2012 YAMAHA XT660Z maintenance

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
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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
EAU23182
Checking and lubricating
the brake pedal
The operation of the \frake pedal
\bhould \fe checked \fefore each ride,
and the pedal pivot \bhould \fe lu\fricat-
ed if nece\b\bary.
Recommended lubric\Mant:Lithium-\boap-\fa\bed grea\be
EAU23202
Checking and lubricating
the sidestand
The operation of the \bide\btand \bhould
\fe checked \fefore each ride, and the
\bide\btand pivot and metal-to-metal
contact \burface\b \bhould \fe lu\fricated
if nece\b\bary.
EWA10730
W\fRNING0
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it. Otherwise,
the sidestand could contact the
ground and distract the operator, re-
sulting in a possible loss of control.
Recommended lubric\Mant:Lithium-\boap-\fa\bed grea\be
EAU23250
Lubricating the rear
suspension
The pivoting point\b of the rear \bu\bpen-
\bion mu\bt \fe lu\fricated at the interval\b
\bpecified in the periodic maintenance
and lu\frication chart.
Recommended lubric\Mant:Lithium-\boap-\fa\bed grea\be
7-27
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-27

PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU23272
Checking the front fork
The condition and o\feration of the
front fork \bust be checked as follows
at the inter vals s\fecified in the
\feriodic \baintenance and lubrication
chart.
To check the condition
Check the inner tubes for scratches,
da\bage and excessive oil leakage.
To check the operation 1. Place the \botorcycle on a level surface and hold it in an u\fright
\fosition. WARNING! To avoid in-
jury, securely support the vehi-
cle so there is no danger of it
falling over.
2. While a\f\flying the front brake, \fush down hard on the handle-
bars several ti\bes to check if the
front fork co\b\fresses and re-
bounds s\boothly.
ECA10590
NOTICE
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAUM1650
Lubricating the swingarm
pivots
The swingar\b \fivots \bust be lubricat-
ed at the intervals s\fecified in the \fe-
riodic \baintenance and lubrication
chart.
Recommended lubric\4ant: Lithiu\b-soa\f-based g\arease
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-28

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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-29
EAU23283
Checking the steering
Worn or loose steerin\f bearin\fs ma\b
cause dan\fer. Therefore, the opera-
tion of the steerin\f must be checked
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart.1. Place a stand under the en\fine to raise the front wheel off the
\fround. (See pa\fe 7-36 for more
information.) W\fRNING! To avoid
injury, securely support the vehi-
cle so there is no danger of it
falling over.
2. Hold the lower ends of the front fork le\fs and tr\b to move them for-
ward and backward. If an\b free
pla\b can be felt, have a Yamaha
dealer check or repair the steerin\f.EAU23290
Checking the wheel bearings
The front and rear wheel bearin\fs
must be checked at the intervals spec-
ified in the periodic maintenance and
lubrication chart. If there is pla\b in the
wheel hub or if the wheel does not turn
smoothl\b, have a Yamaha dealer
check the wheel bearin\fs.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-29

PERIODIC MAINTENANCE AND ADJUSTMENT
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EWA10760
WARNING0
●Electrolyte is poisonous and
dangerous since it contains
sulfuric acid, which causes se-
vere burns. Avoid any contact
with skin, eyes or clothing and
always shield your eyes when
working near batteries. In case
of contact, administer the fol-
lowing FIRST AID.
 EXTERNAL: Flush with plenty
of water.
 INTERNAL: Drink large quan-
tities of water or milk and im-
mediately call a p\4hysician.
 EYES: Flush with water for 1\f
minutes and seek prompt
medical attention.\4
●Batteries produce explosive hy-
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro-
vide sufficient ventilation when
charging it in an enclosed space.
●KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
EAUB1432
Battery
This \fode\b is equipped with a VRLA
(Va\bve Regu\bated Lead Acid) battery.
There is no need to check the e\bec-
tro\byte or to add disti\b\bed water. Howev-
er, the battery \bead connections need
to be checked and, if necessary, tight-
ened.
ECA10620
NOTICE
Never attempt to remove the bat-
tery cell seals, as this would perma-
nently damage the \4battery.
1. Positive battery ter\fina\b
2. Negative battery ter\fina\b
To access the battery
Re\fove the battery ho\bder bracket by
re\foving the bo\bts.
To charge the battery
Have a Ya\faha dea\ber charge the bat-
tery as soon as possib\be if it see\fs to
have discharged. Keep in \find that
the battery tends to discharge \fore
quick\by if the vehic\be is equipped with
optiona\b e\bectrica\b accessories.
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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.
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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

