Read this manual carefully before operating this vehicle.
EAU26945 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. DECLARATION of CONFORMITY We Company: YAMAHA MOTOR ELECTRONICS CO., LTD. Address: 1450-6, Mori, Mori-Machi, Shuchi-gun, Shizuoka-Ken, 437-0292 Japan Hereby declare that the product: Kind of equipment: IMMOBILIZER Type-designation: 5SL-00 is in compliance with following norm(s) or documents: R&TTE Directive(1999/5/EC) EN300 330-2 v1.3.1(2006-01), EN300 330-2 v1.5.
INTRODUCTION EAU10102 Welcome to the Yamaha world of motorcycling! As the owner of the XT660Z - XT660ZA, you are benefiting from Yamaha’s vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your XT660Z - XT660ZA.
IMPORTANT MANUAL INFORMATION EAU10132 Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. WARNING NOTICE TIP A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
IMPORTANT MANUAL INFORMATION EAUS1172 XT660Z - XT660ZA OWNER’S MANUAL ©2012 by MBK INDUSTRIE. 1st edition, March 2012 All rights reserved. Any reprinting or unauthorized use without the written permission of MBK INDUSTRIE is expressly prohibited. Printed in France.
TABLE OF CONTENTS 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 .............
TABLE OF CONTENTS Tail/brake light.................................6-33 Replacing a turn signal light bulb...6-34 Replacing the license plate light bulb .............................................6-34 Replacing an auxiliary light bulb.....6-34 Supporting the motorcycle .............6-35 Front wheel .....................................6-36 Rear wheel ......................................6-37 Troubleshooting ..............................6-38 Troubleshooting charts ...................
SAFETY INFORMATION EAU10318 Be a Responsible Owner As the vehicle’s owner, you are responsible for the safe and proper operation of your motorcycle. Motorcycles are single-track vehicles. Their safe use and operation are dependent upon the use of proper riding techniques as well as the expertise of the operator. Every operator should know the following requirements before riding this motorcycle. He or she should: G Obtain thorough instructions from a competent source on all aspects of motorcycle operation.
SAFETY INFORMATION 1 G G • Always obey the speed limit and never travel faster than warranted by road and traffic conditions. • Always signal before turning or changing lanes. Make sure that other motorists can see you. The posture of the operator and passenger is important for proper control. • The operator should keep both hands on the handlebar and both feet on the operator footrests during operation to maintain control of the motorcycle.
SAFETY INFORMATION G G Do not run engine in poorly ventilated or partially enclosed areas such as barns, garages, or carports. 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 stability and handling if the weight distribution of the motorcycle is changed.
SAFETY INFORMATION mended by Yamaha, even if sold and installed by a Yamaha dealer. 1 Aftermarket Parts, Accessories, and Modifications While you may find aftermarket products similar in design and quality to genuine Yamaha accessories, recognize that some aftermarket accessories or modifications are not suitable because of potential safety hazards to you or others.
SAFETY INFORMATION G G G G G G Remove all loose items from the motorcycle. Check that the fuel cock (if equipped) is in the “OFF” position and that there are no fuel leaks. Point the front wheel straight ahead on the trailer or in the truck bed, and choke it in a rail to prevent movement. Shift the transmission in gear (for models with a manual transmission).
DESCRIPTION EAU32220 Left view XT660Z 2 1. 2. 3. 4. 5. 6. 7. 8. Idle adjusting screw (page 6-16) Owner’s tool kit (page 6-1) Air filter element (page 6-15) Fuse box 1 (page 6-31) Seat lock (page 3-16) Shock absorber assembly spring preload adjusting ring (page 3-18) Shift pedal (page 3-11) Engine oil drain bolt (crankcase) (page 6-11) 9.
DESCRIPTION XT660ZA 2 1. 2. 3. 4. 5. 6. 7. 8. Main fuse (page 6-31) Fuse box 1 (page 6-31) Idle adjusting screw (page 6-16) Fuse box 2 (page 6-31) Fuse box 2 (page 6-31) Seat lock (page 3-16) Shock absorber assembly spring preload adjusting ring (page 3-18) Shift pedal (page 3-11) 9. Engine oil drain bolt (crankcase) (page 6-11) 10. Engine oil drain bolt (oil tank) (page 6-11) 11.
