YAMAHA XT660S Manuals

Manuals and User Guides for YAMAHA XT660S. We have 1 YAMAHA XT660S manual available for free PDF download: Service Manual

YAMAHA XT660S Service Manual

YAMAHA XT660S Service Manual (462 pages)

Motorcycle XT660R; XT660S; XT660X; XT660S

Brand: YAMAHA | Category: Motorcycle | Size: 17.77 MB

Table of Contents

Table of Contents

7
- How to Use this Manual
  5
- Chassis
  6
- Engine
  6
  - Cooling System
    6
- Fuel Injection System
  6
- General Information
  6
- Periodic Checks and Adjustments
  6
- Specifications
  6
- Troubleshooting
  6
  - Electrical System
    6
  - Table of Contents
    7
  - Gen Info
    9
- Chapter 1 General Information
  12
- Motorcycle Identification
  12
  - Vehicle Identification Number
    12
  - Model Label
    12
- Features
  13
  - Outline
    13
  - Fi System
    14
- Important Information
  15
  - Preparation for Removal and Disassembly
    15
  - Replacement Parts
    15
  - Gaskets, Oil Seals and O-Rings
    15
  - Lock Washers/Plates and Cotter Pins
    16
  - Bearings and Oil Seals
    16
  - Circlips
    16
- Checking the Connections
  17
- Special Tools
  18
- Spec
  24
Chapter 2 Specifications

25
- General Specifications
  27
- Engine Specifications
  28
- Chassis Specifications
  37
- Electrical Specifications
  42
- Conversion Table
  45
- General Tightening Torque Specifications
  45
- Tightening Torque
  46
  - Engine Tightening Torque
    46
  - Chassis Tightening Torques
    49
- Lubrication Points and Lubricant Types
  51
  - Engine
    51
  - Chassis
    53
- Cooling System Diagrams
  54
- Lubrication Chart
  56
- Lubrication Diagrams
  57
- Cable Routing
  61
  - Cable Routing
    68
Chapter 3 Periodic Checks and Adjustments

80
- Introduction
  82
- Periodic Maintenance and Lubrication Chart
  82
- Brake Fluid
  83
- Cowling and Cover
  84
  - Cover
    84
  - Cowling
    85
- Fuel Tank
  86
  - Removing the Fuel Tank
    87
  - Removing the Fuel Pump
    87
  - Installing the Fuel Pump
    88
  - Installing the Fuel Hose
    88
- Air Filter Case
  89
  - Rear Mud Guard and Rear Fender
    89
  - Installing the Air Filter Case Joint Clamp
    93
- Engine
  94
  - Adjusting the Valve Clearance
    94
  - Adjusting the Exhaust Gas Volume
    97
  - Adjusting the Engine Idling Speed
    98
  - Adjusting the Throttle Cable Free Play
    98
  - Checking the Spark Plug
    100
  - Checking the Ignition Timing
    101
  - Measuring the Compression Pressure
    102
  - Measuring the Compression Pressure
    103
  - Checking the Engine Oil Level
    104
  - Changing the Engine Oil
    105
  - Adjusting the Clutch Cable Free Play
    108
  - Checking the Air Filter Element
    109
  - Checking the Throttle Body Joint
    110
  - Checking the Fuel Hose
    110
  - Checking the Breather Hose
    111
  - Checking the Exhaust System
    111
  - Checking the Coolant Level
    112
  - Checking the Cooling System
    112
  - Changing the Coolant
    113
- Chassis
  117
  - Adjusting the Rear Brake Pedal
    117
  - Checking the Brake Fluid Level
    118
  - Checking the Front and Rear Brake Pads and Brake Pad Pins
    119
  - Adjusting the Rear Brake Light Switch
    120
  - Checking the Front and Rear Brake Hoses
    120
  - Bleeding the Hydraulic Brake System
    121
  - Adjusting the Shift Pedal
    122
  - Adjusting the Drive Chain Slack
    123
  - Lubricating the Drive Chain
    125
  - Checking and Adjusting the Steering Head
    125
  - Checking the Front Fork
    127
  - Adjusting the Rear Shock Absorber Assembly
    128
  - Checking the Tires
    129
  - Checking and Tightening the Spokes
    132
  - Checking and Lubricating the Cables
    133
  - Lubricating the Levers and Brake Pedal
    133
  - Lubricating the Sidestand
    133
- Chk Adj
  134
- Electrical System
  134
  - Checking and Charging the Battery
    134
  - Checking the Fuses
    139
  - Replacing the Headlight Bulb
    141
  - Adjusting the Headlight Beam
    142
  - Setting the Digital Clock
    143
- Chas
  144
Chapter 4 Chassis

