Yamaha XT660R User manual

2004

XT660R(S)

XT660X(S)

5VK1-AE1

SERVICE MANUAL

EAS00000

XT660R(S)/XT660X(S) 2004

SERVICE MANUAL

First edition, December 2003

Any reproduction or unauthorized use

without the written permission of

MBK Industrie

is expressly prohibited.

EAS00002

NOTICE

This manual was produced by MBK Industrie primarily for use by Yamaha dealers and their quali-

fied mechanics. It is not possible to include all the knowledge of a mechanic in one manual. There-

fore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should

have a basic understanding of mechanics and the techniques to repair these types of vehicles.

Repair and maintenance work attempted by anyone without this knowledge is likely to render the

vehicle unsafe and unfit for use.

Yamaha is continually striving to improve all its models. Modifications and significant changes in

specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in

future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

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IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

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 motorcycle operator, a bystander or a person checking or repairing

the motorcycle.

A CAUTION indicates special precautions that must be taken to avoid dam-

age to the motorcycle.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

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HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are

laid out with the individual steps in sequential order.

1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of

each page indicate the current chapter.

Refer to “SYMBOLS”.

2Each chapter is divided into sections. The current section title is shown at the top of each page,

except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section

title(s) appears.

3Sub-section titles appear in smaller print than the section title.

4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of

each removal and disassembly section.

5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a

disassembly step.

6Symbols indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

8Jobs requiring more information (such as special tools and technical data) are described sequen-

tially.

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SYMBOLS

The following symbols are not relevant to

every vehicle.

Symbols 1to 9indicate the subject of each

chapter.

1General information

2Specifications

3Periodic checks and adjustments

4Chassis

5Engine

6Cooling system

7Fuel injection system

8Electrical system

9Troubleshooting

Symbols 0to Gindicate the following.

0Serviceable with engine mounted

AFilling fluid

BLubricant

CSpecial tool

DTightening torque

EWear limit, clearance

FEngine speed

GElectrical data

Symbols Hto Min the exploded diagrams

indicate the types of lubricants and lubrication

points.

HEngine oil

IGear oil

JMolybdenum-disulfide oil

KWheel-bearing grease

LLithium-soap-based grease

MMolybdenum-disulfide grease

Symbols Nto Oin the exploded diagrams

indicate the following.

NApply locking agent (LOCTITE®)

OReplace the part

EFG

HIJ

KLM

GEN

INFO

SPEC

CHK

ADJ

CHAS

ENG

COOL

FI –+

ELEC

TRBL

SHTG

EGM

BLS M

New

EAS00010

TABLE OF CONTENTS

GENERAL INFORMATION GEN

INFO 1

SPECIFICATIONS SPEC 2

PERIODIC CHECKS AND

ADJUSTMENTS CHK

ADJ 3

CHASSIS CHAS 4

ENGINE ENG 5

COOLING SYSTEM COOL 6

FUEL INJECTION SYSTEM FI 7

ELECTRICAL SYSTEM ELEC 8

TROUBLESHOOTING TRBL

SHTG 9

–+

GEN

INFO 1

GEN

INFO

CHAPTER 1

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION..................................................................1-1

VEHICLE IDENTIFICATION NUMBER .....................................................1-1

MODEL LABEL..........................................................................................1-1

FEATURES......................................................................................................1-2

OUTLINE ...................................................................................................1-2

FI SYSTEM................................................................................................1-3

IMPORTANT INFORMATION .........................................................................1-4

PREPARATION FOR REMOVAL AND DISASSEMBLY...........................1-4

REPLACEMENT PARTS...........................................................................1-4

GASKETS, OIL SEALS AND O-RINGS ....................................................1-4

LOCK WASHERS/PLATES AND COTTER PINS .....................................1-5

BEARINGS AND OIL SEALS ....................................................................1-5

CIRCLIPS ..................................................................................................1-5

CHECKING THE CONNECTIONS ..................................................................1-6

SPECIAL TOOLS ............................................................................................1-7

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