2012 YAMAHA XT660Z check engine

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

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INSTRUMENT \fND CONTRO\b FUNCTIONS
4-3
To unlock the steering
1\f Push
2\f Turn
Push the key into the \bain switch, and
then turn it to “OFF” while still pushing
it\f
EAU10941
F(Parking)
The steering is locked, and the tail-
light, license plate light and auxiliary
lights are on\f The hazard lights and
turn signal lights can be turned on, but
all other electrical syste\bs are off\f The
key can be re\boved\f
The steering \bust be locked before
the key can be turned to “ F”\f
ECA11020NOTICE
Do not use the parking position for
an extended length of time, other-
wise the battery may\ discharge.
EAU11004
Indicator and warning lights
1\f I\b\bobilizer syste\b indicator light “ ”
2\f Neutral indicator light “ N”
3\f Turn signal indicator light “ y”
4\f High bea\b indicator light “ 1”
5\f Engine trouble warning light “ U”
6\f Coolant te\bperature warning light “ u”
EAUB1510
Turn signal indicator light “y”
This indicator light flashes when the
turn signal switch is pushed to the left
or right\f
The electrical circuit of the turn signal
indicator light can be checked by turn-
ing the key to "ON"\f
If the indicator light does not co\be on
for a few seconds, then go off, have a
Ya\baha dealer check the electrical cir-
cuit\f
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-3

INSTRUMENT AND CONTROL FUNCTIONS
4-4
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EAUB1520
Neutral indicator light “ N”
This indica\for li\bh\f comes on when \fhe
\fransmission is in \fh\ae neu\fral posi\fion.
The elec\frical circui\f of \fhe neu\fral indi-
ca\for li\bh\f can be checked by \furnin\b
\fhe key \fo "ON". If \fhe indica\for li\bh\f
does no\f come on for a few seconds,
\fhen \bo off, have a Yamaha dealer
check \fhe elec\frical circui\f.
EAUB1530
High beam indicator light “ 1”
This indica\for li\bh\f comes on when \fhe
hi\bh beam of \fhe headli\bh\f is swi\fched
on. The elec\frical circui\f of \fhe hi\bh
beam indica\for li\bh\f can be checked
by \furnin\b \fhe key \fo "ON". If \fhe indi-
ca\for li\bh\f does no\f come on for a few
seconds, \fhen \bo off, have a Yamaha
dealer check \fhe elec\frical circui\f.
EAU11444
Coolant temperature warning
light “u”
This warnin\b li\bh\f comes on if \fhe en-
\bine overhea\fs. If \fhis occurs, s\fop \fhe
en\bine immedia\fely and allow \fhe en-
\bine \fo cool. The elec\frical circui\f of \fhe
warnin\b li\bh\f can be checked by \furn-
in\b \fhe key \fo "ON". The warnin\b li\bh\f
should come on for a few seconds, and \fhen \bo off. If \fhe warnin\b li\bh\f
does no\f come on ini\fially when \fhe
key is \furned \fo "ON", or if \fhe warnin\b
li\bh\f remains on, have a Yamaha deal-
er check \fhe elec\frical circui\f.
ECA10021
NOTICE
Do not continue to operate the en-
gine if it is overhea\4ting.
TIP
●For radia\for-fan-equipped vehi- cles, \fhe radia\for fan(s) au\foma\fi-
cally swi\fch on or off accordin\b \fo
\fhe coolan\f \fempera\fure in \fhe ra-
dia\for.
●If \fhe en\bine overhea\fs, see pa\be
7-41 for fur\fher ins\fruc\fions.
EAU11534
Engine trouble warning light “ U”
This warnin\b li\bh\f comes on or flashes
if a problem is de\fec\fed in \fhe elec\fri-
cal circui\f moni\forin\b \fhe en\bine. If \fhis
occurs, have a Yamaha dealer check
\fhe self-dia\bnosis sys\fem. (See pa\be
4-8 for an explana\fion of \fhe self-dia\b-
nosis device.) The elec\frical circui\f of
\fhe warnin\b li\bh\f can be checked by \furnin\b \fhe key \fo "ON". The warnin\b
li\bh\f should come on for a few seconds,
and \fhen \bo off. If \fhe warnin\b li\bh\f does
no\f come on ini\fially when \fhe key is
\furned \fo "ON", or if \fhe warnin\b li\bh\f re-
mains on, have a Yamaha dealer check
\fhe elec\frical circui\f.
EAU26876
Immobilizer system indicator
light “ ”
The elec\frical circui\f of \fhe indica\for
li\bh\f can be checked by \furnin\b \fhe
key \fo "ON". The indica\for li\bh\f should
come on for a few seconds, and \fhen
\bo off. If \fhe indica\for li\bh\f does no\f
come on ini\fially when \fhe key is
\furned \fo "ON", or if \fhe indica\for li\bh\f
remains on, have a Yamaha dealer
check \fhe elec\frical circui\f.
When \fhe key is \furned \fo "OFF" and
30 seconds have passed, \fhe indica\for
li\bh\f will s\far\f flashin\b indica\fin\b \fhe
immobilizer sys\fem is enabled. Af\fer
24 hours have passed, \fhe indica\for
li\bh\f will s\fop flashin\b, however \fhe im-
mobilizer sys\fem is s\fill en\aabled.
This model is also equipped wi\fh a
self-dia\bnosis device for \fhe immobi-
lizer sys\fem. (See pa\be 4-8 for an ex-
plana\fion of \fhe self-dia\bnosis device.)
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-4

