2010 YAMAHA XT660Z check engine

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OPERATION AND IMPORTANT RIDING POINTS
EAU15951
Read the Owner's Manual carefully to
become familiar with all controls. If
there is a control or function you do not
understand, ask your Yamaha dealer.
EWA10271
WARNING0
Failure to familiarize yourself with
the controls can lead to loss of con-
trol, which could cause an accident
or injury.
6-1
EAU48020
TIP
This model is equipped with a lean an-
gle sensor to stop the engine in case
of a turnover. In this case, the multi-
function display indicates error code
30, but this is not a malfunction. Turn
the key to "OFF" and then to "ON" to
clear the error code. Failing to do so
will prevent the engine from starting
even though the engine will crank
when pushing the start switch.
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 4-18.
●Never ride with the sidestand
down.
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “
I”.
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OPERATION AND IMPORTANT RIDING POINTS
3. Start the engine by pushing the
start switch.
TIP
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.
ECA11040
NOTICE
For maximum engine life, never ac-
celerate hard when the engine is
cold!
TIP
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.
TIP
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.
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ECAB0070
NOTICE
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 4-3 for the cor-
responding warning and indicator
light circuit check.
2. Shift the transmission into the
neutral position.
TIP
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.
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EAU17101
0-1000 km (0-600 mi)
Avoid prolonged operation above
4500 r/min. NOTICE: After 1000 km
(600 mi) of operation, the engine oil
must be changed, and the oil filter
element replaced.
1000-1600 km (600-1000 mi)
Avoid prolonged operation above
6000 r/min.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.
ECA10310NOTICE
Keep the engine speed out of
the tachometer red zone.
If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the
vehicle.
EAU17213
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EWA10311
WARNING0
Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them and be burned.
Do not park on a slope or on
soft ground, otherwise the ve-
hicle may overturn, increasing
the risk of a fuel leak and fire.
Do not park near grass or other
flammable materials which
might catch fire.
OPERATION AND IMPORTANT RIDING POINTS
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PERIODIC MAINTENANCE AND ADJUSTMENT
EAU46861
TIP
●The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
mileage-based maintenance, is performed instead.
●From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
●Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and tech-
nical skills.
EAU46910Periodic maintenance chart for the emission control system
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NO. ITEM CHECK OR MAINTENANCE JOB
ODOMETER READING
1000 km 10000 km 20000 km 30000 km 40000 km(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
ANNUAL
CHECK
√√ √√ √
√√
√√
√√
√√√ √√ √
√√√ √√
√√ √√ √1✻
2
3
✻
4✻
5✻
6✻
Check fuel hoses for cracks or damage.
Check condition.
Clean and regap.
Replace.
Check valve clearance.
Adjust.
Adjust engine idling speed.
Check the screw clamp(s) for
looseness.
Check the air cut-off valve, reed valve,
and hose for damage.
Replace any damaged parts if necessary. Fuel line
Spark plug
Valves
Fuel injection
Muffler and exhaust
pipe
Air induction system
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-4
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NO. ITEM CHECK OR MAINTENANCE JOB
ODOMETER READING
1000 km 10000 km 20000 km 30000 km 40000 km(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
ANNUAL
CHECK
√√ √√
√√√ √√
√√
√√
√
√√ √√ √
√√√ √√ √
√√ √√
√√ √√
√√ √√
√√
√√√ √√ √
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14
✻
15✻
16✻
18
Check operation and for excessive play.
Lubricate with lithium-soap-based grease.
Check chain slack, alignment and condition.
Adjust and lubricate chain with a special
O-ring chain lubricant thoroughly.
Check bearing play and steering
for roughness.
Lubricate with lithium-soap-based grease.
Make sure that all nuts, bolts and screws
are properly tightened.
Check operation.
Lubricate.
Check operation.
Check operation and for oil leakage.
Check operation and shock absorber
for oil leakage.
Check operation.
Lubricate with lithium-soap-based grease.
Change.
Check oil level and vehicle for oil leakage. Swingarm
Drive chain
Steering bearings
Chassis fasteners
Sidestand
Sidestand switch
Front fork
Shock absorber
assembly
Rear suspension
relay arm and
connecting arm
pivoting points
Engine oil
Every 50000 km (30000 mi) Every 50000 km (30000 mi)
Every 500 km (300 mi) and after
washing the motorcycle or riding
in the rain
9✻
11✻
17✻
12✻
10
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-57-5
EAUM1890
TIP
●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.
NO. ITEM CHECK OR MAINTENANCE JOB
ODOMETER READING
1000 km 10000 km 20000 km 30000 km 40000 km(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
ANNUAL
CHECK
√√ √
√√ √√ √
√√√ √√ √
√√ √√ √
√√ √√ √
√√√ √√ √ Replace.
Check coolant level and vehicle for coolant leakage.
Change.
Check operation.
Lubricate.
Check operation and free play.
Adjust the throttle cable free play
if necessary.
Lubricate the throttle grip housing
and cable.
Check operation.
Adjust headlight beam. Engine oil filter
element
Cooling system
Front and rear brake
switches
Moving parts and
cables
Throttle grip housing
and cable
Lights, signals and
switches
Every 3 years
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22 20
✻
21✻
24✻
23✻
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PERIODIC MAINTENANCE AND ADJUSTMENT
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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).
TIP
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 spark
plug 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 ADJUSTMENT
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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 level
1. Place the vehicle on a level surface
and hold it in an upright position.
TIP
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
TIP
●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)
TIP
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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