2012 YAMAHA XT660Z brake

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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-37
1. Loosen the front wheel axle \finchbolts\b the wheel axle and the
brake cali\fer bolts.
2. Lift the front wheel off the ground according to the \frocedure on
\fage 7-36.
3. Remove the brake cali\fer on each side by removing the bolts.
ECA11050
NOTICE
Do not apply the brake after the
brake calipers have been removed,
otherwise the brake pads will be
forced shut.
4. Pull the wheel axle out\b and then remove the wheel.
EAUB1470
To install the front wheel1. Lift the wheel u\f between the fork legs.
2. Insert the wheel axle.
3. Install the brake cali\fers by in- stalling the bolts.
TIP
Make sure that there is enough s\face
between the brake \fads before in-
stalling the brake cali\fers onto the
brake discs.
4. Lower the front wheel so that it is on the ground.
5. Tighten the wheel axle and the brake cali\fer bolts to the s\fecified
torques.
ECAB0060
NOTICE
Be sure the right brake disc is posi-
tioned exactly in the middle of the
caliper pads to prevent any brake
drag. Tap the side of the right fork
leg to position th\Me disc correctly.
Tightening torques: Wheel axle:60 Nm (6.0 m·kgf\b 44 ft·lbf)
Front wheel axle \fin\xch bolt: 18 Nm (1.8 m·kgf\b 13 ft·lbf)
Brake cali\fer bolt: 40 Nm (4.0 m·kgf\b 29 ft·lbf)
6. Tighten wheel axle \finch bolt A\b and then \finch bolt B to the s\fec-
ified torque.
7. Retighten \finch bolt A to the s\fecified torque.
8. A\f\fly the front brake several times\b and then while holding the
brake lever in\b \fush down hard on
the handlebar several times to
check for \fro\fer fork o\feration.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-37

PERIODIC MAINTENANCE AND ADJUSTMENT
7-38
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TIP
●If the drive chain is difficu\ft to re-
move, remove the \bhee\f ax\fe first,
and then \fift the \bhee\f up\bard
enough to remove the drive chain
from the rear sprocket.
●The drive chain cannot be disas-
semb\fed.
7. Whi\fe suppor ting the brake ca\fiper bracket, pu\f\f the \bhee\f
ax\fe out, and then remove the
\bhee\f. NOTICE: Do not apply
the brake after the wheel has
been removed together with
the brake disc, otherwise the
brake pads will be\4 forced shut.
EAUB1450
To install the rear wheel 1. Insta\f\f the \bhee\f and the brake ca\fiper bracket by inserting the
\bhee\f ax\fe from the right-hand
side.
EAU25080
Rear wheelEAU25312
To remove the rear wheelEWA10821
WARNING0
To avoid injury, securely support
the vehicle so there is no danger of
it falling over.
1. Whee\f ax\fe nut
2. Drive chain s\fack adjusting bo\ft
3. Locknut
4. Drive chain
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1
1. Whee\f ax\fe
2. Drive chain s\fack adjusting bo\ft
3. Locknut
4. Brake ca\fiper
1. Loosen the ax\fe nut.
2. Lift the rear \bhee\f off the groundaccording to the procedure on
page 7-36.
3. Remove the ax\fe nut.
4. Loosen the \focknut on each side of the s\bingarm.
5. Turn the drive chain s\fack adjust- ing bo\fts fu\f\fy in direction (a) and
push the \bhee\f for\bard.
6. Remove the drive chain from the rear sprocket.
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3
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a
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-38

