Yamaha XT660R 2004 Service Manual
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Yamaha XT660R 2004 Service Manual

Yamaha XT660R 2004 Service Manual

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2004
XT660R(S)
XT660X(S)
5VK1-AE1
SERVICE MANUAL

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Summary of Contents for Yamaha XT660R 2004

  • Page 1 2004 XT660R(S) XT660X(S) 5VK1-AE1 SERVICE MANUAL...
  • Page 2 EAS00010 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CHASSIS CHAS ENGINE COOLING SYSTEM COOL FUEL INJECTION SYSTEM – ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...
  • Page 3 INFO...

  • Page 4: Table Of Contents

    INFO CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION..............1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 OUTLINE ....................1-2 FI SYSTEM....................1-3 IMPORTANT INFORMATION ................. 1-4 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-4 REPLACEMENT PARTS................1-4 GASKETS, OIL SEALS AND O-RINGS ............ 1-4 LOCK WASHERS/PLATES AND COTTER PINS ........1-5 BEARINGS AND OIL SEALS ..............

  • Page 5: General Information

    MOTORCYCLE IDENTIFICATION INFO EAS00014 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe. EAS00018 MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.

  • Page 6: Features

    FEATURES INFO EAS00019 FEATURES EAS00896 OUTLINE The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture. In a conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective chamber.

  • Page 7: Fi System

    FEATURES INFO EAS00897 FI SYSTEM The fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the injector at 324 kPa (3.24 kg/cm , 46.1 psi) higher than the intake manifold pressure.

  • Page 8: Important Information

    5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

  • Page 9: Lock Washers/Plates And Cotter Pins

    IMPORTANT INFORMATION INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu-...

  • Page 10: Checking The Connections

    CHECKING THE CONNECTIONS INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector Moisture → Dry with an air blower. Rust/stains →...

  • Page 11: Special Tools

    SPECIAL TOOLS INFO EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
  • Page 12 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration T-handle Damper rod holder T-handle 90890-01326 Holder These tools are used to hold the damper 90890-01460 rod holder when removing or installing the damper rod. Radiator cap tester adaptor 90890-01352 This tool is used to check the cooling sys- tem.
  • Page 13 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Thickness gauge 90890-03079 This tool is used to measure the valve clearance. Compression gauge 90890-03081 These tools are used to measure the engine compression. Pocket tester 90890-03112 This tool is used to check the electrical system.
  • Page 14 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Valve guide remover (ø 6) 90890-04064 This tool is needed to remove and install the valve guides. Valve guide installer (ø 6) 90890-04065 This tool is needed to install the valve guides. Valve guide reamer (ø...
  • Page 15 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Yamaha bond No. 1215 90890-85505 This bond is used to seal two mating sur- faces (e.g., crankcase mating surfaces). 1 - 11...
  • Page 16 SPEC...
  • Page 17 SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-11 ELECTRICAL SPECIFICATIONS ..............2-16 CONVERSION TABLE .................. 2-19 GENERAL TIGHTENING TORQUE SPECIFICATIONS.......2-19 TIGHTENING TORQUE................. 2-20 ENGINE TIGHTENING TORQUE ............2-20 CHASSIS TIGHTENING TORQUES............2-23 LUBRICATION POINTS AND LUBRICANT TYPES ........2-25 ENGINE....................

  • Page 18: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code XT660R: 5VK1 (Europe) ---- 5VK2 (AUS) ---- 5VK3 (GB) ---- XT660X: 1D21 (Europe) ---- 1D22 (AUS) ---- 1D23 (GB) ---- Dimensions Overall length 2,240 mm (88.2 in) (XT660R) ---- 2,150 mm (84.6 in) (XT660X) ---- Overall width...

