XT660R XT660X - hp2.sehp2.se/lager/singles/xtom.pdf · This motorcycle is designed to car-ry the operator and a passenger. The failure of motorists to detect and recognize motorcycles

5VK-F8199-E0

XT660RXT660X

OWNER’S MANUAL

DECLARATION of CONFORMITY

We

Hereby declare that the product:

is in compliance with following norm(s) or documents:

Type-designation: 5SL-00, 5VS-00, 5VX-00, 3HT-00, 5UX-00, 5UX-10, 5KS-00 and 5KS-10

R&TTE Directive(1999/5/EC)EN300 330-2 v1.1.1(2001-6), EN60950(2000)Two or Three-Wheel Motor Vehicles Directive(97/24/EC: Chapter 8, EMC)

Place of issue: Shizuoka, Japan

Date of issue: Aug. 1st 2002

Kind of equipment: IMMOBILIZER

Address: 1450-6 Mori Mori-Machi Shuchi-gun Shizuoka 437-0292 JapanCompany: MORIC CO., LTD.

Kazuji Kawai

representative name and signature

EAU26941

INTRODUCTIONEAU10100

Welcome to the Yamaha world of motorcycling!As the owner of the XT660R/XT660X, you are benefiting from Yamaha’s vast experience and newest technology regardingthe design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability.Please take the time to read this manual thoroughly, so as to enjoy all advantages of your XT660R/XT660X. The owner’smanual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguardyourself 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 anyfurther questions, do not hesitate to contact your Yamaha dealer.The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!

IMPORTANT MANUAL INFORMATIONEAU10150

Particularly important information is distinguished in this manual by the following notations:

NOTE:� This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle

is subsequently sold.� Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most

current product information available at the time of printing, there may be minor discrepancies between your motorcycleand this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.

WARNINGEWA10030

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 motorcycle operator, a bystander, or a person inspecting or repairing the motor-cycle.

A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle.

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

WARNING

CAUTION:

NOTE:

IMPORTANT MANUAL INFORMATION

EAUM1010

XT660R/XT660XOWNER’S MANUAL

©2003 by MBK INDUSTRIE2nd edition, December 2003

All rights reservedAny reprinting or unauthorized use without the written permission of

MBK INDUSTRIE is expressly prohibited.

Printed in France.

TABLE OF CONTENTSSAFETY INFORMATION ..................1-1

DESCRIPTION ..................................2-1Left view ..........................................2-1Right view ........................................2-2Controls and instruments.................2-3

INSTRUMENT AND CONTROL FUNCTIONS .......................................3-1

Immobilizer system .........................3-1Main switch/steering lock ................3-2Indicator and warning lights ............3-3Multi-function display ......................3-5Anti-theft alarm (optional) ...............3-7Handlebar switches ........................3-7Clutch lever .....................................3-9Shift pedal .......................................3-9Brake lever .....................................3-9Brake pedal ..................................3-10Fuel tank cap ................................3-10Fuel ...............................................3-11Catalytic converter ........................3-12Seat ..............................................3-12Storage compartment ...................3-13Adjusting the shock absorber

assembly ...................................3-13Sidestand ......................................3-14Ignition circuit cut-off system ........3-15

PRE-OPERATION CHECKS ..............4-1Pre-operation check list ..................4-2

OPERATION AND IMPORTANT RIDING POINTS................................. 5-1

Starting the engine ......................... 5-1Shifting ........................................... 5-2Tips for reducing fuel

consumption ............................... 5-3Engine break-in .............................. 5-3Parking ........................................... 5-4

PERIODIC MAINTENANCE AND MINOR REPAIR ................................. 6-1

Owner’s tool kit ............................... 6-1Periodic maintenance and

lubrication chart .......................... 6-2Removing and installing cowlings

and panels .................................. 6-5Checking the spark plug ................. 6-7Engine oil and oil filter element ...... 6-9Coolant ......................................... 6-12Replacing the air filter element and

cleaning the check hose ........... 6-15Adjusting the engine idling

speed ........................................ 6-16Adjusting the throttle cable free

play ........................................... 6-17Tires .............................................. 6-17Spoke wheels ............................... 6-19Adjusting the clutch lever free

play ........................................... 6-20Adjusting the rear brake light

switch ........................................ 6-21

Checking the front and rear brake pads ................................ 6-21

Checking the brake fluid level ...... 6-22Drive chain slack .......................... 6-23Lubricating the drive chain ........... 6-24Checking and lubricating the

cables ....................................... 6-25Checking and lubricating the

throttle grip and cable ............... 6-25Checking and lubricating the

brake and clutch levers ............ 6-25Lubricating the brake pedal ......... 6-26Checking and lubricating the

sidestand .................................. 6-26Checking the front fork ................. 6-27Checking the steering .................. 6-27Checking the wheel bearings ....... 6-28Battery ......................................... 6-28Replacing the fuses ..................... 6-30Replacing the headlight bulb ....... 6-31Replacing a turn signal light bulb

or the tail/brake light bulb ......... 6-32Replacing an auxiliary light

bulb ........................................... 6-33Supporting the motorcycle ........... 6-33Front wheel .................................. 6-34Rear wheel ................................... 6-35Troubleshooting ........................... 6-37Troubleshooting charts ................ 6-38

TABLE OF CONTENTSMOTORCYCLE CARE AND STORAGE ..........................................7-1

Care ................................................7-1Storage ...........................................7-3

SPECIFICATIONS .............................8-1

CONSUMER INFORMATION.............9-1Identification numbers ....................9-1

1-1

1

SAFETY INFORMATION EAU10310

MOTORCYCLES ARE SINGLETRACK VEHICLES. THEIR SAFE USEAND OPERATION ARE DEPENDENTUPON THE USE OF PROPER RIDINGTECHNIQUES AS WELL AS THE EX-PERTISE OF THE OPERATOR. EV-ERY OPERATOR SHOULD KNOWTHE FOLLOWING REQUIREMENTSBEFORE RIDING THIS MOTOR-CYCLE.HE OR SHE SHOULD:

� OBTAIN THOROUGH INSTRUC-TIONS FROM A COMPETENTSOURCE ON ALL ASPECTS OFMOTORCYCLE OPERATION.

� OBSERVE THE WARNINGS ANDMAINTENANCE REQUIRE-MENTS IN THE OWNER’S MAN-UAL.

� OBTAIN QUALIFIED TRAININGIN SAFE AND PROPER RIDINGTECHNIQUES.

� OBTAIN PROFESSIONAL TECH-NICAL SERVICE AS INDICATEDBY THE OWNER’S MANUAL

AND/OR WHEN MADE NECES-SARY BY MECHANICAL CONDI-TIONS.

Safe riding� Always make pre-operation

checks. Careful checks may helpprevent an accident.

� This motorcycle is designed to car-ry the operator and a passenger.

� The failure of motorists to detectand recognize motorcycles in traf-fic is the predominating cause ofautomobile/motorcycle accidents.Many accidents have been causedby an automobile driver who didnot see the motorcycle. Makingyourself conspicuous appears tobe very effective in reducing thechance of this type of accident.Therefore:• Wear a brightly colored jacket.• Use extra caution when ap-

proaching and passing throughintersections, since intersec-tions are the most likely placesfor motorcycle accidents to oc-cur.

• Ride where other motorists cansee you. Avoid riding in anothermotorist’s blind spot.

� Many accidents involve inexperi-enced operators. In fact, many op-erators who have been involved inaccidents do not even have a cur-rent motorcycle license.• Make sure that you are qualified

and that you only lend yourmotorcycle to other qualified op-erators.

• Know your skills and limits.Staying within your limits mayhelp you to avoid an accident.

• We recommend that you prac-tice riding your motorcyclewhere there is no traffic until youhave become thoroughly famil-iar with the motorcycle and all ofits controls.

� Many accidents have been causedby error of the motorcycle opera-tor. A typical error made by the op-erator is veering wide on a turn

SAFETY INFORMATION

1-2

1

due to EXCESSIVE SPEED or un-dercornering (insufficient lean an-gle for the speed).• Always obey the speed limit and

never travel faster than warrant-ed by road and traffic conditions.

• Always signal before turning orchanging lanes. Make sure thatother motorists can see you.

� The posture of the operator andpassenger is important for propercontrol.• The operator should keep both

hands on the handlebar andboth feet on the operator foot-rests during operation to main-tain control of the motorcycle.

• The passenger should alwayshold onto the operator, the seatstrap or grab bar, if equipped,with both hands and keep bothfeet on the passenger footrests.

• Never carry a passenger unlesshe or she can firmly place bothfeet on the passenger footrests.

� Never ride under the influence ofalcohol or other drugs.

Protective apparelThe majority of fatalities from motor-cycle accidents are the result of headinjuries. The use of a safety helmet isthe single most critical factor in the pre-vention or reduction of head injuries.

� Always wear an approved helmet.� Wear a face shield or goggles.

Wind in your unprotected eyescould contribute to an impairmentof vision that could delay seeing ahazard.

� The use of a jacket, heavy boots,trousers, gloves, etc., is effective inpreventing or reducing abrasionsor lacerations.

� Never wear loose-fitting clothes,otherwise they could catch on thecontrol levers, footrests, or wheelsand cause injury or an accident.

� Never touch the engine or exhaustsystem during or after operation.They become very hot and cancause burns. Always wear protec-tive clothing that covers your legs,ankles, and feet.

� Passengers should also observethe precautions mentioned above.

ModificationsModifications made to this motorcyclenot approved by Yamaha, or the re-moval of original equipment, may ren-der the motorcycle unsafe for use andmay cause severe personal injury.Modifications may also make yourmotorcycle illegal to use.

Loading and accessoriesAdding accessories or cargo to yourmotorcycle can adversely affect stabili-ty and handling if the weight distributionof the motorcycle is changed. To avoidthe possibility of an accident, use ex-treme caution when adding cargo oraccessories to your motorcycle. Useextra care when riding a motorcyclethat has added cargo or accessories.Here are some general guidelines tofollow if loading cargo or adding acces-sories to your motorcycle:LoadingThe total weight of the operator, pas-senger, accessories and cargo mustnot exceed the maximum load limit of186 kg (410 lb). When loading withinthis weight limit, keep the following inmind:

SAFETY INFORMATION

1-3

1

� Cargo and accessory weightshould be kept as low and close tothe motorcycle as possible. Makesure to distribute the weight asevenly as possible on both sides ofthe motorcycle to minimize imbal-ance or instability.

� Shifting weights can create a sud-den imbalance. Make sure that ac-cessories and cargo are securelyattached to the motorcycle beforeriding. Check accessory mountsand cargo restraints frequently.

� Never attach any large or heavyitems to the handlebar, front fork,or front fender. These items, in-cluding such cargo as sleepingbags, duffel bags, or tents, cancreate unstable handling or a slowsteering response.

AccessoriesGenuine Yamaha accessories havebeen specifically designed for use onthis motorcycle. Since Yamaha cannottest all other accessories that may beavailable, you must personally be re-sponsible for the proper selection, in-stallation and use of non-Yamaha

accessories. Use extreme cautionwhen selecting and installing any ac-cessories.Keep the following guidelines in mind,as well as those provided under “Load-ing” when mounting accessories.

� Never install accessories or carrycargo that would impair the perfor-mance of your motorcycle. Care-fully inspect the accessory beforeusing it to make sure that it doesnot in any way reduce groundclearance or cornering clearance,limit suspension travel, steeringtravel or control operation, or ob-scure lights or reflectors.• Accessories fitted to the handle-

bar or the front fork area cancreate instability due to improperweight distribution or aerody-namic changes. If accessoriesare added to the handlebar orfront fork area, they must be aslightweight as possible andshould be kept to a minimum.

• Bulky or large accessories mayseriously affect the stability ofthe motorcycle due to aerody-namic effects. Wind may at-

tempt to lift the motorcycle, orthe motorcycle may become un-stable in cross winds. These ac-cessories may also causeinstability when passing or beingpassed by large vehicles.

• Certain accessories can dis-place the operator from his orher normal riding position. Thisimproper position limits the free-dom of movement of the opera-tor and may limit control ability,therefore, such accessories arenot recommended.

