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YAMAHA XT660R Service Manual

Motorcycle xt660r; xt660s; xt660x; xt660s.
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Table of Contents
2004
XT660R(S)
XT660X(S)
5VK1-AE1
SERVICE MANUAL

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Table of Contents

   Also See for YAMAHA XT660R

   Summary of Contents for YAMAHA XT660R

  • Page 1 2004 XT660R(S) XT660X(S) 5VK1-AE1 SERVICE MANUAL...
  • Page 3 EAS00000 XT660R(S)/XT660X(S) 2004 SERVICE MANUAL ©2003 by MBK Industrie First edition, December 2003 All rights reserved. Any reproduction or unauthorized use without the written permission of MBK Industrie is expressly prohibited.
  • Page 4 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 5: How To Use This Manual

    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.
  • Page 6: General Information

    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 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system 7 Fuel injection system COOL 8 Electrical system...
  • Page 7: Table Of Contents

    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 9: Gen Info

    INFO...
  • Page 10 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 11 INFO...
  • Page 12: 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 13: 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 14: 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 15: 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 16: 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 17: 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 18: 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 19 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 20 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 21 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 22 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 24: Spec

    SPEC...
  • Page 25 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 26 SPEC...
  • Page 27: Specifications

    ---- 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 845 mm (33.3 in) (XT660R) ---- 865 mm (34.1 in) (XT660X) ---- Overall height 1,230 mm (48.4 in) (XT660R)
  • Page 28: 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 29 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 30 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 31 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 32 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 33 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 34 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 35 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 36 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 37: Chassis Specifications

    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 × 1.85 (XT660R) Size ---- 17M/C ×...
  • Page 38 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) ---- 90 (198 lb) ~ Maximum load* 200 kPa (2.00 kgf/cm, 29 psi) (XT660R) ---- 220 kPa (2.20 kgf/cm, 31 psi) (XT660X)
  • Page 39 32.00 mm × 1 (1.26 in × 1) and Caliper cylinder inside diameter ---- 30.00 mm × 1 (1.18 in × 1) (XT660R) 34.00 mm × 2 (1.34 in × 2) and ---- 30.00 mm × 2 (1.18 in × 2) (XT660X)
  • Page 40 (XT660R) 3.75 N/mm (0.38 kg/mm, 21.41 lb/in) ---- (XT660X) Spring stroke (K1) 0 ~ 120.0 mm (0 ~ 4.72 in) (XT660R) ---- 0 ~ 120.0 mm (0 ~ 4.72 in) (XT660X) ---- Spring rate (K2) 6.00 N/mm (0.61 kg/mm, 34.26 lb/in)
  • Page 41 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 42: 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 43 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 44 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 45: 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 46: 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 47 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 48 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 49: Chassis Tightening Torques

    Clutch lever holder Front brake master cylinder and brake lever Grip end Front brake hose union bolt Front mud guard (XT660R) Front mud guard and front fork protector (XT660R) Stabilizer and front mud guard (XT660X) Stabilizer, front mud guard, and front fork...
  • Page 50 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 51: 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 52 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 53: 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 54: 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 55 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 56: 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 57: Lubrication Diagrams

    SPEC LUBRICATION DIAGRAMS EAS00034 LUBRICATION DIAGRAMS 1 Oil delivery hose 2 2 Oil strainer 3 Oil delivery hose 1 2 - 31...
  • Page 58 SPEC LUBRICATION DIAGRAMS 1 Oil delivery pipe 2 2 Oil delivery pipe 1 3 Oil filter 4 Oil pump 2 - 32...
  • Page 59 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 60 SPEC LUBRICATION DIAGRAMS 1 Camshaft 2 Oil delivery pipe 1 3 Oil filter 4 Main axle 5 Drive axle 6 Crankshaft 2 - 34...
  • Page 61: Cable Routing

    SPEC CABLE ROUTING EAS00035 CABLE ROUTING 1 Left handlebar switch lead 0 Immobilizer unit lead 2 Clutch switch lead 3 Clutch cable 4 Front brake light switch lead 5 Right handlebar switch lead 6 Throttle cable 7 Headlight lead 8 Meter assembly lead 9 Main switch lead 2 - 35...
  • Page 62 SPEC CABLE ROUTING È When fastening the front brake light switch lead, Ì Route the throttle cables, left handlebar switch leave some slack in the lead at the area shown. lead, right handlebar switch lead, front brake É Fasten the right handlebar switch lead, front light switch lead, and clutch switch lead in front brake light switch lead, and throttle cables with a of the steering column, then the clutch cable,...
  • Page 63 SPEC CABLE ROUTING 1 Front turn signal light lead (right) È Fasten the sub-wire harness and meter assem- 2 Meter assembly lead bly lead with a plastic band. Fasten the sub-wire 3 Auxiliary light lead harness at the white tape. Face the end of the 4 Front turn signal light lead (left) plastic band forward.
  • Page 64 SPEC CABLE ROUTING Ë Fasten the left and right front turn signal light Ï 0 ~ 5 mm (0 ~ 0.20 in) for both left and right leads to the headlight stay with a plastic locking sides tie. Ì Pass the left and right front turn signal light leads in front of the headlight stay.
  • Page 65 SPEC CABLE ROUTING 1 Ignition coil lead B Fast idle plunger outlet hose 2 Main switch coupler 3 Immobilizer unit coupler È Fasten the fast idle plunger outlet hose and igni- 4 Air induction system lead tion coil leads with a hose holder. Install the 5 Horn lead hose holder with its fastener facing down.
  • Page 66 SPEC CABLE ROUTING Ê Fasten the main switch lead, immobilizer unit Ì Fasten the clutch cable to the horn bracket with lead, and horn switch lead with a plastic locking a cable holder. Í Install the cable holder as high as possible. tie.
  • Page 67 SPEC CABLE ROUTING 1 Rear brake light switch lead È Fasten the wire harness, negative battery lead, 2 Negative battery lead and rear brake light switch lead to the frame with 3 Lean angle cut-off switch lead a plastic locking tie. 4 Throttle position sensor lead É...
  • Page 68: Cable Routing

