2015 YAMAHA XT660Z check engine

TABLE OF CONTENTSSAFETY 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 lights and warning
lights............................................ 3-4
Multi-function display ..................... 3-6
Handlebar switches ........................ 3-9
Clutch lever .................................. 3-10
Shift pedal .................................... 3-11
Brake lever.................................... 3-11
Brake pedal .................................. 3-11
ABS (for ABS models) .................. 3-12
Fuel tank cap ................................ 3-13
Fuel ............................................... 3-13
Fuel tank breather/overflow
hose .......................................... 3-15
Catalytic converter ....................... 3-15
Seat .............................................. 3-16
Adjusting the front fork ................. 3-16
Adjusting the shock absorber
assembly ................................... 3-18
Sidestand ..................................... 3-19
Ignition circuit cut-off system ....... 3-19FOR 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 ............................... 6-2
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 ..... 6-10
Coolant.......................................... 6-13
Replacing the air filter element
and cleaning the check hose..... 6-14
Adjusting the engine idling
speed ......................................... 6-16
Checking the throttle grip free
play ............................................ 6-16
Valve clearance ............................. 6-17
Tires .............................................. 6-17Spoke 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
Changing the brake fluid .............. 6-23
Drive chain slack........................... 6-23
Cleaning and lubricating the drive
chain.......................................... 6-24
Checking and lubricating the
cables ........................................ 6-25
Checking and lubricating the
throttle grip and cable ............... 6-25
Checking and lubricating the
brake and clutch levers ............. 6-26
Checking and lubricating the
brake pedal ............................... 6-26
Checking and lubricating the
sidestand................................... 6-27
Lubricating the rear suspension ... 6-27
Lubricating the swingarm
pivots......................................... 6-27
Checking the front fork ................. 6-28
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
Replacing an auxiliary light bulb ... 6-34
Tail/brake light .............................. 6-34U2BDE1E0.book Page 1 Tuesday, December 16, 2014 5:38 PM

SAFETY INFORMATION
1-3
1Carbon Monoxide is a colorless, odor-
less, tasteless gas which may be pres-
ent even if you do not see or smell any
engine exhaust. Deadly levels of car-
bon monoxide can collect rapidly and
you can quickly be overcome and un-
able to save yourself. Also, deadly lev-
els of carbon monoxide can linger for
hours or days in enclosed or poorly
ventilated areas. If you experience any
symptoms of carbon monoxide poi-
soning, leave the area immediately, get
fresh air, and SEEK MEDICAL TREAT-
MENT.
Do not run engine indoors. Even if
you try to ventilate engine exhaust
with fans or open windows and
doors, carbon monoxide can rap-
idly reach dangerous levels.
Do not run engine in poorly venti-
lated or partially enclosed areas
such as barns, garages, or car-
ports.
Do not run engine outdoors where
engine exhaust can be drawn into
a building through openings such
as windows and doors.Loading
Adding accessories or cargo to your
motorcycle can adversely affect stabil-
ity and handling if the weight distribu-
tion of the motorcycle is changed. To
avoid the possibility of an accident, use
extreme caution when adding cargo or
accessories to your motorcycle. Use
extra care when riding a motorcycle
that has added cargo or accessories.
Here, along with the information about
accessories below, are some general
guidelines to follow if loading cargo to
your motorcycle:
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit.
Operation of an overloaded vehicle
could cause an accident.
When loading within this weight limit,
keep the following in mind:
Cargo and accessory weight
should be kept as low and close to
the motorcycle as possible. Se-
curely pack your heaviest items asclose to the center of the vehicle
as possible and make sure to dis-
tribute the weight as evenly as
possible on both sides of the mo-
torcycle to minimize imbalance or
instability.
Shifting weights can create a sud-
den imbalance. Make sure that
accessories and cargo are se-
curely attached to the motorcycle
before riding. Check accessory
mounts and cargo restraints fre-
quently.
• Properly adjust the suspension
for your load (suspension-ad-
justable models only), and
check the condition and pres-
sure of your tires.
