2007 XT660R(W) XT660X(W) SUPPLEMENTARY SERVICE MANUAL 5VK-F8197-E2
FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the XT660R(W)/XT660X(W) 2007. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. XT660R(S)/XT660X(S) 2004 SERVICE MANUAL: 5VK1-AE1 XT660R(W)/XT660X(W) 2007 SUPPLEMENTARY SERVICE MANUAL ©2006 by MBK Industrie First edition, July 2006 All rights reserved.
EAS00002 NOTICE This manual was produced by MBK Industrie primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS”. 2 Each chapter is divided into sections.
1 EAS00008 2 GEN INFO SYMBOLS The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. SPEC 3 4 CHK ADJ 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system 7 Fuel injection system 8 Electrical system 9 Troubleshooting CHAS 5 6 ENG COOL 7 8 FI – ELEC 9 Symbols 0 to G indicate the following.
CONTENTS SPECIFICATIONS .............................................................................................. 1 GENERAL SPECIFICATIONS ..................................................................... 1 ENGINE SPECIFICATIONS......................................................................... 2 CHASSIS SPECIFICATIONS....................................................................... 6 ELECTRICAL SPECIFICATIONS ................................................................
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Model code Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Standard Limit XT660R: 5VK8 (Europe) 5VK9 (AUS) XT660X: 10S1 (Europe) 10S2 (AUS) ------------- 2,240 mm (88.2 in) (XT660R) 2,175 mm (85.6 in) (XT660X) 845 mm (33.3 in) (XT660R) 860 mm (33.9 in) (XT660X) 1,230 mm (48.4 in) (XT660R) 1,170 mm (46.1 in) (XT660X) 865 mm (34.1 in) (XT660R) 875 mm (34.
ENGINE SPECIFICATIONS SPEC ENGINE SPECIFICATIONS Item Engine Engine type Displacement Cylinder arrangement Bore × stroke Compression ratio Engine idling speed Water temperature Oil temperature Standard compression pressure (at sea level) Engine oil Lubrication system Recommended oil -20 -10 0 10 20 30 40 50 ˚C SAE 10W-30 Standard Limit Liquid-cooled, 4-stroke, SOHC 660 cm3 Forward-inclined single cylinder 100.0 × 84.0 mm (3.94 × 3.31 in) 10.
ENGINE SPECIFICATIONS Item Standard Camshaft Drive system Intake camshaft lobe dimensions Chain drive (left) SPEC Limit ---- A B Measurement A 43.488 ~ 43.588 mm (1.7121 ~ 1.7161 in) 43.388 mm (1.7082 in) 36.959 ~ 37.059 mm (1.4551 ~ 1.4590 in) 36.859 mm (1.4511 in) Measurement B Exhaust camshaft lobe dimensions A B Measurement A Measurement B Valve timing Intake - open (B.T.D.C.) Intake - closed (A.B.D.C.) Exhaust - open (B.B.D.C.) Exhaust - closed (A.T.D.C.
ENGINE SPECIFICATIONS Item SPEC Standard Piston Piston-to-cylinder clearance Limit 0.030 ~ 0.055 mm (0.0012 ~ 0.0022 in) 0.13 mm (0.0051 in) 99.955 ~ 99.970 mm (3.9352 ~ 3.9358 in) ---- Diameter D H D Height H Piston pin bore (in the piston) Diameter 10.0 mm (0.39 in) ---- 23.004 ~ 23.015 mm (0.9057 ~ 0.9061 in) 23.045 mm (0.9073 in) 0.50 mm (0.0197 in) ---Intake side ---- Offset Offset direction Piston pin Outside diameter 22.991 ~ 23.000 (0.9052 ~ 0.
ENGINE SPECIFICATIONS Item SPEC Standard Limit Oil ring B T Dimensions (B × T) End gap (installed) Ring side clearance Throttle body Model/manufacturer × quantity Intake vacuum pressure Throttle cable free play (at the flange of the throttle grip) ID mark Throttle valve size 2.50 × 3.40 mm (0.098 × 0.134 in) 0.20 ~ 0.70 mm (0.0079 ~ 0.0276 in) 0.060 ~ 0.150 mm (0.0024 ~ 0.0059 in) ---------- 44EHS/MIKUNI × 1 37.6 ~ 40.2 kPa (282 ~ 302 mmHg, 11.1 ~ 11.9 inHg) 3.0 ~ 5.0 mm (0.12 in ~ 0.
