2010 YAMAHA XT660Z light

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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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✻
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24✻
23✻
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-5

PERIODIC MAINTENANCE AND ADJUSTMENT
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.
To install the panel
Place the panel in the original position,
and then install the bolts.
7-6
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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 ADJUSTMENT
7-8
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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
7-9
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 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.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-9

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.
NOTE:
Be sure to wipe off spilled oil on any
parts after the engine and exhaust
system have cooled down.
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.
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.
EAU20253
To check the coolant level1. 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.
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)
PERIODIC MAINTENANCE AND ADJUSTMENT
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PERIODIC MAINTENANCE AND ADJUSTMENT
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ECA10640
NOTICE
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 7-31.)
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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654321Specified 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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PERIODIC MAINTENANCE AND ADJUSTMENT
7-33
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 ADJUSTMENT
7-34
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ECA10650
NOTICE
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.
EAU24204
Replacing a turn signal
light bulb
1. Screw
2. Turn signal light lens
3. Turn signal light bulb
1. Remove the turn signal light lens
by removing the screw.
2. Remove the burnt-out 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.
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