2009 YAMAHA XT660Z light

OPERATION AND IMPORTANT RIDING POINTS
3. Start the engine by pushing thestart switch.
NOTE:
If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any one
attempt.
ECA11040CAUTION:
For maximum engine life, never ac-
celerate hard when the engine is
cold!
NOTE:
The engine is warm when it quickly re-
sponds to the throttle.
EAU16671
Shifting
1. Shift pedal
N. Neutral position
Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing
hills, etc.
The gear positions are shown in the il-
lustration.
NOTE:
To shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.

ECA10260CAUTION:
●Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long
distances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.
●Always use the clutch while
changing gears to avoid dam-
aging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
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OPERATION AND IMPORTANT RIDING POINTS
EAU16810
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the follow-
ing tips to reduce fuel consumption:
●Shift up swiftly, and avoid high en-
gine speeds during acceleration.
●Do not rev the engine while shift-
ing down, and avoid high engine
speeds with no load on the en-
gine.
●Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at traf-
fic lights or at railroad crossings).
EAU16841
Engine break-in
There is never a more important peri-
od in the life of your engine than the
period between 0 and 1600 km (1000
mi). For this reason, you should read
the following material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts
in the engine wear and polish them-
selves to the correct operating clear-
ances. During this period, prolonged
full-throttle operation or any condition
that might result in engine overheating
must be avoided.
EAU17100
0-1000 km (0-600 mi)
Avoid prolonged operation above
4500 r/min.
1000-1600 km (600-1000 mi)
Avoid prolonged operation above
6000 r/min.
ECA10301CAUTION:
After 1000 km (600 mi) of operation,
the engine oil must be changed and
the oil filter cartridge or element re-
placed.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-56-5
NO. ITEMCHECK OR MAINTENANCE JOBODOMETER READING (x 1,000 km)
110203040
ANNUAL
CHECK
• Check the air cut-off valve, reed valve, and hose for damage.
• 5HSODFHDQ\damageGSDUWVLIQHFHVVDU\
• Check the screw clamp for looseness.
• Check operation.
• Adjust headlight beam.
Air induction system
Muffler and exhaust
pipe
Lights, signals and
switches
28
✻
29✻
30✻
EAUM1890
NOTE:
●Replace the air filter element more frequently if you are riding in unusually wet or dusty areas.
●Hydraulic brake service
●Regularly check and, if necessary, correct the brake fluid level.
●Every two years replace the internal components of the brake master cylinder, and change the brake fluid.
●Replace the brake hoses every four years and if cracked or damaged. √√√√ √
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XT660Z 04-06 ING 29-08-2008 15.20 Pagina 6-5

PERIODIC MAINTENANCE AND MINOR REPAIR
EAU18722
Removing and installing the
cowling and panels
The cowling and panels shown need
to be removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each
time the cowling or a panel needs to
be removed and installed.
EAUB1540
Panel A and B
1. Panel mounting bolt
A. Right panel
B. Left panel
To remove one of the panels
Remove the bolts, and then pull the
panel off at the areas shown.

Panel C and D
1. Panel mounting bolt
C. Right panel
D. Left panel
To remove one of the panels
Remove the bolts, and then pull the
panel off at the areas shown.
T
o install the panel
Place the panel in the original position,
and then install the bolts.

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1. Panel
2. Turn signal light coupler
3. Pin
To install the panel
Place the panel in the original position,
and then install the bolts.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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2. Remove the spark plug as shown, with the spark plug wrench includ-
ed in the owner’s tool kit.
To check the spark plug 1. Check that the porcelain insulator around the center electrode of the
spark plug is a medium-to-light
tan (the ideal color when the vehi-
cle is ridden normally).
NOTE:
If the spark plug shows a distinctly dif-
ferent color, the engine could be oper-
ating improperly. Do not attempt to di-
agnose such problems yourself.
Instead, have a Yamaha dealer check
the vehicle.
2. Check the spark plug for elec- trode erosion and excessive car-
bon or other deposits, and re-
place it if necessary.
Specified spark plug:CR7E (NGK)
Spark plug gap:0.7-0.8 mm (0.028-0.032 in)
To install the spark plug
1. Measure the spark plug gap with a wire thickness gauge and, if
necessary, adjust the gap to
specification.
1. Spark plug gap

2. Clean the surface of the sparkplug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the spark plug wrench, and then tight-
en it to the specified torque.
EAU19603
Checking the spark plug
The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause
any spark plug to slowly erode, the
spark plug should be removed and
checked in accordance with the peri-
odic maintenance and lubrication
chart. In addition, the condition of the
spark plug can reveal the condition of
the engine.
To remove the spark plug
1. Spark plug cap
2. Spark plug wrench
1. Remove the spark plug cap.

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
EAUB1560
Engine oil and oil filter
element
The engine oil level should be checked
before each ride. In addition, the oil must
be changed and the oil filter element re-
placed at the intervals specified in the
periodic maintenance and lubrication
chart.
To check the engine oil level1. Place the vehicle on a level surface and hold it in an upright position.
NOTE:
Make sure that the vehicle is posi-
tioned straight up when checking the
oil level. A slight tilt to the side can re-
sult in a false reading.
2. Start the engine, warm it up for 10-15 minutes and then turn it off.
3. Remove the oil filler cap, wipe the dipstick clean, insert it back into
the oil filler hole (without screwing
it in), and then remove it again to
check the oil level.
1. Engine oil filler cap
2. Maximum level mark
3. Minimum level mark
NOTE:
●The engine oil tank is located in-
side of the frame.
●The engine oil should be between
the minimum and maximum level
marks.

Tightening torque:Spark plug:12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)
NOTE:
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is 1/4-
1/2 turn past finger tight. However, the
spark plug should be tightened to the
specified torque as soon as possible.
4. Install the spark plug cap.

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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.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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ECA10640CAUTION:
Do not use a fuse of a higher am-
perage rating than recommended
to avoid causing extensive damage
to the electrical system and possi-
bly a fire.
3. Turn the key to “ON” and turn on the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows again, have a Yamaha dealer
check the electrical system.
1. Parking lighting fuse
2. Signaling system fuse
3. Headlight fuse
4. Ignition fuse
5. Electronic fuel injection fuse
6. Radiator fan fuse
7. Backup fuse
8. Reserve fuses
The main fuse and fuse box are locat-
ed under the seat. (See page 6-31.)
If a fuse is blown, replace it as follows.1. Turn the key to “OFF” and turn off the electrical circuit in question.
2. Remove the blown fuse, and then install a new fuse of the specified
amperage.

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654321
Specified fuses:
Main fuse:30 A
Parking lighting fuse: 10 A
Signalling system fuse: 10 A
Headlight fuse: 20 A
Ignition fuse: 10 A
Fuel injection system fuse: 10 A
Radiator fan fuse: 7.5 A
Backup fuse (for odometer,
clock and immobilizer): 10 A

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