2012 YAMAHA XT660Z 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
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 Always signal before turning or
c\fanging lanes . Make sure t\fat
ot\fer \botorists can see you.
●T\fe posture of t\fe operator and
passenger is i\bportant for proper
control.
 T\fe operator s\fould keep bot\f \fands on t\fe \fandlebar and
bot\f feet on t\fe operator
footrests during operation to
\baintain control of t\fe \botorcy-
cle.
 T\fe passenger s\fould always \fold onto t\fe operator, t\fe seat
strap or grab bar, if equipped,
wit\f bot\f \fands and keep bot\f
feet on t\fe passenger footrests.
Never carry a passenger un-
less \fe or s\fe can fir\bly place
bot\f feet on t\fe passenger
footrests.
●Never ride under t\fe influence of
alco\fol or ot\fer drugs.
2-2
Protective \fpp\frel
T\fe \bajority of fatalities fro\b \botorcy-
cle accidents are t\fe result of \fead in-
juries. T\fe use of a safety \fel\bet is t\fe
single \bost critical factor in t\fe pre-
vention or reduction\c of \fead injuries.
●Always wear an approved \fel\bet.
●Wear a face s\field or goggles.
Wind in your unprotected eyes
could contribute to an i\bpair\bent
of vision t\fat could delay seeing a
\fazard.
●T\fe use of a jacket, \feavy boots,
trousers, gloves, etc., is effective
in preventing or reducing abra-
sions or lacerations.
●Never wear loose-fitting clot\fes,
ot\ferwise t\fey could catc\f on t\fe
control levers, footrests, or
w\feels and cause injury or an ac-
cident.
●Always wear protective clot\fing
t\fat covers your legs, ankles, and
feet. T\fe engine or ex\faust sys-
te\b beco\be very \fot during or af-
ter operation and can cause
burns.
●A passenger s\fould also observe
t\fe above precautions. Avoi\b C\frbon Monoxi\be Poisoning
All engine ex\faust contains carbon
\bonoxide, a deadly gas. Breat\fing car-
bon \bonoxide can cause \feadac\fes,
dizziness, drowsiness, nausea, confu-
sion, and eventually deat\f.
Carbon Monoxide is a colorless, odor-
less, tasteless gas w\fic\f \bay be pre-
sent even if you do not see or s\bell any
engine ex\faust. Deadly levels of carbon
\bonoxide can collect rapidly and you
can quickly be overco\be and unable to
save yourself. Also, deadly levels of car-
bon \bonoxide can linger for \fours or
days in enclosed or poorly ventilated ar-
eas. If you experience any sy\bpto\bs of
carbon \bonoxide poisoning, leave t\fe
area i\b\bediately, get fres\f air, and
SEEK MEDICAL TREATMENT.
●Do not run engine indoors. Even if
you try to ventilate engine ex-
\faust wit\f fans or open windows
and doors, carbon \bonoxide can
rapidly reac\f danger\cous levels.
●Do not run engine in poorly ventilat-
ed or partially enclosed areas suc\f
as barns, garages, or carports.
●Do not run engine outdoors w\fere
engine ex\faust can be drawn into
a building t\froug\f openings suc\f
as windows and doors.
SAFETY INFORMATION
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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
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3-2
DESCRIPTIO\f
10. Grab bar
11. Main fuse (\fage 7-31)
12. \battery (\fage 7-30)
13. Rear brake fluid reservoir (\fage 7-22)14. Coolant reservoir (\fage 7-13) 15. Front brake fluid reservoir (\fage 7-22)
16. Coolant drain bolt (\fage 7-12)
17. Engine oil filter element (\fage 7-11)
18. \brake \fedal (\fage 4-11)
EAU10420Righ\b view
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DESCRIPTION
3-3
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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
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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
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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.)
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INSTRUMENT \fND CONTRO\b FUNCTIONS
4-5
EAUB1501
Multi-function display
1. Tachomete\f
2. Spee\bomete\f
3. O\bomete\f
4. T\fipmete\fs/Fuel \fese\fve t\fipmete\f
5. Clock
6. Fuel mete\f
7. “RESET” button
8. “SELECT” button
EWA12311
W\fRNING0
Be sure to stop the vehicle before
making any setting changes to the
multi-function displ\ ay.
The multi-function \bisplay is equippe\b
with the following:
●a spee\bomete\f (which shows the
\fi\bing spee\b)
●a \bigital tachomete\f (which shows
engine \f/min)
●an o\bomete\f (which shows the to-
tal \bistance t\favele\b)
●two t\fipmete\fs (which show the
\bistance t\favele\b since they we\fe
last set to ze\fo)
●a fuel \fese\fve t\fipmete\f (which
shows the \bistance t\favele\b since
the bottom segment of the fuel
mete\f sta\fte\b flashing)
●a clock
●a fuel mete\f
●a self-\biagnosis \bevice
TIP
●Be su\fe to tu\fn the key to "ON"
befo\fe using the "SELECT" an\b
"RESET" buttons.
●Fo\f the U.K. only: To switch the
spee\bomete\f an\b o\bome-
te\f/t\fipmete\f \bisplays between
kilomete\fs an\b miles, push the
"SELECT" an\b "RESET" buttons
togethe\f an\b tu\fn the key to "ON".
When the \bigits sta\ft flashing,
push the "SELECT" button to
choose kilomete\fs o\f \tmiles.
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