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EAU26944 AMAHA MOTOR ELECTRONICS CO., LTD. 450-6, Mori, Mori-machi, Shuchi-gun, Shizuoka-ken, 437-0292 Japan DECLARATION of CONFORMITY Company: YAMAHA MOTOR ELECTRONICS CO., LTD. Address: 1450-6, Mori, Mori-Machi, Shuchi-gun, Shizuoka-Ken, 437-0292 Japan Hereby declare that the product: Kind of equipment: IMMOBILIZER Type-designation: 5SL-00 is in compliance with following norm(s) or documents: R&TTE Directive(1999/5/EC)
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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.
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 mo- torcycle and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.. EWA10030 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
TABLE OF CONTENTS Fuel tank cap ........3-11 Checking the spark plug ....6-8 SAFETY INFORMATION .....1-1 Engine oil and oil filter element..6-9 Fuel ..........3-12 Safe riding.........1-1 Fuel tank breather hose....3-13 Coolant..........6-12 Protective apparel ......1-2 Catalytic converter ......3-13 Replacing the air filter element Modifications ........1-2 and cleaning the check hose ..6-14 Seat..........3-14...
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TABLE OF CONTENTS Lubricating the rear suspension..6-27 SPECIFICATIONS .......8-1 Lubricating the swingarm pivots ..6-28 Checking the front fork....6-28 CONSUMER INFORMATION....9-1 Checking the steering .....6-29 Identification numbers.......9-1 Checking the wheel bearings..6-29 Battery..........6-30 Replacing the fuses ......6-31 Replacing a headlight bulb .....6-33 Tail/brake light .........6-34 Replacing a turn signal light bulb..6-34 Replacing the license plate...
SAFETY INFORMATION EAU10311 • Ride where other motorists can Safe riding see you. Avoid riding in another ● Always make pre-operation MOTORCYCLES SINGLE motorist's blind spot. checks. Careful checks may help TRACK VEHICLES. THEIR SAFE ● Many accidents involve inexperi- prevent an accident.
Modifications made to this motorcycle warranted by road and traffic cle accidents are the result of head in- not approved by Yamaha, or the re- conditions. juries. The use of a safety helmet is the moval of original equipment, may ren- •...
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If accessories Make sure to distribute the weight stallation and use of non-Yamaha ac- are added to the handlebar or as evenly as possible on both cessories. Use extreme caution when...
SAFETY INFORMATION ● ● • Certain accessories can dis- Never start the engine or let it run When transporting the motorcycle place the operator from his or for any length of time in a closed in another vehicle, make sure that her normal riding position.
DESCRIPTION EAU10430 Controls and instruments 1. Clutch lever (page 3-10) 6. Brake lever (page 3-11) 2. Left handlebar switches (page 3-9) 7. Engine oil filler cap/dipstick (page 6-9) 3. Multi-function meter unit and warning lights (page 3-3, 3-5) 8. Fuel tank cap (page 3-11) 4.
● Do not place any key close to Yamaha dealer to have them re-regis- magnets (this includes, but not tered. Do not use the key with the red limited to, products such as bow for driving.
INSTRUMENT AND CONTROL FUNCTIONS EAU10471 EAU10550 To lock the steering Main switch/steering lock 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. NOTE: The headlights comes on automatical- ly when the engine is started and stay...
"ON". If the indicator light does not come on key to “OFF” or “LOCK”. for a few seconds, then go off, have a Yamaha dealer check the electrical cir- cuit.
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When this oc- If the indicator light does not come on self-diagnosis device for the immobi- curs, have a Yamaha dealer check the for a few seconds, then go off, have a lizer system. (See page 3-7 for an ex- self-diagnosis system.
INSTRUMENT AND CONTROL FUNCTIONS EAUB1501 The multi-function display is equipped NOTE: Multi-function display with the following: ● Be sure to turn the key to "ON" ● a speedometer (which shows the before using the "SELECT" and "RESET" buttons. riding speed) ●...
INSTRUMENT AND CONTROL FUNCTIONS ton switches the display between the Tachometer Tripmeter and tachometer modes various tripmeter modes in the follow- ing order: F-TRIP TRIP 1 TRIP 2 F-TRIP To reset a tripmeter, select it by push- ing the "SELECT" button, and then push the "RESET"...
4. Push the "RESET" button to set ing. is defective, all the segments will start the minutes. If this occurs, have a Yamaha dealer flashing. If this occurs, have a Yamaha 5. Push the "SELECT" button and dealer check the electrical circuit.
