2010 YAMAHA XT660Z immobilizer

TABLE OF CONTENTS
LOCATION OF IMPORTANT LABELS...1-1
SAFETY INFORMATION.....................2-1
Be a Responsible Owner ..................2-1
Safe riding .........................................2-1
Protective apparel .............................2-2
Avoid Carbon Monoxide Poisoning ...2-2
Loading .............................................2-3
Genuine Yamaha Accessories ..........2-3
Aftermarket Parts, Accessories,
and Modifications .......................2-4
Aftermarket Tires and Rims ..............2-4
DESCRIPTION.....................................3-1
Left view ............................................3-1
Right view .........................................3-2
Controls and instruments ..................3-3
INSTRUMENT AND CONTROL
FUNCTIONS........................................4-1
Immobilizer system ...........................4-1
Main switch/steering lock ..................4-2
Indicator and warning lights ..............4-3
Multi-function display ........................4-5
Tachometer .......................................4-6
Tripmeter and tachometer modes .....4-6
Clock mode .......................................4-7
Fuel meter .........................................4-7
Self-diagnosis devices ......................4-7Handlebar switches ...........................4-9
Clutch lever .....................................4-10
Shift pedal .......................................4-10
Brake lever ......................................4-11
Brake pedal .....................................4-11
Fuel tank cap ..................................4-11
Fuel .................................................4-12
Fuel tank breather hose ..................4-13
Catalytic converter ..........................4-13
Seat .................................................4-14
Adjusting the front fork ....................4-15
Adjusting the shock absorber
assembly ..................................4-16
Sidestand ........................................4-17
Ignition circuit cut-off system ..........4-17
FOR YOUR SAFETY -
PRE-OPERATION CHECKS...............5-1
Pre-operation check list ....................5-2
OPERATION AND IMPORTANT
RIDING POINTS..................................6-1
Starting the engine............................6-1
Shifting ..............................................6-2
Tips for reducing fuel consumption ...6-3
Engine break-in .................................6-3
Parking ..............................................6-4PERIODIC MAINTENANCE AND
ADJUSTMENT.....................................7-1
Owner’s tool kit .................................7-1
Periodic maintenance chart for
the emission control system.......7-2
General maintenance
and lubrication chart ..................7-3
Removing and installing
the cowling and panels ..............7-8
Checking the spark plug ...................7-8
Engine oil and oil filter element.........7-9
Coolant ............................................7-12
Replacing the air filter element
and cleaning the check hose ...7-14
Checking the engine idling speed ...7-15
Checking the throttle cable
free play ...................................7-16
Valve clearance ...............................7-16
Tires ................................................7-16
Spoke wheels..................................7-19
Adjusting the clutch lever free play...7-20
Checking the front and rear
brake pads ...............................7-21
Checking the brake fluid level .........7-22
Changing the brake fluid .................7-23
Drive chain slack .............................7-23
Cleaning and lubricating
the drive chain ..........................7-25
XT660Z 01-03 ING-AUS:AUSTRALIA 11-05-2009 9:57 Pagina 6

1
2
3
4
5
6
7
8
9
10
4-1
INSTRUMENT AND CONTROL FUNCTIONS
EAU10976
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 4-3.)
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.
ECA11821NOTICE
●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 standardkey 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 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-1

1
2
3
4
5
6
7
8
9
10
INSTRUMENT AND CONTROL FUNCTIONS
4-3
To unlock the steering
1. Push
2. Turn
Push the key into the main switch, and
then turn it to “OFF” while still pushing
it.
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”.
ECA11020NOTICE
Do not use the parking position for
an extended length of time, other-
wise the battery may discharge.
EAU11004
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 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-3

INSTRUMENT AND CONTROL FUNCTIONS
4-4
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 circuit.
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 indi-
cator light does not come on for a few
seconds, then go off, have a Yamaha
dealer check the electrical circuit.
EAU11444
Coolant temperature warning
light “u”
This warning light comes on if the en-
gine overheats. If this occurs, stop the
engine immediately and allow the en-
gine to cool. The electrical circuit of the
warning light can be checked by turn-
ing the key to "ON". The warning light
should come on for a few seconds,and then go off. If the warning light
does not come on initially when the
key is turned to "ON", or if the warning
light remains on, have a Yamaha deal-
er check the electrical circuit.
ECA10021
NOTICE
Do not continue to operate the en-
gine if it is overheating.
TIP
●For radiator-fan-equipped vehi-
cles, the radiator fan(s) automati-
cally switch on or off according to
the coolant temperature in the ra-
diator.
●If the engine overheats, see page
7-41 for further instructions.
EAU11534
Engine trouble warning light “U”
This warning light comes on or flashes
if a problem is detected in the electri-
cal circuit monitoring the engine. If this
occurs, have a Yamaha dealer check
the self-diagnosis system. (See page
4-8 for an explanation of the self-diag-
nosis device.) The electrical circuit of
the warning light can be checked byturning the key to "ON". The warning
light should come on for a few seconds,
and then go off. If the warning light does
not come on initially when the key is
turned to "ON", or if the warning light re-
mains on, have a Yamaha dealer check
the electrical circuit.
EAU26876
Immobilizer system indicator
light “ ”
The electrical circuit of the indicator
light can be checked by turning the
key to "ON". The indicator light should
come on for a few seconds, and then
go off. If the indicator light does not
come on initially when the key is
turned to "ON", or if the indicator light
remains on, have a Yamaha dealer
check the electrical circuit.
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 4-8 for an ex-
planation of the self-diagnosis device.)
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-4

INSTRUMENT AND CONTROL FUNCTIONS
4-8
1
2
3
4
5
6
7
8
9
10
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.
TIP
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.
TIP
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.
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-8

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.
6-2
1
2
3
4
5
6
7
8
9
10
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.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 6

PERIODIC MAINTENANCE AND ADJUSTMENT
7-32
1
2
3
4
5
6
7
8
9
10
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.
7
8
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
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-32

SPECIFICATIONS
9-3
1
2
3
4
5
6
7
8
9
10
Rear suspension:
Type:
Swingarm (link suspension)
Spring/damper type:
Coil spring/gas-oil damper, spring
preload adjustable
Wheel travel:
200 mm (7.87 in)
Electrical system:
Ignition system:
Transistorized coil ignition (digital)
Charging system:
A.C. magneto
Battery:
Model:
GT9B-4
Voltage, capacity:
12 V, 8 Ah
Headlight:
Bulb type:
Halogen bulb
Bulb voltage, wattage x quantity:Headlight:
12 V, 55 W x 2
Auxiliary light:
12 V, 5 W x 2
Tail/brake light:
LED
Front turn signal light:
12 V, 10 W x 2
Rear turn signal light:
12 V, 10 W x 2
Meter lighting:
LED (backlight)Neutral indicator light:
LED
Turn signal indicator light:
LED
High beam indicator light:
LED
Coolant temperature warning light:
LED
Engine trouble warning light:
LED
Immobilizer system indicator light:
LED
Fuses:Main fuse:
30 A
Headlight fuse:
20 A
Signaling system fuse:
10 A
Ignition fuse:
10 A
Parking lighting fuse:
10 A
Radiator fan fuse:
7.5 A
Fuel injection system fuse:
10 A
Backup fuse (for odometer, clock and
immobilizer):
10 A
XT660Z 08-10 ING-AUS:MY03 07-10 ING 11-05-2009 10:10 Pagina 8