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Yamaha Manuals
Motorcycle
XT660R
Service manual
Yamaha XT660R Service Manual
Motorcycle xt660r; xt660s; xt660x; xt660s
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:
Service manual
(463 pages)
,
Owner's manual
(92 pages)
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
How to Use this Manual
Chassis
Engine
Cooling System
Fuel Injection System
General Information
Periodic Checks and Adjustments
Specifications
Troubleshooting
Electrical System
Table of Contents
Gen Info
Chapter 1 General Information
Motorcycle Identification
Vehicle Identification Number
Model Label
Features
Outline
Fi System
Important Information
Preparation for Removal and Disassembly
Replacement Parts
Gaskets, Oil Seals and O-Rings
Lock Washers/Plates and Cotter Pins
Bearings and Oil Seals
Circlips
Checking the Connections
Special Tools
Spec
Chapter 2 Specifications
General Specifications
Engine Specifications
Chassis Specifications
Electrical Specifications
Conversion Table
General Tightening Torque Specifications
Tightening Torque
Engine Tightening Torque
Chassis Tightening Torques
Lubrication Points and Lubricant Types
Engine
Chassis
Cooling System Diagrams
Lubrication Chart
Lubrication Diagrams
Cable Routing
Cable Routing
Chapter 3 Periodic Checks and Adjustments
Introduction
Periodic Maintenance and Lubrication Chart
Brake Fluid
Cowling and Cover
Cover
Cowling
Fuel Tank
Removing the Fuel Tank
Removing the Fuel Pump
Installing the Fuel Pump
Installing the Fuel Hose
Air Filter Case
Rear Mud Guard and Rear Fender
Installing the Air Filter Case Joint Clamp
Engine
Adjusting the Valve Clearance
Adjusting the Exhaust Gas Volume
Adjusting the Engine Idling Speed
Adjusting the Throttle Cable Free Play
Checking the Spark Plug
Checking the Ignition Timing
Measuring the Compression Pressure
Measuring the Compression Pressure
Checking the Engine Oil Level
Changing the Engine Oil
Adjusting the Clutch Cable Free Play
Checking the Air Filter Element
Checking the Throttle Body Joint
Checking the Fuel Hose
Checking the Breather Hose
Checking the Exhaust System
Checking the Coolant Level
Checking the Cooling System
Changing the Coolant
Chassis
Adjusting the Rear Brake Pedal
Checking the Brake Fluid Level
Checking the Front and Rear Brake Pads and Brake Pad Pins
Adjusting the Rear Brake Light Switch
Checking the Front and Rear Brake Hoses
Bleeding the Hydraulic Brake System
Adjusting the Shift Pedal
Adjusting the Drive Chain Slack
Lubricating the Drive Chain
Checking and Adjusting the Steering Head
Checking the Front Fork
Adjusting the Rear Shock Absorber Assembly
Checking the Tires
Checking and Tightening the Spokes
Checking and Lubricating the Cables
Lubricating the Levers and Brake Pedal
Lubricating the Sidestand
Chk Adj
Electrical System
Checking and Charging the Battery
Checking the Fuses
Replacing the Headlight Bulb
Adjusting the Headlight Beam
Setting the Digital Clock
Chas
Chapter 4 Chassis
Front Wheel and Brake Disc
Front Wheel
Checking the Front Wheel
Removing the Front Wheel
Checking the Front Brake Disc
Installing the Front Wheel
Adjusting the Front Wheel Static Balance
Rear Wheel, Brake Disc, and Rear Wheel Sprocket
Rear Wheel
Brake Disc and Rear Wheel Sprocket
Removing the Rear Wheel
Checking the Rear Wheel
Checking the Rear Brake Disc
Checking the Rear Wheel Drive Hub
Checking and Replacing the Rear Wheel Sprocket
Installing the Rear Wheel
Adjusting the Rear Wheel Static Balance
Front and Rear Brakes
Front Brake Pads (Xt660R)
Front Brake Pads (Xt660X)
Rear Brake Pads
Replacing the Front Brake Pads
Replacing the Rear Brake Pads
Front Brake Master Cylinder
Rear Brake Master Cylinder
Disassembling the Front Brake Master Cylinder
Disassembling the Rear Brake Master Cylinder
Checking the Front and Rear Brake Master Cylinders
Assembling and Installing the Front Brake Master Cylinder
Assembling the Rear Brake Master Cylinder
Installing the Rear Brake Master Cylinder
Front Brake Caliper (Xt660R)
Front Brake Caliper (Xt660X)
Rear Brake Caliper
Removing the Front Brake Caliper
Removing the Rear Brake Caliper
Checking the Front and Rear Brake Calipers
Installing the Front Brake Caliper
Installing the Rear Brake Caliper
Front Fork
Removing the Front Fork Legs
Disassembling the Front Fork Legs
Checking the Front Fork Legs
Assembling the Front Fork Legs
Installing the Front Fork Legs
Handlebar
Removing the Handlebar
Checking the Handlebar
Installing the Handlebar
Steering Head
Lower Bracket
Removing the Lower Bracket
Checking the Steering Head
Installing the Steering Head
Rear Shock Absorber Assembly
Handling the Rear Shock Absorber
Disposing of a Rear Shock Absorber
Removing the Rear Shock Absorber Assembly