This motorcycle can be equipped with times, and then quickly flashes two an optional anti-theft alarm by a Yama- times repeatedly, this error could be ha dealer. Contact a Yamaha dealer for caused by transponder interference. If more information. this occurs, try the following.
INSTRUMENT AND CONTROL FUNCTIONS EAU12347 EAU12460 Right Turn signal switch “y” Handlebar switches To signal a right-hand turn, push this Left switch to “Δ”. To signal a left-hand turn, push this switch to “Ÿ”. When re- leased, the switch returns to the cen- ter position.
INSTRUMENT AND CONTROL FUNCTIONS EAU12733 EAU12820 EAU12870 Hazard switch “ ” Clutch lever Shift pedal With the key in the “ON” or F position, use this switch to turn on the hazard lights (simultaneous flashing of all turn signal lights). The hazard lights are used in case of an emergency or to warn other drivers when your vehicle is stopped where it...
INSTRUMENT AND CONTROL FUNCTIONS EAU26822 EAU12941 EAU13072 Brake lever Brake pedal Fuel tank cap 1. Brake lever 1. Brake pedal 1. Lock cover 2. Position adjusting dial 2. Open 3. Arrow mark The brake pedal is on the right side of 4.
INSTRUMENT AND CONTROL FUNCTIONS EAU13211 ECA10070 To close the fuel tank cap CAUTION: Fuel 1. Push the fuel tank cap into posi- Immediately wipe off spilled fuel tion with the key inserted in the with a clean, dry, soft cloth, since lock.
Make sure that the exhaust system has cooled down before doing any maintenance work. Your Yamaha engine has been de- signed to use premium unleaded gasoline with a research octane num- 1. Fuel tank breather hose 2. Clamp ber of 95 or higher.
INSTRUMENT AND CONTROL FUNCTIONS ECA10700 EAU13870 To install the seat CAUTION: Seat The following precautions must be To remove the seat observed to prevent a fire hazard or other damages. ● Use only unleaded gasoline. The use of leaded gasoline will cause unrepairable damage to the catalytic converter.
INSTRUMENT AND CONTROL FUNCTIONS EAUB1550 EWA10180 NOTE: WARNING Adjusting the front fork Use the 10 mm hexagon wrench in- Always adjust both fork legs equal- cluded in the owner’s tool kit to turn ly, otherwise poor handling and the adjusting bolts. loss of stability may result.
Spring preload setting: will result in poor damping per- ECA10100 Minimum (soft): formance. CAUTION: ● Always have a Yamaha dealer Never attempt to turn an adjusting Standard: service the shock absorber. mechanism beyond the maximum or minimum settings. Maximum (hard):...
● It cuts the running engine when or lower it with your foot while holding a Yamaha dealer repair it if it does the transmission is in gear and the motorcycle upright. not function properly.
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5. Push the start switch. Does the engine start? The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. With the engine still running: 6. Move the sidestand up. 7. Keep the clutch lever pulled.
PRE-OPERATION CHECKS EAU15593 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpected- ly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences.
• If necessary, add recommended coolant to specified level. 6-12 • Check cooling system for leakage. • Check operation. • If soft or spongy, have Yamaha dealer bleed hydraulic system. • Check brake pads for wear. Front brake • Replace if necessary.
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• Make sure that operation is smooth. • Check cable free play. Throttle grip 6-16, 6-26 • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. • Make sure that operation is smooth. 6-25 Control cables •...
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PRE-OPERATION CHECKS ITEM CHECKS PAGE Instruments, lights, • Check operation. 3-3, 3-9 signals and switches • Correct if necessary. Sidestand • Check operation of ignition circuit cut-off system. 3-17 switch • If system is defective, have Yamaha dealer check vehicle.
● The transmission is in the neutral ● Neutral indicator light their functions before riding. position. Consult a Yamaha dealer re- ● Turn signal indicator light ● The transmission is in gear with garding any control or function ●...
OPERATION AND IMPORTANT RIDING POINTS 3. Start the engine by pushing the EAU16671 ECA10260 CAUTION: Shifting start switch. ● Even with the transmission in NOTE: the neutral position, do not coast for long periods of time If the engine fails to start, release the with the engine off, and do not start switch, wait a few seconds, and tow the motorcycle for long...
OPERATION AND IMPORTANT RIDING POINTS EAU16810 EAU16841 EAU17100 0-1000 km (0-600 mi) Tips for reducing fuel Engine break-in Avoid prolonged operation above consumption There is never a more important peri- 4500 r/min. od in the life of your engine than the Fuel consumption depends largely on period between 0 and 1600 km (1000 your riding style.
