Yamaha XT660Z 2008 Manuale utente

SERVICE MANUAL

2008

11D-F8197-E0

XT660Z

XT660Z (2008)

SERVICE MANUAL

First edition, May 2008

unauthorized use without the written

permission of Yamaha Motor Italia S.p.A.

is expressly prohibited.

Printed in Italy

EAS00020

NOTICE

This manual was produced by the Yamaha Motor Italia S.p.A. primarily for use by Yamaha dealers and

their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu-

al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles

should have a basic understanding of mechanics and the techniques to repair these types of vehi-

cles. Repair and maintenance work attempted by anyone without this knowledge is likely to render

the vehicle unsafe and unfit for use.

Yamaha Motor Italia S.p.A. is continually striving to improve all of its models. Modifications and sig-

nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers

and will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

EAS00040

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFE-

TY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to

the motorcycle operator, a bystander or a person checking or repairing the mo-

torcycle.

A CAUTION indicates special precautions that must be taken to avoid damage

to the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

EAS20090

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are

laid out with the individual steps in sequential order.

• The manual is divided into chapters and each chapter is divided into sections. The current section

title “1” is shown at the top of each page.

• Sub-section titles “2” appear in smaller print than the section title.

• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of

each removal and disassembly section.

• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a dis-

assembly step.

• Symbols “5” indicate parts to be lubricated or replaced. Refer to “SYMBOLS”.

• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names

of parts, notes in jobs, etc.

• Jobs “7” requiring more information (such as special tools and technical data) are described

sequentially.

EAS20100

SYMBOLS

The following symbols are used in this manual

for easier understanding.

NOTE:

The following symbols are not relevant to every

vehicle.

1. Serviceable with engine mounted

2. Filling fluid

3. Lubricant

4. Special tool

5. Tightening torque

6. Wear limit, clearance

7. Engine speed

8. Electrical data

9. Engine oil

10. Gear oil

11. Molybdenum disulfide oil

12. Wheel bearing grease

13. Lithium-soap-based grease

14. Molybdenum disulfide grease

15. Apply locking agent (LOCTITE®)

16. Replace the part with a new one.

New

12 3

91110

12 1413

15 16

GENERAL INFORMATION 
TABLE OF CONTENTS
1
SPECIFICATIONS 2
PERIODIC CHECKS AND 
ADJUSTMENTS 3
CHASSIS 4
ENGINE 5
COOLING SYSTEM 6
FUEL INJECTION SYSTEM 7
ELECTRICAL SYSTEM 8
TROUBLESHOOTING 9

GENERAL INFORMATION
IDENTIFICATION............................................................................................ 1-1
VEHICLE IDENTIFICATION NUMBER..................................................... 1-1
MODEL LABEL......................................................................................... 1-1
FEATURES ..................................................................................................... 1-2
OUTLINE OF THE FI SYSTEM................................................................ 1-2
FI SYSTEM............................................................................................... 1-3
INSTRUMENT FUNCTIONS .................................................................... 1-4
IMPORTANT INFORMATION ........................................................................ 1-7
PREPARATION FOR REMOVAL AND DISASSEMBLY ........................... 1-7
REPLACEMENT PARTS .......................................................................... 1-7
GASKETS, OIL SEALS AND O-RINGS ................................................... 1-7
LOCK WASHERS/PLATES AND COTTER PINS..................................... 1-7
BEARINGS AND OIL SEALS ................................................................... 1-8
CIRCLIPS ................................................................................................. 1-8
CHECKING THE CONNECTIONS ................................................................ 1-9
SPECIAL TOOLS ...........................................................................................1-10
1

1-1

IDENTIFICATION

EAS00170

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped

into the right side of the steering head pipe.

EAS00180

MODEL LABEL

The model label “1” is affixed to the frame under

the seat. This information will be needed to or-

der spare parts.

1-2

FEATURES

EAS00019

FEATURES

EAS00896

OUTLINE OF THE FI SYSTEM

The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti-

mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temper-

ature. In a conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the com-

bustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used

in the respective chamber. Despite the same volume of intake air, the fuel volume requirement varies

with the engine operating conditions, such as acceleration, deceleration, or operation under a heavy

load. Carburetors that meter the fuel through the use of jets have been provided with various auxil-

iary devices, so that an optimum air-fuel ratio can be achieved to accommodate the constant changes

in the operating conditions of the engine. As the requirements for engines to deliver more perform-

ance and cleaner exhaust gases increase, it becomes necessary to control the air-fuel ratio in a more

precise and finely tuned manner. To accommodate this need, this model has adopted an electroni-

cally controlled fuel injection (FI) system in place of a conventional carburetor system. This system

can achieve an optimum air-fuel ratio required by the engine at all times by using a microprocessor

that regulates the fuel injection volume according to the engine operating conditions detected by var-

ious sensors. Adoption of the FI system has resulted in a highly precise fuel supply, improved engine

response, better fuel economy, and reduced exhaust emissions. Furthermore, the air induction sys-

tem (AI system) has been placed under computer control together with the FI system in order to re-

alize cleaner exhaust gases.

1. Fuel tank

2. Engine trouble warning light

3. Ignition coil

4. Spark plug

5. Fuel pump

6. Idling adjustment screw

7. Throttle position sensor

8. Intake air pressure sensor

9. Air filter case

10. ECU

11. Lean angle cut-off switch

12. Catalytic converter

13. Fuel injection system relay

14. Battery

15. Intake air temperature sensor

16. Coolant temperature sensor

17. Fuel injector

18. Crankshaft position sensor

19. O2 sensor

20. Air induction system solenoid

21. Air cut-off valve

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