� Use caution when adding electri-cal accessories. If electrical acces-sories exceed the capacity of themotorcycle’s electrical system anelectric failure could result, whichcould cause a dangerous loss oflights or engine power.

Gasoline and exhaust gas� GASOLINE IS HIGHLY FLAMMA-

BLE:• Always turn the engine off when

refueling.

SAFETY INFORMATION

1-4

1

• Take care not to spill any gaso-line on the engine or exhaustsystem when refueling.

• Never refuel while smoking or inthe vicinity of an open flame.

� Never start the engine or let it runfor any length of time in a closedarea. The exhaust fumes are poi-sonous and may cause loss ofconsciousness and death within ashort time. Always operate yourmotorcycle in an area that has ad-equate ventilation.

� Always turn the engine off beforeleaving the motorcycle unattendedand remove the key from the mainswitch. When parking the motor-cycle, note the following:• The engine and exhaust system

may be hot, therefore, park themotorcycle in a place where pe-destrians or children are not like-ly to touch these hot areas.

• Do not park the motorcycle on aslope or soft ground, otherwise itmay fall over.

• Do not park the motorcycle neara flammable source (e.g., a ker-osene heater, or near an openflame), otherwise it could catchfire.

� When transporting the motorcyclein another vehicle, make sure thatit is kept upright and that the fuelcock(s) are turned to “ON” or“RES” (for vacuum type)/“OFF”(for manual type). If the motorcycleshould lean over, gasoline mayleak out of the carburetor or fueltank.

� If you should swallow any gaso-line, inhale a lot of gasoline vapor,or allow gasoline to get into youreyes, see your doctor immediately.If any gasoline spills on your skinor clothing, immediately wash theaffected area with soap and waterand change your clothes.

DESCRIPTION

2-1

2

EAU10410

Left view

1. Windshield2. Idle adjusting 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 3-13)8. Grab bar

9. Seat lock (page 3-12)10.Shift pedal (page 3-9)11.Engine oil drain bolt (crankcase) (page 6-9)

DESCRIPTION

2-2

2

EAU10420

Right view

1. Owner’s tool kit (page 6-1)2. Air filter element (page 6-15)3. Shock absorber assembly spring 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 3-10)

DESCRIPTION

2-3

2

EAU32240

Controls and instruments

XT660R

1. Clutch lever (page 3-9)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)

DESCRIPTION

2-4

2

XT660X

1. Clutch lever (page 3-9)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)

INSTRUMENT AND CONTROL FUNCTIONS

3-1

3

EAU10972

Immobilizer system

This vehicle is equipped with an immo-bilizer system to help prevent theft byre-registering codes in the standardkeys. This system consists of the fol-lowing.

� a code re-registering key (with ared bow)

� two standard keys (with a blackbow) that can be re-registered withnew codes

� a transponder (which is installed inthe code re-registering key)

� an immobilizer unit� an ECU

� an immobilizer system indicatorlight (See page 3-3.)

The key with the red bow is used to reg-ister codes in each standard key. Sincere-registering is a difficult process, takethe vehicle along with all three keys toa Yamaha dealer to have them re-reg-istered. Do not use the key with the redbow for driving. It should only be usedfor re-registering the standard keys. Al-ways use a standard key for driving.

CAUTION:ECA11820

� DO NOT LOSE THE CODE RE-REGISTERING KEY! CONTACTYOUR DEALER IMMEDIATELYIF IT IS LOST! If the code re-reg-istering key is lost, registeringnew codes in the standard keysis impossible. The standardkeys can still be used to startthe vehicle, however if code re-registering is required (i.e., if anew standard key is made or allkeys are lost) the entire immobi-lizer system must be replaced.Therefore, it is highly recom-

mended to use either standardkey and keep the code re-regis-tering key in a safe place.

� Do not submerse any key in wa-ter.

� Do not expose any key to exces-sively high temperatures.

� Do not place any key close tomagnets (this includes, but notlimited to, products such asspeakers, etc.).

� Do not place heavy items on anykey.

� Do not grind any key or alter itsshape.

� Do not disassemble the plasticpart of any key.

� Do not put two keys of any im-mobilizer system on the samekey ring.

� Keep the standard keys as wellas keys of other immobilizersystems away from this vehi-cle’s code re-registering key.

� Keep other immobilizer systemkeys away from the main switchas they may cause signal inter-ference.

1. Code re-registering key (red bow)2. Standard keys (black bow)


3-2

3

EAU10471

Main switch/steering lock

The main switch/steering lock controlsthe ignition and lighting systems, and isused to lock the steering.

NOTE:Be sure to use the standard key (blackbow) for regular use of the vehicle. Tominimize the risk of losing the code re-registering key (red bow), keep it in asafe place and only use it for code re-registering.

EAU10570

ONAll electrical circuits are supplied withpower; the meter lighting, taillight andauxiliary light come on, and the enginecan be started. The key cannot be re-moved.

NOTE:The headlight comes on automaticallywhen the engine is started and stays onuntil the key is turned to “OFF”.

EAU10660

OFFAll electrical systems are off. The keycan be removed.

EAU10680

LOCKThe steering is locked, and all electricalsystems are off. The key can be re-moved.

To lock the steering

1. Turn the handlebars all the way tothe left.

2. Push the key in from the “OFF” po-sition, and then turn it to “LOCK”while still pushing it.

3. Remove the key.

1. Push.2. Turn.


3-3

3

To unlock the steering

Push the key in, and then turn it to“OFF” while still pushing it.

WARNINGEWA10060

Never turn the key to “OFF” or“LOCK” while the vehicle is moving,otherwise the electrical systems willbe switched off, which may result inloss of control or an accident. Makesure that the vehicle is stopped be-fore turning the key to “OFF” or“LOCK”.

EAU33000

(Parking)The steering is locked, and the taillightand auxiliary light are on. The hazardlight and turn signal lights can be turnedon, but all other electrical systems areoff. The key can be removed.The steering must be locked before thekey can be turned to “ ”.

CAUTION:ECA11020

Do not use the parking position foran 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 theturn signal switch is pushed to the left orright.

EAU11060

Neutral indicator light “ ” This indicator light comes on when thetransmission is in the neutral position.

1. Push.2. Turn. 1. Engine trouble warning light “ ”

2. Turn signal indicator light “ ”3. Fuel level warning light “ ”4. High beam indicator light “ ”5. Neutral indicator light “ ”6. Coolant temperature warning light “ ”7. Immobilizer system indicator light “ ”


3-4

3

EAU11080

High beam indicator light “ ” This indicator light comes on when thehigh beam of the headlight is switchedon.

EAU11360

Fuel level warning light “ ” This warning light comes on when thefuel level drops below approximately5.0 L (1.32 US gal) (1.10 Imp.gal).When this occurs, refuel as soon aspossible.The electrical circuit of the warning lightcan be checked by turning the key to“ON”.If the warning light does not come onfor a few seconds, then go off, have aYamaha dealer check the electrical cir-cuit.

NOTE:This model is also equipped with a self-diagnosis device for the fuel level de-tection circuit. If the fuel level detectioncircuit is defective, the following cyclewill be repeated until the malfunction iscorrected: The fuel level warning light

will flash eight times, then go off for 2.5seconds. If this occurs, have a Yamahadealer check the vehicle.

EAU11440

Coolant temperature warning light “ ” This warning light comes on when theengine overheats. When this occurs,stop the engine immediately and allowthe engine to cool.The electrical circuit of the warning lightcan be checked by turning the key to“ON”.If the warning light does not come onfor a few seconds, then go off, have aYamaha dealer check the electrical cir-cuit.

CAUTION:ECA10020

Do not operate the engine if it isoverheated.

EAU11530

Engine trouble warning light “ ” This warning light comes on or flasheswhen an electrical circuit monitoring theengine is defective. When this occurs,have a Yamaha dealer check the self-

diagnosis system. (See page 3-5 for anexplanation of the self-diagnosis de-vice.)The electrical circuit of the warning lightcan be checked by turning the key to“ON”. If the warning light does not comeon for a few seconds, then go off, havea Yamaha dealer check the electricalcircuit.

EAU26871

Immobilizer system indicator light “ ” The electrical circuit of the indicatorlight can be checked by turning the keyto “ON”.If the indicator light does not come onfor a few seconds, then go off, have aYamaha dealer check the electrical cir-cuit.When the key is turned to “OFF” and 30seconds have passed, the indicatorlight will start flashing indicating the im-mobilizer system is enabled. After 24hours have passed, the indicator lightwill stop flashing, however the immobi-lizer system is still enabled.


3-5

3

NOTE:This model is also equipped with a self-diagnosis device for the immobilizersystem. If the immobilizer system is de-fective, the indicator will start flashingand the multi-function meter will displayan error code when the key is turned to“ON”. (See “Self-diagnosis device” onpage 3-5 for details.)

EAUM1662

Multi-function display

The multi-function display is equippedwith the following:

� a speedometer (which shows theriding speed)

� an odometer (which shows the to-tal distance traveled)

� two tripmeters (which show thedistance traveled since they werelast set to zero)

� a fuel reserve tripmeter (whichshows the distance traveled sincethe fuel level warning light cameon)

� a clock� a self-diagnosis device

NOTE:� Be sure to turn the key to “ON” be-

fore using the “SELECT” and “RE-SET” buttons.

� For the U.K. only: To switch thespeedometer and odometer/trip-meter displays between kilometersand miles, press the “SELECT”button for at least two seconds.

Odometer and tripmeter modesPushing the “SELECT” button switchesthe display between the odometermode “ODO” and the tripmeter modes“TRIP 1” and “TRIP 2” in the followingorder:ODO → TRIP 1 → TRIP 2 → ODOIf the fuel level warning light comes on(see page 3-3), the odometer displaywill automatically change to the fuel re-serve tripmeter mode “F-TRIP” andstart counting the distance traveled

1. Multi-function display2. Clock3. Tripmeter 14. Odometer/fuel reserve tripmeter/tripmeter 25. “SELECT” button6. “RESET” button7. Speedometer


3-6

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from that point. In that case, pushingthe “SELECT” button switches the dis-play between the various tripmeter andodometer modes in the following order:F-TRIP → TRIP 1 → TRIP 2 → ODO →F-TRIPTo reset a tripmeter, select it by push-ing the “SELECT” button, and thenpush the “RESET” button for at leastone second while the selected tripme-ter is flashing. If you do not reset thefuel reserve tripmeter manually, it willreset itself automatically and the dis-play will return to the prior mode afterrefueling and traveling 5 km (3 mi).

Clock modeTurn the key to “ON”.

To set the clock:1. Push the “SELECT” button and

“RESET” button together for atleast two seconds.

2. When the hour digits start flashing,push the “RESET” button to set thehours.

3. Push the “SELECT” button to fixthe hours, and the minute digitswill start flashing.

4. Push the “RESET” button to setthe minutes.

5. Push the “SELECT” button to fixthe minutes, and then release it tostart the clock.

Self-diagnosis deviceThis model is equipped with a self-diag-nosis device for various electrical cir-cuits.If any of those circuits are defective, theengine trouble warning light will comeon, and then the multi-function displaywill indicate a two-digit error code (e.g.,11, 12, 13).If the multi-function display indicatessuch an error code, note the code num-ber, and then have a Yamaha dealercheck the vehicle.

CAUTION:ECA11590

If the display indicates an errorcode, the vehicle should be checkedas soon as possible in order to avoidengine damage.

This model is also equipped with a self-diagnosis device for the immobilizersystem.

If any of the immobilizer system circuitsare defective, the immobilizer systemindicator light will flash, and then themulti-function display will indicate atwo-digit error code (e.g., 51, 52, 53)when the key is turned to “ON”.

NOTE:If the multi-function display indicates er-ror code 52, this could be caused bytransponder interference. If this errorappears, try the following.

1. Use the code re-registering key tostart the engine.

NOTE:Make sure there are no other immobi-lizer keys close to the main switch, anddo not keep more than one immobilizerkey on the same key ring! Immobilizersystem keys may cause signal interfer-ence, which may prevent the enginefrom starting.

2. If the engine starts, turn it off, andtry starting the engine with thestandard keys.

3. If one or both of the standard keysdo not start the engine, take thevehicle, the code re-registering


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3

key and both standard keys to aYamaha dealer and have the stan-dard keys re-registered.