● If any engine trouble should oc- switch. cur during the engine break-in EWA10310 period, immediately have a WARNING Yamaha dealer check ● Since the engine and exhaust vehicle. system can become very hot, park in a place where pedestri- ans or children are not likely to touch them.
If you do not have the tools or experi- Periodic inspection, adjustment and ence required for a particular job, have lubrication will keep your vehicle in the a Yamaha dealer perform it for you. safest and most efficient condition possible. The most important points of EWA10350...
● From 50000 km, repeat the maintenance intervals starting from 10000 km. ● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and tech- nical skills. ODOMETER READING (x 1,000 km)
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PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (x 1,000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK • Check for cracks or damage. √ √ √ √ √ Brake hoses ✻ • Replace. Every 4 years • Check runout, spoke tightness and for damage. Wheels ✻...
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PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (x 1,000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK Front fork • Check operation and for oil leakage. ✻ √ √ √ √ Shock absorber • Check operation and shock absorber for oil ✻...
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PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (x 1,000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK • Check the air cut-off valve, reed valve, and hose for damage. √ √ √ √ √ Air induction system ✻ • damage Muffler and exhaust •...
PERIODIC MAINTENANCE AND MINOR REPAIR EAU18722 Panel C and D Removing and installing the cowling and panels The cowling and panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the cowling or a panel needs to be removed and installed.
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PERIODIC MAINTENANCE AND MINOR REPAIR Panel E and F Panel G 1. Panel 1. Panel mounting bolt 2. Pin 1. Panel mounting bolt 2. Quick fastener G. Panel E. Right panel To install the panel F. Left panel Place the panel in the original position, To remove the panel and then install the bolts.
Do not attempt to di- agnose such problems yourself. 1. Spark plug gap Instead, have a Yamaha dealer check the vehicle. Spark plug gap: 0.7-0.8 mm (0.028-0.032 in) 2. Check the spark plug for elec- trode erosion and excessive car- 2.
PERIODIC MAINTENANCE AND MINOR REPAIR EAUB1560 Tightening torque: Engine oil and oil filter Spark plug: element 12.5 Nm (1.25 m·kgf, 9.0 ft·lbf) The engine oil level should be checked before each ride. In addition, the oil must NOTE: be changed and the oil filter element re- If a torque wrench is not available placed at the intervals specified in the when installing a spark plug, a good...
PERIODIC MAINTENANCE AND MINOR REPAIR ECA10010 To change the engine oil CAUTION: (with or without oil filter element Do not operate the vehicle until you replacement) know that the engine oil level is suf- ficient. EWA10360 WARNING Never remove the engine oil tank cap after high-speed operation, otherwise hot engine oil could 1.
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PERIODIC MAINTENANCE AND MINOR REPAIR 10. Install the oil filter element drain NOTE: Tightening torques: bolt. Skip steps 7-9 if the oil filter element is Oil filter element cover bolt: 11. Tighten the oil filter element cover 10 Nm (1.0 m·kgf, 7.2 ft·lbf) not being replaced.
PERIODIC MAINTENANCE AND MINOR REPAIR ECAM1060 ECA11620 EAU20070 CAUTION: CAUTION: Coolant ● In order to prevent clutch slip- The engine oil tank must be filled in The coolant level should be checked 2 steps. First, fill the engine oil tank page (since the engine oil also before each ride.
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Have a Yamaha dealer change the coolant. Coolant reservoir capacity: 0.50 L (0.52 US qt) (0.44 Imp.qt) 6-13...
PERIODIC MAINTENANCE AND MINOR REPAIR EAUB1480 To replace the air filter element Replacing the air filter element and cleaning the check hose The air filter element should be re- placed at the intervals specified in the periodic maintenance and lubrication chart.
2. If dirt or water is visible, remove checked as follows and, if necessary, the hose, clean it, and then install adjusted by a Yamaha dealer at the in- tervals specified in the periodic main- tenance and lubrication chart. Start the engine and warm it up for...
To prevent cycle, note the following points regard- this from occurring, the valve clear- ing the specified tires. ance must be adjusted by a Yamaha Tire air pressure dealer at the intervals specified in the The tire air pressure should be...
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PERIODIC MAINTENANCE AND MINOR REPAIR EWA11020 ● Adjust the suspension and tire WARNING air pressure with regard to the Tire air pressure Because loading has an enormous (measured on cold tires): load. impact on the handling, braking, Up to 90 kg (198 lb): ●...
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The tires must be checked before approved for this model by each ride. If the center tread depth Yamaha Motor Co., Ltd. reaches the specified limit, if the tire has a nail or glass fragments in it, or if the sidewall is cracked, have a Yama- ha dealer replace the tire immediately.
