2009 YAMAHA XT660Z air filter

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU20070
Coolant
The coolant level should be checked
before each ride. In addition, the
coolant must be changed at the inter-
vals specified in the periodic mainte-
nance and lubrication chart.
EAU20252
To check the coolant level 1. Place the vehicle on a level sur- face and hold it in an upright posi-
tion.
NOTE:
●The coolant level must be
checked on a cold engine since
the level varies with engine tem-
perature.
●Make sure that the vehicle is posi-
tioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.
2. Check the coolant level in the coolant reservoir.
ECA11620CAUTION:
● In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a
higher quality than specified. In
addition, do not use oils la-
beled “ENERGY CONSERVING
II” or higher.
● Make sure that no foreign ma-
terial enters the crankcase.
14. Start the engine, and then let it idle for several minutes while
checking it for oil leakage. If oil is
leaking, immediately turn the en-
gine off and check for the cause.
15. Turn the engine off, and then check the oil level and correct it if
necessary.
16. Install the engine guard by in- stalling the screws.
NOTE:
Be sure to wipe off spilled oil on any
parts after the engine and exhaust
system have cooled down.
Recommended engine oil:See page 8-1.
Oil quantity: Without oil filter element
replacement:2.50 L (2.64 US qt) (2.19 Imp.qt)
With oil filter element replacement: 2.60 L (2.73 US qt) (2.26 Imp.qt)
ECAM1060CAUTION:
The engine oil tank must be filled in
2 steps. First, fill the engine oil tank
with 1.90 L (2.0 US qt) (1.67 Imp.qt)
of the recommended engine oil.
Then, start the engine, race it 5 or 6
times, turn it off, and then add the
remainder of the engine oil.

XT660Z 04-06 ING 11-03-2008 8:31 Pagina 6-12

PERIODIC MAINTENANCE AND MINOR REPAIR
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1. Air filter element
ECA10480CAUTION: ● Make sure that the air filter ele-
ment is properly seated in the
air filter case.
● The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
5. Install the air filter case cover by installing the screws.
6. Install the seat.
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EAUB1480
Replacing the air filter
element and cleaning the
check hose
The air filter element should be re-
placed at the intervals specified in the
periodic maintenance and lubrication
chart. Replace the air filter element
more frequently if you are riding in un-
usually wet or dusty areas. In addition,
the air filter check hose must be fre-
quently checked and cleaned if neces-
sary. To replace the air filter element
1. Air filter case
2. Screws
1. Remove the seat. (See page 3-
14.)
2. Remove the air filter case cover by removing the screws.
3. Pull the air filter element out.
4. Insert a new air filter element into the air filter case as shown.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-15
To clean the air filter check hose
1. Air filter check hose
2. Check hose cap
1. Check the hose on the side of theair filter case for accumulated dirt
or water.
2. If dirt or water is visible, remove the hose, clean it, and then install
it.

EAU44730
Checking the engine idling
speed
1. Idle adjusting screw
a. Increasing the engine idling speed
b. Decreasing the engine idling speed
The engine idling speed must be
checked as follows and, if necessary,
adjusted by a Yamaha dealer at the in-
tervals specified in the periodic main-
tenance and lubrication chart.
Start the engine and warm it up for
several minutes at 1000-2000 r/min
while occasionally revving it to 4000-
5000 r/min.

