2012 YAMAHA XT660Z steering

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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SAFETY INFORMATION
Loading
Adding accessories or cargo to your
motorcycle can adversely affect sta\fil-
ity and handling if the weight distri\fu-
tion of the motorcycle is changed\b To
avoid the possi\fility of an accident,
use extreme caution when adding car-
go or accessories to your motorcycle\b
Use extra care when riding a motorcy-
cle that has added cargo or acces-
sories\b Here, along with the informa-
tion a\fout accessories \felow, are
some general guidelines to follow if
loading cargo to y\four motorcycle:
T\fe total \beig\ft of t\fe operator,
passenger, accessories and cargo
must not exceed t\fe maximum load
limit. Operation of an overloaded
ve\ficle could cause a\gn accident.
2-3
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2
3
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9
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curely pack your heaviest items
as close to the center of the vehi-
cle as possi\fle and make sure to
distri\fute the weight as evenly as
possi\fle on \foth sides of the mo-
torcycle to minimize im\falance or
insta\fility\b
●Shifting weights can create a sud-
den im\falance\b Make sure that
accessories and cargo are se-
curely attached to the motorcycle
\fefore riding\b Check accessory
mounts and cargo restraints fre-
quently\b
 Properly adjust the suspension for your load, and check the
condition and pressure of your
tires\b
 Never attach any large or heavy items to the handle\far, front
fork, or front fender\b These
items, including such cargo as
sleeping \fags, duffel \fags, or
tents, can create unsta\fle han-
dling or a slow steering re-
sponse\b
●T\fis ve\ficle is not designed to
pull a trailer or to be attac\fed
to a sidecar. Genuine Yama\fa Accessories
Choosing accessories for your vehicle
is an important decision\b Genuine
Yamaha accessories, which are avail-
a\fle only from a Yamaha dealer, have
\feen designed, tested, and approved
\fy Yamaha for use on your vehicle\b
Many companies with no connection
to Yamaha manufacture parts and ac-
cessories or offer other modifications
for Yamaha vehicles\b Yamaha is not in
a position to test the products that
these aftermarket companies pro-
duce\b Therefore, Yamaha can neither
endorse nor recommend the use of
accessories not sold \fy Yamaha or
modifications not specifically recom-
mended \fy Yamaha, even if sold and
installed \fy a Yamaha dealer\b
Aftermarket Parts, Accessories,
and Modifications
While you may find aftermarket prod-
ucts similar in design and quality to
genuine Yamaha accessories, recog-
nize that some aftermarket acces-
sories or modifications are not suita\fle
\fecause of potentia\fl safety hazards to
you or others\b Installing aftermarket
Maximum load:
190 kg (419 l\f)
When loading within this weight limit,
keep the following in mind:
●Cargo and accessor y weight
should \fe kept as low and close
to the motorcycle as possi\fle\b Se-
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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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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 AND CONTROL FUNCTIONS
4-2
1
2
3
4
\f
6
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8
\b
10
EAU10471
Main switch/steering lock
The main swi\fch/s\feerin\b lock con\frols
\fhe i\bni\fion and li\bh\fin\b sys\fems, and
is used \fo lock \fhe s\feerin\b.
TIP
Be sure \fo use \fhe s\fandard key (black
bow) for re\bular use of \fhe vehicle. To
minimize \fhe risk of losin\b \fhe code re-
re\bis\ferin\b key (red bow), keep i\f in a
safe place and only use i\f for code re-
re\bis\ferin\b.
EAU10550
ON
All elec\frical circui\fs are supplied wi\fh
power, \fhe me\fer li\bh\fin\b, \failli\bh\f, li-
cense pla\fe li\bh\f and auxiliary li\bh\fs
come on, and \fhe en\bine can be s\far\f-
ed. The key canno\f be removed.
TIP
The headli\bh\fs comes on au\foma\fical-
ly when \fhe en\bine is s\far\fed and s\fay
on un\fil \fhe key is \furned \fo “OFF”,
even if \fhe en\bine s\fa\wlls.
EAU10661
OFF
All elec\frical sys\fems are off. The key
can be removed.
EWA10061
WARNING0
Never turn the key to "OFF" or
"LOCK" while the vehicle is moving.
Otherwise the electrical systems
will be switched off, which may re-
sult in loss of control or an acci-
dent.
EAU10691
LOCK
The s\feerin\b is locked, and all elec\fri-
cal sys\fems are off. The key can be re-
moved.
To lock \fhe s\feerin\b
1. Push
2. Turn
1. Turn \fhe handlebars all \fhe way \fo \fhe lef\f or ri\bh\f.
2. Push \fhe key in from \fhe “OFF” posi\fion, and \fhen \furn i\f \fo
“LOCK” while s\fill pushin\w\b i\f.
3. Remove \fhe key.
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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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PERIODIC MAINTENANCE AND ADJUSTMENT
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NO. ITEM CHECK OR MAINTENAN\4CE JOB
ODOMETER READING
1000 km 10000 km 20000 km 30000 km 40000 km(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
ANNUAL
CHECK
√ √ √ √
√ √ √ √ √ √ √
√√
√
√ √ √ √ √
√ √ √ √ √ √ √ √ √ √
√ √ √ √
√ √ √ √
√ √
√ √ √ √ √ √
13
14
✻
1\f✻
16✻
18
 Check operation and for e\fcessive pla\b.
 Lubricate with lithium-\fsoap-based grease.
 Check chain slack, alignment and condition.
 Adjust and lubricate chain with a\f special
O-ring chain lubricant thoroughl\b.
 Check bearing pla\b and steering
for roughness.
 Lubricate with lithium-\fsoap-based grease.
 Make sure that all nuts, bolts and screws
are properl\b tightened.
 Check operation.
 Lubricate.
 Check operation.
 Check operation and for oil leakage.
 Check operation and shock absorber
for oil leakage.
 Check operation.
 Lubricate with lithium-\fsoap-based grease.
 Change.
 Check oil level and vehicle for oil leakage.
Swingarm
Drive chain
Steering bearings
Chassis fasteners
Sidestand
Sidestand switch
Front fork
Shock absorber
assembly
Rear suspension
relay arm and
connecting arm
pivoting points
Engine oil
Ever\b 50000 km (30000 mi)
Ever\b 50000 km (30000 mi)
Ever\b 500 km (300 mi) and after washing the motorc\bcle or riding in the rain
\b✻
11✻
17✻
12✻
10
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