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Summary of Contents for Yamaha XT660RW 2007
- Page 1 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys 2007 XT660R(W) XT660X(W) SUPPLEMENTARY SERVICE MANUAL 5VK-F8197-E2 email: info@motomatrix.co.uk...
- Page 2 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys 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.
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Page 3: Important Manual Information
EAS00002 NOTICE This manual was produced by MBK Industrie primarily for use by Yamaha dealers and their quali- fied mechanics. It is not possible to include all the knowledge of a mechanic in one manual. There- fore, 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. -
Page 4: How To Use This Manual
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys 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. - Page 5 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys EAS00008 SYMBOLS The following symbols are not relevant to SPEC every vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information CHAS 2 Specifications 3 Periodic checks and adjustments 4 Chassis...
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Page 6: Table Of Contents
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CONTENTS SPECIFICATIONS ....................1 GENERAL SPECIFICATIONS ..............1 ENGINE SPECIFICATIONS................. 2 CHASSIS SPECIFICATIONS............... 6 ELECTRICAL SPECIFICATIONS ..............8 TIGHTENING TORQUE ................8 ENGINE TIGHTENING TORQUES ............8 CHASSIS TIGHTENING TORQUES ............. -
Page 7: Specifications
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code XT660R: 5VK8 (Europe) ---- 5VK9 (AUS) ---- XT660X: 10S1 (Europe) ---- 10S2 (AUS) ---- Dimensions Overall length 2,240 mm (88.2 in) (XT660R) ---- 2,175 mm (85.6 in) (XT660X) -
Page 8: Engine Specifications
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid-cooled, 4-stroke, SOHC ---- Displacement 660 cm ---- Cylinder arrangement Forward-inclined single cylinder ---- Bore × stroke 100.0 ×... - Page 9 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshaft Drive system Chain drive (left) ---- Intake camshaft lobe dimensions Measurement A 43.488 ~ 43.588 mm (1.7121 ~ 1.7161 in) 43.388 mm (1.7082 in) Measurement B 36.959 ~ 37.059 mm (1.4551 ~ 1.4590 in) 36.859 mm...
- Page 10 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC ENGINE SPECIFICATIONS Item Standard Limit Piston Piston-to-cylinder clearance 0.030 ~ 0.055 mm (0.0012 ~ 0.0022 in) 0.13 mm (0.0051 in) Diameter D 99.955 ~ 99.970 mm (3.9352 ~ 3.9358 in) ---- Height H 10.0 mm (0.39 in)
- Page 11 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil ring Dimensions (B × T) 2.50 × 3.40 mm (0.098 × 0.134 in) ---- End gap (installed) 0.20 ~ 0.70 mm (0.0079 ~ 0.0276 in) ---- Ring side clearance 0.060 ~ 0.150 mm (0.0024 ~ 0.0059 in)
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Page 12: Chassis Specifications
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Rear wheel Wheel type Spoke wheel ---- 17M/C × MT2.75 (XT660R) Size ---- 17M/C × MT4.25 (XT660X) ---- Material Aluminum ---- Wheel travel... - Page 13 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear tire Tire type With tube ---- Size 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) Model/manufacturer TOURANCE/METZELER, SIRAC A/ ----...
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Page 14: Electrical Specifications
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ELECTRICAL SPECIFICATIONS/ SPEC TIGHTENING TORQUE ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V ---- Ignition system Ignition system type Transistorized coil ignition (digital) ---- Ignition timing 5.0°... -
Page 15: Cable Routing
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING EAS00035 CABLE ROUTING È Fasten the sub-wire harness and meter assem- 1 Front turn signal light lead (right) 2 Meter assembly lead bly lead with a plastic band. Fasten the sub-wire 3 Auxiliary light lead harness at the white tape. - Page 16 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Ê Place the slack of the left and right front turn sig- Í Only the left side is shown in this illustration. nal light leads between the headlight assembly Route the right front turn signal light lead in the and front cowling assembly.