Engine idling speed:1400-1600 r/min

XT660Z 04-06 ING 11-03-2008 8:31 Pagina 6-15

SPECIFICATIONS
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Engine oil:Type: SAE10W30 or SAE10W40 or SAE15W40
or SAE20W40 or SAE20W50
Recommended engine oil grade: API service SE, SF, SG type or higher
Engine oil quantity: Without oil filter element replacement:2.50 L (2.64 US qt) (2.19 Imp.qt)
With oil filter element replacement: 2.60 L (2.73 US qt) (2.26 Imp.qt)
Total amount (dry engine): 2.90 L (3.07 US qt) (2.55 Imp.qt)
Cooling system:Radiator capacity (including all routes): 1.2 L (1.26 US qt) (1.05 Imp.qt) (Radiator) +
0.5 L (0.52 US qt) (0.44 Imp.qt)
(Coolant reservoir)
Coolant reservoir capacity (up to the
maximum level mark): 0.50 L (0.52 US qt) (0.44 Imp.qt)
From low to full level: 0.30 L (0.32 US qt) (0.26 Imp.qt)
Air filter:Air filter element:Paper
Fuel:Recommended fuel:Premium unleaded gasoline only
Fuel tank capacity: 23.0 L (6.07 US gal) (5.06 Imp.gal)
Fuel reserve amount: 6.7 L (1.76 US gal) (1.46 Imp.gal)
Fuel injection:Manufacturer:DENSO
Model: 297500-0390
Spark plug:Manufacturer/model:NGK/CR7EGap:0.7-0.8 mm (0.028-0.032 in)
Clutch:Clutch type:Wet, multiple-disc
Transmission:Primary reduction system:Spur gear
Primary reduction ratio: 75/36 (2.083)
Secondary reduction system: Chain drive
Secondary reduction ratio: 45/15 (3.00)
Transmission type: Constant mesh 5-speed
Dimensions:Overall length:2246 mm (88.42 in)
Overall width: 864 mm (34.01 in)
Overall height: 1477 mm (58.14 in)
Seat height: 896 mm (35.27 in)
Wheelbase: 1500 mm (59.05 in)
Ground clearance: 260 mm (10.23 in)
Minimum turning radius: 1958 mm (77.08 in)
Basic weight:With oil and fuel:208.5 kg (459 lb)
Engine:Engine type:Liquid cooled 4-stroke, SOHC
Cylinder arrangement: Forward-inclined single cylinder
Displacement: 660.0 cm
3(40.27 cu.in)
Bore x stroke: 100.0 x 84.0 mm (3.94 x 3.31 in)
Compression ratio: 10.00 : 1
Starting system: Electric starter
Lubrication system: Dry sump
-20 -10 0 10 20 30 40 50 °C
SAE 10W-30
SAE 10W-40
SAE 20W-40
SAE 20W-50
SAE 15W-40

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INDEX
AAir filter element, cleaning the check hose....................................6-14
Air filter element, replacing ..............6-14
Anti-theft alarm (optional)...................3-8
Auxiliary light bulb, replacing............6-35
B Battery ..............................................6-30 To access the battery ...................6-30
To charge the battery....................6-30
To store the battery.......................6-31
Brake and clutch levers, checking and lubricating ...............6-26
Brake fluid ........................................6-22 Changing ......................................6-23
Checking fluid level .......................6-22
Brake lever .......................................3-11
Brake pads, checking .......................6-21
Brake pedal ......................................3-11 Lubricating ....................................6-27
C Cables, checking and lubricating .....6-25
Care and storage ...............................7-1
Catalytic converter ...........................3-13
Checking and lubricating the brake and clutch levers .................6-26
Checking and lubricating the brake pedal ...................................6-27
Checking and lubricating the cables ...........................................6-25 Checking and lubricating the
sidestand ......................................6-27
Checking and lubricating the throttle grip and cable ...................6-26
Checking the sidestand switch .........3-18
Clock mode ........................................3-7
Clutch lever ......................................3-10
Clutch lever free play, adjusting .......6-20
Consumer information ........................9-1
Controls and instruments ...................2-3
Function ..........................................3-1
Coolant .............................................6-12
Coolant temperature warning light .....3-4
D Description .........................................2-1 Controls and instrument .................2-3
Left view..........................................2-1
Right view .......................................2-2
Dimmer switch....................................3-9
Drive chain, cleaning and lubricating .....................................6-25
Drive chain slack ..............................6-23 Adjusting .......................................6-23
Checking .......................................6-23
Cleaning and lubricating ...............6-25
E Engine break-in ..................................5-3
Engine idling speed, adjusting .........6-15
Engine oil and oil filter element ..........6-9
Engine oil filter element....................6-10 Engine stop switch .............................3-9
Engine trouble warning light...............3-4
F Front fork ..........................................3-15 Adjusting .......................................3-15
Checking .......................................6-28
Front wheel ......................................6-36 Installing........................................6-37
Removing......................................6-36
Fuel ..................................................3-12
Fuel consumption, tips for reducing ...5-3
Fuel meter ..........................................3-7
Fuel tank breather hose ...................3-13
Fuel tank cap ...................................3-11
Fuses, replacing ...............................6-31
H Handlebar switches ............................3-9 Dimmer switch ................................3-9
Engine stop switch ..........................3-9
Hazard switch ...............................3-10
Horn switch .....................................3-9
Pass switch .....................................3-9
Start switch .....................................3-9
Turn signal switch ...........................3-9
Headlight bulb, replacing..................6-33
High beam indicator light ...................3-4
Horn switch ........................................3-9
I Identification numbers ........................9-1
Idling speed, checking .....................6-15