• Never attach any large or heavy
items to the handlebar, front
fork, or front fender. These
items, including such cargo as
sleeping bags, duffel bags, or
tents, can create unstable han-
dling or a slow steering re-
sponse.
This vehicle is not designed to
pull a trailer or to be attached to
a sidecar.
Maximum load:
190 kg (419 lb)
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INSTRUMENT AND CONTROL FUNCTIONS
3-4
3
EAU49398
Indicator lights and warning
lights
EAUB1512
Turn signal indicator light “ ”
This indicator light flashes when a turn
signal light is flashing.
The electrical circuit of the turn signal
indicator light can be checked by turn-
ing 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 cir-
cuit.
EAUB1521
Neutral indicator light “ ”
This indicator light comes on when the
transmission is in the neutral position.
The electrical circuit of the neutral indi-
cator light can be checked by turning
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 cir-
cuit.
EAUB1531
High beam indicator light “ ”
This indicator light comes on when the
high beam of the headlight is switched
on.
The electrical circuit of the high beam
indicator light can be checked by turn-
ing 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 cir-
cuit.
EAU11447
Coolant temperature warning
light “ ”
This warning light comes on if the en-
gine overheats. If this occurs, stop the
engine immediately and allow the en-
gine 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.NOTICE
ECA10022
Do not continue to operate the en-
gine 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 ra-
diator.
1. Anti-lock Brake System (ABS) warning
light “ ” (for ABS models)
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 “ ”
ABS
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INSTRUMENT AND CONTROL FUNCTIONS
3-5
3If the engine overheats, see page
6-41 for further instructions.
EAU11535
Engine trouble warning light “ ”
This warning light comes on or flashes
if a problem is detected in the electrical
circuit monitoring the engine. If this oc-
curs, have a Yamaha dealer 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.
EAU11546
ABS warning light “ ” (for ABS
models)
If this warning light comes on or flashes
while riding, the ABS may not work
correctly. If this occurs, have a Yamaha
dealer check the system as soon aspossible. (See page 3-12.)
WARNING
EWA10082
If the ABS warning light comes on or
flashes while riding, the brake sys-
tem reverts to conventional braking.
Therefore, be careful not to cause
the wheels to lock during emergen-
cy braking. If the warning light
comes on or flashes while riding,
have a Yamaha dealer check the
brake system as soon as possible.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.
EAU26879
Immobilizer system indicator
light “ ”
When the key is turned to “OFF” and
30 seconds have passed, the indicator
light will start flashing indicating the im-mobilizer system is enabled. After 24
hours have passed, the indicator light
will stop flashing, however the immobi-
lizer system is still enabled.
The electrical circuit of the indicator
light can be checked by turning the key
to “ON”. The indicator light should
come on for a few seconds, and then
go off.
If the indicator light does not come on
initially when the key is turned to “ON”,
or if the indicator light remains on, have
a Yamaha dealer check the electrical
circuit.
The self-diagnosis device also detects
problems in the immobilizer system
circuits. (See page 3-8 for an explana-
tion of the self-diagnosis device.)
ABS
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INSTRUMENT AND CONTROL FUNCTIONS
3-8
3 5. Push the “SELECT” button and
then release it to start the clock.
Fuel meter
With the key in the “ON” position, the
fuel meter indicates the amount of fuel
in the fuel tank. When the key is turned
to “ON”, all of the display segments of
the fuel meter appear one after the oth-
er and then disappear in order to test
the electrical circuit. The display seg-
ments of the fuel meter disappear to-
wards “E” (Empty) as the fuel level
decreases. When only one segment is
left near “E” (Empty), refuel as soon as
possible.
TIPThis fuel meter is equipped with a self-
diagnosis system. If the electrical cir-
cuit is defective, all the segments start
flashing. If this occurs, have a Yamaha
dealer check the electrical circuit.Self-diagnosis devices
This model is equipped with a self-di-
agnosis device for various electrical
circuits.
If any engine electrical circuits are de-
fective, the engine trouble warning light
starts flashing. If this occurs, have a
Yamaha dealer check the vehicle.(for ABS models)
If any of the ABS electrical circuits are
defective, the ABS warning light will
come on. If this occurs, have a Yamaha
dealer check the vehicle.
