XT660R XT660X: Owner'S Manual

OWNER’S MANUAL
XT660R
XT660X
5VK-F8199-E1
U5VKE1E0.book Page 1 Tuesday, July 18, 2006 1:00 PM
EAU26943
DECLARATION of CONFORMITY
We
Company: MORIC CO., LTD.
Address: 1450-6 Mori Mori-Machi Shuchi-gun Shizuoka 437-0292 Japan
Hereby declare that the product:
Kind of equipment: IMMOBILIZER
Type-designation: 5SL-00
is in compliance with following norm(s) or documents:
R&TTE Directive(1999/5/EC)
EN300 330-2 v1.1.1(2001-6), EN60950-1(2001)
Two or Three-Wheel Motor Vehicles Directive(97/24/EC: Chapter 8, EMC)
Place of issue: Shizuoka, Japan
Date of issue: 1 Aug. 2002
Revolution record
No. Contents Date
1 To change contact person and integrate type-designation. 9 Jun. 2005
2 Version up the norm of EN60950 to EN60950-1 27 Feb. 2006
General manager of quality assurance div.
representative name and signature
MORIC CO., LTD.

1450-6 Mori-machi Shuchi-gun Shizuoka 437-0292 JAPAN Telephone +81-538-85-0757 Facsimile +81-538-85-0456
URL:http://www.moric-jp.com
INTRODUCTION
EAU10100
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 regarding
the 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’s
manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard
yourself and others from trouble and injury.
In addition, the many tips given in this manual will help keep your motorcycle in the best possible condition. If you have any
further questions, do not hesitate to contact your Yamaha dealer.
The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!
IMPORTANT MANUAL INFORMATION

EAU10151
Particularly important information is distinguished in this manual by the following notations:

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
WARNING 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