DESCRIPTION EAU32230 Right view XT660Z 2 10. 11. 12. 13. 14. 15. 16. 17. Grab bar Main fuse (page 6-31) Battery (page 6-29) Rear brake fluid reservoir (page 6-21) Coolant reservoir (page 6-14) Front brake fluid reservoir (page 6-21) Coolant drain bolt Engine oil filter element (page 6-11) 18.
DESCRIPTION XT660ZA 2 12. 13. 14. 15. 16. 17. 18. 19. Rear brake fluid reservoir (page 6-21) Fuse box 2 (page 6-31) Owner’s tool kit (page 6-1) Coolant reservoir (page 6-14) Battery (page 6-29) Front brake fluid reservoir (page 6-21) Coolant drain bolt Engine oil filter element (page 6-11) 20. Brake pedal (page 3-12) 21.
DESCRIPTION EAU10430 Controls and instruments 2 1. 2. 3. 4. 5. 6. 7. 8. Clutch lever (page 3-11) Left handlebar switches (page 3-9) Multi-function display (page 3-6) Right handlebar switches (page 3-9) Throttle grip (page 6-17) Brake lever (page 3-11) Engine oil filler cap (page 6-11) Fuel tank cap (page 3-13/3-14 ) 9.
INSTRUMENT AND CONTROL FUNCTIONS EAU10976 Immobilizer system G an immobilizer system indicator light (See page 3-4) The key with the red bow is used to register codes in each standard key. Since re-registering is a difficult process, take the vehicle along with all three keys to a Yamaha dealer to have them re-registered. Do not use the key with the red bow for driving. It should only be used for re-registering the standard keys. Always use a standard key for driving. 1.
INSTRUMENT AND CONTROL FUNCTIONS G Keep other immobilizer system keys away from the main switch as they may cause signal interference. EAU10472 Main switch/steering lock power, the meter lighting, taillight, license plate light and auxiliary lights come on, and the engine can be started. The key cannot be removed. TIP The headlights come on automatically when the engine is started and stay on until the key is turned to “OFF”, even if the engine stalls.
INSTRUMENT AND CONTROL FUNCTIONS To lock the steering To unlock the steering EAU10941 (Parking) The steering is locked, and the taillight, license plate light and auxiliary lights are on. The hazard lights and turn signal lights can be turned on, but all other electrical systems are off. The key can be removed. The steering must be locked before the key can be turned to “ ”. 1. Push 2. Turn 1. Turn the handlebars all the way to the left. 2.
INSTRUMENT AND CONTROL FUNCTIONS EAU47040 For XT660ZA If the indicator light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical circuit. Indicator and warning lights For XT660Z EAUB1520 3 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 “ 1. Anti-lock Brake System (ABS) warning light “ ABS ” 2.
INSTRUMENT AND CONTROL FUNCTIONS 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.
INSTRUMENT AND CONTROL FUNCTIONS EAU26877 3 Immobilizer system indicator light “ ” 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.
INSTRUMENT AND CONTROL FUNCTIONS buttons, turn the key to “ON”. When the digits start flashing, push the “SELECT” button to change between kilometers and miles. Tachometer ECA10031 NOTICE Do not operate the engine in the tachometer red zone. Red zone: 7500 r/min and above Tripmeter and tachometer modes When the fuel amount in the fuel tank decreases to XT660Z 6.7 L (1.76 US gal, 1.46 Imp.gal) - XT660ZA 5.8 L (1.53 US gal, 1.28 Imp.
INSTRUMENT AND CONTROL FUNCTIONS Clock mode 5. Push the “SELECT” button and then release it to start the clock. Fuel meter 3 TIP This fuel meter is equipped with a selfdiagnosis system. If the electrical circuit is defective, all the segments start flashing. If this occurs, have a Yamaha dealer check the electrical circuit. Self-diagnosis devices 1. Clock 2. “SELECT” button 3. “RESET” button TIP The clock always shows the time regardless of the main switch position. To set the clock: 1.
INSTRUMENT AND CONTROL FUNCTIONS (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 occurs, have a Yamaha dealer check the vehicle.