PERIODIC MAINTENANCE AND ADJUSTMENT
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ECA10650
NOTICE
Take care not to damage the fol-
lowing parts:
●Headlight bulb  Do not touch the glass part
of the headlight bulb to keep
it free from oil, otherwise the
transparency of the glass,
the luminosity of the bulb,
and the bulb life will be ad-
versely affected. Thoroughly
clean off any dirt and finger-
prints on the headlight bulb
using a cloth moistened with
alcohol or thinner.
●Headlight lens
 Do not affix any type of tinted
film or stickers to the head-
light lens.
 Do not use a headlight bulb
of a wattage higher than
specified. 4. Connect t\fe couple\b, and t\fen in-
stall t\fe \feadlig\ft bulb cove\b.
5. Have a Yama\fa deale\b adjust t\fe \feadlig\ft beam if nec\ essa\by.
EAU24204
Replacing a turn signal
light bulb
1. Sc\bew
2. Tu\bn signal lig\ft lens
3. Tu\bn signal lig\ft bulb
1. Remove t\fe tu\bn signal lig\ft lensby \bemoving t\fe sc\bew.
2. Remove t\fe bu\bnt-out bulb by pus\fing it in and tu\bning it coun-
te\bclockwise.
3. Inse\bt a new bulb into t\fe socket, pus\f it in, and t\fen tu\bn it clock-
wise until it stops.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-34

PERIODIC MAINTENANCE AND ADJUSTMENT
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To service the rear wheel
Raise the rear wheel off the grou\fd by
usi\fg a \botorcycle sta\fd or, if a \bo-
torcycle sta\fd is \fot available, by plac-
i\fg a jack either u\fder each side of the
fra\be i\f fro\ft of the rear wheel or u\f-
der each side of t\uhe swi\fgar\b.EAU24360
Front wheelEAUB1440To remove the front wheel
EWA10820
WARNING0
●It is advisable to have a Yama-
ha dealer service t\4he wheel.
●Securely support the motorcy-
cle so that there is no danger of
it falling over.
1. Wheel axle
2. Brake caliper bolts
A. Fro\ft wheel axle pi\fch bolt
B. Fro\ft wheel axle pi\fch bolt
A
2
B
1
EAU24350
Supporting the motorcycle
Si\fce this \bodel is \fot equipped with
a ce\ftersta\fd, follow these precau-
tio\fs whe\f re\bovi\fg the fro\ft a\fd rear
wheel or perfor\bi\fg other \bai\fte-
\fa\fce requiri\fg the \botorcycle to
sta\fd upright. Check that the \botorcy-
cle is i\f a stable a\fd level positio\f be-
fore star ti\fg a\fy \bai\fte\fa\fce. A
stro\fg woode\f box ca\f be placed u\f-
der the e\fgi\fe for added stability.
To service the front wheel 1. Stabilize the rear of the \botorcy- cle by usi\fg a \botorcycle sta\fd
or, if a\f additio\fal \botorcycle
sta\fd is \fot available, by placi\fg a
jack u\fder the fra\be i\f fro\ft of the
rear wheel.
2. Raise the fro\ft wheel off the grou\fd by usi\fg a \botorcycle
sta\fd.
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