Yamaha XT660XS Owner'S Manual Download Page 87

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INDEX

replacing and cleaning....................... 6-15

Auxiliary light bulb, replacing ................ 6-33

Battery................................................... 6-28
Brake and clutch levers, checking

and lubricating .................................... 6-25

Brake fluid level, checking .................... 6-22
Brake lever.............................................. 3-9
Brake pedal............................................. 3-9
Brake pedal, lubricating ........................ 6-26

Cables, checking and lubricating .......... 6-25
Care ........................................................ 7-1
Catalytic converter ................................ 3-11
Clutch lever ............................................. 3-8
Clutch lever free play, adjusting............ 6-20
Coolant.................................................. 6-12
Coolant temperature warning light .......... 3-4
Cowlings and panels, removing and

installing................................................ 6-5

Dimmer switch ........................................ 3-7
Drive chain, lubricating.......................... 6-24
Drive chain slack................................... 6-23

Engine break-in....................................... 5-3
Engine idling speed............................... 6-16
Engine oil and oil filter element ............... 6-9
Engine stop switch .................................. 3-8
Engine trouble warning light.................... 3-4

Front and rear brake pads, checking .... 6-21

Front fork, checking .............................. 6-27
Fuel....................................................... 3-10
Fuel consumption, tips for reducing........ 5-3
Fuel level warning light ........................... 3-4
Fuel tank cap ........................................ 3-10
Fuses, replacing ................................... 6-30

Handlebar switches ................................ 3-7
Hazard switch ......................................... 3-8
Headlight bulb, replacing ...................... 6-31
High beam indicator light ........................ 3-4
Horn switch............................................. 3-8

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

Key identification number ....................... 9-1

Labels, location of................................... 1-5

Main switch/steering lock........................ 3-2
Model label ............................................. 9-2
Multi-function display .............................. 3-5

Neutral indicator light.............................. 3-3
Noise regulation (for Australia) ............... 9-2

Parking ................................................... 5-4
Part locations.......................................... 2-1
Pass switch............................................. 3-7

Periodic maintenance and lubrication

chart......................................................6-2

Pre-operation check list...........................4-2

Rear brake light switch, adjusting ......... 6-21

Throttle cable free play, adjusting ......... 6-17
Throttle grip and cable, checking

and lubricating .................................... 6-25

Tires ......................................................6-17
Tool kit..................................................... 6-1
Troubleshooting .................................... 6-37
Troubleshooting charts.......................... 6-38
Turn signal indicator light ........................ 3-3
Turn signal light bulb or tail/brake light

bulb, replacing .................................... 6-32

Turn signal switch ...................................3-7

ProCarManuals.com

Summary of Contents for XT660XS

Page 1: ...5VK F8199 20 XT660XS OWNER S MANUAL ProCarManuals com ...

Page 2: ...ProCarManuals com ...

Page 3: ...epancies between your motorcycle and this manual If you have any questions concerning this manual please consult your Yamaha dealer WARNING EWA10030 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE 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 motorcy...

Page 4: ...XT660RS XT660XS OWNER S MANUAL 2004 by MBK INDUSTRIE 1st edition January 2004 All rights reserved Any reprinting or unauthorized use without the written permission of MBK INDUSTRIE is expressly prohibited Printed in France ProCarManuals com ...

Page 5: ...ings and panels 6 5 Checking the spark plug 6 7 Engine oil and oil filter element 6 9 Coolant 6 12 Replacing the air filter element and cleaning the check hose 6 15 Adjusting the engine idling speed 6 16 Adjusting the throttle cable free play 6 17 Tires 6 17 Spoke wheels 6 19 Adjusting the clutch lever free play 6 20 Adjusting the rear brake light switch 6 21 Checking the front and rear brake pads...

Page 6: ...BLE 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 Motorcycle noise regulation for Australia 9 2 ProCarManuals com ...

Page 7: ...ccidents Many accidents have 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 ...

