2009 YAMAHA XT660Z maintenance

PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
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EWA10760
WARNING0
●Electrolyte is poisonous and
dangerous since it contains
sulfuric acid, which causes se-
vere burns. Avoid any contact
with skin, eyes or clothing and
always shield your eyes when
working near batteries. In case
of contact, administer the fol-
lowing FIRST AID.
• EXTERNAL: Flush with plenty
of water.
• INTERNAL: Drink large quan-
tities of water or milk and im-
mediately call a physician.
• EYES: Flush with water for 15
minutes and seek prompt
medical attention.
●Batteries produce explosive hy-
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro-
vide sufficient ventilation when
charging it in an enclosed space.
●KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
EAUB1430
Battery
This model is equipped with a sealed-
type (MF) battery, which does not re-
quire any maintenance. There is no
need to check the electrolyte or to add
distilled water.
ECA10620CAUTION:
Never attempt to remove the bat-
tery cell seals, as this would perma-
nently damage the battery.
To access the battery
Remove the battery holder bracket by
removing the bolts.
1. Positive battery terminal
2. Negative battery terminal
To charge the battery
Have a Yamaha dealer charge the bat-
tery as soon as possible if it seems to
have discharged. Keep in mind that
the battery tends to discharge more
quickly if the vehicle is equipped with
optional electrical accessories.
XT660Z 04-06 ING 31-03-2008 14:05 Pagina 6-30

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-31
To store the battery1. If the vehicle will not be used for more than one month, remove the
battery, fully charge it, and then
place it in a cool, dry place.
2. If the battery will be stored for more than two months, check it at
least once a month and fully
charge it if necessary.
3. Fully charge the battery before in- stallation.
4. After installation, make sure that the battery leads are properly
connected to the battery termi-
nals.ECA10630CAUTION:
●Always keep the battery
charged. Storing a discharged
battery can cause permanent
battery damage.
●To charge a sealed-type (MF)
battery, a special (constant-
voltage) battery charger is re-
quired. Using a conventional
battery charger will damage
the battery. If you do not have
access to a sealed-type (MF)
battery charger, have a Yamaha
dealer charge your battery.
EAUB1490
Replacing the fuses
1. Main fuse
2. Reserve fuse
XT660Z 04-06 ING 31-03-2008 14:05 Pagina 6-31

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.

7
8
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

XT660Z 04-06 ING 11-03-2008 8:31 Pagina 6-32

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-33
EAUB1580
Replacing a headlight bulb
1. Headlight bulb cover
1. Headlight coupler
2. Headlight bulb holder
3. Headlight bulb

EWA10790
WARNING0
Headlight bulbs get very hot. There-
fore, keep flammable products
away from a lit headlight bulb, and
do not touch the bulb until it has
cooled down.3. Place a new headlight bulb into position, and then secure it with
the bulb holder.
1. Do not touch this area

1. Headlight bulb holder
2. Headlight bulb
This model is equipped with quartz
bulb headlights. If a headlight bulb
burns out, replace it as follows.1. Remove the headlight bulb cover, and then disconnect the headlight
coupler.
2. Unhook the headlight bulb holder, and then remove the defective
bulb.

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
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ECA10650CAUTION:
Take care not to damage the fol-
lowing parts:
●Headlight bulb • Do not touch the glass part
of the headlight bulb to keep
it free from oil, otherwise the
transparency of the glass,
the luminosity of the bulb,
and the bulb life will be ad-
versely affected. Thoroughly
clean off any dirt and finger-
prints on the headlight bulb
using a cloth moistened with
alcohol or thinner.
●Headlight lens
• Do not affix any type of tinted
film or stickers to the head-
light lens.
• Do not use a headlight bulb
of a wattage higher than
specified.
4. Connect the coupler, and then in- stall the headlight bulb cover.
5. Have a Yamaha dealer adjust the headlight beam if necessary.
EAU24180
Tail/brake light
This model is equipped with an LED
type of tail/brake light.
If the tail/brake light does not come on,
have a Yamaha dealer check it.
EAU24202
Replacing a turn signal
light bulb
1. Screw
2. Turn signal light lens
3. Turn signal light bulb
1. Remove the turn signal light lensby removing the screw.
2. Remove the defective bulb by pushing it in and turning it coun-
terclockwise.
3. Insert a new bulb into the socket, push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the screw.