- Page 17 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING È Fasten the wire harness and negative battery 1 Rear brake light switch lead 2 Negative battery lead lead to the frame with a plastic locking tie. É...
- Page 18 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING 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. È...
- Page 19 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING 1 Neutral switch connector 0 A.C. magneto lead K Immobilizer unit lead 2 Crankshaft position sensor A Oil tank breather hose L Clutch cable B Oil delivery hose 2 M Main switch lead coupler...
- Page 20 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING È Fasten the left handlebar switch lead, right han- É Fasten the left handlebar switch lead, right han- dlebar switch lead, headlight lead, meter assem- dlebar switch lead, headlight lead, meter assem- bly lead, front brake light switch lead, and clutch bly lead, front brake light switch lead, clutch...
- Page 21 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Ë Fasten the wire harness to the frame at the Ï Fasten the neutral switch lead, crankshaft posi- white tape with a plastic locking tie. tion sensor lead, sidestand switch lead, speed Ì...
- Page 22 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Ò Fasten the wire harness, air-filter-to-air-cut-off- Turn the handlebar completely to the right, and valve hose, and oil delivery hose 2 with a plastic then fasten the left handlebar switch lead, right clamp.
- Page 23 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING È 0 ~ 10 mm (0 ~ 0.39 in) 1 Immobilizer unit coupler É 30 ~ 40 mm (1.18 ~ 1.57 in) 2 Intake air temperature sensor Ê...
- Page 24 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING È Fasten the tail/brake light lead with two plastic 1 Battery 2 Negative battery lead locking ties so that the coupler is positioned to 3 Tail/brake light coupler the inside of where the relays (turn signal/hazard 4 Rear turn signal light connector...
- Page 25 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING Ê Fasten the wire harness with plastic locking ties, Í Fasten the wire harness to the frame with a plas- making sure to install the ties around the taped tic locking tie.
- Page 26 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING È When installing the brake hose onto the brake XT660R master cylinder, make sure that the brake pipe 1 Brake fluid reservoir touches the brake master cylinder as shown. 2 Brake fluid reservoir hose É...
- Page 27 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys SPEC CABLE ROUTING È When installing the brake hose onto the brake XT660X master cylinder, make sure that the brake pipe 1 Brake fluid reservoir touches the brake master cylinder as shown. 2 Brake fluid reservoir hose É...
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Page 28: Periodic Checks And Adjustments
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COWLING AND COVER PERIODIC CHECKS AND ADJUSTMENTS COWLING AND COVER COVER 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft •... -
Page 29: Cowling
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COWLING AND COVER COWLING 8 Nm (0.8 m kg, 5.8 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the cowling (XT660X) Remove the parts in the order listed. -
Page 30: Fuel Tank
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL TANK EAS00040 FUEL TANK 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the fuel tank (XT660X) Remove the parts in the order listed. Seat/side panels (left and right) Refer to “COWLING AND COVER”. - Page 31 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL TANK 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Damper 2 For installation, reverse the removal pro- cedure. – 25 – email: info@motomatrix.co.uk...
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Page 32: Chassis
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE DRIVE CHAIN SLACK 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... - Page 33 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ADJUSTING THE DRIVE CHAIN SLACK È 4. Adjust: • drive chain slack M MMM M MMM M MMM M MMM M MMM a. Loosen the wheel axle nut 1. b.
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Page 34: Checking The Tires
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE TIRES EAS00166 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: • tire pressure Out of specification → Regulate. WARNING •... - Page 35 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE TIRES XT660X Basic weight (with oil and a 186.0 kg (410 lb) full fuel tank) Maximum 186.0 kg (410 lb) load* Cold tire Front Rear pressure 210 kPa 210 kPa...
- Page 36 Tube or tubeless Tubeless wheel 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.
- Page 37 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CHECKING THE TIRES Rear tire (XT660X) Manufacturer Model Size 160/60R PIRELLI DRAGON 17M/C 69H SPORTEC 160/60ZR METZELER 17M/C 69W RADIAL 160/60ZR MICHELIN PILOT 17M/C 69W SPORT WARNING New tires have a relatively low grip on the road surface until they have been slightly worn.
