2015 YAMAHA XT660Z seat adjustment

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

PERIODIC MAINTENANCE AND ADJUSTMENT
6-2
6
EAU17382
Owner’s tool kitThe owner’s tool kit is located under
the seat. (See page 3-16.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.TIPIf you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.1. U2BDE1E0.book Page 2 Tuesday, December 16, 2014 5:38 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-12
66. Remove the oil filter element drain
bolt to drain the oil from the oil fil-
ter element.
TIPSkip steps 7…9 if the oil filter element is
not being replaced.7. Remove the oil filter element cover
by removing the bolts.
8. Remove and replace the oil filter
element and O-rings.TIPMake sure that the O-rings are properly
seated.
9. Install the oil filter element cover
by installing the bolts.
10. Install the oil filter element drain
bolt.
11. Tighten the oil filter element cover
bolts and the oil filter element
drain bolt to their specified
torques.
12. Install the engine oil drain bolts,
and then tighten them to their
specified torques.13. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.
NOTICE
ECAM1063
The engine oil tank must be filled in
2 steps. First, fill the engine oil tank
with 1.90 L (2.0 US qt, 1.67 Imp.qt) of
the recommended engine oil. Then,
start the engine, race it 5 or 6 times,
turn it off, and then add the remain-
der of the engine oil.
1. Oil filter element drain bolt
2. Oil filter element cover bolt
1. Oil filter element
2. O-ringTightening torques:
Oil filter element cover bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil filter element drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Tightening torques:
Engine oil drain bolt (crankcase):
30 Nm
Engine oil drain bolt (oil tank):
18 Nm
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element replace-
ment:
2.50 L (2.64 US qt, 2.20 Imp.qt)
With oil filter element replacement:
2.60 L (2.75 US qt, 2.29 Imp.qt)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-14
6
3. If the coolant is at or below the
minimum level mark, remove pan-
el A (See page 6-8.), remove the
coolant reservoir cap, add coolant
to the maximum level mark, and
then install the reservoir cap and
the panel. WARNING! Remove
only the coolant reservoir cap.
Never attempt to remove the ra-
diator cap when the engine is
hot.
[EWA15162]
NOTICE: If coolant is
not available, use distilled water
or soft tap water instead. Do not
use hard water or salt water
since it is harmful to the engine.If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other-
wise the cooling system will not
be protected against frost and
corrosion. If water has been
added to the coolant, have a
Yamaha dealer check the anti-
freeze content of the coolant as
soon as possible, otherwise the
effectiveness of the coolant will
be reduced.
[ECA10473]
EAU33032
Changing the coolant
The coolant must be changed at the in-
tervals specified in the periodic main-
tenance and lubrication chart. Have a
Yamaha dealer change the coolant.
WARNING! Never attempt to remove
the radiator cap when the engine is
hot.
[EWA10382]EAUB1483
Replacing the air filter ele-
ment and cleaning the check
hoseThe air filter element should be re-
placed at the intervals specified in the
periodic maintenance and lubrication
chart. Replace the air filter element
more frequently if you are riding in un-
usually wet or dusty areas. In addition,
the air filter check hose must be fre-
quently checked and cleaned if neces-
sary.
To replace the air filter element
1. Remove the seat. (See page 3-16.)
2. Remove the air filter case cover by
removing the screws.
1. Coolant reservoir
2. Maximum level mark
3. Minimum level mark
4. Coolant reservoir capZAUM1264
Coolant reservoir capacity (up to
the maximum level mark):
0.50 L (0.53 US qt, 0.44 Imp.qt)
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-15
6 3. Pull the air filter element out.
4. Insert a new air filter element into
the air filter case as shown.
NOTICE: Make sure that the air
filter element is properly seated
in the air filter case. The engine
should never be operated with-
out the air filter element in-
stalled, otherwise the piston(s)
and/or cylinder(s) may become
excessively worn.
[ECA10482]
5. Install the air filter case cover by
installing the screws.
6. Install the seat.
To clean the air filter check hose
1. Check the hose on the side of the
air filter case for accumulated dirt
or water.2. If dirt or water is visible, remove
the hose, clean it, and then install
it.
1. Air filter case cover
2. Screw
1. Air filter element

1. Air filter check hose
2. Air filter check hose plug
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-22
6Rear brake (for XT660Z)
Rear brake (for XT660ZA)
TIPThe rear brake fluid reservoir is located
under the seat. (See page 3-16.)
WARNING
EWA16011
Improper maintenance can result in
loss of braking ability. Observe
these precautions:
Insufficient brake fluid may al-
low air to enter the brake sys-
tem, reducing braking
performance.
Clean the filler cap before re-
moving. Use only DOT 4 brake
fluid from a sealed container.
Use only the specified brake flu-
id; otherwise, the rubber seals
may deteriorate, causing leak-
age.
Refill with the same type of
brake fluid. Adding a brake fluid
other than DOT 4 may result in a
harmful chemical reaction.
Be careful that water or dust
does not enter the brake fluid
reservoir when refilling. Water
will significantly lower the boil-
ing point of the fluid and may re-sult in vapor lock, and
dirt may
clog the ABS hydraulic unit
valves.
NOTICE
ECA17641
Brake fluid may damage painted
surfaces or plastic parts. Always
clean up spilled fluid immediately.As the brake pads wear, it is normal for
the brake fluid level to gradually go
down. A low brake fluid level may indi-
cate worn brake pads and/or brake
system leakage; therefore, be sure to
check the brake pads for wear and the
brake system for leakage. If the brake
fluid level goes down suddenly, have a
Yamaha dealer check the cause before
further riding.
1. Minimum level mark
1. Minimum level mark
Specified brake fluid:
DOT 4
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PERIODIC MAINTENANCE AND ADJUSTMENT
6-29
6
EAU23292
Checking the wheel bearingsThe front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.
EAUS1913
BatteryTo access the battery (XTZ660Z):
The battery is located under the seat.
(See page 3-16.)
Remove the battery bracket by remov-
ing the bolts.
Battery (XTZ660ZA):
The battery is located under the fuel
tank.Have a Yamaha dealer access the bat-
tery.
These models are equipped with a
VRLA (Valve Regulated Lead Acid) bat-
tery. There is no need to check the
electrolyte or to add distilled water.
However, the battery lead connections
need to be checked and, if necessary,
tightened.
WARNING
EWA10761
Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al-
ways shield your eyes when
1. Positive battery terminal
2. Holder
3. Bolt
4. Negative battery terminal
1. Battery
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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
U2BDE1E0.book Page 31 Tuesday, December 16, 2014 5:38 PM