Owner'S Manual: Read This Manual Carefully Before Operating This Vehicle
Owner'S Manual: Read This Manual Carefully Before Operating This Vehicle
Owner'S Manual: Read This Manual Carefully Before Operating This Vehicle
OWNER’S MANUAL
XT660Z
11D-F8199-21
EAU46090
Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
INTRODUCTION
EAU10102
EWA10031
WARNING 0
Please read this manual carefully and completely before operating this motorcycle.
This is the safety alert symbol. It is used to alert you to potential personal injury haz-
ards. Obey all safety messages that follow this symbol to avoid possible injury or
death.
A NOTICE indicates special precautions that must be taken to avoid damage to the
NOTICE
vehicle or other property.
EAUB1011
XT660Z
OWNER'S MANUAL
©2010 by Yamaha Motor España S.A.
1st edition, May 2010
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor España S.A.
is expressly prohibited.
Printed in Spain.
TABLE OF CONTENTS
LOCATION OF IMPORTANT LABELS...1-1 Handlebar switches...........................4-9 PERIODIC MAINTENANCE AND
Clutch lever .....................................4-10 ADJUSTMENT.....................................7-1
SAFETY INFORMATION .....................2-1 Shift pedal .......................................4-10 Owner’s tool kit .................................7-1
Be a Responsible Owner ..................2-1 Brake lever ......................................4-11 Periodic maintenance chart for
Safe riding.........................................2-1 the emission control system.......7-2
Brake pedal .....................................4-11
Protective apparel .............................2-2 General maintenance
Fuel tank cap ..................................4-11
Avoid Carbon Monoxide Poisoning ...2-2 and lubrication chart ..................7-3
Fuel .................................................4-12
Loading .............................................2-3 Removing and installing
Genuine Yamaha Accessories ..........2-3 Fuel tank breather hose..................4-13
the cowling and panels ..............7-8
Aftermarket Parts, Accessories, Catalytic converter ..........................4-13
Checking the spark plug ...................7-8
and Modifications .......................2-4 Seat.................................................4-14
Engine oil and oil filter element.........7-9
Aftermarket Tires and Rims ..............2-4 Adjusting the front fork....................4-15
Coolant............................................7-12
Adjusting the shock absorber
Replacing the air filter element
DESCRIPTION.....................................3-1 assembly ..................................4-16
and cleaning the check hose ...7-14
Left view............................................3-1 Sidestand ........................................4-17 Checking the engine idling speed...7-15
Right view .........................................3-2 Ignition circuit cut-off system ..........4-17 Checking the throttle cable
Controls and instruments..................3-3
free play ...................................7-16
FOR YOUR SAFETY - Valve clearance...............................7-16
INSTRUMENT AND CONTROL
PRE-OPERATION CHECKS ...............5-1 Tires ................................................7-16
FUNCTIONS ........................................4-1
Pre-operation check list ....................5-2 Spoke wheels..................................7-19
Immobilizer system ...........................4-1
Main switch/steering lock ..................4-2 Adjusting the clutch lever free play...7-20
OPERATION AND IMPORTANT Checking the front and rear
Indicator and warning lights ..............4-3
RIDING POINTS ..................................6-1 brake pads ...............................7-21
Multi-function display ........................4-5
Tachometer .......................................4-6 Starting the engine............................6-1 Checking the brake fluid level .........7-22
Tripmeter and tachometer modes .....4-6 Shifting ..............................................6-2 Changing the brake fluid .................7-23
Clock mode .......................................4-7 Tips for reducing fuel consumption...6-3 Drive chain slack.............................7-23
Fuel meter.........................................4-7 Engine break-in.................................6-3 Cleaning and lubricating
Self-diagnosis devices ......................4-7 Parking ..............................................6-4 the drive chain..........................7-25
TABLE OF CONTENTS
Checking and lubricating MOTORCYCLE CARE
the cables.................................7-25 AND STORAGE ...................................8-1
Checking and lubricating Care ..................................................8-1
the throttle grip and cable ........7-26 Storage .............................................8-3
Checking and lubricating the brake
and clutch levers ......................7-26 SPECIFICATIONS ...............................9-1
Lubricating the brake pedal ............7-27
CONSUMER INFORMATION............10-1
Checking and lubricating
Identification numbers.....................10-1
the sidestand............................7-27
Motorcycle noise regulation
Lubricating the rear suspension......7-27
(for Australia)............................10-2
Lubricating the swingarm pivots .....7-28
Checking the front fork....................7-28
Checking the steering .....................7-29
Checking the wheel bearings..........7-29
Battery.............................................7-30
Replacing the fuses ........................7-31
Replacing a headlight bulb .............7-33
Replacing a turn signal light bulb....7-34
Replacing the license plate
light bulb...................................7-35
Replacing an auxiliary light bulb .....7-35
Supporting the motorcycle ..............7-36
Front wheel .....................................7-36
Rear wheel......................................7-38
Troubleshooting ..............................7-39
Troubleshooting charts....................7-40
Read and understand all of the labels on your vehicle. They contain important information for safe and proper operation of
your vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement
1 label is available from your Yamaha dealer.
10
1-1
5
3 4
6
10
1-2
SAFETY INFORMATION
EAU10313
Safe riding • Ride where other motorists can
Be a Responsible Owner Perform the pre-operation checks each see you. Avoid riding in another
As the vehicle's owner, you are re- time you use the vehicle to make sure it is motorist's blind spot.
1 sponsible for the safe and proper op- in safe operating condition. Failure to in- ● Many accidents involve inexperi-
eration of your motorcycle. spect or maintain the vehicle properly in- enced operators. In fact, many op-
Motorcycles are single-track vehicles. creases the possibility of an accident or erators who have been involved in
2 Their safe use and operation are de- accidents do not even have a cur-
equipment damage. See page 5-2 for a
pendent upon the use of proper riding rent motorcycle license.
list of pre-operation checks. • Make sure that you are quali-
3 techniques as well as the expertise of ● This motorcycle is designed to carry fied and that you only lend your
the operator. Every operator should the operator and a passenger. motorcycle to other qualified
4 know the following requirements be- ● The failure of motorists to detect and operators.
fore riding this motorcycle. recognize motorcycles in traffic is the • Know your skills and limits.
