2011 YAMAHA XT660Z service

EAU10318
Be a Responsible Owner
As the vehicle’s owner, you are res-
ponsible for the safe and proper ope-
ration of your motorcycle.
Motorcycles are single-track vehicles.
Their safe use and operation are
dependent upon the use of proper
riding techniques as well as the
expertise of the operator. Every ope-
rator should know the following requi-
rements before riding this motorcycle.
He or she should:
Obtain thorough instructions
from a competent source on all
aspects of motorcycle operation.
Observe the warnings and main-
tenance requirements in this
Owner’s Manual.
Obtain qualified training in safe
and proper riding techniques.
Obtain professional technical
service as indicated in this
Owner’s Manual and/or when
made necessary by mechanical
conditions.
Safe Riding
Perform the pre-operation checkseach time you use the vehicle to
make sure it is in safe operating
condition. Failure to inspect or
maintain the vehicle properly
increases the possibility of an
accident or equipment damage.
See page 4-1 for a list of pre-ope-
ration checks.
This motorcycle is designed to
carry the operator and a passenger.
The failure of motorists to detect
and recognize motorcycles in
traffic is the predominating cause
of automobile/motorcycle acci-
dents. Many accidents have
been caused by an automobile
driver who did not see the
motorcycle. Making yourself
conspicuous appears to be very
effective in reducing the chance
of this type of accident.
Therefore:
• Wear a brightly colored jacket.
• Use extra caution when you
are approaching and passing
through intersections, since
intersections are the most
likely places for motorcycle
accidents to occur.• Ride where other motorists can
see you. Avoid riding in anot-
her motorist’s blind spot.
Many accidents involve inexpe-
rienced operators. In fact, many
operators who have been invol-
ved in accidents do not even
have a current motorcycle licen-
se.
• Make sure that you are quali-
fied and that you only lend your
motorcycle to other qualified
operators.
• Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
• We recommend that you prac-
tice riding your motorcycle
where there is no traffic until
you have become thoroughly
familiar with the motorcycle
and all of its controls.
Many accidents have been cau-
sed by error of the motorcycle
operator. A typical error made by
the operator is veering wide on a
turn due to excessive speed or
undercornering (insufficient lean
angle for the speed).
1
SAFETY INFORMATION
1-1
56P-F8199-E0 30/6/10 09:24 Página 9

EWA10221
This shock absorber assembly
contains highly pressurized nitro-
gen gas. Read and understand the
following information before hand-
ling the shock absorber assembly.
Do not tamper with or attempt
to open the cylinder assembly.
Do not subject the shock
absorber assembly to an open
flame or other high heat sour-
ce. This may cause the unit to
explode due to excessive gas
pressure.
Do not deform or damage the
cylinder in any way. Cylinder
damage will result in poor
damping performance.
Do not dispose of a damaged
or worn-out shock absorber
assembly yourself. Take the
shock absorber assembly to a
Yamaha dealer for any service.
EAU15303
Sidestand
1. Sidestand
The sidestand is located on the left
side of the frame. Raise the sidestand
or lower it with your foot while holding
the vehicle upright.
TIP
The built-in sidestand switch is part of
the ignition circuit cut-off system,
which cuts the ignition in certain
situations. (See page 3-20 for an
explanation of the ignition circuit cut-
off system.)
EWA10240
The vehicle must not be ridden with
the sidestand down, or if the sides-
tand cannot be properly moved up
(or does not stay up), otherwise the
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control. Yama-
ha’s ignition circuit cut-off system
has been designed to assist the
operator in fulfilling the responsibi-
lity of raising the sidestand before
starting off. Therefore, check this
system regularly as described
below and have a Yamaha dealer
repair it if it does not function pro-
perly.
WARNINGWARNING
INSTRUMENT AND CONTROL FUNCTIONS
3-19
3
56P-F8199-E0 30/6/10 09:24 Página 37

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

PERIODIC MAINTENANCE AND ADJUSTMENT
6-7
6
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)
27 *Lights, signals and • Check operation.
switches• Adjust headlight beam.√√ √ √ √ √
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.
56P-F8199-E0 30/6/10 09:24 Página 53

