EAU26943 DECLARATION of CONFORMITY Company: MORIC CO., LTD. Address: 1450-6 Mori Mori-Machi Shuchi-gun Shizuoka 437-0292 Japan Hereby declare that the product: Kind of equipment: IMMOBILIZER Type-designation: 5SL-00 is in compliance with following norm(s) or documents: R&TTE Directive(1999/5/EC) EN300 330-2 v1.1.1(2001-6), EN60950-1(2001) Two or Three-Wheel Motor Vehicles Directive(97/24/EC: Chapter 8, EMC) Place of issue: Shizuoka, Japan Date of issue: 1 Aug.
Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your XT660R/XT660X. The owner’s manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself and others from trouble and injury.
This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual.
TABLE OF CONTENTS SAFETY INFORMATION ....1-1 OPERATION AND IMPORTANT Checking the front and rear brake RIDING POINTS......... 5-1 pads .......... 6-22 DESCRIPTION ........2-1 Starting the engine ......5-1 Checking the brake fluid level ..6-23 Left view ..........2-1 Shifting ........... 5-2 Drive chain slack ......
TABLE OF CONTENTS MOTORCYCLE CARE AND STORAGE ..........7-1 Care ..........7-1 Storage ...........7-3 SPECIFICATIONS ......8-1 CONSUMER INFORMATION.....9-1 Identification numbers ....9-1...
SAFETY INFORMATION EAU10311 AND/OR WHEN MADE NECES- • Ride where other motorists can SARY BY MECHANICAL CONDI- see you. Avoid riding in another MOTORCYCLES SINGLE TIONS. motorist’s blind spot. TRACK VEHICLES. THEIR SAFE USE Many accidents involve inexperi- AND OPERATION ARE DEPENDENT Safe riding enced operators.
Modifications made to this motorcycle gle for the speed). cycle accidents are the result of head not approved by Yamaha, or the re- • Always obey the speed limit and injuries. The use of a safety helmet is moval of original equipment, may ren-...
SAFETY INFORMATION When loading within this weight limit, stallation and use of non-Yamaha namic effects. Wind may at- keep the following in mind: accessories. Use extreme caution tempt to lift the motorcycle, or Cargo accessory weight when selecting and installing any ac-...
SAFETY INFORMATION • Take care not to spill any gaso- • Do not park the motorcycle near line on the engine or exhaust a flammable source (e.g., a ker- system when refueling. osene heater, or near an open • Never refuel while smoking or in flame), otherwise it could catch the vicinity of an open flame.
INSTRUMENT AND CONTROL FUNCTIONS EAU10471 EAU10570 To lock the steering Main switch/steering lock All electrical circuits are supplied with power; the meter lighting, taillight and auxiliary light come on, and the engine can be started. The key cannot be re- moved.
INSTRUMENT AND CONTROL FUNCTIONS To unlock the steering EAU33001 EAU11003 (Parking) Indicator and warning lights The steering is locked, and the taillight and auxiliary light are on. The hazard lights and turn signal lights can be turned on, but all other electrical sys- tems are off.
If the indicator light does not come on for a few seconds, and then go off, Yamaha dealer check the electrical cir- for a few seconds, then go off, have a have a Yamaha dealer check the elec- cuit. Yamaha dealer check the electrical cir- trical circuit.
INSTRUMENT AND CONTROL FUNCTIONS This model is also equipped with a self- EAUM1662 a fuel reserve tripmeter (which Multi-function display diagnosis device for the immobilizer shows the distance traveled since system. (See page 3-5 for an explana- the fuel level warning light came tion of the self-diagnosis device.) a clock a self-diagnosis device...
Clock mode such an error code, note the code num- lizer keys close to the main switch, and ber, and then have a Yamaha dealer Turn the key to “ON”. do not keep more than one immobilizer check the vehicle.
Yamaha If the multi-function display indicates dealer. Contact a Yamaha dealer for any error codes, note the code number, more information. and then have a Yamaha dealer check the vehicle. 1. Pass switch “ ” 2. Dimmer switch “...
INSTRUMENT AND CONTROL FUNCTIONS Right position. To cancel the turn signal EAU12733 Hazard switch “ ” lights, push the switch in after it has re- With the key in the “ON” or “ ” posi- turned to the center position. tion, use this switch to turn on the haz- ard lights (simultaneous flashing of all EAU12500...
INSTRUMENT AND CONTROL FUNCTIONS EAU12820 EAU12870 EAU12890 Clutch lever Shift pedal Brake lever 1. Clutch lever 1. Shift pedal 1. Brake lever The clutch lever is located at the left The shift pedal is located on the left The brake lever is located at the right handlebar grip.
