Yamaha TENERE XT660Z User manual

11D-F8199-21
XT660Z
OWNER’S MANUAL
Read this manual carefully before operating this vehicle.
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EAU46090
Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
XT660Z 01-03 ING-AUS:AUSTRALIA 11-05-2009 9:57 Pagina 2

INTRODUCTION
EAU10102
Welcome to the Yamaha world of motorcycling!
As the owner of the XT660Z Ténéré, 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 Ténéré. The Owner's
Manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard
yourself and others from trouble and injury.
In addition, the many tips given in this manual will help keep your motorcycle in the best possible condition. If you have
any further questions, do not hesitate to contact your Yamaha dealer.
The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most
current product information available at the time of printing, there may be minor discrepancies between your motorcycle
and this manual. If there is any question concerning this manual, please consult a Yamaha dealer.
EWA10031
WARNING
0
Please read this manual carefully and completely before operating this motorcycle.
XT660Z 01-03 ING-AUS:AUSTRALIA 11-05-2009 9:57 Pagina 3

IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations:
WARNING
0
TIP
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 WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to the
vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
EAU10132
NOTICE
XT660Z 01-03 ING-AUS:AUSTRALIA 11-05-2009 9:57 Pagina 4

IMPORTANT MANUAL INFORMATION
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.
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TABLE OF CONTENTS
LOCATION OF IMPORTANT LABELS...1-1
SAFETY INFORMATION .....................2-1
Be a Responsible Owner ..................2-1
Safe riding.........................................2-1
Protective apparel .............................2-2
Avoid Carbon Monoxide Poisoning ...2-2
Loading .............................................2-3
Genuine Yamaha Accessories ..........2-3
Aftermarket Parts, Accessories,
and Modifications .......................2-4
Aftermarket Tires and Rims ..............2-4
DESCRIPTION.....................................3-1
Left view............................................3-1
Right view .........................................3-2
Controls and instruments..................3-3
INSTRUMENT AND CONTROL
FUNCTIONS ........................................4-1
Immobilizer system ...........................4-1
Main switch/steering lock ..................4-2
Indicator and warning lights ..............4-3
Multi-function display ........................4-5
Tachometer .......................................4-6
Tripmeter and tachometer modes .....4-6
Clock mode .......................................4-7
Fuel meter.........................................4-7
Self-diagnosis devices ......................4-7
Handlebar switches...........................4-9
Clutch lever .....................................4-10
Shift pedal .......................................4-10
Brake lever ......................................4-11
Brake pedal .....................................4-11
Fuel tank cap ..................................4-11
Fuel .................................................4-12
Fuel tank breather hose..................4-13
Catalytic converter ..........................4-13
Seat.................................................4-14
Adjusting the front fork....................4-15
Adjusting the shock absorber
assembly ..................................4-16
Sidestand ........................................4-17
Ignition circuit cut-off system ..........4-17
FOR YOUR SAFETY -
PRE-OPERATION CHECKS ...............5-1
Pre-operation check list ....................5-2
OPERATION AND IMPORTANT
RIDING POINTS ..................................6-1
Starting the engine............................6-1
Shifting ..............................................6-2
Tips for reducing fuel consumption...6-3
Engine break-in.................................6-3
Parking ..............................................6-4
PERIODIC MAINTENANCE AND
ADJUSTMENT.....................................7-1
Owner’s tool kit .................................7-1
Periodic maintenance chart for
the emission control system.......7-2
General maintenance
and lubrication chart ..................7-3
Removing and installing
the cowling and panels ..............7-8
Checking the spark plug ...................7-8
Engine oil and oil filter element.........7-9
Coolant............................................7-12
Replacing the air filter element
and cleaning the check hose ...7-14
Checking the engine idling speed...7-15
Checking the throttle cable
free play ...................................7-16
Valve clearance...............................7-16
Tires ................................................7-16
Spoke wheels..................................7-19
Adjusting the clutch lever free play...7-20
Checking the front and rear
brake pads ...............................7-21
Checking the brake fluid level .........7-22
Changing the brake fluid .................7-23
Drive chain slack.............................7-23
Cleaning and lubricating
the drive chain..........................7-25
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Checking and lubricating
the cables.................................7-25
Checking and lubricating
the throttle grip and cable ........7-26
Checking and lubricating the brake
and clutch levers ......................7-26
Lubricating the brake pedal ............7-27
Checking and lubricating
the sidestand............................7-27
Lubricating the rear suspension......7-27
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
MOTORCYCLE CARE
AND STORAGE ...................................8-1
Care ..................................................8-1
Storage .............................................8-3
SPECIFICATIONS ...............................9-1
CONSUMER INFORMATION............10-1
Identification numbers.....................10-1
Motorcycle noise regulation
(for Australia)............................10-2
TABLE OF CONTENTS
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LOCATION OF IMPORTANT LABELS
EAU10383
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
label is available from your Yamaha dealer.