This model is also equipped with a self-
diagnosis device for the immobilizer
system.
If any of the immobilizer system circuits
are defective, the immobilizer system
indicator light starts flashing. If this oc-
curs, have a Yamaha dealer check the
vehicle.
TIPIf the indicator light slowly flashes five
times, and then quickly flashes two
times repeatedly, this error could be
caused by transponder interference. If
this occurs, try the following.1. Use the code re-registering key to
start the engine.
2. If the engine starts, turn it off, and
try starting the engine with the
standard keys.
3. If one or both of the standard keys
do not start the engine, take the
vehicle, the code re-registering
1. Fuel meter
1. Anti-lock Brake System (ABS) warning
light Ž (for ABS models)
2. Immobilizer system indicator light Ž
3. Engine trouble warning light Ž
ABS
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INSTRUMENT AND CONTROL FUNCTIONS
3-15
3
EAUB1302
Fuel tank breather/overflow
hoseBefore operating the motorcycle:
Check the fuel tank breather/over-
flow hose connection.
Check the fuel tank breather/over-
flow hose for cracks or damage,
and replace it if necessary.
Make sure that the end of the fuel
tank breather/overflow hose is not
blocked, and clean it if necessary.
Make sure that the fuel tank
breather/overflow hose is routed
through the clamp.
EAU13434
Catalytic converterThis model is equipped with a catalytic
converter in the exhaust system.
WARNING
EWA10863
The exhaust system is hot after op-
eration. To prevent a fire hazard or
burns:
Do not park the vehicle near
possible fire hazards such as
grass or other materials that
easily burn.
Park the vehicle in a place
where pedestrians or children
are not likely to touch the hot
exhaust system.
Make sure that the exhaust sys-
tem has cooled down before
doing any maintenance work.
Do not allow the engine to idle
more than a few minutes. Long
idling can cause a build-up of
heat.
NOTICE
ECA10702
Use only unleaded gasoline. The use
of leaded gasoline will cause unre-
pairable damage to the catalytic
converter.
1. Fuel tank breather/overflow hose
2. Hose clampU2BDE1E0.book Page 15 Tuesday, December 16, 2014 5:38 PM

INSTRUMENT AND CONTROL FUNCTIONS
3-19
3
EAU15306
SidestandThe sidestand is located on the left
side of the frame. Raise the sidestand
or lower it with your foot while holding
the vehicle upright.TIPThe built-in sidestand switch is part of
the ignition circuit cut-off system,
which cuts the ignition in certain situa-
tions. (See the following section for an
explanation of the ignition circuit cut-
off system.)
WARNING
EWA10242
The vehicle must not be ridden with
the sidestand down, or if the side-
stand cannot be properly moved up
(or does not stay up), otherwise the
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control.
Yamaha’s ignition circuit cut-off
system has been designed to assist
the operator in fulfilling the respon-
sibility of raising the sidestand be-
fore starting off. Therefore, check
this system regularly and have a
Yamaha dealer repair it if it does not
function properly.
EAU15315
Ignition circuit cut-off systemThe ignition circuit cut-off system
(comprising the sidestand switch,
clutch switch and neutral switch) has
the following functions.
It prevents starting when the
transmission is in gear and the
sidestand is up, but the clutch le-
ver is not pulled.
It prevents starting when the
transmission is in gear and the
clutch lever is pulled, but the side-
stand is still down.
It cuts the running engine when
the transmission is in gear and the
sidestand is moved down.
Periodically check the operation of the
ignition circuit cut-off system accord-
ing to the following procedure.TIPThis check is most reliable if performed
with a warmed-up engine.
1. SidestandZAUM1272
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INSTRUMENT AND CONTROL FUNCTIONS
3-20
3
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is set to “
3. Turn the key on.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the start switch.
Does the engine start?
The system is OK. The motorcycle can be ridden.The neutral switch may not be working correctly.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The sidestand switch may not be working correctly.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The clutch switch may not be working correctly.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
YES NO YES NO YES NO
If a malfunction is noted, have a Yamaha
dealer check the system before riding.
WARNING
”.
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