Yamaha XT660R 2007 Supplementary Service Manual
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Yamaha XT660R 2007 Supplementary Service Manual

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2007
XT660R(W)
XT660X(W)
SUPPLEMENTARY
SERVICE MANUAL
5VK-F8197-E2

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Summary of Contents for Yamaha XT660R 2007

  • Page 1 2007 XT660R(W) XT660X(W) SUPPLEMENTARY SERVICE MANUAL 5VK-F8197-E2...
  • Page 2 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the XT660R(W)/XT660X(W) 2007. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. XT660R(S)/XT660X(S) 2004 SERVICE MANUAL: 5VK1-AE1 XT660R(W)/XT660X(W) 2007 SUPPLEMENTARY SERVICE MANUAL...

  • Page 3: Important Manual Information

    EAS00002 NOTICE This manual was produced by MBK Industrie primarily for use by Yamaha dealers and their quali- fied mechanics. It is not possible to include all the knowledge of a mechanic in one manual. There- fore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.

  • Page 4: How To Use This Manual

    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 5 EAS00008 SYMBOLS The following symbols are not relevant to SPEC every vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information CHAS 2 Specifications 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system 7 Fuel injection system COOL 8 Electrical system...

  • Page 6: Table Of Contents

    CONTENTS SPECIFICATIONS ....................1 GENERAL SPECIFICATIONS ..............1 ENGINE SPECIFICATIONS................. 2 CHASSIS SPECIFICATIONS............... 6 ELECTRICAL SPECIFICATIONS ..............8 TIGHTENING TORQUE ................8 ENGINE TIGHTENING TORQUES ............8 CHASSIS TIGHTENING TORQUES ............. 8 CABLE ROUTING ..................9 PERIODIC CHECKS AND ADJUSTMENTS............ 22 COWLING AND COVER ................

  • Page 7: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code XT660R: 5VK8 (Europe) ---- 5VK9 (AUS) ---- XT660X: 10S1 (Europe) ---- 10S2 (AUS) ---- Dimensions Overall length 2,240 mm (88.2 in) (XT660R) ---- 2,175 mm (85.6 in) (XT660X) ---- Overall width 845 mm (33.3 in) (XT660R) ----...

  • Page 8: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid-cooled, 4-stroke, SOHC ---- Displacement 660 cm ---- Cylinder arrangement Forward-inclined single cylinder ---- Bore × stroke 100.0 × 84.0 mm (3.94 × 3.31 in) ---- Compression ratio 10.00 : 1 ---- Engine idling speed 1,400 ~ 1,500 r/min...
  • Page 9 SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshaft Drive system Chain drive (left) ---- Intake camshaft lobe dimensions Measurement A 43.488 ~ 43.588 mm (1.7121 ~ 1.7161 in) 43.388 mm (1.7082 in) Measurement B 36.959 ~ 37.059 mm (1.4551 ~ 1.4590 in) 36.859 mm (1.4511 in) Exhaust camshaft lobe dimensions Measurement A...
  • Page 10 SPEC ENGINE SPECIFICATIONS Item Standard Limit Piston Piston-to-cylinder clearance 0.030 ~ 0.055 mm (0.0012 ~ 0.0022 in) 0.13 mm (0.0051 in) Diameter D 99.955 ~ 99.970 mm (3.9352 ~ 3.9358 in) ---- Height H 10.0 mm (0.39 in) ---- Piston pin bore (in the piston) Diameter 23.004 ~ 23.015 mm (0.9057 ~ 0.9061 in) 23.045 mm (0.9073 in)
  • Page 11 SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil ring Dimensions (B × T) 2.50 × 3.40 mm (0.098 × 0.134 in) ---- End gap (installed) 0.20 ~ 0.70 mm (0.0079 ~ 0.0276 in) ---- Ring side clearance 0.060 ~ 0.150 mm (0.0024 ~ 0.0059 in) ---- Throttle body Model/manufacturer ×...

  • Page 12: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Rear wheel Wheel type Spoke wheel ---- 17M/C × MT2.75 (XT660R) Size ---- 17M/C × MT4.25 (XT660X) ---- Material Aluminum ---- Wheel travel 200.0 mm (7.87 in) (XT660R) ---- 191.0 mm (7.52 in) (XT660X) ---- Wheel runout Maximum radial wheel runout...
  • Page 13 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear tire Tire type With tube ---- Size 130/80-17M/C 65S, 130/80-17M/C 65T ---- (XT660R) 160/60R 17M/C 69H, 160/60ZR 17M/C ---- 69W, 160/60ZR 17M/C 69W (XT660X) Model/manufacturer TOURANCE/METZELER, SIRAC A/ ---- MICHELIN (XT660R) DRAGON/PIRELLI, SPORTEC M1/ ---- METZELER, RADIAL PILOT SPORT/ MICHELIN (XT660X)

  • Page 14: Electrical Specifications

    ELECTRICAL SPECIFICATIONS/ SPEC TIGHTENING TORQUE ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V ---- Ignition system Ignition system type Transistorized coil ignition (digital) ---- Ignition timing 5.0° BTDC at 1,450 r/min ---- Advancer type Electric ---- 192 ~ 288 Ω at 20 °C (68 °F) Crankshaft position senor resistance/ ---- color...