If the multi-function display indicatesany error codes, note the code number,and then have a Yamaha dealer checkthe vehicle.

EAU12330

Anti-theft alarm (optional) This model can be equipped with anoptional anti-theft alarm by a Yamahadealer. Contact a Yamaha dealer formore information.

EAU12343

Handlebar switches

Left

1. Pass switch “ ”2. Dimmer switch “ / ”3. Turn signal switch “ / ”4. Horn switch “ ”5. Hazard switch “ ”


3-8

3

Right

EAU12350

Pass switch “ ” Press this switch to flash the headlight.

EAU12400

Dimmer switch “ / ” Set this switch to “ ” for the highbeam and to “ ” for the low beam.

EAU12460

Turn signal switch “ / ” To signal a right-hand turn, push thisswitch to “ ”. To signal a left-handturn, push this switch to “ ”. When re-leased, the switch returns to the center

position. To cancel the turn signallights, push the switch in after it has re-turned to the center position.

EAU12500

Horn switch “ ” Press this switch to sound the horn.

EAU12660

Engine stop switch “ / ” Set this switch to “ ” before startingthe engine. Set this switch to “ ” tostop the engine in case of an emergen-cy, such as when the vehicle overturnsor when the throttle cable is stuck.

EAU12710

Start switch “ ” Push this switch to crank the enginewith the starter.

CAUTION:ECA10050

See page 5-1 for starting instruc-tions prior to starting the engine.

EAU12731

Hazard switch “ ” With the key in the “ON” or “ ” posi-tion, use this switch to turn on the haz-ard light (simultaneous flashing of allturn signal lights).The hazard light is used in case of anemergency or to warn other driverswhen your vehicle is stopped where itmight be a traffic hazard.

CAUTION:ECA10060

Do not use the hazard light for an ex-tended length of time, otherwise thebattery may discharge.

1. Engine stop switch “ / ”2. Start switch “ ”


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EAU12820

Clutch lever

The clutch lever is located at the lefthandlebar grip. To disengage theclutch, pull the lever toward the handle-bar grip. To engage the clutch, releasethe lever. The lever should be pulledrapidly and released slowly for smoothclutch operation.The clutch lever is equipped with aclutch switch, which is part of the igni-tion circuit cut-off system. (See page3-15.)

EAU12870

Shift pedal

The shift pedal is located on the leftside of the engine and is used in com-bination with the clutch lever whenshifting the gears of the 5-speed con-stant-mesh transmission equipped onthis motorcycle.

EAU12890

Brake lever

The brake lever is located at the righthandlebar grip. To apply the frontbrake, pull the lever toward the handle-bar grip.

1. Clutch lever 1. Shift pedal 1. Brake lever


3-10

3

EAU12941

Brake pedal

The brake pedal is on the right side ofthe motorcycle. To apply the rearbrake, press down on the brake pedal.

EAUM1790

Fuel tank cap

To remove the fuel tank cap1. Open the fuel tank cap lock cover.2. Insert the key into the lock and turn

it 1/4 turn clockwise. The lock willbe released and the fuel tank capcan be removed.

To install the fuel tank cap1. Push and install the fuel tank cap

into position with the key insertedin the lock.

2. Turn the key counterclockwise tothe original position, and then re-move it.

NOTE:The fuel tank cap cannot be installedunless the key is in the lock. In addition,the key cannot be removed if the cap isnot properly installed and locked.

WARNINGEWA11140

Make sure that the fuel tank cap isproperly installed before riding.

1. Brake pedal 1. Fuel tank cap lock cover2. Unlock.


3-11

3

EAU13210

Fuel

Make sure that there is sufficient fuel inthe tank. Fill the fuel tank to the bottomof the filler tube as shown.

WARNINGEWA10880

� Do not overfill the fuel tank, oth-erwise it may overflow when thefuel warms up and expands.

� Avoid spilling fuel on the hot en-gine.

CAUTION:ECA10070

Immediately wipe off spilled fuelwith a clean, dry, soft cloth, sincefuel may deteriorate painted surfac-es or plastic parts.

EAU13390

CAUTION:ECA11400

Use only unleaded gasoline. The useof leaded gasoline will cause severedamage to internal engine parts,such as the valves and piston rings,as well as to the exhaust system.

Your Yamaha engine has been de-signed to use premium unleaded gaso-line with a research octane number of95 or higher. If knocking (or pinging) oc-

curs, use a gasoline of a differentbrand. Use of unleaded fuel will extendspark plug life and reduce maintenancecosts.

1. Fuel tank filler tube2. Fuel level

Recommended fuel:PREMIUM UNLEADED GASOLINE ONLY

Fuel tank capacity:15.0 L (3.96 US gal) (3.30 Imp.gal)

Fuel reserve amount (when the fuel level warning light comes on):

5.0 L (1.32 US gal) (1.10 Imp.gal)


3-12

3

EAU13430

Catalytic converter This model is equipped with a catalyticconverter in the exhaust chamber.

WARNINGEWA10860

The exhaust system is hot after op-eration. Make sure that the exhaustsystem has cooled down before do-ing any maintenance work.

CAUTION:ECA10700

The following precautions must beobserved to prevent a fire hazard orother damages.

� Use only unleaded gasoline.The use of leaded gasoline willcause unrepairable damage tothe catalytic converter.

� Never park the vehicle near pos-sible fire hazards such as grassor other materials that easilyburn.

� Do not allow the engine to idletoo long.

EAU13900

Seat

To remove the seat1. Insert the key into the seat lock,

and then turn it as shown.

2. Pull the seat off.

To install the seat1. Insert the projection on the front of

the seat into the seat holder asshown.

2. Push the rear of the seat down tolock it in place.

3. Remove the key.

NOTE:Make sure that the seat is properly se-cured before riding.

1. Seat lock2. Unlock.

1. Seat holder2. Projection


3-13

3

EAU14421

Storage compartment

This storage compartment is designedto hold a genuine Yamaha U-LOCK.(Other locks may not fit.) When placinga U-LOCK in the storage compartment,securely fasten it with the straps. Whenthe U-LOCK is not in the storage com-partment, be sure to secure the strapsto prevent losing them.

WARNINGEWA10961

� Do not exceed the load limit of 3kg (7 lb) for the storage com-partment.

� Do not exceed the maximumload of 186 kg (410 lb) for the ve-hicle.

EAU14830

Adjusting the shock absorber assembly

This shock absorber assembly isequipped with a spring preload adjust-ing ring.

CAUTION:ECA10100

Never attempt to turn an adjustingmechanism beyond the maximum orminimum settings.

Adjust the spring preload as follows.To increase the spring preload andthereby harden the suspension, turnthe adjusting ring in direction (a). To de-

1. U-LOCK bar (optional)2. Yamaha U-LOCK (optional)3. Strap

1. Spring preload adjusting ring2. Special wrench3. Position indicator


3-14

3

crease the spring preload and therebysoften the suspension, turn the adjust-ing ring in direction (b).

NOTE:Align the appropriate notch in the ad-justing ring with the position indicatoron the shock absorber.

WARNINGEWA10220

This shock absorber contains highlypressurized nitrogen gas. For prop-er handling, read and understandthe following information beforehandling the shock absorber. Themanufacturer cannot be held re-sponsible for property damage orpersonal injury that may result fromimproper handling.

� Do not tamper with or attempt toopen the gas cylinder.

� Do not subject the shock ab-sorber to an open flame or otherhigh heat sources, otherwise itmay explode due to excessivegas pressure.

� Do not deform or damage thegas cylinder in any way, as thiswill result in poor damping per-formance.

� Always have a Yamaha dealerservice the shock absorber.

EAU15300

Sidestand The sidestand is located on the left sideof the frame. Raise the sidestand orlower it with your foot while holding thevehicle upright.

NOTE:The built-in sidestand switch is part ofthe ignition circuit cut-off system, whichcuts the ignition in certain situations.(See further down for an explanation ofthe ignition circuit cut-off system.)

WARNINGEWA10240

The vehicle must not be ridden withthe sidestand down, or if the side-stand cannot be properly moved up(or does not stay up), otherwise thesidestand could contact the groundand distract the operator, resultingin a possible loss of control.Yamaha’s ignition circuit cut-offsystem has been designed to assistthe operator in fulfilling the respon-sibility of raising the sidestand be-fore starting off. Therefore, checkthis system regularly as described

Spring preload setting:Minimum (soft):

1Standard:

2Maximum (hard):

5


3-15

3

below and have a Yamaha dealer re-pair it if it does not function proper-ly.

EAU15311

Ignition circuit cut-off system The ignition circuit cut-off system (com-prising the sidestand switch, clutchswitch and neutral switch) has the fol-lowing functions.

� It prevents starting when the trans-mission is in gear and the side-stand is up, but the clutch lever isnot pulled.

� It prevents starting when the trans-mission is in gear and the clutch le-ver is pulled, but the sidestand isstill down.

� It cuts the running engine when thetransmission is in gear and the sid-estand is moved down.

Periodically check the operation of theignition circuit cut-off system accordingto the following procedure.

WARNINGEWA10250

If a malfunction is noted, have aYamaha dealer check the system be-fore riding.


3-16

3

With the engine turned off:1. Move the sidestand down.2. Make sure that the engine stop switch is turned on.3. Turn the key on. 4. Shift the transmission into the neutral position.5. Push the start switch.Does the engine start?

With the engine still running:6. Move the sidestand up.7. Keep the clutch lever pulled.8. Shift the transmission into gear.9. Move the sidestand down.Does the 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 witha warmed-up engine.

The neutral switch may be defective.The motorcycle should not be ridden untilchecked by a Yamaha dealer.

The sidestand switch may be defective.The motorcycle should not be ridden untilchecked by a Yamaha dealer.

The clutch switch may be defective.The motorcycle should not be ridden untilchecked by a Yamaha dealer.

YES NO

YES NO

YES NO

NOTE:

PRE-OPERATION CHECKS

4-1

4

EAU15591

The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or lossof tire air pressure could have 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 shorttime; and the added safety it assures is more than worth the time involved.

WARNINGEWA11150

If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operatingthe vehicle.


4-2

4

EAU15602

Pre-operation check list ITEM CHECKS PAGE

Fuel• Check fuel level in fuel tank.• Refuel if necessary.• Check fuel line for leakage.

3-11

Engine oil• Check oil level in oil tank.• If necessary, add recommended oil to specified level.• Check vehicle for oil leakage.

6-9

Coolant• Check coolant level in reservoir.• If necessary, add recommended coolant to specified level.• Check cooling system for leakage.

6-12

Front 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 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 fluid level in reservoir.• If necessary, add recommended brake fluid to specified level.• Check hydraulic system for leakage.

6-21, 6-22

Clutch

• Check operation.• Lubricate cable if necessary.• Check lever free play.• Adjust if necessary.

6-20


4-3

4

Throttle grip

• Make sure that operation is smooth.• Check cable free play.• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and

grip housing.

6-17, 6-25

Control cables • Make sure that operation is smooth.• Lubricate if necessary. 6-25

Drive chain

• Check chain slack.• Adjust if necessary.• Check chain condition.• Lubricate if necessary.

6-23, 6-24

Wheels and tires

• Check for damage.• Check tire condition and tread depth.• Check air pressure.• 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 tightened.• Tighten if necessary. —

Instruments, lights, signals and switches

• Check operation.• Correct if necessary. —

Sidestand switch • Check operation of ignition circuit cut-off system.• If system is defective, have Yamaha dealer check vehicle. 3-14

ITEM CHECKS PAGE

OPERATION AND IMPORTANT RIDING POINTS

5-1

5

EAU15950

WARNINGEWA10270

� Become thoroughly familiarwith all operating controls andtheir functions before riding.Consult a Yamaha dealer re-garding any control or functionthat you do not thoroughly un-derstand.

� Never start the engine or oper-ate it in a closed area for anylength of time. Exhaust fumesare poisonous, and inhalingthem can cause loss of con-sciousness and death within ashort time. Always make surethat there is adequate ventila-tion.

� Before starting out, make surethat the sidestand is up. If thesidestand is not raised com-pletely, it could contact theground and distract the opera-tor, resulting in a possible lossof control.