CHASSIS SPECIFICATIONS SPEC CHASSIS SPECIFICATIONS Item Rear wheel Wheel type Rim Size Material Wheel travel Standard Spoke wheel ---- 17M/C × MT2.75 (XT660R) 17M/C × MT4.25 (XT660X) Aluminum 200.0 mm (7.87 in) (XT660R) 191.0 mm (7.
CHASSIS SPECIFICATIONS Item Rear tire Tire type Size Model/manufacturer Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 90 (198 lb) ~ Maximum load* Off-road riding Minimum tire tread depth SPEC Standard Limit With tube 130/80-17M/C 65S, 130/80-17M/C 65T (XT660R) 160/60R 17M/C 69H, 160/60ZR 17M/C 69W, 160/60ZR 17M/C 69W (XT660X) TOURANCE/METZELER, SIRAC A/ MICHELIN (XT660R) DRAGON/PIRELLI, SPORTEC M1/ METZELER, RADIAL PILOT SPORT/ MICHELIN (XT660X) ------- 200 kPa (2.
ELECTRICAL SPECIFICATIONS/ TIGHTENING TORQUE SPEC ELECTRICAL SPECIFICATIONS Item Standard System voltage Ignition system Ignition system type Ignition timing Advancer type Crankshaft position senor resistance/ color Transistorized coil ignition unit model/manufacturer Limit 12 V ---- Transistorized coil ignition (digital) 5.
CABLE ROUTING SPEC EAS00035 CABLE ROUTING 1 Front turn signal light lead (right) 2 Meter assembly lead 3 Auxiliary light lead 4 Front turn signal light lead (left) 5 Headlight lead 6 Sub-wire harness È Fasten the sub-wire harness and meter assembly lead with a plastic band. Fasten the sub-wire harness at the white tape. Face the end of the plastic band forward. É Make sure that there is no slack in the meter assembly lead between the meter assembly and the plastic band.
CABLE ROUTING Ê Place the slack of the left and right front turn signal light leads between the headlight assembly and front cowling assembly. Ë Fasten the left and right front turn signal light leads to the headlight stay with a plastic locking tie, and then cut off the excess end of tie. Ì Pass the left and right front turn signal light leads in front of the headlight stay. SPEC Í Only the left side is shown in this illustration. Route the right front turn signal light lead in the same way.
CABLE ROUTING SPEC È Fasten the wire harness and negative battery lead to the frame with a plastic locking tie. É Fasten the wire harness, negative battery lead, and rear brake light switch lead to the frame with a plastic locking tie. Ê Fasten the rear brake light switch lead to the frame with a plastic locking tie. Ë Fasten the wire harness to the frame at the white tape with a plastic locking tie.
CABLE ROUTING SPEC Ì Route the negative battery lead behind the lean angle cut-off switch bracket. Í Route the rear brake light switch lead between the air filter case and the frame.
CABLE ROUTING 1 Neutral switch connector 2 Crankshaft position sensor coupler 3 A.C. magneto coupler 4 Speed sensor lead 5 Intake air temperature sensor lead 6 ECU lead 7 Starter motor lead 8 Sidestand switch lead 9 Speed sensor 0 A.C.
CABLE ROUTING SPEC É Fasten the left handlebar switch lead, right handlebar switch lead, headlight lead, meter assembly lead, front brake light switch lead, clutch switch lead, radiator fan motor lead, and throttle cables with a plastic band. To fasten the leads and cables, connect the couplers, and then turn the handlebar completely to the right. Ê Route the oil tank breather hose on the outside of the throttle cables.
CABLE ROUTING SPEC Ï Fasten the neutral switch lead, crankshaft position sensor lead, sidestand switch lead, speed sensor lead, starter motor lead, and A.C. magneto lead with a plastic band. Ð Fasten the neutral switch lead, crankshaft position sensor lead, sidestand switch lead, speed sensor lead, and starter motor lead with a plastic band. Ñ Fasten the air-filter-to-air-cut-off-valve hose, oil tank breather hose, and oil delivery hose 2 with a plastic clamp.
CABLE ROUTING Ò Fasten the wire harness, air-filter-to-air-cut-offvalve hose, and oil delivery hose 2 with a plastic clamp. Ó Fasten the left handlebar switch lead, right handlebar switch lead, headlight lead, meter assembly lead, front brake light switch lead, and clutch switch lead with a plastic band.
CABLE ROUTING SPEC È 0 ~ 10 mm (0 ~ 0.39 in) É 30 ~ 40 mm (1.18 ~ 1.57 in) Ê 5 ~ 15 mm (0.20 ~ 0.59 in) Ë Fasten the wire harness to the frame with a plastic locking tie. Ì To the fuel tank Í 0 ~ 5 mm (0 ~ 0.