INSTRUMENT AND CONTROL FUNCTIONS switch to “ ”. To signal a left-hand turn, push this switch to “ ”. When released, the switch returns to the center position. To cancel the turn signal lights, push the switch in after it has returned to the center position. Right EAU12733 3 1. Engine stop switch “ 2. Start switch “ ” / ” EAU12350 Pass switch “ ” Press this switch to flash the headlight.
INSTRUMENT AND CONTROL FUNCTIONS EAU12820 Clutch lever EAU12871 Shift pedal EAU26823 Brake lever 3 1. Clutch lever 1. Shift pedal The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the handlebar grip. To engage the clutch, release 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 ignition circuit cut-off system. (See page 3-20).
INSTRUMENT AND CONTROL FUNCTIONS aligned with the “ brake lever. ” mark on the EAU12941 Brake pedal EAU26794 ABS (for ABS models) The Yamaha ABS (Anti-lock Brake System) features a dual electronic control system, which acts on the front and rear brakes independently. The ABS is monitored by an ECU, which will have recourse to manual braking if a malfunction occurs. 3 EWA10090 WARNING 1. Brake pedal G The brake pedal is on the right side of the motorcycle.
INSTRUMENT AND CONTROL FUNCTIONS G This ABS has a test mode which allows the owner to experience the pulsating at the brake lever or brake pedal when the ABS is operating. However, special tools are required, so please consult your Yamaha dealer when performing this test. EAU13074 Fuel tank cap 3 ECA16120 NOTICE Keep any type of magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.
INSTRUMENT AND CONTROL FUNCTIONS TIP The fuel tank cap cannot be closed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly closed and locked. EWA11091 3 WARNING Make sure that the fuel tank cap is properly closed after filling fuel. Leaking fuel is a fire hazard. EAU13212 Fuel Make sure there is sufficient gasoline in the tank. EWA10881 WARNING Gasoline and gasoline vapors are extremely flammable.
INSTRUMENT AND CONTROL FUNCTIONS vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. ne with a research octane number of 95 or higher. If knocking (or pinging) occurs, use a gasoline of a different brand. Use of unleaded fuel will extend spark plug life and reduce maintenance costs.
INSTRUMENT AND CONTROL FUNCTIONS EAU13445 Catalytic converters This vehicle is equipped with catalytic converters in the exhaust system. EWA10862 WARNING 3 ECA10701 NOTICE Use only unleaded gasoline. The use of leaded gasoline will cause unrepairable damage to the catalytic converter. The exhaust system is hot after operation. To prevent a fire hazard or burns: G Do not park the vehicle near possible fire hazards such as grass or other materials that easily burn.
INSTRUMENT AND CONTROL FUNCTIONS EAUS1920 Adjusting the front fork For XT660Z: This front fork is equipped with spring preload adjusting bolts. EWA10180 3 WARNING 1. Projection 2. Seat holder TIP Make sure that the seat is properly secured before riding. Always adjust both fork legs equally, otherwise poor handling and loss of stability may result. Adjust the spring preload as follows.
INSTRUMENT AND CONTROL FUNCTIONS For XT660ZA: This front fork cannot be adjusted. EAUB1462 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjusting ring. ECA10101 3 NOTICE To avoid damaging the mechanism, do not attempt to turn beyond the maximum or minimum settings. Adjust the spring preload as follows. To increase the spring preload and thereby harden the suspension, turn the adjusting ring in direction (a).
INSTRUMENT AND CONTROL FUNCTIONS EWA10221 WARNING This shock absorber assembly contains highly pressurized nitrogen gas. Read and understand the following information before handling the shock absorber assembly. G Do not tamper with or attempt to open the cylinder assembly. G Do not subject the shock absorber assembly to an open flame or other high heat source. This may cause the unit to explode due to excessive gas pressure. G Do not deform or damage the cylinder in any way.
INSTRUMENT AND CONTROL FUNCTIONS EAU15314 Ignition circuit cut-off system 3 The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. G It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled. G It prevents starting when the transmission is in gear and the clutch lever is pulled, but the sidestand is still down.
INSTRUMENT AND CONTROL FUNCTIONS 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? YES WARNING If a malfunction is noted, have a Yamaha dealer check the system before riding. ”. NO The neutral switch may not be working correctly. The motorcycle should not be ridden until checked by a Yamaha dealer.
FOR YOUR SAFETY – PRE-OPERATION CHECKS EAU15596 Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual. EWA11151 WARNING Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage. Do not operate the vehicle if you find any problem.