EAUM1670

Starting the engine In order for the ignition circuit cut-offsystem to enable starting, one of thefollowing conditions must be met:

� The transmission is in the neutralposition.

� The transmission is in gear withthe clutch lever pulled and the sid-estand up.

WARNINGEWA10290

� Before starting the engine,check the function of the igni-tion circuit cut-off system ac-cording to the proceduredescribed on page 3-15.

� Never ride with the sidestanddown.

1. Turn the key to “ON” and makesure that the engine stop switch isset to “ ”.

CAUTION:ECAM1030

The following warning lights and in-dicator light should come on for afew seconds, then go off.

� Fuel level warning light

� Coolant temperature warninglight

� Engine trouble warning light� Immobilizer system indicator

lightIf a warning or indicator light doesnot go off, see page 3-3 for the corre-sponding warning and indicatorlight circuit check.

2. Shift the transmission into the neu-tral position.

NOTE:When the transmission is in the neutralposition, the neutral indicator lightshould be on, otherwise have aYamaha dealer check the electrical cir-cuit.

3. Start the engine by pushing thestart switch.

NOTE:If the engine fails to start, release thestart switch, wait a few seconds, andthen try again. Each starting attemptshould be as short as possible to pre-


5-2

5

serve the battery. Do not crank the en-gine more than 10 seconds on any oneattempt.

CAUTION:ECA11040

For maximum engine life, never ac-celerate hard when the engine iscold!

NOTE:The engine is warm when it quickly re-sponds to the throttle.

EAU16671

Shifting

Shifting gears lets you control theamount of engine power available forstarting off, accelerating, climbing hills,etc.The gear positions are shown in the il-lustration.

NOTE:To shift the transmission into the neu-tral position, press the shift pedal downrepeatedly until it reaches the end of itstravel, and then slightly raise it.

CAUTION:ECA10260

� Even with the transmission inthe neutral position, do notcoast for long periods of timewith the engine off, and do nottow the motorcycle for long dis-tances. The transmission isproperly lubricated only whenthe engine is running. Inade-quate lubrication may damagethe transmission.

� Always use the clutch whilechanging gears to avoid damag-ing the engine, transmission,and drive train, which are notdesigned to withstand theshock of forced shifting.

1. Shift pedal2. Neutral position


5-3

5

EAU16810

Tips for reducing fuel consumption Fuel consumption depends largely onyour riding style. Consider the followingtips to reduce fuel consumption:

� Shift up swiftly, and avoid high en-gine speeds during acceleration.

� Do not rev the engine while shiftingdown, and avoid high enginespeeds with no load on the engine.

� Turn the engine off instead of let-ting it idle for an extended length oftime (e.g., in traffic jams, at trafficlights or at railroad crossings).

EAU16841

Engine break-in There is never a more important periodin the life of your engine than the periodbetween 0 and 1600 km (1000 mi). Forthis reason, you should read the follow-ing material carefully.Since the engine is brand new, do notput an excessive load on it for the first1600 km (1000 mi). The various parts inthe engine wear and polish themselvesto the correct operating clearances.During this period, prolonged full-throt-tle operation or any condition that mightresult in engine overheating must beavoided.

EAU17030

0–1000 km (0–600 mi)Avoid prolonged operation above 1/3throttle.1000–1600 km (600–1000 mi)Avoid prolonged operation above 1/2throttle.

CAUTION:ECA11440

After 1000 km (600 mi) of operation,the engine oil must be changed, andthe oil filter element cleaned.

1600 km (1000 mi) and beyondThe vehicle can now be operated nor-mally.

CAUTION:ECA10270

If any engine trouble should occurduring the engine break-in period,immediately have a Yamaha dealercheck the vehicle.


5-4

5

EAU17211

Parking When parking, stop the engine, andthen remove the key from the mainswitch.

WARNINGEWA10310

� Since the engine and exhaustsystem can become very hot,park in a place where pedestri-ans or children are not likely totouch them.

� Do not park on a slope or on softground, otherwise the vehiclemay overturn.

CAUTION:ECA10380

Never park in an area where thereare fire hazards such as grass orother flammable materials.

PERIODIC MAINTENANCE AND MINOR REPAIR

6-1

6

EAU17240

Safety is an obligation of the owner. Pe-riodic inspection, adjustment and lubri-cation will keep your vehicle in thesafest and most efficient condition pos-sible. The most important points of in-spection, adjustment, and lubricationare explained on the following pages.The intervals given in the periodicmaintenance and lubrication chartshould be simply considered as a gen-eral guide under normal riding condi-tions. However, DEPENDING ON THEWEATHER, TERRAIN, GEOGRAPHI-CAL LOCATION, AND INDIVIDUALUSE, THE MAINTENANCE INTER-VALS MAY NEED TO BE SHORT-ENED.

WARNINGEWA10320

If you are not familiar with mainte-nance work, have a Yamaha dealerdo it for you.

EAU17520

Owner’s tool kit

The owner’s tool kit is located inside thestorage compartment under the seat.(See page 3-12.)The service information included in thismanual and the tools provided in theowner’s tool kit are intended to assistyou in the performance of preventivemaintenance and minor repairs. How-ever, additional tools such as a torquewrench may be necessary to performcertain maintenance work correctly.

NOTE:If you do not have the tools or experi-ence required for a particular job, havea Yamaha dealer perform it for you.

WARNINGEWA10350

Modifications not approved byYamaha may cause loss of perfor-mance and render the vehicle un-safe for use. Consult a Yamahadealer before attempting any chang-es.

1. Owner’s tool kit2. Engine oil drain attachment


6-2

6

EAU17705

Periodic maintenance and lubrication chart

NOTE:� The annual checks must be performed every year, except if a kilometer-based maintenance is performed in-

stead.� From 50000 km, repeat the maintenance intervals starting from 10000 km.� Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical

skills.

NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1000 km) ANNUAL

CHECK1 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 operation, fluid level and vehicle for fluid leakage. √ √ √ √ √ √

• Replace brake pads. Whenever worn to the limit

8 * Brake hoses• Check for cracks or damage. √ √ √ √ √

• Replace. Every 4 years


6-3

6

9 * Wheels • Check runout, spoke tightness and for damage.• Tighten spokes if necessary. √ √ √ √ √

10 * Tires

• Check tread depth and for damage.• Replace if necessary.• Check air pressure.• Correct if necessary.

√ √ √ √ √

11 * Wheel bearings • Check bearing for looseness or damage. √ √ √ √

12 * Swingarm • Check operation and for excessive play. √ √ √ √

13 Drive chain• Check chain slack.• Make sure that the rear wheel is properly aligned.• Clean and lubricate.

Every 500 km and after washing the motorcycle or riding in the rain

14 * Steering 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 leakage. √ √ √ √

20 *Rear suspension relay arm and connecting arm pivoting points

• Check operation. √ √ √ √

21 * Electronic fuel injection • Adjust engine idling speed. √ √ √ √ √ √

22 Engine oil • Change.• Check oil level and vehicle for oil leakage. √ √ √ √ √ √


CHECK1 10 20 30 40


6-4

6

EAUM1890

NOTE:� Replace the air filter element more frequently if you are riding in unusually wet or dusty areas.� Hydraulic brake service

• Regularly check and, if necessary, correct the brake fluid level.• Every two years replace the internal components of the brake master cylinder, and change the brake fluid.• Replace the brake hoses every four years and if cracked or damaged.

23 Engine oil filter element • Replace. √ √ √

24 * Cooling system• Check coolant 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 the entire air induction system if necessary.

√ √ √ √ √

29 * Mufflers and exhaust pipes • Check the screw clamps for looseness. √ √ √ √ √ √

30 * Lights, signals and switches

• Check operation.• Adjust headlight beam. √ √ √ √ √ √


CHECK1 10 20 30 40


6-5

6

EAU18711

Removing and installing cowlings and panels The cowlings and panels shown needto be removed to perform some of themaintenance jobs described in thischapter. Refer to this section each timea cowling or panel needs to be re-moved and installed.

EAUM1682

Cowling A

To remove the cowlingRemove the bolts and spacers, andthen lift the cowling up to remove it.

To install the cowling1. Place the cowling bracket tab be-

tween the protector and the brack-et on each side.

1. Cowling A

1. Panel A

1. Cowling B2. Panel B

1. Bolt

1. Protector2. Cowling bracket tab3. Bracket


6-6

6

2. Place the cowling in the originalposition, and then install the boltsand spacers.

EAUM1691

Cowling B

To remove the cowling1. Remove the seat and panel B.

(See pages 3-12 and 6-5.)2. Remove the bolts, remove the

quick fastener screws after turningthem 1/4 turn counterclockwise,and then pull the cowling off at thearea shown.

To install the cowling1. Place the cowling in the original

position, and then tighten the quickfastener screws and install thebolts.

2. Install the panel.3. Install the seat.

EAUM1701

Panel A

To remove the panel1. Remove the seat. (See page

3-12.)2. Remove the bolts and the spacer,

and then pull the panel off at thearea shown.

To install the panel1. Place the panel in the original posi-

tion, install spacer, and then installthe bolts.

2. Install the seat.

1. Bolt2. Quick fastener screw

1. Bolt2. Spacer


6-7

6

EAUM1710

Panel B

To remove the panel1. Remove the seat. (See page

3-12.)2. Remove the bolt, and then pull the

panel off at the areas shown.

To install the panel1. Place the panel in the original posi-

tion, and then install the bolt.

2. Install the seat.

EAU19602

Checking the spark plug The spark plug is an important enginecomponent, which is easy to check.Since heat and deposits will cause anyspark plug to slowly erode, the sparkplug should be removed and checkedin 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 plug1. Remove the spark plug cap.

2. Remove the spark plug as shown,with the spark plug wrench includ-ed in the owner’s tool kit.

1. Bolt

1. Spark plug cap


6-8

6

To check the spark plug1. Check that the porcelain insulator

around the center electrode of thespark plug is a medium-to-light tan(the ideal color when the vehicle isridden normally).

NOTE:If the spark plug shows a distinctly dif-ferent color, the engine could be defec-tive. Do not attempt to diagnose suchproblems yourself. Instead, have aYamaha dealer check the vehicle.

2. Check the spark plug for electrodeerosion and excessive carbon orother deposits, and replace it ifnecessary.

To install the spark plug1. Measure 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 pluggasket and its mating surface, andthen wipe off any grime from thespark plug threads.

3. Install the spark plug with thespark plug wrench, and then tight-en it to the specified torque.

NOTE:If a torque wrench is not available wheninstalling a spark plug, a good estimateof the correct torque is 1/4–1/2 turnpast finger tight. However, the sparkplug should be tightened to the speci-fied torque as soon as possible.

4. Install the spark plug cap.

1. Spark plug wrench

Specified spark plug:NGK/CR7E

1. Spark plug gap

Spark plug gap:0.7–0.8 mm (0.028–0.031 in)

Tightening torque:Spark plug:

12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)


6-9

6

EAUM1841

Engine oil and oil filter element The engine oil level should be checkedbefore each ride. In addition, the oilmust be changed and the oil filter ele-ment replaced at the intervals specifiedin the periodic maintenance and lubri-cation chart.

To check the engine oil level1. Place the vehicle on a level sur-

face and hold it in an upright posi-tion.

NOTE:Make sure that the vehicle is positionedstraight up when checking the oil level.A slight tilt to the side can result in afalse 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 cap, wipethe dipstick clean, insert it backinto the oil filler hole (withoutscrewing it in), and then remove itagain 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 levelmarks.

CAUTION:ECA10010

Do not operate the vehicle until youknow that the engine oil level is suf-ficient.

WARNINGEWA10360

Never remove the engine oil tankcap after high-speed operation, oth-erwise hot engine oil could spoutout and cause damage or injury. Al-ways let the engine oil cool downsufficiently before removing the oiltank cap.

4. If the engine oil is below the mini-mum level mark, add sufficient oilof the recommended type to raiseit to the correct level.

