2012 YAMAHA XT660Z lights

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

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

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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
4-10
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\f
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\b
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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

FOR YOUR SAFETY – PRE-OPERATION CHECKS
5-4
1
\f
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\b
7
8
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10
ITEM
Instruments, lights,
signals and switches
Sidestand
switch CHECKS
 Check operation.
 Correct if nece\f\fary.
 Check operation of ignition c\fircuit cut-off \fy\fte\b.\f
 If \fy\fte\b i\f not working correctly, have Ya\baha dealer check vehicle. PAGE
4-3, 4-9
4-17
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 4

ECA10260CAUTION:
Even with the tran\fmi\f\fion in
the neutra\b po\fition, do not
coa\ft for \bong period\f of time
with the engine off, and do not
tow the motorcyc\be for \bong
di\ftance\f. The tran\fmi\f\fion i\f
proper\by \bubricated on\by when
the engine i\f running. Inade-
quate \bubrication may damage
the tran\fmi\f\fion.
A\bway\f u\fe the c\butch whi\be
changing gear\f to avoid dam-
aging the engine, tran\fmi\f\fion,
and drive train, which are not
de\figned to with\ftand the
\fhock of forced \fhifting.
EAU16810
Tip\f for reducing fue\b
con\fumption
Fuel consum\ftion de\fends l\brgely on
your riding style. Consider the follow-
ing ti\fs to reduce f\muel consum\ftion:
Shift u\f swiftly, \bnd \bvoid high en-
gine s\feeds during \bc\mceler\btion.
Do not rev the engine while shift-
ing down, \bnd \bvoid high engine
s\feeds with no lo\bd on the en-
gine.
Turn the engine off inste\bd of let-
ting it idle for \bn extended length
of time (e.g., in tr\bffic j\bms, \bt tr\bf-
fic lights or \bt r\bil\mro\bd crossings).
EAU16841
Engine break-in
There is never \b more im\fort\bnt \feri-
od in the life of your engine th\bn the
\feriod between 0 \bnd 1600 km (1000
mi). For this re\bson, you should re\bd
the following m\bteri\m\bl c\brefully.
Since the engine is br\bnd new, do not
\fut \bn excessive lo\bd on it for the first
1600 km (1000 mi). The v\brious \f\brts
in the engine we\br \bnd \folish them-
selves to the correct o\fer\bting cle\br-
\bnces. During this \feriod, \frolonged
full-throttle o\fer\btion or \bny condition
th\bt might result in engine overhe\bting
must be \bvoided.
OPERATION AND IMPORTANT RIDING POINTS
6-3
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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-57-5
EAUM1890
TIP
●Replace t\fe air filte\tr ele\bent \bore frequen\ttly if you are riding in unusually wet or dusty areas.
●Hydraulic brake service
●Regularly c\feck and, if necessary, correct t\fe brake fluid level.
●Every two years replace t\fe inter\tnal co\bponents of t\fe \tbrake \baster cylinder, and c\fange t\fe brake fluid.
●Replace t\fe brake \foses every four years and if cracked or da\baged.
NO. ITEMCHECK OR M\fINTEN\fNCE\M JOB
ODOMETER RE\fDING
1000 km 10000 km 20000 km 30000 km 40000 km(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
\fNN\b\fL
CHECK
√ √ √
√ √ √ √ √
√ √ √ √ √ √ √ √ √ √ √
√ √ √ √ √
√ √ √ √ √ √ Replace.
 C\feck coolant level and ve\ficle for coolant leakage.
 C\fange.
 C\feck operation.
 Lubricate.
 C\feck operation and free play.
 Adjust t\fe t\frottle cab\tle free play if necessary.
 Lubricate t\fe t\frottle grip \fousing
and cable.
 C\feck operation.
 Adjust \feadlig\ft bea\b.\t
Engine oil filter
element
Cooling system
Front and rear brake
switches
Moving parts and
cables
Throttle grip housing
and cable
Lights, signals and
switches
Every 3 years
19
22 20
✻
21✻
24✻
23✻
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-5

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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
7-39
TIP
●Make sure that the slot in the
brake \faliper bra\fket is fit over the
retainer on the s\bingarm.
●Make sure that there is enough
spa\fe bet\been the brake pads
before installing the\b \bheel.
2. Install the drive \fhain onto the rear spro\fket.
3. Install the axle nut, and then lo\b- er the rear \bheel so that it is on
the ground.
4. Adjust the drive \fhain sla\fk. (See page 7-24.)
5. Apply the rear brake several times, and then tighten the axle
nut to the spe\fified\b torque.
Tightening torque:
Axle nut:105 Nm (10.5 m·kgf, 75 ft·lbf)
EAU25871
Troubleshooting
Although Yamaha motor\fy\fles re\feive
a thorough inspe\ftion before shipment
from the fa\ftory, trouble may o\f\fur
during operation. Any problem in the
fuel, \fompression, or ignition systems,
for example, \fan \fause poor starting
and loss of po\ber.
The follo\bing troubleshooting \fharts
represent qui\fk and easy pro\fedures
for \fhe\fking these vital systems your-
self. Ho\bever, should your motor\fy\fle
require any repair, take it to a Yamaha
dealer, \bhose skilled te\fhni\fians have
the ne\fessary tools, experien\fe, and
kno\b-ho\b to servi\fe the motor\fy\fle
properly.
Use only genuine Yamaha repla\fe-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter servi\fe life and
\fan lead to expensive repair bills.
EWA15141
W\fRNING0
When checking the fuel system, do
not smoke, and make sure there
are no open flames or sparks in the
area, including pilot lights from wa-
ter heaters or furnaces. Gasoline or
gasoline vapors can ignite or ex-
plode, causing severe injury or
property damage.
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