    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 3 A.C. magneto coupler C Radiator fan motor lead N Air-filter-to-air-cut-off-valve 4 Speed sensor lead...
  • Page 69 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 switch lead to the frame with a plastic locking tie.
  • Page 70 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 Fasten the starter motor lead to the frame with a sensor lead, starter motor lead, and A.C.
  • Page 71 SPEC CABLE ROUTING Ò Fasten the wire harness, air-filter-to-air-cut-off- valve hose, and oil delivery hose 2 with a plastic clamp. Ó Fasten the left handlebar switch lead, right han- dlebar switch lead, headlight lead, meter assem- bly lead, front brake light switch lead, and clutch switch lead with a plastic band.
  • Page 72 SPEC CABLE ROUTING 1 Starter motor lead È Fasten the wire harness and starter motor lead 2 Fuse box 1 lead to the frame with a plastic locking tie. 3 Fuse box 2 lead É 45° 4 Tail/brake light lead Ê...
  • Page 73 SPEC CABLE ROUTING 1 Immobilizer unit coupler È 0 ~ 10 mm (0 ~ 0.39 in) 2 Intake air temperature sensor É 30 ~ 40 mm (1.18 ~ 1.57 in) 3 Fuel injector lead Ê 5 ~ 15 mm (0.20 ~ 0.59 in) 4 Fuel pump lead Ë...
  • Page 74 SPEC CABLE ROUTING 1 Battery È Fasten the tail/brake light lead with two plastic 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 relay, headlight relay, radiator fan motor relay, 5 Seat lock cable and relay unit) branch off from the wire harness.
  • Page 75 SPEC CABLE ROUTING Ë Connect the couplers so that they are not pinched between the rear fender and rear fender cover. Ì Fasten the wire harness to the frame with a plas- tic locking tie. Í 0 ~ 5 mm (0 ~ 0.20 in) Î...
  • Page 76 SPEC CABLE ROUTING 1 Front brake hose È To install the brake hose holders, align the edge 2 Front brake master cylinder of each holder with the upper edge of the recess 3 Front mud guard in the brake hose. 4 Front brake caliper É...
  • Page 77 SPEC CABLE ROUTING Ì Route the front brake hose between the front fork and front mud guard and between the bosses on the front fork. Í When installing the brake hose onto the brake caliper, make sure that the brake pipe touches the brake caliper as shown.
  • Page 78 SPEC CABLE ROUTING 1 Brake fluid reservoir È When installing the brake hose onto the brake 2 Brake fluid reservoir hose master cylinder, make sure that the brake pipe 3 Rear brake light switch touches the brake master cylinder as shown. 4 Rear brake master cylinder É...
  • Page 80 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION....................3-1 PERIODIC MAINTENANCE AND LUBRICATION CHART ......3-1 COWLING AND COVER ................. 3-3 COVER...................... 3-3 COWLING ....................3-4 FUEL TANK..................... 3-5 REMOVING THE FUEL TANK ..............3-6 REMOVING THE FUEL PUMP ..............3-6 INSTALLING THE FUEL PUMP..............3-7 INSTALLING THE FUEL HOSE ..............3-7 AIR FILTER CASE ..................
  • Page 81 CHASSIS ....................... 3-36 ADJUSTING THE REAR BRAKE PEDAL ..........3-36 CHECKING THE BRAKE FLUID LEVEL..........3-37 CHECKING THE FRONT AND REAR BRAKE PADS AND BRAKE PAD PINS .................3-38 ADJUSTING THE REAR BRAKE LIGHT SWITCH .........3-38 CHECKING THE FRONT AND REAR BRAKE HOSES......3-39 BLEEDING THE HYDRAULIC BRAKE SYSTEM ........
  • Page 82: Periodic Checks And Adjustments

    • From 50,000 km, repeat the maintenance intervals starting from 10,000 km. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1,000 km)
  • Page 83: Brake Fluid

    PERIODIC MAINTENANCE AND LUBRICATION CHART ODOMETER READING (× 1,000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK Chassis fasteners • Make sure that all nuts, bolts and screws are √ √ √ √ √ 15 * (See page 2-23) properly tightened. Sidestand •...
  • Page 84: Cowling And Cover

    COWLING AND COVER COWLING AND COVER COVER 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the cover Remove the parts in the order listed.
  • Page 85: Cowling

    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 Remove the parts in the order listed. Seat/side panels (left and right) Refer to “COWLING AND COVER”.
  • Page 86: Fuel Tank

    FUEL TANK EAS00040 FUEL TANK 10 Nm (1.0 m kg, 7.2 ft • • Q’ty Remarks Order Job/Part Removing the fuel tank Remove the parts in the order listed. Seat/side panels (left and right) Refer to “COWLING AND COVER”. Fuel Drain.
  • Page 87: Removing The Fuel Tank

    FUEL TANK REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank filler tube with a pump. 2. Remove: • fuel hose CAUTION: Although the fuel has been removed from the fuel tank be careful when removing the fuel hose, since there may be fuel remain- ing in it.
  • Page 88: Installing The Fuel Pump

    FUEL TANK INSTALLING THE FUEL PUMP 1. Install: • fuel pump 4 Nm (0.4 m · kg, 2.9 ft · lb) NOTE: • Do not damage the installation surfaces of the fuel tank when installing the fuel pump. • Always use a new fuel pump gasket. •...
  • Page 89: Air Filter Case

    AIR FILTER CASE AIR FILTER CASE REAR MUD GUARD AND REAR FENDER 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 90 AIR FILTER CASE 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks...
  • Page 91 AIR FILTER CASE EAS00043 AIR FILTER CASE 10 Nm (1.0 m kg, 7.2 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 9 17 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 92 AIR FILTER CASE 10 Nm (1.0 m kg, 7.2 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 9 17 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • •...
  • Page 93: Installing The Air Filter Case Joint Clamp

    AIR FILTER CASE INSTALLING THE AIR FILTER CASE JOINT CLAMP 1. Install: • air filter case joint clamp 1 NOTE: To install the air filter case joint clamp, align its slot a with the projection b on the air filter case.
  • Page 94: Engine

    ADJUSTING THE VALVE CLEARANCE EAS00049 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
  • Page 95 ADJUSTING THE VALVE CLEARANCE 6. Measure: • valve clearance Out of specification → Adjust. Valve clearance (cold) Intake valve 0.09 ~ 0.13 mm (0.0035 ~ 0.0051 in) Exhaust valve 0.16 ~ 0.20 mm (0.0063 ~ 0.0079 in) M MMM M MMM M MMM M MMM M MMM...
  • Page 96 ADJUSTING THE VALVE CLEARANCE d. Hold the adjusting screw to prevent it from moving and tighten the locknut to the speci- fied torque. Locknut 14 Nm (1.4 m · kg, 10 ft · lb) e. Measure the valve clearance again. f.
  • Page 97: Adjusting The Exhaust Gas Volume

    ADJUSTING THE EXHAUST GAS VOLUME EAS00869 ADJUSTING THE EXHAUST GAS VOLUME NOTE: Be sure to set the CO density level to stan- dard, and then adjust the exhaust gas volume. 1. Turn the main switch to “OFF” and set the engine stop switch to “...
  • Page 98: Adjusting The Engine Idling Speed

    ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY EAS00054 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the air filter element should be cleaned, and the engine should have adequate compression. 1. Start the engine and let it warm up for sev- eral minutes.
  • Page 99 ADJUSTING THE THROTTLE CABLE FREE PLAY 1. Check: • throttle cable free play a Out of specification → Adjust. Throttle cable free play (at the flange of the throttle grip) 3.0 ~ 5.0 mm (0.12 ~ 0.20 in) 2. Adjust: •...
  • Page 100: Checking The Spark Plug

    ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUG c. Tighten the locknut. WARNING After adjusting the throttle cable free play, start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change.
  • Page 101: Checking The Ignition Timing

    CHECKING THE SPARK PLUG/ CHECKING THE IGNITION TIMING 7. Install: • spark plug 13 Nm (1.3 m · kg, 9.4 ft · lb) NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 8. Connect: • spark plug cap EAS00064 CHECKING THE IGNITION TIMING NOTE:...
  • Page 102: Measuring The Compression Pressure

    CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE 4. Detach: • timing light 5. Install: • timing mark accessing screw EAS00067 MEASURING THE COMPRESSION PRESSURE NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: • valve clearance Out of specification →...
  • Page 103: Measuring The Compression Pressure

    MEASURING THE COMPRESSION PRESSURE 6. Measure: • compression pressure Out of specification → Refer to steps (c) and (d). Compression pressure (at sea level) Minimum 600 kPa (6.0 kg/cm , 85.3 psi) Standard 650 kPa (6.5 kg/cm , 92.4 psi) Maximum 700 kPa (7.0 kg/cm , 99.6 psi)
  • Page 104: Checking The Engine Oil Level

    MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL 7. Install: • spark plug 13 Nm (1.3 m · kg, 9.4 ft · lb) 8. Connect: • spark plug cap EAS00069 CHECKING THE ENGINE OIL LEVEL 1. Stand the motorcycle on a level surface. NOTE: •...
  • Page 105: Changing The Engine Oil

    CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL 4. Start the engine, warm it up for several min- utes, and then turn it off. 5. Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled.
  • Page 106 CHANGING THE ENGINE OIL 9. If the oil filter element is also to be replaced, perform the following procedure. M MMM M MMM M MMM M MMM M MMM a. Remove the oil filter element cover 1 and oil filter element 2. b.
  • Page 107 CHANGING THE ENGINE OIL 13.Install: • engine oil filler cap • camshaft sprocket cover 10 Nm (1.0 m · kg, 7.2 ft · lb) 14.Start the engine, warm it up for several min- utes, and then turn it off. 15.Check: •...
  • Page 108: Adjusting The Clutch Cable Free Play

    ADJUSTING THE CLUTCH CABLE FREE PLAY EAS00078 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: • clutch cable free play a Out of specification → Adjust. Clutch cable free play (at the end of the clutch lever) 10.0 ~ 15.0 mm (0.39 ~ 0.59 in) 2.
  • Page 109: Checking The Air Filter Element

    CHECKING THE AIR FILTER ELEMENT EAS00086 CHECKING THE AIR FILTER ELEMENT NOTE: There is a check hose 1 at the bottom of the air filter case. If dust and/or water collects in this hose, clean the air filter element and air fil- ter case.
  • Page 110: Checking The Throttle Body Joint

    CHECKING THE AIR FILTER ELEMENT/ CHECKING THE THROTTLE BODY JOINT/ CHECKING THE FUEL HOSE 6. Install: • right side panel • seat Refer to “COWLING AND COVER”. EAS00094 CHECKING THE THROTTLE BODY JOINT 1. Check: • throttle body joint 1 Cracks/damage →...
  • Page 111: Checking The Breather Hose

    CHECKING THE BREATHER HOSE/ CHECKING THE EXHAUST SYSTEM EAS00098 CHECKING THE BREATHER HOSE 1. Check: • crankcase-to-crankcase-breather-chamber hose 1 • air-filter-to-crankcase-breather-chamber hose 2 Cracks/damage → Replace. Loose connection → Connect properly. CAUTION: Make sure the breather hoses are routed correctly. EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the...
  • Page 112: Checking The Coolant Level

    CHECKING THE COOLANT LEVEL/ CHECKING THE COOLING SYSTEM EAS00102 CHECKING THE COOLANT LEVEL 1. Stand the motorcycle on a level surface. NOTE: • Place the motorcycle on a suitable stand. • Make sure the motorcycle is upright. 2. Check: • coolant level The coolant level should be between the maximum level mark a and minimum level mark b.
  • Page 113: Changing The Coolant

    CHECKING THE COOLING SYSTEM/ CHANGING THE COOLANT 2. Check: • radiator 1 • radiator outlet hose 2 • radiator inlet hose 3 • water pump assembly 4 • water pump outlet pipe 5 • water pump outlet hose 6 Cracks/damage → Replace. Refer to “COOLING SYSTEM”...
  • Page 114 CHANGING THE COOLANT 2. Remove: • radiator cap retainer 1 • radiator cap 2 WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause seri- ous injury.
  • Page 115 CHANGING THE COOLANT 10.Fill: • cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Quantity Total amount 1.00 L (0.88 Imp qt, 1.06 US qt) Coolant reservoir capacity 0.25 L (0.22 Imp qt, 0.26 US qt) From minimum to maximum...
  • Page 116 CHANGING THE COOLANT 11.Install: • radiator cap • radiator cap retainer 7 Nm (0.7 m · kg, 5.1 ft · lb) 12.Fill: • coolant reservoir (with the recommended coolant to the maxi- mum level mark a) 13.Install: • coolant reservoir cap 14.Start the engine, warm it up for several min- utes, and then turn it off.
  • Page 117: Chassis

    ADJUSTING THE REAR BRAKE PEDAL EAS00110 CHASSIS ADJUSTING THE REAR BRAKE PEDAL 1. Check: • brake pedal position (distance a from the top of the rider foot- rest to the top of the brake pedal) Out of specification → Adjust. Brake pedal position (below the top of the rider footrest) 12.0 mm (0.47 in)
  • Page 118: Checking The Brake Fluid Level

    ADJUSTING THE REAR BRAKE PEDAL/ CHECKING THE BRAKE FLUID LEVEL 3. Adjust: • rear brake light switch Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH”. EAS00115 CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: •...
  • Page 119: Checking The Front And Rear Brake Pads And Brake Pad Pins

    PADS” in chapter 4. Rear brake pad wear limit 1.0 mm (0.04 in) 4. Check: • brake pad pins Damage/wear → Replace. È Front brake (XT660R) É Front brake (XT660X) Ê Rear brake (XT660R/XT660X) EAS00128 ADJUSTING THE REAR BRAKE LIGHT SWITCH...
  • Page 120: Adjusting The Rear Brake Light Switch

    ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE FRONT AND REAR BRAKE HOSES 1. Check: • rear brake light operation timing Incorrect → Adjust. 2. Adjust: • rear brake light operation timing M MMM M MMM M MMM M MMM M MMM a.
  • Page 121: Bleeding The Hydraulic Brake System

    Install the diaphragm (brake master cylinder reservoir or brake fluid reservoir). c. Connect a clear plastic hose 1 tightly to the bleed screw 2. È Front (XT660R) É Front (XT660X) Ê Rear (XT660R/XT660X) d. Place the other end of the hose into a con- tainer.
  • Page 122: Adjusting The Shift Pedal

    BLEEDING THE HYDRAULIC BRAKE SYSTEM/ ADJUSTING THE SHIFT PEDAL g. Loosen the bleed screw. NOTE: Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend. h.
  • Page 123: Adjusting The Drive Chain Slack

    ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE CHAIN SLACK 2. Adjust: • shift pedal position M MMM M MMM M MMM M MMM M MMM a. Remove the bolt 1. b. Remove the shift pedal 2. c. Install the shift pedal at the correct position. d.
  • Page 124 ADJUSTING THE DRIVE CHAIN SLACK 3. Check: • drive chain slack a Out of specification → Adjust. Drive chain slack 40.0 ~ 55.0 mm (1.57 ~ 2.17 in) 4. Adjust: • drive chain slack M MMM M MMM M MMM M MMM M MMM a.
  • Page 125: Lubricating The Drive Chain

    LUBRICATING THE DRIVE CHAIN/ CHECKING AND ADJUSTING THE STEERING HEAD EAS00142 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained prop- erly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the motorcycle is used in dusty areas.
  • Page 126 CHECKING AND ADJUSTING THE STEERING HEAD 3. Remove: • handlebar protector cover (XT660X) • handlebar protector (XT660X) • handlebar holder caps • upper handlebar holders 1 • handlebar 2 4. Loosen: • upper bracket pinch bolts 1 5. Remove: • steering stem nut 2 •...
  • Page 127: Checking The Front Fork

    CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the upper and lower bearings.
  • Page 128: Adjusting The Rear Shock Absorber Assembly

    CHECKING THE FRONT FORK/ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3. Hold the motorcycle upright and apply the front brake. 4. Check: • front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly.
  • Page 129: Checking The Tires