CABLE ROUTING SPEC È Fasten the tail/brake light lead with two plastic locking ties so that the coupler is positioned to the inside of where the relays (turn signal/hazard relay, headlight relay, radiator fan motor relay, and relay unit) branch off from the wire harness.
CABLE ROUTING Ê Fasten the wire harness with plastic locking ties, making sure to install the ties around the taped sections of the harness. Do not install the plastic locking ties around the sections of the leads that are not covered by the tape and do not fasten the negative battery lead coupler. Ë Fasten the rear turn signal light leads and tail/ brake light lead with a lead holder. Ì Connect the couplers so that they are not pinched between the rear fender and rear fender cover.
CABLE ROUTING XT660R 1 Brake fluid reservoir 2 Brake fluid reservoir hose 3 Rear brake light switch 4 Rear brake master cylinder 5 Rear brake hose 6 Rear brake caliper SPEC È When installing the brake hose onto the brake master cylinder, make sure that the brake pipe touches the brake master cylinder as shown. É Fasten the rear brake hose with the brake hose holder. Ê When installing the brake hose onto the brake caliper, make sure that the brake pipe touches the brake caliper as shown.
CABLE ROUTING È When installing the brake hose onto the brake master cylinder, make sure that the brake pipe touches the brake master cylinder as shown. É Fasten the rear brake hose with the brake hose holder. Ê When installing the brake hose onto the brake caliper, make sure that the brake pipe touches the brake caliper as shown.
COWLING AND COVER CHK ADJ PERIODIC CHECKS AND ADJUSTMENTS COWLING AND COVER COVER T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 3 4 5 4 T. R. 23 Nm (2.3 m • kg, 17 ft • Ib) 2 T. R. Order 1 2 3 4 5 Job/Part Removing the cover (XT660X) Seat Left side panel Right side panel Grab bar Rear cover Q’ty 7 Nm (0.7 m • kg, 5.1 ft • Ib) Remarks Remove the parts in the order listed. 1 1 1 2 1 For installation, reverse the removal procedure.
COWLING AND COVER CHK ADJ COWLING 5 3 4 2 1 T. R. T. R. Order 1 2 3 4 5 8 Nm (0.8 m • kg, 5.8 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) Job/Part Removing the cowling (XT660X) Seat/side panels (left and right) Fuel tank Front fender Front fork protector Meter assembly coupler Sub-wire harness coupler Front cowling assembly Q’ty 1 1 2 1 1 Remarks Remove the parts in the order listed. Refer to “COWLING AND COVER”. Refer to “FUEL TANK”. Disconnect. Disconnect.
FUEL TANK CHK ADJ EAS00040 FUEL TANK T. 9 R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 4 5 3 10 8 6 2 7 1 Order 1 2 3 4 5 6 7 8 Job/Part Removing the fuel tank (XT660X) Seat/side panels (left and right) Fuel Fuel tank left side cover Fuel tank right side cover Intake air guide Fuel tank plate Damper 1 Fuel pump coupler Fuel sender coupler Fuel hose 9 Fuel tank Q’ty 1 1 1 1 1 1 1 1 1 – 24 – Remarks Remove the parts in the order listed. Refer to “COWLING AND COVER”. Drain. Disconnect.
FUEL TANK T. 9 CHK ADJ R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 4 5 3 10 8 6 2 7 1 Order 10 Job/Part Damper 2 Q’ty 1 Remarks For installation, reverse the removal procedure.
ADJUSTING THE DRIVE CHAIN SLACK CHK ADJ EAS00140 CHASSIS ADJUSTING THE DRIVE CHAIN SLACK NOTE: The drive chain slack must be checked at the tightest point on the chain. _ CAUTION: _ A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident. Therefore, keep the drive chain slack within the specified limits. 1. Stand the motorcycle on a level surface.
ADJUSTING THE DRIVE CHAIN SLACK CHK ADJ 4. Adjust: • drive chain slack È ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the wheel axle nut 1. b. Loosen both locknuts 2. c. Turn both adjusting nuts 3 or both adjusting bolt 4 in direction a or b until the specified drive chain slack is obtained. É Direction a Drive chain is tightened. Direction b Drive chain is loosened. NOTE: To maintain the proper wheel alignment, adjust both sides evenly. _ a 2 1 b 4 d.
CHECKING THE TIRES CHK ADJ EAS00166 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: • tire pressure Out of specification → Regulate. WARNING _ • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. • The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed.
