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This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual.
TABLE OF CONTENTS SAFETY INFORMATION ....1-1 OPERATION AND IMPORTANT Adjusting the rear brake light Location of important labels ....1-5 RIDING POINTS......... 5-1 switch ........6-21 Starting and warming up a cold Checking the front and rear DESCRIPTION ........2-1 engine ......... 5-1 brake pads ........
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TABLE OF CONTENTS MOTORCYCLE CARE AND STORAGE ..........7-1 Care ..........7-1 Storage ...........7-3 SPECIFICATIONS ......8-1 CONSUMER INFORMATION.....9-1 Identification numbers ....9-1 Motorcycle noise regulation (for Australia) ......9-2...
SAFETY INFORMATION EAU10290 AND/OR WHEN MADE NECES- • Ride where other motorists can SARY BY MECHANICAL CONDI- see you. Avoid riding in another MOTORCYCLES SINGLE TIONS. motorist’s blind spot. TRACK VEHICLES. THEIR SAFE USE Many accidents involve inexperi- AND OPERATION ARE DEPENDENT Safe riding enced operators.
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Modifications made to this motorcycle the motorcycle as possible. Make injuries. The use of a safety helmet is not approved by Yamaha, or the re- sure to distribute the weight as the single most critical factor in the pre- moval of original equipment, may ren- evenly as possible on both sides of vention or reduction of head injuries.
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Gasoline and exhaust gas been specifically designed for use on lightweight as possible and GASOLINE IS HIGHLY FLAMMA- this motorcycle. Since Yamaha cannot should be kept to a minimum. BLE: test all other accessories that may be • Bulky or large accessories may •...
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SAFETY INFORMATION short time. Always operate your should lean over, gasoline may motorcycle in an area that has ad- leak out of the carburetor or fuel equate ventilation. tank. Always turn the engine off before If you should swallow any gaso- leaving the motorcycle unattended line, inhale a lot of gasoline vapor, and remove the key from the main...
SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle. 4CU-F1568-00...
Do not expose any key to exces- a Yamaha dealer to have them re-reg- sively high temperatures. istered. Do not use the key with the red Do not place any key close to bow for driving.
INSTRUMENT AND CONTROL FUNCTIONS EAU10471 EAU10570 To lock the steering Main switch/steering lock 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 re- moved.
INSTRUMENT AND CONTROL FUNCTIONS To unlock the steering EAU33000 EAU11001 (Parking) Indicator and warning lights 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.
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2.5 diagnosis system. (See page 3-5 for an High beam indicator light “ ” seconds. If this occurs, have a Yamaha explanation of the self-diagnosis de- This indicator light comes on when the dealer check the vehicle.
INSTRUMENT AND CONTROL FUNCTIONS EAUM1960 a fuel reserve tripmeter (which NOTE: Multi-function display shows the distance traveled since This model is also equipped with a self- the fuel level warning light came diagnosis device for the immobilizer system. If the immobilizer system is de- a clock fective, the indicator will start flashing a self-diagnosis device...
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NOTE: To set the clock: ber, and then have a Yamaha dealer Make sure there are no other immobi- 1. Push the “SELECT” button and check the vehicle. lizer keys close to the main switch, and “RESET”...
Yamaha dealer and have the stan- dard keys re-registered. Left If the multi-function display indicates any error codes, note the code number, and then have a Yamaha dealer check the vehicle. 1. Engine stop switch “ ” 2. Start switch “...
INSTRUMENT AND CONTROL FUNCTIONS position. To cancel the turn signal EAU12731 EAU12820 Hazard switch “ ” Clutch lever lights, push the switch in after it has re- With the key in the “ON” or “ ” posi- turned to the center position. tion, use this switch to turn on the haz- ard light (simultaneous flashing of all EAU12500...
INSTRUMENT AND CONTROL FUNCTIONS EAU12870 EAU12890 EAU12941 Shift pedal Brake lever Brake pedal 1. Shift pedal 1. Brake lever 1. Brake pedal The shift pedal is located on the left The brake lever is located at the right The brake pedal is on the right side of side of the engine and is used in com- handlebar grip.
INSTRUMENT AND CONTROL FUNCTIONS EAUM1790 EAU13210 Fuel tank cap NOTE: Fuel 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. EWA11140 WARNING Make sure that the fuel tank cap is...
Do not allow the engine to idle as well as to the exhaust system. too long. Your Yamaha engine has been de- signed to use premium unleaded gaso- line with a research octane number of 95 or higher. If knocking (or pinging) oc-...