130/80-17M/C 65S cluding the tires, should be left each ride. If any damage is found, 130/80-17M/C 65T Manufacturer/model: to a Yamaha dealer, who has have a Yamaha dealer replace the METZELER/TOURANCE necessary professional wheel. Do not attempt even the MICHELIN/SIRAC A knowledge and experience.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU22041 NOTE: Adjusting the clutch lever If the specified clutch lever free play free play could be obtained as described above, tighten the locknut and skip the rest of the procedure, otherwise proceed as follows. 3.
Rear brake ● Use only the recommended qual- suddenly, have a Yamaha dealer ity brake fluid, otherwise the rub- check the cause. ber seals may deteriorate, caus- ing leakage and poor braking performance.
Changing the brake fluid Drive chain slack neutral position. 3. Move the rear wheel by pushing Have a Yamaha dealer change the The drive chain slack should be the motorcycle to locate the tight- brake fluid at the intervals specified in...
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PERIODIC MAINTENANCE AND MINOR REPAIR EAU34311 3. Tighten the locknuts, then the To adjust the drive chain slack axle nut to their specified torques. 1. Loosen the axle nut and the lock- nut on each side of the swingarm. 2. To tighten the drive chain, turn the Tightening torques: adjusting bolt on each side of the Locknut:...
Service the drive aged or does not move smoothly, have they may contain substances that chain as follows. a Yamaha dealer check or replace it. could damage the O-rings. ECA10581 CAUTION: Recommended lubricant:...
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23111 EAU23141 The operation of the brake and clutch Checking and lubricating Checking and lubricating levers should be checked before each the throttle grip and cable the brake and clutch levers ride, and the lever pivots should be lu- bricated if necessary.
EWA10730 Recommended lubricant: WARNING Lithium-soap-based grease Recommended lubricant: If the sidestand does not move up Silicone grease and down smoothly, have a Yamaha dealer check or repair it. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) 6-27...
If any damage is found or the front over. fork does not operate smoothly, have a Yamaha dealer check or re- Check the inner tubes for scratches, pair it. damage and excessive oil leakage.
If any free Worn or loose steering bearings may The front and rear wheel bearings play can be felt, have a Yamaha cause danger. Therefore, the opera- must be checked at the intervals spec- dealer check or repair the steering.
To charge the battery • INTERNAL: Drink large quan- Have a Yamaha dealer charge the bat- To access the battery tities of water or milk and im- tery as soon as possible if it seems to Remove the battery holder bracket by mediately call a physician.
If you do not have 4. After installation, make sure that access to a sealed-type (MF) the battery leads are properly battery charger, have a Yamaha 1. Main fuse connected to the battery termi- 2. Reserve fuse dealer charge your battery.
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2. Signaling system fuse Fuel injection system fuse: 4. If the fuse immediately blows 3. Headlight fuse 10 A again, have a Yamaha dealer 4. Ignition fuse Radiator fan fuse: 5. Electronic fuel injection fuse check the electrical system. 6. Radiator fan fuse 7.5 A...
PERIODIC MAINTENANCE AND MINOR REPAIR EAUB1580 EWA10790 WARNING Replacing a headlight bulb Headlight bulbs get very hot. There- fore, keep flammable products away from a lit headlight bulb, and do not touch the bulb until it has cooled down. 3. Place a new headlight bulb into position, and then secure it with 1.
4. Connect the coupler, and then in- 4. Install the lens by installing the stall the headlight bulb cover. screw. 5. Have a Yamaha dealer adjust the headlight beam if necessary. 6-34...
PERIODIC MAINTENANCE AND MINOR REPAIR ECA11190 EAUM2200 EAU42651 CAUTION: Replacing the license plate Replacing an auxiliary light light bulb bulb Do not overtighten the screw, oth- erwise the lens may break. 1. Bulb socket 1. Auxiliary light socket 2. License plate light bulb 2.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU24350 EAU24360 To service the rear wheel Supporting the motorcycle Front wheel Raise the rear wheel off the ground by EAUB1440 Since this model is not equipped with To remove the front wheel using a motorcycle stand or, if a mo- a centerstand, follow these precau- torcycle stand is not available, by plac- EWA10820...
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PERIODIC MAINTENANCE AND MINOR REPAIR 1. Loosen the front wheel axle pinch EAUB1470 6. Tighten wheel axle pinch bolt A, To install the front wheel bolts, the wheel axle and the and then pinch bolt B to the spec- 1. Lift the wheel up between the fork brake caliper bolts.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU25080 NOTE: Rear wheel ● If the drive chain is difficult to re- EAU25311 move, remove the wheel axle first, To remove the rear wheel EWA10820 and then lift the wheel upward WARNING enough to remove the drive chain from the rear sprocket.
