2011 YAMAHA XT660Z maintenance

SAFETY INFORMATION .....................1-1
DESCRIPTION.....................................2-1
Left view ...........................................2-1
Right view .........................................2-3
Controls and instruments .................2-5
INSTRUMENT AND CONTROL
FUNCTIONS ........................................3-1
Immobilizer system ...........................3-1
Main switch/steering lock .................3-2
Indicator and warning lights .............3-4
Multi-function display .......................3-6
Anti-theft alarm (optional) .................3-9
Handlebar switches ..........................3-9
Pass switch ....................................3-10
Dimmer switch ...............................3-10
Horn switch ...................................3-10
Turn signal switch ..........................3-10
Hazard switch ................................3-10
Engine stop switch ........................3-10
Start switch ....................................3-10
Clutch lever .....................................3-11
Shift pedal.......................................3-11
Brake lever ......................................3-11
Brake pedal.....................................3-12
ABS (for ABS models) ....................3-12
Fuel tank cap ..................................3-13
Fuel .................................................3-14
Fuel tank breather/overflow
hose .............................................3-15
Catalytic converters ........................3-16Seat.................................................3-16
Adjusting the front fork ...................3-17
Adjusting the shock absorber
assembly .....................................3-18
Sidestand ........................................3-19
Ignition circuit cut-off system .........3-20
FOR YOUR SAFETY – PRE-
OPERATION CHECKS ........................4-1
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
ADJUSTMENT ....................................6-1
Owner’s tool kit .................................6-1
Periodic maintenance chart for
the emission control system .........6-3
General maintenance and
lubrication chart ............................6-4
Removing and installing panels........6-8
Checking the spark plug ..................6-9
Engine oil and oil filter element ......6-11
Coolant ...........................................6-14Replacing the air filter element
and cleaning the check hose ......6-15
Checking the engine idling speed ..6-16
Checking the throttle cable free
play ..............................................6-17
Valve clearance ...............................6-17
Tires ................................................6-17
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 ........6-21
Drive chain slack.............................6-23
Cleaning and lubricating the
drive chain ...................................6-24
Checking and lubricating the
cables ..........................................6-25
Checking and lubricating the
brake and clutch levers ...............6-25
Checking and lubricating the
brake pedal .................................6-26
Checking and lubricating the
sidestand .....................................6-26
Lubricating the rear suspension .....6-27
Lubricating the swingarm pivots ....6-27
Checking the front fork ...................6-27
Checking the steering.....................6-28
Checking the wheel bearings .........6-29
Battery ............................................6-29
Replacing the fuses ........................6-31
Replacing a headlight bulb .............6-32
TABLE OF CONTENTS
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vapor, or get some gasoline in your
eyes, see your doctor immediately.
If gasoline spills on your skin, wash
with soap and water. If gasoline
spills on your clothing, change your
clothes.
EAU49460
ECA11400
Use only unleaded gasoline. The
use of leaded gasoline will cause
severe damage to internal engine
parts, such as the valves and piston
rings, as well as to the exhaust sys-
tem.
Your Yamaha engine has been desig-
ned to use premium unleaded gasoli-ne with a research octane number of
95 or higher. If knocking (or pinging)
occurs, use a gasoline of a different
brand. Use of unleaded fuel will
extend spark plug life and reduce
maintenance costs.
EAUB1300
Fuel tank breather/overflow
hose
1. Fuel tank breather/overflow hose
2. Hose clamp
Before operating the motorcycle:
Check the fuel tank breather/over-
flow hose connection.
Check the fuel tank
breather/overflow hose for
cracks or damage, and replace it
if damaged.
Make sure that the end of the fuel
tank breather/overflow hose is
not blocked, and clean it if
necessary.
Make sure that the end of the fuel
tank breather/overflow hose is
positioned inside of the clamp.
NOTICE
Recommended fuel:
PREMIUM UNLEADED
GASOLINE ONLY
Fuel tank capacity:
23.0 L (6.08 US gal, 5.06 Imp.gal)
Fuel reserve amount:
XT660Z 6.7 L (1.76 US gal,
1.46 Imp.gal)
XT660ZA 5.8 L (1.53 US gal,
1.28 Imp.gal)
INSTRUMENT AND CONTROL FUNCTIONS
3-15
3
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EAU13445
Catalytic converters
This vehicle is equipped with catalytic
converters in the exhaust system.
EWA10862
The exhaust system is hot after
operation. To prevent a fire hazard
or burns:
Do not park the vehicle near
possible fire hazards such as
grass or other materials that
easily burn.
Park the vehicle in a place
where pedestrians or children
are not likely to touch the hot
exhaust system.
Make sure that the exhaust
system has cooled down befo-
re doing any maintenance
work.
Do not allow the engine to idle
more than a few minutes. Long
idling can cause a build-up of
heat.
ECA10701
Use only unleaded gasoline. The
use of leaded gasoline will cause
unrepairable damage to the cataly-
tic converter.
EAU13861
Seat
To remove the seat
1. Insert the key into the seat lock,
turn it counterclockwise, and
then pull the seat off.
1. Seat lock
2. Unlock
To install the seat
Insert the projections on the front of
the seat into the seat holders, push
the rear of the seat down to lock it in
place, and then remove the key.
NOTICE
WARNING
INSTRUMENT AND CONTROL FUNCTIONS
3-16
3
56P-F8199-E0 30/6/10 09:24 Página 34

FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-1
4
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the ins-
pection and maintenance procedures and schedules described in the Owner’s Manual.
EWA11151
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment dama-
ge. Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures pro-
vided in this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
WARNING
ITEM CHECKS PAGE
• Check fuel level in fuel tank.
• Refuel if necessary.
Fuel• Check fuel line for leakage. 3-14
• Check the fuel tank breather/overflow hose for obstructions, cracks or
damage, and check the hose connection.
• Check oil level in oil tank.
Engine oil• If necessary, add recommended oil to specified level. 6-11
• Check vehicle for oil leakage.
• Check coolant level in reservoir.
Coolant• If necessary, add recommended coolant to specified level. 6-14
• Check cooling system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check lever free play.
• Adjust if necessary.
Front brake• Check brake pads for wear. 6-21
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-1
6
EAU17243
Periodic inspection, adjustment, and
lubrication will keep your vehicle in
the safest and most efficient condi-
tion possible. Safety is an obligation
of the vehicle owner/operator. The
most important points of vehicle ins-
pection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance charts should be simply
considered as a general guide under
normal riding conditions. However,
depending on the weather, terrain,
geographical location, and individual
use, the maintenance intervals may
need to be shortened.
EWA10321
Failure to properly maintain the
vehicle or performing maintenance
activities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle
service, have a Yamaha dealer per-
form service.
EWA15121
Turn off the engine when perfor-
ming maintenance unless otherwi-
se specified.
A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.
Running the engine while servi-
cing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to
death. See page 1-1 for more
information about carbon
monoxide.
EWA15460
Brake discs, calipers, drums, and
linings can become very hot during
use. To avoid possible burns, let
brake components cool before tou-
ching them.
EAU17381
Owner’s tool kit
1. Owner’s tool kit
The owner’s tool kit is located under
the seat. (See page 3-16).
The service information included in
this manual and the tools provided in
the owner’s tool kit are intended to
assist you in the performance of pre-
ventive maintenance and minor
repairs. However, additional tools
such as a torque wrench may be
necessary to perform certain mainte-
nance work correctly.
WARNING
WARNING
WARNING
56P-F8199-E0 30/6/10 09:24 Página 47

TIP
If you do not have the tools or expe-
rience required for a particular job,
have a Yamaha dealer perform it for
you.
PERIODIC MAINTENANCE AND ADJUSTMENT
6-2
6
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-3
6
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
technical skills.
EAU46910
Periodic maintenance chart for the emission control system
ODOMETER READING
NO. ITEM CHECK OR MAINTENANCE JOBANNUAL
1000 km 10000 km 20000 km 30000 km 40000 kmCHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
1*Fuel line• Check fuel hoses for cracks or
damage.√√√ √√
2Spark plug• Check condition.
• Clean and regap.√√
• Replace.√√
3*Valves• Check valve clearance.
• Adjust.√√
4*Fuel injection• Adjust engine idling speed.√√ √ √ √ √
5*Mufflers and exhaust• Check the screw clamps for
pipeslooseness.√√ √ √ √
• Check the air cut-off valve, reed
6*Air induction systemvalve, and hose for damage.
√√√ √√
• Replace any damaged parts if
necessary.
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
6
EAU1770C
General maintenance and lubrication chart
ODOMETER READING
NO. ITEM CHECK OR MAINTENANCE JOBANNUAL
1000 km 10000 km 20000 km 30000 km 40000 kmCHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
1Air filter element• Replace.√√
2Clutch• Check operation.
• Adjust.√√ √ √ √
3*Front brake• Check operation, fluid level and
vehicle for fluid leakage.√√ √ √ √ √
• Replace brake pads. Whenever worn to the limit
4*Rear brake• Check operation, fluid level and
vehicle for fluid leakage.√√ √ √ √ √
• Replace brake pads. Whenever worn to the limit
5*Brake hoses• Check for cracks or damage.√√√ √√• Replace. Every 4 years
• Check runout, spoke tightness
6*Wheelsand for damage.√√ √ √ √
• Tighten spokes if necessary.
• Check tread depth and for
damage.
7*Tires• Replace if necessary.√√√ √√
• Check air pressure.
• Correct if necessary.
8*Wheel bearings• Check bearing for looseness or
damage.√√√ √
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