2012 YAMAHA XT660Z ESP

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

SAFETY INFORMATION
EAU10313
Be a Respons\fble Owne\b
As the vehicle's owne\f, you \b\fe \fe-
sponsible fo\f the s\bfe \bnd p\fope\f op-
e\f\btion of you\f moto\fcycle.
Moto\fcycles \b\fe single\n-t\f\bck vehicles.
Thei\f s\bfe use \bnd ope\f\btion \b\fe de-
pendent upon the use of p\fope\f \fiding
techniques \bs well \bs the expe\ftise of
the ope\f\bto\f. Eve\fy ope\f\bto\f should
know the following \fequi\fements be-
fo\fe \fiding this moto\fcycl\ne.
He o\f she should:
●Obt\bin tho\fough inst\fuctions f\fom
\b competent sou\fce on \bll \bs-
pects of moto\fcycle\n ope\f\btion.
●Obse\fve the w\b\fnings \bnd m\bin-
ten\bnce \fequi\fements in this
Owne\f's M\bnu\bl.
●Obt\bin qu\blified t\f\bining in s\bfe
\bnd p\fope\f \fiding techniques.
●Obt\bin p\fofession\bl technic\bl se\f-
vice \bs indic\bted in this Owne\f's
M\bnu\bl \bnd/o\f when m\bde nec-
ess\b\fy by mech\bnic\bl conditio\nns.
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Safe \b\fd\fng
Pe\ffo\fm the p\fe-ope\f\btion checks e\bch
time you use the vehicle to m\bke su\fe it is
in s\bfe ope\f\bting condition. F\bilu\fe to in-
spect o\f m\bint\bin the vehicle p\fope\fly in-
c\fe\bses the possibility of \bn \bccident o\f
equipment d\bm\bge. See p\bge 5-2 fo\f \b
list of p\fe-ope\f\btion checks.
●This moto\fcycle is designed to c\b\f\fy
the ope\f\bto\f \bnd \b p\bssenge\f.
●The f\bilu\fe of moto\fists to detect \bnd
\fecognize moto\fcycles in t\f\bffic is the
p\fedomin\bting c\buse of \butomo-
bile/moto\fcycle \bccidents. M\bny \bc-
cidents h\bve been c\bused by \bn
\butomobile d\five\f who did not see
the moto\fcycle. M\bking you\fself
conspicuous \bppe\b\fs to be ve\fy
effective in \feducing the ch\bnce
of this type of \bcc\nident.
The\befo\be:
 We\b\f \b b\fightly colo\fed j\bcket.
 Use ext\f\b c\bution when you \b\fe \bpp\fo\bching \bnd p\bssing
th\fough inte\fsections, since in-
te\fsections \b\fe the most likely
pl\bces fo\f moto\fcycle \bccidents
to occu\f.  Ride whe\fe othe\f moto\fists c\bn
see you. Avoid \fiding in \bnothe\f
moto\fist's blind spot.
●M\bny \bccidents involve inexpe\fi-enced ope\f\bto\fs. In f\bct, m\bny op-
e\f\bto\fs who h\bve been involved in
\bccidents do not even h\bve \b cu\f-
\fent moto\fcycle license.
 M\bke su\fe th\bt you \b\fe qu\bli- fied \bnd th\bt you only lend you\f
moto\fcycle to othe\f qu\blified
ope\f\bto\fs.
 Know you\f skills \bnd limits. St\bying within you\f limits m\by
help you to \bvoid \bn \bccident.
 We \fecommend th\bt you p\f\bc- tice \fiding you\f moto\fcycle
whe\fe the\fe is no t\f\bffic until
you h\bve become tho\foughly
f\bmili\b\f with the moto\fcycle \bnd
\bll of its cont\fols.
●M\bny \bccidents h\bve been c\busedby e\f\fo\f of the moto\fcycle ope\f\b-
to\f. A typic\bl e\f\fo\f m\bde by the op-
e\f\bto\f is vee\fing wide on \b tu\fn
due to excessive speed o\f unde\f-
co\fne\fing (insufficient le\bn \bngle
fo\f the speed).
 Alw\bys obey the speed limit \bnd neve\f t\f\bvel f\bste\f th\bn
w\b\f\f\bnted by \fo\bd \bnd t\f\bffic
conditions.
XT660Z 01-03 ING-AUS:AUSTRALIA 11-05-2009 9:57 Pagina 10

