OWNER’S MANUAL XT660R XT660X 5VK-F8199-E0
EAU26941 DECLARATION of CONFORMITY We Company: MORIC CO., LTD. Address: 1450-6 Mori Mori-Machi Shuchi-gun Shizuoka 437-0292 Japan Hereby declare that the product: Kind of equipment: IMMOBILIZER Type-designation: 5SL-00, 5VS-00, 5VX-00, 3HT-00, 5UX-00, 5UX-10, 5KS-00 and 5KS-10 is in compliance with following norm(s) or documents: R&TTE Directive(1999/5/EC) EN300 330-2 v1.1.
INTRODUCTION EAU10100 Welcome to the Yamaha world of motorcycling! As the owner of the XT660R/XT660X, 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 XT660R/XT660X.
IMPORTANT MANUAL INFORMATION EAU10150 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander, or a person inspecting or repairing the motorcycle. CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle.
IMPORTANT MANUAL INFORMATION EAUM1010 XT660R/XT660X OWNER’S MANUAL ©2003 by MBK INDUSTRIE 2nd edition, December 2003 All rights reserved Any reprinting or unauthorized use without the written permission of MBK INDUSTRIE is expressly prohibited. Printed in France.
TABLE OF CONTENTS SAFETY INFORMATION ..................1-1 DESCRIPTION ..................................2-1 Left view ..........................................2-1 Right view ........................................2-2 Controls and instruments.................2-3 INSTRUMENT AND CONTROL FUNCTIONS .......................................3-1 Immobilizer system .........................3-1 Main switch/steering lock ................3-2 Indicator and warning lights ............3-3 Multi-function display .........
TABLE OF CONTENTS MOTORCYCLE CARE AND STORAGE ..........................................7-1 Care ................................................7-1 Storage ...........................................7-3 SPECIFICATIONS .............................8-1 CONSUMER INFORMATION.............9-1 Identification numbers ....................
SAFETY INFORMATION EAU10310 1 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: ● OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION. ● OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.
SAFETY INFORMATION ● ● due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed). • Always obey the speed limit and never travel faster than warranted by road and traffic conditions. • 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.
SAFETY INFORMATION ● 1 Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability. ● Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely attached to the motorcycle before riding. Check accessory mounts and cargo restraints frequently.
SAFETY INFORMATION ● ● • Take care not to spill any gasoline on the engine or exhaust system when refueling. • Never refuel while smoking or in the vicinity of an open flame. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your motorcycle in an area that has adequate ventilation.
DESCRIPTION EAU10410 Left view 2 1. 2. 3. 4. 5. 6. 7. 8. 9. Seat lock (page 3-12) 10.Shift pedal (page 3-9) 11.
DESCRIPTION EAU10420 Right view 2 1. 2. 3. 4. 5. 6. 7. 8. 9. Engine oil filter element (page 6-9) 10.Coolant drain bolt (page 6-13) 11.
DESCRIPTION EAU32240 Controls and instruments XT660R 2 1. 2. 3. 4. 5. 6. 7. 8.
DESCRIPTION XT660X 2 1. 2. 3. 4. 5. 6. 7. 8.
INSTRUMENT AND CONTROL FUNCTIONS EAU10972 Immobilizer system 3 1. Code re-registering key (red bow) 2. Standard keys (black bow) This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following.
INSTRUMENT AND CONTROL FUNCTIONS EAU10471 Main switch/steering lock EAU10570 ON All electrical circuits are supplied with power; the meter lighting, taillight and auxiliary light come on, and the engine can be started. The key cannot be removed. NOTE: The headlight comes on automatically when the engine is started and stays on until the key is turned to “OFF”. The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering.
INSTRUMENT AND CONTROL FUNCTIONS To unlock the steering EAU33000 (Parking) The steering is locked, and the taillight and auxiliary light are on. The hazard light 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 “ ”. 3 EAU11001 Indicator and warning lights ECA11020 CAUTION: 1. Push. 2. Turn. Push the key in, and then turn it to “OFF” while still pushing it.