INSTRUMENT AND CONTROL FUNCTIONS EAU12941 EAUM1791 Brake pedal Fuel tank cap NOTE: The fuel tank cap cannot be installed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly installed and locked. EWA11140 WARNING Make sure that the fuel tank cap is...
INSTRUMENT AND CONTROL FUNCTIONS EAU13431 EAU13900 Catalytic converter Seat This model is equipped with a catalytic converter in the exhaust system. To remove the seat 1. Insert the key into the seat lock, EWA10860 WARNING and then turn it as shown. The exhaust system is hot after op- eration.
Adjusting the shock absorber load of 186 kg (410 lb) for the ve- assembly hicle. 1. CYCLELOK bar (optional) 2. Yamaha CYCLELOK (optional) 1. Spring preload adjusting ring 3. Strap 2. Special wrench 3. Position indicator This storage compartment is designed...
The built-in sidestand switch is part of formance. the ignition circuit cut-off system, which Spring preload setting: Always have a Yamaha dealer cuts the ignition in certain situations. Minimum (soft): service the shock absorber. (See further down for an explanation of the ignition circuit cut-off system.)
INSTRUMENT AND CONTROL FUNCTIONS below and have a Yamaha dealer re- EAU15311 Ignition circuit cut-off system pair it if it does not function proper- The ignition circuit cut-off system (com- prising the sidestand switch, clutch switch and neutral switch) has the fol- lowing functions.
5. Push the start switch. Does the engine start? The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. With the engine still running: 6. Move the sidestand up. 7. Keep the clutch lever pulled.
PRE-OPERATION CHECKS EAU15591 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences.
• If necessary, add recommended coolant to specified level. 6-13 • Check cooling system for leakage. • Check operation. • If soft or spongy, have Yamaha dealer bleed hydraulic system. • Check brake pads for wear. Front brake • Replace if necessary.
• Make sure that operation is smooth. • Check cable free play. Throttle grip 6-18, 6-27 • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. • Make sure that operation is smooth. Control cables 6-27 •...
OPERATION AND IMPORTANT RIDING POINTS serve the battery. Do not crank the en- EAU16671 ECA10260 Shifting CAUTION: gine more than 10 seconds on any one attempt. Even with the transmission in the neutral position, do not ECA11040 coast for long periods of time CAUTION: with the engine off, and do not For maximum engine life, never ac-...
During this period, prolonged full-throt- ting it idle for an extended length of immediately have a Yamaha dealer tle operation or any condition that might time (e.g., in traffic jams, at traffic check the vehicle.
OPERATION AND IMPORTANT RIDING POINTS EAU17212 Parking When parking, stop the engine, and then remove the key from the main switch. EWA10310 WARNING Since the engine and exhaust system can become very hot, park in a place where pedestri- ans or children are not likely to touch them.
Safety is an obligation of the owner. Pe- ence required for a particular job, have riodic inspection, adjustment and lubri- a Yamaha dealer perform it for you. cation will keep your vehicle in the safest and most efficient condition pos- EWA10350 sible.
The annual checks must be performed every year, except if a kilometer-based maintenance is performed in- stead. From 50000 km, repeat the maintenance intervals starting from 10000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1000 km)
PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK • Check runout, spoke tightness and for damage. √ √ √ √ √ 9 * Wheels • Tighten spokes if necessary. • Check tread depth and for damage. •...
PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK √ √ √ Engine oil filter element • Replace. √ √ √ √ √ • Check coolant level and vehicle for coolant leakage. 24 * Cooling system •...
Refer to this section each time a cowling or panel needs to be re- moved and installed. XT660R 1. Cowling A 1. Panel A XT660R XT660R 1.
To remove the cowling Remove the bolts and spacers, and EAUM1692 Cowling B (XT660R) then lift the cowling up to remove it. To remove the cowling 1. Remove the seat and panel B. (See pages 3-12 and 6-5.) 1.
PERIODIC MAINTENANCE AND MINOR REPAIR EAUM2130 Cowling B (XT660X) To remove the cowling 1. Remove the seat and panel B. (See pages 3-12 and 6-5.) 2. Remove the bolts, and then re- move the quick fastener screw by turning it 1/4 turn counterclock- wise.
PERIODIC MAINTENANCE AND MINOR REPAIR EAUM1710 Panel B To remove the panel 1. Remove the seat. (See page 3-12.) 2. Remove the bolt, and then pull the panel off at the areas shown. 1. Bolt 2. Install the seat. 2. Spacer To install the panel 1.
