2008 YAMAHA XT660Z fuel

TABLE OF CONTENTS
SAFETY INFORMATION.....................1-1
Safe riding .........................................1-1
Protective apparel .............................1-2
Modifications .....................................1-2
Loading and accessories ..................1-2
Gasoline and exhaust gas ................1-4
DESCRIPTION .....................................2-1
Left view ............................................2-1
Right view .........................................2-2
Controls and instruments ..................2-3
INSTRUMENT AND CONTROL
FUNCTIONS ........................................3-1
Immobilizer system ...........................3-1
Main switch/steering lock ..................3-2
Indicator and warning lights ..............3-3
Multi-function display ........................3-5
Tachometer .......................................3-6
Tripmeter and tachometer modes .....3-6
Clock mode .......................................3-7
Fuel meter .........................................3-7
Self-diagnosis devices ......................3-7
Anti-theft alarm (optional) .................3-8
Handlebar switches ...........................3-9
Clutch lever .....................................3-10
Shift pedal .......................................3-10
Brake lever ......................................3-11
Brake pedal .....................................3-11 Fuel tank cap ..................................3-11
Fuel .................................................3-12
Fuel tank breather hose ..................3-13
Catalytic converter ..........................3-13
Seat .................................................3-14
Adjusting the front fork ....................3-15
Adjusting the shock absorber
assembly ..................................3-16
Sidestand ........................................3-17
Ignition circuit cut-off system ..........3-17
PRE-OPERATION CHECKS ...............4-1
Pre-operation check list ....................4-2
OPERATION AND IMPORTANT
RIDING POINTS ..................................5-1
Starting the engine............................5-1
Shifting ..............................................5-2
Tips for reducing fuel consumption ...5-3
Engine break-in .................................5-3
Parking ..............................................5-4
PERIODIC MAINTENANCE
AND MINOR REPAIR .........................6-1
Owner’s tool kit .................................6-1
Periodic maintenance and lubrication chart..........................6-2
Removing and installing the cowling and panels..................................6-8 Checking the spark plug ...................6-8
Engine oil and oil filter element.........6-9
Coolant ............................................6-12
Replacing the air filter element
and cleaning the check hose ..... 6-14
Checking the engine idling speed ...6-15
Checking the throttle cable free play ...................................6-16
Valve clearance ...............................6-16
Tires ................................................6-16
Spoke wheels..................................6-19
Adjusting the clutch lever free play ...................................6-20
Checking the front and rear brake pads ...............................6-21
Checking the brake fluid level .........6-22
Changing the brake fluid .................6-23
Drive chain slack .............................6-23
Cleaning and lubricating the drive chain ................................6-25
Checking and lubricating the cables .......................................6-25
Checking and lubricating the throttle grip and cable ..............6-26
Checking and lubricating the brake and clutch levers ............6-26
Lubricating the brake pedal ............6-27
Checking and lubricating the sidestand ..................................6-27

XT660Z 01-03 ING 10-03-2008 16:11 Pagina 6

1
2
3
4
5
6
7
8
9
10
SAFETY INFORMATION

• Certain accessories can dis-place the operator from his or
her normal riding position. This
improper position limits the
freedom of movement of the
operator and may limit control
ability, therefore, such acces-
sories are not recommended.
●Use caution when adding electri-
cal accessories. If electrical ac-
cessories exceed the capacity of
the motorcycle's electrical sys-
tem, an electric failure could re-
sult, which could cause a danger-
ous loss of lights or engine power.
Gasoline and exhaust gas
●GASOLINE IS HIGHLY FLAMMA-
BLE:
• Always turn the engine off when refueling.
• Take care not to spill any gaso- line on the engine or exhaust
system when refueling.
• Never refuel while smoking or in the vicinity of an open flame.
●Never start the engine or let it run
for any length of time in a closed
area. The exhaust fumes are poi-
sonous and may cause loss of
consciousness and death within a
short time. Always operate your
motorcycle in an area that has ad-
equate ventilation.
●Always turn the engine off before
leaving the motorcycle unattend-
ed and remove the key from the
main switch. When parking the
motorcycle, note the following:
• The engine and exhaust sys-tem may be hot, therefore, park
the motorcycle in a place where
pedestrians or children are not
likely to touch these hot areas.
• Do not park the motorcycle on a slope or soft ground, other-
wise it may fall over.
• Do not park the motorcycle near a flammable source, (e.g.,
a kerosene heater, or near an
open flame), otherwise it could
catch fire.
●When transporting the motorcycle
in another vehicle, make sure that
it is kept upright and that the fuel
cock(s) are turned to “ON” or
“RES” (for vacuum type)/”OFF”
(for manual type). If the motorcy-
cle should lean over, gasoline
may leak out of the carburetor or
fuel tank.
●If you should swallow any gaso-
line, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immediate-
ly. If any gasoline spills on your
skin or clothing, immediately
wash the affected area with soap
and water and change your
clothes.
1-4