your skin, wash with soap and
water. I\f gasoline spills on your
clothing, change your clothes.
EAU13390
ECA11400
\bse only unleaded gasoline. The use
o\f leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,
as well as to the exhaust system.
Your Yamaha en\fine has been \besi\f-
ne\b to use premium unlea\be\b \fasoli-
ne with a research octane number of
95 or hi\fher. If knockin\f (or pin\fin\f)
occurs, use a \fasoline of a \bifferent
bran\b. Use of unlea\be\b fuel will
exten\b spark plu\f life an\b re\buce
maintenance costs.
EAUB1300
Fuel tank breather/over\flow
hose
1. Fuel tank breather/hose
2. Hose clamp
Before operatin\f the motorcycle:
Check the fuel tank breather/over-
flow hose connection.
Check the fuel tank
breather/overflow hose for
cracks or \bama\fe, an\b replace it
if \bama\fe\b.
Make sure that the en\b of the fuel
tank breather/overflow hose is
not blocke\b, an\b clean it if
necessary.
Make sure that the en\b of the fuel
tank breather/overflow hose is
positione\b insi\be of the clamp.
EAU13433
Catalytic converters
This vehicle is equippe\b with catalytic
converters in the exhaust system.
EWA10862
The exhaust system is hot a\fter
operation. To prevent a \fire hazard
or burns:
Do not park the vehicle near
possible \fire hazards such as
grass or other materials that
easily burn.
Park the vehicle in a place
where pedestrians or children
are not likely to touch the hot
exhaust system.
Make sure that the exhaust
system has cooled down be\fo-
re doing any maintenance
work.
Do not allow the engine to idle
more than a \few minutes. Long
idling can cause a build-up o\f
heat.
WARNING
NOTICE
Recommended \fuel:PREMIUM UNLEADED
GASOLINE ONLY
Fuel tank capacity: 23.0 L (6.07 US \fal) (5.05 Imp.\fal)
Fuel reserve amount (when the
\fuel level warning light comes on): 6.7 L (1.77 US \fal) (1.47 Imp.\fal)
INSTR\bMENT AND CONTROL F\bNCTIONS
4-13
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Australia 5/8/10 \g 16:16 Pági\fa 29

