina 6-33

PERIODIC MAINTENANCE AND MINOR REPAIR
6-36
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To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a mo-
torcycle stand is not available, by plac-
ing a jack either under each side of the
frame in front of the rear wheel or un-
der each side of the swingarm.EAU24360
Front wheelEAUB1440To remove the front wheel
EWA10820
WARNING0
●It is advisable to have a Yama-
ha dealer service the wheel.
●Securely support the motorcy-
cle so that there is no danger of
it falling over.
1. Wheel axle
2. Brake caliper bolts
A. Front wheel axle pinch bolt
B. Front wheel axle pinch bolt

A
2
B
1

EAU24350
Supporting the motorcycle
Since this model is not equipped with
a centerstand, follow these precau-
tions when removing the front and rear
wheel or performing other mainte-
nance requiring the motorcycle to
stand upright. Check that the motorcy-
cle is in a stable and level position be-
fore starting any maintenance. A
strong wooden box can be placed un-
der the engine for added stability.
To service the front wheel 1. Stabilize the rear of the motorcy- cle by using a motorcycle stand
or, if an additional motorcycle
stand is not available, by placing a
jack under the frame in front of the
rear wheel.
2. Raise the front wheel off the ground by using a motorcycle
stand.

XT660Z 04-06 ING 11-03-2008 8:31 Pagina 6-36

PERIODIC MAINTENANCE AND MINOR REPAIR
6-38
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NOTE:
●If the drive chain is difficult to re-
move, remove the wheel axle first,
and then lift the wheel upward
enough to remove the drive chain
from the rear sprocket.
●The drive chain cannot be disas-
sembled.
7. While supporting the brake caliper bracket, pull the wheel
axle out, and then remove the
wheel.
ECA11070CAUTION:
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
EAU25080
Rear wheelEAU25311
To remove the rear wheelEWA10820
WARNING0
●It is advisable to have a Yama-
ha dealer service the wheel.
●Securely support the motorcy-
cle so that there is no danger of
it falling over.
1. Wheel axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Drive chain

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1. Wheel axle
2. Drive chain slack adjusting bolt
3. Locknut
4. Brake caliper

1. Loosen the axle nut.
2. Lift the rear wheel off the ground according to the procedure on
page 6-36.
3. Remove the axle nut.
4. Loosen the locknut on each side of the swingarm.
5. Turn the drive chain slack adjust- ing bolts fully in direction (a) and
push the wheel forward.
6. Remove the drive chain from the rear sprocket.

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a

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