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

DESCRIPTION
EAU10430
Controls and instruments
1. Clutch lever (page 3-10)
2. Left handlebar switches (page 3-9)
3. Multi-function meter unit and warning lights (page 3-3, 3-5)
4. Right handlebar switches (page 3-9)
5. Throttle grip (page 6-16)6. Brake lever (page 3-11)
7. Engine oil filler cap/dipstick (page 6-9)
8. Fuel tank cap (page 3-11)
9. Main switch and steering lock (page 3-2)
2-3
1
2
3
4
5
6
7
8
9
10

XT660Z 01-03 ING 10-03-2008 16:11 Pagina 14

1
2
3
4
5
6
7
8
9
10
INSTRUMENT AND CONTROL FUNCTIONS
3-5
EAUB1501
Multi-function display
1. Tachometer
2. Speedometer
3. Odometer
4. Tripmeters/Fuel reserve tripmeter
5. Clock
6. Fuel meter
7. “RESET” button
8. “SELECT” button
EWA12311
WARNING0
Be sure to stop the vehicle before
making any setting changes to the
multi-function display.
The multi-function display is equipped
with the following:
●a speedometer (which shows the
riding speed)
●a digital tachometer (which shows
engine r/min)
●an odometer (which shows the to-
tal distance traveled)
●two tripmeters (which show the
distance traveled since they were
last set to zero)
●a fuel reserve tripmeter (which
shows the distance traveled since
the bottom segment of the fuel
meter started flashing)
●a clock
●a fuel meter
●a self-diagnosis device
NOTE:
●Be sure to turn the key to "ON"
before using the "SELECT" and
"RESET" buttons.
●For the U.K. only: To switch the
speedometer and odometer/trip-
meter displays between kilome-
ters and miles, push the "SE-
LECT" and "RESET" buttons
together and turn the key to "ON".
When the digits start flashing,
push the "SELECT" button to
choose kilometers or miles.
XT660Z 01-03 ING 30-07-2008 11:43 Pagina 3-5

INSTRUMENT AND CONTROL FUNCTIONS
3-6
1
2
3
4
5
6
7
8
9
10
Tachometer
1. Tachometer
2. Red zone
The tachometer allows the rider to
monitor the engine speed and keep it
within the ideal power range.
When the key is turned to "ON", the
tachometer needle will sweep once
across the r/min range and then return
to zero r/min in order to test the elec-
trical circuit.
ECA10030CAUTION:
Do not operate the engine in the
tachometer red zone.
Red zone: 7,500 r/min and above.

Tripmeter and tachometer modes
1. “SELECT” button
2. “RESET” button
Pushing the "SELECT" button switch-
es the display between the tripmeter
modes "TRIP 1" and "TRIP 2" in the
following order:
TRIP 1
6TRIP 2 6TRIP 1
When the fuel amount in the fuel tank
decreases to 6.7 L (1.77 US gal) (1.47
Imp.gal), the bottom segment of the
fuel meter will start flashing, and the
tripmeter display will automatically
change to the fuel reserve tripmeter
mode “F-TRIP” and start counting the
distance traveled from that point. In
that case, pushing the "SELECT" but-

ton switches the display between the
various tripmeter modes in the follow-
ing order:
F-TRIP
6TRIP 1 6TRIP 2 6F-TRIP
To reset a tripmeter, select it by push-
ing the "SELECT" button, and then
push the "RESET" button for at least
four seconds. If you do not reset the
fuel reserve tripmeter manually, it will
reset itself automatically and the dis-
play will return to the prior mode after
refueling and traveling 5 km (3 mi).