CAUTION: the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.
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 motorcycle
and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.
EWA10030
WARNING
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
*Product and specifications are subject to change without notice.
IMPORTANT MANUAL INFORMATION
EAUM1010
XT660R/XT660X
OWNER’S MANUAL
©2006 by MBK INDUSTRIE
1st edition, July 2006
All rights reserved
Any reprinting or unauthorized use
without the written permission of
MBK INDUSTRIE
is expressly prohibited.
Printed in France.
TABLE OF CONTENTS
SAFETY INFORMATION ..................1-1 OPERATION AND IMPORTANT Checking the front and rear brake
RIDING POINTS................................. 5-1 pads .......................................... 6-22
DESCRIPTION ..................................2-1 Starting the engine ......................... 5-1 Checking the brake fluid level ...... 6-23
Left view ..........................................2-1 Shifting ........................................... 5-2 Drive chain slack .......................... 6-24
Right view ........................................2-2 Tips for reducing fuel Cleaning and lubricating the drive
Controls and instruments.................2-3 consumption ............................... 5-3 chain ......................................... 6-26
Engine break-in .............................. 5-3 Checking and lubricating the
INSTRUMENT AND CONTROL Parking ........................................... 5-4 cables ....................................... 6-27
FUNCTIONS .......................................3-1 Checking and lubricating the
Immobilizer system .........................3-1 PERIODIC MAINTENANCE AND throttle grip and cable ............... 6-27
Main switch/steering lock ................3-2 MINOR REPAIR ................................. 6-1 Checking and lubricating the
Indicator and warning lights ............3-3 Owner’s tool kit ............................... 6-1 brake and clutch levers ............ 6-27
Multi-function display ......................3-5 Periodic maintenance and Lubricating the brake pedal ......... 6-28
Anti-theft alarm (optional) ...............3-7 lubrication chart .......................... 6-2 Checking and lubricating the
Handlebar switches ........................3-7 Removing and installing cowlings sidestand .................................. 6-28
Clutch lever .....................................3-9 and panels .................................. 6-5 Checking the front fork ................. 6-29
Shift pedal .......................................3-9 Checking the spark plug ................. 6-9 Checking the steering .................. 6-29
Brake lever .....................................3-9 Engine oil and oil filter element .... 6-10 Checking the wheel bearings ....... 6-30
Brake pedal ..................................3-10 Coolant ......................................... 6-13 Battery ......................................... 6-30
Fuel tank cap ................................3-10 Replacing the air filter element and Replacing the fuses ..................... 6-32
Fuel ...............................................3-11 cleaning the check hose ........... 6-16 Replacing the headlight bulb ....... 6-33
Catalytic converter ........................3-12 Adjusting the engine idling Replacing a turn signal light bulb
Seat ..............................................3-12 speed ........................................ 6-17 or the tail/brake light bulb ......... 6-34
Storage compartment ...................3-13 Checking the throttle cable free Replacing an auxiliary light bulb .. 6-35
Adjusting the shock absorber play ........................................... 6-18 Supporting the motorcycle ........... 6-35
assembly ...................................3-13 Tires ............................................. 6-18 Front wheel .................................. 6-36
Sidestand ......................................3-14 Spoke wheels ............................... 6-21 Rear wheel ................................... 6-37
Ignition circuit cut-off system ........3-15 Adjusting the clutch lever free Troubleshooting ........................... 6-39
play ........................................... 6-21 Troubleshooting charts ................ 6-40
PRE-OPERATION CHECKS ..............4-1 Adjusting the rear brake light
Pre-operation check list ..................4-2 switch ........................................ 6-22
TABLE OF CONTENTS
MOTORCYCLE CARE AND
STORAGE ..........................................7-1
Care ................................................7-1
Storage ...........................................7-3
SPECIFICATIONS .............................8-1
CONSUMER INFORMATION.............9-1
Identification numbers ....................9-1
SAFETY INFORMATION
EAU10311
AND/OR WHEN MADE NECES- • Ride where other motorists can
SARY BY MECHANICAL CONDI- see you. Avoid riding in another
MOTORCYCLES ARE SINGLE TIONS. motorist’s blind spot.
1 TRACK VEHICLES. THEIR SAFE USE ● Many accidents involve inexperi-
AND OPERATION ARE DEPENDENT Safe riding enced operators. In fact, many op-
UPON THE USE OF PROPER RIDING ● Always make pre-operation erators who have been involved in
TECHNIQUES AS WELL AS THE EX- checks. Careful checks may help accidents do not even have a cur-
PERTISE OF THE OPERATOR. EV- prevent an accident. rent motorcycle license.
ERY OPERATOR SHOULD KNOW ● This motorcycle is designed to car- • Make sure that you are qualified
THE FOLLOWING REQUIREMENTS ry the operator and a passenger. and that you only lend your
BEFORE RIDING THIS MOTOR- ● The failure of motorists to detect motorcycle to other qualified op-
CYCLE. and recognize motorcycles in traf- erators.
HE OR SHE SHOULD: fic is the predominating cause of • Know your skills and limits.
● OBTAIN THOROUGH INSTRUC- automobile/motorcycle accidents. Staying within your limits may
TIONS FROM A COMPETENT Many accidents have been caused help you to avoid an accident.
SOURCE ON ALL ASPECTS OF by an automobile driver who did • We recommend that you prac-
MOTORCYCLE OPERATION. not see the motorcycle. Making tice riding your motorcycle
● OBSERVE THE WARNINGS AND yourself conspicuous appears to where there is no traffic until you
MAINTENANCE REQUIRE- be very effective in reducing the have become thoroughly famil-
MENTS IN THE OWNER’S MAN- chance of this type of accident. iar with the motorcycle and all of
UAL. Therefore: its controls.
● OBTAIN QUALIFIED TRAINING • Wear a brightly colored jacket. ● Many accidents have been caused
IN SAFE AND PROPER RIDING • Use extra caution when ap- by error of the motorcycle opera-
TECHNIQUES. proaching and passing through tor. A typical error made by the op-
● OBTAIN PROFESSIONAL TECH- intersections, since intersec- erator is veering wide on a turn
NICAL SERVICE AS INDICATED tions are the most likely places
BY THE OWNER’S MANUAL for motorcycle accidents to oc-
cur.
1-1
SAFETY INFORMATION
due to EXCESSIVE SPEED or un- Protective apparel Modifications
dercornering (insufficient lean an- The majority of fatalities from motor- Modifications made to this motorcycle
gle for the speed). cycle accidents are the result of head not approved by Yamaha, or the re-
• Always obey the speed limit and injuries. The use of a safety helmet is moval of original equipment, may ren- 1
never travel faster than warrant- the single most critical factor in the pre- der the motorcycle unsafe for use and
ed by road and traffic conditions. vention or reduction of head injuries. may cause severe personal injury.
• Always signal before turning or ● Always wear an approved helmet. Modifications may also make your
changing lanes. Make sure that ● Wear a face shield or goggles. motorcycle illegal to use.
other motorists can see you. Wind in your unprotected eyes
● The posture of the operator and could contribute to an impairment Loading and accessories
passenger is important for proper of vision that could delay seeing a Adding accessories or cargo to your
control. hazard. motorcycle can adversely affect stabili-
• The operator should keep both ● The use of a jacket, heavy boots, ty and handling if the weight distribution
hands on the handlebar and trousers, gloves, etc., is effective in of the motorcycle is changed. To avoid
both feet on the operator foot- preventing or reducing abrasions the possibility of an accident, use ex-
rests during operation to main- or lacerations. treme caution when adding cargo or
tain control of the motorcycle. ● Never wear loose-fitting clothes, accessories to your motorcycle. Use
• The passenger should always otherwise they could catch on the extra care when riding a motorcycle
hold onto the operator, the seat control levers, footrests, or wheels that has added cargo or accessories.
strap or grab bar, if equipped, and cause injury or an accident. Here are some general guidelines to
with both hands and keep both ● Never touch the engine or exhaust follow if loading cargo or adding acces-
feet on the passenger footrests. system during or after operation. sories to your motorcycle:
• Never carry a passenger unless They become very hot and can Loading
he or she can firmly place both cause burns. Always wear protec- The total weight of the operator, pas-
feet on the passenger footrests. tive clothing that covers your legs, senger, accessories and cargo must
● Never ride under the influence of ankles, and feet. not exceed the maximum load limit.
alcohol or other drugs. ● Passengers should also observe
the precautions mentioned above. Maximum load:
186 kg (410 lb)
1-2
SAFETY INFORMATION
When loading within this weight limit, stallation and use of non-Yamaha namic effects. Wind may at-
keep the following in mind: accessories. Use extreme caution tempt to lift the motorcycle, or
● Cargo and accessory weight when selecting and installing any ac- the motorcycle may become un-
1 should be kept as low and close to cessories. stable in cross winds. These ac-
the motorcycle as possible. Make Keep the following guidelines in mind, cessories may also cause
sure to distribute the weight as as well as those provided under “Load- instability when passing or being
evenly as possible on both sides of ing” when mounting accessories. passed by large vehicles.
the motorcycle to minimize imbal- ● Never install accessories or carry • Certain accessories can dis-
ance or instability. cargo that would impair the perfor- place the operator from his or
● Shifting weights can create a sud- mance of your motorcycle. Care- her normal riding position. This
den imbalance. Make sure that ac- fully inspect the accessory before improper position limits the free-
cessories and cargo are securely using it to make sure that it does dom of movement of the opera-
attached to the motorcycle before not in any way reduce ground tor and may limit control ability,
riding. Check accessory mounts clearance or cornering clearance, therefore, such accessories are
and cargo restraints frequently. limit suspension travel, steering not recommended.
● Never attach any large or heavy travel or control operation, or ob- ● Use caution when adding electri-
items to the handlebar, front fork, scure lights or reflectors. cal accessories. If electrical acces-
or front fender. These items, in- • Accessories fitted to the handle- sories exceed the capacity of the
cluding such cargo as sleeping bar or the front fork area can motorcycle’s electrical system, an
bags, duffel bags, or tents, can create instability due to improper electric failure could result, which
create unstable handling or a slow weight distribution or aerody- could cause a dangerous loss of
steering response. namic changes. If accessories lights or engine power.
Accessories are added to the handlebar or
Genuine Yamaha accessories have front fork area, they must be as Gasoline and exhaust gas
been specifically designed for use on lightweight as possible and ● GASOLINE IS HIGHLY FLAMMA-
this motorcycle. Since Yamaha cannot should be kept to a minimum. BLE:
test all other accessories that may be • Bulky or large accessories may • Always turn the engine off when
available, you must personally be re- seriously affect the stability of refueling.
sponsible for the proper selection, in- the motorcycle due to aerody-
1-3
SAFETY INFORMATION
• Take care not to spill any gaso- • Do not park the motorcycle near
line on the engine or exhaust a flammable source (e.g., a ker-
system when refueling. osene heater, or near an open
• Never refuel while smoking or in flame), otherwise it could catch 1
the vicinity of an open flame. fire.
● Never start the engine or let it run ● When transporting the motorcycle
for any length of time in a closed in another vehicle, make sure that
area. The exhaust fumes are poi- it is kept upright and that the fuel
sonous and may cause loss of cock(s) are turned to “ON” or
consciousness and death within a “RES” (for vacuum type)/“OFF”
short time. Always operate your (for manual type). If the motorcycle
motorcycle in an area that has ad- should lean over, gasoline may
equate ventilation. leak out of the carburetor or fuel
● Always turn the engine off before tank.
leaving the motorcycle unattended ● If you should swallow any gaso-
and remove the key from the main line, inhale a lot of gasoline vapor,
switch. When parking the motor- or allow gasoline to get into your
cycle, note the following: eyes, see your doctor immediately.
• The engine and exhaust system If any gasoline spills on your skin
may be hot, therefore, park the or clothing, immediately wash the
motorcycle in a place where pe- affected area with soap and water
destrians or children are not like- and change your clothes.
ly to touch these hot areas.
• Do not park the motorcycle on a
slope or soft ground, otherwise it
may fall over.
1-4
DESCRIPTION
EAU10410
Left view
1. Windshield 9. Seat lock (page 3-12 )

