Yamaha xtz660 Manuals

Manuals and User Guides for Yamaha xtz660. We have 1 Yamaha xtz660 manual available for free PDF download: Service Manual

Yamaha xtz660 Service Manual

Yamaha xtz660 Service Manual (399 pages)

Brand: Yamaha | Category: Motorcycle | Size: 26.52 MB

Table of Contents

Table of Contents

6
- How to Use this Manual
  4
- Symbols
  5
- General Information
  7
- Identification
  9
  - Vehicle Identification Number
    9
  - Model Label
    9
- Features
  10
  - Outline of the Fi System
    10
  - Fi System
    11
  - Instrument Functions
    12
- 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
    15
  - Bearings and Oil Seals
    16
  - Circlips
    16
- Checking the Connections
  17
- Special Tools
  18
Specifications

23
- General Specifications
  25
- Engine Specifications
  26
- Chassis Specifications
  35
- Electrical Specifications
  37
- Tightening Torques
  40
- Lubrication Points and Lubricant Types
  49
  - Engine
    49
  - Chassis
    51
- Cooling System Diagrams
  52
- Lubrication Chart
  56
  - Lubrication Diagrams
    57
- Cable Routing
  65
Periodic Checks and Adjustments

85
- Periodic Maintenance
  
  87
  - Introduction
    87
  - Periodic Maintenance and Lubrication Chart
    87
- Engine
  
  89
- Chassis
  
  104
  - Adjusting the Front Brake
    104
    
    Adjusting the Rear Brake Pedal
    104
    
    Checking the Brake Fluid Level
    105
    
    Checking the Front and Rear Brake Pads and Brake Pad Pins
    106
    
    Checking the Front and Rear Brake Hoses
    106
    
    Bleeding the Hydraulic Brake System
    107
    
    Adjusting the Shift Pedal
    107
    
    Adjusting the Drive Chain Slack
    108
    
    Lubricating the Drive Chain
    109
    
    Checking and Adjusting the Steering Head
    109
    
    Checking the Front Fork
    110
    
    Adjusting the Front Fork
    111
    
    Adjusting the Shock Absorber Assembly
    111
    
    Checking the Tires
    112
    
    Checking the Wheels
    114
    
    Spoke Inspection and Tightening
    114
    
    Checking and Lubricating the Cables
    114
    
    Lubricating the Levers and Brake Pedal
    114
    
    Lubricating the Sidestand
    114
    
    Lubricating the Rear Suspension
    115
    
    Lubricating the Swingarm Pivots
    115
- Electrical System
  
  116
  - Checking and Charging the Battery
    116
  - Checking the Fuses
    116
  - Replacing the Headlight Bulb
    116
  - Replacing an Auxiliary Light Bulb
    117
  - Tail/Brake Light
    117
  - Replacing a Turn Signal Light Bulb
    118
  - Replacing the License Plate Light Bulb
    118
  - Adjusting the Headlight Beam
    118
Chassis

119
- General Chassis
  
  121
- Front Wheel
  
  129
  - Removing the Front Wheel
    129
  - Disassembling the Front Wheel
    129
  - Checking the Front Wheel
    129
  - Assembling the Front Wheel
    130
  - Adjusting the Front Wheel Static Balance
    131
  - Checking the Front Brake Discs
    132
  - Installing the Front Wheel (Front Brake Discs)
    132
- Rear Wheel
  
  134
  - Removing the Rear Wheel
    137
  - Disassembling the Rear Wheel
    137
  - Checking the Rear Wheel
    137
  - Checking the Rear Wheel Drive Hub
    138
  - Checking and Replacing the Rear Wheel Sprocket
    138
  - Assembling the Rear Wheel
    138
  - Adjusting the Rear Wheel Static Balance
    138
  - Checking the Rear Brake Disc
    138
  - Installing the Rear Wheel (Rear Brake Disc)
    139
- Front Brake
  