XT660Z 01-03 ING 10-03-2008 16:11 Pagina 3-6

1
2
3
4
5
6
7
8
9
10
INSTRUMENT AND CONTROL FUNCTIONS
3-7
Clock mode
1. Clock
2. “SELECT” button
3. “RESET” button
NOTE:
The clock is displayed even when the
key is turned to "OFF".
T
o set the clock:
1. Push the "SELECT" button for atleast four seconds.
2. When the hour digits start flash- ing, push the "RESET" button to
set the hours.
3. Push the "SELECT" button, and the minute digits will start flashing.
4. Push the "RESET" button to set the minutes.
5. Push the "SELECT" button and then release it to start the clock.
Fuel meter
1. Fuel meter
With the key in the "ON" position, the
fuel meter indicates the amount of fuel
in the fuel tank. When the key is turned
to "ON", all of the display segments of
the fuel meter will appear one after the
other and then disappear in order to
test the electrical circuit. The display
segments of the fuel meter disappear
towards "E" (Empty) as the fuel level
decreases. When only one segment is
left near "E" (Empty), refuel as soon
as possible.
NOTE:
This fuel meter is equipped with a self-
diagnosis system. If the electrical circuit
is defective, all the segments will start
flashing. If this occurs, have a Yamaha
dealer check the electrical circuit.
Self-diagnosis devices
1. Engine trouble warning light “ U”
2. Immobilizer system indicator light “ ”
This model is equipped with a self-di-
agnosis device for various electrical
circuits.
If any of those circuits are defective,
the engine trouble warning light will
start flashing. If this occurs, have a
Yamaha dealer check the vehicle.
This model is also equipped with a
self-diagnosis device for the immobi-
lizer system.
If any of the immobilizer system cir-
cuits are defective, the immobilizer
system indicator light will start flash-
ing.
If this occurs, have a Yamaha dealer
check the vehicle.
XT660Z 01-03 ING 28-07-2008 14:13 Pagina 3-7

1
2
3
4
5
6
7
8
9
10
INSTRUMENT AND CONTROL FUNCTIONS
3-11
EAU26822
Brake lever
1. Brake lever
2. Position adjusting dial
3. Arrow mark
4. Distance
The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the han-
dlebar grip.
The brake lever is equipped with a po-
sition adjusting dial. To adjust the dis-
tance between the brake lever and the
handlebar grip, turn the adjusting dial
while holding the lever pushed away
from the handlebar grip. Make sure
that the appropriate setting on the ad-
justing dial is 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
brake, press down on the brake pedal.

1

EAU13072
Fuel tank cap
1. Lock cover
2. Open
To open the fuel tank cap
Open the fuel tank cap lock cover, in-
sert the key into the lock, and then turn
it 1/4 turn clockwise. The lock will be re-
leased and the fuel tank cap can be
opened.

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

INSTRUMENT AND CONTROL FUNCTIONS
3-12
1
2
3
4
5
6
7
8
9
10
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.
NOTE:
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 locked.
EWA11090
WARNING0
Make sure that the fuel tank cap is
properly closed before riding.

EAU13211
Fuel
1. Fuel tank filler tube
2. Fuel level
Make sure that there is sufficient fuel
in the tank. Fill the fuel tank to the bot-
tom of the filler tube as shown.
EWA10880
WARNING0
• Do not overfill the fuel tank,otherwise it may overflow when
the fuel warms up and expands.
• Avoid spilling fuel on the hot
engine.

ECA10070CAUTION:
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted sur-
faces or plastic parts.
EAU13390
Recommended fuel: PREMIUM UNLEADED
GASOLINE ONLY
Fuel tank capacity: 23.0 L (6.07 US gal) (5.05 Imp.gal)
Fuel reserve amount (when the fuel
level warning light comes on): 6.7 L (1.77 US gal) (1.47 Imp.gal)

XT660Z 01-03 ING 10-03-2008 16:11 Pagina 3-12