2. Idle adjusting screw (page 6-17) 10.Shift pedal (page 3-9)
3. Main fuse (page 6-32) 11.Engine oil drain bolt (crankcase) (page 6-10)
4. Battery (page 6-30)
5. Fuse box 1 (page 6-32)
6. Fuse box 2 (page 6-32)
7. Storage compartment (page 3-13)
8. Grab bar
2-1
DESCRIPTION
EAU10420
Right view
1. Owner’s tool kit (page 6-1) 9. Engine oil filter element (page 6-10)
2. Air filter element (page 6-16) 10.Coolant drain bolt (page 6-14)
3. Shock absorber assembly spring preload adjusting ring (page 3-13) 11.Brake pedal (page 3-10)
4. Rear brake fluid reservoir (page 6-23)
5. Front brake fluid reservoir (page 6-23)
6. Engine oil filler cap (page 6-10)
7. Engine oil drain bolt (oil tank) (page 6-10)
8. Coolant reservoir (page 6-13)
2-2
DESCRIPTION
EAU32240
Controls and instruments

XT660R
1. Clutch lever (page 3-9) 8. Fuel tank cap (page 3-10)

2. Left handlebar switches (page 3-7)
3. Main switch/steering lock (page 3-2)
4. Multi-function display (page 3-5)
5. Right handlebar switches (page 3-7)
6. Brake lever (page 3-9)
7. Throttle grip (page 6-18)
2-3
DESCRIPTION
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 6-18)
8. Fuel tank cap (page 3-10)
2-4
INSTRUMENT AND CONTROL FUNCTIONS

EAU10972
● an immobilizer system indicator mended to use either standard
Immobilizer system light (See page 3-3.) key and keep the code re-regis-
The key with the red bow is used to reg- tering key in a safe place.
ister codes in each standard key. Since ● Do not submerse any key in wa-
re-registering is a difficult process, take ter.
the vehicle along with all three keys to ● Do not expose any key to exces-
a Yamaha dealer to have them re-reg- sively high temperatures.
istered. Do not use the key with the red ● Do not place any key close to
3 bow for driving. It should only be used magnets (this includes, but not
for re-registering the standard keys. Al- limited to, products such as
ways use a standard key for driving. speakers, etc.).
1. Code re-registering key (red bow) ECA11820
● Do not place heavy items on any
2. Standard keys (black bow) CAUTION: key.
● DO NOT LOSE THE CODE RE- ● Do not grind any key or alter its
This vehicle is equipped with an immo-
REGISTERING KEY! CONTACT shape.
bilizer system to help prevent theft by
YOUR DEALER IMMEDIATELY ● Do not disassemble the plastic
re-registering codes in the standard
IF IT IS LOST! If the code re-reg- part of any key.
keys. This system consists of the fol-
istering key is lost, registering ● Do not put two keys of any im-
lowing.
new codes in the standard keys mobilizer system on the same
● a code re-registering key (with a
is impossible. The standard key ring.
red bow)
keys can still be used to start ● Keep the standard keys as well
● two standard keys (with a black
the vehicle, however if code re- as keys of other immobilizer
bow) that can be re-registered with
registering is required (i.e., if a systems away from this vehi-
new codes
new standard key is made or all cle’s code re-registering key.
● a transponder (which is installed in
keys are lost) the entire immobi- ● Keep other immobilizer system
the code re-registering key)
lizer system must be replaced. keys away from the main switch
● an immobilizer unit
Therefore, it is highly recom- as they may cause signal inter-
● an ECU
ference.
3-1

EAU10471 EAU10570
To lock the steering
Main switch/steering lock ON
All electrical circuits are supplied with
power; the meter lighting, taillight and
auxiliary light come on, and the engine
can be started. The key cannot be re-
moved.
NOTE:
The headlight comes on automatically 3
when the engine is started and stays on
until the key is turned to “OFF”. 1. Push.
The main switch/steering lock controls 2. Turn.
the ignition and lighting systems, and is EAU10660
1. Turn the handlebars all the way to
used to lock the steering. OFF
All electrical systems are off. The key the left.
NOTE: can be removed. 2. Push the key in from the “OFF” po-
Be sure to use the standard key (black sition, and then turn it to “LOCK”
bow) for regular use of the vehicle. To EAU10680 while still pushing it.
minimize the risk of losing the code re- LOCK 3. Remove the key.
registering key (red bow), keep it in a The steering is locked, and all electrical
safe place and only use it for code re- systems are off. The key can be re-
registering. moved.
3-2

To unlock the steering EAU33001 EAU11003
(Parking) Indicator and warning lights
The steering is locked, and the taillight
and auxiliary light are on. The hazard
lights and turn signal lights can be
turned on, but all other electrical sys-
tems are off. The key can be removed.
The steering must be locked before the
3 key can be turned to “ ”.
ECA11020
CAUTION:
1. Push. Do not use the parking position for
2. Turn. 1. Engine trouble warning light “ ”
an extended length of time, other- 2. Turn signal indicator light “ ”
Push the key in, and then turn it to wise the battery may discharge. 3. Fuel level warning light “ ”
“OFF” while still pushing it. 4. High beam indicator light “ ”
EWA10060 5. Neutral indicator light “ ”
WARNING 6. Coolant temperature warning light “ ”
Never turn the key to “OFF” or 7. Immobilizer system indicator light “ ”
“LOCK” while the vehicle is moving,
EAU11020
otherwise the electrical systems will Turn signal indicator light “ ”
be switched off, which may result in This indicator light flashes when the
loss of control or an accident. Make turn signal switch is pushed to the left or
sure that the vehicle is stopped be- right.
fore turning the key to “OFF” or
“LOCK”. EAU11060
Neutral indicator light “ ”
This indicator light comes on when the
transmission is in the neutral position.
3-3

EAU11080
will flash eight times, and then go off for diagnosis system. (See page 3-5 for an
High beam indicator light “ ”
3.0 seconds. If this occurs, have a explanation of the self-diagnosis de-
This indicator light comes on when the
Yamaha dealer check the vehicle. vice.)
high beam of the headlight is switched
The electrical circuit of the warning light
on.
EAU11440
can be checked by turning the key to
EAU11361 Coolant temperature warning light “ON”. If the warning light does not come
Fuel level warning light “ ” “ ” on for a few seconds, then go off, have
This warning light comes on when the This warning light comes on when the a Yamaha dealer check the electrical
fuel level drops below approximately engine overheats. When this occurs, circuit. 3
5.0 L (1.32 US gal) (1.10 Imp.gal). stop the engine immediately and allow
When this occurs, refuel as soon as the engine to cool. EAU26873
Immobilizer system indicator light
possible. The electrical circuit of the warning light
“ ”
The electrical circuit of the warning light can be checked by turning the key to
The electrical circuit of the indicator
can be checked by turning the key to “ON”.
light can be checked by turning the key
“ON”. If the warning light does not come on
to “ON”.
If the warning light does not come on for a few seconds, then go off, have a
If the indicator light does not come on
for a few seconds, and then go off, Yamaha dealer check the electrical cir-
for a few seconds, then go off, have a
have a Yamaha dealer check the elec- cuit.
Yamaha dealer check the electrical cir-
trical circuit. ECA10020
CAUTION: cuit.
NOTE: When the key is turned to “OFF” and 30
Do not operate the engine if it is
This model is also equipped with a self- seconds have passed, the indicator
overheated.
diagnosis device for the fuel level de- light will start flashing indicating the im-
tection circuit. If the fuel level detection mobilizer system is enabled. After 24
circuit is defective, the following cycle EAU11530
hours have passed, the indicator light
Engine trouble warning light “ ”
will be repeated until the malfunction is will stop flashing, however the immobi-
This warning light comes on or flashes
corrected: The fuel level warning light lizer system is still enabled.
when an electrical circuit monitoring the
engine is defective. When this occurs,
have a Yamaha dealer check the self-
3-4