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LOCATION OF IMPORTANT LABELS
1-2
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SAFETY INFORMATION
EAU10313
Be a Responsible Owner
As the vehicle's owner, you are re-
sponsible for the safe and proper op-
eration of your motorcycle.
Motorcycles are single-track vehicles.
Their safe use and operation are de-
pendent upon the use of proper riding
techniques as well as the expertise of
the operator. Every operator should
know the following requirements be-
fore riding this motorcycle.
He or she should:
●Obtain thorough instructions from
a competent source on all as-
pects of motorcycle operation.
●Observe the warnings and main-
tenance requirements in this
Owner's Manual.
●Obtain qualified training in safe
and proper riding techniques.
●Obtain professional technical ser-
vice as indicated in this Owner's
Manual and/or when made nec-
essary by mechanical conditions.
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Safe riding
Perform the pre-operation checks each
time you use the vehicle to make sure it is
in safe operating condition. Failure to in-
spect or maintain the vehicle properly in-
creases the possibility of an accident or
equipment damage. See page 5-2 for a
list of pre-operation checks.
●This motorcycle is designed to carry
the operator and a passenger.
●The failure of motorists to detect and
recognize motorcycles in traffic is the
predominating cause of automo-
bile/motorcycle accidents. Many ac-
cidents have been caused by an
automobile driver who did not see
the motorcycle. Making yourself
conspicuous appears to be very
effective in reducing the chance
of this type of accident.
Therefore:
• Wear a brightly colored jacket.
• Use extra caution when you are
approaching and passing
through intersections, since in-
tersections are the most likely
places for motorcycle accidents
to occur.
• Ride where other motorists can
see you. Avoid riding in another
motorist's blind spot.
●Many accidents involve inexperi-
enced operators. In fact, many op-
erators who have been involved in
accidents do not even have a cur-
rent motorcycle license.
• Make sure that you are quali-
fied and that you only lend your
motorcycle to other qualified
operators.
• Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
• We recommend that you prac-
tice riding your motorcycle
where there is no traffic until
you have become thoroughly
familiar with the motorcycle and
all of its controls.
●Many accidents have been caused
by error of the motorcycle opera-
tor. A typical error made by the op-
erator is veering wide on a turn
due to excessive speed or under-
cornering (insufficient lean angle
for the speed).
• Always obey the speed limit
and never travel faster than
warranted by road and traffic
conditions.
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• 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 motorcy-
cle.
• The passenger should always
hold onto the operator, the seat
strap or grab bar, if equipped,
with both hands and keep both
feet on the passenger footrests.
Never carry a passenger un-
less he or she can firmly place
both feet on the passenger
footrests.
●Never ride under the influence of
alcohol or other drugs.
2-2
Protective apparel
The majority of fatalities from motorcy-
cle accidents are the result of head in-
juries.The use of a safety helmet is the
single most critical factor in the pre-
vention or reduction of head injuries.
●Always wear an approved helmet.
●Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.
●The use of a jacket, heavy boots,
trousers, gloves, etc., is effective
in preventing or reducing abra-
sions or lacerations.
●Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or
wheels and cause injury or an ac-
cident.
●Always wear protective clothing
that covers your legs, ankles, and
feet. The engine or exhaust sys-
tem become very hot during or af-
ter operation and can cause
burns.
●A passenger should also observe
the above precautions.
Avoid Carbon Monoxide Poisoning
All engine exhaust contains carbon
monoxide, a deadly gas. Breathing car-
bon monoxide can cause headaches,
dizziness, drowsiness, nausea, confu-
sion, and eventually death.