5. Install the oil filler cap.

To change the engine oil (with orwithout oil filter element replace-ment)

1. Start the engine, warm it up forseveral minutes, and then turn itoff.

2. Install the engine oil drain attach-ment, provided with the owner’stool kit, under the drain bolt of thecrankcase.

1. Engine oil filler cap2. Maximum level mark3. Minimum level mark


6-10

6

3. Place an oil pan under the engineto collect the used oil.

4. Remove the engine oil filler capand the drain bolt to drain the oilfrom the crankcase.

5. Remove the drain bolt to drain theoil from the oil tank.

6. Remove the oil filter element drainbolt to drain the oil from the oil filterelement.

NOTE:Skip steps 7–9 if the oil filter element isnot being replaced.

7. Remove the oil filter element coverby removing the bolts.

8. Remove and replace the oil filterelement 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 bolt2. Oil filter element drain bolt

1. Oil filter element2. O-ring


6-11

6

9. Install the oil filter element cover byinstalling the bolts and the oil filterelement drain bolt, then tighteningthem to the specified torques.

NOTE:Make sure that the O-rings are properlyseated.

10. Install the oil drain bolts, and thentighten them to the specifiedtorques.

11. Add the specified amount of therecommended engine oil, and theninstall and tighten the oil filler cap.

CAUTION:ECAM1060

The engine oil tank must be filled in2 steps. First, fill the engine oil tankwith 1.90 L (2.0 US qt) (1.67 Imp.qt) ofthe recommended engine oil. Then,start the engine, race it 5 or 6 times,turn it off, and then add the remain-der of the engine oil.

CAUTION:ECA11620

� In order to prevent clutch slip-page (since the engine oil alsolubricates the clutch), do notmix any chemical additives. Donot 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” orhigher.

� Make sure that no foreign mate-rial enters the crankcase.

12. Start the engine, and then let it idlefor several minutes while checkingit for oil leakage. If oil is leaking, im-mediately turn the engine off andcheck for the cause.

13. Turn the engine off, and thencheck the oil level and correct it ifnecessary.

Tightening torques:Oil filter element cover bolt:

10 Nm (1.0 m·kgf, 7.2 ft·lbf)Oil filter element drain bolt:

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Tightening torques:Engine oil drain bolt (crankcase):

30 Nm (3.0 m·kgf, 22 ft·lbf)Engine oil drain bolt (oil tank):

18 Nm (1.8 m·kgf, 13 ft·lbf)

Recommended engine oil:See page 8-1.

Oil quantity:Without oil filter element replace-ment:

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)


6-12

6

EAU20070

Coolant The coolant level should be checkedbefore each ride. In addition, the cool-ant must be changed at the intervalsspecified in the periodic maintenanceand lubrication chart.

EAUM1721

To check the coolant level1. Place the vehicle on a level sur-


NOTE:� The coolant level must be checked

on a cold engine since the levelvaries with engine temperature.

� Make sure that the vehicle is posi-tioned straight up when checkingthe coolant level. A slight tilt to theside can result in a false reading.

2. Check the coolant level in the cool-ant reservoir.

NOTE:The coolant should be between theminimum and maximum level marks.

3. If the coolant is at or below theminimum level mark, remove cowl-ing B (See page 6-5.), and thenopen the reservoir cap.

4. Add coolant to the maximum levelmark, and then close the reservoircap.

CAUTION:ECA10470

� If coolant is not available, usedistilled water or soft tap waterinstead. Do not use hard wateror salt water since it is harmfulto the engine.

� If water has been used insteadof coolant, replace it with cool-ant as soon as possible, other-wise the engine may not besufficiently cooled and the cool-ing system will not be protectedagainst frost and corrosion.

� If water has been added to thecoolant, have a Yamaha dealercheck the antifreeze content ofthe coolant as soon as possible,otherwise the effectiveness ofthe coolant will be reduced.

WARNINGEWA10380

Never attempt to remove the radiatorcap when the engine is hot.

5. Install the cowling.

1. Coolant reservoir2. Maximum level mark3. Minimum level mark

Coolant reservoir capacity (up to the maximum level mark):

0.25 L (0.26 US qt) (0.22 Imp.qt)


6-13

6

NOTE:� The radiator fan is automatically

switched on or off according to thecoolant temperature in the radia-tor.

� If the engine overheats, see page6-38 for further instructions.

EAUM1801

To change the coolant1. 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 page6-5.)

4. Place a container under the engineto collect the used coolant.

5. Loosen the radiator cap retainerscrew.

6. Remove the radiator cap and cool-ant reservoir cap.

WARNINGEWA10380

Never attempt to remove the radiatorcap when the engine is hot.

7. Remove the coolant reservoirbolts, and then turn the coolantreservoir upside down to empty it.

8. Install the coolant reservoir byplacing it in the original position,then installing the bolts.

9. Remove the coolant drain bolt todrain the cooling system.

10. After the coolant is completelydrained, thoroughly flush the cool-ing system with clean tap water.

1. Radiator cap2. Radiator cap retaining screw3. Radiator cap retainer4. Coolant reservoir cap

1. Bolt

1. Coolant drain bolt


6-14

6

11. Install the coolant drain bolt, andthen tighten it to the specifiedtorque.

NOTE:Check the washer for damage and re-place it if necessary.

12. Pour the specified amount of rec-ommended coolant into the radia-tor and reservoir.

CAUTION:ECA10470

� If coolant is not available, usedistilled water or soft tap waterinstead. Do not use hard wateror salt water since it is harmfulto the engine.

� If water has been used insteadof coolant, replace it with cool-ant as soon as possible, other-wise the engine may not besufficiently cooled and the cool-ing system will not be protectedagainst frost and corrosion.

� If water has been added to thecoolant, have a Yamaha dealercheck the antifreeze content ofthe coolant as soon as possible,otherwise the effectiveness ofthe coolant will be reduced.

13. Install the coolant reservoir cap.14. Install the radiator cap and radiator

cap retainer by installing thescrew.

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 thecoolant reservoir cap, add coolantto the maximum level mark, andthen install the cap.

17. Start the engine, and then checkthe vehicle for coolant leakage. Ifcoolant is leaking, have a Yamahadealer check the cooling system.

18. Install the cowling, the panel andthe seat.

Tightening torque:Coolant drain bolt:

11 Nm (1.1 m·kgf, 8.0 ft·lbf)

Antifreeze/water mixture ratio:1:1

Recommended antifreeze:High-quality ethylene glycol anti-freeze containing corrosion inhibitors for aluminum engines

Coolant quantity:Radiator capacity (including all routes):

1.00 L (1.06 US qt) (0.88 Imp.qt)Coolant reservoir capacity (up to the maximum level mark):

0.25 L (0.26 US qt) (0.22 Imp.qt)


6-15

6

EAUM1833

Replacing the air filter element and cleaning the check hose The air filter element should be re-placed at the intervals specified in theperiodic maintenance and lubricationchart. Replace the air filter elementmore 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 element1. Remove the seat. (See page

3-12.)2. Remove panel B. (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 theair filter case.

� The engine should never be op-erated without the air filter ele-ment installed, otherwise thepiston(s) and/or cylinder(s) maybecome excessively worn.

6. Install the air filter case cover by in-stalling the screws.

7. Install the panel.8. Install the seat.

To clean the air filter check hose1. Check the hose on the side of the

air filter case for accumulated dirtor water.

1. Air filter case cover2. Screw

1. Air filter element


6-16

6

2. If dirt or water is visible, removethe hose, clean it, and then installit.

EAUM1910

Adjusting the engine idling speed The engine idling speed must bechecked and, if necessary, adjusted asfollows at the intervals specified in theperiodic maintenance and lubricationchart.The engine should be warm beforemaking 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 tachometer to the sparkplug lead.

2. Check the engine idling speedand, if necessary, adjust it to spec-ification by turning the idle adjust-ing screw. To increase the engineidling speed, turn the screw in di-rection (a). To decrease the en-gine idling speed, turn the screw indirection (b).

NOTE:If the specified idling speed cannot beobtained as described above, have aYamaha dealer make the adjustment.

1. Air filter check hose 1. Idle adjusting screw

Engine idling speed:1300–1500 r/min


6-17

6

EAU21380

Adjusting the throttle cable free play

The throttle cable free play should mea-sure 3.0–5.0 mm (0.12–0.20 in) at thethrottle grip. Periodically check thethrottle cable free play and, if neces-sary, have a Yamaha dealer adjust it.

EAU21640

TiresTo maximize the performance, durabil-ity, and safe operation of your motor-cycle, note the following pointsregarding the specified tires.

Tire air pressureThe tire air pressure should be checkedand, if necessary, adjusted before eachride.

WARNINGEWA10500

� The tire air pressure must bechecked and adjusted on coldtires (i.e., when the temperatureof the tires equals the ambienttemperature).

� The tire air pressure must be ad-justed in accordance with theriding speed and with the totalweight of rider, passenger, car-go, and accessories approvedfor 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/cm²)XT660X 210 kPa (30 psi) (2.10 kgf/cm²)

Rear:XT660R 200 kPa (29 psi) (2.00 kgf/cm²)XT660X 210 kPa (30 psi) (2.10 kgf/cm²)

90–186 kg (198–410 lb):Front:



Off-road riding:Front:

XT660R 200 kPa (29 psi) (2.00 kgf/cm²)

Rear:XT660R 200 kPa (29 psi) (2.00 kgf/cm²)

Maximum load*:186 kg (410 lb)

* Total weight of rider, passenger, car-go and accessories


6-18

6

WARNINGEWA11020

Because loading has an enormousimpact on the handling, braking,performance and safety characteris-tics of your motorcycle, you shouldkeep the following precautions inmind.

� NEVER OVERLOAD THEMOTORCYCLE! Operation of anoverloaded motorcycle may re-sult in tire damage, loss of con-trol, or severe injury. Make surethat the total weight of rider,passenger, cargo, and accesso-ries does not exceed the speci-fied maximum load for thevehicle.

� Do not carry along looselypacked items, which can shiftduring a ride.

� Securely pack the heaviestitems close to the center of themotorcycle and distribute theweight evenly on both sides.

� Adjust the suspension and tireair pressure with regard to theload.

� Check the tire condition and airpressure before each ride.

Tire inspection

The tires must be checked before eachride. If the center tread depth reachesthe specified limit, if the tire has a nail orglass fragments in it, or if the sidewall iscracked, have a Yamaha dealer re-place the tire immediately.

NOTE:The tire tread depth limits may differfrom country to country. Always complywith the local regulations.

Tire informationThis motorcycle is equipped with tubetires.

WARNINGEWA10460

� The front and rear tires shouldbe of the same make and de-sign, otherwise the handlingcharacteristics of the vehiclecannot be guaranteed.

� After extensive tests, only thetires listed below have been ap-proved for this model byYamaha Motor Co., Ltd.

1. Tire sidewall2. Tire tread depth

Minimum tire tread depth (front and rear):

1.6 mm (0.06 in)


6-19

6

WARNINGEWA10570

� Have a Yamaha dealer replaceexcessively worn tires. Besidesbeing illegal, operating themotorcycle with excessivelyworn tires decreases riding sta-bility and can lead to loss ofcontrol.

� The replacement of all wheel-and brake-related parts, includ-ing the tires, should be left to a

Yamaha dealer, who has thenecessary professional knowl-edge and experience.

� It is not recommended to patcha punctured tube. If unavoid-able, however, patch the tubevery carefully and replace it assoon as possible with a high-quality product.

EAU21940

Spoke wheels To maximize the performance, durabil-ity, and safe operation of your motor-cycle, note the following pointsregarding the specified wheels.

� The wheel rims should be checkedfor cracks, bends or warpage, andthe spokes for looseness or dam-age before each ride. If any dam-age is found, have a Yamahadealer replace the wheel. Do notattempt even the smallest repair tothe wheel. A deformed or crackedwheel must be replaced.

� The wheel should be balancedwhenever either the tire or wheelhas been changed or replaced. Anunbalanced wheel can result inpoor performance, adverse han-dling characteristics, and a short-ened tire life.

� Ride at moderate speeds afterchanging a tire since the tire sur-face must first be “broken in” for itto develop its optimal characteris-tics.

Front tire:Size:

XT660R 90/90-21M/C 54S, 90/90-21M/C 54TXT660X 120/70R17 M/C 58H

Manufacturer/model:XT660R METZELER/TOURANCE FRONTXT660X PIRELLI/DRAGONXT660R MICHELIN/SIRAC

Rear tire:Size:


Manufacturer/model:XT660R METZELER/TOURANCEXT660X PIRELLI/DRAGONXT660R MICHELIN/SIRAC A


6-20

6

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) asshown. Periodically check the clutch le-ver free play and, if necessary, adjust itas follows.