This model is also equipped with a self- EAUM1662
● a fuel reserve tripmeter (which
diagnosis device for the immobilizer Multi-function display shows the distance traveled since
system. (See page 3-5 for an explana- the fuel level warning light came
tion of the self-diagnosis device.) on)
● a clock
● a self-diagnosis device
NOTE:
3 ● Be sure to turn the key to “ON” be-
fore using the “SELECT” and “RE-
SET” buttons.
● For the U.K. only: To switch the
1. Multi-function display
2. Clock
speedometer and odometer/trip-
3. Tripmeter 1 meter displays between kilometers
4. Odometer/fuel reserve tripmeter/tripmeter 2 and miles, press the “SELECT”
5. “SELECT” button button for at least two seconds.
6. “RESET” button
7. Speedometer
Odometer and tripmeter modes
The multi-function display is equipped Pushing the “SELECT” button switches
with the following: the display between the odometer
● a speedometer (which shows the mode “ODO” and the tripmeter modes
riding speed) “TRIP 1” and “TRIP 2” in the following
● an odometer (which shows the to- order:
tal distance traveled) ODO → TRIP 1 → TRIP 2 → ODO
● two tripmeters (which show the If the fuel level warning light comes on
distance traveled since they were (see page 3-3), the odometer display
last set to zero) will automatically change to the fuel re-
serve tripmeter mode “F-TRIP” and
start counting the distance traveled
3-5

from that point. In that case, pushing 4. Push the “RESET” button to set If any of the immobilizer system circuits
the “SELECT” button switches the dis- the minutes. are defective, the immobilizer system
play between the various tripmeter and 5. Push the “SELECT” button to fix indicator light will flash, and then the
odometer modes in the following order: the minutes, and then release it to multi-function display will indicate a
F-TRIP → TRIP 1 → TRIP 2 → ODO → start the clock. two-digit error code (e.g., 51, 52, 53)
F-TRIP when the key is turned to “ON”.
To reset a tripmeter, select it by push- Self-diagnosis device
NOTE:
ing the “SELECT” button, and then This model is equipped with a self-diag-
If the multi-function display indicates er- 3
push the “RESET” button for at least nosis device for various electrical cir-
ror code 52, this could be caused by
one second while the selected tripme- cuits.
transponder interference. If this error
ter is flashing. If you do not reset the If any of those circuits are defective, the
appears, try the following.
fuel reserve tripmeter manually, it will engine trouble warning light will come
reset itself automatically and the dis- on, and then the multi-function display 1. Use the code re-registering key to
play will return to the prior mode after will indicate a two-digit error code (e.g., start the engine.
refueling and traveling 5 km (3 mi). 11, 12, 13).
NOTE:
If the multi-function display indicates
Make sure there are no other immobi-
Clock mode such an error code, note the code num-
lizer keys close to the main switch, and
Turn the key to “ON”. ber, and then have a Yamaha dealer
do not keep more than one immobilizer
check the vehicle.
key on the same key ring! Immobilizer
To set the clock: ECA11590
CAUTION: system keys may cause signal interfer-

1. Push the “SELECT” button and
ence, which may prevent the engine
“RESET” button together for at If the display indicates an error
from starting.
least two seconds. code, the vehicle should be checked
2. When the hour digits start flashing, as soon as possible in order to avoid 2. If the engine starts, turn it off, and
push the “RESET” button to set the engine damage. try starting the engine with the
hours. standard keys.
This model is also equipped with a self-
3. Push the “SELECT” button to fix 3. If one or both of the standard keys
diagnosis device for the immobilizer
the hours, and the minute digits do not start the engine, take the
system.
will start flashing. vehicle, the code re-registering
3-6

key and both standard keys to a EAU12331 EAU12347
Yamaha dealer and have the stan- Anti-theft alarm (optional) Handlebar switches
dard keys re-registered. This model can be equipped with an
Left
If the multi-function display indicates optional anti-theft alarm by a Yamaha
any error codes, note the code number, dealer. Contact a Yamaha dealer for
and then have a Yamaha dealer check more information.
the vehicle.
1. Pass switch “ ”
2. Dimmer switch “ / ”
3. Turn signal switch “ / ”
4. Horn switch “ ”
5. Hazard switch “ ”
3-7

Right position. To cancel the turn signal EAU12733
Hazard switch “ ”
lights, push the switch in after it has re-
With the key in the “ON” or “ ” posi-
turned to the center position.
tion, use this switch to turn on the haz-
EAU12500
ard lights (simultaneous flashing of all
Horn switch “ ” turn signal lights).
Press this switch to sound the horn. The hazard lights are used in case of
an emergency or to warn other drivers
EAU12660
when your vehicle is stopped where it 3
Engine stop switch “ / ”
might be a traffic hazard.
Set this switch to “ ” before starting ECA10061
1. Engine stop switch “ / ” the engine. Set this switch to “ ” to CAUTION:
2. Start switch “ ” stop the engine in case of an emergen-
Do not use the hazard lights for an
cy, such as when the vehicle overturns
EAU12350 extended length of time with the en-
or when the throttle cable is stuck.
Pass switch “ ” gine not running, otherwise the bat-
Press this switch to flash the headlight. EAU12710 tery may discharge.
Start switch “ ”
EAU12400
Push this switch to crank the engine
Dimmer switch “ / ”
with the starter.
Set this switch to “ ” for the high ECA10050
beam and to “ ” for the low beam. CAUTION:
EAU12460 See page 5-1 for starting instruc-
Turn signal switch “ / ” tions prior to starting the engine.
To signal a right-hand turn, push this
switch to “ ”. To signal a left-hand
turn, push this switch to “ ”. When re-
leased, the switch returns to the center
3-8

EAU12820 EAU12870 EAU12890
Clutch lever Shift pedal Brake lever
1. Clutch lever 1. Shift pedal 1. Brake lever
The clutch lever is located at the left The shift pedal is located on the left The brake lever is located at the right
handlebar grip. To disengage the side of the engine and is used in com- handlebar grip. To apply the front
clutch, pull the lever toward the handle- bination with the clutch lever when brake, pull the lever toward the handle-
bar grip. To engage the clutch, release shifting the gears of the 5-speed con- bar grip.
the lever. The lever should be pulled stant-mesh transmission equipped on
rapidly and released slowly for smooth this motorcycle.
clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the igni-
tion circuit cut-off system. (See page
3-15.)
3-9

EAU12941 EAUM1791
Brake pedal Fuel tank cap NOTE:

