2015 YAMAHA XT660Z clutch

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

DESCRIPTION
2-5
2
EAU10431
Controls and instruments1. Clutch lever (page 3-10)
2. Left handlebar switches (page 3-9)
3. Multi-function display (page 3-6)
4. Right handlebar switches (page 3-9)
5. Throttle grip (page 6-16)
6. Brake lever (page 3-11)
7. Engine oil filler cap (page 6-10)
8. Fuel tank cap (page 3-13)9. Main switch/steering lock (page 3-2)
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INSTRUMENT AND CONTROL FUNCTIONS
3-10
3 ter position. To cancel the turn signal
lights, push the switch in after it has re-
turned to the center position.
EAU12501
Horn switch “ ”
Press this switch to sound the horn.
EAU12661
Engine stop switch “ / ”
Set this switch to “ ” before starting
the engine. Set this switch to “ ” to
stop the engine in case of an emergen-
cy, such as when the vehicle overturns
or when the throttle cable is stuck.
EAU12713
Start switch “ ”
Push this switch to crank the engine
with the starter. See page 5-1 for start-
ing instructions prior to starting the en-
gine.
EAU44712
The engine trouble warning light and
ABS warning light (ABS model only)
may come on when the key is turned to
“ON” and the start switch is pushed,
but this does not indicate a malfunc-
tion.
EAU12735
Hazard switch “ ”
With the key in the “ON” or “ ” posi-
tion, use this switch to turn on the haz-
ard lights (simultaneous flashing of all
turn signal lights).
The hazard lights are used in case of an
emergency or to warn other drivers
when your vehicle is stopped where it
might be a traffic hazard.NOTICE
ECA10062
Do not use the hazard lights for an
extended length of time with the en-
gine not running, otherwise the bat-
tery may discharge.
EAU12821
Clutch leverThe clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the han-
dlebar grip. To engage the clutch, re-
lease the lever. The lever should be
pulled rapidly and released slowly for
smooth clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the igni-
tion circuit cut-off system. (See page
3-19.)1. Clutch lever
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INSTRUMENT AND CONTROL FUNCTIONS
3-11
3
EAU12872
Shift pedalThe shift pedal is located on the left
side of the motorcycle and is used in
combination with the clutch lever when
shifting the gears of the 5-speed con-
stant-mesh transmission equipped on
this motorcycle.
EAU26825
Brake leverThe brake lever is located on the right
side of the handlebar. To apply the
front brake, pull the lever toward the
throttle grip.
The brake lever is equipped with a
brake lever position adjusting dial. To
adjust the distance between the brake
lever and the throttle grip, turn the ad-
justing dial while holding the lever
pushed away from the throttle grip.
Make sure that the appropriate setting
on the adjusting dial is aligned with
the “ ” mark on the brake lever.
EAU12944
Brake pedalThe brake pedal is located on the right
side of the motorcycle. To apply the
rear brake, press down on the brake
pedal.
1. Shift pedalZAUM1260
1. Brake lever
2. Position adjusting dial
3. Arrow mark
4. Distance between brake lever and handle-
bar grip
11
1
ZAUM1251
1. Brake pedal
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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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FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-2
4
Rear brake• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
• Replace if necessary.
• Check fluid level in reservoir.
• If necessary, add specified brake fluid to specified level.
• Check hydraulic system for leakage.6-21, 6-21
Clutch• Check operation.
• Lubricate cable if necessary.
• Check lever free play.
• Adjust if necessary.6-20
Throttle grip• Make sure that operation is smooth.
• Check throttle grip free play.
• If necessary, have Yamaha dealer adjust throttle grip free play and lubricate ca-
ble and grip housing.6-16, 6-25
Control cables• Make sure that operation is smooth.
• Lubricate if necessary.6-25
Drive chain• Check chain slack.
• Adjust if necessary.
• Check chain condition.
• Lubricate if necessary.6-23, 6-24
Wheels and tires• Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary.6-17, 6-19
Brake pedal• Make sure that operation is smooth.
• Lubricate pedal pivoting point if necessary.6-26
Brake and clutch levers• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.6-26
Sidestand• Make sure that operation is smooth.
• Lubricate pivot if necessary.6-27 ITEM CHECKS PAGE
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OPERATION AND IMPORTANT RIDING POINTS
5-1
5
EAU15952
Read the Owner’s Manual carefully to
become familiar with all controls. If
there is a control or function you do not
understand, ask your Yamaha dealer.
WARNING
EWA10272
Failure to familiarize yourself with
the controls can lead to loss of con-
trol, which could cause an accident
or injury.
EAU48021
TIPThis model is equipped with a lean an-
gle sensor to stop the engine in case of
a turnover. In this case, the multi-func-
tion display indicates error code 30,
but this is not a malfunction. Turn the

the error code. Failing to do so will pre-
vent the engine from starting even
though the engine will crank when
pushing the start switch.
EAUS1952
Starting the engineIn order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
The transmission is in the neutral
position.
The transmission is in gear with
the clutch lever pulled and the
sidestand up.
WARNING
EWA10291
Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-19.
Never ride with the sidestand
down.1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “ ”.NOTICE
ECAS0041
The following warning lights and in-
dicator lights should come on for a
few seconds, then go off.
Neutral indicator light
Turn signal indicator light
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