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Page 38: Chassis
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET CHASSIS REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET REAR WHEEL 105 Nm (10.5 m kg, 75 ft •... - Page 39 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET 105 Nm (10.5 m kg, 75 ft • • 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
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Page 40: Removing The Rear Wheel (Xt660R)
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET 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. -
Page 41: Removing The Rear Wheel (Xt660X)
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET 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. -
Page 42: Installing The Rear Wheel (Xt660X)
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET 2. Install: • rear wheel • washer (O) • wheel axle • washer (N) • wheel axle nut NOTE: Install the washer with the “N”... - Page 43 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET 2. Install: • chain puller (left) 1 • chain puller (right) 2 • rear wheel • washer • wheel axle •...
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Page 44: Swingarm And Drive Chain
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET EAS00700 SWINGARM AND DRIVE CHAIN 10 Nm (1.0 m kg, 7.2 ft 59 Nm (5.9 m kg, 43 ft •... - Page 45 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET 10 Nm (1.0 m kg, 7.2 ft 59 Nm (5.9 m kg, 43 ft • • • • 23 Nm (2.3 m kg, 17 ft •...
- Page 46 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET 10 Nm (1.0 m kg, 7.2 ft 59 Nm (5.9 m kg, 43 ft • • • • 23 Nm (2.3 m kg, 17 ft •...
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Page 47: Engine
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys ENGINE REMOVAL EAS00188 ENGINE ENGINE REMOVAL EXHAUST PIPES AND MUFFLERS 27 Nm (2.7 m kg, 19 ft • • 45 Nm (4.5 m kg, 32 ft • •... -
Page 48: Cylinder Head
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEAD EAS00221 CYLINDER HEAD 20 Nm (2.0 m kg, 14 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 50 Nm (5.0 m kg, 36 ft •... - Page 49 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER HEAD 20 Nm (2.0 m kg, 14 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 50 Nm (5.0 m kg, 36 ft •...
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Page 50: Cylinder And Piston
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER AND PISTON EAS00251 CYLINDER AND PISTON 1st 15Nm (1.5 m kg, 11 ft • • 2nd 50Nm (5.0m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft •... - Page 51 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys CYLINDER AND PISTON 1st 15Nm (1.5 m kg, 11 ft • • 2nd 50Nm (5.0m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
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Page 52: Cooling System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL RADIATOR EAS00454 COOLING SYSTEM RADIATOR 7 Nm (0.7 m kg, 5.1 ft • • 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Part Q’ty Remarks Removing the radiator (XT660X) Remove the parts in the order listed. - Page 53 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys COOL RADIATOR 7 Nm (0.7 m kg, 5.1 ft • • 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Part Q’ty Remarks Radiator outlet hose Refer to “INSTALLING THE RADIATOR”...
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Page 54: Fuel Injection System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM EAS00894 FUEL INJECTION SYSTEM EAS00895 FUEL INJECTION SYSTEM 1 Air cut-off valve 9 Intake air temperature sensor H Coolant temperature sensor 2 Air induction system solenoid 0 Air filter case I Spark plug 3 Engine trouble warning light... -
Page 55: Wiring Diagram
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM EAS00898 WIRING DIAGRAM 1 Crankshaft position sensor 3 Neutral switch 4 Main switch 6 Battery 7 Main fuse 0 Fuel injection system fuse D Engine stop switch G Relay unit I Fuel injection system relay J Sidestand switch... -
Page 56: Fail-Safe Action Table
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM FAIL-SAFE ACTION TABLE Self-diagnostic function Fault Item Symptom Fail-safe action Startability Driveability code No. Crankshaft position No normal signals are — sensor received from the sensor. Intake air pressure Open or short circuit is •... - Page 57 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault Item Symptom Fail-safe action Startability Driveability code No. Vehicle system power Power supply to the fuel injec- supply (monitor volt- tion system relay is not nor- —...