The fuel tank cap cannot be installed
unless the key is in the lock. In addition,
the key cannot be removed if the cap is
not properly installed and locked.
EWA11140
WARNING
Make sure that the fuel tank cap is 3
properly installed before riding.
1. Brake pedal 1. Fuel tank cap lock cover

2. Unlock.
The brake pedal is on the right side of
the motorcycle. To apply the rear
To remove the fuel tank cap
brake, press down on the brake pedal.
1. Open the fuel tank cap lock cover.
2. Insert the key into the lock and turn
it 1/4 turn clockwise. The lock will
be released and the fuel tank cap
can be removed.
To install the fuel tank cap

1. Push and install the fuel tank cap
into position with the key inserted
in the lock.
2. Turn the key counterclockwise to
the original position, and then re-
move it.
3-10

EAU13211 ECA10070
curs, use a gasoline of a different
Fuel CAUTION: brand. Use of unleaded fuel will extend
Immediately wipe off spilled fuel spark plug life and reduce maintenance
with a clean, dry, soft cloth, since costs.
fuel may deteriorate painted surfac-
es or plastic parts.
EAU13390
3
Recommended fuel:
1. Fuel tank filler tube PREMIUM UNLEADED GASOLINE
ONLY
2. Fuel level
Fuel tank capacity:
Make sure that there is sufficient fuel in 15.0 L (3.96 US gal) (3.30 Imp.gal)
Fuel reserve amount (when the fuel
the tank. Fill the fuel tank to the bottom level warning light comes on):
of the filler tube as shown. 5.0 L (1.32 US gal) (1.10 Imp.gal)
EWA10880
WARNING ECA11400
● Do not overfill the fuel tank, oth- CAUTION:

erwise it may overflow when the Use only unleaded gasoline. The use
fuel warms up and expands. of leaded gasoline will cause severe
● Avoid spilling fuel on the hot en- damage to internal engine parts,
gine. 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 of
95 or higher. If knocking (or pinging) oc-
3-11

EAU13431 EAU13900
Catalytic converter Seat

This model is equipped with a catalytic
converter in the exhaust system. To remove the seat
EWA10860
1. Insert the key into the seat lock,
WARNING and then turn it as shown.
The exhaust system is hot after op-
eration. Make sure that the exhaust
system has cooled down before do- 3
ing any maintenance work.
1. Seat holder
ECA10700
2. Projection
CAUTION:
The following precautions must be 2. Push the rear of the seat down to
observed to prevent a fire hazard or lock it in place.
other damages. 3. Remove the key.
● Use only unleaded gasoline. 1. Seat lock NOTE:
The use of leaded gasoline will 2. Unlock.
Make sure that the seat is properly se-
cause unrepairable damage to 2. Pull the seat off. cured before riding.
the catalytic converter.
● Never park the vehicle near pos- To install the seat
sible fire hazards such as grass 1. Insert the projection on the front of
or other materials that easily the seat into the seat holder as
burn. shown.
● Do not allow the engine to idle
too long.
3-12

EAU14422
● Do not exceed the maximum EAU14830
Storage compartment load of 186 kg (410 lb) for the ve- Adjusting the shock absorber
hicle. assembly
1. CYCLELOK bar (optional)

2. Yamaha CYCLELOK (optional) 1. Spring preload adjusting ring
3. Strap 2. Special wrench
3. Position indicator
This storage compartment is designed
to hold a genuine Yamaha This shock absorber assembly is
CYCLELOK. (Other locks may not fit.) equipped with a spring preload adjust-
When placing a CYCLELOK in the storing ring.
age compartment, securely fasten it ECA10100
with the straps. When the CYCLELOK CAUTION:

is not in the storage compartment, be Never attempt to turn an adjusting
sure to secure the straps to prevent los- mechanism beyond the maximum or
ing them. minimum settings.
EWA10961
WARNING Adjust the spring preload as follows.

● Do not exceed the load limit of 3 To increase the spring preload and
kg (7 lb) for the storage com- thereby harden the suspension, turn
partment. the adjusting ring in direction (a). To de-
3-13

crease the spring preload and thereby ● Do not subject the shock ab- EAU15301
soften the suspension, turn the adjust- sorber to an open flame or other Sidestand
ing ring in direction (b). high heat sources, otherwise it The sidestand is located on the left side
may explode due to excessive of the frame. Raise the sidestand or
NOTE: lower it with your foot while holding the
gas pressure.
Align the appropriate notch in the ad- vehicle upright.
● Do not deform or damage the
justing ring with the position indicator
gas cylinder in any way, as this NOTE:
on the shock absorber.
will result in poor damping per- The built-in sidestand switch is part of
formance. 3
the ignition circuit cut-off system, which
Spring preload setting: ● Always have a Yamaha dealer cuts the ignition in certain situations.
Minimum (soft): service the shock absorber.
1
(See further down for an explanation of
Standard: the ignition circuit cut-off system.)
2 EWA10240
Maximum (hard):
WARNING
5
The vehicle must not be ridden with
EWA10220
the sidestand down, or if the side-
WARNING stand cannot be properly moved up
This shock absorber contains highly (or does not stay up), otherwise the
pressurized nitrogen gas. For prop- sidestand could contact the ground
er handling, read and understand and distract the operator, resulting
the following information before in a possible loss of control.
handling the shock absorber. The Yamaha’s ignition circuit cut-off
manufacturer cannot be held re- system has been designed to assist
sponsible for property damage or the operator in fulfilling the respon-
personal injury that may result from sibility of raising the sidestand be-
improper handling. fore starting off. Therefore, check
● Do not tamper with or attempt to this system regularly as described
open the gas cylinder.
3-14

below and have a Yamaha dealer re- EAU15311
pair it if it does not function proper- Ignition circuit cut-off system

ly. The ignition circuit cut-off system (com-
prising the sidestand switch, clutch
switch and neutral switch) has the fol-
lowing functions.
● It prevents starting when the trans-
mission is in gear and the side-
3 stand is up, but the clutch lever is
not pulled.
● It prevents starting when the trans-
mission is in gear and the clutch le-
ver is pulled, but the sidestand is
still down.
● It cuts the running engine when the
transmission is in gear and the sid-
estand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.
EWA10250
WARNING
If a malfunction is noted, have a
Yamaha dealer check the system be-
fore riding.
3-15
With the engine turned off:

NOTE:
1. Move the sidestand down.
2. Make sure that the engine stop switch is turned on.
This check is most reliable if performed with
3. Turn the key on. a warmed-up engine.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
The neutral switch may be defective. 3
YES NO The motorcycle should not be ridden until
checked by a Yamaha dealer.
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?
The sidestand switch may be defective.
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 clutch switch may be defective.
The system is OK. The motorcycle can be ridden.
3-16
PRE-OPERATION CHECKS
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 loss
of 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 short
time; and the added safety it assures is more than worth the time involved.
EWA11150
4
WARNING
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the vehicle.
4-1
EAU15605
Pre-operation check list

ITEM CHECKS PAGE
• Check fuel level in fuel tank.