    • Operation of an overloaded motorcycle could cause tire damage, an accident or an injury. NEVER OVERLOAD THE MOTORCYCLE. XT660R Basic weight (with oil and a 181.0 kg (399 lb) full fuel tank) Maximum 186.0 kg (410 lb)
  • Page 130 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 Up to 90 kg (2.10 kgf/cm (2.10 kgf/cm load* 30 psi) 30 psi)
  • Page 131 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 132: Checking And Tightening The Spokes

    CHECKING THE TIRES/ CHECKING AND TIGHTENING THE SPOKES 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. NOTE: For tires with a direction of rotation mark 1: •...
  • Page 133: Checking And Lubricating The Cables

    CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE LEVERS AND BRAKE PEDAL/ LUBRICATING THE SIDESTAND EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables. WARNING Damaged outer cable may cause the cable to corrode and interfere with its movement.
  • Page 134: Chk Adj

    CHECKING AND CHARGING THE BATTERY EAS00178 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries.
  • Page 135 CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
  • Page 136 CHECKING AND CHARGING THE BATTERY 5. Charge: Charging Ambient temperature • battery (refer to the appropriate charging method illustration) WARNING Do not quick charge a battery. Time (minutes) Check the open-circuit CAUTION: voltage. • Never remove the MF battery sealing caps.
  • Page 137 CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger Charger Ammeter NOTE: Measure the open-circuit Leave the battery unused for voltage prior to charging. more than 30 minutes before measuring its open-circuit voltage. Connect a charger and NOTE: Set the charging voltage to 16 ~ ammeter to the battery and...
  • Page 138 CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger NOTE: Measure the open-circuit Leave the battery unused for voltage prior to charging. more than 30 minutes before measuring its open-circuit voltage. Connect a charger and ammeter to the battery and start charging.
  • Page 139: Checking The Fuses

    CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Install: • battery 7. Connect: • battery leads (to the battery terminals) CAUTION: First, connect the positive battery lead 1, then the negative battery lead 2. 8. Check: • battery terminals Dirt →...
  • Page 140 CHECKING THE FUSES 2. Check: • fuse 1 • fuse box 1 2 • fuse box 2 3 M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “Ω...
  • Page 141: Replacing The Headlight Bulb

    CHECKING THE FUSES/ REPLACING THE HEADLIGHT BULB WARNING Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rat- ing may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire.
  • Page 142: Adjusting The Headlight Beam

    REPLACING THE HEADLIGHT BULB/ ADJUSTING THE HEADLIGHT BEAM 5. Install: • headlight bulb • headlight bulb holder • headlight bulb holder cover CAUTION: Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected.
  • Page 143: Setting The Digital Clock

    SETTING THE DIGITAL CLOCK EAS00187 SETTING THE DIGITAL CLOCK 1. Set: • digital clock 1 M MMM M MMM M MMM M MMM M MMM a. Set the main switch to “ON”. b. Push the “SELECT” button 2 and “RESET” button 3 together for at least two seconds.
  • Page 144: Chas

    CHAS...
  • Page 145 CHECKING AND REPLACING THE REAR WHEEL SPROCKET ..4-17 INSTALLING THE REAR WHEEL............4-17 ADJUSTING THE REAR WHEEL STATIC BALANCE......4-18 FRONT AND REAR BRAKES............... 4-19 FRONT BRAKE PADS (XT660R)............4-19 FRONT BRAKE PADS (XT660X)............4-20 REAR BRAKE PADS................4-21 REPLACING THE FRONT BRAKE PADS ..........4-22 REPLACING THE REAR BRAKE PADS..........
  • Page 146 CHAS FRONT FORK....................4-51 REMOVING THE FRONT FORK LEGS..........4-55 DISASSEMBLING THE FRONT FORK LEGS ........4-55 CHECKING THE FRONT FORK LEGS ..........4-57 ASSEMBLING THE FRONT FORK LEGS ..........4-58 INSTALLING THE FRONT FORK LEGS ..........4-62 HANDLEBAR ....................4-63 REMOVING THE HANDLEBAR..............4-65 CHECKING THE HANDLEBAR ..............4-65 INSTALLING THE HANDLEBAR ............
  • Page 147: Front Wheel And Brake Disc

    CHAS FRONT WHEEL AND BRAKE DISC EAS00512 CHASSIS FRONT WHEEL AND BRAKE DISC 18 Nm (1.8 m kg, 13 ft • • 59 Nm (5.9 m kg, 43 ft • • 40 Nm (4.0 m kg, 29 ft • • 23 Nm (2.3 m kg, 17 ft •...
  • Page 148: Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISC EAS00518 FRONT WHEEL Order Job/Part Q’ty Remarks Disassembling the front wheel Remove the parts in the order listed. Oil seal Bearing Spacer For assembly, reverse the disassembly procedure. 4 - 2...
  • Page 149: Removing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISC EAS00519 REMOVING THE FRONT WHEEL 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 front wheel is elevated.
  • Page 150 CHAS FRONT WHEEL AND BRAKE DISC 3. Check: • spokes Bends/damage → Replace. Loose → Tighten. Tap the spokes with a screwdriver. NOTE: A tight spoke will emit a clear, ringing tone, a loose spoke will sound flat. 4. Tighten: •...
  • Page 151 CHAS FRONT WHEEL AND BRAKE DISC 7. Check: • wheel bearings Front wheel turns roughly or is loose → Replace the wheel bearings. • oil seals Damage/wear → Replace. 8. Replace: • oil seals • wheel bearings M MMM M MMM M MMM M MMM M MMM...
  • Page 152: Checking The Front Brake Disc

    CHAS FRONT WHEEL AND BRAKE DISC EAS00527 CHECKING THE FRONT BRAKE DISC 1. Check: • brake disc Damage/galling → Replace. 2. Measure: • brake disc deflection Out of specification → Correct the brake disc deflection or replace the brake disc. Brake disc deflection limit (maxi- mum) 0.15 mm (0.006 in)
  • Page 153: Installing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISC 4. Adjust: • brake disc deflection M MMM M MMM M MMM M MMM M MMM a. Remove the brake disc. b. Rotate the brake disc by one bolt hole. c. Install the brake disc. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern.
  • Page 154: Adjusting The Front Wheel Static Balance

    CHAS FRONT WHEEL AND BRAKE DISC 2. Tighten: • wheel axle 1 59 Nm (5.9 m · kg, 43 ft · lb) • wheel axle pinch bolts 2 18 Nm (1.8 m · kg, 13 ft · lb) CAUTION: Before tightening the wheel axle nut, push down hard on the handlebar several times and check if the front fork rebounds smoothly.
  • Page 155 CHAS FRONT WHEEL AND BRAKE DISC 2. Find: • front wheel’s heavy spot NOTE: Place the front wheel on a suitable balancing stand. M MMM M MMM M MMM M MMM M MMM a. Spin the front wheel. b. When the front wheel stops, put an “X ”...
  • Page 156: Rear Wheel, Brake Disc, And Rear Wheel Sprocket

    Remove the parts in the order listed. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. Stabilizer XT660X Chain cover XT660X Chain cover XT660R Locknut Loosen. Adjusting nut Loosen. Wheel axle nut Washer (N) Refer to “INSTALLING THE REAR WHEEL”.
  • Page 157 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET 105 Nm (10.5 m kg, 75 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 158: Brake Disc And Rear Wheel Sprocket