FOR YOUR SAFETY – PRE-OPERATION CHECKS ITEM Rear brake Clutch Throttle grip Control cables Drive chain Wheels and tires Brake pedal Brake and clutch levers Sidestand Chassis fasteners Instruments, lights, signals and switches CHECKS • 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 recommended brake fluid to specified level. • Check hydraulic system for leakage.
FOR YOUR SAFETY – PRE-OPERATION CHECKS ITEM Sidestand switch CHECKS • Check operation of ignition circuit cut-off system. • If system is not working correctly, have Yamaha dealer check vehicle.
OPERATION AND IMPORTANT RIDING POINTS EAU15951 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. EWA10271 WARNING Failure to familiarize yourself with the controls can lead to loss of control, which could cause an accident or injury. EAU45310 TIP This model is equipped with a lean angle sensor to stop the engine in case of a turnover.
OPERATION AND IMPORTANT RIDING POINTS ECAS0040 5 NOTICE The following warning lights and indicator lights should come on for a few seconds, then go off. G Neutral indicator light G Turn signal indicator light G High beam indicator light G Engine trouble warning light G Coolant temperature warning light G Immobilizer system indicator light G 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 indicator light circuit check. 3.
OPERATION AND IMPORTANT RIDING POINTS ECA10260 NOTICE G Even with the transmission in the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long distances. The transmission is properly lubricated only when the engine is running. Inadequate lubrication may damage the transmission.
OPERATION AND IMPORTANT RIDING POINTS 1600 km (1000 mi) and beyond G The vehicle can now be operated normally. ECA10310 5 NOTICE G Keep the engine speed out of the tachometer red zone. G If any engine trouble should occur during the engine breakin period, immediately have a Yamaha dealer check the vehicle. EAU17213 Parking When parking, stop the engine, and then remove the key from the main switch.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU17243 Periodic inspection, adjustment, and lubrication will keep your vehicle in the safest and most efficient condition possible. Safety is an obligation of the vehicle owner/operator. The most important points of vehicle inspection, adjustment, and lubrication are explained on the following pages. The intervals given in the periodic maintenance charts should be simply considered as a general guide under normal riding conditions.
PERIODIC MAINTENANCE AND ADJUSTMENT TIP If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU46861 TIP G G G The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a mileage-based maintenance, is performed instead. From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi). Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU1770C General maintenance and lubrication chart ODOMETER READING NO. 1 2 ITEM CHECK OR MAINTENANCE JOB 1000 km (600 mi) 10000 km (6000 mi) 40000 km (24000 mi) ANNUAL CHECK Air filter element • Replace. Clutch • Check operation. • Adjust. 3 3 3 3 3 • Check operation, fluid level and vehicle for fluid leakage. 3 3 3 3 3 3 3 3 3 3 3 * Front brake 3 • Replace brake pads.
PERIODIC MAINTENANCE AND ADJUSTMENT ODOMETER READING NO. ITEM 9 * Swingarm 10 Drive chain 11 * Steering bearings 12 * Chassis fasteners CHECK OR MAINTENANCE JOB 1000 km (600 mi) • Check operation and for excessive play. 10000 km (6000 mi) 3 • Lubricate with lithium-soapbased grease. 3 3 40000 km (24000 mi) ANNUAL CHECK 3 Every 50000 km (30000 mi) • Check chain slack, alignment and condition. • Adjust and lubricate chain with a special O-ring chain lubricant thoroughly.
PERIODIC MAINTENANCE AND ADJUSTMENT ODOMETER READING NO. 6 ITEM CHECK OR MAINTENANCE JOB 1000 km (600 mi) 10000 km (6000 mi) 20000 km 30000 km (12000 mi) (18000 mi) 40000 km (24000 mi) 18 * Front fork • Check operation and for oil leakage. 3 3 3 3 Shock absorber 19 * assembly • Check operation and shock absorber for oil leakage. 3 3 3 3 Rear suspension relay arm and 20 * connecting arm pivoting points • Check operation. 3 3 3 3 • Lubricate with lithium-soapbased grease.