Page 8: ... the engine or exhaust system during or after operation They become very hot and can cause burns Always wear protec tive clothing that covers your legs ankles and feet Modifications Modifications made to this motorcycle not approved by Yamaha or the re moval of original equipment may ren der the motorcycle unsafe for use and may cause severe personal injury Modifications may also make your motorcy...

Page 9: ... due to improper weight distribution or aerody namic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody namic effects Wind may at tempt to lift the motorcycle or the motorcycle may become un stable in cross winds The...

Page 10: ...wise 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 ON or RES for vacuum type OFF for manual type If the motorcycle should lean over gasoline may leak out of the carburetor or fue...

Page 11: ...SAFETY INFORMATION 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 ProCarManuals com ...

Page 12: ...usting screw page 6 16 3 Main fuse page 6 30 4 Battery page 6 28 5 Fuse box 1 page 6 30 6 Fuse box 2 page 6 30 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 9 ProCarManuals com ...

Page 13: ...g preload adjusting ring page 3 13 4 Rear brake fluid reservoir page 6 22 5 Front brake fluid reservoir page 6 22 6 Engine oil filler cap page 6 9 7 Engine oil drain bolt oil tank page 6 9 8 Coolant reservoir page 6 12 9 Engine oil filter element page 6 9 10 Coolant drain bolt page 6 13 11 Brake pedal page 3 9 ProCarManuals com ...

Page 14: ... 1 Clutch lever page 3 8 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 17 8 Fuel tank cap page 3 10 ProCarManuals com ...

Page 15: ...age 3 8 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 17 8 Fuel tank cap page 3 10 ProCarManuals com ...

Page 16: ...MMEDIATELY IF IT IS LOST 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...

Page 17: ...its 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 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 ke...

Page 18: ...ectrical systems are off 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 EAU11001 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 Neu...

Page 19: ...l The electrical circuit 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 def...

Page 20: ...tance traveled since the fuel level warning light came on a clock a self diagnosis device NOTE Be sure 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 o...

Page 21: ...a two digit error code e 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...

Page 22: ... switches Left Right EAU12350 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 swit...

Page 23: ... With the key in the ON or posi tion use this switch to turn on the haz ard light simultaneous flashing of all turn signal lights The hazard light is used in case of an emergency or to warn other drivers when your vehicle is stopped where it might be a traffic hazard CAUTION ECA10060 Do not use the hazard light for an ex tended length of time otherwise the battery may discharge EAU12820 Clutch lev...

Page 24: ...e 5 speed con stant mesh 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 ProCarManuals com ...

Page 25: ... then re move it 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 WARNING EWA11140 Make sure that the fuel tank cap is properly installed before riding EAU13210 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 EWA...

Page 26: ...intenance costs EAU13430 Catalytic converter This model is equipped with a catalytic converter in the exhaust chamber 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 ...

Page 27: ... sure that the seat is properly 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...

Page 28: ... the spring preload and thereby 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 can...

Page 29: ...art of the ignition circuit 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 possi...

Page 30: ...stand is up but the clutch 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 malfunctio...

Page 31: ... engine stall After the engine 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...

Page 32: ...ave serious consequences 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 ch...

Page 33: ...ck 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 necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 21 6 22 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check brake pads for wear Replace if necessary Check flui...

Page 34: ...ressure Correct if necessary 6 17 6 19 Brake pedal Make sure that operation is smooth Lubricate pedal pivoting point if necessary 6 26 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 25 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 26 Chassis fasteners Make sure that all nuts bolts and screws are properly tight...

Page 35: ...s in gear with the clutch 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 com...

Page 36: ...he il lustration NOTE To 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 ...

Page 37: ...son you should read the 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 A...

Page 38: ...EWA10310 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 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 ProCarManuals com ...

Page 39: ...liar with mainte nance work 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 ...

Page 40: ...s NO ITEM CHECK OR MAINTENANCE 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...

Page 41: ...teering 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 ...

Page 42: ... level and vehicle for coolant 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 t...