  • Page 19: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid-cooled, 4-stroke, SOHC ---- Displacement 660 cm (40.27 cu · in) ---- Cylinder arrangement Forward-inclined single cylinder ---- Bore × stroke 100.0 × 84.0 mm (3.94 × 3.31 in) ---- Compression ratio 10.00 : 1...
  • Page 20 SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil pump Oil pump type Trochoid ---- Inner-rotor-to-outer-rotor-tip clear- 0.07 ~ 0.12 mm (0.0028 ~ 0.0047 in) 0.2 mm ance (0.008 in) Outer-rotor-to-oil-pump-housing 0.03 ~ 0.08 mm (0.0012 ~ 0.0031 in) 0.15 mm clearance (0.0059 in) Oil-pump-housing-to-inner-rotor-and- 0.03 ~ 0.08 mm (0.0012 ~ 0.0031 in)
  • Page 21 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) 43.338 mm (1.7062 in) Measurement B 36.959 ~ 37.059 mm (1.4551 ~ 1.4590 in) 36.840 mm (1.4504 in) Exhaust camshaft lobe dimensions Measurement A...
  • Page 22 SPEC ENGINE SPECIFICATIONS Item Standard Limit Rocker arm/rocker arm shaft Rocker arm inside diameter 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) 12.036 mm (0.4739 in) Shaft outside diameter 11.981 ~ 11.991 mm (0.4717 ~ 0.4721 in) 11.955 mm (0.4707 in) Arm-to-shaft clearance 0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.081 mm...
  • Page 23 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve-stem-to-valve-guide clearance Intake 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.08 mm (0.0031 in) Exhaust 0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in) 0.10 mm (0.0039 in) Valve stem runout ---- 0.010 mm (0.0004 in) Valve seat width Intake...
  • Page 24 SPEC ENGINE SPECIFICATIONS Item Standard Limit Cylinder Cylinder arrangement Forward-inclined single cylinder ---- Bore × stroke 100.0 × 84.0 mm (3.94 × 3.31 in) ---- Compression ratio 10 : 1 ---- Bore 100.000 ~ 100.010 (3.9370 ~ 3.9374 in) 100.080 mm (3.9402 in) Maximum taper ----...
  • Page 25 SPEC ENGINE SPECIFICATIONS Item Standard Limit 2nd ring Ring type Taper ---- Dimensions (B × T) 1.20 × 4.00 mm (0.047 × 0.157 in) ---- End gap (installed) 0.35 ~ 0.50 mm (0.0138 ~ 0.0197 in) 0.85 mm (0.0335 in) Ring side clearance 0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in) 0.11 mm...
  • Page 26 SPEC ENGINE SPECIFICATIONS Item Standard Limit Clutch Clutch type Wet, multiple disc ---- Clutch release method Outer pull, rack and pinion pull ---- Operation Left-hand operation ---- Clutch cable free play 10.0 ~ 15.0 mm (0.39 ~ 0.59 in) ---- (at the end of the clutch lever) Friction plates 1 (inside dia.: 120 mm)
  • Page 27 SPEC ENGINE SPECIFICATIONS Item Standard Limit Maximum main axle runout ---- 0.08 mm (0.0031 in) Maximum drive axle runout ---- 0.08 mm (0.0031 in) Shifting mechanism Shift mechanism type Shift drum and guide bar ---- Decompression device Device type Auto decomp ---- Air filter type Oil-coated paper element...