CHECKING THE TIRES CHK ADJ XT660X Basic weight (with oil and a full fuel tank) 186.0 kg (410 lb) Maximum load* 186.0 kg (410 lb) Cold tire pressure Front Rear Up to 90 kg load* 210 kPa 210 kPa (2.10 kgf/cm2, (2.10 kgf/cm2, 30 psi) 30 psi) 90 kg ~ maximum load* 230 kPa 220 kPa (2.20 kgf/cm2, (2.30 kgf/cm2, 31 psi) 33 psi) * Total weight of rider, passenger, cargo and accessories WARNING _ It is dangerous to ride with a worn-out tire.
CHECKING THE TIRES È É CHK ADJ • Patching a punctured tube is not recommended. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality replacement. È Tire É Wheel Tube wheel Tube tire only Tubeless wheel Tube or tubeless tire • After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design.
CHECKING THE TIRES CHK ADJ Rear tire (XT660X) Manufacturer Model Size PIRELLI DRAGON 160/60R 17M/C 69H METZELER SPORTEC M1 160/60ZR 17M/C 69W MICHELIN RADIAL PILOT SPORT 160/60ZR 17M/C 69W WARNING _ New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done.
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET CHAS CHASSIS REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET REAR WHEEL 8 11 T. 10 R. 105 Nm (10.5 m • kg, 75 ft • lb) T. R. 9 16 Nm (1.6 m • kg, 11 ft • Ib) 13 4 5 6 3 12 4 3 LS 7 2 1 T. R.
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET CHAS 8 11 T. 10 R. 105 Nm (10.5 m • kg, 75 ft • lb) T. R. 9 16 Nm (1.6 m • kg, 11 ft • Ib) 13 4 5 6 3 12 4 3 LS 7 2 1 T. R. Order 12 13 Job/Part Chain puller (left) Chain puller (right) Q’ty 1 1 – 33 – 7 Nm (0.7 m • kg, 5.1 ft • Ib) Remarks Refer to “INSTALLING THE REAR WHEEL (XT660X)”. For installation, reverse the removal procedure.
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET CHAS EAS00561 REMOVING THE REAR WHEEL (XT660R) 1. Stand the motorcycle on a level surface. WARNING _ Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. _ 2. • • 3.
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET CHAS EAS00561 REMOVING THE REAR WHEEL (XT660X) 1. Stand the motorcycle on a level surface. WARNING _ Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. _ 3 2 1 2. • • 3.
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET 2. • • • • • CHAS Install: rear wheel washer (O) wheel axle washer (N) wheel axle nut NOTE: Install the washer with the “N” mark on the right-hand side of the vehicle and the washer with the “O” mark on the left-hand side of the vehicle. Be sure to install both washers with the marks facing outward. 3. Adjust: • drive chain slack Drive chain slack 40.0 ~ 55.0 mm (1.57 ~ 2.17 in) Refer to “ADJUSTING THE DRIVE CHAIN SLACK”. 4. Tighten: • wheel axle nut T. R.
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET 2 a 1 2. • • • • • • CHAS Install: chain puller (left) 1 chain puller (right) 2 rear wheel washer wheel axle wheel axle nut NOTE: Install the chain puller with the mark a on the left side of the swingarm. 3. Adjust: • drive chain slack Drive chain slack 40.0 ~ 55.0 mm (1.57 ~ 2.17 in) Refer to “ADJUSTING THE DRIVE CHAIN SLACK”. 4. Tighten: • wheel axle nut T. R. 105 Nm (10.5 m · kg, 75 ft · lb) 5. Install: • chain cover • chain cover bolts T. R.
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET CHAS EAS00700 SWINGARM AND DRIVE CHAIN R. R. T. T. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 3 59 Nm (5.9 m • kg, 43 ft • Ib) T. R. T. R. 120 Nm (12.0 m • kg, 85 ft • lb) 2 23 Nm (2.3 m • kg, 17 ft • Ib) T. R. 92Nm (9.2 m • kg, 66 ft • Ib) LS 1 New LS 11 T. R. 48 Nm (4.8 m • kg, 35 ft • Ib) 23 Nm (2.3 m • kg, 17 ft • Ib) T. R. 6 9 7 LS 8 New 17 18 11 10 10 15 14 18 14 10 15 16 LS 12 LS 5 4 19 LS LS T. R. T. R.
