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Manuals and User Guides for YAMAHA XT660S. We have
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YAMAHA XT660S manual available for free PDF download: Service Manual
YAMAHA XT660S Service Manual (462 pages)
Motorcycle XT660R; XT660S; XT660X; XT660S
Brand:
YAMAHA
| Category:
Motorcycle
| Size: 17.77 MB
Table of Contents
Table of Contents
7
How to Use this Manual
5
Chassis
6
Engine
6
Cooling System
6
Fuel Injection System
6
General Information
6
Periodic Checks and Adjustments
6
Specifications
6
Troubleshooting
6
Electrical System
6
Table of Contents
7
Gen Info
9
Chapter 1 General Information
12
Motorcycle Identification
12
Vehicle Identification Number
12
Model Label
12
Features
13
Outline
13
Fi System
14
Important Information
15
Preparation for Removal and Disassembly
15
Replacement Parts
15
Gaskets, Oil Seals and O-Rings
15
Lock Washers/Plates and Cotter Pins
16
Bearings and Oil Seals
16
Circlips
16
Checking the Connections
17
Special Tools
18
Spec
24
Chapter 2 Specifications
25
General Specifications
27
Engine Specifications
28
Chassis Specifications
37
Electrical Specifications
42
Conversion Table
45
General Tightening Torque Specifications
45
Tightening Torque
46
Engine Tightening Torque
46
Chassis Tightening Torques
49
Lubrication Points and Lubricant Types
51
Engine
51
Chassis
53
Cooling System Diagrams
54
Lubrication Chart
56
Lubrication Diagrams
57
Cable Routing
61
Cable Routing
68
Chapter 3 Periodic Checks and Adjustments
80
Introduction
82
Periodic Maintenance and Lubrication Chart
82
Brake Fluid
83
Cowling and Cover
84
Cover
84
Cowling
85
Fuel Tank
86
Removing the Fuel Tank
87
Removing the Fuel Pump
87
Installing the Fuel Pump
88
Installing the Fuel Hose
88
Air Filter Case
89
Rear Mud Guard and Rear Fender
89
Installing the Air Filter Case Joint Clamp
93
Engine
94
Adjusting the Valve Clearance
94
Adjusting the Exhaust Gas Volume
97
Adjusting the Engine Idling Speed
98
Adjusting the Throttle Cable Free Play
98
Checking the Spark Plug
100
Checking the Ignition Timing
101
Measuring the Compression Pressure
102
Measuring the Compression Pressure
103
Checking the Engine Oil Level
104
Changing the Engine Oil
105
Adjusting the Clutch Cable Free Play
108
Checking the Air Filter Element
109
Checking the Throttle Body Joint
110
Checking the Fuel Hose
110
Checking the Breather Hose
111
Checking the Exhaust System
111
Checking the Coolant Level
112
Checking the Cooling System
112
Changing the Coolant
113
Chassis
117
Adjusting the Rear Brake Pedal
117
Checking the Brake Fluid Level
118
Checking the Front and Rear Brake Pads and Brake Pad Pins
119
Adjusting the Rear Brake Light Switch
120
Checking the Front and Rear Brake Hoses
120
Bleeding the Hydraulic Brake System
121
Adjusting the Shift Pedal
122
Adjusting the Drive Chain Slack
123
Lubricating the Drive Chain
125
Checking and Adjusting the Steering Head
125
Checking the Front Fork
127
Adjusting the Rear Shock Absorber Assembly
128
Checking the Tires
129
Checking and Tightening the Spokes
132
Checking and Lubricating the Cables
133
Lubricating the Levers and Brake Pedal
133
Lubricating the Sidestand
133
Chk Adj
134
Electrical System
134
Checking and Charging the Battery
134
Checking the Fuses
139
Replacing the Headlight Bulb
141
Adjusting the Headlight Beam
142
Setting the Digital Clock
143
Chas
144
Chapter 4 Chassis
145
Front Wheel and Brake Disc
147
Front Wheel
148
Checking the Front Wheel
149
Removing the Front Wheel
149
Checking the Front Brake Disc
152
Installing the Front Wheel
153
Adjusting the Front Wheel Static Balance
154
Rear Wheel, Brake Disc, and Rear Wheel Sprocket
156
Rear Wheel
156
Brake Disc and Rear Wheel Sprocket
158
Removing the Rear Wheel
160
Checking the Rear Wheel
160