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Page 58: Diagnostic Mode
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM 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. - Page 59 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM 8. Verify the operation of the sensor or actua- tor. • Sensor operation The data representing the operating condi- tions of the sensor appears on the odome- ter/fuel reserve tripmeter/tripmeter 2 LCD.
- Page 60 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM EAS00906 Diagnostic monitoring code table Fault Symptom Probable cause of malfunction Diagnostic code code No. No normal signals are received from • Open or short circuit in wire harness the crankshaft position sensor.
- Page 61 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault Symptom Probable cause of malfunction Diagnostic code code No. Open or short circuit is detected in the • Open or short circuit in wire harness lean angle cut-off switch.
- Page 62 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM 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: •...
- Page 63 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Diagnostic Data displayed on meter Item Action code (reference value) Radiator fan motor relay The engine stop switch is set to “ “, the radiator Check that the operating sound of the fan motor relay operates 5 times, 5 seconds each radiator fan motor relay is generated...
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Page 64: Troubleshooting Details
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM 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”... - Page 65 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit is detected from the intake air pressure sensor. Used diagnostic code No. 03 (intake air pressure sensor) Order Item/components Check or maintenance job...
- Page 66 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor hose is disconnected or clogged. Used diagnostic code No. 03 (intake air pressure sensor) Order Item/components Check or maintenance job Restore method Disconnected, clogged, kinked, or...
- Page 67 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom The throttle position sensor is detected stuck. Used diagnostic code No. 01 (throttle position sensor) Order Item/components Check or maintenance job Restore method Defective throttle position sensor Replace the sensor if it is defective.
- Page 68 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom 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...
- Page 69 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom No normal signal is received from the O sensor. Used diagnostic code No. – – Order Item/components Check or maintenance job Restore method Installed state of O sensor.
- Page 70 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom 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...
- Page 71 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary lead of the ignition coil. Used diagnostic code No. 30 (ignition coil) Order Item/components Check or maintenance job Restore method Coupler and connector connections Check the coupler and connector for any pins...
- Page 72 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom 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.
- Page 73 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom 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.
- Page 74 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom The ECU is unable to monitor the battery voltage. Used diagnostic code No. 09, 50 (fuel system voltage) Order Item/components Check or maintenance job Restore method Coupler connections...
- Page 75 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Symptom Error is detected while reading or writing on EEPROM (CO adjustment value). Used diagnostic code No. 60 (EEPROM improper cylinder indication) Order Item/components Check or maintenance job...
- Page 76 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signals are received from the ECU. Used diagnostic code No. – – Order Item/components Check or maintenance job Restore method Coupler connections Check the couplers for any pins that may have...
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Page 77: Electrical System
Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC ELECTRICAL COMPONENTS EAS00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 1 Spark plug 8 Main switch E Lean angle cut-off switch 2 Spark plug cap 9 Fuel pump F Turn signal/hazard relay 3 Ignition coil 0 Clutch switch... - Page 78 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys – ELEC ELECTRICAL COMPONENTS L Fuse box 2 W Speed sensor M Starter relay X Starter motor N Main fuse Y Radiator fan motor O Rectifier/regulator Z Horn P ECU [ Air induction system solenoid Q Intake air temperature sensor...
- Page 79 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys XT660R(W)/XT660X(W) 2007 WIRING DIAGRAM 1 Crankshaft position sensor m Rear turn signal light (left) COLOR CODE 2 A.C. magneto n Front turn signal light (left) B ....Black 3 Neutral switch o Front turn signal light (right) Br ...Brown...
- Page 80 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys email: info@motomatrix.co.uk...
- Page 81 Manuals by Motomatrix / www.motomatrix.co.uk / The Solution For Lost Motorcycle Coded Keys XT660R(W)/XT660X(W) 2007 XT660R(W)/XT660X(W) 2007 XT660R(W)/XT660X(W) 2007 XT660R(W)/XT660X(W) 2007 XT660R(W)/XT660X(W) 2007 WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO Ch Lg MAIN HARNESS SUB-WIRE HARNESS Gy G/W G/W L/Y Gy/G Br/R...
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