He or she should: predominating cause of automo- Staying within your limits may
5 ● Obtain thorough instructions from help you to avoid an accident.
bile/motorcycle accidents. Many ac-
a competent source on all as- cidents have been caused by an • We recommend that you prac-
6 pects of motorcycle operation. automobile driver who did not see tice riding your motorcycle
● Observe the warnings and main- where there is no traffic until
the motorcycle. Making yourself
tenance requirements in this you have become thoroughly
7 conspicuous appears to be very familiar with the motorcycle and
Owner's Manual. effective in reducing the chance
● Obtain qualified training in safe
all of its controls.
of this type of accident. ● Many accidents have been caused
8 and proper riding techniques.
by error of the motorcycle opera-
● Obtain professional technical ser- Therefore: tor. A typical error made by the op-
9 vice as indicated in this Owner's • Wear a brightly colored jacket. erator is veering wide on a turn
Manual and/or when made nec- • Use extra caution when you are due to excessive speed or under-
essary by mechanical conditions. approaching and passing cornering (insufficient lean angle
10
through intersections, since in- for the speed).
tersections are the most likely • Always obey the speed limit
places for motorcycle accidents and never travel faster than
warranted by road and traffic
to occur.
conditions.
2-1
SAFETY INFORMATION
• Always signal before turning or Protective apparel Avoid Carbon Monoxide Poisoning
changing lanes. Make sure that The majority of fatalities from motorcy- All engine exhaust contains carbon
other motorists can see you. cle accidents are the result of head in- monoxide, a deadly gas. Breathing car-
● The posture of the operator and juries. The use of a safety helmet is the bon monoxide can cause headaches, 1
passenger is important for proper single most critical factor in the pre- dizziness, drowsiness, nausea, confu-
control. vention or reduction of head injuries. sion, and eventually death.
• The operator should keep both ● Always wear an approved helmet. Carbon Monoxide is a colorless, odor- 2
hands on the handlebar and ● Wear a face shield or goggles. less, tasteless gas which may be pre-
both feet on the operator Wind in your unprotected eyes sent even if you do not see or smell any 3
footrests during operation to could contribute to an impairment engine exhaust. Deadly levels of carbon
maintain control of the motorcy- of vision that could delay seeing a monoxide can collect rapidly and you
cle. hazard. can quickly be overcome and unable to 4
• The passenger should always ● The use of a jacket, heavy boots, save yourself. Also, deadly levels of car-
hold onto the operator, the seat trousers, gloves, etc., is effective bon monoxide can linger for hours or 5
strap or grab bar, if equipped, in preventing or reducing abra- days in enclosed or poorly ventilated ar-
with both hands and keep both sions or lacerations. eas. If you experience any symptoms of
feet on the passenger footrests. ● Never wear loose-fitting clothes, carbon monoxide poisoning, leave the 6
Never carry a passenger un- otherwise they could catch on the area immediately, get fresh air, and
less he or she can firmly place control levers, footrests, or SEEK MEDICAL TREATMENT. 7
both feet on the passenger wheels and cause injury or an ac- ● Do not run engine indoors. Even if
footrests. cident. you try to ventilate engine ex-
● Never ride under the influence of haust with fans or open windows 8
● Always wear protective clothing
alcohol or other drugs. that covers your legs, ankles, and and doors, carbon monoxide can
feet. The engine or exhaust sys- rapidly reach dangerous levels. 9
tem become very hot during or af- ● Do not run engine in poorly ventilat-
ter operation and can cause ed or partially enclosed areas such
as barns, garages, or carports. 10
burns.
● A passenger should also observe ● Do not run engine outdoors where
the above precautions. engine exhaust can be drawn into
a building through openings such
as windows and doors.
2-2
SAFETY INFORMATION
Loading curely pack your heaviest items Genuine Yamaha Accessories
Adding accessories or cargo to your as close to the center of the vehi- Choosing accessories for your vehicle
motorcycle can adversely affect stabil- cle as possible and make sure to is an important decision. Genuine
1 ity and handling if the weight distribu- distribute the weight as evenly as Yamaha accessories, which are avail-
tion of the motorcycle is changed. To possible on both sides of the mo- able only from a Yamaha dealer, have
2 avoid the possibility of an accident, torcycle to minimize imbalance or been designed, tested, and approved
use extreme caution when adding car- instability. by Yamaha for use on your vehicle.
go or accessories to your motorcycle. ● Shifting weights can create a sud- Many companies with no connection
3 Use extra care when riding a motorcy- den imbalance. Make sure that to Yamaha manufacture parts and ac-
cle that has added cargo or acces- accessories and cargo are se- cessories or offer other modifications
4 sories. Here, along with the informa- curely attached to the motorcycle for Yamaha vehicles. Yamaha is not in
tion about accessories below, are before riding. Check accessory a position to test the products that
some general guidelines to follow if mounts and cargo restraints fre- these aftermarket companies pro-
5
loading cargo to your motorcycle: quently. duce. Therefore, Yamaha can neither
The total weight of the operator, • Properly adjust the suspension endorse nor recommend the use of
6 passenger, accessories and cargo for your load, and check the accessories not sold by Yamaha or
must not exceed the maximum load condition and pressure of your modifications not specifically recom-
limit. Operation of an overloaded tires. mended by Yamaha, even if sold and
7 • Never attach any large or heavy
vehicle could cause an accident. installed by a Yamaha dealer.
