2012 YAMAHA XT660Z brake light

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
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Checking and lubricating the cables ..................\7...............7\f25
Checking and lubricating the throttle gri\b and cable ........7\f26
Checking and lubricating the brake and clutch levers ..................\7....7\f26
Lubricating the brake \bedal ............7\f27
Checking and lubricating the sidestand ..................\7..........7\f27
Lubricating the rear sus\bension......7\f27
Lubricating the swingarm \bivots .....7\f28
Checking the front fork..................\7..7\f28
Checking the steering ..................\7...7\f29
Checking the wheel bearings..........7\f29
Battery ..................\7..................\7.........7\f30
Re\blacing the fuses ..................\7......7\f31
Re\blacing a headlight bulb .............7\f33
Re\blacing a turn signal light bulb....7\f34
Re\blacing the license \blate light bulb ..................\7.................7\f\735
Re\blacing an auxiliary light bulb .....7\f35
Su\b\borting the motorcycle ..............7\f36
Front wheel ..................\7..................\7.7\f36
Rear wheel ..................\7..................\7..7\f38
Troubleshooting ..................\7............7\f39
Troubleshooting charts..................\7..7\f40 MOTORCYCLE CARE
AND STORAGE
..................\7.................8\7\f1
Care ..................\7..................\7..............8\f1
Storage ..................\7..................\7.........8\f3
SPECIFICATIONS ..................\7.............9\f1
CONSUMER INFORMATION ............10\f1
Identification numbers ..................\7...10\f1
Motorcycle noise regulation (for Australia) ..................\7..........10\f2
TABLE OF CONTENTS
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DESCRIPTION
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EAU10430
Cont\bols and inst\buments
1. Clutch lever \fpage 4-10\b
2. Left handlebar switches \fpage 4-9\b
3. Multi-function meter unit and warning lights \fpage 4-3, 4-5\b
4. Right handlebar switches \fpage 4-9\b
5. Throttle grip \fpage 7-16\b 6. Brake lever \fpage 4-11\b
7. Engine oil filler cap/dipstick \fpage 7-9\b
8. Fuel tank cap \fpage 4-11\b
9. Main switch and steering lock \fpage 4-2\b
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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✻
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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
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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
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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.
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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
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