2012 YAMAHA XT660Z ABS

TABLE OF CONTENTS
LOCATION OF IMPORTANT LABELS...1-1
SAFETY INFORMATION ..................\r...2-1
Be a Responsible Owner ..................\r2-1
\fafe riding ..................\r..................\r.....2-1
\brotective apparel ..................\r...........2-2
Avoid Carbon Monoxide \boisoning ...2-2
Loading ..................\r..................\r.........2-3
Genuine Yamaha Accessories ..........2-3
Aftermarket \barts, Accessories, and Modifications ..................\r.....2-4
Aftermarket Tires and Rims ..............2-4
DESCRIPTION ..................\r..................\r.3-1
Left view ..................\r..................\r........3-1
Right view ..................\r..................\r.....3-2
Controls and instruments ..................\r3-3
INSTRUMENT AND CONTROL
FUNCTIONS ..................\r..................\r....4-1
Immobilizer system ..................\r.........4-1
Main switch/steering lock ..................\r4-2
Indicator and warning lights ..............4-3
Multi-function display ..................\r......4-5
Tachometer ..................\r..................\r...4-6
Tripmeter and tachometer modes .....4-6
Clock mode ..................\r..................\r...4-7
Fuel meter ..................\r..................\r.....4-7
\felf-diagnosis devices ..................\r....4-7 Handlebar switches ..................\r.........4-9
Clutch lever ..................\r..................\r.4-10
\fhift pedal ..................\r..................\r...4-10
Brake lever ..................\r..................\r..4-11
Brake pedal ..................\r..................\r.4-11
Fuel tank cap ..................\r................4-\r11
Fuel ..................\r..................\r.............4-12
Fuel tank breather hose ..................\r4-13
Catalytic converter ..................\r........4-13
\feat ..................\r..................\r.............4-14
Adjusting the front fork ..................\r..4-15
Adjusting the shock absorber
assembly ..................\r................4-\r16
\fidestand ..................\r..................\r....4-17
Ignition circuit cut-off system ..........4-17
FOR YOUR SAFETY -
PRE-OPERATION C\fECKS ...............5-1\r
\bre-operation check list ..................\r..5-2
OPERATION AND IMPORTANT
RIDING POINTS ..................\r................6-\r1
\ftarting the engine..................\r..........6-1
\fhifting ..................\r..................\r..........6-2
Tips for reducing fuel consumption ...6-3
Engine break-in ..................\r...............6-3\r
\barking ..................\r..................\r..........6-4 PERIODIC MAINTENANCE AND
ADJUSTMENT
..................\r..................\r.7-1
Owner’s tool kit ..................\r...............7-1\r
\beriodic maintenance chart for the emission control system.......7-2
General maintenance and lubrication chart ..................\r7-3
Removing and installing the cowling and panels ..............7-8
Checking the spark plug ..................\r.7-8
Engine oil and oil filter element.........7-9
Coolant ..................\r..................\r........7-12
Replacing the air filter element and cleaning the check hose ...7-14
Checking the engine idling speed ...7-15
Checking the throttle cable free play ..................\r.................7\r-16
Valve clearance ..................\r.............7-16
Tires ..................\r..................\r............7-16
\fpoke wheels..................\r................7-\r19
Adjusting the clutch lever free play ...7-20
Checking the front and rear brake pads ..................\r.............7-21
Checking the brake fluid level .........7-22
Changing the brake fluid .................7\r-23
Drive chain slack ..................\r...........7-23
Cleaning and lubricating the drive chain ..................\r........7-25
XT660Z 01-03 ING-AUS:AUSTRALIA 11-05-2009 9:57 Pagina 6

3-1
1
2
3
4
5
6
7
8
9
10
DESCRIPTIO\f
EAU10410Lef\b view
1. Idle adjust\fng sc\bew (page 7-15)
2. Owne\b’s tool k\ft (page 7-1)
3. A\f\b f\flte\b element (page 7-14)
4. Fuse box (page 7-31)
5. Seat lock (page 4-14) 6. Shock abso\bbe\b assembly/sp\b\fng p\beload adjust\fng \b\fng (page 4-16)
7. Sh\fft pedal (page 4-10)
8. Eng\fne o\fl d\ba\fn bolt (c\bankcase) (page 7-10)
9. Eng\fne o\fl d\ba\fn bolt (o\fl tank) (page 7-10)
XT660Z 01-03 ING-AUS:AUSTRALIA 11-05-2009 9:57 Pagina 14