  141
- Rear Brake
  
  152
  - Introduction
    157
  - Checking the Rear Brake Disc
    157
  - Replacing the Rear Brake Pads
    157
  - Removing the Rear Brake Caliper
    158
  - Disassembling the Rear Brake Caliper
    158
  - Checking the Rear Brake Caliper
    159
  - Assembling the Rear Brake Caliper
    159
  - Installing the Rear Brake Caliper
    159
  - Removing the Rear Brake Master Cylinder
    160
  - Checking the Rear Brake Master Cylinder
    161
  - Assembling the Rear Brake Master Cylinder
    161
  - Installing the Rear Brake Master Cylinder
    161
- Handlebar
  
  163
  - Removing the Handlebar
    165
  - Checking the Handlebar
    165
  - Installing the Handlebar
    165
- Front Fork
  
  168
  - Removing the Front Fork Legs
    171
  - Disassembling the Front Fork Legs
    171
  - Checking the Front Fork Legs
    172
  - Assembling the Front Fork Legs
    173
- Steering Head
  
  177
  - Removing the Lower Bracket
    179
  - Checking the Steering Head
    179
  - Installing the Steering Head
    179
- Rear Shock Absorber Assembly
  
  181
- Swingarm
  
  184
  - Removing the Swingarm
    186
  - Checking the Swingarm
    186
  - Installing the Swingarm
    187
- Chain Drive
  
  189
  - Removing the Drive Chain
    190
  - Checking the Drive Chain
    190
  - Removing the Drive Sprocket
    191
  - Checking the Drive Sprocket
    191
  - Checking the Rear Wheel Sprocket
    191
  - Checking the Rear Wheel Drive Hub
    191
  - Installing the Drive Chain
    191
Engine

193
- Engine Removal
  
  195
  - Installing the Engine
    201
- Cylinder Head
  
  202
- Rocker Arms and Camshaft
  
  209
- Valves and Valve Springs
  
  213
  - Removing the Valves
    214
  - Checking the Valves and Valve Guides
    214
  - Checking the Valve Seats
    216
  - Checking the Valve Springs
    217
  - Installing the Valves
    218
- Cylinder and Piston
  
  220
  - Removing the Cylinder and Piston
    221
  - Checking the Cylinder and Piston
    221
  - Checking the Piston Rings
    222
  - Checking the Piston Pin
    223
  - Installing the Piston and Cylinder
    223
- Clutch
  
  226
  - Clutch Cover
    226
  - Clutch
    227
  - Removing the Clutch
    229
  - Checking the Friction Plates
    229
  - Checking the Clutch Plates
    229
  - Checking the Clutch Springs
    230
  - Checking the Clutch Housing
    230
  - Checking the Clutch Boss
    230
  - Checking the Pressure Plate
    231
  - Checking the Pull Lever Shaft and Pull Rod
    231
  - Checking the Primary Driven Gear
    231
  - Installing the Clutch
    231
- Oil Pump
  
  234
  - Checking the Oil Pump
    237
  - Checking the Oil Delivery Pipes and Hoses
    237
  - Assembling the Oil Pump
    238
  - Installing the Oil Pump
    238
- Balancer Driven Gear
  
  239
- Shift Shaft
  
  242
  - Shift Shaft and Stopper Lever
    242
  - Checking the Shift Shaft
    244
  - Checking the Stopper Lever
    244
  - Installing the Shift Shaft
    244
- Starter Clutch and A.C. Magneto
  
  247
- Electric Starter
  
  251
  - Checking the Starter Motor
    252
  - Assembling the Starter Motor
    253
- Crankcase
  
  254
- Crankshaft
  
  260
  - Removing the Crankshaft Assembly
    261
  - Checking the Crankshaft
    261
  - Installing the Crankshaft
    262
- Transmission
  
  263
  - Checking the Shift Forks
    266
  - Checking the Shift Drum Assembly
    266
  - Checking the Transmission
    266
  - Assembling the Main Axle and Drive Axle
    267
  - Installing the Transmission
    267
Cooling System

269
- Radiator
  
  271
  - Checking the Radiator
    272
  - Installing the Radiator
    272
- Thermostat
  