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET BRAKE DISC AND REAR WHEEL SPROCKET 13 Nm (1.3 m kg, 9.4 ft • • 69 Nm (6.9 m kg, 50 ft • • Order Job/Part Q’ty Remarks Removing the brake disc and rear Remove the parts in the order listed.
  • Page 159 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET Order Job/Part Q’ty Remarks Disassembling the rear wheel Remove the parts in the order listed. Bearing Oil seal Spacer For assembly, reverse the disassembly procedure. 4 - 13...
  • Page 160: Removing The Rear Wheel

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET EAS00561 REMOVING THE REAR WHEEL 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.
  • Page 161: Checking The Rear Brake Disc

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET 2. Check: • tire • rear wheel Damage/wear → Replace. Refer to “CHECKING THE TIRES” in chap- ter 3. 3. Check: • spokes Refer “CHECKING FRONT WHEEL”. 4. Measure: • radial wheel runout •...
  • Page 162: Checking The Rear Wheel Drive Hub

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET 3. Measure: • brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification → Replace. Brake disc thickness limit (mini- mum) 4.5 mm (0.18 in) 4.
  • Page 163: Checking And Replacing The Rear Wheel Sprocket

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET EAS00568 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1. Check: • rear wheel sprocket More than 1/4 tooth a wear → Replace the rear wheel sprocket. Bent teeth → Replace the rear wheel sprocket.
  • Page 164: Adjusting The Rear Wheel Static Balance

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET 2. Install: • rear wheel • washer (O) • rear axle • washer (N) • rear axle nut NOTE: Install the washer with the “N” mark on the right-hand side of the vehicle and the washer with the “O”...
  • Page 165: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS (XT660R) 14 Nm (1.4 m kg, 10 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed.
  • Page 166: Front Brake Pads (xt660x)

    CHAS FRONT AND REAR BRAKES FRONT BRAKE PADS (XT660X) 14 Nm (1.4 m kg, 10 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed. Brake caliper bolt Brake pad clip Brake pad pin...
  • Page 167: Rear Brake Pads

    CHAS FRONT AND REAR BRAKES EAS00578 REAR BRAKE PADS 14 Nm (1.4 m kg, 10 ft • • Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. Rear wheel Refer to “REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET”.
  • Page 168: Replacing The Front Brake Pads

    • brake caliper bolts 1 • brake caliper 2 • brake pad clip(s) 3 É • brake pad pin(s) 4 • brake pads 5 • brake pad springs (XT660R) • brake pad spring 6 (XT660X) È XT660R É XT660X 4 - 22...
  • Page 169 È • brake pad wear limit a Out of specification → Replace the brake pads as a set. Brake pad wear limit 1.0 mm (0.04 in) È XT660R É XT660X 3. Check: É • brake pad pin(s) Damage/wear → Replace.
  • Page 170: Replacing The Rear Brake Pads

    Install new brake pads and new brake pad È springs. NOTE: The arrow a on the brake pad spring must point in the direction of rotation. È XT660R É XT660X L LLL L LLL L LLL L LLL L LLL 5.
  • Page 171 CHAS FRONT AND REAR BRAKES 3. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set. Brake pad wear limit 1.0 mm (0.04 in) 4. Install: • brake pad springs • brake pads NOTE: Always replace the brake pads and brake pad springs as a set.
  • Page 172: Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00584 FRONT BRAKE MASTER CYLINDER 7 Nm (0.7 m kg, 5.1 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed.
  • Page 173 CHAS FRONT AND REAR BRAKES 7 Nm (0.7 m kg, 5.1 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Part Q’ty Remarks Front brake light switch Disconnect.
  • Page 174 CHAS FRONT AND REAR BRAKES EAS00585 Order Job/Part Q’ty Remarks Disassembling the front brake mas- Remove the parts in the order listed. ter cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder For assembly, reverse the disassembly procedure. 4 - 28...
  • Page 175: Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER 30 Nm (3.0 m kg, 22 ft • • 18 Nm (1.8 m kg, 13 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Part Q’ty Remarks Removing the rear brake master cyl- Remove the parts in the order listed.
  • Page 176 CHAS FRONT AND REAR BRAKES 30 Nm (3.0 m kg, 22 ft • • 18 Nm (1.8 m kg, 13 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Part Q’ty Remarks Cotter pin Washer Refer to “INSTALLING THE REAR BRAKE MASTER CYLINDER”.
  • Page 177 CHAS FRONT AND REAR BRAKES EAS00587 Order Job/Part Q’ty Remarks Disassembling the rear brake mas- Remove the parts in the order listed. ter cylinder Hose joint Brake master cylinder kit Refer to “ASSEMBLING THE REAR Brake master cylinder BRAKE MASTER CYLINDER”. For assembly, reverse the disassembly procedure.
  • Page 178: Disassembling The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Disconnect: • front brake light switch 1 NOTE: Push the fastener to remove the front brake light switch from the brake master cylinder.
  • Page 179: Checking The Front And Rear Brake Master Cylinders

    CHAS FRONT AND REAR BRAKES EAS00592 È CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to both of the brake master cylinders. 1. Check: • brake master cylinder 1 Damage/scratches/wear → Replace. • brake fluid delivery passages (brake master cylinder body) Obstruction →...
  • Page 180: Assembling And Installing The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES 5. Check: • brake hoses Cracks/damage/wear → Replace. EAS00598 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. •...
  • Page 181 CHAS FRONT AND REAR BRAKES 3. Fill: • brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
  • Page 182: Assembling The Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00608 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING • All internal brake components should be cleaned and lubricated with new brake fluid only before installation. Recommended brake fluid DOT 4 • Whenever a master cylinder is disassem- bled, replace the piston seals and dust seals.
  • Page 183 CHAS FRONT AND REAR BRAKES 2. Install: • right side heel plate 23 Nm (2.3 m · kg, 17 ft · lb) • copper washers • brake hose 1 • union bolt 2 30 Nm (3.0 m · kg, 22 ft · lb) WARNING Proper brake hose routing is essential to insure safe motorcycle operation.
  • Page 184 CHAS FRONT AND REAR BRAKES 4. Bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 5. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level.
  • Page 185: Front Brake Caliper (xt660r)

    CHAS FRONT AND REAR BRAKES EAS00612 FRONT BRAKE CALIPER (XT660R) 40 Nm (4.0 m kg, 29 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Part Q’ty Remarks Removing the front brake caliper Remove the parts in the order listed.
  • Page 186 CHAS FRONT AND REAR BRAKES EAS00614 14 Nm (1.4 m kg, 10 ft • • Order Job/Part Q’ty Remarks Disassembling the front brake cali- Remove the parts in the order listed. Brake pad clip Brake pad pin Refer to “INSTALLING THE FRONT Brake pad BRAKE CALIPER”.
  • Page 187: Front Brake Caliper (xt660x)

    CHAS FRONT AND REAR BRAKES FRONT BRAKE CALIPER (XT660X) 30 Nm (3.0 m kg, 22 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Part Q’ty Remarks Removing the front brake caliper Remove the parts in the order listed. Brake fluid Drain.
  • Page 188 CHAS FRONT AND REAR BRAKES 14 Nm (1.4 m kg, 10 ft • • Order Job/Part Q’ty Remarks Disassembling the front brake cali- Remove the parts in the order listed. Brake pad clip Brake pad pin Refer to “INSTALLING THE FRONT Brake pad spring BRAKE CALIPER”.
  • Page 189: Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS00616 REAR BRAKE CALIPER 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed.
  • Page 190 CHAS FRONT AND REAR BRAKES EAS00617 14 Nm (1.4 m kg, 10 ft • • Order Job/Part Q’ty Remarks Disassembling the rear brake cali- Remove the parts in the order listed. Brake caliper bracket Brake pad clip Brake pad pin Refer to “INSTALLING THE REAR BRAKE CALIPER”.
  • Page 191: Removing The Front Brake Caliper