Checking the Rear Brake Disc
161
Checking the Rear Wheel Drive Hub
162
Checking and Replacing the Rear Wheel Sprocket
163
Installing the Rear Wheel
163
Adjusting the Rear Wheel Static Balance
164
Front and Rear Brakes
165
Front Brake Pads (Xt660R)
165
Front Brake Pads (Xt660X)
166
Rear Brake Pads
167
Replacing the Front Brake Pads
168
Replacing the Rear Brake Pads
170
Front Brake Master Cylinder
172
Rear Brake Master Cylinder
175
Disassembling the Front Brake Master Cylinder
178
Disassembling the Rear Brake Master Cylinder
178
Checking the Front and Rear Brake Master Cylinders
179
Assembling and Installing the Front Brake Master Cylinder
180
Assembling the Rear Brake Master Cylinder
182
Installing the Rear Brake Master Cylinder
182
Front Brake Caliper (Xt660R)
185
Front Brake Caliper (Xt660X)
187
Rear Brake Caliper
189
Removing the Front Brake Caliper
191
Removing the Rear Brake Caliper
191
Checking the Front and Rear Brake Calipers
192
Installing the Front Brake Caliper
193
Installing the Rear Brake Caliper
195
Front Fork
197
Removing the Front Fork Legs
201
Disassembling the Front Fork Legs
201
Checking the Front Fork Legs
203
Assembling the Front Fork Legs
204
Installing the Front Fork Legs
208
Handlebar
209
Removing the Handlebar
211
Checking the Handlebar
211
Installing the Handlebar
211
Steering Head
215
Lower Bracket
215
Removing the Lower Bracket
217
Checking the Steering Head
217
Installing the Steering Head
218
Rear Shock Absorber Assembly
220
Handling the Rear Shock Absorber
222
Disposing of a Rear Shock Absorber
222
Removing the Rear Shock Absorber Assembly
223
Checking the Rear Shock Absorber Assembly
224
Checking the Connecting Arms and Relay Arm
224
Installing the Relay Arm
224
Installing the Rear Shock Absorber Assembly
225
Swingarm and Drive Chain
226
Removing the Swingarm
228
Removing the Drive Sprocket
229
Removing the Drive Chain
229
Checking the Swingarm
229
Checking the Drive Chain
230
Installing the Swingarm
232
Eng
235
Chapter 5 Engine
236
Engine Removal
240
Exhaust Pipes and Mufflers
240
Leads, Cables, Hoses, and Ignition Coil
241
Engine
244
Installing the Engine
246
Cylinder Head
247
Removing the Cylinder Head
249
Checking the Cylinder Head
250
Checking the Tappet Covers and Camshaft Sprocket Cover
251
Checking the Timing Chain Tensioner
251
Checking the Camshaft Sprocket
251
Installing the Cylinder Head
251
Rocker Arms and Camshaft
255
Removing the Rocker Arms and Camshaft
257
Checking the Camshaft
257
Checking the Decompression System
258
Checking the Rocker Arms and Rocker Arm Shafts
259
Installing the Camshaft and Rocker Arms
260
Valves and Valve Springs
262
Removing the Valves
263
Checking the Valves and Valve Guides
264
Checking the Valve Seats
266
Checking the Valve Springs
268
Cylinder and Piston
271
Removing the Cylinder and Piston
273
Checking the Cylinder and Piston
273
Checking the Piston Rings
275
Checking the Piston Pin
276
Installing the Piston and Cylinder
277
Clutch Cover
279
Pull Lever Shaft
280
Clutch
281
Removing the Clutch
283
Checking the Friction Plates
283
Checking the Clutch Plates
284
Checking the Clutch Springs
284
Checking the Clutch Housing
285
Checking the Clutch Boss
285
Checking the Pressure Plate
285
Checking the Pull Lever Shaft and Pull Rod
285
Checking the Primary Driven Gear
286
Installing the Clutch
286
Oil Pump
289
Checking the Oil Pump
292
Checking the Oil Delivery Pipes and Hoses
293
Assembling the Oil Pump
293
Installing the Oil Pump
294
Balancer Driven Gear
295
Removing the Balancer Driven Gear and Balancer Drive Gear
297
Checking the Balancer Driven Gear, Water Pump Drive Gear, Primary Drive Gear, and Balancer Drive Gear
297
Installing the Balancer Driven Gear and Balancer Drive Gear
298
Shift Shaft
299
Shift Shaft and Stopper Lever
299
Checking the Shift Shaft