INSTRUMENT AND CONTROL FUNCTIONS EAU11080 High beam indicator light “ ” This indicator light comes on when the high beam of the headlight is switched on. will flash eight times, then go off for 2.5 seconds. If this occurs, have a Yamaha dealer check the vehicle. EAU11440 EAU11360 Fuel level warning light “ ” This warning light comes on when the fuel level drops below approximately 5.0 L (1.32 US gal) (1.10 Imp.gal). When this occurs, refuel as soon as possible.
INSTRUMENT AND CONTROL FUNCTIONS EAUM1662 3 NOTE: This model is also equipped with a selfdiagnosis device for the immobilizer system. If the immobilizer system is defective, the indicator will start flashing and the multi-function meter will display an error code when the key is turned to “ON”. (See “Self-diagnosis device” on page 3-5 for details.) Multi-function display ● ● ● 1. 2. 3. 4. 5. 6. 7.
INSTRUMENT AND CONTROL FUNCTIONS from that point. In that case, pushing the “SELECT” button switches the display between the various tripmeter and odometer modes in the following order: F-TRIP → TRIP 1 → TRIP 2 → ODO → F-TRIP To reset a tripmeter, select it by pushing the “SELECT” button, and then push the “RESET” button for at least one second while the selected tripmeter is flashing.
INSTRUMENT AND CONTROL FUNCTIONS key and both standard keys to a Yamaha dealer and have the standard keys re-registered. If the multi-function display indicates any error codes, note the code number, and then have a Yamaha dealer check the vehicle. EAU12330 Anti-theft alarm (optional) This model can be equipped with an optional anti-theft alarm by a Yamaha dealer. Contact a Yamaha dealer for more information. EAU12343 Handlebar switches Left 3 1. 2. 3. 4. 5.
INSTRUMENT AND CONTROL FUNCTIONS position. To cancel the turn signal lights, push the switch in after it has returned to the center position. Right EAU12500 Horn switch “ ” Press this switch to sound the horn. EAU12660 1. Engine stop switch “ 2. Start switch “ ” / ” EAU12350 Pass switch “ ” Press this switch to flash the headlight. EAU12400 Dimmer switch “ / ” Set this switch to “ ” for the high beam and to “ ” for the low beam.
INSTRUMENT AND CONTROL FUNCTIONS EAU12820 EAU12870 EAU12890 Clutch lever Shift pedal Brake lever 1. Clutch lever 1. Shift pedal 1. Brake lever The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the handlebar grip. To engage the clutch, release the lever. The lever should be pulled rapidly and released slowly for smooth clutch operation. The clutch lever is equipped with a clutch switch, which is part of the ignition circuit cut-off system.
INSTRUMENT AND CONTROL FUNCTIONS EAU12941 Brake pedal EAUM1790 NOTE: The fuel tank cap cannot be installed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly installed and locked. Fuel tank cap EWA11140 WARNING Make sure that the fuel tank cap is properly installed before riding. 1. Brake pedal The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal. 1. Fuel tank cap lock cover 2. Unlock.
INSTRUMENT AND CONTROL FUNCTIONS EAU13210 Fuel ECA10070 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. EAU13390 3 1. Fuel tank filler tube 2. Fuel level Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. Recommended fuel: PREMIUM UNLEADED GASOLINE ONLY Fuel tank capacity: 15.0 L (3.96 US gal) (3.30 Imp.
INSTRUMENT AND CONTROL FUNCTIONS EAU13430 Catalytic converter EAU13900 Seat This model is equipped with a catalytic converter in the exhaust chamber. EWA10860 WARNING To remove the seat 1. Insert the key into the seat lock, and then turn it as shown. The exhaust system is hot after operation. Make sure that the exhaust system has cooled down before doing any maintenance work. 3 1. Seat holder 2.
INSTRUMENT AND CONTROL FUNCTIONS EAU14421 Storage compartment ● Do not exceed the maximum load of 186 kg (410 lb) for the vehicle. EAU14830 Adjusting the shock absorber assembly 3 1. U-LOCK bar (optional) 2. Yamaha U-LOCK (optional) 3. Strap 1. Spring preload adjusting ring 2. Special wrench 3. Position indicator This storage compartment is designed to hold a genuine Yamaha U-LOCK. (Other locks may not fit.) When placing a U-LOCK in the storage compartment, securely fasten it with the straps.