However, should your motorcycle before installing the wheel. require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and 2. Install the drive chain onto the know-how to service the motorcycle rear sprocket.
Remove the spark plug spark plug. and check the electrodes. The engine does not start. Have a Yamaha dealer check the Dry. Check the battery. vehicle. 4. Battery The engine turns The battery is good.
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Start the engine. If the engine overheats again, have is OK. a Yamaha dealer check and repair the cooling system. NOTE: If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant as soon as possible.
MOTORCYCLE CARE AND STORAGE ● EAU26000 3. Remove extremely stubborn dirt, Do not use any harsh chemical Care like oil burnt onto the crankcase, products on plastic parts. Be with a degreasing agent and a sure to avoid using cloths or While the open design of a motorcycle brush, but never apply such prod- sponges which have been in...
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MOTORCYCLE CARE AND STORAGE ● For motorcycles equipped with After riding in the rain, near the sea After cleaning a windshield: Do not use strong or on salt-sprayed roads 1. Dry motorcycle with cleaners or hard sponges as Since sea salt or salt sprayed on roads chamois or an absorbing cloth.
MOTORCYCLE CARE AND STORAGE EWA10930 NOTE: EAUM1900 WARNING Storage Consult a Yamaha dealer for advice on ● Make sure that there is no oil or Short-term what products to use. wax on the brakes or tires. If Always store your motorcycle in a cool,...
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MOTORCYCLE CARE AND STORAGE Long-term EWA10950 7. Remove the battery and fully WARNING Before storing your motorcycle for sev- charge it. Store it in a cool, dry To prevent damage or injury from eral months: place and charge it once a month. sparking, make sure to ground the 1.
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: -20 -10 0 10 20 30 40 50 °C 864 mm (34.01 in) Recommended fuel: Overall height: Premium unleaded gasoline only...
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SPECIFICATIONS Operation: Manufacturer/model: Front wheel: Left foot operation METZELER/TOURANCE Type: Gear ratio: MICHELIN/SIRAC A Spoke wheel Rim size: Load: 30/12 (2.500) 21 x 1.85 Maximum load: 26/16 (1.625) Rear wheel: 190 kg (419 lb) Type: (Total weight of rider, passenger, cargo 23/20 (1.150) and accessories) Spoke wheel...
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SPECIFICATIONS Rear suspension: Neutral indicator light: Type: Turn signal indicator light: Swingarm (link suspension) Spring/damper type: High beam indicator light: Coil spring/gas-oil damper, spring preload adjustable Coolant temperature warning light: Wheel travel: 200 mm (7.87 in) Engine trouble warning light: Electrical system: Ignition system: Immobilizer system indicator light:...
Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the ve- hicle is stolen. KEY IDENTIFICATION NUMBER: 1.
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1. Model label The model label is affixed to the frame under the seat. (See page 3-14.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
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INDEX Checking and lubricating the Engine stop switch ......3-9 Air filter element, cleaning the sidestand ........6-27 Engine trouble warning light....3-4 check hose........6-14 Checking and lubricating the Air filter element, replacing ....6-14 throttle grip and cable ....6-26 Front fork ..........3-15 Anti-theft alarm (optional)....3-8 Checking the sidestand switch..3-18 Adjusting ........3-15 Auxiliary light bulb, replacing....6-35...
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INDEX Ignition circuit cut-off system....3-17 Model label.........9-2 Checking operation procedure..3-18 Multi-function display......3-5 Safety information ......1-1 Immobilizer system ......3-1 Clock mode........3-7 Seat..........3-14 Immobilizer system indicator light ..3-4 Self-diagnosis devices .......3-7 Self-diagnosis devices ....3-7 Indicator and warning lights ....3-3 Shift pedal ........3-10 Tachometer ........3-6 Coolant temperature warning Shifting ..........5-2...
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INDEX Tire information......6-18 Tire inspection ......6-18 Tool kit ..........6-1 Tripmeter and tachometer modes ..3-6 Troubleshooting ........6-39 Troubleshooting charts ....6-40 Engine overheating.......6-41 Turn signal indicator light ....3-3 Turn signal light bulb, replacing..6-34 Turn signal switch.......3-9 Valve clearance ........6-16 Vehicle identification number .....9-1 Warning lights ........3-3 Wheel bearings, checking ....6-29 Wheels, spoke........6-19...
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YAMAHA MOTOR ITALIA S.P.A. PRINTED IN ITALY...