INSTRUMENT AND CONTROL FUNCTIONS
4-16
1
2
3
4
\f
6
7
8
\b
10
Adjust the spring prel\fad as f\fll\fws\b
T\f increase the spring prel\fad and
thereby harden the suspensi\fn, turn
the adjusting ring in directi\fn (a\l)\b
T\f decrease the spring prel\fad and
thereby s\fften the suspensi\fn, turn
the adjusting ring in directi\fn (b\l)\b
TIP
Align the appr\fpriate n\ftch in the ad-
justing ring with the p\fsiti\fn indicat\fr
\fn the sh\fck abs\frber\b
EWAB0020
WARNING0
Never adjust the spring preload un-
til the exhaust system has cooled
down.
EWA10221
WARNING0
This shock absorber assembly con-
tains highly pressurized nitrogen
gas. Read and understand the fol-
lowing information before handling
the shock absorber \4assembly.
●Do not tamper with or attempt
to open the cylind\4er assembly.
●Do not subject the shock ab-
sorber assembly to an open
flame or other high heat
source. 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.\4
●Do not dispose of a damaged
or worn-out shock absorber
assembly yourself. Take the
shock absorber assembly to a
Yamaha dealer for any s\4ervice.
EAUB1461
Adjusting the shock
absorber assembly
1\b Spring prel\fad adjusting ring
2\b P\fsiti\fn indicat\fr
(a) Increasing the spring prel\fad
(b) Decreasing the spring prel\fad
This sh\fck abs\frber assembly is
equipped with a spring prel\fad adjust-
ing ring\b
ECA10100
NOTICE
Never attempt to turn an adjusting
mechanism beyond the maximum
or minimum setting\4s.
Spring preload set\
ting: Minimum (s\fft):1
Standard: 2
Maximum (hard): 9
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-16

PERIODIC MAINTENANCE AND ADJUSTMENT
7-4
1
2
3
4
\f
6
7
8
\b
10
NO. ITEM CHECK OR MAINTENAN\4CE JOB
ODOMETER READING
1000 km 10000 km 20000 km 30000 km 40000 km(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
ANNUAL
CHECK
√ √ √ √
√ √ √ √ √ √ √
√√
√
√ √ √ √ √
√ √ √ √ √ √ √ √ √ √
√ √ √ √
√ √ √ √
√ √
√ √ √ √ √ √
13
14
✻
1\f✻
16✻
18
 Check operation and for e\fcessive pla\b.
 Lubricate with lithium-\fsoap-based grease.
 Check chain slack, alignment and condition.
 Adjust and lubricate chain with a\f special
O-ring chain lubricant thoroughl\b.
 Check bearing pla\b and steering
for roughness.
 Lubricate with lithium-\fsoap-based grease.
 Make sure that all nuts, bolts and screws
are properl\b tightened.
 Check operation.
 Lubricate.
 Check operation.
 Check operation and for oil leakage.
 Check operation and shock absorber
for oil leakage.
 Check operation.
 Lubricate with lithium-\fsoap-based grease.
 Change.
 Check oil level and vehicle for oil leakage.
Swingarm
Drive chain
Steering bearings
Chassis fasteners
Sidestand
Sidestand switch
Front fork
Shock absorber
assembly
Rear suspension
relay arm and
connecting arm
pivoting points
Engine oil
Ever\b 50000 km (30000 mi)
Ever\b 50000 km (30000 mi)
Ever\b 500 km (300 mi) and after washing the motorc\bcle or riding in the rain
\b✻
11✻
17✻
12✻
10
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-4

1
2
3
4
5
6
7
8
9
10
MOTORCYCLE C\fRE \fND STOR\f\bE
8-2
●For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the wind-
shield. Test the product on a
small hidden part of the wind-
shield to make sure that it does
not leave any marks. If the
windshield is scratched, use a
quality plastic polishing com-
pound after washing\ .After normal use
Remove d\frt w\fth warm water, a m\fld
deter\bent, and a soft, clean spon\be,
and then r\fnse thorou\bhly w\fth clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn d\frt
and \fnsects w\fll come off more eas\fly \ff
the area \fs covered w\fth a wet cloth for
a few m\fnutes before clean\fn\b.
After r\fd\fn\b \fn the ra\fn, near the sea
or on salt-sprayed roads
S\fnce sea salt or salt sprayed on roads
dur\fn\b w\fnter are extremely corros\fve
\fn comb\fnat\fon w\fth water, carry out
the follow\fn\b steps after each r\fde \fn
the ra\fn, near the sea or on salt-
sprayed roads.
TIP
Salt sprayed on roads \fn the w\fnter
may rema\fn well \fnto spr\fn\b.
1. Clean the motorcycle w\fth cold water and a m\fld deter\bent, after
the en\b\fne has cooled down. NO-
TICE: Do not use warm water
since it increases the corrosive
action of the salt. 2. Apply a corros\fon protect\fon
spray on all metal, \fnclud\fn\b
chrome- and n\fckel-plated, sur-
faces to prevent corros\fon.
\ffter cleaning 1. Dr y the motorcycle w\fth a chamo\fs or an absor\db\fn\b cloth.
2. Immed\fately dry the dr\fve cha\fn and lubr\fcate \ft to prevent \ft from
rust\fn\b.
3. Use a chrome pol\fsh to sh\fne chrome, alum\fnum and sta\fnless-
steel parts, \fnclud\fn\b the exhaust
system. (Even the thermally \fn-
duced d\fscolor\fn\b of sta\fnless-
steel exhaust systems can be re-
moved throu\bh pol\fsh\fn\b.)\d
4. To prevent corros\fon, \ft \fs recom- mended to apply a corros\fon pro-
tect\fon spray on all metal, \fnclud-
\fn\b chrome- and n\fckel-plated,
surfaces.
5. Use spray o\fl as a un\fversal clean- er to remove any rema\fn\fn\b d\frt.
6. Touch up m\fnor pa\fnt dama\be caused by stones, etc.
7. Wax all pa\fnted surfaces.
XT660Z 08-10 ING-AUS:MY03 07-10 ING 11-05-2009 10:10 Pagina 3

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
Australia 5/8/10 \á 16:21 Pá\fina 94