Fuel • Refuel if necessary. 3-11
• Check fuel line for leakage.
• Check oil level in oil tank.
Engine oil • If necessary, add recommended oil to specified level. 6-10
• Check vehicle for oil leakage.
• Check coolant level in reservoir.
Coolant • If necessary, add recommended coolant to specified level. 6-13
• Check cooling system for leakage. 4
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
Front brake • Replace if necessary. 6-22, 6-23
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
Rear brake • Replace if necessary. 6-22, 6-23
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Lubricate cable if necessary.
Clutch 6-21
• Check lever free play.
• Adjust if necessary.
4-2
ITEM CHECKS PAGE
• Make sure that operation is smooth.

• Check cable free play.
Throttle grip 6-18, 6-27
• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.
Control cables 6-27
• Lubricate if necessary.
• Check chain slack.
• Adjust if necessary.
Drive chain 6-24, 6-26
• Check chain condition.
• Lubricate if necessary.
4 • Check for damage.
• Check tire condition and tread depth.
Wheels and tires 6-18, 6-21
• Check air pressure.
• Correct if necessary.
Brake pedal 6-28
• Lubricate pedal pivoting point if necessary.
Brake and clutch levers 6-27
• Lubricate lever pivoting points if necessary.
Sidestand 6-28
• Lubricate pivot if necessary.
• Make sure that all nuts, bolts and screws are properly tightened.
Chassis fasteners —
• Tighten if necessary.
Instruments, lights, signals • Check operation.
—
and switches • Correct if necessary.
• Check operation of ignition circuit cut-off system.
Sidestand switch 3-14
• If system is defective, have Yamaha dealer check vehicle.
4-3
OPERATION AND IMPORTANT RIDING POINTS

EAU15950 EAUM1670
● Coolant temperature warning
Starting the engine light
EWA10270
In order for the ignition circuit cut-off ● Engine trouble warning light
WARNING system to enable starting, one of the ● Immobilizer system indicator
● Become thoroughly familiar following conditions must be met: light
with all operating controls and ● The transmission is in the neutral If a warning or indicator light does
their functions before riding. position. not go off, see page 3-3 for the corre-
Consult a Yamaha dealer re- ● The transmission is in gear with sponding warning and indicator
garding any control or function the clutch lever pulled and the sid- light circuit check.
that you do not thoroughly un- estand up.
derstand. EWA10290 2. Shift the transmission into the neu-
● Never start the engine or oper- WARNING tral position.
ate it in a closed area for any ● Before starting the engine, NOTE:
length of time. Exhaust fumes check the function of the igni- 5
When the transmission is in the neutral
are poisonous, and inhaling tion circuit cut-off system ac- position, the neutral indicator light
them can cause loss of con- cording to the procedure should be on, otherwise have a
sciousness and death within a described on page 3-15. Yamaha dealer check the electrical cir-
short time. Always make sure ● Never ride with the sidestand cuit.
that there is adequate ventila- down.
tion. 3. Start the engine by pushing the
1. Turn the key to “ON” and make start switch.
● Before starting out, make sure
sure that the engine stop switch is
that the sidestand is up. If the NOTE:
set to “ ”.
sidestand is not raised com- ECAM1030 If the engine fails to start, release the
pletely, it could contact the CAUTION: start switch, wait a few seconds, and
ground and distract the opera- then try again. Each starting attempt
The following warning lights and in-
tor, resulting in a possible loss should be as short as possible to pre-
dicator light should come on for a
of control.
few seconds, then go off.
● Fuel level warning light
5-1

serve the battery. Do not crank the en- EAU16671 ECA10260
gine more than 10 seconds on any one Shifting CAUTION:

attempt. ● Even with the transmission in
ECA11040
the neutral position, do not
CAUTION: coast for long periods of time
with the engine off, and do not
For maximum engine life, never ac-
tow the motorcycle for long dis-
celerate hard when the engine is
tances. The transmission is
cold!
properly lubricated only when
the engine is running. Inade-
NOTE:
quate lubrication may damage
The engine is warm when it quickly re-
1. Shift pedal the transmission.
sponds to the throttle. 2. Neutral position ● Always use the clutch while
5
Shifting gears lets you control the changing gears to avoid damag-
amount of engine power available for ing the engine, transmission,
starting off, accelerating, climbing hills, and drive train, which are not
etc. designed to withstand the
The gear positions are shown in the il- shock of forced shifting.
lustration.
NOTE:
To shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.
5-2

EAU16810 EAU16841 ECA11440
Tips for reducing fuel con- Engine break-in CAUTION:

sumption There is never a more important period After 1000 km (600 mi) of operation,
Fuel consumption depends largely on in the life of your engine than the period the engine oil must be changed, and
your riding style. Consider the following between 0 and 1600 km (1000 mi). For the oil filter element cleaned.
tips to reduce fuel consumption: this reason, you should read the follow-
● Shift up swiftly, and avoid high en- ing material carefully. 1600 km (1000 mi) and beyond
gine speeds during acceleration. Since the engine is brand new, do not The vehicle can now be operated nor-
● Do not rev the engine while shifting put an excessive load on it for the first mally.
ECA10270
down, and avoid high engine 1600 km (1000 mi). The various parts in
CAUTION:
speeds with no load on the engine. the engine wear and polish themselves
● Turn the engine off instead of let- to the correct operating clearances. If any engine trouble should occur
ting it idle for an extended length of During this period, prolonged full-throt- during the engine break-in period,
tle operation or any condition that might immediately have a Yamaha dealer 5
time (e.g., in traffic jams, at traffic
lights or at railroad crossings). result in engine overheating must be check the vehicle.
avoided.
EAU17030
0–1000 km (0–600 mi)

Avoid prolonged operation above 1/3
throttle.
1000–1600 km (600–1000 mi)
Avoid prolonged operation above 1/2
throttle.
5-3

EAU17212
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EWA10310
WARNING
● Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.
● Do not park on a slope or on soft
5 ground, otherwise the vehicle
may overturn.
ECA10380
CAUTION:
Never park in an area where there
are fire hazards such as grass or
other flammable materials.
5-4
PERIODIC MAINTENANCE AND MINOR REPAIR

EAU17240 EAU17520
Owner’s tool kit NOTE:

Safety is an obligation of the owner. Pe- If you do not have the tools or experi-
riodic inspection, adjustment and lubri- ence required for a particular job, have
cation will keep your vehicle in the a Yamaha dealer perform it for you.
safest and most efficient condition pos- EWA10350
sible. The most important points of in- WARNING

spection, adjustment, and lubrication Modifications not approved by
are explained on the following pages. Yamaha may cause loss of perfor-
The intervals given in the periodic mance and render the vehicle un-
maintenance and lubrication chart safe for use. Consult a Yamaha
should be simply considered as a gen- 1. Owner’s tool kit dealer before attempting any chang-
eral guide under normal riding condi- 2. Engine oil drain attachment es.
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI- The owner’s tool kit is located inside the
CAL LOCATION, AND INDIVIDUAL storage compartment under the seat. 6
USE, THE MAINTENANCE INTER- (See page 3-12.)
VALS MAY NEED TO BE SHORT- The service information included in this
ENED. manual and the tools provided in the
EWA10320 owner’s tool kit are intended to assist
WARNING you in the performance of preventive
If you are not familiar with mainte- maintenance and minor repairs. How-
nance work, have a Yamaha dealer ever, additional tools such as a torque
do it for you. wrench may be necessary to perform
certain maintenance work correctly.
6-1