TIP
Using the alignment marks on each
side of the swingarm, make sure that
both drive chain pullers are in the
same position for proper wheel align-
ment.
3. Tighten the axle nut, then the
locknuts to their specified tor-
ques.
EAU23025
Cleaning and lubricating the
drive chain
The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly
wear out, especially when riding in
dusty or wet areas. Service the drive
chain as follows.
ECA10583
The drive chain must be lubricated
after washing the motorcycle,
riding in the rain or riding in wet
areas.
1. Clean the drive chain with kero-
sene and a small soft brush.
NOTICE: To prevent damaging
the O-rings, do not clean the
drive chain with steam clea-
ners, high-pressure washers or
inappropriate solvents.
[ECA11121]
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant. NOTICE: Do not use
engine oil or any other lubri-cants for the drive chain, as
they may contain substances
that could damage the O-rings.
[ECA11111]
NOTICETightening torques:
Axle nut:
16 Nm (1.6 m·kgf, 11 ft·lbf)
Locknut:
105 Nm (10.5 m·kgf, 75 ft·lbf)
PERIODIC MAINTENANCE AND ADJUSTMENT
6-24
6
56P-F8199-E0 30/6/10 09:24 Página 70

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
6-35
6
56P-F8199-E0 30/6/10 09:24 Página 81

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)
PERIODIC MAINTENANCE AND ADJUSTMENT
6-38
6
56P-F8199-E0 30/6/10 09:24 Página 84

Dimensions:Overall length:
XT660Z 2246 mm (88.42 in)
XT660ZA 2260 mm (89.0 in)
Overall width:
900 mm (35.4 in)
Overall height:
XT660Z 1477 mm (57.1 in)
XT660ZA 1450 mm (57.1 in)
Seat height:
XT660Z 896 mm (35.27 in)
XT660ZA 865 mm (34.1 in)
Wheelbase:
XT660Z 1500 mm (59.05 in)
XT660ZA 1505 mm (59.3 in)
Ground clearance:
XT660Z 260 mm (10.23 in)
XT660ZA 205 mm (8.07 in)
Minimum turning radius:
1980 mm (78.0 in)
Weight:With oil and fuel:
XT660Z 208.5 kg (459 lb)
XT660ZA 215 kg (474 lb)
Engine:Engine type:
Liquid cooled 4-stroke, SOHC
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
660 cm
3
Bore x stroke:
100.0 x 84.0 mm (3.94 x 3.31 in)Compression ratio:
10.00 :1
Starting system:
Electric starter
Lubrication system:
Dry sump
Engine oil:Recommended brand:
YAMALUBE
Type:
SAE 10W-30, SAE 10W-40, SAE 15W-40,
SAE 20W-40 or SAE 20W-50
Recommended engine oil grade:
API service SE, SF, SG type or higher,
JASO standard MA
Engine oil quantity:Without oil filter element replacement:
2.50 L (2.64 US qt, 2.20 Imp.qt)
With oil filter element replacement:
2.60 L (2.75 US qt, 2.29 Imp.qt)
Cooling system:Coolant reservoir capacity (up to the maxi-
mum level mark):
0.50 L (0.53 US qt, 0.44 Imp.qt)
Radiator capacity (including all routes):
1.20 L (1.26 US qt, 1.05 Imp.qt)
Air filter:Air filter element:
Dry element
Fuel: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)
Throttle body:ID mark:
5YK2 11
Manufacturer:
MIKUNI
Spark plug(s):Manufacturer/model:
NGK/CR7E
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
Clutch:Clutch type:
Wet. multiple-disc
Transmission:Primary reduction system:
Spur gear
-20 -10 0
10 20 30
40
50 ˚C
SAE 10W-30
SAE 15W-40
SAE 20W-40
SAE 20W-50
SAE 10W-40
SAE 10W-50
SPECIFICATIONS
8-1
8
56P-F8199-E0 30/6/10 09:24 Página 92