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-35
EAU42651
Replacing an auxiliary light
bulb
1. Auxiliary light socket
2. Auxiliary light bulb
This model is equipped with two auxil-
iary lights. If an auxiliary light bulb
burns out, replace it as follows.1. Remove panel G. (See page 6-7.)
2. Remove the auxiliary light socket (to- gether with the bulb) by pulling it out.
3. Remove the burnt out bulb by pulling it out.
4. Insert a new bulb into the socket.
5. Install the auxiliary light socket (together with the bulb) by push-
ing it in.
6. Install the panel.

EAUM2200
Replacing the license plate
light bulb
1. Bulb socket
2. License plate light bulb
1. Remove the socket (together with the bulb) by pulling it out.
2. Remove the defective bulb by pulling it out.
3. Insert a new bulb into the socket.
4. Install the socket (together with the bulb) by pushing it in.

ECA11190CAUTION:
Do not overtighten the screw, oth-
erwise the lens may break.

XT660Z 04-06 ING 11-03-2008 8:31 Pagina 6-35

PERIODIC MAINTENANCE AND MINOR REPAIR
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To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a mo-
torcycle stand is not available, by plac-
ing a jack either under each side of the
frame in front of the rear wheel or un-
der each side of the swingarm.EAU24360
Front wheelEAUB1440To remove the front wheel
EWA10820
WARNING0
●It is advisable to have a Yama-
ha dealer service the wheel.
●Securely support the motorcy-
cle so that there is no danger of
it falling over.
1. Wheel axle
2. Brake caliper bolts
A. Front wheel axle pinch bolt
B. Front wheel axle pinch bolt

A
2
B
1

EAU24350
Supporting the motorcycle
Since this model is not equipped with
a centerstand, follow these precau-
tions when removing the front and rear
wheel or performing other mainte-
nance requiring the motorcycle to
stand upright. Check that the motorcy-
cle is in a stable and level position be-
fore starting any maintenance. A
strong wooden box can be placed un-
der the engine for added stability.
To service the front wheel 1. Stabilize the rear of the motorcy- cle by using a motorcycle stand
or, if an additional motorcycle
stand is not available, by placing a
jack under the frame in front of the
rear wheel.
2. Raise the front wheel off the ground by using a motorcycle
stand.

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-37
1. Loosen the front wheel axle pinchbolts, the wheel axle and the
brake caliper bolts.
2. Lift the front wheel off the ground according to the procedure on
page 6-36.
3. Remove the brake caliper on each side by removing the bolts.
ECA11050CAUTION:
Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will be
forced shut.
4. Pull the wheel axle out, and then remove the wheel.
EAUB1470
To install the front wheel1. Lift the wheel up between the fork legs.
2. Insert the wheel axle.
3. Install the brake calipers by in- stalling the bolts.
NOTE:
Make sure that there is enough space
between the brake pads before in-
stalling the brake calipers onto the
brake discs.
4. Lower the front wheel so that it is on the ground.
5. Tighten the wheel axle and the brake caliper bolts to the specified
torques.
ECAB0060CAUTION:
Be sure the right brake disc is posi-
tioned exactly in the middle of the
caliper pads to prevent any brake
drag. Tap the side of the right fork
leg to position the disc correctly.
Tightening torques: Wheel axle:60 Nm (6.0 m·kgf, 44 ft·lbf)
Front wheel axle pinch bolt: 18 Nm (1.8 m·kgf, 13 ft·lbf)
Brake caliper bolt: 40 Nm (4.0 m·kgf, 29 ft·lbf)
6. Tighten wheel axle pinch bolt A, and then pinch bolt B to the spec-
ified torque.
7. Retighten pinch bolt A to the specified torque.
8. Apply the front brake several times, and then while holding the
brake lever in, push down hard on
the handlebar several times to
check for proper fork operation.

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