Yamaha XT660XS 2004 Manuals

Manuals and User Guides for Yamaha XT660XS 2004. We have 3 Yamaha XT660XS 2004 manuals available for free PDF download: Service Manual

Yamaha XT660XS 2004 Service Manual (462 pages)

5VK1-AE1

Brand: Yamaha | Category: Motorcycle | Size: 36.46 MB

Table of Contents

7
- Important Manual Information
  4
- How to Use this Manual
  5
- Chassis
  6
- Cooling System
  6
- Electrical System
  6
- Engine
  6
- Fuel Injection System
  6
- General Information
  6
- Periodic Checks and Adjustments
  6
- Specifications
  6
- Troubleshooting
  6
  - Table of Contents
    7
- 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
- Chk Adj
  79
Adj Chapter 3 Periodic Checks and Adjustments

80
- Chapter 3 Periodic Checks and Adjustments
  82
- Introduction
  82
- Periodic Maintenance and Lubrication Chart
  82
- 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
  - 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
- 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
    180
  - Cylinder
    182
  - 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
  - Installing the Valves
    269
- 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
    280
  - 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
Cool Chapter 6 Cooling System

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
Fi Chapter 7 Fuel Injection System

342
- Chapter 7 Fuel Injection System
  344
- 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
  - Checking the Fuel Injector
    369
  - Checking the Throttle Body
    369
  - Installing the Throttle Body Assembly
    370
  - Checking the Fuel Pump
    371
  - Checking and Adjusting the Throttle Position
    372
  - Sensor
    372
- 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

YAMAHA XT660XS 2004 Service Manual (462 pages)

Motorcycle XT660R; XT660S; XT660X; XT660S

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

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

Yamaha XT660XS 2004 Service Manual (463 pages)

Brand: Yamaha | Category: Motorcycle | Size: 14.79 MB

Table of Contents

8
- Important Manual Information
  5
- How to Use this Manual
  6
- Chassis
  7
- Engine
  7
- Fuel Injection System
  7
- General Information
  7
- Periodic Checks and Adjustments
  7
- Specifications
  7
- Troubleshooting
  7
  - Table of Contents
    8
  - Gen Info
    10
- Chapter 1 General Information
  13
- Motorcycle Identification
  13
  - Vehicle Identification Number
    13
  - Model Label
    13
- Features
  14
  - Outline
    14
  - Fi System
    15
- Important Information
  16
  - Preparation for Removal and Disassembly
    16
  - Replacement Parts
    16
  - Gaskets, Oil Seals and O-Rings
    16
  - Lock Washers/Plates and Cotter Pins
    17
  - Bearings and Oil Seals
    17
  - Circlips
    17
- Checking the Connections
  18
- Special Tools
  19
- Spec
  25
Chapter 2 Specifications

26
- General Specifications
  28
- Engine Specifications
  29
- Chassis Specifications
  38
- Electrical Specifications
  43
- Conversion Table
  46
- General Tightening Torque Specifications
  46
- Tightening Torque
  47
  - Engine Tightening Torque
    47
  - Chassis Tightening Torques
    50
- Lubrication Points and Lubricant Types
  52
  - Engine
    52
  - Chassis
    54
- Cooling System Diagrams
  55
- Lubrication Chart
  57
- Lubrication Diagrams
  58
- Cable Routing
  62
Chapter 3 Periodic Checks and Adjustments