  • Page 15: Cable Routing

    SPEC CABLE ROUTING EAS00035 CABLE ROUTING È Fasten the sub-wire harness and meter assem- 1 Front turn signal light lead (right) 2 Meter assembly lead bly lead with a plastic band. Fasten the sub-wire 3 Auxiliary light lead harness at the white tape. Face the end of the 4 Front turn signal light lead (left) plastic band forward.
  • Page 16 SPEC CABLE ROUTING Ê Place the slack of the left and right front turn sig- Í Only the left side is shown in this illustration. nal light leads between the headlight assembly Route the right front turn signal light lead in the and front cowling assembly.
  • Page 17 SPEC CABLE ROUTING È Fasten the wire harness and negative battery 1 Rear brake light switch lead 2 Negative battery lead lead to the frame with a plastic locking tie. É Fasten the wire harness, negative battery lead, 3 Lean angle cut-off switch lead 4 Throttle position sensor lead and rear brake light switch lead to the frame with 5 Coolant temperature sensor lead...
  • Page 18 SPEC CABLE ROUTING Ì Route the negative battery lead behind the lean angle cut-off switch bracket. Í Route the rear brake light switch lead between the air filter case and the frame. È É Ê Ë Í Ì Ê – 12 –...
  • Page 19 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 sensor lead 4 Speed sensor lead...
  • Page 20 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 21 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 22 SPEC CABLE ROUTING Ò Fasten the wire harness, air-filter-to-air-cut-off- Turn the handlebar completely to the right, and valve hose, and oil delivery hose 2 with a plastic then fasten the left handlebar switch lead, right clamp. handlebar switch lead, headlight lead, meter Ó...
  • Page 23 SPEC CABLE ROUTING È 0 ~ 10 mm (0 ~ 0.39 in) 1 Immobilizer unit coupler É 30 ~ 40 mm (1.18 ~ 1.57 in) 2 Intake air temperature sensor Ê 5 ~ 15 mm (0.20 ~ 0.59 in) 3 Fuel injector lead Ë...
  • Page 24 SPEC CABLE ROUTING È Fasten the tail/brake light lead with two plastic 1 Battery 2 Negative battery lead locking ties so that the coupler is positioned to 3 Tail/brake light coupler the inside of where the relays (turn signal/hazard 4 Rear turn signal light connector relay, headlight relay, radiator fan motor relay, 5 Seat lock cable and relay unit) branch off from the wire harness.
  • Page 25 SPEC CABLE ROUTING Ê Fasten the wire harness with plastic locking ties, Í Fasten the wire harness to the frame with a plas- making sure to install the ties around the taped tic locking tie. Î 0 ~ 5 mm (0 ~ 0.20 in) sections of the harness.
  • Page 26 SPEC CABLE ROUTING È When installing the brake hose onto the brake XT660R master cylinder, make sure that the brake pipe 1 Brake fluid reservoir touches the brake master cylinder as shown. 2 Brake fluid reservoir hose É Fasten the rear brake hose with the brake hose 3 Rear brake light switch holder.
  • Page 27 SPEC CABLE ROUTING È When installing the brake hose onto the brake XT660X master cylinder, make sure that the brake pipe 1 Brake fluid reservoir touches the brake master cylinder as shown. 2 Brake fluid reservoir hose É Fasten the rear brake hose with the brake hose 3 Rear brake light switch holder.

  • Page 28: Periodic Checks And Adjustments

    COWLING AND COVER PERIODIC CHECKS AND ADJUSTMENTS COWLING AND COVER COVER 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the cover (XT660X)

  • Page 29: 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 (XT660X) Remove the parts in the order listed. Seat/side panels (left and right) Refer to “COWLING AND COVER”.

  • Page 30: Fuel Tank

    FUEL TANK EAS00040 FUEL TANK 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the fuel tank (XT660X) Remove the parts in the order listed. Seat/side panels (left and right) Refer to “COWLING AND COVER”. Fuel Drain.
  • Page 31 FUEL TANK 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Damper 2 For installation, reverse the removal pro- cedure. – 25 –...