Checking the Rear Shock Absorber Assembly
Checking the Connecting Arms and Relay Arm
Installing the Relay Arm
Installing the Rear Shock Absorber Assembly
Swingarm and Drive Chain
Removing the Swingarm
Removing the Drive Sprocket
Removing the Drive Chain
Checking the Swingarm
Checking the Drive Chain
Installing the Swingarm
Eng
Chapter 5 Engine
Engine Removal
Exhaust Pipes and Mufflers
Leads, Cables, Hoses, and Ignition Coil
Engine
Installing the Engine
Cylinder Head
Removing the Cylinder Head
Checking the Cylinder Head
Checking the Tappet Covers and Camshaft Sprocket Cover
Checking the Timing Chain Tensioner
Checking the Camshaft Sprocket
Installing the Cylinder Head
Rocker Arms and Camshaft
Removing the Rocker Arms and Camshaft
Checking the Camshaft
Checking the Decompression System
Checking the Rocker Arms and Rocker Arm Shafts
Installing the Camshaft and Rocker Arms
Valves and Valve Springs
Removing the Valves
Checking the Valves and Valve Guides
Checking the Valve Seats
Checking the Valve Springs
Cylinder and Piston
Removing the Cylinder and Piston
Checking the Cylinder and Piston
Checking the Piston Rings
Checking the Piston Pin
Installing the Piston and Cylinder
Clutch Cover
Pull Lever Shaft
Clutch
Removing the Clutch
Checking the Friction Plates
Checking the Clutch Plates
Checking the Clutch Springs
Checking the Clutch Housing
Checking the Clutch Boss
Checking the Pressure Plate
Checking the Pull Lever Shaft and Pull Rod
Checking the Primary Driven Gear
Installing the Clutch
Oil Pump
Checking the Oil Pump
Checking the Oil Delivery Pipes and Hoses
Assembling the Oil Pump
Installing the Oil Pump
Balancer Driven Gear
Removing the Balancer Driven Gear and Balancer Drive Gear
Checking the Balancer Driven Gear, Water Pump Drive Gear, Primary Drive Gear, and Balancer Drive Gear
Installing the Balancer Driven Gear and Balancer Drive Gear
Shift Shaft
Shift Shaft and Stopper Lever
Checking the Shift Shaft
Checking the Stopper Lever
Installing the Shift Shaft
Starter Clutch and A.C. Magneto
Removing the A.C. Magneto Rotor
Checking the Stator Coil and Crankshaft Position Sensor
Checking the Starter Clutch
Checking the Torque Limiter
Installing the A.C. Magneto Rotor
Crankcase
Crankcase Bearings
Separating the Crankcase
Checking the Oil Strainer and Oil Delivery Pipe 3
Checking the Timing Chain and Timing Chain Guides
Checking the Bearings and Oil Seals
Checking the Crankcase
Assembling the Crankcase
Crankshaft
Crankshaft and Balancer
Removing the Crankshaft Assembly
Checking the Crankshaft
Installing the Crankshaft
Transmission
Main Axle
Drive Axle
Checking the Shift Forks
Checking the Shift Drum Assembly
Checking the Transmission
Assembling the Main Axle and Drive Axle
Installing the Transmission
Cool
6 Cool
Chapter 6 Cooling System
Radiator
Checking the Radiator
Installing the Radiator
Thermostat
Checking the Thermostat
Installing the Thermostat
Water Pump
Disassembling the Water Pump
Checking the Water Pump
Assembling the Water Pump
Installing the Water Pump
Chapter 7 Fuel Injection System
Wiring Diagram
Ecu Self-Diagnostic Function
Alternate Operation Control (Fail-Safe Action)
Fail-Safe Action Table
Communication Error with Meter
Troubleshooting Chart
Diagnostic Mode
Diagnostic Monitoring Code Table
Troubleshooting Details
Throttle Body Assembly
Checking the Fuel Injector
Checking the Throttle Body
Installing the Throttle Body Assembly
Checking the Fuel Pump
Checking and Adjusting the Throttle Position Sensor
Air Induction System
Air Injection
Air Cut-Off Valve
Air Induction System Diagrams
Air Cut-Off Valve Assembly
Checking the Air Induction System
Elec
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Quick Links
1
Checking the Engine Oil Level
Download this manual
See also:
Owner's Manual
2004
XT660R(S)
XT660X(S)
5VK1-AE1
SERVICE MANUAL
Table of
Contents
Previous
Page
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Page
1
2
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4
5
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Chapters
Table of Contents
7
Chapter 2 Specifications
25
Chapter 3 Periodic Checks and Adjustments
80
Chapter 4 Chassis
145
Chapter 5 Engine
236
6 Cool
325
Chapter 7 Fuel Injection System
342
Chapter 8 Electrical System
381
Trbl Shtg
450
Table of Contents
Troubleshooting
GENERAL INFORMATION
6
TROUBLESHOOTING CHART
349
TROUBLESHOOTING DETAILS
355
TROUBLESHOOTING
395
TROUBLESHOOTING
401
TROUBLESHOOTING
411
TROUBLESHOOTING
414
TROUBLESHOOTING
421
TROUBLESHOOTING
432
TROUBLESHOOTING
440
TROUBLESHOOTING
450
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This manual is also suitable for:
Xt660s
2004 xt660r(s)
2004 xt660x(s)
Xt660x
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