2012 YAMAHA XT660Z clutch

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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1\f
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
XT660Z 01-03 ING-AUS:AUSTRALIA 11-05-2009 9:57 Pagina 16

INSTRUMENT AND CONTROL FUNCTIONS
4-10
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\f
6
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8
\b
10
EAU12733
Hazard switch “r”
With the key in the \fON” \br Fp\bsiti\bn,
use this switch t\b turn \bn the hazard
lights (simultane\bus flashing \bf all turn
signal lights).
The hazard lights are used in case \bf
an emergency \br t\b warn \bther drivers
when y\bur vehicle is st\bpped where it
might be a traffic hazard.
ECA10061
NOTICE
Do not use the hazard lights for an
extended length of time with the
engine not running, otherwise the
battery may discha\4rge.
EAU12820
Clutch lever
1. Clutch lever
The clutch lever is l\bcated at the left
handlebar grip. T\b disengage the
clutch, pull the lever t\bward the han-
dlebar grip. T\b engage the clutch, re-
lease the lever. The lever sh\buld be
pulled rapidly and released sl\bwly f\br
sm\b\bth clutch \bperati\bn.
The clutch lever is equipped with a
clutch switch, which is part \bf the igni-
ti\bn circuit cut-\bff system. (See page
4-17).
1
EAU12870
Shift pedal
1. Shift pedal
The shift pedal is l\bcated \bn the left
side \bf the engine and is used in c\bm-
binati\bn with the clutch lever when
shifting the gears \bf the 5-speed c\bn-
stant-mesh transmissi\bn equipped \bn
this m\bt\brcycle.
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-10

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.
4-18
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2
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7
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9
10
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

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FOR YOUR SAFE\fY – PRE-OPERA\f\bON CHECKS
5-3
\b\fEM
Clutch
\fhrottle grip
Control cables
Drive chain
Wheels and tires
Brake and shift pedals
Brake and
clutch levers
Sidestand
Chassis fasteners CHECKS
 Check operation.
 L\fbricate cable if nece\b\bary.
 Check lever free play.
 Adj\f\bt if nece\b\bary.
 Make \b\fre that operation i\b \bmooth.
 Check cable free play.
 If nece\b\bary, have Yamaha dealer adj\f\bt \Lcable free play and l\fbricate cable and grip ho\f\bing.
 Make \b\fre that operation i\b \bmooth.
 L\fbricate if nece\b\bary.
 Check chain \black.
 Adj\f\bt if nece\b\bary.
 Check chain condition.\L
 L\fbricate if nece\b\bary.
 Check for damage.
 Check tire condition a\Lnd tread depth.
 Check air pre\b\b\fre.
 Correct if nece\b\bary.
 Make \b\fre that operation i\b \bmooth.
 L\fbricate pedal pivoting point\b if nec\Le\b\bary.
 Make \b\fre that operation i\b \bmooth.
 L\fbricate lever pivoting point\b if nec\Le\b\bary.
 Make \b\fre that operation i\b \bmooth.
 L\fbricate pivot if nece\b\bary.
 Make \b\fre that all n\ft\b, bolt\b and \bcrew\b are properly tightened.
 Tighten if nece\b\bary. PAGE
4-10, 7-20, 7-26
7-16, 7-267-25
7-23, 7-24, 7-25
7-16, 7-197-27
7-26
7-27–
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 3

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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