2011 YAMAHA XT660Z Owners Manual

5. Install the auxiliary light socket
(together with the bulb) by pus-
hing it in.
6. Install the panel.EAU24350
Supporting the motorcycle
Since this model is not equipped with
a centerstand, follow these precau-
tions when removing the front and
rear wheel or performing other main-
tenance requiring the motorcycle to
stand upright.
Check that the motorcycle is in a sta-
ble and level position before starting
any maintenance. A strong wooden
box can be placed under the engine
for added stability.
To service the front wheel
1. Stabilize the rear of the motorcy-
cle by using a motorcycle stand
or, if an additional motorcycle
stand is not available, by placing
a jack under the frame in front of
the rear wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a
motorcycle stand is not available, byplacing a jack either under each side
of the frame in front of the rear wheel
or under each side of the swingarm.
PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU44790
Front wheelEWA14840
For the ABS model, have a Yamaha
dealer remove and install the whe-
el.
EAUB1441
To remove the front wheelEWA10821
To avoid injury, securely support
the vehicle so there is no danger of
it falling over.
1. Loosen the front wheel axle pinch
bolts, the wheel axle and the bra-
ke caliper bolts.
1. Wheel axle
2. Brake caliper bolt
3. Front wheel axle pinch bolt
4. Front wheel axle pinch bolt
2. Lift the front wheel off the ground
according to the procedure on
page 6-35.
3. Remove the brake caliper on
each side by removing the bolts.
NOTICE: Do not apply the bra-
ke after the brake calipers have
been removed, otherwise the
brake pads will be forced shut.
[ECA11051]
4. Pull the wheel axle out, and then
remove the wheel.
EAUB1472
To install the front wheel
1. Lift the wheel up between the
fork legs.
2. Insert the wheel axle.
3. Install the brake calipers by insta-
lling the bolts.
TIP
Make sure that there is enough space
between the brake pads before insta-
lling the brake calipers onto the brake
discs.
4. Lower the front wheel so that it is
on the ground.
5. Tighten the wheel axle and the
brake caliper bolts to the speci-
fied torques.
ECAB0061
Be sure the right brake disc is posi-
tioned exactly between the brake
pads to prevent any brake drag.
Tap the side of the right fork leg to
position the disc correctly.
6. Tighten wheel axle pinch bolt A,
and then pinch bolt B to their
specified torque.
NOTICE
WARNING
WARNING
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7. Retighten pinch bolt A to the spe-
cified torque.
8. Apply the brake lever several
times, and then while holding the
brake lever in, push down hard
on the handlebar several times to
check for proper fork operation.EAU44800
Rear wheelEWA14840
For the ABS model, have a Yamaha
dealer remove and install the wheel.
EAU25314
To remove the rear wheelEWA10821
To avoid injury, securely support
the vehicle so there is no danger of
it falling over.
1. Loosen the axle nut.
1. Wheel axle nut
2. Drive chain slack adjusting bolt
3. Locknut
4. Drive chain
2. Lift the rear wheel off the ground
according to the procedure on
page 6-35.
3. Remove the axle nut.
1. Wheel axle
2. Drive chain slack adjusting bolt
3. Locknut
4. Brake caliper
4. Fully loosen the locknut on each
side of the swingarm.
5. Turn the drive chain slack adjus-
ting bolts fully in direction (a) and
push the wheel forward.
6. Remove the drive chain from the
rear sprocket.
TIP
If the drive chain is difficult to
remove, remove the wheel axle
WARNING
WARNING
Tightening torques:
Wheel axle:
60 Nm (6.0 m·kgf, 44 ft·lbf)
Front wheel axle pinch bolt:
18 Nm (1.8 m·kgf, 13 ft·lbf)
Brake caliper bolt:
40 Nm (4.0 m·kgf, 29 ft·lbf)
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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 cali-
per bracket, pull the wheel axle
out, and then remove the wheel.
