2009 YAMAHA XT660Z immobilizer

DECLARATION of CONFORMITY
 \b
\b\f
 

\f
\f
\f \f \f
  

General manager of quality assurance div.
1Version up the norm of EN60950 to EN60950-1
To change company name27 Feb. 2006
1 Mar. 20072
3
Revision record
No. Contents Date
To change contact person and integrate type-designation. 9 Jun. 2005
Date of issue: 1 Aug. 2002
Place of issue: Shizuoka, Japan
R&TTE Directive(1999/5/EC)
EN300 330-2 v1.1.1(2001-6), EN60950-1(2001)
Two or Three-Wheel Motor Vehicles Directive(97/24/EC: Chapter 8, EMC) is in compliance with following norm(s) or documents:
Kind of equipment: IMMOBILIZER
Type-designation: 5SL-00 Hereby declare that the product:
Company: YAMAHA MOTOR ELECTRONICS CO., LTD.
Address: 1450-6, Mori, Mori-Machi, Shuchi-gun, Shizuoka-Ken, 437-0292 JapanWe

EAU26944

XT660Z 01-03 ING 10-03-2008 16:11 Pagina 2

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

XT660Z 01-03 ING 10-03-2008 16:11 Pagina 6

1
2
3
4
5
6
7
8
9
10
3-1
INSTRUMENT AND CONTROL FUNCTIONS
EAU10973
Immobilizer system
1. Code re-registering key (red bow)
2. Standard keys (black bow)
This vehicle is equipped with an im-
mobilizer system to help prevent theft
by re-registering codes in the standard
keys. This system consists of the fol-
lowing.
●a code re-registering key (with a
red bow)
●two standard keys (with a black
bow) that can be re-registered
with new codes
●a transponder (which is installed
in the code re-registering key)
●an immobilizer unit
●an ECU

●an immobilizer system indicator
light (See page 3-3.)
The key with the red bow is used to reg-
ister codes in each standard key. Since
re-registering is a difficult process, take
the vehicle along with all three keys to a
Yamaha dealer to have them re-regis-
tered. Do not use the key with the red
bow for driving. It should only be used
for re-registering the standard keys. Al-
ways use a standard key for driving.
ECA11821CAUTION:
●DO NOT LOSE THE CODE RE-
REGISTERING KEY! CONTACT
YOUR DEALER IMMEDIATELY
IF IT IS LOST! If the code re-reg-
istering key is lost, registering
new codes in the standard keys
is impossible. The standard keys
can still be used to start the ve-
hicle, however if code re-regis-
tering is required (i.e., if a new
standard key is made or all keys
are lost) the entire immobilizer
system must be replaced.
Therefore, it is highly recom-
mended to use either standard key and keep the code re-regis-
tering key in a safe place.
●Do not submerse any key in water.
●Do not expose any key to exces-
sively high temperatures.
●Do not place any key close to
magnets (this includes, but not
limited to, products such as
speakers, etc.).
●Do not place items that transmit
electrical signals close to any key.
●Do not place heavy items on
any key.
●Do not grind any key or alter its
shape.
●Do not disassemble the plastic
part of any key.
●Do not put two keys of any immobi-
lizer system on the same key ring.
●Keep the standard keys as well
as keys of other immobilizer
systems away from this vehi-
cle's code re-registering key.
●Keep other immobilizer system
keys away from the main switch
as they may cause signal inter-
ference.

XT660Z 01-03 ING 10-03-2008 16:11 Pagina 3-1

1
2
3
4
5
6
7
8
9
10
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.

XT660Z 01-03 ING 10-03-2008 16:11 Pagina 3-3

INSTRUMENT AND CONTROL FUNCTIONS
3-4
1
2
3
4
5
6
7
8
9
10
EAUB1520
Neutral indicator light “ N”
This indicator light comes on when the
transmission is in the neutral position.
The electrical circuit of the neutral indi-
cator light can be checked by turning
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.
EAUB1530
High beam indicator light “ 1”
This indicator light comes on when the
high beam of the headlight is switched
on. The electrical circuit of the high
beam indicator light can be checked
by turning 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.
EAU11440
Coolant temperature warning
light “u ”
This warning light comes on when the
engine overheats. When this occurs,
stop the engine immediately and allow
the engine to cool. The electrical circuit of the warning
light can be checked by turning the
key to “ON”.
If the warning light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.
ECA10020
CAUTION:
Do not operate the engine if it is
overheated.
EAU11530
Engine trouble warning light “ U”
This warning light comes on or flashes
when an electrical circuit monitoring
the engine is defective. When this oc-
curs, have a Yamaha dealer check the
self-diagnosis system. (See page 3-7
for an explanation of the self-diagnosis
device.)
The electrical circuit of the warning
light can be checked by turning the
key to “ON”. If the warning light does
not come on for a few seconds, then
go off, have a Yamaha dealer check
the electrical circuit.
EAU26873
Immobilizer system indicator
light “ ”
The electrical circuit of the indicator
light can be checked by turning the
key to “ON”.
If the inidcator light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.
When the key is turned to “OFF” and
30 seconds have passed, the indicator
light will start flashing indicating the
immobilizer system is enabled. After
24 hours have passed, the indicator
light will stop flashing, however the im-
mobilizer system is still enabled.
This model is also equipped with a
self-diagnosis device for the immobi-
lizer system. (See page 3-7 for an ex-
planation of the self-diagnosis device.)