1. Loosen the locknut at the clutch le-ver.

2. To increase the clutch lever freeplay, turn the adjusting bolt in di-rection (a). To decrease the clutchlever free play, turn the adjustingbolt in direction (b).

NOTE:If the specified clutch lever free playcould be obtained as described above,tighten the locknut and skip the rest ofthe procedure, otherwise proceed asfollows.

3. Fully turn the adjusting bolt at theclutch lever in direction (a) to loos-en the clutch cable.

4. Loosen the locknut at the crank-case.

5. To increase the clutch lever freeplay, turn the adjusting nut in direc-tion (a). To decrease the clutch le-ver free play, turn the adjusting nutin direction (b).

6. Tighten the locknut at the clutch le-ver and the crankcase.

1. Locknut2. Clutch lever free play adjusting bolt3. Clutch lever free play

1. Locknut2. Clutch lever free play adjusting nut

(crankcase)


6-21

6

EAU22270

Adjusting the rear brake light switch

The rear brake light switch, which is ac-tivated by the brake pedal, is properlyadjusted when the brake light comeson just before braking takes effect. Ifnecessary, adjust the brake light switchas follows.Turn the adjusting nut while holding therear brake light switch in place. Tomake the brake light come on earlier,turn the adjusting nut in direction (a). Tomake the brake light come on later, turnthe adjusting nut in direction (b).

EAU22390

Checking the front and rear brake pads The front and rear brake pads must bechecked for wear at the intervals spec-ified in the periodic maintenance andlubrication chart.

EAU22430

Front brake pads

Each front brake pad is provided withwear indicator grooves, which allowyou to check the brake pad wear with-out having to disassemble the brake.To check the brake pad wear, checkthe wear indicator grooves. If a brakepad has worn to the point that the wear

indicator grooves have almost disap-peared, have a Yamaha dealer replacethe brake pads as a set.

EAU22500

Rear brake pads

Check each rear brake pad for damageand measure the lining thickness. If abrake pad is damaged or if the liningthickness is less than 1.0 mm (0.04 in),have a Yamaha dealer replace thebrake pads as a set.

1. Rear brake light switch2. Rear brake light switch adjusting nut

1. Brake pad wear indicator groove

1. Lining thickness


6-22

6

EAU22580

Checking the brake fluid level

Front brake

Rear brake

Insufficient brake fluid may allow air toenter the brake system, possibly caus-ing it to become ineffective.

Before riding, check that the brake fluidis above the minimum level mark andreplenish if necessary. A low brake fluidlevel may indicate worn brake padsand/or brake system leakage. If thebrake fluid level is low, be sure to checkthe brake pads for wear and the brakesystem for leakage.Observe these precautions:

� When checking the fluid level,make sure that the top of the brakefluid reservoir is level.

� Use only the recommended qualitybrake fluid, otherwise the rubberseals may deteriorate, causingleakage and poor braking perfor-mance.

� Refill with the same type of brakefluid. Mixing fluids may result in aharmful chemical reaction andlead to poor braking performance.

� Be careful that water does not en-ter the brake fluid reservoir whenrefilling. Water will significantlylower the boiling point of the fluidand may result in vapor lock.

� Brake fluid may deteriorate paint-ed surfaces or plastic parts. Al-ways clean up spilled fluidimmediately.

� As the brake pads wear, it is nor-mal for the brake fluid level to grad-ually go down. However, if thebrake fluid level goes down sud-denly, have a Yamaha dealercheck the cause.

1. Minimum level mark

1. Minimum level mark

Recommended brake fluid:DOT 4


6-23

6

EAU22760

Drive chain slack The drive chain slack should bechecked before each ride and adjustedif necessary.

EAU22780

To check the drive chain slack

1. Place the motorcycle on a levelsurface and hold it in an upright po-sition.

NOTE:When checking and adjusting the drivechain slack, the motorcycle should bepositioned straight up and there shouldbe no weight on it.

2. Shift the transmission into the neu-tral position.

3. Move the rear wheel by pushingthe motorcycle to locate the tight-est portion of the drive chain, andthen measure the drive chain slackas shown.

4. If the drive chain slack is incorrect,adjust it as follows.

NOTE:When checking the drive chain slack,the chain tensioner should not betouching the drive chain.

EAU22930

To adjust the drive chain slack1. Loosen the axle nut, then loosen

the locknut at each end of theswingarm.

2. To tighten the drive chain, turn theadjusting nut at each end of theswingarm in direction (a). To loos-en the drive chain, turn the adjust-ing nut at each end of theswingarm in direction (b), and thenpush the rear wheel forward.

NOTE:Using the alignment marks on eachside of the swingarm, make sure thatboth adjusting nuts are in the same po-sition for proper wheel alignment.

CAUTION:ECA10570

Improper drive chain slack will over-load the engine as well as other vitalparts of the motorcycle and can leadto chain slippage or breakage. Toprevent this from occurring, keepthe drive chain slack within thespecified limits.

1. Drive chain slack

Drive chain slack:40.0–55.0 mm (1.57–2.17 in)

1. Axle nut2. Drive chain slack adjusting nut3. Locknut4. Alignment marks


6-24

6

3. Tighten the locknuts, and thentighten the axle nut to the specifiedtorque.

EAU23021

Lubricating the drive chain The drive chain must be cleaned andlubricated at the intervals specified inthe periodic maintenance and lubrica-tion chart, otherwise it will quickly wearout, especially when riding in dusty orwet areas. Service the drive chain asfollows.

CAUTION:ECA10581

The drive chain must be lubricatedafter washing the motorcycle andriding in the rain.

1. Clean the drive chain with kero-sene and a small soft brush.

CAUTION:ECA11120

To prevent damaging the O-rings, donot clean the drive chain with steamcleaners, high-pressure washers orinappropriate solvents.

2. Wipe the drive chain dry.3. Thoroughly lubricate the drive

chain with a special O-ring chainlubricant.

CAUTION:ECA11110

Do not use engine oil or any other lu-bricants for the drive chain, as theymay contain substances that coulddamage the O-rings.

Tightening torque:Axle nut:

104 Nm (10.4 m·kgf, 75 ft·lbf)


6-25

6

EAU23100

Checking and lubricating the cables The operation of all control cables andthe condition of the cables should bechecked before each ride, and the ca-bles and cable ends should be lubricat-ed if necessary. If a cable is damagedor does not move smoothly, have aYamaha dealer check or replace it.

WARNINGEWA10720

Damage to the outer sheath may in-terfere with proper cable operationand will cause the inner cable torust. Replace a damaged cable assoon as possible to prevent unsafeconditions.

EAU23110

Checking and lubricating the throttle grip and cable The operation of the throttle grip shouldbe checked before each ride. In addi-tion, the cable should be lubricated orreplaced at the intervals specified in theperiodic maintenance chart.

EAU23140

Checking and lubricating the brake and clutch levers

Brake lever

Clutch lever

The operation of the brake and clutchlevers should be checked before eachride, and the lever pivots should be lu-bricated if necessary.

Recommended lubricant:Engine oil


6-26

6

EAU23180

Lubricating the brake pedal

The operation of the brake pedalshould be checked before each ride,and the pedal pivot should be lubricat-ed if necessary.

EAU23200

Checking and lubricating the sidestand

The operation of the sidestand shouldbe checked before each ride, and thesidestand pivot and metal-to-metalcontact surfaces should be lubricated ifnecessary.

WARNINGEWA10730

If the sidestand does not move upand down smoothly, have a Yamahadealer check or repair it.

Recommended lubricant:Lithium-soap-based grease (all-pur-pose grease)




6-27

6

EAU23271

Checking the front fork The condition and operation of the frontfork must be checked as follows at theintervals specified in the periodic main-tenance and lubrication chart.

To check the condition

WARNINGEWA10750

Securely support the vehicle so thatthere is no danger of it falling over.

Check the inner tubes for scratches,damage and excessive oil leakage.

To check the operation1. Place the vehicle on a level sur-


2. While applying the front brake,push down hard on the handlebarsseveral times to check if the frontfork compresses and reboundssmoothly.

CAUTION:ECA10590

If any damage is found or the frontfork does not operate smoothly,have a Yamaha dealer check or re-pair it.

EAU23280

Checking the steering Worn or loose steering bearings maycause danger. Therefore, the operationof the steering must be checked as fol-lows at the intervals specified in the pe-riodic maintenance and lubricationchart.

1. Place a stand under the engine toraise the front wheel off theground.

WARNINGEWA10750

Securely support the vehicle so thatthere is no danger of it falling over.

2. Hold the lower ends of the frontfork legs and try to move them for-ward and backward. If any freeplay can be felt, have a Yamahadealer check or repair the steering.


6-28

6

EAU23290

Checking the wheel bearings The front and rear wheel bearings mustbe checked at the intervals specified inthe periodic maintenance and lubrica-tion chart. If there is play in the wheelhub or if the wheel does not turnsmoothly, have a Yamaha dealer checkthe wheel bearings.

EAUM1730

Battery This model is equipped with a sealed-type (MF) battery, which does not re-quire any maintenance. There is noneed to check the electrolyte or to adddistilled water.

CAUTION:ECA10620

Never attempt to remove the batterycell seals, as this would permanent-ly damage the battery.

To access the battery1. Remove the seat. (See page

3-12.)2. Remove the battery cover by re-

moving the bolts.


6-29

6To charge the batteryHave a Yamaha dealer charge the bat-tery as soon as possible if it seems tohave discharged. Keep in mind that thebattery tends to discharge more quicklyif the vehicle is equipped with optionalelectrical accessories.

WARNINGEWA10760

� Electrolyte is poisonous anddangerous since it contains sul-furic acid, which causes severeburns. Avoid any contact withskin, eyes or clothing and al-ways shield your eyes when

working near batteries. In caseof contact, administer the fol-lowing FIRST AID.• EXTERNAL: Flush with plenty

of water.• INTERNAL: Drink large quan-

tities of water or milk and im-mediately call a physician.

• EYES: Flush with water for 15minutes and seek promptmedical attention.

� Batteries produce explosive hy-drogen gas. Therefore, keepsparks, flames, cigarettes, etc.,away from the battery and pro-vide sufficient ventilation whencharging it in an enclosedspace.

� KEEP THIS AND ALL BATTER-IES OUT OF THE REACH OFCHILDREN.

To store the battery1. If the vehicle will not be used for

more than one month, remove thebattery, fully charge it, and thenplace it in a cool, dry place.

2. If the battery will be stored for morethan two months, check it at leastonce a month and fully charge it ifnecessary.

3. Fully charge the battery before in-stallation.

4. After installation, make sure thatthe battery leads are properly con-nected to the battery terminals.

CAUTION:ECA10630

� Always keep the batterycharged. Storing a dischargedbattery can cause permanentbattery damage.

� To charge a sealed-type (MF)battery, a special (constant-volt-age) battery charger is required.Using a conventional batterycharger will damage the battery.If you do not have access to asealed-type (MF) battery charg-er, have a Yamaha dealercharge your battery.

1. Negative battery terminal2. Positive battery terminal3. Bolt4. Battery cover


6-30

6

EAUM1740

Replacing the fuses The main fuse is located behind panelA. (See page 6-5.)

Fuse box 1 and fuse box 2 are locatedunder the seat. (See page 3-12.)

If a fuse is blown, replace it as follows.1. Turn the key to “OFF” and turn off

the electrical circuit in question.2. Remove the blown fuse, and then

install a new fuse of the specifiedamperage.

CAUTION:ECA10640

Do not use a fuse of a higher amper-age rating than recommended toavoid causing extensive damage tothe electrical system and possibly afire.