145
- Front Wheel and Brake Disc
  147
- Front Wheel
  148
- Checking the Front Wheel
  149
- Removing the Front Wheel
  149
- Checking the Front Brake Disc
  152
- Installing the Front Wheel
  153
- Adjusting the Front Wheel Static Balance
  154
- Rear Wheel, Brake Disc, and Rear Wheel Sprocket
  156
  - Rear Wheel
    156
  - Brake Disc and Rear Wheel Sprocket
    158
  - Removing the Rear Wheel
    160
  - Checking the Rear Wheel
    160
  - Checking the Rear Brake Disc
    161
  - Checking the Rear Wheel Drive Hub
    162
  - Checking and Replacing the Rear Wheel Sprocket
    163
  - Installing the Rear Wheel
    163
  - Adjusting the Rear Wheel Static Balance
    164
- Front and Rear Brakes
  165
  - Front Brake Pads (Xt660R)
    165
  - Front Brake Pads (Xt660X)
    166
  - Rear Brake Pads
    167
  - Replacing the Front Brake Pads
    168
  - Replacing the Rear Brake Pads
    170
  - Front Brake Master Cylinder
    172
  - Rear Brake Master Cylinder
    175
  - Disassembling the Front Brake Master Cylinder
    178
  - Disassembling the Rear Brake Master Cylinder
    178
  - Checking the Front and Rear Brake Master Cylinders
    179
  - Assembling and Installing the Front Brake Master Cylinder
    180
  - Assembling the Rear Brake Master Cylinder
    182
  - Installing the Rear Brake Master Cylinder
    182
  - Front Brake Caliper (Xt660R)
    185
  - Front Brake Caliper (Xt660X)
    187
  - Rear Brake Caliper
    189
  - Removing the Front Brake Caliper
    191
  - Removing the Rear Brake Caliper
    191
  - Checking the Front and Rear Brake Calipers
    192
  - Installing the Front Brake Caliper
    193
  - Installing the Rear Brake Caliper
    195
- Front Fork
  197
  - Removing the Front Fork Legs
    201
  - Disassembling the Front Fork Legs
    201
  - Checking the Front Fork Legs
    203
  - Assembling the Front Fork Legs
    204
  - Installing the Front Fork Legs
    208
- Handlebar
  209
  - Removing the Handlebar
    211
  - Checking the Handlebar
    211
  - Installing the Handlebar
    211
- Steering Head
  215
  - Lower Bracket
    215
  - Removing the Lower Bracket
    217
  - Checking the Steering Head
    217
  - Installing the Steering Head
    218
- Rear Shock Absorber Assembly
  220
- Swingarm and Drive Chain
  226
  - Removing the Swingarm
    228
  - Removing the Drive Sprocket
    229
  - Removing the Drive Chain
    229
  - Checking the Swingarm
    229
  - Checking the Drive Chain
    230
  - Installing the Swingarm
    232
- Eng
  235
Chapter 5 Engine

236
- Engine Removal
  240
  - Exhaust Pipes and Mufflers
    240
  - Leads, Cables, Hoses, and Ignition Coil
    241
  - Engine
    244
  - Installing the Engine
    246
- Cylinder Head
  247
- Rocker Arms and Camshaft
  255
- Valves and Valve Springs
  262
  - Removing the Valves
    263
  - Checking the Valves and Valve Guides
    264
  - Checking the Valve Seats
    266
  - Checking the Valve Springs
    268
- Cylinder and Piston
  271
  - Removing the Cylinder and Piston
    273
  - Checking the Cylinder and Piston
    273
  - Checking the Piston Rings
    275
  - Checking the Piston Pin
    276
  - Installing the Piston and Cylinder
    277
  - Clutch Cover
    279
  - Pull Lever Shaft
    280
  - Clutch
    281
  - Removing the Clutch
    283
  - Checking the Friction Plates
    283
  - Checking the Clutch Plates
    284
  - Checking the Clutch Springs
    284
  - Checking the Clutch Housing
    285
  - Checking the Clutch Boss
    285
  - Checking the Pressure Plate
    285
  - Checking the Pull Lever Shaft and Pull Rod
    285
  - Checking the Primary Driven Gear
    286
  - Installing the Clutch
    286
- Oil Pump
  289
  - Checking the Oil Pump
    292
  - Checking the Oil Delivery Pipes and Hoses
    293
  - Assembling the Oil Pump
    293
  - Installing the Oil Pump
    294
- Balancer Driven Gear
  295
- Shift Shaft
  299
  - Shift Shaft and Stopper Lever
    299
  - Checking the Shift Shaft
    301
  - Checking the Stopper Lever
    301
  - Installing the Shift Shaft
    301
- Starter Clutch and A.C. Magneto
  302
- Crankcase
  308
  - Crankcase Bearings
    310
  - Separating the Crankcase
    311
  - Checking the Oil Strainer and Oil Delivery Pipe 3
    311
  - Checking the Timing Chain and Timing Chain Guides
    312
  - Checking the Bearings and Oil Seals
    312
  - Checking the Crankcase
    312
  - Assembling the Crankcase
    313
- Crankshaft
  315
  - Crankshaft and Balancer
    315
  - Removing the Crankshaft Assembly
    316
  - Checking the Crankshaft
    316
  - Installing the Crankshaft
    317
- Transmission
  318
  - Main Axle
    319
  - Drive Axle
    320
  - Checking the Shift Forks
    321
  - Checking the Shift Drum Assembly
    321
  - Checking the Transmission
    321
  - Assembling the Main Axle and Drive Axle
    322
  - Installing the Transmission
    323
- Cool
  324
6 Cool