INSTRUMENT AND CONTROL FUNCTIONS EAU13900 EAU14451 Seat Storage compartment To remove the seat 1. Insert the key into the seat lock, and then turn it as shown. 1. Seat holder 2. Projection 1. Storage compartment 2. Push the rear of the seat down to The storage compartment is located lock it in place.
INSTRUMENT AND CONTROL FUNCTIONS When washing the vehicle, be careful EAU14830 crease the spring preload and thereby Adjusting the shock absorber not to let any water enter the storage soften the suspension, turn the adjust- assembly compartment. ing ring in direction (b). NOTE: Align the appropriate notch in the ad- justing ring with the position indicator...
INSTRUMENT AND CONTROL FUNCTIONS Do not subject the shock ab- EAU15300 below and have a Yamaha dealer re- Sidestand sorber to an open flame or other pair it if it does not function proper- The sidestand is located on the left side high heat sources, otherwise it of the frame.
Periodically check the operation of the ignition circuit cut-off system according to the following procedure. EWA10250 WARNING If a malfunction is noted, have a Yamaha dealer check the system be- fore riding. 3-15...
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5. Push the start switch. Does the engine start? The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. With the engine still running: 6. Move the sidestand up. 7. Keep the clutch lever pulled.
PRE-OPERATION CHECKS 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.
• If necessary, add recommended coolant to specified level. 6-12 • Check cooling system for leakage. • Check operation. • If soft or spongy, have Yamaha dealer bleed hydraulic system. • Check brake pads for wear. Front brake • Replace if necessary.
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• Make sure that operation is smooth. • Check cable free play. Throttle grip 6-17, 6-25 • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. • Make sure that operation is smooth. Control cables 6-25 •...
Always make sure described on page 3-15. Yamaha dealer check the electrical cir- that there is adequate ventila- Never ride with the sidestand cuit. tion. down.
OPERATION AND IMPORTANT RIDING POINTS serve the battery. Do not crank the en- EAU16671 ECA10260 Shifting CAUTION: gine more than 10 seconds on any one attempt. Even with the transmission in the neutral position, do not ECA11130 coast for long periods of time CAUTION: with the engine off, and do not For maximum engine life, always...
During this period, prolonged full-throt- ting it idle for an extended length of immediately have a Yamaha dealer tle operation or any condition that might time (e.g., in traffic jams, at traffic check the vehicle.
OPERATION AND IMPORTANT RIDING POINTS EAU17211 Parking When parking, stop the engine, and then remove the key from the main switch. EWA10310 WARNING Since the engine and exhaust system can become very hot, park in a place where pedestri- ans or children are not likely to touch them.
Safety is an obligation of the owner. Pe- ence required for a particular job, have riodic inspection, adjustment and lubri- a Yamaha dealer perform it for you. cation will keep your vehicle in the safest and most efficient condition pos- EWA10350 sible.
The annual checks must be performed every year, except if a kilometer-based maintenance is performed in- stead. 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)
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PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK • Check runout, spoke tightness and for damage. √ √ √ √ √ 9 * Wheels • Tighten spokes if necessary. • Check tread depth and for damage. •...
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PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK √ √ √ Engine oil filter element • Replace. √ √ √ √ √ • Check coolant level and vehicle for coolant leakage. 24 * Cooling system •...
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 re- moved and installed.
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PERIODIC MAINTENANCE AND MINOR REPAIR 2. Place the cowling in the original To install the cowling position, and then install the bolts 1. Place the cowling in the original and spacers. position, and then tighten the quick fastener screws and install the bolts.
PERIODIC MAINTENANCE AND MINOR REPAIR EAUM1710 EAU19602 Panel B Checking the spark plug The spark plug is an important engine To remove the panel component, which is easy to check. 1. Remove the seat. (See page Since heat and deposits will cause any 3-12.) spark plug to slowly erode, the spark 2.
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Do not attempt to diagnose such problems yourself. Instead, have a 2. Clean the surface of the spark plug Yamaha dealer check the vehicle. gasket and its mating surface, and then wipe off any grime from the 2. Check the spark plug for electrode spark plug threads.
PERIODIC MAINTENANCE AND MINOR REPAIR EAUM1841 EWA10360 Engine oil and oil filter NOTE: WARNING The engine oil tank is located in- element Never remove the engine oil tank side of the frame. The engine oil level should be checked cap after high-speed operation, oth- The engine oil should be between before each ride.
