Yamaha XT660RW Owner'S Manual Download

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-5

EAU18712

Removing and installing cowl-
ings and panels

The cowlings and panels shown need
to be removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each time
a cowling or panel needs to be re-
moved and installed.

XT660R

XT660X

XT660R

XT660X

XT660R

1. Cowling A

1. Panel A

1. Cowling B

2. Panel B

U5VK21E0.book Page 5 Tuesday, July 18, 2006 1:12 PM

ProCarManuals.com

Summary of Contents for XT660RW

Page 1: ...5VK F8199 21 XT660RW XT660XW OWNER S MANUAL ProCarManuals com ...

Page 2: ...U5VK21E0 book Page 2 Tuesday July 18 2006 1 12 PM ProCarManuals com ...

Page 3: ... 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 In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha dealer...

Page 4: ...ave any questions concerning this manual please consult your Yamaha dealer WARNING EWA10030 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE Product and specifications are subject to change without notice The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the ...

Page 5: ...MANUAL 2006 by MBK INDUSTRIE 1st edition July 2006 All rights reserved Any reprinting or unauthorized use without the written permission of MBK INDUSTRIE is expressly prohibited Printed in France U5VK21E0 book Page 2 Tuesday July 18 2006 1 12 PM ProCarManuals com ...

Page 6: ... 5 Checking the spark plug 6 9 Engine oil and oil filter element 6 10 Coolant 6 13 Replacing the air filter element and cleaning the check hose 6 16 Adjusting the engine idling speed 6 17 Checking the throttle cable free play 6 18 Tires 6 18 Spoke wheels 6 21 Adjusting the clutch lever free play 6 21 Adjusting the rear brake light switch 6 22 Checking the front and rear brake pads 6 22 Checking th...

Page 7: ...6 40 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Motorcycle noise regulation for Australia 9 2 U5VK21E0 book Page 2 Tuesday July 18 2006 1 12 PM ProCarManuals com ...

Page 8: ...ve been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when ap proaching and passing through intersections since intersec tions are the most likely places for motorcycle accidents to oc cur Ride where other motorists can ...

Page 9: ...e use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Never touch the engine or exhaust system during or after operation They become very hot and can cause burns Always wear protec tive clothing that covers...

Page 10: ...ur motorcycle Care fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance limit suspension travel steering travel or control operation or ob scure lights or reflectors Accessories fitted to the handle bar or the front fork area can create instability due to improper weight distribution or aerody namic changes If accessori...

Page 11: ...re pe destrians or children are not like ly to touch these hot areas Do not park the motorcycle on a slope or soft ground otherwise it may fall over Do not park the motorcycle near a flammable source e g a ker osene heater or near an open flame otherwise it could catch fire When transporting the motorcycle in another vehicle make sure that it is kept upright and that the fuel cock s are turned to ...

Page 12: ...ON 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle 1 2 1 2 4CU F1568 00 U5VK21E0 book Page 5 Tuesday July 18 2006 1 12 PM ProCarManuals com ...

Page 13: ...Main fuse page 6 32 4 Battery page 6 30 5 Fuse box 1 page 6 32 6 Fuse box 2 page 6 32 7 Storage compartment page 3 12 8 Grab bar 9 Seat lock page 3 12 10 Shift pedal page 3 9 11 Engine oil drain bolt crankcase page 6 10 U5VK21E0 book Page 1 Tuesday July 18 2006 1 12 PM ProCarManuals com ...

Page 14: ...age 3 13 4 Rear brake fluid reservoir page 6 23 5 Front brake fluid reservoir page 6 23 6 Engine oil filler cap page 6 10 7 Engine oil drain bolt oil tank page 6 10 8 Coolant reservoir page 6 13 9 Engine oil filter element page 6 10 10 Coolant drain bolt page 6 14 11 Brake pedal page 3 9 U5VK21E0 book Page 2 Tuesday July 18 2006 1 12 PM ProCarManuals com ...

Page 15: ...2 Left handlebar switches page 3 7 3 Main switch steering lock page 3 2 4 Multi function display page 3 5 5 Right handlebar switches page 3 7 6 Brake lever page 3 9 7 Throttle grip page 6 18 8 Fuel tank cap page 3 10 U5VK21E0 book Page 3 Tuesday July 18 2006 1 12 PM ProCarManuals com ...

