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  • SERVICE MANUAL

    2008

    11D-F8197-E0

    XT660Z

  • XT660Z (2008)SERVICE MANUAL

    2008 by Yamaha Motor Italia S.p.A.First edition, May 2008

    All rights reserved. Any reproduction orunauthorized use without the written

    permission of Yamaha Motor Italia S.p.A.is expressly prohibited.

    Printed in Italy

  • EAS00020

    NOTICEThis manual was produced by the Yamaha Motor Italia S.p.A. primarily for use by Yamaha dealers andtheir 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 vehiclesshould 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 renderthe 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 dealersand will appear in future editions of this manual where applicable.

    NOTE: Designs and specifications are subject to change without notice.

    EAS00040

    IMPORTANT MANUAL INFORMATIONParticularly 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 tothe motorcycle operator, a bystander or a person checking or repairing the mo-torcycle.

    A CAUTION indicates special precautions that must be taken to avoid damageto the motorcycle.

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

    WARNING

    CAUTION:

  • EAS20090

    HOW TO USE THIS MANUALThis manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensiveexplanations of all installation, removal, disassembly, assembly, repair and check procedures arelaid 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

    SYMBOLSThe following symbols are used in this manualfor easier understanding.NOTE: The following symbols are not relevant to everyvehicle.

    1. Serviceable with engine mounted2. Filling fluid3. Lubricant4. Special tool5. Tightening torque6. Wear limit, clearance7. Engine speed8. Electrical data9. Engine oil10. Gear oil11. Molybdenum disulfide oil12. Wheel bearing grease13. Lithium-soap-based grease14. Molybdenum disulfide grease15. Apply locking agent (LOCTITE)16. Replace the part with a new one.

    New

    1 2 3

    4 5

    7 8

    6

    9 1110

    12 1413

    15 16

  • GENERAL INFORMATION

    TABLE OF CONTENTS

    1

    SPECIFICATIONS 2PERIODIC CHECKS AND ADJUSTMENTS 3

    CHASSIS 4

    ENGINE 5

    COOLING SYSTEM 6

    FUEL INJECTION SYSTEM 7

    ELECTRICAL SYSTEM 8

    TROUBLESHOOTING 9

  • GENERAL INFORMATION

    IDENTIFICATION............................................................................................ 1-1VEHICLE IDENTIFICATION NUMBER..................................................... 1-1MODEL LABEL......................................................................................... 1-1

    FEATURES ..................................................................................................... 1-2OUTLINE OF THE FI SYSTEM................................................................ 1-2FI SYSTEM............................................................................................... 1-3INSTRUMENT FUNCTIONS .................................................................... 1-4

    IMPORTANT INFORMATION ........................................................................ 1-7PREPARATION FOR REMOVAL AND DISASSEMBLY ........................... 1-7REPLACEMENT PARTS .......................................................................... 1-7GASKETS, OIL SEALS AND O-RINGS ................................................... 1-7LOCK WASHERS/PLATES AND COTTER PINS..................................... 1-7BEARINGS AND OIL SEALS................................................................... 1-8CIRCLIPS ................................................................................................. 1-8

    CHECKING THE CONNECTIONS ................................................................ 1-9

    SPECIAL TOOLS ...........................................................................................1-10

    1

  • 1-1

    IDENTIFICATION

    1

    IDENTIFICATIONEAS00170

    VEHICLE IDENTIFICATION NUMBERThe vehicle identification number 1 is stampedinto the right side of the steering head pipe.

    EAS00180

    MODEL LABELThe model label 1 is affixed to the frame underthe seat. This information will be needed to or-der spare parts.

  • 1-2

    FEATURES

    EAS00019

    FEATURESEAS00896

    OUTLINE OF THE FI SYSTEMThe 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 usedin the respective chamber. Despite the same volume of intake air, the fuel volume requirement varieswith the engine operating conditions, such as acceleration, deceleration, or operation under a heavyload. 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 changesin 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 moreprecise 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 systemcan achieve an optimum air-fuel ratio required by the engine at all times by using a microprocessorthat 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 engineresponse, 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 tank2. Engine trouble warning light3. Ignition coil4. Spark plug5. Fuel pump6. Idling adjustment screw 7. Throttle position sensor8. Intake air pressure sensor9. Air filter case10. ECU11. Lean angle cut-off switch

    12. Catalytic converter13. Fuel injection system relay14. Battery15. Intake air temperature sensor16. Coolant temperature sensor17. Fuel injector18. Crankshaft position sensor19. O2 sensor20. Air induction system solenoid21. Air cut-off valve

  • 1-3

    FEATURES

    EAS00897

    FI SYSTEMThe fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fu-el pressure that is applied to the injector at 324 kPa (3.24 kg/cm2, 46.1 psi) higher than the intakemanifold pressure. Accordingly, when the energizing signal from the ECU energizes the injector, thefuel passage opens, causing the fuel to be injected into the intake manifold only during the time thepassage remains open. Therefore, the longer the length of time the injector is energized (injection du-ration), the greater the volume of fuel that is supplied. Conversely, the shorter the length of time theinjector is energized (injection duration), the lesser the volume of fuel that is supplied.The injection duration and the injection timing are controlled by the ECU. Signals that are input fromthe throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake air temper-ature sensor, coolant temperature sensor and O2 sensor enable the ECU to determine the injectionduration. The injection timing is determined through the signal from the crankshaft position sensor.As a result, the volume of fuel that is required by the engine can be supplied at all times in accor-dance with the driving conditions.

    Illustration is for reference only.

    1. Fuel pump2. Pressure regulator3. Fuel injector4. Throttle body5. Intake air temperature sensor6. Throttle position sensor7. Intake air pressure sensor8. ECU9. Coolant temperature sensor10. Crankshaft position sensor11. O2 sensor12. Catalytic converter

    A. Fuel systemB. Air systemC. Control system

  • 1-4

    FEATURES

    INSTRUMENT FUNCTIONSEAUB1500

    Multi-function display

    1. Tachometer2. Speedometer3. Odometer4. Tripmeters/Fuel reserve tripmeter5. Clock6. Fuel meter7. RESET button8. SELECT