81
- Introduction
  83
- Periodic Maintenance and Lubrication Chart
  83
- Brake Fluid
  84
- Cowling and Cover
  85
  - Cover
    85
  - Cowling
    86
- Fuel Tank
  87
  - Removing the Fuel Tank
    88
  - Removing the Fuel Pump
    88
  - Installing the Fuel Pump
    89
  - Installing the Fuel Hose
    89
- Air Filter Case
  90
  - Rear Mud Guard and Rear Fender
    90
  - Installing the Air Filter Case Joint Clamp
    94
- Engine
  95
  - Adjusting the Valve Clearance
    95
  - Adjusting the Valve Clearance
    97
  - Adjusting the Exhaust Gas Volume
    98
  - Adjusting the Engine Idling Speed
    99
  - Adjusting the Throttle Cable Free Play
    99
  - Checking the Spark Plug
    101
  - Checking the Ignition Timing
    102
  - Measuring the Compression Pressure
    103
  - Checking the Engine Oil Level
    105
  - Measuring the Compression Pressure
    105
  - Changing the Engine Oil
    106
  - Adjusting the Clutch Cable Free Play
    109
  - Checking the Air Filter Element
    110
  - Checking the Throttle Body Joint
    111
  - Checking the Fuel Hose
    111
  - Checking the Breather Hose
    112
  - Checking the Exhaust System
    112
  - Checking the Coolant Level
    113
  - Checking the Cooling System
    113
  - Changing the Coolant
    114
- Chassis
  118
  - Adjusting the Rear Brake Pedal
    118
  - Checking the Brake Fluid Level
    119
  - Checking the Front and Rear Brake Pads and Brake Pad Pins
    120
  - Adjusting the Rear Brake Light Switch
    121
  - Checking the Front and Rear Brake Hoses
    121
  - Bleeding the Hydraulic Brake System
    122
  - Adjusting the Shift Pedal
    123
  - Adjusting the Drive Chain Slack
    124
  - Adjusting the Drive Chain Slack
    125
  - Lubricating the Drive Chain
    126
  - Checking and Adjusting the Steering Head
    126
  - Checking the Front Fork
    128
  - Adjusting the Rear Shock Absorber Assembly
    129
  - Checking the Tires
    130
  - Checking and Tightening the Spokes
    133
  - Checking and Lubricating the Cables
    134
  - Lubricating the Levers and Brake Pedal
    134
  - Lubricating the Sidestand
    134
- Chk Adj
  135
- Electrical System
  135
  - Checking and Charging the Battery
    135
  - Checking the Fuses
    140
  - Replacing the Headlight Bulb
    142
  - Adjusting the Headlight Beam
    143
  - Setting the Digital Clock
    144
- Chas
  145
Chapter 4 Chassis

146
- Front Wheel and Brake Disc
  148
- Front Wheel
  149
- Checking the Front Wheel
  150
- Removing the Front Wheel
  150
- Checking the Front Brake Disc
  153
- Installing the Front Wheel
  154
- Adjusting the Front Wheel Static Balance
  155
- Rear Wheel, Brake Disc, and Rear Wheel Sprocket
  157
  - Rear Wheel
    157
  - Brake Disc and Rear Wheel Sprocket
    159
  - Removing the Rear Wheel
    161
  - Checking the Rear Wheel
    161
  - Checking the Rear Brake Disc
    162
  - Checking the Rear Wheel Drive Hub
    163
  - Checking and Replacing the Rear Wheel Sprocket
    164
  - Installing the Rear Wheel
    164
  - Adjusting the Rear Wheel Static Balance
    165
- Front and Rear Brakes
  166
  - Front Brake Pads (Xt660R)
    166
  - Front Brake Pads (Xt660X)
    167
  - Rear Brake Pads
    168
  - Replacing the Front Brake Pads
    169
  - Replacing the Rear Brake Pads
    171
  - Front Brake Master Cylinder
    173
  - Rear Brake Master Cylinder
    176
  - Disassembling the Front Brake Master Cylinder
    179
  - Disassembling the Rear Brake Master Cylinder
    179
  - Checking the Front and Rear Brake Master Cylinders
    180
  - Assembling and Installing the Front Brake Master Cylinder
    181
  - Assembling the Rear Brake Master Cylinder
    183
  - Installing the Rear Brake Master Cylinder
    183
  - Front Brake Caliper (Xt660R)
    186
  - Front Brake Caliper (Xt660X)
    188
  - Rear Brake Caliper
    190
  - Removing the Front Brake Caliper
    192
  - Removing the Rear Brake Caliper
    192
  - Checking the Front and Rear Brake Calipers
    193
  - Installing the Front Brake Caliper
    194
  - Installing the Rear Brake Caliper
    196
- Front Fork
  198
  - Removing the Front Fork Legs
    202
  - Disassembling the Front Fork Legs
    202
  - Checking the Front Fork Legs
    204
  - Assembling the Front Fork Legs
    205
  - Installing the Front Fork Legs
    209
- Handlebar
  210
  - Removing the Handlebar
    212
  - Checking the Handlebar
    212
  - Installing the Handlebar
    212
- Steering Head
  216
  - Lower Bracket
    216
  - Removing the Lower Bracket
    218
  - Checking the Steering Head
    218
  - Installing the Steering Head
    219
- Rear Shock Absorber Assembly
  221
- Swingarm and Drive Chain
  227
  - Removing the Swingarm
    229
  - Removing the Drive Sprocket
    230
  - Removing the Drive Chain
    230
  - Checking the Swingarm
    230
  - Checking the Drive Chain
    231
  - Installing the Swingarm
    233
- Eng
  236
Chapter 5 Engine