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PERIODIC MAINTENANCE AND MINOR REPAIR 1. Engine oil drain bolt (crankcase) 1. Engine oil drain bolt (oil tank) 1. Oil filter element cover bolt 2. Engine oil drain attachment 2. Oil filter element drain bolt 6. Remove the oil filter element drain 3.
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PERIODIC MAINTENANCE AND MINOR REPAIR 9. Install the oil filter element cover by ECAM1060 addition, do not use oils labeled CAUTION: installing the bolts and the oil filter “ENERGY CONSERVING II” or element drain bolt, then tightening higher. The engine oil tank must be filled in them to the specified torques.
If water has been added to the on a cold engine since the level ing B (See page 6-5.), and then coolant, have a Yamaha dealer varies with engine temperature. open the reservoir cap. check the antifreeze content of 4.
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PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: The radiator fan is automatically switched on or off according to the coolant temperature in the radia- tor. If the engine overheats, see page 6-38 for further instructions. EAUM1801 1. Radiator cap 1. Bolt To change the coolant 2.
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If If water has been used instead coolant is leaking, have a Yamaha Tightening torque: dealer check the cooling system. of coolant, replace it with cool- Coolant drain bolt: 18.
PERIODIC MAINTENANCE AND MINOR REPAIR EAUM1833 ECA10480 Replacing the air filter element CAUTION: and cleaning the check hose Make sure that the air filter ele- The air filter element should be re- ment is properly seated in the placed at the intervals specified in the air filter case.
If the specified idling speed cannot be 1. Attach the tachometer to the spark obtained as described above, have a plug lead. Yamaha dealer make the adjustment. 2. Check the engine idling speed and, if necessary, adjust it to spec- ification by turning the idle adjust- ing screw.
XT660R 225 kPa (33 psi) (2.25 throttle cable free play and, if neces- temperature). kgf/cm²) sary, have a Yamaha dealer adjust it. The tire air pressure must be ad- XT660X 230 kPa (33 psi) (2.30 justed in accordance with the kgf/cm²)
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(minimum tread depth), if the tire has a during a ride. nail or glass fragments in it, or if the Securely pack the heaviest sidewall is cracked, have a Yamaha items close to the center of the dealer replace the tire immediately. motorcycle and distribute the weight evenly on both sides.
XT660R MICHELIN/SIRAC quality product. age before each ride. If any dam- Rear tire: Size: age is found, have a Yamaha XT660R 130/80-17M/C 65S, dealer replace the wheel. Do not 130/80-17M/C 65T attempt even the smallest repair to XT660X 160/60R17 M/C 69H the wheel.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU22041 5. To increase the clutch lever free Adjusting the clutch lever free NOTE: play, turn the adjusting nut in direc- If the specified clutch lever free play play tion (a). To decrease the clutch le- could be obtained as described above, ver free play, turn the adjusting nut tighten the locknut and skip the rest of...
EAU22270 EAU22390 indicator grooves have almost disap- Adjusting the rear brake light Checking the front and rear peared, have a Yamaha dealer replace switch brake pads the brake pads as a set. The front and rear brake pads must be...
However, if the Use only the recommended quality brake fluid level goes down sud- 1. Minimum level mark brake fluid, otherwise the rubber denly, have a Yamaha dealer Rear brake seals may deteriorate, causing check the cause. leakage and poor braking perfor- mance.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU22760 3. Move the rear wheel by pushing Drive chain slack NOTE: the motorcycle to locate the tight- Using the alignment marks on each The drive chain slack should be est portion of the drive chain, and side of the swingarm, make sure that checked before each ride and adjusted then measure the drive chain slack...
PERIODIC MAINTENANCE AND MINOR REPAIR 3. Tighten the locknuts, and then EAU23021 ECA11110 Lubricating the drive chain CAUTION: tighten the axle nut to the specified The drive chain must be cleaned and torque. Do not use engine oil or any other lu- lubricated at the intervals specified in bricants for the drive chain, as they the periodic maintenance and lubrica-...
If a cable is damaged periodic maintenance chart. or does not move smoothly, have a Yamaha dealer check or replace it. Recommended lubricant: Engine oil EWA10720 Clutch lever...
Recommended lubricant: necessary. Lithium-soap-based grease (all-pur- EWA10730 pose grease) WARNING If the sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it. Recommended lubricant: Lithium-soap-based grease (all-pur- pose grease) 6-26...