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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-39
TIP
●Make sure that the slot in the
brake \faliper bra\fket is fit over the
retainer on the s\bingarm.
●Make sure that there is enough
spa\fe bet\been the brake pads
before installing the\b \bheel.
2. Install the drive \fhain onto the rear spro\fket.
3. Install the axle nut, and then lo\b- er the rear \bheel so that it is on
the ground.
4. Adjust the drive \fhain sla\fk. (See page 7-24.)
5. Apply the rear brake several times, and then tighten the axle
nut to the spe\fified\b torque.
Tightening torque:
Axle nut:105 Nm (10.5 m·kgf, 75 ft·lbf)
EAU25871
Troubleshooting
Although Yamaha motor\fy\fles re\feive
a thorough inspe\ftion before shipment
from the fa\ftory, trouble may o\f\fur
during operation. Any problem in the
fuel, \fompression, or ignition systems,
for example, \fan \fause poor starting
and loss of po\ber.
The follo\bing troubleshooting \fharts
represent qui\fk and easy pro\fedures
for \fhe\fking these vital systems your-
self. Ho\bever, should your motor\fy\fle
require any repair, take it to a Yamaha
dealer, \bhose skilled te\fhni\fians have
the ne\fessary tools, experien\fe, and
kno\b-ho\b to servi\fe the motor\fy\fle
properly.
Use only genuine Yamaha repla\fe-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter servi\fe life and
\fan lead to expensive repair bills.
EWA15141
W\fRNING0
When checking the fuel system, do
not smoke, and make sure there
are no open flames or sparks in the
area, including pilot lights from wa-
ter heaters or furnaces. Gasoline or
gasoline vapors can ignite or ex-
plode, causing severe injury or
property damage.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-39

MOTORCYCLE CARE AND STORAGE
8-1
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EAU26004
Care
While the ope\f desig\f o\b a motorcycle
reveals the attractive\fess o\b the tech-
\fology, it also makes it more vul\fera-
ble. Rust a\fd corrosio\f ca\f develop
eve\f i\b high-quality compo\fe\fts are
used. A rusty exhaust pipe may go u\f-
\foticed o\f a car, however, it detracts
\brom the overall appeara\fce o\b a mo-
torcycle. Freque\ft a\fd proper care
does \fot o\fly comply with the terms o\b
the warra\fty, but it will also keep your
motorcycle looki\fg good, exte\fd its
li\be a\fd optimize its per\borma\fce.
Before cleaning 1. Cover the mu\b\bler outlet with a plastic bag a\bter the e\fgi\fe has
cooled dow\f.
2. Make sure that all caps a\fd cov- ers as well as all electrical cou-
plers a\fd co\f\fectors, i\fcludi\fg
the spark plug cap, are tightly i\f-
stalled. 3. Remove extremely stubbor\f dirt,
like oil bur\ft o\fto the cra\fkcase,
with a degreasi\fg age\ft a\fd a
brush, but \fever apply such prod-
ucts o\fto seals, gaskets, sprockets,
the drive chai\f a\fd wheel axles. Al-
ways ri\fse the dirt a\fd degreaser
o\b\b with water.
Cleaning
ECA10772
NOTICE
●Avoid using strong acidic
wheel cleaners, especially on
spoked wheels. If such prod-
ucts are used on hard-to-re-
move dirt, do not leave the
cleaner on the affected area
any longer than instructed. Al-
so, thoroughly rinse the area
off with water, immediately dry
it, and then apply a corrosion
protection 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 wa- ter to clean plastic. However, if
the plastic parts cannot be
thoroughly cleaned with water,
diluted mild detergent with wa-
ter may be used. Be sure to
rinse off any detergent residue
using plenty of water, as it is
harmful to plastic p\5arts.
●Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.
●Do not use high-pressure
washers or steam-jet cleaners
since they cause water seep-
age and deterioration in the fol-
lowing areas: seals (of wheel
and swingarm bearings, fork
and brakes), electric compo-
nents (couplers, connectors,
instruments, switches and
lights), breather hoses and
vents.
XT660Z 08-10 ING-AUS:MY03 07-10 ING 11-05-2009 10:10 Pagina 2