XT660Z 01-03 ING 10-03-2008 16:11 Pagina 3-4

1
2
3
4
5
6
7
8
9
10
INSTRUMENT AND CONTROL FUNCTIONS
3-7
Clock mode
1. Clock
2. “SELECT” button
3. “RESET” button
NOTE:
The clock is displayed even when the
key is turned to "OFF".
T
o set the clock:
1. Push the "SELECT" button for atleast four seconds.
2. When the hour digits start flash- ing, push the "RESET" button to
set the hours.
3. Push the "SELECT" button, and the minute digits will start flashing.
4. Push the "RESET" button to set the minutes.
5. Push the "SELECT" button and then release it to start the clock.
Fuel meter
1. Fuel meter
With the key in the "ON" position, the
fuel meter indicates the amount of fuel
in the fuel tank. When the key is turned
to "ON", all of the display segments of
the fuel meter will appear one after the
other and then disappear in order to
test the electrical circuit. The display
segments of the fuel meter disappear
towards "E" (Empty) as the fuel level
decreases. When only one segment is
left near "E" (Empty), refuel as soon
as possible.
NOTE:
This fuel meter is equipped with a self-
diagnosis system. If the electrical circuit
is defective, all the segments will start
flashing. If this occurs, have a Yamaha
dealer check the electrical circuit.
Self-diagnosis devices
1. Engine trouble warning light “ U”
2. Immobilizer system indicator light “ ”
This model is equipped with a self-di-
agnosis device for various electrical
circuits.
If any of those circuits are defective,
the engine trouble warning light will
start flashing. If this occurs, have a
Yamaha dealer check the vehicle.
This model is also equipped with a
self-diagnosis device for the immobi-
lizer system.
If any of the immobilizer system cir-
cuits are defective, the immobilizer
system indicator light will start flash-
ing.
If this occurs, have a Yamaha dealer
check the vehicle.
XT660Z 01-03 ING 28-07-2008 14:13 Pagina 3-7

INSTRUMENT AND CONTROL FUNCTIONS
3-8
1
2
3
4
5
6
7
8
9
10
NOTE:
If the indicator light slowly flashes five
times, and then quickly flashes two
times repeatedly, this error could be
caused by transponder interference. If
this occurs, try the following. 1. Use the code re-registering key to start the engine.
NOTE:
Make sure there are no other immobi-
lizer keys close to the main switch, and
do not keep more than one immobiliz-
er key on the same key ring! Immobi-
lizer system keys may cause signal in-
terference, which may prevent the
engine from starting.
2. If the engine starts, turn it off, and try starting the engine with the
standard keys.
3. If one or both of the standard keys do not start the engine, take the
vehicle, the code re-registering
key and both standard keys to a
Yamaha dealer and have the
standard keys re-registered. If the immobilizer system indicator
light continues to flash, have a Yama-
ha dealer check the vehicle.
EAU12331
Anti-theft alarm (optional)
This motorcycle can be equipped with
an optional anti-theft alarm by a Yama-
ha dealer. Contact a Yamaha dealer for
more information.
XT660Z 01-03 ING 30-07-2008 11:43 Pagina 3-8

1
2
3
4
5
6
7
8
9
10
OPERATION AND IMPORTANT RIDING POINTS
EAU15950
EWA10270
WARNING0
●Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.
●Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
●Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.

EAUB1570
Starting the engine
In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
●The transmission is in the neutral
position.
●The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EWA10290
WARNING0
●Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure de-
scribed on page 3-18.
●Never ride with the sidestand
down.
1. Turn the key to “ON” and make sure that the engine stop switch is
set to “
I”.

ECAB0070CAUTION:
The following warning lights and in-
dicator lights should come on for a
few seconds, then go off.
●Neutral indicator light
●Turn signal indicator light
●High beam indicator light
●Engine trouble warning light
●Coolant temperature warning
light
●Immobilizer system indicator
light
If a warning or indicator light does
not go off, see page 3-3 for the cor-
responding warning and indicator
light circuit check.
2. Shift the transmission into the neutral position.
NOTE:
When the transmission is in the neu-
tral position, the neutral indicator light
should be on, otherwise have a Yama-
ha dealer check the electrical circuit.
5-1

XT660Z 04-06 ING 11-03-2008 8:30 Pagina 5-1