    • brake caliper 4 É NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. È XT660R É XT660X EAS00626 REMOVING THE REAR BRAKE CALIPER NOTE: Before removing the brake caliper, drain the brake fluid from the entire brake system.
  • Page 192: Checking The Front And Rear Brake Calipers

    • brake caliper body 2 Cracks/damage → Replace the brake cali- per. • brake caliper Brake fluid leakage → Replace the brake caliper. È Front (XT660R) É É Front (XT660X) Ê Rear (XT660R/XT660X) 2. Check: • brake caliper bracket Cracks/damage → Replace.
  • Page 193: Installing The Front Brake Caliper

    XT660X When installing the brake hose onto the brake caliper 1, make sure the brake pipe È a touches the projection c on the brake caliper. È XT660R É XT660X É 4 - 47...
  • Page 194 CHAS FRONT AND REAR BRAKES 3. Fill: • brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING • Use only the designated brake fluid. Other brake fluids may cause the piston seals to deteriorate, causing leakage and poor brake performance.
  • Page 195: Installing The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS00642 INSTALLING THE REAR BRAKE CALIPER 1. Install: • brake caliper springs • brake pads • brake pad pin • brake pad clip Refer to “REAR BRAKE PADS”. 2. Install: • brake caliper • rear wheel Refer to “REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET”.
  • Page 196 CHAS FRONT AND REAR BRAKES WARNING • Use only the designated brake fluid. Other brake fluids may cause the piston seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
  • Page 197: Front Fork

    Refer to “COWLING AND COVER” in Front fork protector chapter 3. Front cowling assembly Front wheel Refer to “FRONT WHEEL AND BRAKE DISC”. Front mud guard XT660R Front mud guard stay XT660R Stabilizer XT660X Front mud guard XT660X Brake hose holder Refer to “INSTALLING THE FRONT...
  • Page 198 Loosen. Refer to “REMOVING THE FRONT FORK Cap bolt Loosen. LEGS” and “INSTALLING Lower bracket pinch bolt Loosen. THE FRONT FORK LEGS”. Front fork leg XT660R Front fork leg XT660X For installation, reverse the removal pro- cedure. 4 - 52...
  • Page 199 CHAS FRONT FORK EAS00648 18 Nm (1.8 m kg, 13 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Part Q’ty Remarks Disassembling the front fork legs Remove the parts in the order listed. NOTE: The following the procedure applies to both of the front fork legs.
  • Page 200 • • Order Job/Part Q’ty Remarks Oil seal Washer Refer to “ASSEMBLING THE FRONT Outer tube bushing FORK LEGS”. Oil flow stopper Inner tube bushing Outer tube XT660R Outer tube XT660X For assembly, reverse the disassembly procedure. 4 - 54...
  • Page 201: Removing The Front Fork Legs

    CHAS FRONT FORK EAS00649 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 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 front wheel is elevated.
  • Page 202 CHAS FRONT FORK 2. Drain: • fork oil NOTE: Stroke the outer tube several times while draining the fork oil. 3. Remove: • dust seal 1 • oil seal clip 2 (with a flat-head screwdriver) CAUTION: Do not scratch the inner tube. 4.
  • Page 203: Checking The Front Fork Legs

    • outer tube 2 Bends/damage/scratches → Replace. WARNING Do not attempt to straighten a bent inner É tube as this may dangerously weaken it. È XT660R É XT660X 2. Measure: • spring free length a Out of specification → Replace. Spring free length XT660R 633.0 mm (24.92 in)
  • Page 204: Assembling The Front Fork Legs

    CHAS FRONT FORK 3. Check: • damper rod 1 Damage/wear → Replace. Obstruction → Blow out all of the oil pas- sages with compressed air. • oil flow stopper 2 Damage → Replace. CAUTION: • The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction, which are particu- larly sensitive to foreign material.
  • Page 205 CHAS FRONT FORK 2. Lubricate: • inner tube’s outer surface Recommended lubricant Fork oil 10 W or equivalent 3. Tighten: • damper rod bolt 1 Damper rod bolt 30 Nm (3.0 m · kg, 22 ft · lb) ® LOCTITE NOTE: While holding the damper rod with the damper rod holder 2 and T-handle 3, tighten the...
  • Page 206 CHAS FRONT FORK 5. Install: • oil seal 1 (with the fork seal driver weight 2 and fork seal driver attachment 3) CAUTION: Make sure the numbered side of the oil seal faces up. NOTE: • Before installing the oil seal, lubricate its lips with lithium-soap-based grease.
  • Page 207 FRONT FORK 8. Fill: • front fork leg (with the specified amount of the recom- mended fork oil) Quantity (each front fork leg) XT660R 640.0 cm (22.53 Imp oz, 21.64 US oz) XT660X 600.0 cm (21.12 Imp oz, 20.29 US oz)
  • Page 208: Installing The Front Fork Legs

    CHAS FRONT FORK EAS00662 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: • front fork leg Temporarily tighten the lower bracket pinch bolts. NOTE: To install the front fork leg, align the inner tube a with the lower edge b of the bevel on the upper bracket as shown.
  • Page 209: Handlebar

    CHAS HANDLEBAR EAS00664 HANDLEBAR 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty...
  • Page 210 CHAS HANDLEBAR 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Clutch lever...
  • Page 211: Removing The Handlebar

    CHAS HANDLEBAR EAS00666 REMOVING THE HANDLEBAR 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: • front brake light switch 1 • clutch switch NOTE: •...
  • Page 212 CHAS HANDLEBAR 2. Install: • handlebar 1 • upper handlebar holders 2 23 Nm (2.3 m · kg, 17 ft · lb) • handlebar protector (XT660X) • handlebar protector cover (XT660X) CAUTION: • First, tighten the bolts on the front side of the upper handlebar holder, then the bolts on the rear side.
  • Page 213 CHAS HANDLEBAR 4. Install: • left handlebar switch 1 NOTE: Align the projection a on the left handlebar switch with the hole b in the handlebar. 5. Install: • clutch lever • clutch lever holder 1 7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE: Align the mating surfaces of the clutch lever holder with the punch mark a on the handle-...
  • Page 214 CHAS HANDLEBAR 8. Install: • brake master cylinder • brake master cylinder holder Refer to “FRONT AND REAR BRAKES”. 9. Adjust: • clutch cable free play Refer to “ADJUSTING THE CLUTCH CABLE FREE PLAY” in chapter 3. Clutch cable free play (at the end of the clutch lever) 10.0 ~ 15.0 mm (0.39 ~ 0.59 in) 10.Adjust:...
  • Page 215: Steering Head

    CHAS STEERING HEAD EAS00675 STEERING HEAD LOWER BRACKET 32 Nm (3.2 m kg, 23 ft 130 Nm (13.0 m kg, 94 ft • • • • 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft •...
  • Page 216 CHAS STEERING HEAD 32 Nm (3.2 m kg, 23 ft 130 Nm (13.0 m kg, 94 ft • • • • 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft • • 32 Nm (3.2 m kg, 23 ft •...
  • Page 217: Removing The Lower Bracket