301
Checking the Stopper Lever
301
Installing the Shift Shaft
301
Starter Clutch and A.C. Magneto
302
Removing the A.C. Magneto Rotor
304
Checking the Stator Coil and Crankshaft Position Sensor
305
Checking the Starter Clutch
305
Checking the Torque Limiter
306
Installing the A.C. Magneto Rotor
306
Crankcase
308
Crankcase Bearings
310
Separating the Crankcase
311
Checking the Oil Strainer and Oil Delivery Pipe 3
311
Checking the Timing Chain and Timing Chain Guides
312
Checking the Bearings and Oil Seals
312
Checking the Crankcase
312
Assembling the Crankcase
313
Crankshaft
315
Crankshaft and Balancer
315
Removing the Crankshaft Assembly
316
Checking the Crankshaft
316
Installing the Crankshaft
317
Transmission
318
Main Axle
319
Drive Axle
320
Checking the Shift Forks
321
Checking the Shift Drum Assembly
321
Checking the Transmission
321
Assembling the Main Axle and Drive Axle
322
Installing the Transmission
323
Cool
324
6 Cool
325
Chapter 6 Cooling System
327
Radiator
327
Checking the Radiator
329
Installing the Radiator
330
Thermostat
331
Checking the Thermostat
332
Installing the Thermostat
332
Water Pump
334
Disassembling the Water Pump
337
Checking the Water Pump
337
Assembling the Water Pump
338
Installing the Water Pump
340
Chapter 7 Fuel Injection System
342
Wiring Diagram
345
Ecu Self-Diagnostic Function
346
Alternate Operation Control (Fail-Safe Action)
347
Fail-Safe Action Table
347
Communication Error with Meter
348
Troubleshooting Chart
349
Diagnostic Mode
350
Diagnostic Monitoring Code Table
352
Troubleshooting Details
355
Throttle Body Assembly
366
Checking the Fuel Injector
369
Checking the Throttle Body
369
Installing the Throttle Body Assembly
370
Checking the Fuel Pump
371
Checking and Adjusting the Throttle Position Sensor
372
Air Induction System
375
Air Injection
375
Air Cut-Off Valve
375
Air Induction System Diagrams
376
Air Cut-Off Valve Assembly
377
Checking the Air Induction System
379
Elec
380
Chapter 8 Electrical System
381
Electrical Components
383
Checking Switch Continuity
385
Checking the Switches
387
Checking the Bulbs and Bulb Sockets
389
Types of Bulbs
389
Checking the Condition of the Bulbs
390
Checking the Condition of the Bulb Sockets
391
CHECKING the Leds
391
Ignition System
394
Circuit Diagram
394
Troubleshooting
395
Electric Starting System
399
Circuit Diagram
399
Starting Circuit Cut-Off System Operation
400
Troubleshooting
401
Starter Motor
405
Checking the Starter Motor
407
Assembling the Starter Motor
409
Charging System
410
Circuit Diagram
410
Troubleshooting
411
Lighting System
413
Circuit Diagram
413
Troubleshooting
414
Checking the Lighting System
416
Signaling System
419
Circuit Diagram
419
Troubleshooting
421
Checking the Signaling System
422
Cooling System
431
Circuit Diagram
431
Troubleshooting
432
Immobilizer System
434
Circuit Diagram
434
General Information
435
Key Code Registration
436
Self-Diagnosis Malfunction Codes
439
Troubleshooting
440
Checking the Immobilizer System
441
Self-Diagnosis
445
Trbl Shtg
449
Trbl Shtg
450
Troubleshooting
450
Troubleshooting Trbl
450
Chapter 9
452
Engine
452
Fuel System
452
Starting Failures
452
Electrical Systems
453
Incorrect Engine Idling Speed
453
Engine
453
Fuel System
453
Faulty Clutch
454
Clutch Slips
454
Clutch Drags
454
Faulty Gear Shifting
454
Shifting Is Difficult
454
Shift Pedal Does Not Move
454
Jumps out of Gear
454
Poor Medium-And-High-Speed Performance
454
Engine
454
Fuel System
454
Overcooling
455
Overheating
455
Engine
455
Cooling System
455
Fuel System
455
Chassis
455
Electrical Systems
455
Poor Braking Performance
455
Faulty Front Fork Legs
456
Leaking Oil
456
Malfunction
456
Unstable Handling
456
Faulty Lighting or Signaling System
457
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