Securely support the vehicle so that fork does not operate smoothly, damage and excessive oil leakage. there is no danger of it falling over. have a Yamaha dealer check or re- pair it. To check the operation 2. Hold the lower ends of the front 1.
If there is play in the wheel need to check the electrolyte or to add hub or if the wheel does not turn distilled water. smoothly, have a Yamaha dealer check ECA10620 CAUTION: the wheel bearings. Never attempt to remove the battery cell seals, as this would permanent- ly damage the battery.
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To charge the battery vide sufficient ventilation when To charge a sealed-type (MF) Have a Yamaha dealer charge the bat- charging it in an enclosed battery, a special (constant-volt- tery as soon as possible if it seems to space.
PERIODIC MAINTENANCE AND MINOR REPAIR EAUM1740 Specified fuses: Replacing the fuses Main fuse: The main fuse is located behind panel 30.0 A A. (See page 6-5.) Fuse box 1: Headlight fuse: 20.0 A Signaling system fuse: 10.0 A Radiator fan fuse: 7.5 A Ignition fuse: 1.
PERIODIC MAINTENANCE AND MINOR REPAIR 4. If the fuse immediately blows EAUM1750 Replacing the headlight bulb again, have a Yamaha dealer This model is equipped with a quartz check the electrical system. bulb headlight. If the headlight bulb burns out, replace it as follows.
1. Do not touch the glass part of the bulb. 1. Screw 5. Install the bulb cover, and then connect the coupler. 6. Install the cowling together with the headlight unit. 7. Have a Yamaha dealer adjust the headlight beam if necessary. 1. Screw 6-32...
PERIODIC MAINTENANCE AND MINOR REPAIR EAUM1820 EAU24350 a jack either under each side of the Replacing an auxiliary light Supporting the motorcycle frame in front of the rear wheel or under bulb Since this model is not equipped with a each side of the swingarm.
XT660X Front wheel EAUM1761 To remove the front wheel EWA10820 WARNING It is advisable to have a Yamaha dealer service the wheel. Securely support the motor- cycle so that there is no danger 1. Bolt 1. Wheel axle of it falling over.
Make sure that there is enough space EWA10820 between the brake pads before install- WARNING ing the brake caliper onto the brake It is advisable to have a Yamaha disc. dealer service the wheel. 5. Tighten the wheel axle to the spec- Securely support the motor- ified torque.
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PERIODIC MAINTENANCE AND MINOR REPAIR 3. Lift the rear wheel off the ground ECA11070 NOTE: CAUTION: according to the procedure on Install the washer with the “N” page 6-33. Do not apply the brake after the mark on the right-hand side and 4.
However, should your motorcycle require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the motorcycle properly.
Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Check the battery. 4. Battery The engine turns over The battery is good.
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Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. NOTE: If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant as soon as possible.
MOTORCYCLE CARE AND STORAGE EAU26000 ucts onto seals, gaskets, sprock- cleaning products, solvent or Care ets, the drive chain and wheel thinner, fuel (gasoline), rust re- While the open design of a motorcycle axles. Always rinse the dirt and de- movers or inhibitors, brake flu- reveals the attractiveness of the tech- greaser off with water.
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MOTORCYCLE CARE AND STORAGE After normal use ECA10790 5. Use spray oil as a universal clean- CAUTION: Remove dirt with warm water, a mild er to remove any remaining dirt. detergent, and a soft, clean sponge, 6. Touch up minor paint damage Do not use warm water since it in- and then rinse thoroughly with clean caused by stones, etc.
CAUTION: NOTE: the spark plug, and then place Storing the motorcycle in a Consult a Yamaha dealer for advice on the spark plug on the cylinder poorly ventilated room or cover- what products to use. head so that the electrodes are ing it with a tarp, while it is still grounded.
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MOTORCYCLE CARE AND STORAGE 4. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side- stand/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.
Record the key identification number, vehicle identification number and mod- el label information in the spaces pro- vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi- cle is stolen. KEY IDENTIFICATION NUMBER: 1.
This information b. The use of the vehicle after such will be needed when ordering spare device or element of design has parts from a Yamaha dealer. been removed or rendered inoper- ative by any person.
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INDEX Front fork, checking ......6-27 Periodic maintenance and lubrication Fuel............3-10 chart............6-2 Air filter element and check hose, Fuel consumption, tips for reducing..5-3 Pre-operation check list......4-2 replacing and cleaning....... 6-15 Fuel level warning light ......3-4 Auxiliary light bulb, replacing ....6-33 Fuel tank cap ........