    CHAS STEERING HEAD EAS00679 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: • upper ring nut 1 • rubber washer •...
  • Page 218: Installing The Steering Head

    CHAS STEERING HEAD 3. Replace: • bearings • bearing races M MMM M MMM M MMM M MMM M MMM a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer.
  • Page 219 CHAS STEERING HEAD 3. Install: • upper bracket • steering stem nut NOTE: Temporarily tighten the steering stem nut. 4. Install: • front fork legs Refer to “INSTALLING THE FRONT FORK LEGS”. NOTE: Temporarily tighten the lower bracket pinch bolts. 5.
  • Page 220: Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00685 REAR SHOCK ABSORBER ASSEMBLY 59 Nm (5.9 m kg, 43 ft • • 59 Nm (5.9 m kg, 43 ft • • 42 Nm (4.2 m kg, 30 ft • • 59 Nm (5.9 m kg, 43 ft •...
  • Page 221 CHAS REAR SHOCK ABSORBER ASSEMBLY 59 Nm (5.9 m kg, 43 ft • • 59 Nm (5.9 m kg, 43 ft • • 42 Nm (4.2 m kg, 30 ft • • 59 Nm (5.9 m kg, 43 ft • •...
  • Page 222: Handling The Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00686 HANDLING THE REAR SHOCK ABSORBER WARNING This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following informa- tion. The manufacturer cannot be held responsible for property damage or per- sonal injury that may result from improper handling of the rear shock absorber.
  • Page 223: Removing The Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00690 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 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.
  • Page 224: Checking The Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00695 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: • rear shock absorber rod Bends/damage → Replace the rear shock absorber assembly. • rear shock absorber Gas leaks/oil leaks → Replace the rear shock absorber assembly. •...
  • Page 225: Installing The Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00697 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Lubricate: • bearings • bolts Recommended lubricant Lithium-soap-based grease 2. Install: • rear shock absorber assembly NOTE: When installing the rear shock absorber assembly, lift up the swingarm. 3.
  • Page 226: Swingarm And Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN EAS00700 SWINGARM AND DRIVE CHAIN 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 • • 120 Nm (12.0 m kg, 85 ft •...
  • Page 227 CHAS SWINGARM AND DRIVE CHAIN 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 • • 120 Nm (12.0 m kg, 85 ft • •...
  • Page 228: Removing The Swingarm

    CHAS SWINGARM AND DRIVE CHAIN EAS00703 REMOVING THE SWINGARM 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.
  • Page 229: Removing The Drive Sprocket

    CHAS SWINGARM AND DRIVE CHAIN REMOVING THE DRIVE SPROCKET NOTE: Loosen the drive sprocket nut before removing the rear wheel. 1. Remove: • drive sprocket cover • chain guard 2. Straighten the lock washer tab a 3. Remove: • drive sprocket nut 1 •...
  • Page 230: Checking The Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN 2. Check: • pivot shaft Roll the pivot shaft on a flat surface. Bends → Replace. WARNING Do not attempt to straighten a bent pivot shaft. 3. Wash: • pivot shaft • dust covers • spacer •...
  • Page 231 CHAS SWINGARM AND DRIVE CHAIN 2. Check: • drive chain Stiffness → Clean and lubricate or replace. 3. Clean: • drive chain M MMM M MMM M MMM M MMM M MMM a. Wipe the drive chain with a clean cloth. b.
  • Page 232: Installing The Swingarm

    CHAS SWINGARM AND DRIVE CHAIN 5. Lubricate: • drive chain Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains 6. Check: • drive sprocket • rear wheel sprocket More than 1/4 tooth a wear → Replace the drive chain sprockets as a set. Bent teeth →...
  • Page 233 CHAS SWINGARM AND DRIVE CHAIN 3. Install: • swingarm • pivot shaft • pivot shaft nut 92 Nm (9.2 m · kg, 66 ft · lb) 4. Install: • connecting arm bolt • washer • connecting arm nut 59 Nm (5.9 m · kg, 43 ft · lb) •...
  • Page 236 CHAPTER 5 ENGINE ENGINE REMOVAL ..................5-1 EXHAUST PIPES AND MUFFLERS ............5-1 LEADS, CABLES, HOSES, AND IGNITION COIL ........5-2 ENGINE..................... 5-5 INSTALLING THE ENGINE............... 5-7 CYLINDER HEAD.................... 5-8 REMOVING THE CYLINDER HEAD............5-10 CHECKING THE CYLINDER HEAD ............5-11 CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER ....................
  • Page 237 CLUTCH ......................5-40 CLUTCH COVER ..................5-40 PULL LEVER SHAFT ................5-41 CLUTCH ....................5-42 REMOVING THE CLUTCH ..............5-44 CHECKING THE FRICTION PLATES.............5-44 CHECKING THE CLUTCH PLATES ............5-45 CHECKING THE CLUTCH SPRINGS.............5-45 CHECKING THE CLUTCH HOUSING ............5-46 CHECKING THE CLUTCH BOSS............5-46 CHECKING THE PRESSURE PLATE ............5-46 CHECKING THE PULL LEVER SHAFT AND PULL ROD ......5-46 CHECKING THE PRIMARY DRIVEN GEAR ..........5-47...
  • Page 238 CRANKCASE ....................5-69 CRANKCASE BEARINGS............... 5-71 SEPARATING THE CRANKCASE............5-72 CHECKING THE OIL STRAINER AND OIL DELIVERY PIPE 3 ..... 5-72 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDES ..5-73 CHECKING THE BEARINGS AND OIL SEALS........5-73 CHECKING THE CRANKCASE ..............5-73 ASSEMBLING THE CRANKCASE............
  • Page 240: Engine

    ENGINE REMOVAL EAS00188 ENGINE ENGINE REMOVAL EXHAUST PIPES AND MUFFLERS 27 Nm (2.7 m kg, 19 ft 27 Nm (2.7 m kg, 19 ft • • • • 20 Nm (2.0 m kg, 14 ft • • 20 Nm (2.0 m kg, 14 ft •...
  • Page 241: Leads, Cables, Hoses, And Ignition Coil

    ENGINE REMOVAL LEADS, CABLES, HOSES, AND IGNITION COIL Apply sealant 10 Nm (1.0 m kg, 7.2 ft • • Yamaha bond No. 1215 90890-85505 ∗ 7 Nm (0.7 m kg, 5.1 ft • • 16 Nm (1.6 m kg, 11 ft •...
  • Page 242 ENGINE REMOVAL Apply sealant 10 Nm (1.0 m kg, 7.2 ft • • Yamaha bond No. 1215 90890-85505 ∗ 7 Nm (0.7 m kg, 5.1 ft • • 16 Nm (1.6 m kg, 11 ft • • Order Job/Part Q’ty...
  • Page 243 ENGINE REMOVAL Apply sealant 10 Nm (1.0 m kg, 7.2 ft • • Yamaha bond No. 1215 90890-85505 ∗ 7 Nm (0.7 m kg, 5.1 ft • • 16 Nm (1.6 m kg, 11 ft • • Order Job/Part Q’ty...
  • Page 244: Engine

    ENGINE REMOVAL EAS00191 ENGINE 73 Nm (7.3 m kg, 53 ft • • 55 Nm (5.5m kg, 40 ft • • 73 Nm (7.3 m kg, 53 ft • • 73 Nm (7.3 m kg, 53 ft • • Order Job/Part Q’ty Remarks...
  • Page 245 ENGINE REMOVAL 73 Nm (7.3 m kg, 53 ft • • 55 Nm (5.5m kg, 40 ft • • 73 Nm (7.3 m kg, 53 ft • • 73 Nm (7.3 m kg, 53 ft • • Order Job/Part Q’ty Remarks Engine upper bracket (right) Engine upper bracket (left)
  • Page 246: Installing The Engine