MOTORCYCLE CARE AND STORAGE
8-3
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8. Let the motorcycle dry completely before \ftoring or co\bering it.
EWA11131
WARNING0
Contaminants on the brakes or
tires can cause loss \5of control.
●Make sure that there is no oil or
wax on the brakes \5or tires.
●If necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or
acetone, and wash the tires
with warm water and a mild de-
tergent. Before riding at higher
speeds, test the motorcycle's
braking performance and cor-
nering behavior.
ECA10800
NOTICE
●Apply spray oil and wax spar-
ingly and make sure to wipe off
any excess
●Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
●Avoid using abrasive polishing
compounds as they will wear
away the paint.
TIP
●Con\fult a Yamaha dealer for ad-
\bice on what product\f\f to u\fe.
●Wa\fhing, rainy weather or humid
climate\f can cau\fe the headlight
len\f to fog. Turning the headlight
on for a \fhort period of time will
help remo\be the moi\fture from
the len\f.
EAUM1901
Storage
Short-term
Alway\f \ftore your motorcycle in a cool,
dry place and, if nece\f\fary, protect it
again\ft du\ft with a porou\f co\ber.
ECA10810
NOTICE
●Storing the motorcycle in a
poorly ventilated room or cov-
ering it with a tarp, while it is
still wet, will allow water and
humidity to seep in and cause
rust.
●To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.
XT660Z 08-10 ING-AUS:MY03 07-10 ING 11-05-2009 10:10 Pagina 4

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SPECIFICATIO\fS
9-2
Operation:Left foot operation
Gear ratio: 1
st:\f0/12 (2\b500)
2
nd:
26/16 (1\b625)
\f
rd: 2\f/20 (1\b150)
4
th: 20/22 (0\b909)
5
th: 20/26 (0\b769)
Chass\bs:
Frame type:
Diamond
Caster angle: 28°
Trail: 11\f\b0 mm (4\b44 in)
Front t\bre:
Type:With tube
Size: 90/90-21M/C 54S,
90/90-21M/C 54T
Manufacturer/model: METZELER/TOURANCE FRONT
MICHELIN/SIRAC
Rear t\bre:
Type:With tube
Size: 1\f0/80-17M/C 65S,
1\f0/80-17M/C 65T Manufacturer/model:
METZELER/TOURANCE
MICHELIN/SIRAC A
Load:
Maximum load:190 kg (419 lb)
(Total weight of rider, passenger, cargo
and accessories)
T\bre a\br pressure
(measured on cold t\bres):
Load:Up to 90 kg (0-198 lb)
Front: 210 kPa (\f0 psi) (2\b1 kgf/cm
2)
Rear: 2\f0 kPa (\f\f psi) (2\b\f kgf/cm
2)
Load: 90-190 kg (198-419 lb)
Front: 2\f0 kPa (\f\f psi) (2\b\f kgf/cm
2)
Rear: 250 kPa (\f6 psi) (2\b5 kgf/cm
2)
Off-road riding:
Front: 200 kPa (29 psi) (2\b0 kgf/cm
2)
Rear: 200 kPa (29 psi) (2\b0 kgf/cm
2)
High-speed riding:
Front: 210 kPa (\f0 psi) (2\b1 kgf/cm
2)
Rear: 2\f0 kPa (\f\f psi) (2\b\f kgf/cm
2)
Front wheel:
Type:
Spoke wheel
Rim size: 21 x 1\b85
Rear wheel:
Type:Spoke wheel
Rim size: 17M/C x MT2\b75
Front brake:
Type:Dual disc brake
Operation: Right hand
Fluid: DOT 4
Rear brake:
Type:Single disc brake
Operation: Right foot
Fluid: DOT 4
Front suspens\bon:
Type:Telescopic fork
Spring/damper type: Coil spring/oil damper
Wheel travel: 210 mm (8\b26 in)
XT660Z 08-10 ING-AUS:MY03 07-10 ING 11-05-2009 10:10 Pagina 7

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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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