  • Page 32: Chassis

    ADJUSTING THE DRIVE CHAIN SLACK EAS00140 CHASSIS ADJUSTING THE DRIVE CHAIN SLACK NOTE: The drive chain slack must be checked at the tightest point on the chain. CAUTION: A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident.
  • Page 33 ADJUSTING THE DRIVE CHAIN SLACK È 4. Adjust: • drive chain slack M MMM M MMM M MMM M MMM M MMM a. Loosen the wheel axle nut 1. b. Loosen both locknuts 2. c. Turn both adjusting nuts 3 or both adjust- ing bolt 4 in direction a or b until the specified drive chain slack is obtained.

  • Page 34: Checking The Tires

    CHECKING THE TIRES EAS00166 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: • tire pressure Out of specification → Regulate. WARNING • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature.
  • Page 35 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 36 Tube or tubeless Tubeless wheel tire • After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design.
  • Page 37 CHECKING THE TIRES Rear tire (XT660X) Manufacturer Model Size 160/60R PIRELLI DRAGON 17M/C 69H SPORTEC 160/60ZR METZELER 17M/C 69W RADIAL 160/60ZR MICHELIN PILOT 17M/C 69W SPORT WARNING New tires have a relatively low grip on the road surface until they have been slightly worn.

  • Page 38: Chassis

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET CHASSIS REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET REAR WHEEL 105 Nm (10.5 m kg, 75 ft • • 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 39 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET 105 Nm (10.5 m kg, 75 ft • • 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Chain puller (left) Refer to “INSTALLING THE REAR WHEEL (XT660X)”.

  • Page 40: Removing The Rear Wheel (Xt660R)

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET EAS00561 REMOVING THE REAR WHEEL (XT660R) 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.

  • Page 41: Removing The Rear Wheel (Xt660X)

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET EAS00561 REMOVING THE REAR WHEEL (XT660X) 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.

  • Page 42: Installing The Rear Wheel (Xt660X)

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET 2. Install: • rear wheel • washer (O) • wheel axle • washer (N) • wheel axle nut NOTE: Install the washer with the “N” mark on the right-hand side of the vehicle and the washer with the “O”...
  • Page 43 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET 2. Install: • chain puller (left) 1 • chain puller (right) 2 • rear wheel • washer • wheel axle • wheel axle nut NOTE: Install the chain puller with the mark a on the left side of the swingarm.

  • Page 44: Swingarm And Drive Chain

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET EAS00700 SWINGARM AND DRIVE CHAIN 10 Nm (1.0 m kg, 7.2 ft 59 Nm (5.9 m kg, 43 ft • • • • 23 Nm (2.3 m kg, 17 ft • •...
  • Page 45 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET 10 Nm (1.0 m kg, 7.2 ft 59 Nm (5.9 m kg, 43 ft • • • • 23 Nm (2.3 m kg, 17 ft • • 120 Nm (12.0 m kg, 85 ft •...

  • Page 46: Drive Chain

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET 10 Nm (1.0 m kg, 7.2 ft 59 Nm (5.9 m kg, 43 ft • • • • 23 Nm (2.3 m kg, 17 ft • • 120 Nm (12.0 m kg, 85 ft •...

  • Page 47: Engine

    ENGINE REMOVAL EAS00188 ENGINE ENGINE REMOVAL EXHAUST PIPES AND MUFFLERS 27 Nm (2.7 m kg, 19 ft • • 45 Nm (4.5 m kg, 32 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 27 Nm (2.7 m kg, 19 ft •...

  • Page 48: 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 49 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 50: Cylinder And Piston

    CYLINDER AND PISTON EAS00251 CYLINDER AND PISTON 1st 15Nm (1.5 m kg, 11 ft • • 2nd 50Nm (5.0m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 51 CYLINDER AND PISTON 1st 15Nm (1.5 m kg, 11 ft • • 2nd 50Nm (5.0m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks 2nd ring...

  • Page 52: Cooling System

    COOL RADIATOR EAS00454 COOLING SYSTEM RADIATOR 7 Nm (0.7 m kg, 5.1 ft • • 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Part Q’ty Remarks Removing the radiator (XT660X) Remove the parts in the order listed. Seat/side panels (left and right) Refer to “COWLING AND COVER”.
  • Page 53 COOL RADIATOR 7 Nm (0.7 m kg, 5.1 ft • • 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Part Q’ty Remarks Radiator outlet hose Refer to “INSTALLING THE RADIATOR” in chapter 6. (Manual No.: 5VK1-AE1) Radiator inlet hose Radiator fan motor coupler Disconnect.