INSTRUMENT AND CONTROL FUNCTIONS crease the spring preload and thereby soften the suspension, turn the adjusting ring in direction (b). NOTE: Align the appropriate notch in the adjusting ring with the position indicator on the shock absorber. Spring preload setting: Minimum (soft): 1 Standard: 2 Maximum (hard): 5 ● ● ● Do not subject the shock absorber to an open flame or other high heat sources, otherwise it may explode due to excessive gas pressure.
INSTRUMENT AND CONTROL FUNCTIONS below and have a Yamaha dealer repair it if it does not function properly. 3 EAU15311 Ignition circuit cut-off system The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. ● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled.
INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is turned on. 3. Turn the key on. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? YES NOTE: This check is most reliable if performed with a warmed-up engine. NO The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. NO The sidestand switch may be defective.
PRE-OPERATION CHECKS EAU15591 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, 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. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.
PRE-OPERATION CHECKS EAU15602 Pre-operation check list ITEM CHECKS PAGE Fuel • Check fuel level in fuel tank. • Refuel if necessary. • Check fuel line for leakage. 3-11 Engine oil • Check oil level in oil tank. • If necessary, add recommended oil to specified level. • Check vehicle for oil leakage. 6-9 Coolant • Check coolant level in reservoir. • If necessary, add recommended coolant to specified level. • Check cooling system for leakage. 6-12 Front brake • • • • • • • Check operation.
PRE-OPERATION CHECKS ITEM CHECKS PAGE Throttle grip • Make sure that operation is smooth. • Check cable free play. • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. 6-17, 6-25 Control cables • Make sure that operation is smooth. • Lubricate if necessary. Drive chain • • • • Check chain slack. Adjust if necessary. Check chain condition. Lubricate if necessary. 6-23, 6-24 Wheels and tires • • • • Check for damage.
OPERATION AND IMPORTANT RIDING POINTS EAU15950 EAUM1670 Starting the engine EWA10270 WARNING ● ● ● Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. Never start the engine or operate it in a closed area for any length of time. Exhaust fumes are poisonous, and inhaling them can cause loss of consciousness and death within a short time.
OPERATION AND IMPORTANT RIDING POINTS serve the battery. Do not crank the engine more than 10 seconds on any one attempt. EAU16671 Shifting ECA10260 CAUTION: ● ECA11040 CAUTION: For maximum engine life, never accelerate hard when the engine is cold! NOTE: The engine is warm when it quickly responds to the throttle. 5 1. Shift pedal 2. Neutral position ● Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc.
OPERATION AND IMPORTANT RIDING POINTS EAU16810 Tips for reducing fuel consumption Fuel consumption depends largely on your riding style. Consider the following tips to reduce fuel consumption: ● Shift up swiftly, and avoid high engine speeds during acceleration. ● Do not rev the engine while shifting down, and avoid high engine speeds with no load on the engine. ● Turn the engine off instead of letting it idle for an extended length of time (e.g.
OPERATION AND IMPORTANT RIDING POINTS EAU17211 Parking When parking, stop the engine, and then remove the key from the main switch. EWA10310 WARNING ● 5 ● Since the engine and exhaust system can become very hot, park in a place where pedestrians or children are not likely to touch them. Do not park on a slope or on soft ground, otherwise the vehicle may overturn. ECA10380 CAUTION: Never park in an area where there are fire hazards such as grass or other flammable materials.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU17240 EAU17520 Owner’s tool kit Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of inspection, adjustment, and lubrication are explained on the following pages. The intervals given in the periodic maintenance and lubrication chart should be simply considered as a general guide under normal riding conditions.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU17705 Periodic maintenance and lubrication chart NOTE: ● The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. ● 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 technical skills. ODOMETER READING (× 1000 km) NO.
PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) NO. ITEM CHECK OR MAINTENANCE JOB 9 * Wheels • Check runout, spoke tightness and for damage. • Tighten spokes if necessary. 10 * Tires • • • • 1 10 20 30 40 √ √ √ √ √ √ √ √ √ Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary. 11 * Wheel bearings • Check bearing for looseness or damage. √ √ √ √ 12 * Swingarm • Check operation and for excessive play.
PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) NO. ITEM CHECK OR MAINTENANCE JOB 1 23 Engine oil filter element 24 * Cooling system Front and rear brake 25 * switches 10 √ • Replace. 30 √ √ • Check coolant level and vehicle for coolant leakage. 20 • Change. √ 40 ANNUAL CHECK √ √ √ √ Every 3 years √ • Check operation. √ √ √ √ √ 26 Moving parts and cables • Lubricate. √ √ √ √ √ 27 * Throttle grip housing and cable • Check operation and free play.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU18711 Removing and installing cowlings and panels The cowlings and panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a cowling or panel needs to be removed and installed. 1. Panel A 1. Bolt To install the cowling 1. Place the cowling bracket tab between the protector and the bracket on each side. 1. Cowling A 1. Cowling B 2.
PERIODIC MAINTENANCE AND MINOR REPAIR 2. Place the cowling in the original position, and then install the bolts and spacers. EAUM1691 Cowling B To install the cowling 1. Place the cowling in the original position, and then tighten the quick fastener screws and install the bolts. To remove the cowling 1. Remove the seat and panel B. (See pages 3-12 and 6-5.) 2. Remove the bolts, remove the quick fastener screws after turning them 1/4 turn counterclockwise, and then pull the cowling off at the area shown.
PERIODIC MAINTENANCE AND MINOR REPAIR EAUM1710 EAU19602 Checking the spark plug Panel B To remove the panel 1. Remove the seat. (See page 3-12.) 2. Remove the bolt, and then pull the panel off at the areas shown. 2. Install the seat. The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accordance with the periodic maintenance and lubrication chart.
PERIODIC MAINTENANCE AND MINOR REPAIR Specified spark plug: NGK/CR7E To install the spark plug 1. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification. 1. Spark plug wrench 6 To check the spark plug 1. Check that the porcelain insulator around the center electrode of the spark plug is a medium-to-light tan (the ideal color when the vehicle is ridden normally). NOTE: If the spark plug shows a distinctly different color, the engine could be defective.
PERIODIC MAINTENANCE AND MINOR REPAIR EAUM1841 Engine oil and oil filter element The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter element replaced at the intervals specified in the periodic maintenance and lubrication chart. EWA10360 NOTE: ● The engine oil tank is located inside of the frame. ● The engine oil should be between the minimum and maximum level marks. 2. Start the engine, warm it up for 10– 15 minutes, and then turn it off. 3.
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Engine oil drain bolt (crankcase) 2. Engine oil drain attachment 6 3. Place an oil pan under the engine to collect the used oil. 4. Remove the engine oil filler cap and the drain bolt to drain the oil from the crankcase. 5. Remove the drain bolt to drain the oil from the oil tank. 1. Engine oil drain bolt (oil tank) 6. Remove the oil filter element drain bolt to drain the oil from the oil filter element. 1. Oil filter element cover bolt 2.
PERIODIC MAINTENANCE AND MINOR REPAIR 9. Install the oil filter element cover by installing the bolts and the oil filter element drain bolt, then tightening them to the specified torques. Tightening torques: Oil filter element cover bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Oil filter element drain bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) NOTE: Make sure that the O-rings are properly seated. 10. Install the oil drain bolts, and then tighten them to the specified torques.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU20070 ECA10470 Coolant CAUTION: The coolant level should be checked before each ride. In addition, the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart. ● ● EAUM1721 To check the coolant level 1. Place the vehicle on a level surface and hold it in an upright position. 6 NOTE: ● The coolant level must be checked on a cold engine since the level varies with engine temperature.
PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: ● The radiator fan is automatically switched on or off according to the coolant temperature in the radiator. ● If the engine overheats, see page 6-38 for further instructions. EAUM1801 To change the coolant 1. Place the vehicle on a level surface and let the engine cool if necessary. 2. Remove the seat and panel B. (See pages 3-12 and 6-5.) 3. Remove cowling B. (See page 6-5.) 4. Place a container under the engine to collect the used coolant. 5.
PERIODIC MAINTENANCE AND MINOR REPAIR 11. Install the coolant drain bolt, and then tighten it to the specified torque. ECA10470 CAUTION: ● NOTE: Check the washer for damage and replace it if necessary. ● Tightening torque: Coolant drain bolt: 11 Nm (1.1 m·kgf, 8.0 ft·lbf) 12. Pour the specified amount of recommended coolant into the radiator and reservoir.