items to the handlebar, front
8 fork, or front fender. These
items, including such cargo as Aftermarket Parts, Accessories,
Maximum load:
190 kg (419 lb) sleeping bags, duffel bags, or and Modifications
9 tents, can create unstable han- While you may find aftermarket prod-
When loading within this weight limit, dling or a slow steering re- ucts similar in design and quality to
10 keep the following in mind: sponse. genuine Yamaha accessories, recog-
● This vehicle is not designed to nize that some aftermarket acces-
● Cargo and accessory weight
should be kept as low and close pull a trailer or to be attached sories or modifications are not suitable
to the motorcycle as possible. Se- to a sidecar. because of potential safety hazards to
you or others. Installing aftermarket
2-3
SAFETY INFORMATION
products or having other modifications lightweight as possible and Aftermarket Tires and Rims
performed to your vehicle that change should be kept to a minimum. The tires and rims that came with your
any of the vehicle's design or opera- • Bulky or large accessories may motorcycle were designed to match
tion characteristics can put you and seriously affect the stability of the performance capabilities and to 1
others at greater risk of serious injury the motorcycle due to aerody- provide the best combination of han-
or death. You are responsible for in- namic effects. Wind may at- dling, braking, and comfort. Other 2
juries related to changes in the vehi- tempt to lift the motorcycle, or tires, rims, sizes, and combinations
cle. the motorcycle may become may not be appropriate. Refer to page
Keep the following guidelines in mind, unstable in cross winds. These 7-16 for tire specifications and more 3
as well as those provided under accessories may also cause in- information on replacing your tires.
"Loading" when mounting acces- stability when passing or being 4
sories. passed by large vehicles.
● Never install accessories or carry • Certain accessories can dis-
5
cargo that would impair the perfor- place the operator from his or
mance of your motorcycle. Care- her normal riding position. This
fully inspect the accessory before improper position limits the 6
using it to make sure that it does freedom of movement of the
not in any way reduce ground operator and may limit control 7
clearance or cornering clearance, ability, therefore, such acces-
limit suspension travel, steering sories are not recommended.
8
travel or control operation, or ob- ● Use caution when adding electri-
scure lights or reflectors. cal accessories. If electrical ac-
• Accessories fitted to the han- cessories exceed the capacity of 9
dlebar or the front fork area can the motorcycle's electrical sys-
create instability due to improp- tem, an electric failure could re- 10
er weight distribution or aerody- sult, which could cause a danger-
namic changes. If accessories ous loss of lights or engine power.
are added to the handlebar or
front fork area, they must be as
2-4
DESCRIPTION
EAU10410
Left view
10 1. Idle adjusting screw (page 7-15) 6. Shock absorber assembly/spring preload adjusting ring (page 4-16)
2. Owner’s tool kit (page 7-1) 7. Shift pedal (page 4-10)
3. Air filter element (page 7-14) 8. Engine oil drain bolt (crankcase) (page 7-10)
4. Fuse box (page 7-31) 9. Engine oil drain bolt (oil tank) (page 7-10)
5. Seat lock (page 4-14)
3-1
DESCRIPTION
EAU10420
Right view
10. Grab bar 15. Front brake fluid reservoir (page 7-22) 10
11. Main fuse (page 7-31) 16. Coolant drain bolt (page 7-12)
12. Battery (page 7-30) 17. Engine oil filter element (page 7-11)
13. Rear brake fluid reservoir (page 7-22) 18. Brake pedal (page 4-11)
14. Coolant reservoir (page 7-13)
3-2
DESCRIPTION
EAU10430
3-3
3 TIP
The headlights comes on automatical-
4 ly when the engine is started and stay
on until the key is turned to “OFF”,
even if the engine stalls.
5
The main switch/steering lock controls EAU10661
Be sure to use the standard key (black WARNING 0 1. Turn the handlebars all the way to
8 bow) for regular use of the vehicle. To Never turn the key to "OFF" or the left or right.
minimize the risk of losing the code re- "LOCK" while the vehicle is moving. 2. Push the key in from the “OFF”
9 registering key (red bow), keep it in a Otherwise the electrical systems position, and then turn it to
safe place and only use it for code re- will be switched off, which may re- “LOCK” while still pushing it.
registering. sult in loss of control or an acci-
10 3. Remove the key.
dent.
4-2
1. Push ECA11020 4
2. Turn NOTICE
1. Immobilizer system indicator light “ ”
Do not use the parking position for 2. Neutral indicator light “N” 5
Push the key into the main switch, and 3. Turn signal indicator light “y”
an extended length of time, other- 4. High beam indicator light “1”
then turn it to “OFF” while still pushing wise the battery may discharge. 5. Engine trouble warning light “U”
it. 6. Coolant temperature warning light “u”
6
EAUB1510
7
Turn signal indicator light “y”
This indicator light flashes when the
turn signal switch is pushed to the left 8
or right.
The electrical circuit of the turn signal 9
indicator light can be checked by turn-
ing the key to "ON".
If the indicator light does not come on 10
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.
4-3
WARNING 0 8
Be sure to stop the vehicle before
making any setting changes to the 9
multi-function display.
10
4-5
4-6
”
3 2. Start switch “J”
1. Pass switch “1” EAU12660 5
2. Dimmer switch “2 / 1”
B
EAU12350
Engine stop switch “I/ ”
3. Horn switch “o”
Pass switch “1” Set this switch to “I” before starting the
4. Turn signal switch “y” 6
5. Hazard switch “r” Press this switch to flash the head-
B
engine. Set this switch to “ ” to stop
light. the engine in case of an emergency,
such as when the motorcycle overturns 7
EAU12400
4-9
NOTICE
1. Clutch lever 1. Shift pedal
5 Do not use the hazard lights for an
extended length of time with the The clutch lever is located at the left The shift pedal is located on the left
6 engine not running, otherwise the handlebar grip. To disengage the side of the engine and is used in com-
battery may discharge. clutch, pull the lever toward the han- bination with the clutch lever when
dlebar grip. To engage the clutch, re- shifting the gears of the 5-speed con-
7 lease the lever. The lever should be stant-mesh transmission equipped on
pulled rapidly and released slowly for this motorcycle.
8 smooth clutch operation.
The clutch lever is equipped with a
9 clutch switch, which is part of the igni-
tion circuit cut-off system. (See page
4-17).