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.
ODOMETER READING (× 1000 km) ANNUAL

NO. ITEM CHECK OR MAINTENANCE JOB
1 10 20 30 40 CHECK
1 * Fuel line • Check fuel hoses for cracks or damage. √ √ √ √ √

• Check condition.
√ √
2 Spark plug • Clean and regap.
6 • Replace. √ √
• Check valve clearance.
3 * Valves √ √
• Adjust.
4 Air filter element • Replace. √ √
5 Clutch √ √ √ √ √
• Adjust.
• Check operation, fluid level and vehicle for fluid leakage. √ √ √ √ √ √
6 * Front brake
• Replace brake pads. Whenever worn to the limit
• Check operation, fluid level and vehicle for fluid leakage. √ √ √ √ √ √
7 * Rear brake
• Replace brake pads. Whenever worn to the limit
• Check for cracks or damage. √ √ √ √ √
8 * Brake hoses
• Replace. Every 4 years
6-2

1 10 20 30 40 CHECK
• Check runout, spoke tightness and for damage.

9 * Wheels √ √ √ √ √
• Tighten spokes if necessary.
• Check tread depth and for damage.
• Replace if necessary.
10 * Tires √ √ √ √ √
• Check air pressure.
• Correct if necessary.
11 * Wheel bearings • Check bearing for looseness or damage. √ √ √ √
12 * Swingarm • Check operation and for excessive play. √ √ √ √
• Check chain slack, alignment and condition.
Every 500 km and after washing the motorcycle or
13 Drive chain • Adjust and lubricate chain with a special O-ring chain lu-
riding in the rain
bricant thoroughly.
• Check bearing play and steering for roughness. √ √ √ √ √
14 * Steering bearings
• Lubricate with lithium-soap-based grease. Every 20000 km
6
• Make sure that all nuts, bolts and screws are properly
15 * Chassis fasteners √ √ √ √ √
tightened.
16 Sidestand √ √ √ √ √
• Lubricate.
17 * Sidestand switch • Check operation. √ √ √ √ √ √
18 * Front fork • Check operation and for oil leakage. √ √ √ √
Shock absorber assem-
19 * • Check operation and shock absorber for oil leakage. √ √ √ √
bly
Rear suspension relay
20 * arm and connecting • Check operation. √ √ √ √
arm pivoting points
21 * Fuel injection • Adjust engine idling speed. √ √ √ √ √ √
• Change.
22 Engine oil √ √ √ √ √ √
• Check oil level and vehicle for oil leakage.
6-3

1 10 20 30 40 CHECK
23 Engine oil filter element • Replace. √ √ √

• Check coolant level and vehicle for coolant leakage. √ √ √ √ √
24 * Cooling system
• Change. Every 3 years
Front and rear brake
25 * • Check operation. √ √ √ √ √ √
switches
Moving parts and ca-
26 • Lubricate. √ √ √ √ √
bles
• Check operation and free play.
Throttle grip housing
27 * • Adjust the throttle cable free play if necessary. √ √ √ √ √
and cable
• Lubricate the throttle grip housing and cable.
• Check the air cut-off valve, reed valve, and hose for dam-
28 * Air induction system age. √ √ √ √ √
• Replace the entire air induction system if necessary.
6
Mufflers and exhaust
29 * • Check the screw clamps for looseness. √ √ √ √ √ √
pipes
Lights, signals and • Check operation.
30 * √ √ √ √ √ √
switches • Adjust headlight beam.
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.
6-4

EAU18712
XT660X XT660X
Removing and installing cowl-
ings and panels 1
The cowlings and panels shown need
to be removed to perform some of the
maintenance jobs described in this
chapter. Refer to this section each time
a cowling or panel needs to be re- 1
moved and installed.
XT660R
1. Cowling A 1. Panel A
XT660R XT660R
1. Cowling A
1. Panel A 1. Cowling B
2. Panel B
6-5

XT660X XT660R
2 1
1. Protector
1. Cowling B 1. Bolt 2. Cowling bracket tab
2. Panel B 3. Bracket
XT660X
EAUM1682
1 2. Place the cowling in the original
Cowling A position, and then install the bolts
6 and spacers.
To remove the cowling
Remove the bolts and spacers, and EAUM1692
then lift the cowling up to remove it. Cowling B (XT660R)

1. Remove the seat and panel B.
1. Bolt (See pages 3-12 and 6-5.)
2. Remove the bolts, and then re-
To install the cowling move the quick fastener screws by
1. Place the cowling bracket tab be- turning them 1/4 turn counterclock-
tween the protector and the brack- wise.
et on each side. 3. Pull the cowling off at the area
shown.
6-6

EAUM2130
Cowling B (XT660X)

1. Remove the seat and panel B.
(See pages 3-12 and 6-5.)
2. Remove the bolts, and then re-
move the quick fastener screw by
turning it 1/4 turn counterclock-
wise.
1. Bolt 3. Pull the cowling off at the area 2. Install the panel.
2. Quick fastener screw shown. 3. Install the seat.
To install the cowling EAUM1701
1. Place the cowling in the original 1 Panel A
position, and then install the quick
6
fastener screws and the bolts. To remove the panel
1. Remove the seat. (See page
3-12.)
2. Remove the bolts and the spacer,
2 and then pull the panel off at the
area shown.
1. Bolt
2. Quick fastener screw
To install the cowling

1. Place the cowling in the original
2. Install the panel. position, and then install the quick
3. Install the seat. fastener screw and the bolts.
6-7

EAUM1710
Panel B
To remove the panel

3-12.)
2. Remove the bolt, and then pull the
panel off at the areas shown.
1. Bolt
2. Install the seat.
2. Spacer
To install the panel

1. Place the panel in the original posi-
tion, install spacer, and then install
6
the bolts.
1. Bolt
To install the panel

1. Place the panel in the original posi-
tion, and then install the bolt.
2. Install the seat.
6-8

EAU19603
2. Check the spark plug for electrode
Checking the spark plug erosion and excessive carbon or
The spark plug is an important engine other deposits, and replace it if
component, which is easy to check. necessary.
Since heat and deposits will cause any
spark plug to slowly erode, the spark Specified spark plug:
plug should be removed and checked NGK/CR7E
in accordance with the periodic mainte-
nance and lubrication chart. In addition, To install the spark plug
the condition of the spark plug can re- 1. Measure the spark plug gap with a
1. Spark plug wrench
veal the condition of the engine. wire thickness gauge and, if nec-
To check the spark plug essary, adjust the gap to specifica-
To remove the spark plug tion.
1. Remove the spark plug cap. 1. Check that the porcelain insulator
around the center electrode of the
spark plug is a medium-to-light tan 6
(the ideal color when the vehicle is
ridden normally).
NOTE:
If the spark plug shows a distinctly dif-
ferent color, the engine could be oper-
ating improperly. Do not attempt to
diagnose such problems yourself. In-
1. Spark plug gap
1. Spark plug cap stead, have a Yamaha dealer check
the vehicle. Spark plug gap:
2. Remove the spark plug as shown,
0.7–0.8 mm (0.028–0.031 in)
with the spark plug wrench includ-
ed in the owner’s tool kit.
6-9

