2015 YAMAHA XT660Z ignition

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

INSTRUMENT AND CONTROL FUNCTIONS
3-2
3 Keep other immobilizer system
keys away from the main switch
as they may cause signal inter-
ference.
EAU10474
Main switch/steering lockThe main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering. The various
positions are described below.TIPBe sure to use the standard key (black
bow) for regular use of the vehicle. To
minimize the risk of losing the code re-
registering key (red bow), keep it in a
safe place and only use it for code re-
registering.
EAU36871
ON
All electrical circuits are supplied with
power, the meter lighting, taillight, li-
cense plate light and auxiliary lights
come on, and the engine can be start-
ed. The key cannot be removed.TIPThe headlight comes on automatically
when the engine is started and stays

even if the engine stalls.
EAU10662
OFF
All electrical systems are off. The key
can be removed.
WARNING
EWA10062
Never turn the key to “OFF” or
“LOCK” while the vehicle is moving.
Otherwise the electrical systems will
be switched off, which may result in
loss of control or an accident.
P
ON
OFF
LOCK
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INSTRUMENT AND CONTROL FUNCTIONS
3-13
3
EAU13075
Fuel tank capTo open the fuel tank cap
Open the fuel tank cap lock cover, in-
sert the key into the lock, and then turn
it 1/4 turn clockwise. The lock will be
released and the fuel tank cap can be
opened.
To close the fuel tank cap
1. Push the fuel tank cap into posi-
tion with the key inserted in the
lock.
2. Turn the key counterclockwise to
the original position, remove it,
and then close the lock cover.
TIPThe fuel tank cap cannot be closed un-
less the key is in the lock. In addition,
the key cannot be removed if the cap is
not properly closed and locked.
WARNING
EWA11092
Make sure that the fuel tank cap is
properly closed after filling fuel.
Leaking fuel is a fire hazard.
EAU13222
FuelMake sure there is sufficient gasoline in
the tank.
WARNING
EWA10882
Gasoline and gasoline vapors are
extremely flammable. To avoid fires
and explosions and to reduce the
risk of injury when refueling, follow
these instructions.1. Before refueling, turn off the en-
gine and be sure that no one is sit-
ting on the vehicle. Never refuel
while smoking, or while in the vi-
cinity of sparks, open flames, or
other sources of ignition such as
the pilot lights of water heaters
and clothes dryers.
2. Do not overfill the fuel tank. When
refueling, be sure to insert the
pump nozzle into the fuel tank filler
hole. Stop filling when the fuel
reaches the bottom of the filler
tube. Because fuel expands when
it heats up, heat from the engine or
the sun can cause fuel to spill out
of the fuel tank.
1. Lock cover
2. Open.U2BDE1E0.book Page 13 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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FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-3
4
Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.—
Instruments, lights, signals
and switches• Check operation.
• Correct if necessary.—
Sidestand switch • Check operation of ignition circuit cut-off system.
• If system is not working correctly, have Yamaha dealer check vehicle.3-19 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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PERIODIC MAINTENANCE AND ADJUSTMENT
6-31
6
EAUS1934
Replacing the fusesTo replace the fuses (XT660Z):
The main fuse and fuse box 1 (for indi-
vidual circuits) are located under the
seat. (See page 3-16.)
To replace the fuses (XT660ZA):
The main fuse and fuse box 1 (for ABS
model only), which are in a different
and hard-to-reach location, must be
replaced by a Yamaha dealer.
Fuse box 2 (for ABS model only) and
fuse box 3 (for individual circuits) are
located under the seat. (See page
3-16.)To access fuse box 2, pull it upward
and then open it.
If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off
the electrical circuit in question.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage. WARNING! Do not1. Main fuse
2. Spare main fuse
1. Fuse box 1
2. Parking lighting fuse
3. Signaling system fuse
4. Headlight fuse
5. Ignition fuse
6. ECU fuse
7. Radiator fan motor fuse
8. Backup fuse
9. Spare fuseZAUM1269
1. Fuse box 2
2. ABS control unit fuse
3. Spare fuse
4. Fuse box 3
5. Parking lighting fuse
6. Signaling system fuse
7. Headlight fuse
8. Ignition fuse
9. ECU fuse
10.Radiator fan motor fuse
11.Backup fuse
2
34567
1SPA RE
SPA RE SPA RE
ZAUM1247
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-32
6use a fuse of a higher amperage
rating than recommended to
avoid causing extensive dam-
age to the electrical system and
possibly a fire.
[EWA15132]
3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
EAUB1583
Replacing a headlight bulbThis model is equipped with halogen
bulb headlights. If a headlight bulb
burns out, replace it as follows.NOTICE
ECA10651
Take care not to damage the follow-
ing parts:
Headlight bulb
Do not touch the glass part of
the headlight bulb to keep it free
from oil, otherwise the transpar-
ency of the glass, the luminosity
of the bulb, and the bulb life will
be adversely affected. Thor-
oughly clean off any dirt and fin-
gerprints on the headlight bulb
using a cloth moistened with al-
cohol or thinner.
Headlight lens
Do not affix any type of tinted
film or stickers to the headlight
lens.
Do not use a headlight bulb of a
wattage higher than specified.
Specified fuses:
Main fuse:
30.0 A
Parking lighting fuse:
10.0 A
Signaling system fuse:
10.0 A
Headlight fuse:
20.0 A
Ignition fuse:
10.0 A
Fuel injection system fuse:
10.0 A
Radiator fan motor fuse:
7.5 A
Backup fuse:
10.0 A
ABS motor fuse:
XT660ZA 30.0 A
ABS solenoid fuse:
XT660ZA 20.0 A
ABS control unit fuse:
XT660ZA 5.0 A
U2BDE1E0.book Page 32 Tuesday, December 16, 2014 5:38 PM