10
4-10
1 4
1. Brake lever 1. Brake pedal 1. Lock cover
2. Position adjusting dial 2. Open 5
3. Arrow mark
4. Distance The brake pedal is on the right side of
the motorcycle. To apply the rear To open the fuel tank cap
6
brake, press down on the brake pedal. Open the fuel tank cap lock cover, in-
The brake lever is located at the right
sert the key into the lock, and then turn
handlebar grip. To apply the front
it 1/4 turn clockwise. The lock will be re- 7
brake, pull the lever toward the han-
leased and the fuel tank cap can be
dlebar grip.
opened. 8
The brake lever is equipped with a po-
sition adjusting dial. To adjust the dis-
tance between the brake lever and the 9
handlebar grip, turn the adjusting dial
while holding the lever pushed away
10
from the handlebar grip. Make sure
that the appropriate setting on the ad-
justing dial is aligned with the “˙”
mark on the brake lever.
4-11
ter. If gasoline spills on your cloth- Fuel tank breather hose Catalytic converter
ing, change your clothes. This model is equipped with a catalyt-
ic converter in the exhaust system. 1
EAU13390
EWA10862
Recommended fuel:
PREMIUM UNLEADED WARNING 0 2
GASOLINE ONLY The exhaust system is hot after op-
Fuel tank capacity: eration. To prevent a fire hazard or 3
23.0 L (6.07 US gal) (5.05 Imp.gal) burns:
Fuel reserve amount (when the fuel ● Do not park the vehicle near 4
level warning light comes on): possible fire hazards such as
6.7 L (1.77 US gal) (1.47 Imp.gal) 1. Fuel tank breather hose grass or other materials that
2. Clamp 5
ECA11400 easily burn.
NOTICE ● Park the vehicle in a place
Before operating the motorcycle:
Use only unleaded gasoline. The use where pedestrians or children 6
● Check the fuel tank breather hose
of leaded gasoline will cause severe connection. are not likely to touch the hot
damage to internal engine parts, ● Check the fuel tank breather hose
exhaust system. 7
such as the valves and piston rings, for cracks or damage, and replace ● Make sure that the exhaust
as well as to the exhaust system. it if damaged. system has cooled down be-
8
● Make sure that the fuel tank fore doing any maintenance
Your Yamaha engine has been de- breather hose is not blocked, and work.
signed to use premium unleaded clean it if necessary. ● Do not allow the engine to idle 9
gasoline with a research octane num- more than a few minutes. Long
ber of 95 or higher. If knocking (or idling can cause a build-up of 10
pinging) occurs, use a gasoline of a heat.
different brand. Use of unleaded fuel
will extend spark plug life and reduce
maintenance costs.
4-13
4
1. Projections
2. Seat holders
5 1. Seat lock
2. Unlock 1. Insert the projection on the front of
6 the seat into the seat holder as
1. Insert the key into the seat lock, and shown.
then turn it counterclockwise. 2. Push the rear of the seat down to
7 2. While holding the key in that posi- lock it in place.
tion, lift the rear of the seat up, and 3. Remove the key.
8 then pull the seat off.
TIP
9 Make sure that the seat is properly se-
cured before riding.
10
4-14
10
4-15
4-16
4-17
4-18
Inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition. Always follow the in-
spection and maintenance procedures and schedules described in the Owner's Manual. 1
EWA11151
WARNING 0
2
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. If a problem cannot be corrected by the procedures provided
3
in this manual, have the vehicle inspected by a Yamaha dealer.
10
5-1
5-2
5-3
10
5-4
WARNING 0
● Before starting the engine, 5
check the function of the igni-
tion circuit cut-off system ac- 6
cording to the procedure de-
scribed on page 4-18.
7
● Never ride with the sidestand
down.
8
1. Turn the key to “ON” and make
sure that the engine stop switch is 9
set to “I”.
10
6-1
6-2
6-3
6-4
7-1
TIP
● The annual checks must be performed every year, except if a kilometer-based maintenance, or for the UK, a
1 mileage-based maintenance, is performed instead.
● From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
2 ● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and tech-
nical skills.
3
EAU46910
Periodic maintenance chart for the emission control system
4
ODOMETER READING
ANNUAL
5 NO. ITEM CHECK OR MAINTENANCE JOB 1000 km 10000 km 20000 km 30000 km 40000 km CHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
1 ✻ Fuel line • Check fuel hoses for cracks or damage. √ √ √ √ √
6
• Check condition.
2 Spark plug • Clean and regap. √ √
7
• Replace. √ √
3 • Check valve clearance.
8 ✻ Valves √ √
• Adjust.
4 ✻ Fuel injection • Adjust engine idling speed. √ √ √ √ √ √
9
5 ✻
Muffler and exhaust • Check the screw clamp(s) for
pipe looseness. √ √ √ √ √
10
• Check the air cut-off valve, reed valve,
6 ✻ Air induction system and hose for damage. √ √ √ √ √
• Replace any damaged parts if necessary.
7-2
7-3
7-4
TIP 9
● Replace the air filter element more frequently if you are riding in unusually wet or dusty areas.
● Hydraulic brake service 10
● Regularly check and, if necessary, correct the brake fluid level.
● Every two years replace the internal components of the brake master cylinder, and change the brake fluid.
● Replace the brake hoses every four years and if cracked or damaged.
7-5
7-6
1 3
E-F 2
2 4
1. Panel
1. Panel mounting bolt
1. Panel mounting bolt 2. Pin
2. Quick fastener
E. Right panel G. Panel 5
F. Left panel To install the panel
To remove the panel Place the panel in the original position,
To remove one of the panels Remove the bolts, and then pull the and then install the bolts. 6
1. Remove the bolts. panel off at the areas shown.
2. Remove the quick fastener and then 7
pull the panel off at the areas
shown.
8
To install the panel
1. Place the panel in the original posi- 9
tion.
2. Install the quick fastener and the
10
bolts.
7-7
7-8
7-9
WARNING 0
3 Never remove the engine oil tank
cap after high-speed operation,
otherwise hot engine oil could 1. Engine oil crankcase drain bolt
4
spout out and cause damage or in-
jury. Always let the engine oil cool
5 down sufficiently before removing 1. Mounting screw
the oil tank cap. 2. Engine guard
6
4. If the engine oil is below the mini- 1. Start the engine, warm it up for sev-
mum level mark, add sufficient oil eral minutes, and then turn it off.
