2012 YAMAHA XT660Z checking oil

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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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-9
EAUB1560
Engine oil and oil filter
element
The engine oi\f \feve\f shou\f\b be checke\b
before each ri\be. In a\b\bition, the oi\f must
be change\b an\b the oi\f fi\fter e\fement re-
p\face\b at the interva\fs specifie\b in the
perio\bic maintenance an\b \fubrication
chart.
To check the engine oil level1. P\face the vehic\fe on a \feve\f surface an\b ho\f\b it in an upright position.
TIP
Make sure that the vehic\fe is posi-
tione\b straight up when checking the
oi\f \feve\f. A s\fight ti\ft to the si\be can re-
su\ft in a fa\fse rea\bing.
2. Start the engine, warm it up for 10-15 minutes an\b then turn it off.
3. Remove the oi\f fi\f\fer cap, wipe the \bipstick c\fean, insert it back into
the oi\f fi\f\fer ho\fe (without screwing
it in), an\b then remove it again to
check the oi\f \feve\f.
1. Engine oi\f fi\f\fer cap
2. Maximum \feve\f mark
3. Minimum \feve\f mark
TIP
●The engine oi\f tank is \focate\b in-
si\be of the frame.
●The engine oi\f shou\f\b be between
the minimum an\b maximum \feve\f
marks.
Tightening torque:Spark p\fug:12.5 Nm (1.25 m·kg\of, 9.0 ft·\fbf)
TIP
If a torque wrench is not avai\fab\fe
when insta\f\fing a spark p\fug, a goo\b
estimate of the correct torque is 1/4-
1/2 turn past finger tight. However, the
spark p\fug shou\f\b be tightene\b to the
specifie\b torque as s\ooon as possib\fe.
4. Insta\f\f the spark p\fug cap.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-9

ECAM1060CAUTION:
The engine oil tank \fust be \billed in
2 steps. First, \bill the engine oil tank
with 1.90 L (2.0 US qt) (1.67 I\fp.qt)
o\b the reco\f\fended engine oil.
Then, start the engine, race it 5 or 6
ti\fes, turn it o\b\b, and then add the
re\fainder o\b the eng\kine oil.
NOTE:
Be sure to wipe off spi\f\fed oi\f on an\b
parts after the engine and exhaust
s\bstem have coo\fed d\fown.
ECA11620CAUTION: In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
\fix any che\fical additives. Do
not use oils with a diesel speci-
\bication o\b “CD” or oils o\b a
higher quality than speci\bied. In
addition, do not use oils la-
beled “ENERGY CONSERVING
II” or higher.
Make sure that no \boreign \fa-
terial enters the c\krankcase.
14. Start the engine, and then \fet it id\fe for severa\f minutes whi\fe
checking it for oi\f \feakage. If oi\f is
\feaking, immediate\f\b turn the en-
gine off and check for the \fcause.
15. Turn the engine off, and then check the oi\f \feve\f and correct it if
necessar\b.
16. Insta\f\f the engine guard b\b in- sta\f\fing the screws.\f
EAU20070
Coolant
The coo\fant \feve\f sho\fu\fd be checked
before each ride. In addition, the
coo\fant must be changed at the inter-
va\fs specified in the periodic mainte-
nance and \fubrication \fchart.
EAU20253
To check the coolant level1. P\face the vehic\fe on a \feve\f sur- face and ho\fd it in an upright posi-
tion.
NOTE:
The coo\fant \feve\f must be
checked on a co\fd engine since
the \feve\f varies with engine tem-
perature.
Make sure that the vehic\fe is posi-
tioned straight up when checking
the coo\fant \feve\f. A s\fight ti\ft to the
side can resu\ft in a \ffa\fse reading.
2. Check the coo\fant \feve\f in the coo\fant reservoir.
Reco\f\fended engine \koil:See page 8-1.
Oil quantity: Without oi\f fi\fter e\f\fement
rep\facement:2.50 L (2.64 US qt) (2.19 I\fmp.qt)
With oi\f fi\fter e\fem\fent rep\facement: 2.60 L (2.73 US qt) (2.26 Im\fp.qt)
PERIODIC MAINTENANCE AND ADJUSTMENT
7-12
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PERIODIC MAINTENANCE AND ADJUSTMENT
7-22
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Insufficient brake fluid \fay allow air to
enter t\be brake syste\f, possibly caus-
ing it to beco\fe ine\dffective.
Before riding, c\beck t\bat t\be brake flu-
id is above t\be \fini\fu\f level \fark
and replenis\b if ne\dcessary.
A low brake fluid level \fay indicate
worn brake pads and/or brake syste\f
leakage. If t\be brake fluid level is low,
be sure to c\beck t\be brake pads for
wear and t\be brake syste\f for leak-
age.
Observe t\bese precautions\d:
●W\ben c\becking t\be fluid level,
\fake sure t\bat t\be top of t\be
brake fluid reservoir is level.
●Use only t\be reco\f\fended qual-
ity brake fluid, ot\berwise t\be rub-
ber seals \fay deteriorate, caus-
ing leakage and poor braking
perfor\fance.
●Refill wit\b t\be sa\fe type of brake
fluid. Mixing fluids \fay result in a
\bar\fful c\be\fical reaction and
lead to poor braking perfor\fance.
●Be careful t\bat water does not en-
ter t\be brake fluid reservoir w\ben
refilling. Water will significantly
lower t\be boiling point of t\be fluid
and \fay result in vapor lock.
●Brake fluid \fay deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid i\f\fe-
diately.
●As t\be brake pads wear, it is nor-
\fal for t\be brake fluid level to
gradually go down. However, if
t\be brake fluid level goes down
suddenly, \bave a Ya\fa\ba dealer
c\beck t\be cause.
Recommended brake f\4luid: DOT 4
EAU22580
Checking the brake fluid
level
Front brake
1. Mini\fu\f level \fark
Rear brake
1. Mini\fu\f level \fark
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-22

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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

PERIODIC MAINTENANCE AND ADJUSTMENT
7-28
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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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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

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
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