  • Page 28: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Diamond ---- Caster angle 27.25° (XT660R) ---- 26° (XT660X) ---- Trail 107 mm (4.21 in) (XT660R) ---- 94 mm (3.70 in) (XT660X) ---- Front wheel Wheel type Spoke wheel ---- 21 ×...
  • Page 29 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front tire Tire type With tube ---- Size 90/90-21M/C 54S, 90/90-21M/C 54T ---- (XT660R) 120/70R 17M/C 58 H (XT660X) ---- Model/manufacturer TOURANCE FRONT/METZELER, ---- SIRAC/MICHELIN (XT660R) DRAGON/PIRELLI (XT660X) ---- Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 200 kPa (2.00 kgf/cm, 29 psi) (XT660R) ---- 210 kPa (2.10 kgf/cm, 30 psi) (XT660X)
  • Page 30 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front brakes Brake type Single-disc brake ---- Operation Right-hand operation ---- Recommended fluid DOT 4 ---- Brake discs Diameter × thickness 298.0 × 4.5 mm (11.73 × 0.18 in) ---- (XT660R) 320.0 × 4.5 mm (12.60 × 0.18 in) ---- (XT660X) Minimum thickness...
  • Page 31 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Steering Steering bearing type Taper roller bearing ---- Lock to lock angle (left) 44.0° ---- Lock to lock angle (right) 44.0° ---- Front suspension Suspension type Telescopic fork ---- Front fork type Coil spring/oil damper ---- Front fork travel 225.0 mm (8.86 in) (XT660R)
  • Page 32 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear suspension Suspension type Swingarm (monocross) ---- Rear shock absorber assembly type Coil spring/gas-oil damper ---- Rear shock absorber assembly travel 65.0 mm (2.56 in) ---- Spring Free length 216.0 mm (8.50 in) 205 mm (8.07 in) Installed length 206.0 mm (8.11 in)

  • Page 33: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V ---- Ignition system Ignition system type Transistorized coil ignition (digital) ---- Ignition timing 9.0° BTDC at 1,400 r/min ---- Advancer type Electric ---- 192 ~ 288 Ω at 20 °C (68 °F) Crankshaft position senor resistance/ ---- color...
  • Page 34 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Bulbs (voltage/wattage × quantity) 12 V 55.0 W/60.0 W × 1 Headlight ---- 12 V 5.0 W × 1 Auxiliary light ---- 12 V 5.0 W/21.0 W × 1 Tail/brake light ---- 12 V 10.0 W × 2 Front turn signal light ---- 12 V 10.0 W ×...
  • Page 35 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Headlight relay Model/manufacturer ACM33211 M04/MATSUSHITA ---- Radiator fan Model/manufacturer 5VW/KTM ---- Fan motor relay Model/manufacturer ACM33211 M04/MATSUSHITA ---- Intake air pressure sensor Thermostat type/manufacturer 5PS1/DENSO ---- Output voltage 3.4 ~ 3.8 V ---- Intake air temperature sensor Model/manufacturer 5VU1/DENSO ----...

  • Page 36: Conversion Table

    CONVERSION TABLE/ SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EAS00028 EAS00030 CONVERSION TABLE GENERAL TIGHTENING TORQUE All specification data in this manual are listed SPECIFICATIONS in SI and METRIC UNITS. This chart specifies tightening torques for stan- Use this table to convert METRIC unit data to dard fasteners with a standard ISO thread IMPERIAL unit data.

  • Page 37: Tightening Torque

    SPEC TIGHTENING TORQUE TIGHTENING TORQUE ENGINE TIGHTENING TORQUE Tightening torque Thread Part to be tightened Part name Q’ty Remarks size Nm m · kg ft · lb Cylinder head (exhaust pipe) Stud bolt Cylinder head (left side) Bolt = 145 mm (5.71 in) Cylinder head (right side) Bolt = 135 mm (5.31 in)
  • Page 38 SPEC TIGHTENING TORQUE Tightening torque Thread Part to be tightened Part name Q’ty Remarks size Nm m · kg ft · lb Oil strainer Bolt Oil pump Screw Oil baffle plate 2 Bolt Oil pump assembly Screw Engine oil drain bolt (crankcase) Bolt Oil filter element cover Bolt...
  • Page 39 SPEC TIGHTENING TORQUE Tightening torque Thread Part to be tightened Part name Q’ty Remarks size Nm m · kg ft · lb Starter clutch Bolt Stator coil Bolt Crankshaft position sensor Bolt Starter motor and crankcase Bolt Starter motor lead Brush holder and starter motor yoke Starter motor assembly Bolt...