PERIODIC MAINTENANCE AND MINOR REPAIR EAUM1833 ECA10480 Replacing the air filter element and cleaning the check hose The air filter element should be replaced at the intervals specified in the periodic maintenance and lubrication chart. Replace the air filter element more frequently if you are riding in unusually wet or dusty areas. In addition, the air filter check hose must be frequently checked and cleaned if necessary. To replace the air filter element 1. Remove the seat. (See page 3-12.) 2.
PERIODIC MAINTENANCE AND MINOR REPAIR EAUM1910 Adjusting the engine idling speed 1. Air filter check hose 2. If dirt or water is visible, remove the hose, clean it, and then install it. 6 The engine idling speed must be checked and, if necessary, adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart. The engine should be warm before making this adjustment. NOTE: ● The engine is warm when it quickly responds to the throttle.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU21380 Adjusting the throttle cable free play EAU21640 Tires To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified tires. Tire air pressure The tire air pressure should be checked and, if necessary, adjusted before each ride. EWA10500 WARNING 1. Throttle cable free play The throttle cable free play should measure 3.0–5.0 mm (0.12–0.20 in) at the throttle grip.
PERIODIC MAINTENANCE AND MINOR REPAIR EWA11020 WARNING 6 Because loading has an enormous impact on the handling, braking, performance and safety characteristics of your motorcycle, you should keep the following precautions in mind. ● NEVER OVERLOAD THE MOTORCYCLE! Operation of an overloaded motorcycle may result in tire damage, loss of control, or severe injury. Make sure that the total weight of rider, passenger, cargo, and accessories does not exceed the specified maximum load for the vehicle.
PERIODIC MAINTENANCE AND MINOR REPAIR Front tire: Size: XT660R 90/90-21M/C 54S, 90/9021M/C 54T XT660X 120/70R17 M/C 58H Manufacturer/model: XT660R METZELER/TOURANCE FRONT XT660X PIRELLI/DRAGON XT660R MICHELIN/SIRAC Rear tire: Size: XT660R 130/80-17M/C 65S, 130/80-17M/C 65T XT660X 160/60R17 M/C 69H Manufacturer/model: XT660R METZELER/TOURANCE XT660X PIRELLI/DRAGON XT660R MICHELIN/SIRAC A ● Yamaha dealer, who has the necessary professional knowledge and experience.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU22041 Adjusting the clutch lever free play NOTE: If the specified clutch lever free play could be obtained as described above, tighten the locknut and skip the rest of the procedure, otherwise proceed as follows. 3. Fully turn the adjusting bolt at the clutch lever in direction (a) to loosen the clutch cable. 4. Loosen the locknut at the crankcase. 1. Locknut 2. Clutch lever free play adjusting bolt 3.
PERIODIC MAINTENANCE AND MINOR REPAIR Checking the front and rear brake pads indicator grooves have almost disappeared, have a Yamaha dealer replace the brake pads as a set. The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. Rear brake pads EAU22270 Adjusting the rear brake light switch EAU22390 EAU22500 EAU22430 Front brake pads 1. Rear brake light switch 2.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU22580 Checking the brake fluid level Front brake 1. Minimum level mark Rear brake 6 Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn brake pads and/or brake system leakage. If the brake fluid level is low, be sure to check the brake pads for wear and the brake system for leakage.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. EAU22780 To check the drive chain slack 3. Move the rear wheel by pushing the motorcycle to locate the tightest portion of the drive chain, and then measure the drive chain slack as shown. NOTE: Using the alignment marks on each side of the swingarm, make sure that both adjusting nuts are in the same position for proper wheel alignment.
PERIODIC MAINTENANCE AND MINOR REPAIR 3. Tighten the locknuts, and then tighten the axle nut to the specified torque. Tightening torque: Axle nut: 104 Nm (10.4 m·kgf, 75 ft·lbf) EAU23021 CAUTION: The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrication chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas. Service the drive chain as follows.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23100 EAU23110 Checking and lubricating the cables Checking and lubricating the throttle grip and cable The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it. The operation of the throttle grip should be checked before each ride.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23180 Recommended lubricant: Lithium-soap-based grease (all-purpose grease) 6 Lubricating the brake pedal The operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricated if necessary.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23271 EAU23280 Checking the front fork Checking the steering The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 1.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23290 EAUM1730 Checking the wheel bearings Battery The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. This model is equipped with a sealedtype (MF) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water.
