2013 YAMAHA XT660Z engine coolant

SAFETY INFORMATION .....................1-1
DESCRIPTION.....................................2-1
Left view ...........................................2-1
Right view .........................................2-3
Controls and instruments .................2-5
INSTRUMENT AND CONTROL
FUNCTIONS ........................................3-1
Immobilizer system ...........................3-1
Main switch/steering lock .................3-2
Indicator and warning lights .............3-4
Multi-function display .......................3-6
Anti-theft alarm (optional) .................3-9
Handlebar switches ..........................3-9
Pass switch ....................................3-10
Dimmer switch ...............................3-10
Horn switch ...................................3-10
Turn signal switch ..........................3-10
Hazard switch ................................3-10
Engine stop switch ........................3-10
Start switch ....................................3-10
Clutch lever .....................................3-11
Shift pedal.......................................3-11
Brake lever ......................................3-11
Brake pedal.....................................3-12
ABS (for ABS models) ....................3-12
Fuel tank cap ..................................3-13
Fuel .................................................3-14
Fuel tank breather/overflow
hose .............................................3-15
Catalytic converters ........................3-16Seat.................................................3-16
Adjusting the front fork ...................3-17
Adjusting the shock absorber
assembly .....................................3-18
Sidestand ........................................3-19
Ignition circuit cut-off system .........3-20
FOR YOUR SAFETY – PRE-
OPERATION CHECKS ........................4-1
OPERATION AND IMPORTANT
RIDING POINTS ..................................5-1
Starting the engine ...........................5-1
Shifting ..............................................5-2
Tips for reducing fuel
consumption..................................5-3
Engine break-in.................................5-3
Parking ..............................................5-4
PERIODIC MAINTENANCE AND
ADJUSTMENT ....................................6-1
Owner’s tool kit .................................6-1
Periodic maintenance chart for
the emission control system .........6-3
General maintenance and
lubrication chart ............................6-4
Removing and installing panels........6-8
Checking the spark plug ..................6-9
Engine oil and oil filter element ......6-11
Coolant ...........................................6-14Replacing the air filter element
and cleaning the check hose ......6-15
Checking the engine idling speed ..6-16
Checking the throttle cable free
play ..............................................6-17
Valve clearance ...............................6-17
Tires ................................................6-17
Spoke wheels .................................6-19
Adjusting the clutch lever free
play ..............................................6-20
Checking the front and rear brake
pads.............................................6-21
Checking the brake fluid level ........6-21
Drive chain slack.............................6-23
Cleaning and lubricating the
drive chain ...................................6-24
Checking and lubricating the
cables ..........................................6-25
Checking and lubricating the
brake and clutch levers ...............6-25
Checking and lubricating the
brake pedal .................................6-26
Checking and lubricating the
sidestand .....................................6-26
Lubricating the rear suspension .....6-27
Lubricating the swingarm pivots ....6-27
Checking the front fork ...................6-27
Checking the steering.....................6-28
Checking the wheel bearings .........6-29
Battery ............................................6-29
Replacing the fuses ........................6-31
Replacing a headlight bulb .............6-32
TABLE OF CONTENTS

EAU32230
Right view
XT660Z
DESCRIPTION
2-3
2
10. Grab bar
11. Main fuse (page 6-31)
12. Battery (page 6-29)
13. Rear brake fluid reservoir (page 6-21)
14. Coolant reservoir (page 6-14)
15. Front brake fluid reservoir (page 6-21)
16. Coolant drain bolt
17. Engine oil filter element (page 6-11)18. Brake pedal (page 3-12)

XT660ZA
DESCRIPTION
2-4
2
12. Rear brake fluid reservoir (page 6-21)
13. Fuse box 2 (page 6-31)
14. Owner’s tool kit (page 6-1)
15. Coolant reservoir (page 6-14)
16. Battery (page 6-29)
17. Front brake fluid reservoir (page 6-21)
18. Coolant drain bolt
19. Engine oil filter element (page 6-11)20. Brake pedal (page 3-12)
21. Rear wheel hub

EAU47040
Indicator and warning lights
For XT660Z
1. Immobilizer system indicator light
2. Neutral indicator light “ ”
3. Turn signal indicator light “ ”
4. High beam indicator light “ ”
5. Engine trouble warning light “ ”
6. Coolant temperature warning light “ ”
For XT660ZA
1. Anti-lock Brake System (ABS) warning light
“”
2. Immobilizer system indicator light
3. Neutral indicator light “ ”
4. Turn signal indicator light “ ”
5. High beam indicator light “ ”
6. Engine trouble warning light “ ”
7. Coolant temperature warning light “ ”
EAUB1510
Turn signal indicator light “ ”
This indicator light flashes when the
turn signal switch is pushed to the left
or right.
The electrical circuit of the turn signal
indicator light can be checked by tur-
ning the key to “ON”.If the indicator light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical
circuit.
EAUB1520
Neutral indicator light “ ”
This indicator light comes on when
the transmission is in the neutral posi-
tion.
The electrical circuit of the neutral
indicator light can be checked by tur-
ning the key to “ON”.
If the indicator light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical
circuit.
EAUB1530
High beam indicator light “ ”
This indicator light comes on when
the high beam of the headlight is swit-
ched on.
The electrical circuit of the high beam
indicator light can be checked by tur-
ning the key to “ON”.
If the indicator light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical
circuit.
ABS
INSTRUMENT AND CONTROL FUNCTIONS
3-4
3

