2009 YAMAHA XT660Z maintenance

PERIODIC MAINTENANCE AND MINOR REPAIR
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NOTE:
●If the drive chain is difficult to re-
move, remove the wheel axle first,
and then lift the wheel upward
enough to remove the drive chain
from the rear sprocket.
●The drive chain cannot be disas-
sembled.
7. While supporting the brake caliper bracket, pull the wheel
axle out, and then remove the
wheel.
ECA11070CAUTION:
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
EAU25080
Rear wheelEAU25311
To remove the rear wheelEWA10820
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 nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Drive chain

3
4
1

1. Wheel axle
2. Drive chain slack adjusting bolt
3. Locknut
4. Brake caliper

1. Loosen the axle nut.
2. Lift the rear wheel off the ground according to the procedure on
page 6-36.
3. Remove the axle nut.
4. Loosen the locknut on each side of the swingarm.
5. Turn the drive chain slack adjust- ing bolts fully in direction (a) and
push the wheel forward.
6. Remove the drive chain from the rear sprocket.

4
3
1
2
a

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PERIODIC MAINTENANCE AND MINOR REPAIR
6-39
EAUB1450
To install the rear wheel1. Install the wheel and the brake caliper bracket by inserting the
wheel axle from the right-hand
side.
NOTE:
●Make sure that the slot in the
brake caliper bracket is fit over the
retainer on the swingarm.
●Make sure that there is enough
space between the brake pads
before installing the wheel.
2. Install the drive chain onto the rear sprocket.
3. Install the axle nut, and then low- er the rear wheel so that it is on
the ground.
4. Adjust the drive chain slack. (See page 6-24.)
5. Apply the rear brake several times, and then tighten the axle
nut to the specified torque.
Tightening torque:
Axle nut:105 Nm (10.5 m·kgf, 75 ft·lbf)
EAU25870
Troubleshooting
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur
during operation. Any problem in the
fuel, compression, or ignition systems,
for example, can cause poor starting
and loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.

XT660Z 04-06 ING 11-03-2008 8:31 Pagina 6-39

PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU42130Troubleshooting charts
Starting problems or poor engine performanceEWA10840
WARNING0
Keep away open flames and do not smoke while checking or working on the \
fuel system.

1. Fuel
2. Compression
3. Ignition
4. Battery
Check the fuel level in the
fuel tank.
Operate the electric
starter.
Remove the spark plug
and check the electrodes.
Operate the electric
starter.
There is enough
fuel.
There is
compression.
Wet.
The engine turns
over quickly.
There is no fuel.
There is no
compression.
Dry.
The engine turns
over slowly.
Check the
compression.
Check the ignition.
Wipe off with a dry cloth and correct
the spark plug gap, or replace the
spark plug.
The battery is good.
Have a Yamaha dealer check the
vehicle.
Check the battery lead connections,
and charge the battery if necessary.
Open the throttle halfway and
operate the electric starter.
The engine does not start.
Check the battery.
The engine does
not start. Have a
Yamaha dealer
check the vehicle.
Supply fuel.
Have a Yamaha dealer check
the vehicle.
The engine does not start.
Check the compression.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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Engine overheatingEWA10400
WARNING0
●Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.
●After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, a\
nd then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hiss-
ing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.

NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended
coolant as soon as possible.
Wait until the
engine has cooled.Check the coolant level
in the reservoir and radiator.
The coolant level is low.
Check the cooling
system for leakage.
The coolant level
is OK.
There is
leakage.
There is no
leakage.
Have a Yamaha dealer check
and repair the cooling system.
Start the engine. If the engine overheats again, have
a Yamaha dealer check and repair the cooling system.
Add coolant. (See NOTE.)

XT660Z 04-06 ING 11-03-2008 8:31 Pagina 6-41

INDEX
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3
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6
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9
10
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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