7 of the recommended type to raise 2. To reach the drain bolt of the
it to the correct level. crankcase and the drain bolt of
8 5. Install the oil filler cap. the oil tank, remove the engine
guard by removing the screws. 1
3. Place an oil pan under the engine 1. Engine oil tank drain bolt
9
to collect the used oil.
4. Remove the engine oil filler cap 6. Remove the oil filter element
10 and the drain bolt to drain the oil drain bolt to drain the oil from the
from the crankcase. oil filter element.
5. Remove the drain bolt to drain the
oil from the oil tank.
7-10
9
1
10
1. Engine oil filter element drain bolt
2. Oil filter element cover bolts
7-11
7-12
7-14
4
1. Air filter check hose
2. Check hose cap
5
1. Idle adjusting screw
1. Check the hose on the side of the a. Increasing the engine idling speed
air filter case for accumulated dirt b. Decreasing the engine idling speed 6
or water.
2. If dirt or water is visible, remove The engine idling speed must be
the hose, clean it, and then install 7
checked as follows and, if necessary,
it. adjusted by a Yamaha dealer at the in-
tervals specified in the periodic main- 8
tenance and lubrication chart.
Start the engine and warm it up for 9
several minutes at 1000-2000 r/min
while occasionally revving it to 4000-
10
5000 r/min.
7-15
5 WARNING 0
1. Throttle cable free play
Operation of this vehicle with im-
6 proper tire pressure may cause se-
The throttle cable free play should vere injury or death from loss of
measure 3.0-5.0 mm (0.12-0.20 in) at control.
7 ● The tire air pressure must be
the throttle grip. Periodically check the
throttle cable free play and, if neces- checked and adjusted on cold
8 sary, have a Yamaha dealer adjust it. tires (i.e., when the tempera-
ture of the tires equals the am-
9 bient temperature).
● The tire air pressure must be
adjusted in accordance with
10 the riding speed and with the
total weight of rider, passenger,
cargo, and accessories ap-
proved for this model.
7-16
WARNING 0 WARNING 0
Tire air pressure
(measured on cold tires): Never overload your vehicle. Oper- The front and rear tires should be of
Up to 90 kg (198 lb): ation of an overloaded vehicle the same make and design, other- 1
Front: could cause an accident. wise the handling characteristics of
210 kPa (30 psi) (2.1 kgf/cm2) the vehicle may be different, which
Rear: 2
230 kPa (33 psi) (2.3 kgf/cm2) could lead to an accident.
90 kg (198 lb) to maximum load:
Front: 3
230 kPa (33 psi) (2.3 kgf/cm2)
Rear:
250 kPa (36 psi) (2.5 kgf/cm2) 4
Off-road riding:
Front:
200 kPa (29 psi) (2.0 kgf/cm2) 5
Rear:
200 kPa (29 psi) (2.0 kgf/cm2)
6
High-speed riding:
Front:
210 kPa (30 psi) (2.1 kgf/cm2) 7
Rear:
230 kPa (33 psi) (2.3 kgf/cm2)
Maximum load*: 8
190 kg (419 lb)
* Total weight of rider, passenger,
cargo and accessories 9
10
7-17
2 Front tire:
Size:
90/90-21M/C 54S
3 90/90-21M/C 54T
Manufacturer/model:
METZELER/TOURANCE
4 FRONT
1. Tire sidewall
2. Tire tread depth
MICHELIN/SIRAC
5 Rear tire:
Size:
The tires must be checked before 130/80-17M/C 65S
6 each ride. If the center tread depth 130/80-17M/C 65T
reaches the specified limit, if the tire Manufacturer/model:
has a nail or glass fragments in it, or if METZELER/TOURANCE
7 MICHELIN/SIRAC A
the sidewall is cracked, have a Yama-
ha dealer replace the tire immediately.
8
Minimum tire tread depth
9 (front and rear):
1.0 mm (0.04 in)
10
7-18
10
7-19
7-20
Checking the front and rear Front brake pads Rear brake pads
brake pads
The front and rear brake pads must be 1
checked for wear at the intervals spec-
ified in the periodic maintenance and 2
lubrication chart.
3
4
1. Front brake pad wear indicator groove 1. Rear brake pad lining thickness
5
Each front brake pad is provided with Check each rear brake pad for dam-
a wear indicator groove, which allows age and measure the lining thickness. 6
you to check the brake pad wear with- If a brake pad is damaged or if the lin-
out having to disassemble the brake. ing thickness is less than 1.0 mm
To check the brake pad wear, check (0.04 in), have a Yamaha dealer re- 7
the wear indicator groove. If a brake place the brake pads as a set.
pad has worn to the point that the 8
wear indicator groove has almost dis-
appeared, have a Yamaha dealer re- 9
place the brake pads as a set.
10
7-21
7-22
TIP 9
When checking and adjusting the dri-
ve chain slack, there should be no 10
weight on the motorcycle.
7-23
10
7-24
Cleaning and lubricating 3. Thoroughly lubricate the drive Checking and lubricating
the drive chain chain with a special O-ring chain the cables
The drive chain must be cleaned and lubricant. NOTICE: Do not use The operation of all control cables and 1
lubricated at the intervals specified in engine oil or any other lubri- the condition of the cables should be
the periodic maintenance and lubrica- cants for the drive chain, as checked before each ride, and the ca- 2
tion chart, otherwise it will quickly they may contain substances bles and cable ends should be lubri-
wear out, especially when riding in that could damage the O-rings. cated if necessary. If a cable is dam-
3
dusty or wet areas. Service the drive aged or does not move smoothly, have
chain as follows. a Yamaha dealer check or replace it.
WARNING! Damage to the outer 4
ECA10581
7-25
Clutch lever
7-26
5
The operation of the sidestand should The pivoting points of the rear suspen-
The operation of the brake pedal
be checked before each ride, and the sion must be lubricated at the intervals 6
should be checked before each ride,
sidestand pivot and metal-to-metal specified in the periodic maintenance
and the pedal pivot should be lubricat-
contact surfaces should be lubricated and lubrication chart.
ed if necessary. 7
if necessary.