Do not attempt to diagnose such problems yourself. In- 1. Spark plug gap stead, have a Yamaha dealer check 1. Spark plug cap the vehicle. Spark plug gap: 2. Remove the spark plug as shown, 0.7–0.8 mm (0.028–0.031 in)
PERIODIC MAINTENANCE AND MINOR REPAIR 2. Clean the surface of the spark plug EAUM1841 Engine oil and oil filter ele- NOTE: gasket and its mating surface, and The engine oil tank is located in- ment then wipe off any grime from the side of the frame.
PERIODIC MAINTENANCE AND MINOR REPAIR EWA10360 WARNING Never remove the engine oil tank cap after high-speed operation, oth- erwise hot engine oil could spout out and cause damage or injury. Al- ways let the engine oil cool down sufficiently before removing the oil tank cap.
PERIODIC MAINTENANCE AND MINOR REPAIR 9. Install the oil filter element cover by ECAM1060 CAUTION: installing the bolts and the oil filter element drain bolt, then tightening The engine oil tank must be filled in them to the specified torques. 2 steps.
PERIODIC MAINTENANCE AND MINOR REPAIR addition, do not use oils labeled EAU20070 Coolant “ENERGY CONSERVING II” or The coolant level should be checked higher. before each ride. In addition, the cool- Make sure that no foreign mate- ant must be changed at the intervals rial enters the crankcase.
If water has been added to the 2. Remove the seat and panel B. 7. Remove the coolant reservoir coolant, have a Yamaha dealer (See pages 3-12 and 6-5.) bolts, and then turn the coolant check the antifreeze content of 3.
If water has been added to the diator and reservoir. coolant, have a Yamaha dealer check the antifreeze content of Antifreeze/water mixture ratio: the coolant as soon as possible, Recommended antifreeze:...
Replace the air filter element the vehicle for coolant leakage. If more frequently if you are riding in un- coolant is leaking, have a Yamaha usually wet or dusty areas. In addition, dealer check the cooling system. the air filter check hose must be fre- 18.
PERIODIC MAINTENANCE AND MINOR REPAIR ECA10480 EAUM1910 Adjusting the engine idling CAUTION: speed Make sure that the air filter ele- The engine idling speed must be ment is properly seated in the checked and, if necessary, adjusted as air filter case. follows at the intervals specified in the The engine should never be op- periodic maintenance and lubrication...
Yamaha dealer make the adjustment. sary, have a Yamaha dealer adjust it. The tire air pressure must be ad- justed in accordance with the riding speed and with the total...
0–90 kg (0–198 lb): Because loading has an enormous Front: impact on the handling, braking, Tire inspection XT660R 200 kPa (29 psi) (2.00 performance and safety characteris- kgf/cm²) tics of your motorcycle, you should XT660X 210 kPa (30 psi) (2.10 kgf/cm²)
EWA10570 Front tire: NOTE: WARNING Size: The tire tread depth limits may differ Have a Yamaha dealer replace XT660R 90/90-21M/C 54S, from country to country. Always comply 90/90-21M/C 54T excessively worn tires. Besides with the local regulations. XT660X 120/70R17 M/C 58H,...
PERIODIC MAINTENANCE AND MINOR REPAIR 5. To increase the clutch lever free EAU22270 EAU22390 Adjusting the rear brake light Checking the front and rear play, turn the adjusting nut in direc- switch brake pads tion (a). To decrease the clutch le- The front and rear brake pads must be ver free play, turn the adjusting nut checked for wear at the intervals spec-...
EAU22580 Before riding, check that the brake fluid Checking the brake fluid level peared, have a Yamaha dealer replace is above the minimum level mark and the brake pads as a set. replenish if necessary. A low brake fluid...
NOTE: ually go down. However, if the brake fluid level goes down sud- When checking the drive chain slack, denly, have a Yamaha dealer the chain tensioner should not be check the cause. touching the drive chain. EAU22932 1.
PERIODIC MAINTENANCE AND MINOR REPAIR 3. Tighten the locknuts, and then NOTE: tighten the axle nut to the specified Using the alignment marks on each torque. side of the swingarm, make sure that both adjusting nuts are in the same po- Tightening torque: sition for proper wheel alignment.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23022 ECA11110 Tightening torques: Cleaning and lubricating the CAUTION: Locknut: drive chain Do not use engine oil or any other lu- 16 Nm (1.6 m·kgf, 11 ft·lbf) The drive chain must be cleaned and Axle nut: bricants for the drive chain, as they 104 Nm (10.4 m·kgf, 75 ft·lbf) lubricated at the intervals specified in...