PERIODIC MAINTENANCE AND MINOR REPAIR 1. 2. 3. 4. Negative battery terminal Positive battery terminal Bolt Battery cover ● To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories. ● working near batteries. In case of contact, administer the following FIRST AID. • EXTERNAL: Flush with plenty of water.
PERIODIC MAINTENANCE AND MINOR REPAIR EAUM1740 Replacing the fuses The main fuse is located behind panel A. (See page 6-5.) 1. Main fuse 2. Spare main fuse 6 Fuse box 1 and fuse box 2 are located under the seat. (See page 3-12.) 1. 2. 3. 4. 5. 6. 7. Fuse box 1 Signaling system fuse Headlight fuse Ignition fuse Electronic fuel injection fuse Radiator fan fuse Backup fuse (for odometer, clock and immobilizer system) 8. Parking lighting fuse 9. Fuse box 2 10.
PERIODIC MAINTENANCE AND MINOR REPAIR 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. EAUM1750 Replacing the headlight bulb This model is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows. 1. Remove cowling A together with the headlight unit. (See page 6-5.) 2. Disconnect the headlight coupler, and then remove the headlight bulb cover. 1. Headlight bulb holder 2.
PERIODIC MAINTENANCE AND MINOR REPAIR fected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner. EAU24281 Replacing a turn signal light bulb or the tail/brake light bulb 1. Remove the lens by removing the screws. 2. Remove the defective bulb by pushing it in and turning it counterclockwise. 3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 4. Install the lens by installing the screws.
PERIODIC MAINTENANCE AND MINOR REPAIR EAUM1820 Replacing an auxiliary light bulb If the auxiliary light bulb burns out, replace it as follows. 1. Remove cowling A together with the headlight unit. (See page 6-5.) 2. Remove the auxiliary light socket (together with the bulb) by pulling it out. 1. Auxiliary light bulb socket 3. Remove the defective bulb by pulling it out. 4. Insert a new bulb into the socket. 5. Install the auxiliary light socket (together with the bulb) by pushing it in. 6.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU24360 Front wheel XT660X EAUM1761 To remove the front wheel EWA10820 WARNING ● ● It is advisable to have a Yamaha dealer service the wheel. Securely support the motorcycle so that there is no danger of it falling over. 1. Loosen the front wheel axle pinch bolts, then the wheel axle and the brake caliper bolts. 6 XT660R 1. Wheel axle 2. Front wheel axle pinch bolt A 3. Front wheel axle pinch bolt B 2.
PERIODIC MAINTENANCE AND MINOR REPAIR 4. Install the brake caliper by installing the bolts. NOTE: Make sure that there is enough space between the brake pads before installing the brake caliper onto the brake disc. 5. Tighten the wheel axle to the specified torque. 6. Tighten the wheel axle pinch bolt A and pinch bolt B to the specified torques. 7. Retighten the wheel axle pinch bolt A to the specified torque. 8. Tighten the brake caliper bolts to the specified torques.
PERIODIC MAINTENANCE AND MINOR REPAIR 3. Lift the rear wheel off the ground according to the procedure on page 6-33. 4. Loosen the locknut on each side of the swingarm. 5. Turn the drive chain slack adjusting nuts fully in direction (a). 6. Remove the wheel axle by removing the axle nut. 7. Push the wheel forward, and then remove the drive chain from the rear sprocket.
PERIODIC MAINTENANCE AND MINOR REPAIR 4. Adjust the drive chain slack. (See page 6-23.) 5. Tighten the axle nut to the specified torque. Tightening torque: Axle nut: 104 Nm (10.4 m·kgf, 75 ft·lbf) 6. Install the drive chain guard by installing the bolts. EAU25870 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU25921 Troubleshooting charts Starting problems or poor engine performance EWA10840 WARNING Keep away open flames and do not smoke while checking or working on the fuel system. 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle. Check the fuel level in the fuel tank. The engine does not start. Check the compression. 2.