PERIODIC MAINTENANCE AND ADJUSTMENT ODOMETER READING NO. ITEM Lights, signals and 27 * switches CHECK OR MAINTENANCE JOB • Check operation. • Adjust headlight beam. 1000 km (600 mi) 10000 km (6000 mi) 3 3 20000 km 30000 km (12000 mi) (18000 mi) 3 3 40000 km (24000 mi) 3 ANNUAL CHECK 3 EAUM1890 TIP G G Replace the air filter element more frequently if you are riding in unusually wet or dusty areas. Hydraulic brake service • Regularly check and, if necessary, correct the brake fluid level.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU18771 Removing and installing panels To install the panel Place the panel in the original position, and then install the bolts. The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. EAUB1541 Panels A and B To remove one of the panels Remove the bolts, and then pull the panel off at the areas shown. 6 1. Panel mounting bolt C. Right panel D.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU19604 Checking the spark plug 1. Panel mountign bolt 2. Quick fastener E. Right panel F. Left panel To install the panel 1. Place the panel in the original position. 2. Install the quick fastener and the bolts. 1. Panel mountign bolt G. Panel The spark plug is an important engine component, which is easy to check.
PERIODIC MAINTENANCE AND ADJUSTMENT 2. Remove the spark plug as shown, with the spark plug wrench included in the owner’s tool kit. 3. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification. To check the spark plug 1. Check that the porcelain insulator around the center electrode of the spark plug is a medium-tolight tan (the ideal color when the vehicle is ridden normally).
PERIODIC MAINTENANCE AND ADJUSTMENT EAUB1561 TIP Engine oil and oil filter element G The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter element replaced at the intervals specified in the periodic maintenance and lubrication chart. G The engine oil tank is located inside of the frame. The engine oil should be between the minimum and maximum level marks. To change the engine oil (with or without oil filter element replacement) 1.
PERIODIC MAINTENANCE AND ADJUSTMENT 3. Place an oil pan under the engine to collect the used oil. 4. Remove the engine oil filler cap and the drain bolt to drain the oil from the crankcase. 6. Remove the oil filter element drain bolt to drain the oil from the oil filter element. TIP Skip steps 7–9 if the oil filter element is not being replaced. 7. Remove the oil filter element cover by removing the bolts. 1. Oil filter element 2. O-ring 6 1. Engine oil drain bolt (crankcase) 5.
PERIODIC MAINTENANCE AND ADJUSTMENT Tightening torques: Engine oil drain bolt (crankcase): 30 Nm (3.0 m·kgf, 22 ft·lbf) Engine oil drain bolt (oil tank): 18 Nm (1.8 m·kgf, 12.9 ft·lbf) TIP Be sure to wipe off spilled oil on any parts after the engine and exhaust system have cooled down. 16. Install the engine guard by installing the screws. ECA11620 13. Add the specified amount of the recommended engine oil, and then install and tighten the oil filler cap.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU20070 Coolant The coolant level should be checked before each ride. In addition, the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart. EAU20253 To check the coolant level 1. Place the vehicle on a level surface and hold it in an upright position. TIP G 6 G The coolant level must be checked on a cold engine since the level varies with engine temperature.
PERIODIC MAINTENANCE AND ADJUSTMENT EAUB1481 EAU33031 Changing the coolant The coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart. Have a Yamaha dealer change the coolant. WARNING! Never attempt to remove the radiator cap when the engine is hot. [EWA10381] Replacing the air filter element and cleaning the check hose The air filter element should be replaced at the intervals specified in the periodic maintenance and lubrication chart.
PERIODIC MAINTENANCE AND ADJUSTMENT 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. EAU44734 Checking the engine idling speed Check the engine idling speed and, if necessary, have it corrected by a Yamaha dealer. Engine idling speed: 1400–1600 r/min 1. Air filter element 5. Install the air filter case cover by installing the screws. 6. Install the seat.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU21383 Checking the throttle cable free play EAU21401 EAU21642 Valve clearance Tires The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.
PERIODIC MAINTENANCE AND ADJUSTMENT 6 Tire air pressure (measured on cold tires): 0–90 kg (0–198 lb): Front: 210 kPa (2.10 kgf/cm2, 30 psi, 2.10 bar) Rear: 230 kPa (2.30 kgf/cm2, 33 psi, 2.30 bar) XT660Z 90–190 kg (198–419 lb) XT660ZA 90–188 kg (198–414 lb): Front: 230 kPa (2.30 kgf/cm2, 33 psi, 2.30 bar) Rear: 250 kPa (2.50 kgf/cm2, 36 psi, 2.50 bar) Off-road riding: Front: 200 kPa (2.00 kgf/cm2, 29 psi, 2.00 bar) Rear: 200 kPa (2.00 kgf/cm2, 29 psi, 2.00 bar) High-speed riding: Front: 210 kPa (2.