Carbon Monoxide is a colorless, odor-
less, tasteless gas which may be pre-
sent even if you do not see or smell any
engine exhaust. Deadly levels of carbon
monoxide can collect rapidly and you
can quickly be overcome and unable to
save yourself. Also, deadly levels of car-
bon monoxide can linger for hours or
days in enclosed or poorly ventilated ar-
eas. If you experience any symptoms of
carbon monoxide poisoning, leave the
area immediately, get fresh air, and
SEEK MEDICAL TREATMENT.
●Do not run engine indoors. Even if
you try to ventilate engine ex-
haust with fans or open windows
and doors, carbon monoxide can
rapidly reach dangerous levels.
●Do not run engine in poorly ventilat-
ed 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.
SAFETY INFORMATION
XT660Z 01-03 ING-AUS:AUSTRALIA 11-05-2009 9:57 Pagina 11

SAFETY INFORMATION
Loading
Adding accessories or cargo to your
motorcycle can adversely affect stabil-
ity and handling if the weight distribu-
tion of the motorcycle is changed. To
avoid the possibility of an accident,
use extreme caution when adding car-
go or accessories to your motorcycle.
Use extra care when riding a motorcy-
cle that has added cargo or acces-
sories. Here, along with the informa-
tion about accessories below, are
some general guidelines to follow if
loading cargo to your motorcycle:
The total weight of the operator,
passenger, accessories and cargo
must not exceed the maximum load
limit. Operation of an overloaded
vehicle could cause an accident.
2-3
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curely pack your heaviest items
as close to the center of the vehi-
cle as possible and make sure to
distribute the weight as evenly as
possible on both sides of the mo-
torcycle to minimize imbalance or
instability.
●Shifting weights can create a sud-
den imbalance. Make sure that
accessories and cargo are se-
curely attached to the motorcycle
before riding. Check accessory
mounts and cargo restraints fre-
quently.
• Properly adjust the suspension
for your load, and check the
condition and pressure of your
tires.
• Never attach any large or heavy
items to the handlebar, front
fork, or front fender. These
items, including such cargo as
sleeping bags, duffel bags, or
tents, can create unstable han-
dling or a slow steering re-
sponse.
●This vehicle is not designed to
pull a trailer or to be attached
to a sidecar.
Genuine Yamaha Accessories
Choosing accessories for your vehicle
is an important decision. Genuine
Yamaha accessories, which are avail-
able only from a Yamaha dealer, have
been designed, tested, and approved
by Yamaha for use on your vehicle.
Many companies with no connection
to Yamaha manufacture parts and ac-
cessories or offer other modifications
for Yamaha vehicles. Yamaha is not in
a position to test the products that
these aftermarket companies pro-
duce. Therefore, Yamaha can neither
endorse nor recommend the use of
accessories not sold by Yamaha or
modifications not specifically recom-
mended by Yamaha, even if sold and
installed by a Yamaha dealer.
Aftermarket Parts, Accessories,
and Modifications
While you may find aftermarket prod-
ucts similar in design and quality to
genuine Yamaha accessories, recog-
nize that some aftermarket acces-
sories or modifications are not suitable
because of potential safety hazards to
you or others. Installing aftermarket
Maximum load:
190 kg (419 lb)
When loading within this weight limit,
keep the following in mind:
●Cargo and accessory weight
should be kept as low and close
to the motorcycle as possible. Se-
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SAFETY INFORMATION
products or having other modifications
performed to your vehicle that change
any of the vehicle's design or opera-
tion characteristics can put you and
others at greater risk of serious injury
or death. You are responsible for in-
juries related to changes in the vehi-
cle.
Keep the following guidelines in mind,
as well as those provided under
"Loading" when mounting acces-
sories.
●Never install accessories or carry
cargo that would impair the perfor-
mance of your motorcycle. Care-
fully inspect the accessory before
using it to make sure that it does
not in any way reduce ground
clearance or cornering clearance,
limit suspension travel, steering
travel or control operation, or ob-
scure lights or reflectors.
• Accessories fitted to the han-
dlebar or the front fork area can
create instability due to improp-
er weight distribution or aerody-
namic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.
• Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerody-
namic effects. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become
unstable in cross winds. These
accessories may also cause in-
stability when passing or being
passed by large vehicles.
• Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the
freedom of movement of the
operator and may limit control
ability, therefore, such acces-
sories are not recommended.