237
- Engine Removal
  241
  - Exhaust Pipes and Mufflers
    241
  - Leads, Cables, Hoses, and Ignition Coil
    242
  - Engine
    245
  - Installing the Engine
    247
- Cylinder Head
  248
- Rocker Arms and Camshaft
  256
- Valves and Valve Springs
  263
  - Removing the Valves
    264
  - Checking the Valves and Valve Guides
    265
  - Checking the Valve Seats
    267
  - Checking the Valve Springs
    269
- Cylinder and Piston
  272
  - Removing the Cylinder and Piston
    274
  - Checking the Cylinder and Piston
    274
  - Checking the Piston Rings
    276
  - Checking the Piston Pin
    277
  - Installing the Piston and Cylinder
    278
  - Clutch Cover
    280
  - Pull Lever Shaft
    281
  - Clutch
    282
  - Removing the Clutch
    284
  - Checking the Friction Plates
    284
  - Checking the Clutch Plates
    285
  - Checking the Clutch Springs
    285
  - Checking the Clutch Housing
    286
  - Checking the Clutch Boss
    286
  - Checking the Pressure Plate
    286
  - Checking the Pull Lever Shaft and Pull Rod
    286
  - Checking the Primary Driven Gear
    287
  - Installing the Clutch
    287
- Oil Pump
  290
  - Checking the Oil Pump
    293
  - Checking the Oil Delivery Pipes and Hoses
    294
  - Assembling the Oil Pump
    294
  - Installing the Oil Pump
    295
- Balancer Driven Gear
  296
- Shift Shaft
  300
  - Shift Shaft and Stopper Lever
    300
- Starter Clutch and A.C. Magneto
  303
- Crankcase
  309
  - Crankcase Bearings
    311
  - Separating the Crankcase
    312
  - Checking the Oil Strainer and Oil Delivery Pipe 3
    312
  - Checking the Timing Chain and Timing Chain Guides
    313
  - Checking the Bearings and Oil Seals
    313
  - Checking the Crankcase
    313
  - Assembling the Crankcase
    314
- Crankshaft
  316
  - Crankshaft and Balancer
    316
  - Removing the Crankshaft Assembly
    317
  - Checking the Crankshaft
    317
  - Installing the Crankshaft
    318
- Transmission
  319
  - Main Axle
    320
  - Drive Axle
    321
  - Checking the Shift Forks
    322
  - Checking the Shift Drum Assembly
    322
  - Checking the Transmission
    322
  - Assembling the Main Axle and Drive Axle
    323
  - Installing the Transmission
    324
- Cool
  325
6 Cool

326
- Chapter 6 Cooling System
  328
- Radiator
  328
  - Checking the Radiator
    330
  - Installing the Radiator
    331
- Thermostat
  332
  - Checking the Thermostat
    333
  - Installing the Thermostat
    333
- Water Pump
  335
  - Disassembling the Water Pump
    338
  - Checking the Water Pump
    338
  - Assembling the Water Pump
    339
  - Installing the Water Pump
    341
Chapter 7 Fuel Injection System

343
- Wiring Diagram
  346
- Ecu Self-Diagnostic Function
  347
- Alternate Operation Control (Fail-Safe Action)
  348
- Fail-Safe Action Table
  348
- Communication Error with Meter
  349
- Troubleshooting Chart
  350
- Diagnostic Mode
  351
- Diagnostic Monitoring Code Table
  353
- Troubleshooting Details
  356
- Throttle Body Assembly
  367
- Air Induction System
  376
  - Air Injection
    376
  - Air Cut-Off Valve
    376
  - Air Induction System Diagrams
    377
  - Air Cut-Off Valve Assembly
    378
  - Checking the Air Induction System
    380
- Elec
  381

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Yamaha XT660XS 2004 Manuals

Yamaha XT660XS 2004 Service Manual (462 pages)

Table of Contents

Table of Contents

Chapter 2 Specifications

Adj Chapter 3 Periodic Checks and Adjustments

Chapter 4 Chassis

Chapter 5 Engine

Cool Chapter 6 Cooling System

Fi Chapter 7 Fuel Injection System

YAMAHA XT660XS 2004 Service Manual (462 pages)

Table of Contents

Table of Contents

Chapter 2 Specifications

Chapter 3 Periodic Checks and Adjustments

Chapter 4 Chassis

Chapter 5 Engine

6 Cool

Chapter 7 Fuel Injection System

Yamaha XT660XS 2004 Service Manual (463 pages)

Table of Contents

Table of Contents

Chapter 2 Specifications

Chapter 3 Periodic Checks and Adjustments

Chapter 4 Chassis

Chapter 5 Engine

6 Cool

Chapter 7 Fuel Injection System

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