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET R. R. T. T. 10 Nm (1.0 m • kg, 7.2 ft • Ib) CHAS 3 59 Nm (5.9 m • kg, 43 ft • Ib) T. R. T. R. 120 Nm (12.0 m • kg, 85 ft • lb) 2 23 Nm (2.3 m • kg, 17 ft • Ib) T. R. 92Nm (9.2 m • kg, 66 ft • Ib) LS 1 New LS 11 T. R. 48 Nm (4.8 m • kg, 35 ft • Ib) 23 Nm (2.3 m • kg, 17 ft • Ib) T. R. 6 9 7 LS 8 New 17 18 11 10 10 15 14 18 14 10 15 16 LS 12 LS 5 4 19 LS LS T. R. T. R. 23 Nm (2.
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET R. R. T. T. 10 Nm (1.0 m • kg, 7.2 ft • Ib) CHAS 3 59 Nm (5.9 m • kg, 43 ft • Ib) T. R. T. R. 120 Nm (12.0 m • kg, 85 ft • lb) 2 23 Nm (2.3 m • kg, 17 ft • Ib) T. R. 92Nm (9.2 m • kg, 66 ft • Ib) LS 1 New LS 11 T. R. 48 Nm (4.8 m • kg, 35 ft • Ib) 23 Nm (2.3 m • kg, 17 ft • Ib) T. R. 6 9 7 LS 8 New 17 18 11 10 10 15 14 18 14 10 15 16 LS 12 LS 5 4 19 LS LS T. R. T. R. 23 Nm (2.
ENGINE REMOVAL ENG EAS00188 ENGINE ENGINE REMOVAL EXHAUST PIPES AND MUFFLERS T. R. 27 Nm (2.7 m • kg, 19 ft • Ib) T. R. 45 Nm (4.5 m • kg, 32 ft • Ib) T. 10 Nm (1.0 m • kg, 7.2 ft • Ib) R. T. R. 27 Nm (2.7 m • kg, 19 ft • Ib) 3 1 T. R. 20 Nm (2.0 m • kg, 14 ft • Ib) 2 5 New LS 4 New 5 3 LT LT LS 6 5 New T. R. 27 Nm (2.7 m • kg, 19 ft • Ib) T. R. T. R. 20 Nm (2.0 m • kg, 14 ft • Ib) T. R. 23 Nm (2.3 m • kg, 17 ft • Ib) T. R.
ENG CYLINDER HEAD EAS00221 CYLINDER HEAD T. 20 Nm (2.0 m • kg, 14 ft • Ib) R. T. 13 Nm (1.3 m • kg, 9.4 ft • Ib) R. T. R. 50 Nm (5.0 m • kg, 36 ft • Ib) T. 20 Nm (2.0 m • kg, 14 ft • Ib) R. E T. 1 R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) New New 3 (4) 7 LS New 8 New New New 12 3 E New 3 6 10 11 (4) 3 9 LS 2 New 4 New 5 New New T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) E LS T. R. T. R. 10 Nm (1.0 m • kg, 7.
ENG CYLINDER HEAD T. 20 Nm (2.0 m • kg, 14 ft • Ib) R. T. 13 Nm (1.3 m • kg, 9.4 ft • Ib) R. T. R. 50 Nm (5.0 m • kg, 36 ft • Ib) T. 20 Nm (2.0 m • kg, 14 ft • Ib) R. E T. 1 R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) New New 3 (4) 7 LS New 8 New New New 12 3 E New 3 6 10 11 (4) 3 9 LS 2 New 4 New 5 New New T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) E LS T. R. T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. T. R. R. 20 Nm (2.0 m • kg, 14 ft • Ib) 45 Nm (4.
CYLINDER AND PISTON ENG EAS00251 CYLINDER AND PISTON 1 R. New T. E 1st 15Nm (1.5 m • kg, 11 ft • lb) 2nd 50Nm (5.0m • kg, 5.1 ft • lb) New T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) New E New LS E 4 10 11 12 3 New 9 5 New 2 UP 6 New 7 6 T. 8 R. 10 Nm (1.0 m • kg, 7.
CYLINDER AND PISTON New R. E T. 1 ENG 1st 15Nm (1.5 m • kg, 11 ft • lb) 2nd 50Nm (5.0m • kg, 5.1 ft • lb) New T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) New E New LS E 4 10 11 12 3 New 9 5 New 2 UP 6 New 7 6 T. 8 R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) E Order 11 12 Job/Part 2nd ring Oil ring 7 New Q’ty 1 1 – 45 – Remarks Refer to “REMOVING THE CYLINDER AND PISTON” and “INSTALLING THE PISTON AND CYLINDER”. (Manual No.: 5VK1-AE1) For installation, reverse the removal procedure.
