2008 YAMAHA XT660Z ESP

SAFETY INFORMATION

Loading
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit.
●Never attach any large or heavy
items to the handlebar, front fork,
or front fender. These items, in-
cluding such cargo as sleeping
bags, duffel bags, or tents, can
create unstable handling or a
slow steering response.
Accessor
ies
Genuine Yamaha accessories have
been specifically designed for use on
this motorcycle. Since Yamaha cannot
test all other accessories that may be
available, you must personally be re-
sponsible for the proper selection, in-
stallation and use of non-Yamaha ac-
cessories. Use extreme caution when
selecting and installing any acces-
sories.
Keep the following guidelines in mind,
as well as those provided under "Load-
ing" when mounting accessories.
●Never install accessories or carry
cargo that would impair the perfor-
mance of your motorcycle. Care-
fully inspect the accessory before
using it to make sure that it does
not in any way reduce ground
clearance or cornering clearance,
limit suspension travel, steering
travel or control operation, or ob-
scure lights or reflectors.
• Accessories fitted to the han- dlebar or the front fork area can
create instability due to improp-
er weight distribution or aerody-
namic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.
• Bulky or large accessories may seriously affect the stability of
the motorcycle due to aerody-
namic effects. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become
unstable in cross winds. These
accessories may also cause in-
stability when passing or being
passed by large vehicles.
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Maximum load: 190 kg (419 lb)
When loading within this weight limit,
keep the following in mind:
●Cargo and accessory weight
should be kept as low and close
to the motorcycle as possible.
Make sure to distribute the weight
as evenly as possible on both
sides of the motorcycle to mini-
mize imbalance or instability.
●Shifting weights can create a sud-
den imbalance. Make sure that
accessories and cargo are se-
curely attached to the motorcycle
before riding. Check accessory
mounts and cargo restraints fre-
quently.

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INSTRUMENT AND CONTROL FUNCTIONS
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Adjust the spring preload as follows.
To increase the spring preload and
thereby harden the suspension, turn
the adjusting ring in direction (a).
To decrease the spring preload and
thereby soften the suspension, turn
the adjusting ring in direction (b).
NOTE:
Align the appropriate notch in the ad-
justing ring with the position indicator
on the shock absorber.
EWAB0020
WARNING0
Never adjust the spring preload un-
til the exhaust system has cooled
down.

EWA10220
WARNING0
This shock absorber contains high-
ly pressurized nitrogen gas. For
proper handling, read and under-
stand the following information be-
fore handling the shock absorber.
The manufacturer cannot be held
responsible for property damage or
personal injury that may result from
improper handling.
●Do not tamper with or attempt
to open the gas cylinder.
●Do not subject the shock ab-
sorber to an open flame or oth-
er high heat sources, otherwise
it may explode due to exces-
sive gas pressure.
●Do not deform or damage the
gas cylinder in any way, as this
will result in poor damping per-
formance.
●Always have a Yamaha dealer
service the shock absorber.

EAUB1460
Adjusting the shock
absorber assembly
1. Spring preload adjusting ring
2. Position indicator
(a) Increasing the spring preload
(b) Decreasing the spring preload
This shock absorber assembly is
equipped with a spring preload adjust-
ing ring.
ECA10100CAUTION:
Never attempt to turn an adjusting
mechanism beyond the maximum
or minimum settings.

Spring preload setting: Minimum (soft):1
Standard: 2
Maximum (hard): 9

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

EWA10240
WARNING0
The vehicle must not be ridden
with the sidestand down, or if the
sidestand cannot be properly
moved up (or does not stay up),
otherwise the sidestand could con-
tact the ground and distract the
operator, resulting in a possible
loss of control. Yamaha’s ignition
circuit cut-off system has been de-
signed to assist the operator in ful-
filling the responsibility of raising
the sidestand before starting off.
Therefore, check this system regu-
larly as described below and have
a Yamaha dealer repair it if it does
not function properly.

EAU15301
Sidestand
1. Sidestand
The sidestand is located on the left
side of the frame. Raise the sidestand
or lower it with your foot while holding
the motorcycle upright.
NOTE:
The built-in sidestand switch is part of
the ignition circuit cut-off system,
which cuts the ignition in certain situa-
tions. (See further down for an expla-
nation of the ignition circuit cut-off sys-
tem.)

