2008 YAMAHA XT660Z steering

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

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TABLE OF CONTENTS
Lubricating the rear suspension......6-27
Lubricating the swingarm pivots .....6-28
Checking the front fork ....................6-28
Checking the steering .....................6-29
Checking the wheel bearings..........6-29
Battery.............................................6-30
Replacing the fuses ........................6-31
Replacing a headlight bulb .............6-33
Tail/brake light .................................6-34
Replacing a turn signal light bulb....6-34
Replacing the license plate light bulb ...................................6-35
Replacing an auxiliary light bulb .....6-35
Supporting the motorcycle ..............6-36
Front wheel .....................................6-36
Rear wheel ......................................6-38
Troubleshooting ...............................6-39
Troubleshooting charts ....................6-40
MOTORCYCLE CARE
AND STORAGE ...................................7-1
Care ..................................................7-1
Storage..............................................7-3 SPECIFICATIONS
...............................8-1
CONSUMER INFORMATION ..............9-1
Identification numbers .......................9-1

XT660Z 01-03 ING 10-03-2008 16:11 Pagina 7

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.
1-3
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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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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
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INSTRUMENT AND CONTROL FUNCTIONS
3-2
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EAU10471
Main switch/steering lock
The main switch/steering lock controls
the ignition and lighting systems, and
is used to lock the steering.
NOTE:
Be sure to use the standard key (black
bow) for regular use of the vehicle. To
minimize the risk of losing the code re-
registering key (red bow), keep it in a
safe place and only use it for code re-
registering.

EAU10550
ON
All electrical circuits are supplied with
power, the meter lighting, taillight, li-
cense plate light and auxiliary lights
come on, and the engine can be start-
ed. The key cannot be removed.
NOTE:
The headlights comes on automatical-
ly when the engine is started and stay
on until the key is turned to “OFF”,
even if the engine stalls.
EAU10660
OFF
All electrical systems are off. The key
can be removed.
EAU10680
LOCK
The steering is locked, and all electri-
cal systems are off. The key can be re-
moved T
o lock the steering
1. Push
2. Turn
1. Turn the handlebars all the way to
the left.
2. Push the key in from the “OFF” position, and then turn it to
“LOCK” while still pushing it.
3. Remove the key.

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INSTRUMENT AND CONTROL FUNCTIONS
3-3
To unlock the steering
1. Push
2. Turn
Push the key in, and then turn it to
“OFF” while still pushing it.
EWA10060
WARNING0
Never turn the key to “OFF” or
“LOCK” while the vehicle is mov-
ing, otherwise the electrical sys-
tems will be switched off, which
may result in loss of control or an
accident. Make sure that the vehi-
cle is stopped before turning the
key to “OFF” or “LOCK”.

EAU10941
F(Parking)
The steering is locked, and the tail-
light, license plate light and auxiliary
lights are on. The hazard lights and
turn signal lights can be turned on, but
all other electrical systems are off. The
key can be removed.
The steering must be locked before
the key can be turned to “ F”.
ECA11020CAUTION:
Do not use the parking position for
an extended length of time, other-
wise the battery may discharge.
EAU11003
Indicator and warning lights
1. Immobilizer system indicator light “ ”
2. Neutral indicator light “ N”
3. Turn signal indicator light “ y”
4. High beam indicator light “ 1”
5. Engine trouble warning light “ U”
6. Coolant temperature warning light “ u”
EAUB1510
Turn signal indicator light “ y”
This indicator light flashes when the
turn signal switch is pushed to the left
or right.
The electrical circuit of the turn signal
indicator light can be checked by turn-
ing the key to "ON".
If the indicator light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUALCHECK
√√√√ √
√√√√
√√√√ √
√√√√
√√√√
√√√√√ √√√√ √
√√√√ √
√√√√√ √8✻
9✻
10✻
11✻
12✻
13
14
✻
15✻
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✻
• Check for cracks or damage.
• Replace.
• Check runout, spoke tightness and for damage.
• Tighten spokes if necessary.
• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
• Check bearing for looseness
or damage.
• Check operation and for excessive play.
• Lubricate with lithium-soap-based grease.
• Check chain slack, alignment and condition.
• Adjust and lubricate chain with a special O-ring
chain lubricant thoroughly.
• Check bearing play and steering for roughness.
• Lubricate with lithium-soap-based grease.
• Make sure that all nuts, bolts and screws are
properly tightened.
• Check operation.
• Lubricate.
• Check operation.
Every 4 years
Brake hoses
Wheels
Tires
Wheel bearings
Swingarm
Drive chain
Steering bearings
Chassis fasteners
Sidestand
Sidestand switch
Every 50000 km
Every 500 km and after washing
the motorcycle or riding in the rain
Every 20000 km

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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.

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