RADIATOR COOL EAS00454 COOLING SYSTEM RADIATOR 8 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 9 12 2 5 3 3 4 11 6 10 7 T. R. Order 1 2 3 4 5 6 5 Nm (0.5 m • kg, 3.
RADIATOR COOL 8 T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 9 12 2 5 3 3 4 11 6 10 7 T. R. Order 7 8 9 10 11 12 5 Nm (0.5 m • kg, 3.6 ft • Ib) Job/Part Radiator outlet hose Radiator inlet hose Radiator fan motor coupler Radiator guard Radiator Radiator fan Q’ty Remarks 1 Refer to “INSTALLING THE RADIATOR” in chapter 6. (Manual No.: 5VK1-AE1) 1 1 Disconnect. 1 1 1 For installation, reverse the removal procedure.
FI FUEL INJECTION SYSTEM EAS00894 FUEL INJECTION SYSTEM EAS00895 FUEL INJECTION SYSTEM 1 Air cut-off valve 2 Air induction system solenoid 3 Engine trouble warning light 4 Fuel tank 5 Fuel pump (include fuel pressure regulator) 6 Fuel hose 7 Fuel injector 8 Throttle position sensor 1 2 9 Intake air temperature sensor 0 Air filter case A Fuel injection system relay B Battery C Catalytic converter D ECU E Lean angle cut-off switch F Fast idle plunger G Crankshaft position sensor 3 4 5 6 7 H Coolant
W G/W L/Y W Gy G/W ON OFF P 4 W W W W 3 R/G B2 B B1 BB B B B R 5 BB4 BB1 BB B1 BB3 BB4 BB2 BB1 R/G G/L R/W BB Y/L B W W W BB3 BB2 B B { z R/W Lg Y /L B2 B1 A B B B R/G W W W Y/L G/L R/W R Br/R Br/L Sb R W W W Br/L Br/R 1 Br/L Br/R R L 2 Gy G/W B R – 49 – Br/R Br/L Br/L Br/L y x w v R R R Br R/L Br R B A 0 Br R/G Br B L/R B 6 B R B B B R R B B L G/Y R/W Br B L q 9 L R R 7 8 R R R L Br L/W R/W R/W R L/R Y G/Y R
FI FUEL INJECTION SYSTEM FAIL-SAFE ACTION TABLE Self-diagnostic function Fault code No. Item Symptom Fail-safe action Startability Driveability — No No Yes Yes Yes Yes 12 Crankshaft position sensor No normal signals are received from the sensor. 13 Intake air pressure sensor (open or short circuit) Open or short circuit is detected. • Fixes the intake air pressure to 101 kPa (760 mmHg, 29.9 inHg).
FI FUEL INJECTION SYSTEM Fault code No. 46 50 Item Symptom Fail-safe action Startability Driveability Vehicle system power supply (monitor voltage) Power supply to the fuel injection system relay is not normal. — Yes Yes ECU internal malfunction (memory check error) Faulty ECU memory. When this malfunction is detected, the code number might not appear on the meter. — No Yes Start unable warning Relay is not turned ON even if the crank signal is input while the start switch is turned ON.
FUEL INJECTION SYSTEM FI EAS00905 DIAGNOSTIC MODE Setting the diagnostic mode 1. Set the main switch to “OFF” and set the engine stop switch to “ ”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “SELECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more. NOTE: All displays on the meter disappear “dIAG” appears on the odometer/fuel reserve tripmeter/tripmeter 2 LCD. _ 4.
FUEL INJECTION SYSTEM FI 8. Verify the operation of the sensor or actuator. • Sensor operation The data representing the operating conditions of the sensor appears on the odometer/fuel reserve tripmeter/tripmeter 2 LCD. • Actuator operation Set the engine stop switch to “ ” to operate the actuator. NOTE: If the engine stop switch is set to “ “ ”, and then set it to “ ” again. _ ”, set it to 9. Set the main switch to “OFF” to cancel the diagnostic mode.
FUEL INJECTION SYSTEM FI EAS00906 Diagnostic monitoring code table Fault code No. Symptom No normal signals are received from the crankshaft position sensor. 14 Open or short circuit in wire harness Defective crankshaft position sensor Disconnected crankshaft position sensor coupler Malfunction in A.C. magneto rotor Malfunction in ECU Improperly installed crankshaft position sensor — Open or short circuit is detected in the intake air pressure sensor.
FUEL INJECTION SYSTEM Fault code No. Symptom Probable cause of malfunction FI Diagnostic code Open or short circuit is detected in the lean angle cut-off switch. • • • • Open or short circuit in wire harness Defective lean angle cut-off switch Disconnected lean angle cut-off switch coupler Malfunction in ECU 08 No normal signals are received from the speed sensor or an open or short circuit is detected in the neutral switch.