Page 16: ...switches page 3 7 3 Main switch steering lock page 3 2 4 Multi function display page 3 5 5 Right handlebar switches page 3 7 6 Brake lever page 3 9 7 Throttle grip page 6 18 8 Fuel tank cap page 3 10 U5VK21E0 book Page 4 Tuesday July 18 2006 1 12 PM ProCarManuals com ...

Page 17: ...If the code re reg istering key is lost registering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle however if code re registering is required i e if a new standard key is made or all keys are lost the entire immobi lizer system must be replaced Therefore it is highly recom mended to use either standard key and keep the code re regis tering key...

Page 18: ...er the meter lighting taillight and auxiliary light come on and the engine can be started The key cannot be re moved NOTE The headlight comes on automatically when the engine is started and stays on until the key is turned to OFF EAU10660 OFF All electrical systems are off The key can be removed EAU10680 LOCK The steering is locked and all electrical systems are off The key can be re moved To lock...

Page 19: ... The key can be removed The steering must be locked before the key can be turned to CAUTION ECA11020 Do not use the parking position for an extended length of time other wise the battery may discharge EAU11003 Indicator and warning lights EAU11020 Turn signal indicator light This indicator light flashes when the turn signal switch is pushed to the left or right EAU11060 Neutral indicator light Thi...

Page 20: ...uit of the warning light can be checked by turning the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrical cir cuit CAUTION ECA10020 Do not operate the engine if it is overheated EAU11530 Engine trouble warning light This warning light comes on or flashes when an electrical circuit monitoring the engine is defective When this occu...

Page 21: ...e to turn the key to ON before using the SELECT and RESET but tons Odometer and tripmeter modes Pushing the SELECT button switches the display between the odometer mode ODO and the tripmeter modes TRIP 1 and TRIP 2 in the following order ODO TRIP 1 TRIP 2 ODO If the fuel level warning light comes on see page 3 3 the odometer display will automatically change to the fuel re serve tripmeter mode F T...

Page 22: ... g 11 12 13 If the multi function display indicates such an error code note the code num ber and then have a Yamaha dealer check the vehicle CAUTION ECA11590 If the display indicates an error code the vehicle should be checked as soon as possible in order to avoid engine damage This model is also equipped with a self diagnosis device for the immobilizer system If any of the immobilizer system circ...

Page 23: ...2350 Pass switch Press this switch to flash the headlight EAU12400 Dimmer switch Set this switch to for the high beam and to for the low beam EAU12460 Turn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When re leased the switch returns to the center 1 Pass switch 2 Dimmer switch 3 Turn signal switch 4 Horn switch 5 Hazard switch 1 Engi...

Page 24: ...this switch to turn on the haz ard lights simultaneous flashing of all turn signal lights The hazard lights are used in case of an emergency or to warn other drivers when your vehicle is stopped where it might be a traffic hazard CAUTION ECA10061 Do not use the hazard lights for an extended length of time with the en gine not running otherwise the bat tery may discharge EAU12820 Clutch lever The c...

Page 25: ...transmission equipped on this motorcycle EAU12890 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip EAU12941 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Shift pedal 1 Brake lever 1 Brake pedal U5VK21E0 book Page 9 Tuesday July 18 2006 1 ...

Page 26: ... 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 WARNING EWA11140 Make sure that the fuel tank cap is properly installed before riding EAU13211 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown WARNING EWA10880 Do not overfill the...

Page 27: ...Catalytic converter This model is equipped with a catalytic converter in the exhaust system WARNING EWA10860 The exhaust system is hot after op eration Make sure that the exhaust system has cooled down before do ing any maintenance work CAUTION ECA10700 The following precautions must be observed to prevent a fire hazard or other damages Use only unleaded gasoline The use of leaded gasoline will ca...

Page 28: ...perly se cured before riding EAU14451 Storage compartment The storage compartment is located under the seat See page 3 12 WARNING EWA10961 Do not exceed the load limit of 3 kg 7 lb for the storage com partment Do not exceed the maximum load of 186 kg 410 lb for the ve hicle When storing the owner s manual or other documents in the storage com partment be sure to wrap them in a plastic bag so that ...