  • Page 40: Chassis Tightening Torques

    SPEC TIGHTENING TORQUE CHASSIS TIGHTENING TORQUES Tightening torque Thread Part to be tightened Remarks size Nm m · kg ft · lb Engine mounting: Engine upper bracket and frame Engine upper bracket and engine Engine front bracket and frame Engine front bracket and engine Engine and frame Radiator cap retainer Coolant reservoir...
  • Page 41 SPEC TIGHTENING TORQUE Tightening torque Thread Part to be tightened Remarks size Nm m · kg ft · lb Fuel tank and frame Fuel pump and fuel tank Rectifier/regulator and air filter case ECU and air filter case Horn bracket and frame Side panels (left and right) and frame Grab bar, rear cover and frame Rear mud guard and frame...

  • Page 42: Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication Point Symbol Oil seal lips O-rings Bearings Cylinder head tightening bolts Cylinder tightening bolts Crankshaft pin Timing chain sprocket inner surface Connecting rod big end thrust surface Piston pin Piston and ring groove Balancer weight tightening nut...
  • Page 43 SPEC LUBRICATION POINTS AND LUBRICANT TYPES Lubrication Point Symbol Yamaha bond Crankcase mating surface No.1215 Yamaha bond A.C. magnet lead grommet (A.C. magneto cover) No.1215 Yamaha bond Oil seal holder tightening bolt No.1215 Yamaha bond Oil delivery hose 2 tightening bolt No.1215...

  • Page 44: Chassis

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS Lubrication Point Symbol Front wheel oil seal lips (left and right) Rear wheel oil seal lips (left and right) Rear wheel drive hub contact surface Rear arm pivot shaft outer surface and bush outer surface and oil seal lip Dust cover thrust surface Relay arm and rear shock absorber mounting bolt outer surface Relay arm and rear shock absorber oil seal lips...

  • Page 45: Cooling System Diagrams

    SPEC COOLING SYSTEM DIAGRAMS EAS00033 COOLING SYSTEM DIAGRAMS 1 Water jacket joint È From the radiator 2 Water pump outlet hose É To the cylinder 3 Water pump outlet pipe 4 Water pump È É È 2 - 28...
  • Page 46 SPEC COOLING SYSTEM DIAGRAMS 1 Fast idle plunger outlet hose È From the fast idle plunger 2 Coolant reservoir breather hose É To the cylinder 3 Coolant reservoir hose Ê From the thermostat 4 Radiator cap 5 Radiator 6 Coolant reservoir cap 7 Coolant reservoir 8 Radiator outlet hose 9 Water pump...

  • Page 47: Lubrication Chart

    SPEC LUBRICATION CHART LUBRICATION CHART : Pressure feed : Splashed scavenge Camshaft Cylinder head Oil tank Oil filter Crankshaft Drive axle Main axle Connecting Check ball Oil pump rotor 1 Oil pump rotor 2 Oil strainer Oil pan 2 - 30...

  • Page 48: Lubrication Diagrams

    SPEC LUBRICATION DIAGRAMS EAS00034 LUBRICATION DIAGRAMS 1 Oil delivery hose 2 2 Oil strainer 3 Oil delivery hose 1 2 - 31...
  • Page 49 SPEC LUBRICATION DIAGRAMS 1 Oil delivery pipe 2 2 Oil delivery pipe 1 3 Oil filter 4 Oil pump 2 - 32...
  • Page 50 SPEC LUBRICATION DIAGRAMS 1 Oil delivery hose 2 È To oil tank 2 Oil delivery pipe 2 3 Oil filter 4 Oil pump rotor 1 5 Oil pump rotor 2 6 Main axle 7 Oil delivery pipe 3 È 2 - 33...
  • Page 51 SPEC LUBRICATION DIAGRAMS 1 Camshaft 2 Oil delivery pipe 1 3 Oil filter 4 Main axle 5 Drive axle 6 Crankshaft 2 - 34...
  • Page 52 Download the full PDF manual instantly. Our customer service e-mail: aservicemanualpdf@yahoo.com...

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