FUEL INJECTION SYSTEM FI EAS00907 Diagnostic mode table Switch the meter display from the regular mode to the diagnostic mode. To switch the display, refer to “DIAGNOSTIC MODE”. NOTE: • Check the intake air temperature and coolant temperature as close as possible to the intake air temperature sensor and the coolant temperature sensor respectively. • If it is not possible to check the intake air temperature, use the ambient temperature as reference. _ Diagnostic code Item Displays the throttle angle.
FUEL INJECTION SYSTEM Diagnostic code Item The engine stop switch is set to “ “, the radiator fan motor relay operates 5 times, 5 seconds each time (2 seconds on, 3 seconds off), and the engine trouble warning light comes on. • If the engine stop switch is set to “ ”, set it to “ ”, and then set it to “ ” again. Check that the operating sound of the radiator fan motor relay is generated and that the radiator fan motor is operated 5 times when the engine stop switch is set to “ ”.
FUEL INJECTION SYSTEM FI EAS00908 TROUBLESHOOTING DETAILS This section describes the countermeasures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order in the “TROUBLESHOOTING CHART” in chapter 7. (Manual No.: 5VK1-AE1) After the checking and servicing the malfunctioning part, reset the meter display. Refer to “Restore method”. Fault code No.
FUEL INJECTION SYSTEM Fault code No. 13 Symptom FI Open or short circuit is detected from the intake air pressure sensor. Used diagnostic code No. 03 (intake air pressure sensor) Order 1 Item/components Check or maintenance job Restore method Coupler connections Intake air pressure sensor coupler ECU coupler Sub-wire harness coupler Check the couplers for any pins that may have pulled out. Check that the couplers are securely locked. Reinstated by cranking the engine.
FI FUEL INJECTION SYSTEM Fault code No. 14 Symptom Intake air pressure sensor hose is disconnected or clogged. Used diagnostic code No. 03 (intake air pressure sensor) Order 1 Item/components Check or maintenance job Restore method Disconnected, clogged, kinked, or pinched intake air pressure sensor hose Repair or replace the hose. Reinstated by starting the engine and operating it at idle. Intake air pressure sensor malfunc- Check and repair the connection.
FUEL INJECTION SYSTEM Fault code No. 16 Symptom FI The throttle position sensor is detected stuck. Used diagnostic code No. 01 (throttle position sensor) Order Item/components Check or maintenance job Restore method 1 Defective throttle position sensor Replace the sensor if it is defective. Refer to “THROTTLE BODY ASSEMBLY” in chapter 7. (Manual No.: 5VK1-AE1) 2 Throttle position sensor installation Execute the diagnostic mode. (Code No. 01) Check the sensor for looseness or pinching.
FUEL INJECTION SYSTEM Fault code No. 22 Symptom FI Open or short circuit is detected from the intake air temperature sensor. Used diagnostic code No. 05 (intake air temperature sensor) Order Item/components Check or maintenance job Restore method 1 Intake air temperature sensor installation Check the sensor looseness or pinching. 2 Coupler connections Check the couplers for any pins that may have Intake air temperature sensor cou- pulled out. pler Check that the couplers are securely locked.
FUEL INJECTION SYSTEM Fault code No. 24 Symptom FI No normal signal is received from the O2 sensor. Used diagnostic code No. – – Order Item/components Check or maintenance job Restore method 1 Installed state of O2 sensor. Check for looseness or pinching. 2 Connections O2 sensor coupler ECU coupler Check the coupler for any pins that may be pulled out. Check the locking condition of the coupler. Starting the engine and operating it at idle.
FUEL INJECTION SYSTEM Fault code No. 31 Symptom FI The amount of air-fuel ratio feedback compensation is maintained continuously in the vicinity of the upper limit. Used diagnostic code No. – – Order Item/components Check or maintenance job Restore method 1 Installed state of O2 sensor. Check for looseness or pinching. 2 Connections O2 sensor coupler ECU coupler Check the coupler for any pins that may be pulled out. Check the locking condition of the coupler.
FI FUEL INJECTION SYSTEM Fault code No. 33 Symptom Malfunction detected in the primary lead of the ignition coil. Used diagnostic code No. 30 (ignition coil) Order 1 Item/components Check or maintenance job Restore method Coupler and connector connections Ignition coil primary connector (Orange) ECU coupler Check the coupler and connector for any pins that may have pulled out. Check the connector and coupler are securely locked. Reinstated by starting the engine and operating it at idle.