3. Turn the key to “ON” and turn onthe electrical circuit in question tocheck if the device operates.

1. Main fuse2. Spare main fuse

1. Fuse box 12. Signaling system fuse3. Headlight fuse4. Ignition fuse5. Electronic fuel injection fuse6. Radiator fan fuse7. Backup fuse (for odometer, clock and

immobilizer system)8. Parking lighting fuse9. Fuse box 210.Spare fuse

Specified fuses:Main fuse:

30.0 AFuse box 1:

Headlight fuse:20.0 A

Signaling system fuse:10.0 A

Radiator fan fuse:7.5 A

Ignition fuse:10.0 A

Electronic fuel injection fuse:10.0 A

Backup fuse:10.0 A

Fuse box 2:Parking lighting fuse:

10.0 A


6-31

6

4. If the fuse immediately blowsagain, have a Yamaha dealercheck the electrical system.

EAUM1750

Replacing the headlight bulb This model is equipped with a quartzbulb headlight. If the headlight bulbburns out, replace it as follows.

1. Remove cowling A together withthe headlight unit. (See page 6-5.)

2. Disconnect the headlight coupler,and then remove the headlightbulb cover.

3. Remove the headlight bulb holderby turning it counterclockwise, andthen remove the defective bulb.

WARNINGEWA10790

Headlight bulbs get very hot. There-fore, keep flammable products awayfrom a lit headlight bulb, and do nottouch the bulb until it has cooleddown.

4. Place a new bulb into position, andthen secure it with the bulb holder.

CAUTION:ECA10660

Do not touch the glass part of theheadlight bulb to keep it free fromoil, otherwise the transparency ofthe glass, the luminosity of the bulb,and the bulb life will be adversely af-

1. Headlight bulb cover2. Headlight coupler

1. Headlight bulb holder2. Headlight bulb


6-32

6

fected. Thoroughly clean off any dirtand fingerprints on the headlightbulb using a cloth moistened with al-cohol or thinner.

5. Install the bulb cover, and thenconnect the coupler.

6. Install the cowling together withthe headlight unit.

7. Have a Yamaha dealer adjust theheadlight beam if necessary.

EAU24281

Replacing a turn signal light bulb or the tail/brake light bulb

1. Remove the lens by removing thescrews.

2. Remove the defective bulb bypushing 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 thescrews.

CAUTION:ECA10680

Do not overtighten the screws, oth-erwise the lens may break.

1. Do not touch the glass part of the bulb.1. Screw

1. Screw


6-33

6

EAUM1820

Replacing an auxiliary light bulb If the auxiliary light bulb burns out, re-place it as follows.

1. Remove cowling A together withthe headlight unit. (See page 6-5.)

2. Remove the auxiliary light socket(together with the bulb) by pulling itout.

3. Remove the defective bulb by pull-ing it out.

4. Insert a new bulb into the socket.5. Install the auxiliary light socket (to-

gether with the bulb) by pushing itin.

6. Install the cowling together withthe headlight unit.

EAU24350

Supporting the motorcycle Since this model is not equipped with acenterstand, follow these precautionswhen removing the front and rearwheel or performing other maintenancerequiring the motorcycle to stand up-right. Check that the motorcycle is in astable and level position before startingany maintenance. A strong woodenbox can be placed under the engine foradded stability.

To service the front wheel1. Stabilize the rear of the motorcycle

by using a motorcycle stand or, ifan additional motorcycle stand isnot available, by placing a jack un-der the frame in front of the rearwheel.

2. Raise the front wheel off theground by using a motorcyclestand.

To service the rear wheelRaise the rear wheel off the ground byusing a motorcycle stand or, if a motor-cycle stand is not available, by placing

a jack either under each side of theframe in front of the rear wheel or undereach side of the swingarm.

1. Auxiliary light bulb socket


6-34

6

EAU24360

Front wheel

EAUM1761

To remove the front wheel

WARNINGEWA10820

� It is advisable to have a Yamahadealer service the wheel.

� Securely support the motor-cycle so that there is no dangerof it falling over.

1. Loosen the front wheel axle pinchbolts, then the wheel axle and thebrake caliper bolts.

XT660R

XT660X

2. Lift the front wheel off the groundaccording to the procedure onpage 6-33.

3. Remove the brake caliper by re-moving the bolts.

CAUTION:ECA11070

Do not apply the brake after thewheel has been removed togetherwith the brake disc, otherwise thebrake pads will be forced shut.

4. Pull the wheel axle out, and thenremove the wheel.

EAUM1811

To install the front wheel1. 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. Wheel axle2. Front wheel axle pinch bolt A3. Front wheel axle pinch bolt B

1. Wheel axle2. Front wheel axle pinch bolt A3. Front wheel axle pinch bolt B

1. Bolt2. Brake caliper


6-35

6

4. Install the brake caliper by install-ing the bolts.

NOTE:Make sure that there is enough spacebetween the brake pads before install-ing the brake caliper onto the brakedisc.

5. Tighten the wheel axle to the spec-ified torque.

6. Tighten the wheel axle pinch bolt Aand pinch bolt B to the specifiedtorques.

7. Retighten the wheel axle pinch boltA to the specified torque.

8. Tighten the brake caliper bolts tothe specified torques.

9. Push down hard on the handlebarseveral times to check for properfork operation.

EAU25080

Rear wheel

EAUM1771

To remove the rear wheel

WARNINGEWA10820

� It is advisable to have a Yamahadealer service the wheel.

� Securely support the motor-cycle so that there is no dangerof it falling over.

1. Remove the drive chain guard byremoving the bolts.

XT660R

XT660X

2. Loosen the axle nut.

Tightening torques:Wheel axle:

59 Nm (5.9 m·kgf, 43 ft·lbf)Front wheel axle pinch bolt:

18 Nm (1.8 m·kgf, 13 ft·lbf)Brake caliper bolt:

40 Nm (4.0 m·kgf, 29 ft·lbf)

1. Bolt2. Drive chain guard

1. Bolt2. Drive chain guard

1. Axle nut2. Drive chain slack adjusting nut3. Locknut4. Brake caliper bracket5. Brake caliper


6-36

6

3. Lift the rear wheel off the groundaccording to the procedure onpage 6-33.

4. Loosen the locknut on each side ofthe swingarm.

5. Turn the drive chain slack adjust-ing nuts fully in direction (a).

6. Remove the wheel axle by remov-ing the axle nut.

7. Push the wheel forward, and thenremove the drive chain from therear sprocket.

NOTE:The drive chain cannot be disassem-bled.

8. Pull the wheel backward and movethe brake caliper away from thewheel.

CAUTION:ECA11070

Do not apply the brake after thewheel has been removed togetherwith the brake disc, otherwise thebrake pads will be forced shut.

EAUM1781

To install the rear wheel1. 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 andthe washer with the “O” mark onthe left-hand side. Be sure to installboth washers with their marks fac-ing outward.

� Make sure that the retainer on theswingarm is inserted into the slot inthe brake caliper bracket.

� Make sure that there is enoughspace between the brake pads be-fore installing the wheel.

3. Lower the rear wheel so that it ison the ground.

1. Brake caliper2. Brake disc

1. Retainer2. Slot


6-37

6

4. Adjust the drive chain slack. (Seepage 6-23.)

5. Tighten the axle nut to the speci-fied torque.

6. Install the drive chain guard by in-stalling the bolts.

EAU25870

Troubleshooting Although Yamaha motorcycles receivea thorough inspection before shipmentfrom the factory, trouble may occur dur-ing operation. Any problem in the fuel,compression, or ignition systems, forexample, can cause poor starting andloss of power.The following troubleshooting chartsrepresent quick and easy proceduresfor checking these vital systems your-self. However, should your motorcyclerequire any repair, take it to a Yamahadealer, whose skilled technicians havethe necessary tools, experience, andknow-how to service the motorcycleproperly.Use only genuine Yamaha replace-ment parts. Imitation parts may look likeYamaha parts, but they are often inferi-or, have a shorter service life and canlead to expensive repair bills.

Tightening torque:Axle nut:

104 Nm (10.4 m·kgf, 75 ft·lbf)


6-38

6

EAU25921

Troubleshooting charts

Starting problems or poor engine performance

WARNINGEWA10840

Keep away open flames and do not smoke while checking or working on the fuel system.

Check the fuel level inthe fuel tank.

1. FuelThere is enough fuel.

There is no fuel.

Check the compression.

Supply fuel. The engine does not start. Check the compression.

Operate the electric starter.

2. CompressionThere is compression.

There is no compression.

Check the ignition.

Have a Yamaha dealercheck the vehicle.

Remove the spark plugand check the electrodes.

3. Ignition Wipe off with a dry cloth and correct thespark plug gap, or replace the spark plug.

Have a Yamaha dealer check the vehicle.

The engine does not start.Have a Yamaha dealercheck the vehicle.

The engine does not start.Check the battery.

Operate the electric starter.

4. BatteryThe engine turns over quickly.

The engine turns over slowly.

The battery is good.

Check the battery lead connections,and charge the battery if necessary.

Dry

WetOpen the throttle halfway and operatethe electric starter.


6-39

6

Engine overheating

WARNINGEWA10400

� Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may beblown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.

� After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and thenslowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hissingsound 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 coolantas 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 cooling systemfor leakage.

Have a Yamaha dealer checkand repair the cooling system.

Add coolant. (See NOTE.)

Start the engine. If the engine overheats again, have a Yamaha dealer check and repair the cooling system.

There isleakage.

There is no leakage.

MOTORCYCLE CARE AND STORAGE

7-1

7

EAU26000

Care While the open design of a motorcyclereveals the attractiveness of the tech-nology, it also makes it more vulnera-ble. Rust and corrosion can developeven if high-quality components areused. A rusty exhaust pipe may go un-noticed on a car, however, it detractsfrom the overall appearance of a motor-cycle. Frequent and proper care doesnot only comply with the terms of thewarranty, but it will also keep yourmotorcycle looking good, extend its lifeand optimize its performance.

Before cleaning1. Cover the muffler outlet with a

plastic bag after the engine hascooled down.

2. Make sure that all caps and coversas well as all electrical couplersand connectors, including thespark plug cap, are tightly in-stalled.

3. Remove extremely stubborn dirt,like oil burnt onto the crankcase,with a degreasing agent and abrush, but never apply such prod-

ucts onto seals, gaskets, sprock-ets, the drive chain and wheelaxles. Always rinse the dirt and de-greaser off with water.

Cleaning

CAUTION:ECA10770

� Avoid using strong acidic wheelcleaners, especially on spokedwheels. If such products areused on hard-to-remove dirt, donot leave the cleaner on the af-fected area any longer than in-structed. Also, thoroughly rinsethe area off with water, immedi-ately dry it, and then apply a cor-rosion protection spray.

� Improper cleaning can damagewindshields, cowlings, panelsand other plastic parts. Use onlya soft, clean cloth or spongewith mild detergent and water toclean plastic.

� Do not use any harsh chemicalproducts on plastic parts. Besure to avoid using cloths orsponges which have been incontact with strong or abrasive

cleaning products, solvent orthinner, fuel (gasoline), rust re-movers or inhibitors, brake flu-id, antifreeze or electrolyte.

� Do not use high-pressure wash-ers or steam-jet cleaners sincethey cause water seepage anddeterioration in the following ar-eas: seals (of wheel and swing-arm bearings, fork and brakes),electric components (couplers,connectors, instruments,switches and lights), breatherhoses and vents.

� For motorcycles equipped witha windshield: Do not use strongcleaners or hard sponges asthey will cause dulling orscratching. Some cleaning com-pounds for plastic may leavescratches on the windshield.Test the product on a small hid-den part of the windshield tomake sure that it does not leaveany marks. If the windshield isscratched, use a quality plasticpolishing compound afterwashing.


7-2

7

After normal useRemove dirt with warm water, a milddetergent, and a soft, clean sponge,and then rinse thoroughly with cleanwater. Use a toothbrush or bottlebrushfor hard-to-reach areas. Stubborn dirtand insects will come off more easily ifthe area is covered with a wet cloth fora few minutes before cleaning.

After riding in the rain, near the sea oron salt-sprayed roadsSince sea salt or salt sprayed on roadsduring winter are extremely corrosive incombination with water, carry out thefollowing steps after each ride in therain, near the sea or on salt-sprayedroads.

NOTE:Salt sprayed on roads in the winter mayremain well into spring.

1. Clean the motorcycle with cold wa-ter and a mild detergent, after theengine has cooled down.

CAUTION:ECA10790

Do not use warm water since it in-creases the corrosive action of thesalt.

