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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2
3
4
5
6
7
8
9
10
4-1
INSTRUMENT \fND CONTRO\b FUNCTIONS
EAU10976
Immobilizer system
1. Code re-regi\ftering ke\b (red bow)
2. Standard ke\b\f (black bow)
Thi\f vehicle i\f equipped with an im-
mobilizer \f\b\ftem to help prevent theft
b\b re-regi\ftering code\f in the \ftandard
ke\b\f. Thi\f \f\b\ftem con\fi\ft\f of the fol-
lowing.
●a code re-regi\ftering ke\b (with a
red bow)
●two \ftandard ke\b\f (with a black
bow) that can be re-regi\ftered
with new code\f
●a tran\fponder (which i\f in\ftalled
in the code re-regi\f\itering ke\b)
●an immobilizer unit
●an ECU
●an immobilizer \f\b\ftem indicator
light (See page 4-3.\i)
The ke\b with the red bow i\f u\fed to reg-
i\fter code\f in each \ftandard ke\b. Since
re-regi\ftering i\f a difficult proce\f\f, take
the vehicle along with all three ke\b\f to a
Yamaha dealer to have them re-regi\f-
tered. Do not u\fe the ke\b with the red
bow for driving. It \fhould onl\b be u\fed
for re-regi\ftering the \ftandard ke\b\f. Al-
wa\b\f u\fe a \ftandard ke\b for driving.
ECA11821NOTICE
●DO NOT \bOSE THE CODE RE-
REGISTERING KEY! CONT\fCT
YOUR DE\f\bER IMMEDI\fTE\bY
IF IT IS \bOST! If the code re-reg-
istering key is lost, registering
new codes in the standard keys
is impossible. The standard keys
can still be used to start the ve-
hicle, however if code re-regis-
tering is required (i.e., if a new
standard key is made or all keys
are lost) the entire immobilizer
system must be replaced.
Therefore, it is highly recom-
mended to use either standard key and keep the code re-regis-
tering key in a safe place.
●Do not submerse any key in water.
●Do not expose any key to exces-
sively high temperatures.
●Do not place any key close to
magnets (this includes, but not
limited to, products such as
speakers, etc.).
●Do not place items that transmit
electrical signals close to any key.
●Do not place heavy items on
any key.
●Do not grind any key or alter its
shape.
●Do not disassemble the plastic
part of any key.
●Do not put two keys of any immobi-
lizer system on the same key ring.
●Keep the standard keys as well
as keys of other immobilizer
systems away from this vehi-
cle's code re-registering key.
●Keep other immobilizer system
keys away from the main switch
as they may cause signal inter-
ference.
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-1
INSTRUMENT AND CONTROL FUNCTIONS
4-4
1
2
3
4
\f
6
7
8
\b
10
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
INSTRUMENT AND CONTROL FUNCTIONS
4-8
1
2
3
4
\f
6
7
8
\b
10
Self-diagnosis devices
1. Engine trouble warning lig\ft “ U”
2. \bmmobilizer system indicator lig\ft “ ”
T\fis model is equipped wit\f a self-di-
agnosis device for various electrical
circuits.
\bf any of t\fose circuits are defective,
t\fe engine trouble warning lig\ft will
start flas\fing. \bf t\fis occurs, \fave a
Yama\fa dealer c\feck t\fe ve\ficle.
T\fis model is also equipped wit\f a
self-diagnosis device for t\fe immobi-
lizer system.
\bf any of t\fe immobilizer system cir-
cuits are defective, t\fe immobilizer
system indicator lig\ft will start flas\f-
ing.
\bf t\fis occurs, \fave a Yama\fa dealer
c\feck t\fe ve\ficle.
TIP
\bf t\fe indicator lig\ft slowly flas\fes five
times, and t\fen quickly flas\fes two
times repeatedly, t\fis error could be
caused by transponder interference. \bf
t\fis occurs, try t\fe following.
1. Use t\fe code re-registering key to start t\fe engine.
TIP
Make sure t\fere are no ot\fer immobi-
lizer keys close to t\fe main switc\f, and
do not keep more t\fan one immobiliz-
er key on t\fe same key ring! \bmmobi-
lizer system keys may cause signal in-
terference, w\fic\f may prevent t\fe
engine from starting. 2. \bf t\fe engine starts, turn it off, and
try starting t\fe engine wit\f t\fe
standard keys.
3. \bf one or bot\f of t\fe standard keys do not start t\fe engine, take t\fe
ve\ficle, t\fe code re-registering
key and bot\f standard keys to a
Yama\fa dealer and \fave t\fe
standard keys re-registered.
\bf t\fe immobilizer system indicator
lig\ft continues to flas\f, \fave a Yama-
\fa dealer c\feck t\fe ve\ficle.
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-8
SPECIFICATIONS
9-3
1
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9
1\f
Rea\b suspension:
Type: Swingarm (lin\f suspension\b
Spring/damper type: Coil spring/gas-oil damper, spring
preload adjustable
Wheel travel: 200 mm (7.87 in\b
Elect\bical system:
Ignition system:Transistorized coil ignition (digital\b
Charging system: A.C. magneto
Batte\by:
Model:GT9B-4
Voltage, capacity: 12 V, 8 Ah
Headlight:
Bulb type:Halogen bulb
Bulb voltage, wattage x quantity:Headlight:12 V, 55 W x 2
Auxiliary light: 12 V, 5 W x 2
Tail/bra\fe light: LED
Front turn signal light: 12 V, 10 W x 2
Rear turn signal light: 12 V, 10 W x 2
Meter lighting: LED (bac\flight\b Neutral indicator light:
LED
Turn signal indicator light: LED
High beam indicator light: LED
Coolant temperature warning light: LED
Engine trouble warning light: LED
Immobilizer system indicator light: LED
Fuses:Main fuse:
30 A
Headlight fuse: 20 A
Signaling system fuse: 10 A
Ignition fuse: 10 A
Par\fing lighting fuse: 10 A
Radiator fan fuse: 7.5 A
Fuel injection system fuse: 10 A
Bac\fup fuse (for odometer, cloc\f and immobilizer\b:
10 A
XT660Z 08-10 ING-AUS:MY03 07-10 ING 11-05-2009 10:10 Pagina 8
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
Australia 5/8/10 \á 16:21 Pá\fina 94