PERIODIC MAINTENANCE AND ADJUSTMENT Front tire: Size: XT660Z 90/90-21M/C 54S XT660Z 90/90-21M/C 54T XT660ZA 90/90-21M/C 54S Manufacturer/model: XT660Z METZELER/ TOURANCE XT660Z MICHELIN/SIRAC XT660ZA PIRELLI/SCORPION TRAIL Rear tire: Size: XT660Z 130/80-17M/C 65S XT660Z 130/80-17M/C 65T XT660ZA 130/80-17M/C 65S Manufacturer/model: XT660Z METZELER/ TOURANCE XT660Z MICHELIN/SIRAC XT660ZA PIRELLI/SCORPION TRAIL G ding the tires, should be left to a Yamaha dealer, who has the necessary professional knowledge
PERIODIC MAINTENANCE AND ADJUSTMENT EAU22043 Adjusting the clutch lever free play 6 The clutch lever free play should measure 10.0–15.0 mm (0.39–0.59 in) as shown. Periodically check the clutch lever free play and, if necessary, adjust it as follows. 1. Slide the rubber cover back at the clutch lever. 2. Loosen the locknut. 3. To increase the clutch lever free play, turn the adjusting bolt in direction (a). To decrease the clutch lever free play, turn the adjusting bolt in direction (b). 1.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU22392 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. disappeared, have a Yamaha dealer replace the brake pads as a set. EAU22500 Rear brake pads EAU38640 Checking the brake fluid level Front brake EAU22420 Front brake pads 1. Lining thickness 1.
PERIODIC MAINTENANCE AND ADJUSTMENT Rear brake (for XT660ZA) 1. Minimum level mark 6 Observe these precautions: G When checking the fluid level, make sure that the top of the brake fluid reservoir is level. G Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. Recommended brake fluid: DOT 4 Insufficient brake fluid may allow air to enter the brake system, possibly causing it to become ineffective.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. 3. Move the rear wheel by pushing the motorcycle to locate the tightest portion of the drive chain, and then measure the drive chain slack as shown. EAU22783 To check the drive chain slack Drive chain slack: XT660Z 50.0-60.0 mm (1.96-2.36 in) XT660ZA 40.0-55.0 mm (1.57-2.17 in) 4. If the drive chain slack is incorrect, adjust it as follows. 1.
PERIODIC MAINTENANCE AND ADJUSTMENT TIP Using the alignment marks on each side of the swingarm, make sure that both drive chain pullers are in the same position for proper wheel alignment. 3. Tighten the axle nut, then the locknuts to their specified torques.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU23093 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it. EAU23142 Checking and lubricating the brake and clutch levers ride, and the lever pivots should be lubricated if necessary.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU23182 6 EAU23202 Checking and lubricating the brake pedal Checking and lubricating the sidestand The operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary. The operation of the sidestand should be checked before each ride, and the sidestand pivot and metal-to-metal contact surfaces should be lubricated if necessary.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU23251 Lubricating the rear suspension EAUM1651 Lubricating the swingarm pivots The swingarm pivots must be lubricated by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. Recommended lubricant: Lithium-soap-based grease EAU23272 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU23283 Checking the steering ECA10590 6 NOTICE If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or repair it. Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 1. Place a stand under the engine to raise the front wheel off the ground. (See page 6-35 for more information.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU23291 Checking the wheel bearings EAUS1910 Battery To access the battery (XT660Z): The battery is located under the seat. (See page 3-16). Remove the battery holder bracket by removing the bolts. 1. Battery The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication 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. 1. 2. 3. 4.
PERIODIC MAINTENANCE AND ADJUSTMENT EWA10760 G 6 G WARNING Electrolyte is poisonous and dangerous since it contains sulfuric acid, which causes severe burns. Avoid any contact with skin, eyes or clothing and always shield your eyes when working near batteries. In case of contact, administer the following FIRST AID. • EXTERNAL: Flush with plenty of water. • INTERNAL: Drink large quantities of water or milk and immediately call a physician.
PERIODIC MAINTENANCE AND ADJUSTMENT EAUS1930 Replacing the fuses To replace the fuses (XT660Z): The main fuse and fuse box 1 (for individual circuits) are located under the seat. (See page 3-16). 1. Fuse box 1 2. Parking lighting fuse 3. Signaling system fuse 4. Headlight fuse 5. Ignition fuse 6. ECU fuse 7. Radiator fan fuse 8. Backup fuse 9. Spare fuse 1. Main fuse 2.
PERIODIC MAINTENANCE AND ADJUSTMENT 6 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 fuse: 7.5 A Backup fuse: 10.0 A ABS motor fuse (for ABS model): 30.0 A ABS solenoid fuse (for ABS model): 20.0 A ABS control unit fuse (for ABS model): 5.0 A 3. Turn the key to “ON” and turn on the electrical circuit in question to check if the device operates. 4.
PERIODIC MAINTENANCE AND ADJUSTMENT EWA10790 WARNING Headlight bulbs get very hot. Therefore, keep flammable products away from a lit headlight bulb, and do not touch the bulb until it has cooled down. 1. Headlight bulb holder 2. Headlight bulb 2. Unhook the headlight bulb holder, and then remove the defective bulb. EAU24181 Tail/brake light 3. Place a new headlight bulb into position, and then secure it with the bulb holder. 4. Connect the coupler, and then install the headlight bulb cover. 5.
PERIODIC MAINTENANCE AND ADJUSTMENT EAUM2202 EAU24204 Replacing a turn signal light bulb 1. Remove the turn signal light lens by removing the screw. 6 1. Screw 2. Turn signal light lens 3. Turn signal light bulb 2. Remove the burnt-out bulb by pushing it in and turning it counterclockwise. 3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 4. Install the lens by installing the screw. NOTICE: Do not overtighten the screw, otherwise the lens may break.
PERIODIC MAINTENANCE AND ADJUSTMENT 5. Install the auxiliary light socket (together with the bulb) by pushing it in. 6. Install the panel. EAU24350 Supporting the motorcycle Since this model is not equipped with a centerstand, follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle to stand upright. Check that the motorcycle is in a stable and level position before starting any maintenance.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU44790 EAUB1472 To install the front wheel 1. Lift the wheel up between the fork legs. 2. Insert the wheel axle. 3. Install the brake calipers by installing the bolts. Front wheel EWA14840 WARNING For the ABS model, have a Yamaha dealer remove and install the wheel. EAUB1441 To remove the front wheel EWA10821 WARNING 6 To avoid injury, securely support the vehicle so there is no danger of it falling over. 1.
PERIODIC MAINTENANCE AND ADJUSTMENT 7. Retighten pinch bolt A to the specified torque. EAU44800 Rear wheel EWA14840 WARNING Tightening torques: Wheel axle: 60 Nm (6.0 m·kgf, 44 ft·lbf) Front wheel axle pinch bolt: 18 Nm (1.8 m·kgf, 13 ft·lbf) Brake caliper bolt: 40 Nm (4.0 m·kgf, 29 ft·lbf) 2. Lift the rear wheel off the ground according to the procedure on page 6-35. 3. Remove the axle nut. For the ABS model, have a Yamaha dealer remove and install the wheel.
PERIODIC MAINTENANCE AND ADJUSTMENT G first, and then lift the wheel upward enough to remove the drive chain from the rear sprocket. The drive chain cannot be disassembled. 7. While supporting the brake caliper bracket, pull the wheel axle out, and then remove the wheel. NOTICE: Do not apply the brake after the wheel has been removed together with the brake disc, otherwise the brake pads will be forced shut. [ECA11071] 6 2. Install the drive chain onto the rear sprocket. 3.
PERIODIC MAINTENANCE AND ADJUSTMENT area, including pilot lights from water heaters or furnaces. Gasoline or gasoline vapors can ignite or explode, causing severe injury or property damage.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU42131 Troubleshooting charts Starting problems or poor engine performance 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle. Check the fuel level in the fuel tank. The engine does not start. Check the compression. 2. Compression Operate the electric starter. 6 3.
PERIODIC MAINTENANCE AND ADJUSTMENT Engine overheating EWA10400 WARNING G G Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled. After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape.
MOTORCYCLE CARE AND STORAGE EAU37833 Matte color caution ECA15192 NOTICE Some models are equipped with matte colored finished parts. Be sure to consult a Yamaha dealer for advice on what products to use before cleaning the vehicle. Using a brush, harsh chemical products or cleaning compounds when cleaning these parts will scratch or damage their surface. Wax also should not be applied to any matte colored finished parts.
MOTORCYCLE CARE AND STORAGE G G G water, diluted mild detergent with water may be used. Be sure to rinse off any detergent residue using plenty of water, as it is harmful to plastic parts. Do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.
MOTORCYCLE CARE AND STORAGE 4. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces. 5. Use spray oil as a universal cleaner to remove any remaining dirt. 6. Touch up minor paint damage caused by stones, etc. 7. Wax all painted surfaces. 8. Let the motorcycle dry completely before storing or covering it. ECA10800 NOTICE G Apply spray oil and wax sparingly and make sure to wipe off any excess.
MOTORCYCLE CARE AND STORAGE stabilizer (if available) to prevent the fuel tank from rusting and the fuel from deteriorating. 3. Perform the following steps to protect the cylinder, piston rings, etc. from corrosion. a. Remove the spark plug cap and spark plug. b. Pour a teaspoonful of engine oil into the spark plug bore. c. Install the spark plug cap onto the spark plug, and then place the spark plug on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.
SPECIFICATIONS Dimensions: Overall length: XT660Z 2246 mm (88.42 in) XT660ZA 2260 mm (89.0 in) Overall width: 900 mm (35.4 in) Overall height: XT660Z 1477 mm (57.1 in) XT660ZA 1450 mm (57.1 in) Seat height: XT660Z 896 mm (35.27 in) XT660ZA 865 mm (34.1 in) Wheelbase: XT660Z 1500 mm (59.05 in) XT660ZA 1505 mm (59.3 in) Ground clearance: XT660Z 260 mm (10.23 in) XT660ZA 205 mm (8.07 in) Minimum turning radius: 1980 mm (78.0 in) Weight: 8 With oil and fuel: XT660Z 208.
SPECIFICATIONS Primary reduction ratio: 75/36 (2.083) Secondary reduction system: Chain drive Secondary reduction ratio: 45/15 (3.000) Transmission type: Constant mesh 5-speed Operation: Left foot operation Gear ratio: 1st: 30/12 2nd: 26/16 3rd: 23/20 4th: 20/22 5th: 20/26 (2.500) (1.625) (1.150) (0.
SPECIFICATIONS Rear brake: Type: Single disc brake Operation: Right foot operation Recommended fluid: DOT 4 Front suspension: Type: Telescopic fork Spring/shock absorber type: Coil spring/oil damper Wheel travel: XT660Z 210.0 mm (8.26 in) XT660ZA 160.0 mm (6.30 in) Rear suspension: Type: Swingarm (link suspension) Spring/shock absorber type: Coil spring/gas-oil damper Wheel travel: XT660Z 200.0 mm (7.87 in) XT660ZA 145.0 mm (5.
CONSUMER INFORMATION EAU48610 Identification numbers EAU26400 Vehicle identification number Record the vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. EAU26520 Model label FOR XT660Z VEHICLE IDENTIFICATION NUMBER: 1. Vehicle identification number MODEL LABEL INFORMATION: The vehicle identification number is stamped into the steering head pipe.
CONSUMER INFORMATION under the passenger seat. (See page 3-16). Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
INDEX A F ABS (for ABS models)..............................3-12 ABS warning light (for ABS models) ..........3-5 Air filter element and check hose, replacing and cleaning ..........................................6-15 Anti-theft alarm (optional) ..........................3-9 Auxiliary light bulb, replacing...................6-34 Front and rear brake pads, checking ......6-21 Front fork, adjusting.................................3-17 Front fork, checking .................................6-27 Fuel .......
INDEX W Wheel (front).............................................6-36 Wheel (rear) ..............................................6-37 Wheel bearings, checking........................6-29 Wheels .....................................................
MBK Industrie Z.I. de Rouvroy 02100 Saint Quentin Société Anonyme au capital de 45 000 000 e R.
