2012 YAMAHA XT660Z clutch

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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-3
NO. ITEMCHECK OR M\fINTEN\fNCE\M JOB
ODOMETER RE\fDING
1000 km 10000 km 20000 km 30000 km 40000 km(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
\fNN\b\fL
CHECK
√ √
√ √ √ √ √
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√
√ √ √ √ √ √
√ √ √ √ √
√ √ √ √
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√ √ √ √1
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 Replace.
 Check operatio\f.
 Adj\bst.
 Check operatio\f, fl\bid level a\fd vehicle
for fl\bid leakage.
 Replace brake pads.
 Check operatio\f, fl\bid level a\fd vehicle
for fl\bid leakage.
 Replace brake pads.
 Check for cracks or damage.
 Replace.
 Check r\b\fo\bt, spoke tight\fess a\fd for damage.
 Tighte\f spokes if \fecessary.
 Check tread depth a\fd for damage.
 Replace if \fecessar\iy.
 Check air press\bre.
 Correct if \fecessar\iy.
 Check beari\fg for loose\fess or dam\iage.
\fir filter element
Clutch
Front brake
Rear brake
Brake hoses
Wheels
Tires
Wheel bearings
EAU1770C
Ge\feral mai\fte\fa\fce a\fd l\bb\iricatio\f chart
Whe\fever wor\f to the limit
Whe\fever wor\f to the limit Every 4 years
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-3

ECAM1060CAUTION:
The engine oil tank \fust be \billed in
2 steps. First, \bill the engine oil tank
with 1.90 L (2.0 US qt) (1.67 I\fp.qt)
o\b the reco\f\fended engine oil.
Then, start the engine, race it 5 or 6
ti\fes, turn it o\b\b, and then add the
re\fainder o\b the eng\kine oil.
NOTE:
Be sure to wipe off spi\f\fed oi\f on an\b
parts after the engine and exhaust
s\bstem have coo\fed d\fown.
ECA11620CAUTION: In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
\fix any che\fical additives. Do
not use oils with a diesel speci-
\bication o\b “CD” or oils o\b a
higher quality than speci\bied. In
addition, do not use oils la-
beled “ENERGY CONSERVING
II” or higher.
Make sure that no \boreign \fa-
terial enters the c\krankcase.
14. Start the engine, and then \fet it id\fe for severa\f minutes whi\fe
checking it for oi\f \feakage. If oi\f is
\feaking, immediate\f\b turn the en-
gine off and check for the \fcause.
15. Turn the engine off, and then check the oi\f \feve\f and correct it if
necessar\b.
16. Insta\f\f the engine guard b\b in- sta\f\fing the screws.\f
EAU20070
Coolant
The coo\fant \feve\f sho\fu\fd be checked
before each ride. In addition, the
coo\fant must be changed at the inter-
va\fs specified in the periodic mainte-
nance and \fubrication \fchart.
EAU20253
To check the coolant level1. P\face the vehic\fe on a \feve\f sur- face and ho\fd it in an upright posi-
tion.
NOTE:
The coo\fant \feve\f must be
checked on a co\fd engine since
the \feve\f varies with engine tem-
perature.
Make sure that the vehic\fe is posi-
tioned straight up when checking
the coo\fant \feve\f. A s\fight ti\ft to the
side can resu\ft in a \ffa\fse reading.
2. Check the coo\fant \feve\f in the coo\fant reservoir.
Reco\f\fended engine \koil:See page 8-1.
Oil quantity: Without oi\f fi\fter e\f\fement
rep\facement:2.50 L (2.64 US qt) (2.19 I\fmp.qt)
With oi\f fi\fter e\fem\fent rep\facement: 2.60 L (2.73 US qt) (2.26 Im\fp.qt)
PERIODIC MAINTENANCE AND ADJUSTMENT
7-12
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-20
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3. To increase the cl\ftch lever free pla\b, t\frn the adj\fsting bolt in di-
rection (a). To decrease the cl\ftch
lever free pla\b, t\frn the adj\fsting
bolt in direction (\lb).
TIP
If the specified cl\ftch lever free pla\b
co\fld be obtained as described above,
skip steps 4-7.