Page 43: ...fer to this section each time a cowling or panel needs to be re moved and installed EAUM1682 Cowling A To remove the cowling Remove the bolts and spacers and then lift the cowling up to remove it To install the cowling 1 Place the cowling bracket tab be tween the protector and the brack et on each side 1 Cowling A 1 Panel A 1 Cowling B 2 Panel B 1 Bolt 1 Protector 2 Cowling bracket tab 3 Bracket P...

Page 44: ...owling off at the area shown To install the cowling 1 Place the cowling in the original position and then tighten the quick fastener screws and install 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 at the area shown To install the panel 1 Place the panel in the orig...

Page 45: ... The spark plug is an important engine component which is easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checked in accordance with the periodic mainte nance and lubrication chart In addition the condition of the spark plug can re veal the condition of the engine To remove the spark plug 1 Remove the spark plug cap 2 Remove the ...

Page 46: ... the spark plug gap with a wire thickness gauge and if nec essary adjust the gap to specifica tion 2 Clean the surface of the spark plug gasket and its mating surface and then wipe off any grime from the spark plug threads 3 Install the spark plug with the spark plug wrench and then tight en it to the specified torque NOTE If a torque wrench is not available when installing a spark plug a good est...

Page 47: ...again to check the oil level NOTE The engine oil tank is located in side of the frame The engine oil should be between the minimum and maximum level marks CAUTION ECA10010 Do not operate the vehicle until you know that the engine oil level is suf ficient WARNING EWA10360 Never remove the engine oil tank cap after high speed operation oth erwise hot engine oil could spout out and cause damage or in...

Page 48: ... oil filter element drain bolt to drain the oil from the oil filter element NOTE Skip steps 7 9 if the oil filter element is not being replaced 7 Remove the oil filter element cover by removing the bolts 8 Remove and replace the oil filter element and O rings 1 Engine oil drain bolt crankcase 2 Engine oil drain attachment 1 Engine oil drain bolt oil tank 1 Oil filter element cover bolt 2 Oil filte...

Page 49: ...e 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 addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase 12 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking im mediately turn the eng...

Page 50: ...ark remove cowl ing B See page 6 5 and then open the reservoir cap 4 Add coolant to the maximum level mark and then close the reservoir cap CAUTION ECA10470 If coolant is not available use distilled water or soft tap water instead Do not use hard water or salt water since it is harmful to the engine If water has been used instead of coolant replace it with cool ant as soon as possible other wise t...

Page 51: ...olant 5 Loosen the radiator cap retainer screw 6 Remove the radiator cap and cool ant reservoir cap WARNING EWA10380 Never attempt to remove the radiator cap when the engine is hot 7 Remove the coolant reservoir bolts and then turn the coolant reservoir upside down to empty it 8 Install the coolant reservoir by placing it in the original position then installing the bolts 9 Remove the coolant drai...

Page 52: ...e 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 minutes and then turn it off 16 Check the coolant level in the res ervoir If necessary remove the coolant reservoir cap add coolant to the maximum level mark and then install the cap 17 Sta...

Page 53: ... See page 6 5 3 Remove the air filter case cover by removing the screws 4 Pull the air filter element out 5 Insert a new air filter element into the air filter case as shown CAUTION ECA10480 Make sure that the air filter ele ment is properly seated in the air filter case The engine should never be op erated without the air filter ele ment installed otherwise the piston s and or cylinder s may beco...

Page 54: ...it quickly responds to the throttle A diagnostic tachometer is needed to make this adjustment 1 Attach the tachometer to the spark plug lead 2 Check the engine idling speed and if necessary adjust it to spec ification by turning the idle adjust ing screw To increase the engine idling speed turn the screw in di rection a To decrease the en gine idling speed turn the screw in direction b NOTE If the...

Page 55: ... the temperature of the tires equals the ambient temperature The tire air pressure must be ad justed in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model 1 Throttle cable free play 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 XT660R ...

Page 56: ...and tire air pressure with regard to the load Check the tire condition and air pressure 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 NOTE The tire tread depth limits may differ from count...

Page 57: ... bends or warpage and the spokes for looseness or dam age before each ride If any dam age is found have a Yamaha dealer replace the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced The wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dling cha...