EWA10730
Recommended lubricant:
Lithium-soap-based grease
7-27
NOTICE
7-28
Checking the steering fork legs and try to move them for- Checking the wheel bearings
Worn or loose steering bearings may ward and backward. If any free The front and rear wheel bearings
cause danger. Therefore, the opera- play can be felt, have a Yamaha must be checked at the intervals spec- 1
tion of the steering must be checked dealer check or repair the steering. ified in the periodic maintenance and
as follows at the intervals specified in lubrication chart. If there is play in the 2
the periodic maintenance and lubrica- wheel hub or if the wheel does not turn
tion chart. smoothly, have a Yamaha dealer
check the wheel bearings. 3
7-29
Battery WARNING 0
This model is equipped with a VRLA ● Electrolyte is poisonous and
1 (Valve Regulated Lead Acid) battery. dangerous since it contains
There is no need to check the elec- sulfuric acid, which causes se-
trolyte or to add distilled water. Howev- vere burns. Avoid any contact
2
er, the battery lead connections need with skin, eyes or clothing and
to be checked and, if necessary, tight- always shield your eyes when
3 ened. working near batteries. In case
of contact, administer the fol-
ECA10620
lowing FIRST AID. 1. Positive battery terminal
4 NOTICE 2. Negative battery terminal
• EXTERNAL: Flush with plenty
Never attempt to remove the bat- of water.
5 To access the battery
tery cell seals, as this would perma- • INTERNAL: Drink large quan-
nently damage the battery. Remove the battery holder bracket by
tities of water or milk and im-
6 removing the bolts.
mediately call a physician.
• EYES: Flush with water for 15
To charge the battery
7 minutes and seek prompt
Have a Yamaha dealer charge the bat-
medical attention.
tery as soon as possible if it seems to
8 ● Batteries produce explosive hy- have discharged. Keep in mind that
drogen gas. Therefore, keep the battery tends to discharge more
sparks, flames, cigarettes, etc., quickly if the vehicle is equipped with
9
away from the battery and pro- optional electrical accessories.
vide sufficient ventilation when
10 charging it in an enclosed space.
● KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
7-30
7-31
7-32
1. Headlight coupler
2. Headlight bulb holder 10
3. Headlight bulb
7-33
7-34
screw. NOTICE: Do not over- Replacing the license plate Replacing an auxiliary light
tighten the screw, otherwise light bulb bulb
the lens may break. 1
5
1. Bulb socket 1. Auxiliary light socket
2. License plate light bulb 2. Auxiliary light bulb
6
1. Remove the socket (together with This model is equipped with two auxil-
the bulb) by pulling it out. iary lights. If an auxiliary light bulb 7
2. Remove the burnt-out bulb by burns out, replace it as follows.
pulling it out. 1. Remove panel G. (See page 7-7.)
3. Insert a new bulb into the socket. 2. Remove the auxiliary light socket (to- 8
4. Install the socket (together with gether with the bulb) by pulling it out.
the bulb) by pushing it in. 3. Remove the burnt-out bulb by 9
pulling it out.
4. Insert a new bulb into the socket. 10
5. Install the auxiliary light socket
(together with the bulb) by push-
ing it in.
6. Install the panel.
7-35
Supporting the motorcycle Raise the rear wheel off the ground by Front wheel
EAUB1440
Since this model is not equipped with using a motorcycle stand or, if a mo- To remove the front wheel
1 a centerstand, follow these precau- torcycle stand is not available, by plac- EWA10820
tions when removing the front and rear ing a jack either under each side of the WARNING 0
2 wheel or performing other mainte- frame in front of the rear wheel or un- ● It is advisable to have a Yama-
nance requiring the motorcycle to der each side of the swingarm. ha dealer service the wheel.
stand upright. Check that the motorcy- ● Securely support the motorcy-
3 cle is in a stable and level position be- cle so that there is no danger of
fore starting any maintenance. A it falling over.
4 strong wooden box can be placed un-
der the engine for added stability.
5
To service the front wheel
1. Stabilize the rear of the motorcy-
6 cle by using a motorcycle stand 2
or, if an additional motorcycle
B
7 stand is not available, by placing a
jack under the frame in front of the
rear wheel.
8 A
2. Raise the front wheel off the 1
ground by using a motorcycle 1. Wheel axle
9 stand. 2. Brake caliper bolts
A. Front wheel axle pinch bolt
B. Front wheel axle pinch bolt
10
7-36
7-37
7-38
7-39
7-40
WARNING 0
● Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be 1
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 2
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hiss-
ing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap. 3
The coolant level Start the engine. If the engine overheats again, have 7
is OK. a Yamaha dealer check and repair the cooling system.
8
TIP
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended 9
coolant as soon as possible.