4. F\fll\b t\frn the adj\fsting bolt at the cl\ftch lever in direction (a) to
loosen the cl\ftch ca\lble.
5. Loosen the lockn\ft at the crankcase.1. Lockn\ft
2. Cl\ftch lever free pla\b adj\fsting n\ft(crankcase)
6. To increase the cl\ftch lever free
pla\b, t\frn the adj\fsting n\ft in di-
rection (a). To decrease the cl\ftch
lever free pla\b, t\frn the adj\fsting
n\ft in direction (b)\l.
7. Tighten the lockn\ft at the crankcase.
8. Tighten the lockn\ft at the cl\ftch lever and then slide the r\fbber
cover to its original position.
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b
a
2
EAU22043
Adjusting the clutch lever
free play
1. Lockn\ft
2. Adj\fsting bolt
3. Cl\ftch lever free pla\b
The cl\ftch lever free pla\b sho\fld mea-
s\fre 10.0-15.0 mm (0.39-0.59 in) as
shown. Periodicall\b check the cl\ftch
lever free pla\b and, if necessar\b, ad-
j\fst it as follows.
1. Slide the r\fbber cover back at the cl\ftch lever.
2. Loosen the lockn\ft.
31
2
b
a
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-20

EAU23111
Checking and lubricating
the throttle grip and cable
The operation of the throttle \frip
should \be checked \before each ride.
In addition, the ca\ble should \be lu\bri-
cated at the intervals specified in the
periodic maintenance\l chart.
EAU23142
Checking and lubricating
the brake and clutch lever\f
Brake lever
Clutch leverThe operation of the \brake and clutch
levers should \be checked \before each
ride, and the lever pivots should \be lu-
\bricated if necessa\lry.
Recommended lubrican\vt\f\b
Brake lever:Silicone \frease
Clutch lever: Lithium-soap-\based \fr\lease
PERIODIC MAINTENANCE AND ADJUSTMENT
7-26
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SPECIFICATIONS
9-1
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1\f
Engin\b oil:Type: SAE10W30 or SAE10W40 or SAE15W40
or SAE\f0W40 or SAE\f0W50
Recomme\bded e\bgi\be oil grade: API service SE, SF, SG type or higher
E\bgi\be oil qua\btity: Without oil filter eleme\bt replaceme\bt:\f.50 L (\f.64 US qt) (\f.19 Imp.qt)
With oil filter eleme\bt replaceme\bt: \f.60 L (\f.73 US qt) (\f.\f6 Imp.qt)
Total amou\bt (dry e\bgi\be): \f.90 L (3.07 US qt) (\f.55 Imp.qt)
Cooling syst\bm:Radiator capacity (i\bcludi\bg all routes): 1.\f L (1.\f6 US qt) (1.05 Imp.qt) (Radiator) +
0.5 L (0.5\f US qt) (0.44 Imp.qt)
(Coola\bt reservoir)
Coola\bt reservoir capacity (up to the
maximum level mark): 0.50 L (0.5\f US qt) (0.44 Imp.qt)
From low to full level: 0.30 L (0.3\f US qt) (0.\f6 Imp.qt)
Air filt\br:Air filter eleme\bt:Paper
Fu\bl:Recomme\bded fuel:Premium u\bleaded gasoli\be o\bly
Fuel ta\bk capacity: \f3.0 L (6.07 US gal) (5.06 Imp.gal)
Fuel reserve amou\bt: 6.7 L (1.76 US gal) (1.46 Imp.gal)
Fu\bl inj\bction:Ma\bufacturer:DENSO
Model: \f97500-0390
Spark plug:Ma\bufacturer/model:NGK/CR7EGap:0.7-0.8 mm (0.0\f8-0.03\f i\b)
Clutch:Clutch type:Wet, multiple-disc
Transmission:Primary reductio\b system:Spur gear
Primary reductio\b ratio: 75/36 (\f.083)
Seco\bdary reductio\b system: Chai\b drive
Seco\bdary reductio\b ratio: 45/15 (3.00)
Tra\bsmissio\b type: Co\bsta\bt mesh 5-speed
Dim\bnsions:Overall le\bgth:\f\f46 mm (88.4\f i\b)
Overall width: 864 mm (34.01 i\b)
Overall height: 1477 mm (58.14 i\b)
Seat height: 896 mm (35.\f7 i\b)
Wheelbase: 1500 mm (59.05 i\b)
Grou\bd cleara\bce: \f60 mm (10.\f3 i\b)
Mi\bimum tur\bi\bg radius: 1958 mm (77.08 i\b)
Basic w\bight:With oil a\bd fuel:\f08.5 kg (459 lb)
Engin\b:E\bgi\be type:Liquid cooled 4-stroke, SOHC
Cyli\bder arra\bgeme\bt: Forward-i\bcli\bed si\bgle cyli\bder
Displaceme\bt: 660.0 cm
3(40.\f7 cu.i\b)
Bore x stroke: 100.0 x 84.0 mm (3.94 x 3.31 i\b)
Compressio\b ratio: 10.00 : 1
Starti\bg system: Electric starter
Lubricatio\b system: Dry sump
-\f0 -10 0 10 \f0 30 40 50 °C
SAE 10W-30
SAE 10W-40
SAE \f0W-40
SAE \f0W-50
SAE 15W-40
XT660Z 08-10 ING-AUS:MY03 07-10 ING 11-05-2009 10:10 Pagina 6

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INDEX
AAftermarket Parts, Accessories, and Modifications ...................................\f\.-4
Aftermarket Tires and \bims ...............\f-4
Air filter element, cleaning the check hose ....................................\...........7-14
Air filter element, replacing ..............7-14
Auxiliary light bulb, replacing............7-35
Avoid Carbon Monoxide poisoning ....\f-\f
B Battery ....................................\...........7-30 To access the battery ...................7-30
To charge the battery....................7-30
To store the battery.......................7-31
Be a \besponsible Owner ...................\f-1
Brake and clutch levers, checking and lubricating ..............................7-\f6\.
Brake fluid ....................................\.....7-\f\f Changing ....................................\...7-\f3
Checking fluid level .......................7-\f\f
Brake lever ....................................\....4-11
Brake pads, checking .......................7-\f1
Brake pedal ....................................\...4-11 Checking ....................................\....7-\f7
Lubricating ....................................\.7-\f7
C Cables, checking and lubricating .....7-\f5
Carbon Monoxide (avoid Carbon Monoxide poisoning).......................\f-\f
Care and storage ...............................8-1\. Catalytic converter ...........................4-13
Checking and lubricating the brake
and clutch levers ...........................7-\f6
Checking and lubricating the brake pedal ....................................\..........7-\f7
Checking and lubricating the cables..7-\f5
Checking and lubricating the sidestand ....................................\...7-\f7
Checking and lubricating the throttle grip and cable ...............................7-\f\.6
Checking the brake pedal ................7-\f7
Checking the sidestand switch .........4-18
Clock mode ....................................\.....4-7
Clutch lever ....................................\...4-10
Clutch lever free play, adjusting .......7-\f0
Consumer information ......................10-1
Controls and instruments ...................3-3 Function ....................................\.......4-1
Coolant ....................................\..........7-1\f
Coolant temperature warning light .....4-4
D Description ....................................\......3-1 Controls and instrument .................3-3
Left view....................................\.......3-1
\bight view ....................................\....3-\f
Dimmer switch....................................\.4-9
Drive chain, cleaning and lubricating ..............................7-\f5\.
Drive chain slack ..............................7-\f3\. Adjusting ....................................\....7-\f3
Checking ....................................\....7-\f3 Cleaning and lubricating ...............7-\f5
E Emission control system (periodic maintenance chart) .........................7-\f
Engine break-in ..................................6\.-3
Engine idling speed, adjusting .........7-15
Engine oil and oil filter element ..........7-9
Engine oil filter element....................7-10
Engine stop switch .............................4-9
Engine trouble warning light...............4-4
F For your safety - Pre-operation checks ....................................\..........5-1
Front fork ....................................\.......4-15 Adjusting ....................................\....4-15
Checking ....................................\....7-\f8
Front wheel ....................................\...7-36 Installing....................................\.....7-37
\bemoving....................................\...7-36
Fuel ....................................\...............4-1\f
Fuel consumption, tips for reducing ...6-3
Fuel meter ....................................\.......4-7
Fuel tank breather hose ...................4-13
Fuel tank cap ...................................4\.-11
Fuses, replacing ...............................7-3\.1
\f Genuine Yamaha Accessories ...........\f-3
H Handlebar switches ............................4-9
XT660Z 08-10 ING-AUS:MY03 07-10 ING 11-05-2009 10:10 Pagina 1

Dimmer switch ..................\o..............4-9
Engine sto\f switch..................\o........4-9
Hazar\b switch ..................\o.............4-10
Horn switch ..................\o..................\o.4-9
Pass switch ..................\o..................\o.4-9
Start switch ..................\o..................\o.4-9
Turn signal switch ..................\o.........4-9
Hea\blight bulb, re\flacing .................7\o-33
High beam in\bicator light ..................\o.4-4
Horn switch ..................\o..................\o....4-9
I I\bentification numbers ..................\o....10-1
I\bling s\fee\b, checking ..................\o...7-15
Ignition circuit cut-off system............4-17 Checking o\feration \froce\bure .....4-18
Immobilizer system ..................\o..........4-1
Immobilizer system in\bicator light ......4-4
In\bicator an\b warning lights ...............4-3\o Coolant tem\ferature warning light ..................\o..................\o.........4-4
Engine trouble warning light ...........4-4
High beam in\bicator light ................4-\o4
Immobilizer system in\bicator light ..................\o..................\o.........4-4
Neutral in\bicator light ..................\o....4-4
Turn signal in\bicator light................4-\o3
Instruments ..................\o..................\o....4-3
Instrument an\b control functions ........4-1
K Keys ..................\o..................\o...............4-1\o L
Labels (location of im\fortant labels) ..1-1
License \flate light bulb, re\flacing....7-35
Location of im\fortant labels ...............1-1\o
Loa\bing ..................\o..................\o..........2-3
Lubricating the brake an\b clutch levers ..................\o................7-\o26
Lubricating the brake \fe\bal..............7\o-27
Lubricating the cables ..................\o....7-25
Lubricating the \brive chain ...............7-2\o5
Lubricating the si\bestan\b .................7\o-27
Lubricating the throttle gri\f an\b cable ..................\o..................\o..7-26
Lubricating the swingarm \fivots.......7-28
M Main switch/steering lock ..................\o.4-2
Mo\bel label ..................\o..................\o...10-1
Motorcycle noise regulation (for Australia) ..................\o..............10-2\o
Multi-function \bis\flay..................\o........4-5 Clock mo\be ..................\o..................\o.4-7
Self-\biagnosis \bevices ..................\o..4-7
Tachometer ..................\o..................\o.4-6
Tri\fmeter an\b tachometer mo\bes ..4-6
N Neutral in\bicator light ..................\o.......4-4
O Oil filter element ..................\o.............7-10
O\feration an\b im\fortant ri\bing \foints ..................\o..................\o..........6-1 Owner’s tool kit ..................\o................7-\o1
P Panels, removing an\b installing .........7-6
Parking ..................\o..................\o...........6-4
Pass switch ..................\o..................\o....4-9
Perio\bic maintenance an\b a\bjustment ..................\o.............7-1
Perio\bic maintenance chart for the emission control system ...........7-2
Pre-o\feration check list ..................\o...5-2
Pre-o\feration checks ..................\o.......5-1
R Rear sus\fension, lubricating............7-27
Rear wheel ..................\o..................\o...7-38 Installing..................\o..................\o....7-39
Removing..................\o..................\o..7-38
Recor\b the i\bentification numbers ...10-1
S Safety information ..................\o............2-1
Seat ..................\o..................\o..............4-14\o
Self-\biagnosis \bevices ..................\o.....4-7
Shift \fe\bal ..................\o..................\o....4-10
Shifting ..................\o..................\o...........6-2
Shock absorber assembly (a\bjusting) ..................\o..................\o.4-16
Si\bestan\b ..................\o..................\o.....4-17
Si\bestan\b, checking an\b lubricating ..................\o..................\o.7-27
Si\bestan\b switch, checking ..............4-18\o
S\fark \flug, checking..................\o........7-8
INDEX
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