2012 YAMAHA XT660Z service

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PERIODIC M\fINTEN\fNCE \fND \fDJ\bSTMENT
EAU17241
Periodic inspection\f adjust\bent\f and
lubrication will keep your vehicle in the
safest and \bost efficient condition
possible. Safety is an obligation of the
vehicle owner/operator. The \bost i\b-
portant points of vehicle inspection\f
adjust\bent\f and lubrication are ex-
plained on the following pages.
The intervals given in the periodic
\baintenance and lubrication char t
should be si\bply considered as a gen-
eral guide under nor\bal riding condi-
tions. However\f depending on the
weather\f terrain\f geographical loca-
tion\f and individual use\f the \bainte-
nance intervals \bay need to be short-
ened.
EWA10321
W\fRNING0
Failure to properly maintain the ve-
hicle or performing maintenance
activities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle
service, have a Yamaha dealer per-
form service.
EAU17391
Owner’s tool kit
1. Owner’s tool kit
The owner’s tool kit is located under
the seat. (See page 4-14).
The service infor\bation included in this
\banual and the tools provided in the
owner’s tool kit are intended to assist
you in the perfor\bance of preventive
\baintenance and \binor repairs. How-
ever\f additional tools such as a torque
wrench \bay be necessary to perfor\b
certain \baintenance work correctly.
TIP
If you do not have the tools or experi-
ence required for a particular job\f have
a Ya\baha dealer perfor\b it for you.
7-1
EWA15121
W\fRNING0
Turn off the engine when perform-
ing maintenance unless otherwise
specified.
\f running engine has moving parts
that can catch on body parts or
clothing and electrical parts that
can cause shocks or\M fires.
Running the engine while servicing
can lead to eye injury, burns, fire, or
carbon monoxide poisoning - pos-
sibly leading to death. See page 2-2
for more information about carbon
monoxide.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:09 Pagina 7-1

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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
7-25
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
7-36
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To service the rear wheel
Raise the rear wheel off the grou\fd by
usi\fg a \botorcycle sta\fd or, if a \bo-
torcycle sta\fd is \fot available, by plac-
i\fg a jack either u\fder each side of the
fra\be i\f fro\ft of the rear wheel or u\f-
der each side of t\uhe swi\fgar\b.EAU24360
Front wheelEAUB1440To remove the front wheel
EWA10820
WARNING0
●It is advisable to have a Yama-
ha dealer service t\4he wheel.
●Securely support the motorcy-
cle so that there is no danger of
it falling over.
1. Wheel axle
2. Brake caliper bolts
A. Fro\ft wheel axle pi\fch bolt
B. Fro\ft wheel axle pi\fch bolt
A
2
B
1
EAU24350
Supporting the motorcycle
Si\fce this \bodel is \fot equipped with
a ce\ftersta\fd, follow these precau-
tio\fs whe\f re\bovi\fg the fro\ft a\fd rear
wheel or perfor\bi\fg other \bai\fte-
\fa\fce requiri\fg the \botorcycle to
sta\fd upright. Check that the \botorcy-
cle is i\f a stable a\fd level positio\f be-
fore star ti\fg a\fy \bai\fte\fa\fce. A
stro\fg woode\f box ca\f be placed u\f-
der the e\fgi\fe for added stability.
To service the front wheel 1. Stabilize the rear of the \botorcy- cle by usi\fg a \botorcycle sta\fd
or, if a\f additio\fal \botorcycle
sta\fd is \fot available, by placi\fg a
jack u\fder the fra\be i\f fro\ft of the
rear wheel.
2. Raise the fro\ft wheel off the grou\fd by usi\fg a \botorcycle
sta\fd.
XT660Z 05-07 ING-AUS:MY03 04-06 ING 11-05-2009 10:10 Pagina 7-36

SPECIFICATIONS
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1\f
Engin\b oil:Type: SAE10W30 or SAE10W40 or SAE15W40
or SAE\f0W40 or SAE\f0W50
Recomme\bded e\bgi\be oil grade: API service SE, SF, SG type or higher
E\bgi\be oil qua\btity: Without oil filter eleme\bt replaceme\bt:\f.50 L (\f.64 US qt) (\f.19 Imp.qt)
With oil filter eleme\bt replaceme\bt: \f.60 L (\f.73 US qt) (\f.\f6 Imp.qt)
Total amou\bt (dry e\bgi\be): \f.90 L (3.07 US qt) (\f.55 Imp.qt)
Cooling syst\bm:Radiator capacity (i\bcludi\bg all routes): 1.\f L (1.\f6 US qt) (1.05 Imp.qt) (Radiator) +
0.5 L (0.5\f US qt) (0.44 Imp.qt)
(Coola\bt reservoir)
Coola\bt reservoir capacity (up to the
maximum level mark): 0.50 L (0.5\f US qt) (0.44 Imp.qt)
From low to full level: 0.30 L (0.3\f US qt) (0.\f6 Imp.qt)
Air filt\br:Air filter eleme\bt:Paper
Fu\bl:Recomme\bded fuel:Premium u\bleaded gasoli\be o\bly
Fuel ta\bk capacity: \f3.0 L (6.07 US gal) (5.06 Imp.gal)
Fuel reserve amou\bt: 6.7 L (1.76 US gal) (1.46 Imp.gal)
Fu\bl inj\bction:Ma\bufacturer:DENSO
Model: \f97500-0390
Spark plug:Ma\bufacturer/model:NGK/CR7EGap:0.7-0.8 mm (0.0\f8-0.03\f i\b)
Clutch:Clutch type:Wet, multiple-disc
Transmission:Primary reductio\b system:Spur gear
Primary reductio\b ratio: 75/36 (\f.083)
Seco\bdary reductio\b system: Chai\b drive
Seco\bdary reductio\b ratio: 45/15 (3.00)
Tra\bsmissio\b type: Co\bsta\bt mesh 5-speed
Dim\bnsions:Overall le\bgth:\f\f46 mm (88.4\f i\b)
Overall width: 864 mm (34.01 i\b)
Overall height: 1477 mm (58.14 i\b)
Seat height: 896 mm (35.\f7 i\b)
Wheelbase: 1500 mm (59.05 i\b)
Grou\bd cleara\bce: \f60 mm (10.\f3 i\b)
Mi\bimum tur\bi\bg radius: 1958 mm (77.08 i\b)
Basic w\bight:With oil a\bd fuel:\f08.5 kg (459 lb)
Engin\b:E\bgi\be type:Liquid cooled 4-stroke, SOHC
Cyli\bder arra\bgeme\bt: Forward-i\bcli\bed si\bgle cyli\bder
Displaceme\bt: 660.0 cm
3(40.\f7 cu.i\b)
Bore x stroke: 100.0 x 84.0 mm (3.94 x 3.31 i\b)
Compressio\b ratio: 10.00 : 1
Starti\bg system: Electric starter
Lubricatio\b system: Dry sump
-\f0 -10 0 10 \f0 30 40 50 °C
SAE 10W-30
SAE 10W-40
SAE \f0W-40
SAE \f0W-50
SAE 15W-40
XT660Z 08-10 ING-AUS:MY03 07-10 ING 11-05-2009 10:10 Pagina 6