●Use caution when adding electri-
cal accessories. If electrical ac-
cessories exceed the capacity of
the motorcycle's electrical sys-
tem, an electric failure could re-
sult, which could cause a danger-
ous loss of lights or engine power.
Aftermarket Tires and Rims
The tires and rims that came with your
motorcycle were designed to match
the performance capabilities and to
provide the best combination of han-
dling, braking, and comfort. Other
tires, rims, sizes, and combinations
may not be appropriate. Refer to page
7-16 for tire specifications and more
information on replacing your tires.
2-4
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3-1
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DESCRIPTION
EAU10410
Left view
1. Idle adjusting screw (page 7-15)
2. Owner’s tool kit (page 7-1)
3. Air filter element (page 7-14)
4. Fuse box (page 7-31)
5. Seat lock (page 4-14)
6. Shock absorber assembly/spring preload adjusting ring (page 4-16)
7. Shift pedal (page 4-10)
8. Engine oil drain bolt (crankcase) (page 7-10)
9. Engine oil drain bolt (oil tank) (page 7-10)
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3-2
DESCRIPTION
10. Grab bar
11. Main fuse (page 7-31)
12. Battery (page 7-30)
13. Rear brake fluid reservoir (page 7-22)
14. Coolant reservoir (page 7-13)
15. Front brake fluid reservoir (page 7-22)
16. Coolant drain bolt (page 7-12)
17. Engine oil filter element (page 7-11)
18. Brake pedal (page 4-11)
EAU10420
Right view
XT660Z 01-03 ING-AUS:AUSTRALIA 11-05-2009 9:57 Pagina 15

DESCRIPTION
3-3
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EAU10430
Controls and instruments
1. Clutch lever (page 4-10)
2. Left handlebar switches (page 4-9)
3. Multi-function meter unit and warning lights (page 4-3, 4-5)
4. Right handlebar switches (page 4-9)
5. Throttle grip (page 7-16)
6. Brake lever (page 4-11)
7. Engine oil filler cap/dipstick (page 7-9)
8. Fuel tank cap (page 4-11)
9. Main switch and steering lock (page 4-2)
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4-1
INSTRUMENT AND CONTROL FUNCTIONS
EAU10976
Immobilizer system
1. Code re-registering key (red bow)
2. Standard keys (black bow)
This vehicle is equipped with an im-
mobilizer system to help prevent theft
by re-registering codes in the standard
keys. This system consists of the fol-
lowing.
●a code re-registering key (with a
red bow)
●two standard keys (with a black
bow) that can be re-registered
with new codes
●a transponder (which is installed
in the code re-registering key)
●an immobilizer unit
●an ECU
●an immobilizer system indicator
light (See page 4-3.)
The key with the red bow is used to reg-
ister 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-regis-
tered. Do not use the key with the red
bow for driving. It should only be used
for re-registering the standard keys. Al-
ways use a standard key for driving.
ECA11821
NOTICE
●DO NOT LOSE THE CODE RE-
REGISTERING KEY! CONTACT
YOUR DEALER IMMEDIATELY
IF IT IS LOST! If the code re-reg-
istering key is lost, registering
new codes in the standard keys
is impossible. The standard keys
can still be used to start the ve-
hicle, however if code re-regis-
tering is required (i.e., if a new
standard key is made or all keys
are lost) the entire immobilizer
system must be replaced.
Therefore, it is highly recom-
mended to use either standard
key and keep the code re-regis-
tering key in a safe place.
●Do not submerse any key in water.
●Do not expose any key to exces-
sively high temperatures.
●Do not place any key close to
magnets (this includes, but not
limited to, products such as
speakers, etc.).
●Do not place items that transmit
electrical signals close to any key.
●Do not place heavy items on
any key.
●Do not grind any key or alter its
shape.
●Do not disassemble the plastic
part of any key.
●Do not put two keys of any immobi-
lizer system on the same key ring.
●Keep the standard keys as well
as keys of other immobilizer
systems away from this vehi-
cle's code re-registering key.
●Keep other immobilizer system
keys away from the main switch
as they may cause signal inter-
ference.
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INSTRUMENT AND CONTROL FUNCTIONS
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EAU10471
Main switch/steering lock
The main switch/steering lock controls
the ignition and lighting systems, and
is used to lock the steering.
TIP
Be sure to use the standard key (black
bow) for regular use of the vehicle. To
minimize the risk of losing the code re-
registering key (red bow), keep it in a
safe place and only use it for code re-
registering.