  • Page 54: Fuel Injection System

    FUEL INJECTION SYSTEM EAS00894 FUEL INJECTION SYSTEM EAS00895 FUEL INJECTION SYSTEM 1 Air cut-off valve 9 Intake air temperature sensor H Coolant temperature sensor 2 Air induction system solenoid 0 Air filter case I Spark plug 3 Engine trouble warning light A Fuel injection system relay sensor 4 Fuel tank...

  • Page 55: Wiring Diagram

    FUEL INJECTION SYSTEM EAS00898 WIRING DIAGRAM 1 Crankshaft position sensor 3 Neutral switch 4 Main switch 6 Battery 7 Main fuse 0 Fuel injection system fuse D Engine stop switch G Relay unit I Fuel injection system relay J Sidestand switch K Fuel pump L ECU M Ignition coil...

  • Page 56: Fail-Safe Action Table

    FUEL INJECTION SYSTEM FAIL-SAFE ACTION TABLE Self-diagnostic function Fault Item Symptom Fail-safe action Startability Driveability code No. Crankshaft position No normal signals are — sensor received from the sensor. Intake air pressure Open or short circuit is • Fixes the intake air pres- sensor (open or short detected.
  • Page 57 FUEL INJECTION SYSTEM Fault Item Symptom Fail-safe action Startability Driveability code No. Vehicle system power Power supply to the fuel injec- supply (monitor volt- tion system relay is not nor- — age) mal. ECU internal malfunc- Faulty ECU memory. When tion (memory check this malfunction is detected, —...

  • Page 58: Diagnostic Mode

    FUEL INJECTION SYSTEM EAS00905 DIAGNOSTIC MODE Setting the diagnostic mode 1. Set the main switch to “OFF” and set the engine stop switch to “ ”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press hold “SELECT”...
  • Page 59 FUEL INJECTION SYSTEM 8. Verify the operation of the sensor or actua- tor. • Sensor operation The data representing the operating condi- tions of the sensor appears on the odome- ter/fuel reserve tripmeter/tripmeter 2 LCD. • Actuator operation Set the engine stop switch to “ ”...
  • Page 60 FUEL INJECTION SYSTEM EAS00906 Diagnostic monitoring code table Fault Symptom Probable cause of malfunction Diagnostic code code No. No normal signals are received from • Open or short circuit in wire harness the crankshaft position sensor. • Defective crankshaft position sensor •...
  • Page 61 FUEL INJECTION SYSTEM Fault Symptom Probable cause of malfunction Diagnostic code code No. Open or short circuit is detected in the • Open or short circuit in wire harness lean angle cut-off switch. • Defective lean angle cut-off switch • Disconnected lean angle cut-off switch coupler •...
  • Page 62 FUEL INJECTION SYSTEM EAS00907 Diagnostic mode table Switch the meter display from the regular mode to the diagnostic mode. To switch the display, refer to “DIAGNOSTIC MODE”. NOTE: • Check the intake air temperature and coolant temperature as close as possible to the intake air temperature sensor and the coolant temperature sensor respectively.
  • Page 63 FUEL INJECTION SYSTEM Diagnostic Data displayed on meter Item Action code (reference value) Radiator fan motor relay The engine stop switch is set to “ “, the radiator Check that the operating sound of the fan motor relay operates 5 times, 5 seconds each radiator fan motor relay is generated time (2 seconds on, 3 seconds off), and the engine and that the radiator fan motor is...