NOTICE: Do not apply the bra-
ke after the wheel has been
removed together with the bra-
ke disc, otherwise the brake
pads will be forced shut.
[ECA11071]
EAUB1450
To install the rear wheel
1. Install the wheel and the brake
caliper bracket by inserting the
wheel axle from the left-hand
side.
TIP
Make sure that the slot in the bra-
ke 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
lower the rear wheel so that it is
on the ground.
4. Adjust the drive chain slack. (See
page 6-23).
5. Apply the rear brake several
times, and then tighten the axle
nut to the specified torque.EAU25871
Troubleshooting
Although Yamaha motorcycles recei-
ve a thorough inspection before ship-
ment 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 motorcy-
cle require any repair, take it to a
Yamaha dealer, whose skilled techni-
cians have the necessary tools, expe-
rience, 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.
EWA15141
When checking the fuel system, do
not smoke, and make sure there
are no open flames or sparks in the
WARNING
Tightening torque:
Axle nut:
105 Nm (10.5 m·kgf, 75 ft·lbf)
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area, including pilot lights from
water heaters or furnaces. Gasoli-
ne or gasoline vapors can ignite or
explode, causing severe injury or
property damage.
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EAU42131
Troubleshooting charts
Starting problems or poor engine performance
Check the fuel level in
the fuel tank.
1. FuelThere is enough fuel.
There is no fuel.Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.
2. CompressionThere is compression.
There is no compression.Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plug
and check the electrodes.
3. IgnitionWipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.
4. BatteryThe engine turns over
quickly.
The engine turns over
slowly.The battery is good.
Check the battery lead connections,
and charge the battery if necessary.
Dry
We tOperate the electric starter.
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Engine overheatingEWA10400
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, and then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the his-
sing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
TIP
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 OK.
The coolant level is low.
Check the cooling system
for leakage.
Have a Yamaha dealer checkand repair the cooling system.
Add coolant. (See TIP.)
Start the engine. If the engine overheats again, have a
Yamaha dealer check and repair the cooling system.
There is
leakage.
There is
no leakage.
WARNING
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EAU37833
Matte color cautionECA15192
Some models are equipped with
matte colored finished parts. Be
sure to consult a Yamaha dealer for
advice on what products to use
before cleaning the vehicle.
Using a brush, harsh chemical pro-
ducts or cleaning compounds
when cleaning these parts will
scratch or damage their surface.
Wax also should not be applied to
any matte colored finished parts.
EAU26004
Care
While the open design of a motorcy-
cle reveals the attractiveness of the
technology, it also makes it more vul-
nerable. Rust and corrosion can
develop even if high-quality compo-
nents are used. A rusty exhaust pipe
may go unnoticed on a car, however,
it detracts from the overall appearan-
ce of a motorcycle. Frequent and pro-
per care does not only comply with
the terms of the warranty, but it will
also keep your motorcycle looking
good, extend its life and optimize its
performance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and
covers as well as all electrical
couplers and connectors, inclu-
ding the spark plug cap, are
tightly installed.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and abrush, but never apply such pro-
ducts onto seals, gaskets, sproc-
kets, the drive chain and wheel
axles. Always rinse the dirt and
degreaser off with water.
Cleaning
ECA10772
Avoid using strong acidic whe-
el cleaners, especially on spo-
ked wheels. If such products
are used on hard-to-remove
dirt, do not leave the cleaner on
the affected area any longer
than instructed. Also, tho-
roughly rinse the area off with
water, immediately dry it, and
then apply a corrosion protec-
tion spray.
Improper cleaning can damage
plastic parts (such as cowlings,
panels, windshields, headlight
lenses, meter lenses, etc.) and
the mufflers. Use only a soft,
clean cloth or sponge with
water to clean plastic. Howe-
ver, if the plastic parts cannot
be thoroughly cleaned with
NOTICE
NOTICE
MOTORCYCLE CARE AND STORAGE
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