Page 29: ...ereby soften the suspension turn the adjust ing ring in direction b NOTE Align the appropriate notch in the ad justing ring with the position indicator on the shock absorber WARNING EWA10220 This shock absorber contains highly pressurized nitrogen gas For prop er handling read and understand the following information before handling the shock absorber The manufacturer cannot be held re sponsible f...

Page 30: ...t cut off system which cuts the ignition in certain situations See further down for an explanation of the ignition circuit cut off system WARNING EWA10240 The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwise the sidestand could contact the ground and distract the operator resulting in a possible loss of control Yamaha...

Page 31: ...h lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure WARNING EWA10250 If a malfunction is noted have a Yamaha ...

Page 32: ...gine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden This check is most reliable if performed with a warmed up engine The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycle should not...

Page 33: ...Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved WARNING EWA11150 If any item in the Pre operation check list is not working p...

Page 34: ...spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 22 6 23 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check fluid level in reservoir If ...

Page 35: ...ary 6 18 6 21 Brake pedal Make sure that operation is smooth Lubricate pedal pivoting point if necessary 6 28 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 27 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 28 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary...

Page 36: ... lever pulled and the sid estand up WARNING EWA10290 Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 15 Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop switch is set to CAUTION ECAM1030 The following warning lights and in dicator light should come on for a few seconds th...

Page 37: ...shift the transmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it CAUTION ECA10260 Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is runnin...

Page 38: ...follow ing material carefully Since the engine is brand new do not put an excessive load on it for the first 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided EAU17030 0 1000 km 0 600 mi Avoid prolonged operation...

Page 39: ... and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them Do not park on a slope or on soft ground otherwise the vehicle may overturn CAUTION ECA10380 Never park in an area where there are fire hazards such as grass or other flammable materials U5VK21E0 book Page 4 Tuesday July 18 2006 1 12 PM ProCarManuals com ...

Page 40: ...rk have a Yamaha dealer do it for you EAU17520 Owner s tool kit The owner s tool kit is located inside the storage compartment under the seat See page 3 12 The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be ne...

Page 41: ...NANCE JOB ODOMETER READING 1000 km ANNUAL CHECK 1 10 20 30 40 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plug Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust 4 Air filter element Replace 5 Clutch Check operation Adjust 6 Front brake Check operation fluid level and vehicle for fluid leakage Replace brake pads Whenever worn to the limit 7 Rear brake Check...

Page 42: ...ing bearings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 20000 km 15 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 16 Sidestand Check operation Lubricate 17 Sidestand switch Check operation 18 Front fork Check operation and for oil leakage 19 Shock absorber assem bly Check operation and shock absorber for oil leak...

Page 43: ...olant leakage Change Every 3 years 25 Front and rear brake switches Check operation 26 Moving parts and ca bles Lubricate 27 Throttle grip housing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 28 Air induction system Check the air cut off valve reed valve and hose for dam age Replace the entire air induction s...

Page 44: ... be removed to perform some of the maintenance jobs described in this chapter Refer to this section each time a cowling or panel needs to be re moved and installed XT660R XT660X XT660R XT660X XT660R 1 Cowling A 1 Cowling A 1 Panel A 1 1 Panel A 1 Cowling B 2 Panel B 1 U5VK21E0 book Page 5 Tuesday July 18 2006 1 12 PM ProCarManuals com ...

Page 45: ... 2 Place the cowling in the original position and then install the bolts and spacers EAUM1692 Cowling B XT660R 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 screws by turning them 1 4 turn counterclock wise 3 Pull the cowling off at the area shown 1 Cowling B 2 Panel B 2 1 1 Bolt 1 Bolt 1 1 Protector 2 Cowling brac...

Page 46: ...e quick fastener screw by turning it 1 4 turn counterclock wise 3 Pull the cowling off at the area shown To install the cowling 1 Place the cowling in the original position and then install the quick fastener screw and the bolts 2 Install the panel 3 Install the seat EAUM1701 Panel A To remove the panel 1 Remove the seat See page 3 12 2 Remove the bolts and the spacer and then pull the panel off a...