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INSTRUMENT AND CONTROL FUNCTIONS
3-17
EAU15312
Ignition circuit cut-off
system
The ignition circuit cut-off system
(comprising the sidestand switch,
clutch switch and neutral switch) has
the following functions.
●It prevents starting when the
transmission is in gear and the
sidestand is up, but the clutch
lever is not pulled.
●It prevents starting when the
transmission is in gear and the
clutch lever is pulled, but the side-
stand is still down.
●It cuts the running engine when
the transmission is in gear and
the sidestand is moved down.
Periodically check the operation of the
ignition circuit cut-off system accord-
ing to the following procedure.
EWA10250
WARNING0
If a malfunction is noted, have a
Yamaha dealer check the system
before riding.

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PRE-OPERATION CHECKS
4-1
EAU15593
The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpected-
ly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage
or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough vi-
sual inspection, to check the following points before each ride.
NOTE:
Pre-operation checks should be made each time the vehicle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved.
EWA11150
WARNING0
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operat-
ing the vehicle.

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OPERATION AND IMPORTANT RIDING POINTS
EAU15950
EWA10270
WARNING0
●Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.
●Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
●Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.

EAUB1570
Starting the engine
In 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.
EWA10290
WARNING0
●Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure de-
scribed on page 3-18.
●Never ride with the sidestand
down.
1. Turn the key to “ON” and make sure that the engine stop switch is
set to “
I”.

ECAB0070CAUTION:
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
●High beam indicator light
●Engine trouble warning light
●Coolant temperature warning
light
●Immobilizer system indicator
light
If a warning or indicator light does
not go off, see page 3-3 for the cor-
responding warning and indicator
light circuit check.
2. Shift the transmission into the neutral position.
NOTE:
When the transmission is in the neu-
tral position, the neutral indicator light
should be on, otherwise have a Yama-
ha dealer check the electrical circuit.
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PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU23022
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.
ECA10581CAUTION:
The drive chain must be lubricated
after washing the motorcycle and
riding in the rain.
1. Clean the drive chain with kerosene and a small soft brush.
ECA11120CAUTION:
To prevent damaging the O-rings,
do not clean the drive chain with
steam cleaners, high-pressure
washers or inappropriate solvents. 2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
ECA11110CAUTION:
Do not use engine oil or any other
lubricants for the drive chain, as
they may contain substances that
could damage the O-rings.
EAU23100
Checking and lubricating
the cables
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubri-
cated if necessary. If a cable is dam-
aged or does not move smoothly, have
a Yamaha dealer check or replace it.
Recommended lubricant: Engine oil
EWA10720
WARNING0
Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions.

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MOTORCYCLE CARE AND STORAGE
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EAU26000
Care
While the open design of a motorcycle
reveals the attractiveness of the tech-
nology, it also makes it more vulnera-
ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go un-
noticed on a car, however, it detracts
from the overall appearance of a mo-
torcycle. Frequent and proper care
does not only comply with the terms of
the warranty, but it will also keep your
motorcycle looking good, extend its
life and optimize its performance.
Before cleaning 1. Cover the muffler outlet with a plastic bag after the engine has
cooled down.
2. Make sure that all caps and cov- ers as well as all electrical cou-
plers and connectors, including
the spark plug cap, are tightly in-
stalled. 3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-
ucts onto seals, gaskets, sprock-
ets, the drive chain and wheel
axles. Always rinse the dirt and
degreaser off with water.
Cleaning
ECA10770CAUTION:
●Avoid using strong acidic
wheel cleaners, especially on
spoked wheels. If such prod-
ucts are used on hard-to-re-
move dirt, do not leave the
cleaner on the affected area
any longer than instructed. Al-
so, thoroughly rinse the area
off with water, immediately dry
it, and then apply a corrosion
protection spray.
●Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use on-
ly a soft, clean cloth or sponge
with mild detergent and water
to clean plastic.
●Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.
●Do not use high-pressure
washers or steam-jet cleaners
since they cause water seep-
age and deterioration in the fol-
lowing areas: seals (of wheel
and swingarm bearings, fork
and brakes), electric compo-
nents (couplers, connectors,
instruments, switches and
lights), breather hoses and
vents.

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