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INDEX
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Ignition circuit cut-off system............3-17 Checking operation procedure......3-18
Immobilizer system ............................3-1
Immobilizer system indicator light ......3-4
Indicator and warning lights ...............3-3 Coolant temperature warning
light .................................................3-4
Engine trouble warning light ...........3-4
High beam indicator light ................3-4
Immobilizer system indicator light...3-4
Neutral indicator light ......................3-4
Turn signal indicator light ................3-3
Instruments ........................................2-3
Instrument and control functions........3-1
K Key identification number ...................9-1
Keys ...................................................3-1
L License plate light bulb, replacing ....6-35
Lubricating the brake and clutch levers ..................................6-26
Lubricating the brake pedal..............6-27
Lubricating the cables ......................6-25
Lubricating the drive chain ...............6-25
Lubricating the sidestand .................6-27
Lubricating the throttle grip and cable .............................................6-26
Lubricating the swingarm pivots.......6-28
M Main switch/steering lock ...................3-2 Model label .........................................9-2
Multi-function display..........................3-5
Clock mode .....................................3-7
Self-diagnosis devices ....................3-7
Tachometer .....................................3-6
Tripmeter and tachometer modes ...3-6
N Neutral indicator light .........................3-4
O Oil filter element ...............................6-10
Operation and important riding points ..............................................5-1
Owner’s tool kit...................................6-1
P Panels, removing and installing .........6-6
Parking ...............................................5-4
Pass switch ........................................3-9
Periodic maintenance and lubrication chart ..............................6-2
Periodic maintenance and minor repair...............................................6-1
Pre-operation check list......................4-2
Pre-operation checks .........................4-1
R Rear suspension, lubricating............6-27
Rear wheel .......................................6-38 Installing........................................6-39
Removing......................................6-38
Record the identification numbers .....9-1 S
Safety information ..............................1-1
Seat ..................................................3-14
Self-diagnosis devices .......................3-7
Shift pedal ........................................3-10
Shifting ...............................................5-2
Shock absorber assembly (adjusting) .....................................3-16
Sidestand .........................................3-17
Sidestand, checking and lubricating .....................................6-27
Sidestand switch, checking ..............3-18
Spark plug, checking..........................6-8
Specifications .....................................8-1
Spoke wheels ...................................6-19
Start switch ........................................3-9
Starting the engine.............................5-1
Steering, checking............................6-29
Steering lock ......................................3-2
Storage...............................................7-3
Supporting the motorcycle ...............6-36
Swingarm, lubricating the pivots ......6-28
T Tachometer ........................................3-6
Tail/brake light ..................................6-34
Throttle cable free play, checking.....6-16
Throttle grip and cable, checking and lubricating ..............................6-26
Tips for reducing fuel consumption ....5-3
Tires .................................................6-16 Air pressure ..................................6-16

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