EAU10550
ON
All electrical circuits are supplied with
power, the meter lighting, taillight, li-
cense plate light and auxiliary lights
come on, and the engine can be start-
ed. The key cannot be removed.
TIP
The headlights comes on automatical-
ly when the engine is started and stay
on until the key is turned to “OFF”,
even if the engine stalls.
EAU10661
OFF
All electrical systems are off. The key
can be removed.
EWA10061
WARNING
0
Never turn the key to "OFF" or
"LOCK" while the vehicle is moving.
Otherwise the electrical systems
will be switched off, which may re-
sult in loss of control or an acci-
dent.
EAU10691
LOCK
The steering is locked, and all electri-
cal systems are off. The key can be re-
moved.
To lock the steering
1. Push
2. Turn
1. Turn the handlebars all the way to
the left or right.
2. Push the key in from the “OFF”
position, and then turn it to
“LOCK” while still pushing it.
3. Remove the key.
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INSTRUMENT AND CONTROL FUNCTIONS
4-3
To unlock the steering
1. Push
2. Turn
Push the key into the main switch, and
then turn it to “OFF” while still pushing
it.
EAU10941
F(Parking)
The steering is locked, and the tail-
light, 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 “F”.
ECA11020
NOTICE
Do not use the parking position for
an extended length of time, other-
wise the battery may discharge.
EAU11004
Indicator and warning lights
1. Immobilizer system indicator light “ ”
2. Neutral indicator light “N”
3. Turn signal indicator light “y”
4. High beam indicator light “1”
5. Engine trouble warning light “U”
6. Coolant temperature warning light “u”
EAUB1510
Turn signal indicator light “y”
This indicator light flashes when the
turn signal switch is pushed to the left
or right.
The electrical circuit of the turn signal
indicator light can be checked by turn-
ing the key to "ON".
If the indicator light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir-
cuit.
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INSTRUMENT AND CONTROL FUNCTIONS
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EAUB1520
Neutral indicator light “N”
This indicator light comes on when the
transmission is in the neutral position.
The electrical circuit of the neutral indi-
cator light can be checked by turning
the key to "ON". If the indicator light
does not come on for a few seconds,
then go off, have a Yamaha dealer
check the electrical circuit.
EAUB1530
High beam indicator light “1”
This indicator light comes on when the
high beam of the headlight is switched
on. The electrical circuit of the high
beam indicator light can be checked
by turning the key to "ON". If the indi-
cator light does not come on for a few
seconds, then go off, have a Yamaha
dealer check the electrical circuit.
EAU11444
Coolant temperature warning
light “u”
This warning light comes on if the en-
gine overheats. If this occurs, stop the
engine immediately and allow the en-
gine to cool.The electrical circuit of the
warning light can be checked by turn-
ing the key to "ON". The warning light
should come on for a few seconds,
and then go off. If the warning light
does not come on initially when the
key is turned to "ON", or if the warning
light remains on, have a Yamaha deal-
er check the electrical circuit.
ECA10021
NOTICE
Do not continue to operate the en-
gine if it is overheating.
TIP
●For radiator-fan-equipped vehi-
cles, the radiator fan(s) automati-
cally switch on or off according to
the coolant temperature in the ra-
diator.
●If the engine overheats, see page
7-41 for further instructions.
EAU11534
Engine trouble warning light “U”
This warning light comes on or flashes
if a problem is detected in the electri-
cal circuit monitoring the engine. If this
occurs, have a Yamaha dealer check
the self-diagnosis system. (See page
4-8 for an explanation of the self-diag-
nosis device.) 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. If the warning light does
not come on initially when the key is
turned to "ON", or if the warning light re-
mains on, have a Yamaha dealer check
the electrical circuit.
EAU26876
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.
When the key is turned to "OFF" and
30 seconds have passed, the indicator
light will start flashing indicating the
immobilizer system is enabled. After
24 hours have passed, the indicator
light will stop flashing, however the im-
mobilizer system is still enabled.
This model is also equipped with a
self-diagnosis device for the immobi-
lizer system. (See page 4-8 for an ex-
planation of the self-diagnosis device.)
XT660Z 04-04 ING-AUS:MY03 01-03 ING 11-05-2009 9:54 Pagina 4-4