Page 47: ...2 Install the seat 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 To install the panel 1 Place the panel in the original posi tion and then install the bolt 2 Install the seat 1 Bolt 2 Spacer 1 Bolt U5VK21E0 book Page 8 Tuesday July 18 2006 1 12 PM ProCarManuals com ...

Page 48: ... that the porcelain insulator around the center electrode of the spark plug is a medium to light tan the ideal color when the vehicle is ridden normally NOTE If the spark plug shows a distinctly dif ferent color the engine could be oper ating improperly Do not attempt to diagnose such problems yourself In stead have a Yamaha dealer check the vehicle 2 Check the spark plug for electrode erosion and...

Page 49: ...ubri cation chart To check the engine oil level 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE Make sure that the vehicle is positioned straight up when checking the oil level A slight tilt to the side can result in a false reading 2 Start the engine warm it up for 10 15 minutes and then turn it off 3 Wait a few minutes until the oil set tles remove the oil filler...

Page 50: ... several minutes and then turn it off 2 Install the engine oil drain attach ment provided with the owner s tool kit under the drain bolt of the crankcase 3 Place an oil pan under the engine to collect the used oil 4 Remove the engine oil filler cap and the drain bolt to drain the oil from the crankcase 5 Remove the drain bolt to drain the oil from the oil tank 6 Remove the oil filter element drain...

Page 51: ...f and then add the remain der of the engine oil CAUTION ECA11620 In order to prevent clutch slip page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci fication of CD or oils of a high er quality than specified In 1 Oil filter element cover bolt 2 Oil filter element drain bolt 1 Oil filter element 2 O ring Tightening torques Oil f...

Page 52: ...ce the vehicle on a level sur face and hold it in an upright posi tion NOTE The coolant level must be checked on a cold engine since the level varies with engine temperature Make sure that the vehicle is posi tioned straight up when checking the coolant level A slight tilt to the side can result in a false reading 2 Check the coolant level in the cool ant reservoir NOTE The coolant should be betwe...

Page 53: ...r off according to the coolant temperature in the radia tor If the engine overheats see page 6 40 for further instructions EAUM1802 To change the coolant 1 Place the vehicle on a level sur face and let the engine cool if nec essary 2 Remove the seat and panel B See pages 3 12 and 6 5 3 Remove cowling B See page 6 5 4 Place a container under the engine to collect the used coolant 5 Loosen the radia...

Page 54: ...tem will not be protected against frost and corrosion If water has been added to the coolant have a Yamaha dealer check the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced 13 Install the coolant reservoir cap 14 Install the radiator cap and radiator cap retainer by installing the screw 15 Start the engine let it idle for sev eral min...

Page 55: ...ment should be re placed at the intervals specified in the periodic maintenance and lubrication chart Replace the air filter element more frequently if you are riding in un usually wet or dusty areas In addition the air filter check hose must be fre quently checked and cleaned if neces sary To replace the air filter element 1 Remove the seat See page 3 12 2 Remove panel B See page 6 5 3 Remove the...

Page 56: ...install it EAUM1910 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart The engine should be warm before making this adjustment NOTE The engine is warm when it quickly responds to the throttle A diagnostic tachometer is needed to make this adjustment 1 Attach the ...

Page 57: ...peration of your motor cycle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10500 The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature The tire air pressure must be ad justed in accordance with the ...

Page 58: ...ure before each ride Tire inspection The tires must be checked before each ride If the tire shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked have a Yamaha dealer replace the tire immediately Tire air pressure measured on cold tires 0 90 kg 0 198 lb Front XT660R 200 kPa 29 psi 2 00 kgf cm XT660X 210 kPa 30 psi 2 10 kgf cm Rear X...

Page 59: ...d brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience It is not recommended to patch a punctured tube If unavoid able however patch the tube very carefully and replace it as soon as possible with a high quality product Front tire Size XT660R 90 90 21M C 54S 90 90 21M C 54T XT660X 120 70R17 M C 58H 120 70ZR17 M C 58...

Page 60: ... broken in for it to develop its optimal characteris tics EAU22041 Adjusting the clutch lever free play The clutch lever free play should mea sure 10 0 15 0 mm 0 39 0 59 in as shown Periodically check the clutch le ver free play and if necessary adjust it as follows 1 Loosen the locknut at the clutch le ver 2 To increase the clutch lever free play turn the adjusting bolt in di rection a To decreas...