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SAFETY INF\fRMATI\fN
products or having other modifications
performed to your vehic\fe that change
any of the vehic\fe's design or opera-
tion characteristics can put you and
others at greater risk of serious in\bury
or death. You are responsib\fe for in-
\buries re\fated to changes in the vehi-
c\fe.
Keep the fo\f\fowing guide\fines in mind,
as we\f\f as those provided under
"Loading" when mounting acces-
sories.
●Never insta\f\f accessories or carry
cargo that wou\fd impair the perfor-
mance of your motorcyc\fe. Care-
fu\f\fy inspect the accessory before
using it to make sure that it does
not in any way reduce ground
c\fearance or cornering c\fearance,
\fimit suspension trave\f, steering
trave\f or contro\f operation, or ob-
scure \fights or ref\fectors.
 Accessories fitted to the han-d\febar or the front fork area can
create instabi\fity due to improp-
er weight distribution or aerody-
namic changes. If accessories
are added to the hand\febar or
front fork area, they must be as \fightweight as possib\fe and
shou\fd be kept to a minimum.
 Bu\fky or \farge accessories may serious\fy affect the stabi\fity of
the motorcyc\fe due to aerody-
namic effects. Wind may at-
tempt to \fift the motorcyc\fe, or
the motorcyc\fe may become
unstab\fe in cross winds. These
accessories may a\fso cause in-
stabi\fity when passing or being
passed by \farge vehic\fes.
 Certain accessories can dis- p\face the operator from his or
her norma\f riding position. This
improper position \fimits the
freedom of movement of the
operator and may \fimit contro\f
abi\fity, therefore, such acces-
sories are not recomm\yended.
●Use caution when adding e\fectri-
ca\f accessories. If e\fectrica\f ac-
cessories exceed the capacity of
the motorcyc\fe's e\fectrica\f sys-
tem, an e\fectric fai\fure cou\fd re-
su\ft, which cou\fd cause a danger-
ous \foss of \fights or engine power. Af\bermarke\b Tires and Rims
The tires and rims that came with your
motorcyc\fe were designed to match
the performance capabi\fities and to
provide the best combination of han-
d\fing, braking, and comfort. Other
tires, rims, sizes, and combinations
may not be appropriate. Refer to page
7-16 for tire specifications and more
information on rep\facing\y your tires.
2-4
XT660Z 01-03 ING-AUS:AUSTRALIA 11-05-2009 9:57 Pagina 13

EWA10240
WARNING0
The vehicle must n\ft be ridden
\bith the sidestand d\f\bn, \fr if the
sidestand cann\ft be pr\fperly
m\fved up (\fr d\fes n\ft stay up),
\fther\bise the sidestand c\fuld c\fn-
tact the gr\fund and distract the
\fperat\fr, resulting in a p\fssible
l\fss \ff c\fntr\fl. Yamaha’s igniti\fn
circuit cut-\fff system has been de-
signed t\f assist the \fperat\fr in ful-
filling the resp\fnsibility \ff raising
the sidestand bef\fre starting \fff.
Theref\fre, check this system regu-
larly as described bel\f\b and have
a Yamaha dealer repair it if it d\fes
n\ft functi\fn pr\fperly.
EAU15301
Sidestand
1. Sidestand
\fhe sidestand is l\bcated \bn the left
side \bf the frame. Raise the sidestand
\br l\bwer it with y\bur f\b\bt while h\blding
the m\bt\brcycle upright.
TIP
\fhe built-in sidestand switch is part \bf
the igniti\bn circuit cut-\bff system,
which cuts the igniti\bn in certain situa-
ti\bns. (See further d\bwn f\br an expla-
nati\bn \bf the igniti\bn circuit cut-\bff sys-
tem.)
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INSTRUMENT AND CONTROL FUNCTIONS
4-17
EAU15314
Igniti\fn circuit cut-\fff
system
\fhe igniti\bn circuit cut-\bff system
(c\bmprising the sidestand switch,
clutch switch and neutral switch) has
the f\bll\bwing functi\bns.
●It prevents star ting when the
transmissi\bn is in gear and the
sidestand is up, but the clutch
lever is n\bt pulled.
●It prevents star ting when the
transmissi\bn is in gear and the
clutch lever is pulled, but the side-
stand is still d\bwn.
●It cuts the running engine when
the transmissi\bn is in gear and
the sidestand is m\bved d\bwn.
Peri\bdically check the \bperati\bn \bf the
igniti\bn circuit cut-\bff system acc\brd-
ing t\b the f\bll\bwing pr\bcedure.
TIP
\fhis check is m\bst reliable if per-
f\brmed with a warmed-up engine.
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:55 Pagina 4-17

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.
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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

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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-25
EAU23023
Cleaning and lubricating
the drive chain
The drive chai\f mus\b be clea\fed a\fd
lubrica\bed a\b \bhe i\f\bervals specified i\f
\bhe periodic mai\f\be\fa\fce a\fd lubrica-
\bio\f char\b, o\bherwise i\b will quickly
wear ou\b, especially whe\f ridi\fg i\f
dus\by or we\b areas. Service \bhe drive
chai\f as follows.
ECA10581
NOTICE
The drive chain must be lubricated
after washing the motorcycle and
riding in the rain.\M
1. Clea\f \bhe drive chai\f wi\bh kerose\fe a\fd a small sof\b brush. NOTICE:
To prevent damaging the O-
rings, do not clean the drive
chain with steam cleaners,
high-pressure washers or inap-
propriate solvents. 2. Wipe \bhe drive chai\f dry.
3. Thoroughly lubrica\be \bhe drive
chai\f wi\bh a special O-ri\fg chai\f
lubrica\f\b. NOTICE: Do not use
engine oil or any other lubri-
cants for the drive chain, as
they may contain substances
that could damage the O-rings.
EAU23101
Checking and lubricating
the cables
The opera\bio\f of all co\f\brol cables a\fd
\bhe co\fdi\bio\f of \bhe cables should be
checked before each ride, a\fd \bhe ca-
bles a\fd cable e\fds should be lubri-
ca\bed if \fecessary. If a cable is dam-
aged or does \fo\b move smoo\bhly, have
a Yamaha dealer check or replace i\b.
W\fRNING! Damage to the outer
sheath may interfere with proper
cable operation and will cause the
inner cable to rust. Replace a dam-
aged cable as soon as possible to
prevent unsafe condit\Mions.
Recommended lubrican\Mt: E\fgi\fe oil
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-25

MOTORCYCLE CARE AND STORAGE
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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

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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