325
- Chapter 6 Cooling System
  327
- Radiator
  327
  - Checking the Radiator
    329
  - Installing the Radiator
    330
- Thermostat
  331
  - Checking the Thermostat
    332
  - Installing the Thermostat
    332
- Water Pump
  334
  - Disassembling the Water Pump
    337
  - Checking the Water Pump
    337
  - Assembling the Water Pump
    338
  - Installing the Water Pump
    340
Chapter 7 Fuel Injection System

342
- Wiring Diagram
  345
- Ecu Self-Diagnostic Function
  346
- Alternate Operation Control (Fail-Safe Action)
  347
- Fail-Safe Action Table
  347
- Communication Error with Meter
  348
- Troubleshooting Chart
  349
- Diagnostic Mode
  350
- Diagnostic Monitoring Code Table
  352
- Troubleshooting Details
  355
- Throttle Body Assembly
  366
- Air Induction System
  375
  - Air Injection
    375
  - Air Cut-Off Valve
    375
  - Air Induction System Diagrams
    376
  - Air Cut-Off Valve Assembly
    377
  - Checking the Air Induction System
    379
- Elec
  380
Chapter 8 Electrical System

381
- Electrical Components
  383
- Checking Switch Continuity
  385
- Checking the Switches
  387
- Checking the Bulbs and Bulb Sockets
  389
  - Types of Bulbs
    389
  - Checking the Condition of the Bulbs
    390
  - Checking the Condition of the Bulb Sockets
    391
  - CHECKING the Leds
    391
- Ignition System
  394
  - Circuit Diagram
    394
  - Troubleshooting
    395
- Electric Starting System
  399
  - Circuit Diagram
    399
  - Starting Circuit Cut-Off System Operation
    400
  - Troubleshooting
    401
- Starter Motor
  405
  - Checking the Starter Motor
    407
  - Assembling the Starter Motor
    409
- Charging System
  410
  - Circuit Diagram
    410
  - Troubleshooting
    411
- Lighting System
  413
  - Circuit Diagram
    413
  - Troubleshooting
    414
  - Checking the Lighting System
    416
- Signaling System
  419
  - Circuit Diagram
    419
  - Troubleshooting
    421
  - Checking the Signaling System
    422
- Cooling System
  431
  - Circuit Diagram
    431
  - Troubleshooting
    432
- Immobilizer System
  434
  - Circuit Diagram
    434
  - General Information
    435
  - Key Code Registration
    436
  - Self-Diagnosis Malfunction Codes
    439
  - Troubleshooting
    440
  - Checking the Immobilizer System
    441
- Self-Diagnosis
  445
- Trbl Shtg
  449
Trbl Shtg

450
- Troubleshooting
  450
  - Troubleshooting Trbl
    450
  - Chapter 9
    452
- Engine
  452
- Fuel System
  452
- Starting Failures
  452
- Electrical Systems
  453
- Incorrect Engine Idling Speed
  453
  - Engine
    453
  - Fuel System
    453
- Faulty Clutch
  454
  - Clutch Slips
    454
  - Clutch Drags
    454
- Faulty Gear Shifting
  454
  - Shifting Is Difficult
    454
  - Shift Pedal Does Not Move
    454
  - Jumps out of Gear
    454
- Poor Medium-And-High-Speed Performance
  454
  - Engine
    454
  - Fuel System
    454
- Overcooling
  455
- Overheating
  455
  - Engine
    455
  - Cooling System
    455
  - Fuel System
    455
  - Chassis
    455
  - Electrical Systems
    455
- Poor Braking Performance
  455
- Faulty Front Fork Legs
  456
  - Leaking Oil
    456
  - Malfunction
    456
- Unstable Handling
  456
  - Faulty Lighting or Signaling System
    457

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