  274
  - Checking the Thermostat
    275
  - Installing the Thermostat
    275
- Water Pump
  
  279
  - Disassembling the Water Pump
    279
  - Checking the Water Pump
    279
  - Assembling the Water Pump
    280
  - Installing the Water Pump
    281
Fuel Injection System

283
- Fuel Tank
  
  286
  - Removing the Fuel Tank
    286
  - Removing the Fuel Pump
    286
  - Installing the Fuel Pump
    287
  - Installing the Fuel Hose
    287
  - Checking the Fuel Sender
    287
- Throttle Body Assembly
  
  288
  - Checking the Fuel Injector
    291
  - Checking the Throttle Body
    291
  - Installing the Throttle Body Assembly
    291
  - Checking the Fuel Pump
    292
  - Checking the Throttle Position Sensor
    293
  - Adjusting the Throttle Position Sensor
    293
- Air Induction System
  
  295
  - Air Injection
    295
  - Air Cut-Off Valve
    295
  - Air Induction System Diagrams
    296
  - Air Cut-Off Valve Assembly
    297
  - Checking the Air Induction System
    299
- Fuel Injection System
  
  301
  - Wiring Diagram
    301
    
    Ecu's Self-Diagnostic Function
    303
    
    Self-Diagnostic Function Table
    304
    
    Fail-Safe Action Table
    304
    
    Troubleshooting Chart
    306
    
    Diagnostic Mode
    307
    
    Troubleshooting Details
    313
Electrical System

325
- Ignition System
  327
  - Circuit Diagram
    327
  - Troubleshooting
    329
- Electric Starting System
  331
  - Circuit Diagram
    331
  - Starting Circuit Cut-Off System Operation
    333
  - Troubleshooting
    335
- Charging System
  337
  - Circuit Diagram
    337
  - Troubleshooting
    339
- Lighting System
  341
  - Circuit Diagram
    341
  - Troubleshooting
    343
- Signaling System
  345
  - Circuit Diagram
    345
  - Troubleshooting
    347
- Cooling System
  351
  - Circuit Diagram
    351
  - Troubleshooting
    353
- Immobilizer System
  355
  - Circuit Diagram
    355
  - General Information
    357
  - Part Replacement and Key Code Registration Requirements
    357
  - Troubleshooting
    361
  - Self-Diagnosis Fault Code Indication
    362
- Electrical Components
  365
  - Checking the Switches
    369
  - Checking the Bulbs and Bulb Sockets
    372
  - Checking the Leds
    373
  - Checking the Fuses
    374
  - Checking and Charging the Battery
    375
  - Checking the Relays
    377
  - Checking the Turn Signal/Hazard Relay
    379
  - Checking the Relay Unit (Diode)
    379
  - Checking the Spark Plug Cap
    380
  - Checking the Ignition Coil
    380
  - Checking the Ignition Spark Gap
    381
  - Checking the Crankshaft Position Sensor
    381
  - Checking the Lean Angle Cut-Off Switch
    382
  - Checking the Stator Coil
    382
  - Checking the Horn
    383
  - Checking the Coolant Temperature Sensor
    383
  - Checking the Fuel Sender
    384
  - Checking the Speed Sensor
    384
  - Checking the Throttle Position Sensor
    385
  - Checking the Fuel Pump
    385
  - Checking the Intake Air Pressure Sensor
    386
  - Checking the Intake Air Temperature Sensor
    386
  - Checking the Radiator Fan Motor
    386
  - Checking the Starter Motor
    387
Troubleshooting

389
- General Information
  391
- Incorrect Engine Idling Speed
  391
- Starting Failures
  391
- Troubleshooting
  391
- Faulty Clutch
  392
- Faulty Gear Shifting
  392
- Poor Medium-And-High-Speed Performance
  392
- Faulty Front Fork Legs
  393
- Overcooling
  393
- Overheating
  393
- Poor Braking Performance
  393
- Unstable Handling
  393
- Faulty Lighting or Signaling System
  394

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