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

INSTRUMENT AND CONTROL FUNCTIONS
WARNING0
If a \falfun\btion is noted, have a Ya\faha dealer
\bhe\bk the syste\f befo\are riding.
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With the engine turned off:
1\f Move the sidest\bnd down\f
2\f M\bke sure th\bt the engine stop switch is set to
“ I”\f
3\f Turn the key on\f
4\f Shift the tr\bnsmission into the neutr\bl position\f
5\f Push the st\brt switch\f
Does the engine start?
With the engine still running:
6\f Move the sidest\bnd up\f
7\f Keep the clutch lever pulled\f
8\f Shift the tr\bnsmission into ge\br\f
9\f Move the sidest\bnd down\f
Does the engine stall?
The neutr\bl switch m\by not be working correctly\f
The \fotor\by\ble should not be ridden until checked by \b
Y\bm\bh\b de\bler\f
The sidest\bnd switch m\by not be working correctly\f
The \fotor\by\ble should not be ridden until checked by \b
Y\bm\bh\b de\bler\f
The clutch switch m\by not be working correctly\f
The \fotor\by\ble should not be ridden until checked by \b
Y\bm\bh\b de\bler\f
After the engine h\:\bs st\blled:
10\f Move the sidest\bnd up\f
11\f Keep the clutch lever pulled\f
12\f Push the st\brt switch\f
Does the engine start\a?
The system is OK\f The \fotor\by\ble \ban be ridden. YES
NO
NO
YES
NO
YES
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:55 Pagina 4-18

EAU15605
Before using t\fis ve\ficle\b c\feck t\fe following points:
ITEMCHECKS PAGE
 C\feck fuel level in fuel tank.
 Refuel if necessary.
Fuel  C\feck fuel line for leakage. 4-12\b 4-13
 C\feck t\fe fuel tank breat\fer/overflow \fose for obstructions\b cracks or
damage\b and c\feck t\fe \fose connection.
 C\feck oil level in oil tank.
Engine \fil  If necessary\b add recommended oil to specified level. 7-9
 C\feck ve\ficle for oil leakage.
 C\feck coolant level in reservoir.
C\f\flant  If necessary\b add recommended coolant to specified level. 7-12
 C\feck cooling system for leakage.
 C\feck operation.
 If soft or spongy\b \fave Yama\fa dealer bleed \fydraulic system.
 C\feck brake pads for wear.
Fr\fnt \brake  Replace if necessary. 4-11\b 7\b21\b 7-22\b 7-26
 C\feck fluid level in reservoir.
 If necessary\b add recommended brake fluid to specified level.
 C\feck \fydraulic system for leakage.
 C\feck operation.
 If soft or spongy\b \fave Yama\fa dealer bleed \fydraulic system.
 C\feck brake pads for wear.
Rear \brake  Replace if necessary. 4-11\b 7\b21\b 7-22\b 7-27
 C\feck fluid level in reservoir.
 If necessary\b add recommended brake fluid to specified level.
 C\feck \fydraulic system for leakage.
FOR YOUR SAFETY - PRE-OPERATION CHECKS
5-2
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Australia 4/8/10 \n 18:04 Página \f6

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OPERATION AN\f IMPORTANT RI\fING POINTS
EAU15951
Read the Owner's \fanual care\bully to
become \bamiliar with all controls. I\b
there is a control or \bunction you do not
understand, ask your Yamaha dealer.
EWA10271
\bARNING0
Failure to familiarize yourself with
the controls can lead to loss of con-
trol, which could cause an accident
or injury.
6-1
EAU48020
TIP
This model is equipped with a lean an-
gle sensor to stop the engine in case
o\b a turnover. In this case, the multi-
\bunction display indicates error code
30, but this is not a mal\bunction. Turn
the key to "OFF" and then to "ON" to
clear the error code. Failing to do so
will prevent the engine \brom starting
even though the engine will crank
when pushing the st\sart switch.
EAUB1570
Starting the engine
In order \bor the ignition circuit cut-o\b\b
system to enable starting, one o\b the
\bollowing conditions must be met:
●The transmission is in the neutral
position.
●The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EWA10290
\bARNING0
●Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure de-
scribed on page 4-18\ .
●Never ride with the sidestand
down.
1. Turn the key to “ON” and make sure that the engine stop switch is
set to “
I”.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 5