    ENGINE REMOVAL EAS00192 INSTALLING THE ENGINE 1. Install: • engine front bracket 1 • engine front bracket bolt/nut 2 • engine front mounting bolt/nut 3 • engine rear mounting bolt/nut 4 • engine front bracket bolt/nut 5 • engine front mounting bolt/nut 6 •...
  • Page 247: Cylinder Head

    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 • • 20 Nm (2.0 m kg, 14 ft • •...
  • Page 248 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 • • 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 249: Removing The Cylinder Head

    CYLINDER HEAD EAS00225 REMOVING THE CYLINDER HEAD 1. Align: • “I” mark a on the A.C. magneto rotor (with the stationary pointer b on the A.C. magneto cover) M MMM M MMM M MMM M MMM M MMM a. Turn the crankshaft counterclockwise. b.
  • Page 250: Checking The Cylinder Head

    CYLINDER HEAD EAS00229 CHECKING THE CYLINDER HEAD 1. Eliminate: • combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damag- ing or scratching: • spark plug bore threads • valve seats 2. Check: •...
  • Page 251: Checking The Tappet Covers And Camshaft Sprocket Cover

    CYLINDER HEAD EAS00212 CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER 1. Check: • tappet covers 1 • camshaft sprocket cover 2 • O-rings 3 Damage/wear → Replace the defective part(s). EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • timing chain tensioner Cracks/damage →...
  • Page 252 CYLINDER HEAD 2. Install: • cylinder head • washers • cylinder head bolts NOTE: • Lubricate the cylinder head bolt threads and muting surface with engine oil. • Install the washers with their blunt surface facing the bolt seat. 3. Tighten: •...
  • Page 253 CYLINDER HEAD c. Install the timing chain 1 onto the camshaft sprocket 2, then the camshaft sprocket onto the camshaft, and then finger tighten the camshaft sprocket bolts. NOTE: To install the camshaft sprocket sprocket, install the projection 3 on the camshaft sprocket into the slot a in the decompression lever.
  • Page 254 CYLINDER HEAD d. Install the spring and timing chain tensioner cap bolt. Timing chain tensioner cap bolt 20 Nm (2.0 m · kg, 14 ft · lb) L LLL L LLL L LLL L LLL L LLL 6. Turn: • crankshaft (several turns counterclockwise) 7.
  • Page 255: Rocker Arms And Camshaft

    ROCKER ARMS AND CAMSHAFT ROCKER ARMS AND CAMSHAFT 14 Nm (1.4 m kg, 10 ft • • 14 Nm (1.4 m kg, 10 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the rocker arms and cam- Remove the parts in the order listed.
  • Page 256 ROCKER ARMS AND CAMSHAFT 14 Nm (1.4 m kg, 10 ft • • 14 Nm (1.4 m kg, 10 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Decompressor lever pin Refer to “REMOVING THE ROCKER ARMS AND CAMSHAFT”...
  • Page 257: Removing The Rocker Arms And Camshaft

    ROCKER ARMS AND CAMSHAFT EAS00202 REMOVING THE ROCKER ARMS AND CAMSHAFT 1. Loosen: • locknuts • adjusting screws 2. Remove: • camshaft retainer 1 3. Remove: • intake rocker arm shaft • exhaust rocker arm shaft • intake rocker arm •...
  • Page 258: Checking The Decompression System

    ROCKER ARMS AND CAMSHAFT 2. Measure: • camshaft lobe dimensions a and b Out of specification → Replace the cam- shaft. Camshaft lobe dimensions Intake a 43.488 ~ 43.588 mm (1.7121 ~ 1.7161 in) <Limit>: 43.388 mm (1.7062 in) b 36.959 ~ 37.059 mm (1.4551 ~ 1.4590 in) <Limit>: 36.840 mm (1.4504 in)
  • Page 259: Checking The Rocker Arms And Rocker Arm Shafts

    ROCKER ARMS AND CAMSHAFT EAS00206 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedure applies to both of the rocker arms and rocker arm shafts. 1. Check: • rocker arm Damage/wear → Replace. 2. Check: • rocker arm shaft Blue discoloration/excessive wear/pitting/ scratches →...
  • Page 260: Installing The Camshaft And Rocker Arms

    ROCKER ARMS AND CAMSHAFT 5. Calculate: • rocker-arm-to-rocker-arm-shaft clearance NOTE: Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter. Above 0.081 mm (0.0032 in) → Replace the defective part(s). Rocker-arm-to-rocker-arm-shaft clearance 0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in) <Limit>: 0.081 mm (0.0032 in) EAS00220...
  • Page 261 ROCKER ARMS AND CAMSHAFT 3. Install: • decompressor lever pin 1 • decompressor lever 2 NOTE: Install the decompressor lever pin 1 and decompressor lever 2 in the camshaft 3 as shown in the illustration. 4. Install: • camshaft 1 NOTE: Install the camshaft on the slot a facing up.
  • Page 262: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS00236 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valve Remove the parts in the order listed. springs Cylinder head Refer to “CYLINDER HEAD”. Rocker arms/rocker arm shafts/cam- Refer to “ROCKER ARMS AND CAM- shaft SHAFT”.
  • Page 263: Removing The Valves

    VALVES AND VALVE SPRINGS EAS00237 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.
  • Page 264: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS 3. Remove: • valve spring retainer 1 • valve spring 2 • valve stem seal 3 • valve spring seat 4 • valve 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. EAS00239 CHECKING THE VALVES AND VALVE GUIDES...
  • Page 265 VALVES AND VALVE SPRINGS 2. Replace: • valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °C (212 °F) in an oven. M MMM M MMM M MMM M MMM M MMM a.
  • Page 266: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 6. Measure: • valve stem runout Out of specification → Replace the valve. NOTE: • When installing a new valve, always replace the valve guide. • If the valve is removed or replaced, always replace the valve stem seal. Valve stem runout 0.010 mm (0.0004 in) EAS00240...
  • Page 267 VALVES AND VALVE SPRINGS 4. Lap: • valve face • valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. M MMM M MMM M MMM M MMM M MMM a.
  • Page 268: Checking The Valve Springs

    VALVES AND VALVE SPRINGS EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: • valve spring free length a Out of specification → Replace the valve spring. Valve spring free length Intake 40.38 mm (1.59 in) <Limit>: 38.36 mm (1.51 in) Exhaust...
  • Page 269 VALVES AND VALVE SPRINGS EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: • valve stem end (with an oil stone) 2. Lubricate: • valve stem 1 • valve stem seal 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil...
  • Page 270 VALVES AND VALVE SPRINGS 4. Install: • valve cotters NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attach- ment 2. Valve spring compressor 98090-04019 Valve spring compressor attach- ment 90890-01243 5.
  • Page 271: Cylinder And Piston

    CYLINDER AND PISTON EAS00251 CYLINDER AND PISTON 1st 15 Nm (1.5 m kg, 11 ft • • 2nd 50 Nm (5.0 m kg, 36 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 272 CYLINDER AND PISTON 1st 15 Nm (1.5 m kg, 11 ft • • 2nd 50 Nm (5.0 m kg, 36 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • •...