2012 YAMAHA XT660Z light

FOR YOUR SAFETY – PRE-OPERATION CHECKS
5-4
1
\f
3
4
5
\b
7
8
9
10
ITEM
Instruments, lights,
signals and switches
Sidestand
switch CHECKS
 Check operation.
 Correct if nece\f\fary.
 Check operation of ignition c\fircuit cut-off \fy\fte\b.\f
 If \fy\fte\b i\f not working correctly, have Ya\baha dealer check vehicle. PAGE
4-3, 4-9
4-17
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 4

OPERATION AND IMPORTANT RIDING POINTS
3. Start the engine by pushing thestart switch.
TIP
\ff the engine fails to start\b release the
start switch\b wait a few seconds\b 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 max\fmum en\b\fne l\ffe, never ac-
celerate hard when the en\b\fne \fs
cold!
TIP
The engine is warm when it quickly re-
sponds to the thrott\cle.
EAU16671
Sh\fft\fn\b
1. Shift pedal
N. Neutral position
Shifting gears lets you control the
amount of engine power available for
star ting off\b accelerating\b climbing
hills\b etc.
The gear positions are shown in the il-
lustration.
TIP
To shift the transmission into the neu-
tral position\b press the shift pedal down
repeatedly until it reaches the end of its
travel\b and then slightly raise it.
6-2
1
2
3
4
5
6
7
8
9
10
ECAB0070
NOTICE
The follow\fn\b warn\fn\b l\f\bhts and \fn-
d\fcator l\f\bhts should come on for a
few seconds, then \bo o\xff.
●Neutral \fnd\fcator l\f\b\xht
●Turn s\f\bnal \fnd\fcator l\f\bht\x
●H\f\bh beam \fnd\fcator l\f\b\xht
●En\b\fne trouble warn\fn\b l\f\bht
●Coolant temperature warn\fn\b
l\f\bht
●Immob\fl\fzer system \fnd\fcator
l\f\bht
If a warn\fn\b or \fnd\fcator l\f\bht does
not \bo off, see pa\be 4-3 for the cor-
respond\fn\b warn\fn\b and \fnd\fcator
l\f\bht c\frcu\ft check.
2. Shift the transmission into the neutral position.
TIP
When the transmission is in the neu-
tral position\b the neutral indicator light
should be on\b 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

ECA10260CAUTION:
Even with the tran\fmi\f\fion in
the neutra\b po\fition, do not
coa\ft for \bong period\f of time
with the engine off, and do not
tow the motorcyc\be for \bong
di\ftance\f. The tran\fmi\f\fion i\f
proper\by \bubricated on\by when
the engine i\f running. Inade-
quate \bubrication may damage
the tran\fmi\f\fion.
A\bway\f u\fe the c\butch whi\be
changing gear\f to avoid dam-
aging the engine, tran\fmi\f\fion,
and drive train, which are not
de\figned to with\ftand the
\fhock of forced \fhifting.
EAU16810
Tip\f for reducing fue\b
con\fumption
Fuel consum\ftion de\fends l\brgely on
your riding style. Consider the follow-
ing ti\fs to reduce f\muel consum\ftion:
Shift u\f swiftly, \bnd \bvoid high en-
gine s\feeds during \bc\mceler\btion.
Do not rev the engine while shift-
ing down, \bnd \bvoid high engine
s\feeds with no lo\bd on the en-
gine.
Turn the engine off inste\bd of let-
ting it idle for \bn extended length
of time (e.g., in tr\bffic j\bms, \bt tr\bf-
fic lights or \bt r\bil\mro\bd crossings).
EAU16841
Engine break-in
There is never \b more im\fort\bnt \feri-
od in the life of your engine th\bn the
\feriod between 0 \bnd 1600 km (1000
mi). For this re\bson, you should re\bd
the following m\bteri\m\bl c\brefully.
Since the engine is br\bnd new, do not
\fut \bn excessive lo\bd on it for the first
1600 km (1000 mi). The v\brious \f\brts
in the engine we\br \bnd \folish them-
selves to the correct o\fer\bting cle\br-
\bnces. During this \feriod, \frolonged
full-throttle o\fer\btion or \bny condition
th\bt might result in engine overhe\bting
must be \bvoided.
OPERATION AND IMPORTANT RIDING POINTS
6-3
6
03 ingles -austral\:ia 3/5/10 06:00 \:\fágina 41

1
2
3
4
5
6
7
8
9
10
PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-57-5
EAUM1890
TIP
●Replace t\fe air filte\tr ele\bent \bore frequen\ttly if you are riding in unusually wet or dusty areas.
●Hydraulic brake service
●Regularly c\feck and, if necessary, correct t\fe brake fluid level.
●Every two years replace t\fe inter\tnal co\bponents of t\fe \tbrake \baster cylinder, and c\fange t\fe brake fluid.
●Replace t\fe brake \foses every four years and if cracked or da\baged.
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
√ √ √
√ √ √ √ √
√ √ √ √ √ √ √ √ √ √ √
√ √ √ √ √
√ √ √ √ √ √ Replace.
 C\feck coolant level and ve\ficle for coolant leakage.
 C\fange.
 C\feck operation.
 Lubricate.
 C\feck operation and free play.
 Adjust t\fe t\frottle cab\tle free play if necessary.
 Lubricate t\fe t\frottle grip \fousing
and cable.
 C\feck operation.
 Adjust \feadlig\ft bea\b.\t
Engine oil filter
element
Cooling system
Front and rear brake
switches
Moving parts and
cables
Throttle grip housing
and cable
Lights, signals and
switches
Every 3 years
19
22 20
✻
21✻
24✻
23✻
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-5

PERIODIC MAINTENANCE AND ADJUSTMENT
EAU18722
Remov\fng an\b \fnstall\fng the
cowl\fng an\b panels
The cowling an\f panels shown nee\f
to \be remove\f to perform some of the
maintenance jo\bs \fescri\be\f in this
chapter. Refer to this section each
time the cowling or a panel nee\fs to
\be remove\f an\f installe\f.
EAUB1540
Panel A an\b B
1. Panel mounting \bolt
A. Right panel
B. Left panel
To remove one of the panels
Remove the \bolts, an\f then pull the
panel off at the area\as shown.
Panel C an\b D
1. Panel mounting \bolt
C. Right panel
D. Left panel
To remove one of the panels
Remove the \bolts, an\f then pull the
panel off at the area\as shown.
To install the panel
Place the panel in the original position,
an\f then install the \b\aolts.
7-6
1
2
3
4
5
6
7
8
9
10
1. Panel
2. Turn signal light coupler
3. Pin
To install the panel
Place the panel in the original position,
an\f then install the \b\aolts.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-6

PERIODIC MAINTENANCE AND ADJUSTMENT
7-8
1
2
3
4
\f
6
7
8
\b
10
2. Remove the spark pl\fg as shown\b with the spark pl\fg wrench incl\fd-
ed in the owner’s tool kit.
To check the spark plug 1. Check that the porcelain ins\flator aro\fnd the center electrode of the
spark pl\fg is a medi\fm-to-light
tan (the ideal color when the vehi-
cle is ridden normally).
TIP
If the spark pl\fg shows a distinctly dif-
ferent color\b the engine co\fld be oper-
ating improperly. Do not attempt to di-
agnose s\fch problems yo\frself.
Instead\b have a Yamaha dealer check
the vehicle.
2. Check the spark pl\fg for elec- trode erosion and excessive car-
bon or other deposits\b and re-
place it if necessa\lry.
Specified spark plu\4g:CR7E (NGK)
Spark plug gap:0.7-0.8 mm (0.028-0\l.032 in)
To install the spark plug
1. Meas\fre the spark pl\fg gap with a wire thickness ga\fge and\b if
necessar y\b adj\fst the gap to
specification.
1. Spark pl\fg gap
2. Clean the s\frface of the sparkpl\fg gasket and its mating s\fr-
face\b and then wipe off any grime
from the spark pl\fg threads.
3. Install the spark pl\fg with the spark pl\fg wrench\b and then tight-
en it to the specif\lied torq\fe.
EAU19603
Checking the spark plug
The spark pl\fg is an important engine
component\b which is easy to check.
Since heat and deposits will ca\fse
any spark pl\fg to slowly erode\b the
spark pl\fg sho\fld be removed and
checked in accordance with the peri-
odic maintenance and l\fbrication
chart. In addition\b the condition of the
spark pl\fg can reveal the condition of
the engine.
To remove the spark plug
1. Spark pl\fg cap
2. Spark pl\fg wrench
1. Remove the spark pl\fg cap.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-8

PERIODIC MAINTENANCE AND ADJUSTMENT
7-32
1
2
3
4
\f
6
7
8
\b
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 th\f k\fy to \bON” and turn on th\f \fl\fctrical circuit in qu\fstion to
ch\fck if th\f d\fvic\f op\frat\fs.
4. If th\f fus\f imm\fdiat\fly blows again, hav\f a Yamaha d\fal\fr
ch\fck th\f \fl\fctrical syst\fm.
1. Parking lighting fus\f
2. Signaling syst\fm fus\f
3. H\fadlight fus\f
4. Ignition fus\f
5. El\fctronic fu\fl inj\fction fus\f
6. Radiator fan fus\f
7. Backup fus\f
8. R\fs\frv\f fus\fs
Th\f main fus\f and fus\f box ar\f locat-
\fd und\fr th\f s\fat. (S\f\f pag\f 7-31.)
If a fus\f is blown, r\fplac\f it as follows.1. Turn th\f k\fy to \bOFF” and turn off th\f \fl\fctrical circuit in qu\fstio\hn.
2. R\fmov\f th\f blown fus\f, and th\fn install a n\fw fus\f of th\f sp\fcifi\fd
amp\frag\f.
7
8
654321Specified fuses:
Main fus\f:30 A
Parking lighting fus\f: 10 A
Signalling syst\fm fus\h\f: 10 A
H\fadlight fus\f: 20 A
Ignition fus\f: 10 A
Fu\fl inj\fction syst\fm \hfus\f: 10 A
Radiator fan fus\f: 7.5 A
Backup fus\f (for odom\ft\fr,
clock and immobiliz\fr): 10 A
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-32

1
2
3
4
5
6
7
8
9
10
PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-33
EAUB1580
Replacing a headlight bulb
1. Headli\fht b\blb cover
1. Headli\fht co\bpler
2. Headli\fht b\blb holder
3. Headli\fht b\blb
EWA10790
W\fRNING0
Headlight bulbs get very hot. There-
fore, keep flammable products
away from a lit headlight bulb, and
do not touch the bulb until it has
cooled down.3. Place a new headli\fht b\blb into position, and then sec\bre it with
the b\blb holder.
1. Do not to\bch this area
1. Headli\fht b\blb holder
2. Headli\fht b\blb
This model is eq\bipped with q\bartz
b\blb headli\fhts. If a headli\fht b\blb
b\brns o\bt, replace it a\is follows.1. Remove the headli\fht b\blb cover, and then disconnect the headli\fht
co\bpler.
2. Unhook the headli\fht b\blb holder, and then remove the defective
b\blb.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-33