Page 58: ... the specified clutch lever free play could be obtained as described above tighten the locknut and skip the rest of the procedure otherwise proceed as follows 3 Fully turn the adjusting bolt at the clutch lever in direction a to loos en the clutch cable 4 Loosen the locknut at the crank case 5 To increase the clutch lever free play turn the adjusting nut in direc tion a To decrease the clutch le v...

Page 59: ...ar at the intervals spec ified in the periodic maintenance and lubrication chart EAU22430 Front brake pads Each front brake pad is provided with wear indicator grooves which allow you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that the wear indicator grooves have almost disap...

Page 60: ... level Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boiling poi...

Page 61: ...er should not be touching the drive chain EAU22930 To adjust the drive chain slack 1 Loosen the axle nut then loosen the locknut at each end of the swingarm 2 To tighten the drive chain turn the adjusting nut at each end of the swingarm in direction a To loos en the drive chain turn the adjust ing nut at each end of the swingarm in direction b and then push the rear wheel forward NOTE Using the al...

Page 62: ... The drive chain must be lubricated after washing the motorcycle and riding 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 ...

Page 63: ... and will cause the inner cable to rust Replace a damaged cable as soon as possible to prevent unsafe conditions EAU23110 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 or replaced at the intervals specified in the periodic maintenance chart EAU23140 Checking and lubricating the ...

Page 64: ...he sidestand should be checked 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 l...

Page 65: ...rs several times to check 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 mainte...

Page 66: ... turn smoothly have a Yamaha 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 ...

Page 67: ... from the battery and pro 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 ...

Page 68: ...ng extensive damage to 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 Electronic fuel injection fuse 6 Radiator fan fuse 7 Backup fuse for odometer clock and immobilizer system 8 Parking lighting fuse 9 ...

Page 69: ...the headlight bulb holder 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 ke...

Page 70: ...the headlight beam if necessary 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 sc...

Page 71: ...he front and rear wheel or 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 ...

Page 72: ...ocedure on page 6 33 3 Remove 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 t...

Page 73: ...ard on the handlebar several times to check for proper fork operation EAU25080 Rear wheel EAUM1771 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 Tightening torques Wheel axle 59 ...

Page 74: ...d together with the brake disc otherwise the brake pads will be forced shut EAUM1781 To install the rear wheel 1 Install the drive chain onto the rear sprocket 2 Install the wheel the washers and the brake caliper bracket by insert ing the wheel axle from the left hand side NOTE Install the washer with the N mark on the right hand side and the washer with the O mark on the left hand side Be sure t...

Page 75: ... 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 and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imi...

Page 76: ...sion There is no compression 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 sta...

Page 77: ...o escape When the hissing 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 lev...

Page 78: ... hard to remove dirt do not 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 chemic...

Page 79: ...o prevent corrosion After cleaning 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 corro...

Page 80: ...rcycle for sev eral months 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 sp...

Page 81: ...ls a little every month in 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...

Page 82: ...ade API service SE SF SG type or higher 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 c...

Page 83: ...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 Front XT660R 200 kPa 29 psi 2 00 kgf cm XT660X 220 kPa 32 psi 2 20 kgf cm Rear XT660R 225 ...

Page 84: ... type Halogen bulb Bulb voltage wattage x quantity Headlight 12 V 55 W 60 0 W 1 Tail brake light 12 V 5 0 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 temperature indicator light LED Engi...

Page 85: ...ATION EAU26381 Key identification 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 ...

Page 86: ...SE CON TROL SYSTEM PROHIBITED 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 ...

Page 87: ... Horn switch 3 8 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 locati...

Page 88: ...INDEX V Vehicle identification number 9 1 W Wheel bearings checking 6 28 Wheel front 6 34 Wheel rear 6 35 Wheels 6 19 ProCarManuals com ...

Page 89: ...ProCarManuals com ...

Page 90: ...ProCarManuals com ...

Page 91: ...YAMAHA MOTOR CO LTD PRINTED IN FRANCE 2004 02 E ProCarManuals com ...

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Yamaha XT660XS, Owner'S Manual

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