2. Apply a corrosion protection sprayon all metal, including chrome- andnickel-plated, surfaces to preventcorrosion.

After cleaning1. Dry the motorcycle with a chamois

or an absorbing cloth.2. Immediately dry the drive chain

and lubricate it to prevent it fromrusting.

3. Use a chrome polish to shinechrome, aluminum and stainless-steel parts, including the exhaustsystem. (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 apply a corrosion pro-tection spray on all metal,including chrome- and nickel-plat-ed, surfaces.

5. Use spray oil as a universal clean-er to remove any remaining dirt.

6. Touch up minor paint damagecaused by stones, etc.

7. Wax all painted surfaces.8. Let the motorcycle dry completely

before storing or covering it.

WARNINGEWA10930

� Make sure that there is no oil orwax on the brakes or tires. Ifnecessary, clean the brakediscs and brake linings with aregular brake disc cleaner or ac-etone, and wash the tires withwarm water and a mild deter-gent.

� Before operating the motor-cycle test its braking perfor-mance and cornering behavior.

CAUTION:ECA10800

� Apply spray oil and wax spar-ingly and make sure to wipe offany excess.


7-3

7

� Never apply oil or wax to anyrubber and plastic parts, buttreat them with a suitable careproduct.

� Avoid using abrasive polishingcompounds as they will wearaway the paint.

NOTE:Consult a Yamaha dealer for advice onwhat products to use.

EAUM1900

Storage

Short-termAlways store your motorcycle in a cool,dry place and, if necessary, protect itagainst dust with a porous cover.

CAUTION:ECA10810

� Storing the motorcycle in apoorly ventilated room or cover-ing it with a tarp, while it is stillwet, will allow water and humid-ity to seep in and cause rust.

� To prevent corrosion, avoiddamp cellars, stables (becauseof the presence of ammonia)and areas where strong chemi-cals are stored.

Long-termBefore storing your motorcycle for sev-eral months:

1. Follow all the instructions in the“Care” section of this chapter.

2. Fill up the fuel tank and add fuelstabilizer (if available) to preventthe fuel tank from rusting and thefuel 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 the spark plug cap onto

the spark plug, and then placethe spark plug on the cylinderhead so that the electrodes aregrounded. (This will limit spark-ing during the next step.)

d. Turn the engine over severaltimes with the starter. (This willcoat the cylinder wall with oil.)

e. Remove the spark plug capfrom the spark plug, and theninstall the spark plug and thespark plug cap.

WARNINGEWA10950

To prevent damage or injury fromsparking, make sure to ground thespark plug electrodes while turningthe engine over.


7-4

7

4. Lubricate all control cables and thepivoting points of all levers andpedals as well as of the side-stand/centerstand.

5. Check and, if necessary, correctthe tire air pressure, and then liftthe motorcycle so that both of itswheels are off the ground. Alterna-tively, turn the wheels a little everymonth in order to prevent the tiresfrom becoming degraded in onespot.

6. Cover the muffler outlets with plas-tic bags to prevent moisture fromentering them.

7. Remove the battery and fullycharge it. Store it in a cool, dryplace and charge it once a month.Do not store the battery in an ex-cessively cold or warm place [lessthan 0 °C (30 °F) or more than 30°C (90 °F)]. For more informationon storing the battery, see page6-28.

NOTE:Make any necessary repairs beforestoring the motorcycle.

SPECIFICATIONS

8-1

8

Dimensions:Overall length:

XT660R 2240 mm (88.2 in)XT660X 2150 mm (84.6 in)

Overall width:XT660R 845 mm (33.3 in)XT660X 865 mm (34.1 in)

Overall height:XT660R 1230 mm (48.4 in)XT660X 1210 mm (47.6 in)

Seat height:XT660R 865 mm (34.1 in)XT660X 870 mm (34.3 in)

Wheelbase:XT660R 1505 mm (59.3 in)XT660X 1490 mm (58.7 in)

Ground clearance:XT660R 210 mm (8.27 in)XT660X 205 mm (8.07 in)

Minimum turning radius:2400 mm (94.5 in)

Weight:With oil and fuel:

XT660R 181.0 kg (399 lb)XT660X 186.0 kg (410 lb)

Engine:Engine type:

Liquid cooled 4-stroke, SOHCCylinder arrangement:

Forward-inclined single cylinderDisplacement:

660.0 cm³ (40.27 cu.in)Bore × stroke:

100.0 × 84.0 mm (3.94 × 3.31 in)

Compression ratio:10.00 :1

Starting system:Electric starter

Lubrication system:Dry sump

Engine oil:Type:

SAE10W30 or SAE10W40 or SAE15W40 or SAE20W40 or SAE20W50

Recommended engine oil grade: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-coated paper elementFuel:

Recommended fuel:Premium unleaded gasoline only

Fuel tank capacity:15.0 L (3.96 US gal) (3.30 Imp.gal)

Fuel reserve amount:5.0 L (1.32 US gal) (1.10 Imp.gal)

Electronic fuel injection:Manufacturer:

DENSOModel:

297500-0390Spark plug(s):

Manufacturer/model:NGK/CR7E

Spark plug gap:0.7–0.8 mm (0.028–0.031 in)

Clutch:Clutch type:

Wet, multiple-discTransmission:

Primary reduction system:Spur gear

Primary reduction ratio:75/36 (2.083)

Secondary reduction system:Chain drive

Secondary reduction ratio:45/15 (3.000)

Transmission type:Constant mesh 5-speed

-20 -10 0 10 20 30 40 50 ˚C

SAE 10W-30

SAE 15W-40

SAE 20W-40

SAE 20W-50

SAE 10W-40

SPECIFICATIONS

8-2

8

Operation:Left foot operation

Gear ratio:1st:

30/12 (2.500)2nd:

26/16 (1.625)3rd:

23/20 (1.150)4th:

20/22 (0.909)5th:

20/26 (0.769)Chassis:

Frame type:Diamond

Caster angle:XT660R 27.25 °XT660X 26.00 °

Trail:XT660R 107.0 mm (4.21 in)XT660X 94.0 mm (3.70 in)

Front tire:Type:

With tubeSize:


Manufacturer/model:XT660R METZELER/TOURANCE FRONTXT660X PIRELLI/DRAGON

Manufacturer/model:XT660R MICHELIN/SIRAC

Rear tire:Type:

With tubeSize:


Manufacturer/model:XT660R METZELER/TOURANCEXT660X PIRELLI/DRAGON

Manufacturer/model:XT660R MICHELIN/SIRAC A

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:



Loading condition:90–186 kg (198–410 lb)Front:



Off-road riding:Front:

XT660R 200 kPa (29 psi) (2.00 kgf/cm²)Rear:

XT660R 200 kPa (29 psi) (2.00 kgf/cm²)Front wheel:

Wheel type:Spoke wheel

Rim size:XT660R 21x1.85XT660X 17M/C x MT3.50

Rear wheel:Wheel type:

Spoke wheelRim size:

XT660R 17M/C x MT2.75XT660X 17M/C x MT4.25

Front brake:Type:

Single disc brakeOperation:

Right hand operationRecommended fluid:

DOT 4Rear brake:

Type:Single disc brake

Operation:Right foot operation

Recommended fluid:DOT 4

SPECIFICATIONS

8-3

8

Front suspension:Type:

Telescopic forkSpring/shock absorber type:

Coil spring/oil damperWheel travel:

XT660R 225.0 mm (8.86 in)XT660X 200.0 mm (7.87 in)

Rear suspension:Type:

Swingarm (monocross)Spring/shock absorber type:

Coil spring/gas-oil damperWheel travel:

XT660R 200.0 mm (7.87 in)XT660X 191.0 mm (7.52 in)

Electrical system:Ignition system:

Transistorized coil ignition (digital)Charging system:

A.C. magnetoBattery:

Model:GT9B-4

Voltage, capacity:12 V, 8.0 Ah

Headlight:Bulb type:

Halogen bulbBulb 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

Engine trouble warning light:LED

Immobilizer system indicator light:LED

Fuses:Main fuse:

30.0 AHeadlight fuse:

20.0 ASignaling system fuse:

10.0 AIgnition fuse:

10.0 AParking lighting fuse:

10.0 A

Radiator fan fuse:7.5 A

Electronic fuel injection fuse:10.0 A

Backup fuse:10.0 A

CONSUMER INFORMATION

9-1

9

EAU26351

Identification numbers Record the key identification number,vehicle identification number and mod-el label information in the spaces pro-vided below for assistance whenordering spare parts from a Yamahadealer or for reference in case the vehi-cle is stolen.KEY IDENTIFICATION NUMBER:

VEHICLE IDENTIFICATION NUMBER:

MODEL LABEL INFORMATION:

EAU26381

Key identification number

The key identification number isstamped into the key tag. Record thisnumber in the space provided and useit for reference when ordering a newkey.

EAU26410

Vehicle identification number

The vehicle identification number isstamped into the frame.

NOTE:The vehicle identification number isused to identify your vehicle and maybe used to register it with the licensingauthority in your area.

1. Key identification number2. Code re-registering key (red bow)3. Standard keys (black bow)

1. Vehicle identification number

CONSUMER INFORMATION

9-2

9

EAU26540

Model label

The model label is affixed to the frameunder the seat. (See page 3-12.)Record the information on this label inthe space provided. This informationwill be needed when ordering spareparts from a Yamaha dealer.

1. Model label

INDEXA

Air filter element and check hose, replacing and cleaning ....................... 6-15

Anti-theft alarm (optional) ....................... 3-7Auxiliary light bulb, replacing ................ 6-33

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

and lubricating .................................... 6-25Brake fluid level, checking .................... 6-22Brake lever ............................................. 3-9Brake pedal .......................................... 3-10Brake pedal, lubricating ........................ 6-26

CCables, checking and lubricating.......... 6-25Care........................................................ 7-1Catalytic converter................................ 3-12Clutch lever............................................. 3-9Clutch lever free play, adjusting ........... 6-20Coolant ................................................. 6-12Coolant temperature warning light.......... 3-4Cowlings and panels, removing and

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

Dimmer switch ........................................ 3-8Drive chain, lubricating ......................... 6-24Drive chain slack .................................. 6-23

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

FFront and rear brake pads, checking ....6-21Front fork, checking...............................6-27Fuel .......................................................3-11Fuel consumption, tips for reducing ........5-3Fuel level warning light............................3-4Fuel tank cap.........................................3-10Fuses, replacing....................................6-30

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

IIdentification numbers .............................9-1Ignition circuit cut-off system.................3-15Immobilizer system .................................3-1Immobilizer system indicator light ...........3-4Indicator and warning lights ....................3-3

KKey identification number........................9-1

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

NNeutral indicator light ..............................3-3

PParking ....................................................5-4Part locations ..........................................2-1Pass switch .............................................3-8Periodic maintenance and lubrication

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

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

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

Safety information................................... 1-1Seat ...................................................... 3-12Shifting.................................................... 5-2Shift pedal............................................... 3-9Shock absorber assembly, adjusting .... 3-13Sidestand.............................................. 3-14Sidestand, checking and lubricating ..... 6-26Spark plug, checking .............................. 6-7Specifications.......................................... 8-1Starting the engine.................................. 5-1Start switch ............................................. 3-8Steering, checking ................................ 6-27Storage ................................................... 7-3Storage compartment ........................... 3-13Supporting the motorcycle .................... 6-33

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

and lubricating .................................... 6-25Tires...................................................... 6-17Tool kit .................................................... 6-1Troubleshooting .................................... 6-37Troubleshooting charts ......................... 6-38Turn signal indicator light ........................ 3-3Turn signal light bulb or tail/brake

light bulb, replacing............................. 6-32Turn signal switch ................................... 3-8

VVehicle identification number.................. 9-1

INDEXW

Wheel bearings, checking..................... 6-28Wheel (front) ......................................... 6-34Wheel (rear) .......................................... 6-35Wheels .................................................. 6-19

YAMAHA MOTOR CO., LTD.PRINTED IN FRANCE

2004.02 (E)

Documents

XT660R XT660X - hp2.sehp2.se/lager/singles/xtom.pdf · This motorcycle is designed to car-ry the operator and a passenger. The failure of motorists to detect and recognize motorcycles