EAU11444
Coolant temperature warning light
“”
This warning light comes on if the
engine overheats. If this occurs, stop
the engine immediately and allow the
engine to cool.
The electrical circuit of the warning
light can be checked by turning the
key to “ON”. The warning light should
come on for a few seconds, and then
go off.
If the warning light does not come on
initially when the key is turned to
“ON”, or if the warning light remains
on, have a Yamaha dealer check the
electrical circuit.
ECA10021
Do not continue to operate the
engine if it is overheating.
TIP
For radiator-fan-equipped vehi-
cles, the radiator fan(s) automati-
cally switch on or off according to
the coolant temperature in the
radiator.
If the engine overheats, see page
6-40 for further instructions.
EAU11534
Engine trouble warning light “ ”
This warning light comes on or flas-
hes if a problem is detected in the
electrical circuit monitoring the engi-
ne. If this occurs, have a Yamaha dea-
ler check the self-diagnosis system.
(See page 3-8 for an explanation of
the self-diagnosis device.)
The electrical circuit of the warning
light can be checked by turning the
key to “ON”. The warning light should
come on for a few seconds, and then
go off.
If the warning light does not come on
initially when the key is turned to
“ON”, or if the warning light remains
on, have a Yamaha dealer check the
electrical circuit.
EAU11545
ABS warning light “ ” (for ABS
models)
If this warning light comes on or flas-
hes while riding, the ABS may not
work correctly. If this occurs, have aYamaha dealer check the system as
soon as possible. (See page 3-12).
EWA10081
If the ABS warning light comes on
or flashes while riding, the brake
system reverts to conventional bra-
king. Therefore, be careful not to
cause the wheels to lock during
emergency braking. If the warning
light comes on or flashes while
riding, have a Yamaha dealer check
the brake system as soon as possi-
ble.
The electrical circuit of the warning
light can be checked by turning the
key to “ON”. The warning light should
come on for a few seconds, and then
go off.
If the warning light does not come on
initially when the key is turned to
“ON”, or if the warning light remains
on, have a Yamaha dealer check the
electrical circuit.
WARNING
ABS
NOTICE
INSTRUMENT AND CONTROL FUNCTIONS
3-5
3

FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-1
4
EAU15596
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the ins-
pection and maintenance procedures and schedules described in the Owner’s Manual.
EWA11151
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment dama-
ge. Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures pro-
vided in this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
WARNING
ITEM CHECKS PAGE
• Check fuel level in fuel tank.
• Refuel if necessary.
Fuel• Check fuel line for leakage. 3-14
• Check the fuel tank breather/overflow hose for obstructions, cracks or
damage, and check the hose connection.
• Check oil level in oil tank.
Engine oil• If necessary, add recommended oil to specified level. 6-11
• Check vehicle for oil leakage.
• Check coolant level in reservoir.
Coolant• If necessary, add recommended coolant to specified level. 6-14
• Check cooling system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check lever free play.
• Adjust if necessary.
Front brake• Check brake pads for wear. 6-21
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.

ECAS0040
The following warning lights and
indicator lights should come on for
a few seconds, then go off.
Neutral indicator light
Turn signal indicator light
High beam indicator light
Engine trouble warning light
Coolant temperature warning
light
Immobilizer system indicator
light
ABS warning light (for ABS
model)
If a warning or indicator light does
not go off, see page 3-4 for the
corresponding warning and indica-
tor light circuit check.
2. Shift the transmission into the
neutral position.
TIP
When the transmission is in the neu-
tral position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical
circuit.
3. Start the engine by pushing the
start switch. NOTICE: For maxi-
mum engine life, never accele-
rate hard when the engine is
cold!
[ECA11041]
TIP
If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the
engine more than 10 seconds on any
one attempt.
TIP
The engine is warm when it quickly
responds to the throttle.
EAU16671
Shifting
1. Shift pedal
2. Neutral position
Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing
hills, etc.
The gear positions are shown in the
illustration.
TIP
To shift the transmission into the neu-
tral position, press the shift pedal
down repeatedly until it reaches the
end of its travel, and then slightly rai-
se it.
NOTICE
OPERATION AND IMPORTANT RIDING POINTS
5-2
5

PERIODIC MAINTENANCE AND ADJUSTMENT
6-6
6
ODOMETER READING
NO. ITEM CHECK OR MAINTENANCE JOBANNUAL
1000 km 10000 km 20000 km 30000 km 40000 kmCHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
18 *Front fork• Check operation and for oil
leakage.333 3
19 *Shock absorber • Check operation and shock
assemblyabsorber for oil leakage.333 3
Rear suspension• Check operation.333 3
20 *relay arm and
• Lubricate with lithium-soap-
connecting arm
33
pivoting pointsbased grease.
• Change.
21Engine oil• Check oil level and vehicle for 33 3 3 3 3
oil leakage.
22Engine oil filter
element• Replace.33 3
• Check coolant level and vehicle
23 *Cooling systemfor coolant leakage.333 33
• Change. Every 3 years
24 *Front and rear brake
switches• Check operation.33 3 3 3 3
25Moving parts and
cables• Lubricate.333 33
• Check operation and free play.
Throttle grip • Adjust the throttle cable free
26 *housingplay if necessary.333 33
and cable• Lubricate the throttle grip housing
and cable.