FUEL INJECTION SYSTEM Fault code No. 42 Symptom FI A. No normal signals are received from the speed sensor. B. Open or short circuit is detected in the neutral switch. Used diagnostic code No. 07 (speed sensor) → A1 ~ A4 / No. 21 (neutral switch) → B1 ~ B4 Order A-1 Item/components Check or maintenance job Restore method Coupler connections Speed sensor coupler ECU coupler Check the couplers for any pins that may have pulled out. Check that the couplers are securely locked.
FUEL INJECTION SYSTEM Fault code No. 42 Symptom FI A. No normal signals are received from the speed sensor. B. Open or short circuit is detected in the neutral switch. Used diagnostic code No. 07 (speed sensor) → A1 ~ A4 / No. 21 (neutral switch) → B1 ~ B4 Order B-1 Item/components Check or maintenance job Restore method Coupler connections Neutral switch connector Wiring harness ECU coupler Check the couplers for any pins that may have pulled out. Check that the couplers are securely locked.
FUEL INJECTION SYSTEM Fault code No. 43 Symptom FI The ECU is unable to monitor the battery voltage. Used diagnostic code No. 09, 50 (fuel system voltage) Order 1 Item/components Check or maintenance job Restore method Coupler connections Fuel injection system relay coupler Wiring harness ECU coupler Check the couplers for any pins that may have pulled out. Check that the couplers are securely locked. Reinstated by starting the engine and operating it at idle.
FUEL INJECTION SYSTEM Fault code No. 44 Symptom FI Error is detected while reading or writing on EEPROM (CO adjustment value). Used diagnostic code No. 60 (EEPROM improper cylinder indication) Order 1 Item/components Check or maintenance job Restore method Malfunction in ECU Execute the diagnostic mode. (Code No. 60) • Check the faulty cylinder. • Readjust the CO of the displayed cylinder. Refer to “ADJUSTING THE EXHAUST GAS VOLUME” in chapter 3. (Manual No.
FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom FI No signals are received from the ECU. Used diagnostic code No. – – Order 1 Item/components Check or maintenance job Restore method Coupler connections ECU coupler Meter couplers Check the couplers for any pins that may have pulled out. Check that the couplers are securely locked. Reinstated automatically when it receives a normal signal. If there is a malfunction, repair it and connect it securely.
– ELEC ELECTRICAL COMPONENTS + EAS00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 1 Spark plug 2 Spark plug cap 3 Ignition coil 4 Intake air pressure sensor 5 Front brake light switch 6 Right handlebar switch 7 Immobilizer unit 8 Main switch 9 Fuel pump 0 Clutch switch A Left handlebar switch B Throttle position sensor C Coolant temperature sensor D Fuel injector 9 6 3 0 E Lean angle cut-off switch F Turn signal/hazard relay G Headlight relay H Radiator fan motor relay I Relay unit J Battery K Fuse b
L Fuse box 2 M Starter relay N Main fuse O Rectifier/regulator P ECU Q Intake air temperature sensor R Sidestand switch S Neutral switch T Crankshaft position sensor U Stator coil V Rear brake light switch 3 + W Speed sensor X Starter motor Y Radiator fan motor Z Horn [ Air induction system solenoid \ O2 sensor 9 6 – ELEC ELECTRICAL COMPONENTS 0 A B 8 7 D 4 C E 5 2 H G 1 I Z F [ J K Y L \ M W X N V O T U S – 72 – R Q P
XT660R(W)/XT660X(W) 2007 WIRING DIAGRAM 1 Crankshaft position sensor 2 A.C.
XT660R(W)/XT660X(W) 2007 WIRING DIAGRAM XT660R(W)/XT660X(W) 2007 SCHALTPLAN XT660R(W)/XT660X(W) 2007 SCHÉMA DE CÂBLAGE XT660R(W)/XT660X(W) 2007 DIAGRAMA ELÉCTRICO XT660R(W)/XT660X(W) 2007 SCHEMA ELETTRICO A Ch Lg L/R G Y B L/R G Ch B Y Dg Gy G/W W W W W Gy G/W G/W L/Y MAIN HARNESS SUB-WIRE HARNESS 1 W W W W W 2 W W W 5 R B Sb R R R R R R P L/W B/Y R/L L B 3 R B B B R 7 8 6 W W W R/W R/B R Gy L/W R/L B R 4 ON OFF P B Br/R Br/R R R Br/L Br/L L/W R/B L/W Br 9 G