PERIODIC MAINTENANCE AND MINOR REPAIR Engine overheating EWA10400 WARNING ● ● Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be 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 slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape.
MOTORCYCLE CARE AND STORAGE ucts onto seals, gaskets, sprockets, the drive chain and wheel axles. Always rinse the dirt and degreaser off with water. EAU26000 Care While the open design of a motorcycle reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop even if high-quality components are used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts from the overall appearance of a motorcycle.
MOTORCYCLE CARE AND STORAGE After normal use Remove dirt with warm water, a mild detergent, and a soft, clean sponge, and then rinse thoroughly with clean water. Use a toothbrush or bottlebrush for hard-to-reach areas. Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning.
MOTORCYCLE CARE AND STORAGE ● ● Never apply oil or wax to any rubber and plastic parts, but treat them with a suitable care product. Avoid using abrasive polishing compounds as they will wear away the paint. NOTE: Consult a Yamaha dealer for advice on what products to use. EAUM1900 Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover.
MOTORCYCLE CARE AND STORAGE 4. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/centerstand. 5. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the ground. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 6. Cover the muffler outlets with plastic bags to prevent moisture from entering them. 7.
SPECIFICATIONS Dimensions: Overall length: XT660R 2240 mm (88.2 in) XT660X 2150 mm (84.6 in) Overall width: XT660R 845 mm (33.3 in) XT660X 865 mm (34.1 in) Overall height: XT660R 1230 mm (48.4 in) XT660X 1210 mm (47.6 in) Seat height: XT660R 865 mm (34.1 in) XT660X 870 mm (34.3 in) Wheelbase: XT660R 1505 mm (59.3 in) XT660X 1490 mm (58.7 in) Ground clearance: XT660R 210 mm (8.27 in) XT660X 205 mm (8.07 in) Minimum turning radius: 2400 mm (94.5 in) Weight: 8 With oil and fuel: XT660R 181.
SPECIFICATIONS Operation: Left foot operation Gear ratio: 1st: 30/12 (2.500) 2nd: 26/16 (1.625) 3rd: 23/20 (1.150) 4th: 20/22 (0.909) 5th: 20/26 (0.769) Chassis: Frame type: Diamond Caster angle: XT660R 27.25 ° XT660X 26.00 ° Trail: XT660R 107.0 mm (4.21 in) XT660X 94.0 mm (3.
SPECIFICATIONS Front suspension: Type: Telescopic fork Spring/shock absorber type: Coil spring/oil damper Wheel travel: XT660R 225.0 mm (8.86 in) XT660X 200.0 mm (7.87 in) Rear suspension: Type: Swingarm (monocross) Spring/shock absorber type: Coil spring/gas-oil damper Wheel travel: XT660R 200.0 mm (7.87 in) XT660X 191.0 mm (7.52 in) Electrical system: Ignition system: Transistorized coil ignition (digital) Charging system: A.C. magneto Battery: 8 Model: GT9B-4 Voltage, capacity: 12 V, 8.
CONSUMER INFORMATION EAU26351 Identification numbers EAU26381 EAU26410 Key identification number Vehicle identification number 1. Key identification number 2. Code re-registering key (red bow) 3. Standard keys (black bow) 1. Vehicle identification number 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 vehicle is stolen.
CONSUMER INFORMATION EAU26540 Model label 1. Model label The model label is affixed to the frame under the seat. (See page 3-12.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
INDEX A F Air filter element and check hose, replacing and cleaning ....................... 6-15 Anti-theft alarm (optional) ....................... 3-7 Auxiliary light bulb, replacing ................ 6-33 B Battery .................................................. 6-28 Brake and clutch levers, checking and lubricating .................................... 6-25 Brake fluid level, checking .................... 6-22 Brake lever ............................................. 3-9 Brake pedal ................
INDEX W Wheel bearings, checking..................... 6-28 Wheel (front) ......................................... 6-34 Wheel (rear) .......................................... 6-35 Wheels ..................................................
YAMAHA MOTOR CO., LTD. PRINTED IN FRANCE 2004.