Page 61: ...e To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b EAU22390 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals spec ified in the periodic maintenance and lubrication chart EAU22430 Front brake pads Each front brake pad is provided with...

Page 62: ...above the minimum level mark and replenish if necessary A low brake fluid level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for leakage Observe these precautions When checking the fluid level make sure that the top of the brake fluid reservoir is level Use only the recommended quality brake f...

Page 63: ...justing the drive chain slack there should be no weight on the motorcycle 2 Shift the transmission into the neu tral position 3 Move the rear wheel by pushing the motorcycle to locate the tight est portion of the drive chain and then measure the drive chain slack as shown 4 If the drive chain slack is incorrect adjust it as follows NOTE When checking the drive chain slack the chain tensioner shoul...

Page 64: ...rection a To loos en the drive chain turn the adjust ing bolt on each side of the swingarm in direction b and then push the rear wheel forward NOTE Using the alignment marks on each side of the swingarm make sure that both chain pullers are in the same posi tion for proper wheel alignment CAUTION ECA10570 Improper drive chain slack will over load the engine as well as other vital parts of the moto...

Page 65: ... in the rain 1 Clean the drive chain with kero sene and a small soft brush CAUTION ECA11120 To prevent damaging the O rings do not clean the drive chain with steam cleaners high pressure washers or inappropriate solvents 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant CAUTION ECA11110 Do not use engine oil or any other lu bricants for the dri...

Page 66: ... inner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EAU23111 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated at the intervals specified in the periodic maintenance chart EAU23140 Checking and lubricating the brake and clutch levers Brake l...

Page 67: ...ecked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary WARNING EWA10730 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 Recommended lubricant Lithium soap based grease all pur pose grease Recommended lubricant Lithium soap bas...

Page 68: ...if the front fork compresses and rebounds smoothly CAUTION ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23280 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication char...

Page 69: ...ha dealer check the wheel bearings EAUM1730 Battery This model is equipped with a sealed type MF battery which does not re quire any maintenance There is no need to check the electrolyte or to add distilled water CAUTION ECA10620 Never attempt to remove the battery cell seals as this would permanent ly damage the battery To access the battery 1 Remove the seat See page 3 12 2 Remove the battery co...

Page 70: ... vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN To store the battery 1 If the vehicle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place 2 If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary 3 ...

Page 71: ... the electrical system and possibly a fire 3 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 1 Main fuse 2 Spare main fuse 1 Fuse box 1 2 Signaling system fuse 3 Headlight fuse 4 Ignition fuse 5 Fuel injection system fuse 6 Radiator fan fuse 7 Backup fuse for odometer clock and immo bilizer system 8 Parking lighting fuse 9 Fuse box 2 10 Spare fuse ...

Page 72: ... by turning it counterclockwise and then remove the defective bulb WARNING EWA10790 Headlight bulbs get very hot There fore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down 4 Place a new bulb into position and then secure it with the bulb holder CAUTION ECA10660 Do not touch the glass part of the headlight bulb to keep it free from oil other...

Page 73: ...essary EAU24281 Replacing a turn signal light bulb or the tail brake light bulb 1 Remove the lens by removing the screws 2 Remove the defective bulb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screws CAUTION ECA10680 Do not overtighten the screws oth erwise the lens ...

Page 74: ...r performing other maintenance requiring the motorcycle to stand up right Check that the motorcycle is in a stable and level position before starting any maintenance A strong wooden box can be placed under the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a ja...

Page 75: ...ove the brake caliper by re moving the bolts CAUTION ECA11070 Do not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut 4 Pull the wheel axle out and then remove the wheel EAUM1811 To install the front wheel 1 Lift the wheel up between the fork legs 2 Insert the wheel axle 3 Lower the front wheel so that it is on the ground 1 ...

Page 76: ...times to check for proper fork operation EAU25080 Rear wheel EAUM1773 To remove the rear wheel WARNING EWA10820 It is advisable to have a Yamaha dealer service the wheel Securely support the motor cycle so that there is no danger of it falling over 1 Remove the drive chain guard by removing the bolts XT660R XT660X 2 Loosen the axle nut XT660R Tightening torques Wheel axle 59 Nm 5 9 m kgf 43 ft lbf...