  • Page 64: Troubleshooting Details

    FUEL INJECTION SYSTEM EAS00908 TROUBLESHOOTING DETAILS This section describes the countermeasures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order in the “TROUBLESHOOTING CHART” in chapter 7. (Manual No.: 5VK1-AE1) After the checking and servicing the malfunctioning part, reset the meter display.
  • Page 65 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit is detected from the intake air pressure sensor. Used diagnostic code No. 03 (intake air pressure sensor) Order Item/components Check or maintenance job Restore method Coupler connections Check the couplers for any pins that may have Reinstated by crank- Intake air pressure sensor coupler pulled out.
  • Page 66 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor hose is disconnected or clogged. Used diagnostic code No. 03 (intake air pressure sensor) Order Item/components Check or maintenance job Restore method Disconnected, clogged, kinked, or Repair or replace the hose. Reinstated by start- pinched intake air pressure sensor ing the engine and...
  • Page 67 FUEL INJECTION SYSTEM Fault code No. Symptom The throttle position sensor is detected stuck. Used diagnostic code No. 01 (throttle position sensor) Order Item/components Check or maintenance job Restore method Defective throttle position sensor Replace the sensor if it is defective. Reinstated by start- Refer to “THROTTLE BODY ASSEMBLY”...
  • Page 68 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit is detected from the intake air temperature sensor. Used diagnostic code No. 05 (intake air temperature sensor) Order Item/components Check or maintenance job Restore method Intake air temperature sensor Check the sensor looseness or pinching.
  • Page 69 FUEL INJECTION SYSTEM Fault code No. Symptom No normal signal is received from the O sensor. Used diagnostic code No. – – Order Item/components Check or maintenance job Restore method Installed state of O sensor. Check for looseness or pinching. Starting the engine and operating it at Connections...
  • Page 70 FUEL INJECTION SYSTEM Fault code No. Symptom The amount of air-fuel ratio feedback compensation is maintained continuously in the vicinity of the upper limit. Used diagnostic code No. – – Order Item/components Check or maintenance job Restore method Installed state of O sensor.
  • Page 71 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary lead of the ignition coil. Used diagnostic code No. 30 (ignition coil) Order Item/components Check or maintenance job Restore method Coupler and connector connections Check the coupler and connector for any pins Reinstated by start- Ignition coil primary connector that may have pulled out.
  • Page 72 FUEL INJECTION SYSTEM Fault code No. Symptom A. No normal signals are received from the speed sensor. B. Open or short circuit is detected in the neutral switch. Used diagnostic code No. 07 (speed sensor) → A1 ~ A4 / No. 21 (neutral switch) → B1 ~ B4 Order Item/components Check or maintenance job...
  • Page 73 FUEL INJECTION SYSTEM Fault code No. Symptom A. No normal signals are received from the speed sensor. B. Open or short circuit is detected in the neutral switch. Used diagnostic code No. 07 (speed sensor) → A1 ~ A4 / No. 21 (neutral switch) → B1 ~ B4 Order Item/components Check or maintenance job...
  • Page 74 FUEL INJECTION SYSTEM Fault code No. Symptom The ECU is unable to monitor the battery voltage. Used diagnostic code No. 09, 50 (fuel system voltage) Order Item/components Check or maintenance job Restore method Coupler connections Check the couplers for any pins that may have Reinstated by start- Fuel injection system relay cou- pulled out.
  • Page 75 FUEL INJECTION SYSTEM Fault code No. Symptom Error is detected while reading or writing on EEPROM (CO adjustment value). Used diagnostic code No. 60 (EEPROM improper cylinder indication) Order Item/components Check or maintenance job Restore method Malfunction in ECU Execute the diagnostic mode. (Code No. 60) Reinstated by set- •...
  • Page 76 FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signals are received from the ECU. Used diagnostic code No. – – Order Item/components Check or maintenance job Restore method Coupler connections Check the couplers for any pins that may have Reinstated automati- ECU coupler pulled out.

  • Page 77: Electrical System

    – ELEC ELECTRICAL COMPONENTS EAS00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 1 Spark plug 8 Main switch E Lean angle cut-off switch 2 Spark plug cap 9 Fuel pump F Turn signal/hazard relay 3 Ignition coil 0 Clutch switch G Headlight relay 4 Intake air pressure sensor A Left handlebar switch H Radiator fan motor relay...
  • Page 78 – ELEC ELECTRICAL COMPONENTS L Fuse box 2 W Speed sensor M Starter relay X Starter motor N Main fuse Y Radiator fan motor O Rectifier/regulator Z Horn P ECU [ Air induction system solenoid Q Intake air temperature sensor sensor R Sidestand switch S Neutral switch...
  • Page 79 XT660R(W)/XT660X(W) 2007 WIRING DIAGRAM 1 Crankshaft position sensor m Rear turn signal light (left) COLOR CODE 2 A.C. magneto n Front turn signal light (left) B ....Black 3 Neutral switch o Front turn signal light (right) Br ...Brown 4 Main switch p Rear turn signal light (right) Ch ..Chocolate 5 Rectifier/regulator...

  • Page 81: Xt660R(W)/Xt660X(W) 2007 Wiring Diagram

    XT660R(W)/XT660X(W) 2007 XT660R(W)/XT660X(W) 2007 XT660R(W)/XT660X(W) 2007 XT660R(W)/XT660X(W) 2007 XT660R(W)/XT660X(W) 2007 WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO Ch Lg MAIN HARNESS SUB-WIRE HARNESS Gy G/W G/W L/Y Gy/G Br/R G/R Br/W B/L /R W W W Br/R Br/R (GRAY) Br L/W...

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