10
7-41
10
8-3
SPECIFICATIONS
Dimensions: Engine oil: Air filter:
Overall length: Type: Air filter element:
2246 mm (88.42 in) SAE10W30 or SAE10W40 or SAE15W40 Paper
Overall width: or SAE20W40 or SAE20W50 Fuel:
1 864 mm (34.01 in) -20 -10 0 10 20 30 40 50 °C Recommended fuel:
Overall height: Premium unleaded gasoline only
1477 mm (58.14 in) SAE 10W-30
2 Fuel tank capacity:
Seat height: SAE 10W-40 23.0 L (6.07 US gal) (5.06 Imp.gal)
896 mm (35.27 in) Fuel reserve amount:
Wheelbase: SAE 15W-40
3 6.7 L (1.76 US gal) (1.46 Imp.gal)
1500 mm (59.05 in)
SAE 20W-40 Fuel injection:
Ground clearance:
Manufacturer:
4 260 mm (10.23 in) SAE 20W-50 DENSO
Minimum turning radius:
Model:
1958 mm (77.08 in) Recommended engine oil grade:
297500-0390
5 Basic weight: API service SE, SF, SG type or higher
Engine oil quantity: Spark plug:
With oil and fuel:
Without oil filter element replacement: Manufacturer/model:
208.5 kg (459 lb)
6 2.50 L (2.64 US qt) (2.19 Imp.qt) NGK/CR7E
Engine: Gap:
With oil filter element replacement:
Engine type: 0.7-0.8 mm (0.028-0.032 in)
2.60 L (2.73 US qt) (2.26 Imp.qt)
7 Liquid cooled 4-stroke, SOHC
Total amount (dry engine): Clutch:
Cylinder arrangement:
2.90 L (3.07 US qt) (2.55 Imp.qt) Clutch type:
Forward-inclined single cylinder
Cooling system: Wet, multiple-disc
8 Displacement:
660.0 cm3 (40.27 cu.in) Radiator capacity (including all routes): Transmission:
1.2 L (1.26 US qt) (1.05 Imp.qt) (Radiator) + Primary reduction system:
Bore x stroke:
9 0.5 L (0.52 US qt) (0.44 Imp.qt) Spur gear
100.0 x 84.0 mm (3.94 x 3.31 in)
(Coolant reservoir) Primary reduction ratio:
Compression ratio:
Coolant reservoir capacity (up to the 75/36 (2.083)
10.00 : 1
10 maximum level mark): Secondary reduction system:
Starting system:
Electric starter 0.50 L (0.52 US qt) (0.44 Imp.qt) Chain drive
From low to full level: Secondary reduction ratio:
Lubrication system:
0.30 L (0.32 US qt) (0.26 Imp.qt) 45/15 (3.00)
Dry sump
Transmission type:
Constant mesh 5-speed
9-1
SPECIFICATIONS
Operation: Manufacturer/model: Front wheel:
Left foot operation METZELER/TOURANCE Type:
Gear ratio: MICHELIN/SIRAC A Spoke wheel
1st:
30/12 (2.500) Load: Rim size:
1
2nd: Maximum load: 21 x 1.85
26/16 (1.625) 190 kg (419 lb) Rear wheel:
3rd:
23/20 (1.150) (Total weight of rider, passenger, cargo Type: 2
4th: and accessories) Spoke wheel
20/22 (0.909) Rim size:
5th: Tire air pressure 3
17M/C x MT2.75
20/26 (0.769) (measured on cold tires):
Load:
Front brake:
Chassis: Type: 4
Frame type: Up to 90 kg (0-198 lb)
Front: Dual disc brake
Diamond Operation:
Caster angle: 210 kPa (30 psi) (2.1 kgf/cm2) 5
Rear: Right hand
28°
230 kPa (33 psi) (2.3 kgf/cm2) Fluid:
Trail:
Load: DOT 4 6
113.0 mm (4.44 in)
90-190 kg (198-419 lb) Rear brake:
Front tire: Front: Type:
Type: 7
230 kPa (33 psi) (2.3 kgf/cm2) Single disc brake
With tube
Rear: Operation:
Size:
250 kPa (36 psi) (2.5 kgf/cm2) Right foot
90/90-21M/C 54S, 8
Off-road riding: Fluid:
90/90-21M/C 54T
Manufacturer/model: Front: DOT 4
METZELER/TOURANCE FRONT 200 kPa (29 psi) (2.0 kgf/cm2) Front suspension: 9
MICHELIN/SIRAC Rear: Type:
200 kPa (29 psi) (2.0 kgf/cm2) Telescopic fork
Rear tire: 10
High-speed riding: Spring/damper type:
Type:
With tube Front: Coil spring/oil damper
Size: 210 kPa (30 psi) (2.1 kgf/cm2) Wheel travel:
130/80-17M/C 65S, Rear: 210 mm (8.26 in)
130/80-17M/C 65T 230 kPa (33 psi) (2.3 kgf/cm2)
9-2
SPECIFICATIONS
Rear suspension: Neutral indicator light:
Type: LED
Swingarm (link suspension) Turn signal indicator light:
Spring/damper type: LED
1 Coil spring/gas-oil damper, spring High beam indicator light:
preload adjustable LED
Wheel travel: Coolant temperature warning light:
2 LED
200 mm (7.87 in)
Engine trouble warning light:
Electrical system: LED
3 Ignition system: Immobilizer system indicator light:
Transistorized coil ignition (digital) LED
Charging system:
4 A.C. magneto
Fuses:
Battery: Main fuse:
5 Model: 30 A
GT9B-4 Headlight fuse:
Voltage, capacity: 20 A
6 12 V, 8 Ah Signaling system fuse:
Headlight: 10 A
Bulb type: Ignition fuse:
7 Halogen bulb 10 A
Bulb voltage, wattage x quantity: Parking lighting fuse:
Headlight: 10 A
8 Radiator fan fuse:
12 V, 55 W x 2
Auxiliary light: 7.5 A
12 V, 5 W x 2 Fuel injection system fuse:
9
Tail/brake light: 10 A
LED Backup fuse (for odometer, clock and
10 Front turn signal light: immobilizer):
12 V, 10 W x 2 10 A
Rear turn signal light:
12 V, 10 W x 2
Meter lighting:
LED (backlight)
9-3
CONSUMER INFORMATION
EAU26352 EAU26381 EAU26400
10-1
CONSUMER INFORMATION
EAU26480 EAU26570
10
10-2
INDEX
A Catalytic converter ...........................4-13 Cleaning and lubricating ...............7-25
Aftermarket Parts, Accessories, and Checking and lubricating the brake
E
Modifications...................................2-4 and clutch levers...........................7-26
Emission control system (periodic
Aftermarket Tires and Rims ...............2-4 Checking and lubricating the brake 1
maintenance chart).........................7-2
Air filter element, cleaning the check pedal .............................................7-27
Engine break-in ..................................6-3
hose ..............................................7-14 Checking and lubricating the cables..7-25
Engine idling speed, adjusting .........7-15 2
Air filter element, replacing ..............7-14 Checking and lubricating the
sidestand ......................................7-27 Engine oil and oil filter element..........7-9
Auxiliary light bulb, replacing............7-35
Checking and lubricating the throttle Engine oil filter element....................7-10
Avoid Carbon Monoxide poisoning ....2-2 3
grip and cable ...............................7-26 Engine stop switch .............................4-9
B Checking the brake pedal ................7-27 Engine trouble warning light...............4-4
Battery..............................................7-30 Checking the sidestand switch.........4-18 4
F
To access the battery ...................7-30 Clock mode ........................................4-7 For your safety - Pre-operation
To charge the battery....................7-30 Clutch lever ......................................4-10 checks.............................................5-1 5
To store the battery.......................7-31 Clutch lever free play, adjusting .......7-20 Front fork ..........................................4-15
Be a Responsible Owner ...................2-1 Consumer information......................10-1 Adjusting .......................................4-15
Brake and clutch levers, checking Controls and instruments ...................3-3 6
Checking .......................................7-28
and lubricating ..............................7-26 Function ..........................................4-1 Front wheel ......................................7-36
Brake fluid ........................................7-22 Coolant.............................................7-12 Installing........................................7-37 7