Page 77: ...N ECA11070 Do not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut EAUM2140 To install the rear wheel 1 Install the drive chain onto the rear sprocket 2 Install the wheel the washer s and the brake caliper bracket by inserting the wheel axle from the left hand side NOTE XT660R Install the washer with the N mark on the right ...

Page 78: ...uble may occur dur ing operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power 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 an...

Page 79: ...on Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Battery The engine ...

Page 80: ...sound has stopped press down on the cap while turning it counterclockwise and then remove the cap 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 Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the coolin...

Page 81: ...ot leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any harsh chemical products on plastic pa...

Page 82: ...ing 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Immediately dry the drive chain and lubricate it to prevent it from rusting 3 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even the thermally in duced discoloring of stainless steel exhaust systems can be re moved through polishing 4 To prevent corrosion it is recom mended to appl...

Page 83: ...s 1 Follow all the instructions in the Care section of this chapter 2 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 3 Perform the following steps to pro tect the cylinder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install t...

Page 84: ...n order to prevent the tires from becoming degraded in one spot 6 Cover the muffler outlets with plas tic bags to prevent moisture from entering them 7 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more information on storing the battery see ...

Page 85: ...igher Engine oil quantity Without oil filter element replacement 2 50 L 2 64 US qt 2 20 Imp qt With oil filter element replacement 2 60 L 2 75 US qt 2 29 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator capacity including all routes 1 00 L 1 06 US qt 0 88 Imp qt Air filter Air filter element Oil coated paper element Fuel Recommend...

Page 86: ...N METZELER SPORTEC M1 MICHELIN RADIAL PILOT SPORT Loading Maximum load 186 kg 410 lb Total weight of rider passenger cargo and accessories Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front XT660R 200 kPa 29 psi 2 00 kgf cm XT660X 210 kPa 30 psi 2 10 kgf cm Rear XT660R 200 kPa 29 psi 2 00 kgf cm XT660X 210 kPa 30 psi 2 10 kgf cm Loading condition 90 186 kg 198 410 lb...

Page 87: ...apacity 12 V 8 0 Ah Headlight Bulb type Halogen bulb Bulb voltage wattage quantity Headlight 12 V 55 W 60 0 W 1 Tail brake light 12 V 5 0 W 21 0 W 1 Front turn signal light 12 V 10 0 W 2 Rear turn signal light 12 V 10 0 W 2 Auxiliary light 12 V 5 0 W 1 Meter lighting EL Neutral indicator light LED High beam indicator light LED Turn signal indicator light LED Fuel level warning light LED Coolant te...

Page 88: ...fication number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU26410 Vehicle identification number The vehicle identification number is stamped into the frame NOTE The vehicle identification number is used to identify your vehicle and may be used to register it with the licensing authority in yo...

Page 89: ...ITED Owners are warned that the law may prohibit a The removal or rendering inopera tive by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the pur pose of noise control prior to its sale or delivery to the ultimate pur chaser or while it is in use and b The use of the vehicle after such device or elem...

Page 90: ...I Identification numbers 9 1 Ignition circuit cut off system 3 15 Immobilizer system 3 1 Immobilizer system indicator light 3 4 Indicator and warning lights 3 3 K Key identification number 9 1 L Labels location of 1 5 M Main switch steering lock 3 2 Model label 9 2 Multi function display 3 5 N Neutral indicator light 3 3 Noise regulation for Australia 9 2 P Parking 5 4 Part locations 2 1 Pass swit...

Page 91: ...INDEX V Vehicle identification number 9 1 W Wheel bearings checking 6 30 Wheel front 6 36 Wheel rear 6 37 Wheels 6 21 U5VK21E0 book Page 2 Tuesday July 18 2006 1 12 PM ProCarManuals com ...

Page 92: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ProCarManuals com ...

Page 93: ...A5 yoko_Blank fm Page 1 Tuesday April 8 2003 11 43 AM ProCarManuals com ...

Page 94: ...YAMAHA MOTOR CO LTD PRINTED IN FRANCE 2006 07 E ProCarManuals com ...

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Yamaha XT660RW, Owner'S Manual

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