Recommended lubricant: necessary. Lithium-soap-based grease (all-pur- EWA10730 pose grease) WARNING If the sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it. Recommended lubricant: Lithium-soap-based grease (all-pur- pose grease) 6-28...
Securely support the vehicle so that fork does not operate smoothly, damage and excessive oil leakage. there is no danger of it falling over. have a Yamaha dealer check or re- pair it. To check the operation 2. Hold the lower ends of the front 1.
If there is play in the wheel need to check the electrolyte or to add hub or if the wheel does not turn distilled water. smoothly, have a Yamaha dealer check ECA10620 CAUTION: the wheel bearings. Never attempt to remove the battery cell seals, as this would permanent- ly damage the battery.
To charge the battery vide sufficient ventilation when To charge a sealed-type (MF) Have a Yamaha dealer charge the bat- charging it in an enclosed battery, a special (constant-volt- tery as soon as possible if it seems to space.
PERIODIC MAINTENANCE AND MINOR REPAIR EAUM1740 Specified fuses: Replacing the fuses Main fuse: The main fuse is located behind panel 30.0 A A. (See page 6-5.) Fuse box 1: Headlight fuse: 20.0 A Signaling system fuse: 10.0 A Radiator fan fuse: 7.5 A Ignition fuse: 1.
PERIODIC MAINTENANCE AND MINOR REPAIR 4. If the fuse immediately blows EAUM1750 Replacing the headlight bulb again, have a Yamaha dealer This model is equipped with a quartz check the electrical system. bulb headlight. If the headlight bulb burns out, replace it as follows.
1. Do not touch the glass part of the bulb. 1. Screw 5. Install the bulb cover, and then connect the coupler. 6. Install the cowling together with the headlight unit. 7. Have a Yamaha dealer adjust the headlight beam if necessary. 1. Screw 6-34...
PERIODIC MAINTENANCE AND MINOR REPAIR EAUM1820 EAU24350 a jack either under each side of the Replacing an auxiliary light Supporting the motorcycle frame in front of the rear wheel or under bulb Since this model is not equipped with a each side of the swingarm.
XT660X Front wheel EAUM1761 To remove the front wheel EWA10820 WARNING It is advisable to have a Yamaha dealer service the wheel. Securely support the motor- cycle so that there is no danger 1. Bolt 1. Wheel axle of it falling over.
Make sure that there is enough space EWA10820 between the brake pads before install- WARNING ing the brake caliper onto the brake It is advisable to have a Yamaha disc. dealer service the wheel. 5. Tighten the wheel axle to the spec- Securely support the motor- ified torque.
5. Turn the drive chain slack adjust- NOTE: with the brake disc, otherwise the ing nuts (or bolts according to the XT660R: Install the washer with brake pads will be forced shut. model) fully in direction (a). the “N” mark on the right-hand side 6.
The following troubleshooting charts represent quick and easy procedures for checking these vital systems your- self. However, should your motorcycle require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the motorcycle properly.
Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Check the battery. 4. Battery The engine turns over The battery is good.
Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. NOTE: If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant as soon as possible.
MOTORCYCLE CARE AND STORAGE EAU26001 ucts onto seals, gaskets, sprock- cleaning products, solvent or Care ets, the drive chain and wheel thinner, fuel (gasoline), rust re- While the open design of a motorcycle axles. Always rinse the dirt and de- movers or inhibitors, brake flu- reveals the attractiveness of the tech- greaser off with water.
MOTORCYCLE CARE AND STORAGE After normal use ECA10790 5. Use spray oil as a universal clean- CAUTION: Remove dirt with warm water, a mild er to remove any remaining dirt. detergent, and a soft, clean sponge, 6. Touch up minor paint damage Do not use warm water since it in- and then rinse thoroughly with clean caused by stones, etc.
CAUTION: NOTE: the spark plug, and then place Storing the motorcycle in a Consult a Yamaha dealer for advice on the spark plug on the cylinder poorly ventilated room or cover- what products to use. head so that the electrodes are ing it with a tarp, while it is still grounded.
MOTORCYCLE CARE AND STORAGE 4. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side- stand/centerstand. 5. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the ground.
Record the key identification number, vehicle identification number and mod- el label information in the spaces pro- vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi- cle is stolen. KEY IDENTIFICATION NUMBER: 1.
1. Model label The model label is affixed to the frame under the seat. (See page 3-12.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
INDEX Pre-operation check list ......4-2 Air filter element and check hose, Front and rear brake pads, checking ..6-22 replacing and cleaning ....... 6-16 Front fork, checking.......6-29 Rear brake light switch, adjusting ..6-22 Anti-theft alarm (optional) ....... 3-7 Fuel ............3-11 Auxiliary light bulb, replacing ....