Changing ......................................7-23 Coolant temperature warning light .....4-4 Removing......................................7-36
Checking fluid level .......................7-22
D Fuel ..................................................4-12
Brake lever .......................................4-11 8
Description .........................................3-1 Fuel consumption, tips for reducing ...6-3
Brake pads, checking.......................7-21
Controls and instrument .................3-3 Fuel meter ..........................................4-7
Brake pedal ......................................4-11
Left view..........................................3-1 Fuel tank breather hose ...................4-13 9
Checking .......................................7-27
Right view .......................................3-2 Fuel tank cap ...................................4-11
Lubricating ....................................7-27
Dimmer switch....................................4-9 Fuses, replacing...............................7-31
C Drive chain, cleaning 10
G
Cables, checking and lubricating .....7-25 and lubricating ..............................7-25
Genuine Yamaha Accessories ...........2-3
Carbon Monoxide (avoid Carbon Drive chain slack ..............................7-23
Monoxide poisoning).......................2-2 Adjusting .......................................7-23 H
Care and storage ...............................8-1 Checking .......................................7-23 Handlebar switches............................4-9
INDEX
Dimmer switch ................................4-9 L Owner’s tool kit...................................7-1
Engine stop switch .........................4-9 Labels (location of important labels) ..1-1
P
Hazard switch ...............................4-10 License plate light bulb, replacing....7-35
Panels, removing and installing .........7-6
1 Horn switch .....................................4-9 Location of important labels...............1-1
Loading ..............................................2-3 Parking ...............................................6-4
Pass switch .....................................4-9
Lubricating the brake and clutch Pass switch ........................................4-9
Start switch .....................................4-9
2 levers ............................................7-26 Periodic maintenance
Turn signal switch ...........................4-9 and adjustment ...............................7-1
Headlight bulb, replacing..................7-33 Lubricating the brake pedal..............7-27
Lubricating the cables ......................7-25 Periodic maintenance chart for
3 High beam indicator light ...................4-4 the emission control system ...........7-2
Lubricating the drive chain ...............7-25
Horn switch ........................................4-9 Pre-operation check list......................5-2
Lubricating the sidestand .................7-27
4 I Lubricating the throttle grip Pre-operation checks .........................5-1
Identification numbers ......................10-1 and cable ......................................7-26
R
Idling speed, checking .....................7-15 Lubricating the swingarm pivots.......7-28
5 Rear suspension, lubricating............7-27
Ignition circuit cut-off system............4-17 M Rear wheel .......................................7-38
Checking operation procedure......4-18 Main switch/steering lock ...................4-2 Installing........................................7-39
6 Immobilizer system ............................4-1 Model label.......................................10-2 Removing......................................7-38
Immobilizer system indicator light ......4-4 Motorcycle noise regulation Record the identification numbers ...10-1
7 Indicator and warning lights ...............4-3 (for Australia) ................................10-2
Coolant temperature warning light..4-4 Multi-function display..........................4-5 S
Engine trouble warning light ...........4-4 Clock mode.....................................4-7 Safety information ..............................2-1
8 Self-diagnosis devices ....................4-7 Seat..................................................4-14
High beam indicator light ................4-4
Tachometer .....................................4-6 Self-diagnosis devices .......................4-7
Immobilizer system indicator light...4-4
Tripmeter and tachometer modes...4-6 Shift pedal ........................................4-10
9 Neutral indicator light......................4-4
Shifting ...............................................6-2
Turn signal indicator light ................4-3 N Shock absorber assembly
10 Instruments ........................................3-3 Neutral indicator light .........................4-4 (adjusting) .....................................4-16
Instrument and control functions........4-1
O Sidestand .........................................4-17
K Oil filter element ..............................7-10 Sidestand, checking and lubricating..7-27
Key identification number .................10-1 Operation and important riding Sidestand switch, checking ..............4-18
Keys ...................................................4-1 points ..............................................6-1 Spark plug, checking..........................7-8
INDEX
Specifications .....................................9-1 V
Spoke wheels...................................7-19 Valve clearance ................................7-16
Start switch ........................................4-9 Vehicle identification number ...........10-1
Starting the engine.............................6-1 W 1
Steering, checking............................7-29 Warning lights ....................................4-3
Steering lock ......................................4-2 Wheel bearings, checking ................7-29 2
Storage...............................................8-3 Wheels, spoke..................................7-19
Supporting the motorcycle ...............7-36
Swingarm, lubricating the pivots ......7-28 3
T
Tachometer ........................................4-6 4
Throttle cable free play, checking.....7-16
Throttle grip and cable, checking 5
and lubricating ..............................7-26
Tips for reducing fuel consumption ....6-3
Tires .................................................7-16 6
Air pressure ..................................7-16
Tire information.............................7-18 7
Tire inspection ..............................7-18
Tool kit ................................................7-1
8
Tripmeter and tachometer modes ......4-6
Troubleshooting ................................7-39
Troubleshooting charts .................7-40 9
Engine overheating.......................7-41
Turn signal indicator light ...................4-3 10
Turn signal light bulb, replacing........7-34
Turn signal switch...............................4-9