2. Clean the surface of the spark plug EAUM1841
Engine oil and oil filter ele- NOTE:

gasket and its mating surface, and
ment ● The engine oil tank is located in-
then wipe off any grime from the
The engine oil level should be checked side of the frame.
spark plug threads.
before each ride. In addition, the oil ● The engine oil should be between
3. Install the spark plug with the
must be changed and the oil filter ele- the minimum and maximum level
spark plug wrench, and then tight-
ment replaced at the intervals specified marks.
en it to the specified torque.
in the periodic maintenance and lubri-
Tightening torque: cation chart.
Spark plug:
12.5 Nm (1.25 m·kgf, 9.0 ft·lbf) To check the engine oil level
1. Place the vehicle on a level sur-
NOTE: face and hold it in an upright posi-
If a torque wrench is not available when tion.
installing a spark plug, a good estimate
NOTE:
6 of the correct torque is 1/4–1/2 turn
Make sure that the vehicle is positioned
past finger tight. However, the spark
straight up when checking the oil level. 1. Engine oil filler cap
plug should be tightened to the speci-
A slight tilt to the side can result in a 2. Maximum level mark
fied torque as soon as possible. 3. Minimum level mark
false reading.
4. Install the spark plug cap. ECA10010
2. Start the engine, warm it up for 10–
15 minutes, and then turn it off. CAUTION:
3. Wait a few minutes until the oil set- Do not operate the vehicle until you
tles, remove the oil filler cap, wipe know that the engine oil level is suf-
the dipstick clean, insert it back ficient.
into the oil filler hole (without
screwing it in), and then remove it
again to check the oil level.
6-10

EWA10360
WARNING
Never remove the engine oil tank
cap after high-speed operation, oth-
erwise hot engine oil could spout
out and cause damage or injury. Al-
ways let the engine oil cool down
sufficiently before removing the oil
tank cap.
4. If the engine oil is below the mini- 1. Engine oil drain bolt (crankcase) 1. Engine oil drain bolt (oil tank)
mum level mark, add sufficient oil 2. Engine oil drain attachment
6. Remove the oil filter element drain
of the recommended type to raise 3. Place an oil pan under the engine bolt to drain the oil from the oil filter
it to the correct level. to collect the used oil. element.
5. Install the oil filler cap. 4. Remove the engine oil filler cap
NOTE:
and the drain bolt to drain the oil 6
To change the engine oil (with or from the crankcase. Skip steps 7–9 if the oil filter element is
without oil filter element replace- 5. Remove the drain bolt to drain the not being replaced.
ment) oil from the oil tank. 7. Remove the oil filter element cover
1. Start the engine, warm it up for
by removing the bolts.
several minutes, and then turn it
off.
2. Install the engine oil drain attach-
ment, provided with the owner’s
tool kit, under the drain bolt of the
crankcase.
6-11

9. Install the oil filter element cover by ECAM1060
installing the bolts and the oil filter CAUTION:

element drain bolt, then tightening The engine oil tank must be filled in
them to the specified torques. 2 steps. First, fill the engine oil tank
with 1.90 L (2.0 US qt) (1.67 Imp.qt) of
Tightening torques: the recommended engine oil. Then,
Oil filter element cover bolt: start the engine, race it 5 or 6 times,
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil filter element drain bolt: turn it off, and then add the remain-
10 Nm (1.0 m·kgf, 7.2 ft·lbf) der of the engine oil.
1. Oil filter element cover bolt
2. Oil filter element drain bolt NOTE: Recommended engine oil:
Make sure that the O-rings are properly See page 8-1.
8. Remove and replace the oil filter Oil quantity:
element and O-rings. seated. Without oil filter element replace-
ment:
10. Install the oil drain bolts, and then
6 2.50 L (2.64 US qt) (2.20 Imp.qt)
tighten them to the specified With oil filter element replacement:
torques. 2.60 L (2.75 US qt) (2.29 Imp.qt)
Tightening torques: ECA11620
Engine oil drain bolt (crankcase): CAUTION:

30 Nm (3.0 m·kgf, 22 ft·lbf)
● In order to prevent clutch slip-
Engine oil drain bolt (oil tank):
18 Nm (1.8 m·kgf, 13 ft·lbf) page (since the engine oil also
lubricates the clutch), do not
1. Oil filter element 11. Add the specified amount of the mix any chemical additives. Do
2. O-ring recommended engine oil, and then not use oils with a diesel speci-
install and tighten the oil filler cap. fication of “CD” or oils of a high-
er quality than specified. In
6-12

addition, do not use oils labeled EAU20070
“ENERGY CONSERVING II” or Coolant

higher. The coolant level should be checked
● Make sure that no foreign mate- before each ride. In addition, the cool-
rial enters the crankcase. ant must be changed at the intervals
specified in the periodic maintenance
12. Start the engine, and then let it idle and lubrication chart.
for several minutes while checking
it for oil leakage. If oil is leaking, im- EAUM1722
mediately turn the engine off and To check the coolant level
check for the cause. 1. Place the vehicle on a level sur- 1. Coolant reservoir
13. Turn the engine off, and then face and hold it in an upright posi- 2. Maximum level mark
check the oil level and correct it if tion. 3. Minimum level mark
necessary. NOTE: 3. If the coolant is at or below the
● The coolant level must be checked minimum level mark, remove cowl-
on a cold engine since the level ing B (See page 6-5.), and then 6
varies with engine temperature. open the reservoir cap.
● Make sure that the vehicle is posi- 4. Add coolant to the maximum level
tioned straight up when checking mark, and then close the reservoir
the coolant level. A slight tilt to the cap.
side can result in a false reading.
Coolant reservoir capacity (up to the
2. Check the coolant level in the cool- maximum level mark):
ant reservoir. 0.25 L (0.26 US qt) (0.22 Imp.qt)
NOTE:
The coolant should be between the
minimum and maximum level marks.
6-13

ECA10471
CAUTION: NOTE:
● The radiator fan is automatically
● If coolant is not available, use
switched on or off according to the
distilled water or soft tap water
coolant temperature in the radia-
instead. Do not use hard water
tor.
or salt water since it is harmful
● If the engine overheats, see page
to the engine.
6-40 for further instructions.
● If water has been used instead
of coolant, replace it with cool-
ant as soon as possible, other- EAUM1802
1. Radiator cap
To change the coolant
wise the cooling system will not 2. Radiator cap retaining screw
1. Place the vehicle on a level sur-
be protected against frost and 3. Radiator cap retainer
face and let the engine cool if nec-
corrosion. 4. Coolant reservoir cap
essary.
● If water has been added to the
2. Remove the seat and panel B. 7. Remove the coolant reservoir
coolant, have a Yamaha dealer
6 (See pages 3-12 and 6-5.) bolts, and then turn the coolant
check the antifreeze content of
3. Remove cowling B. (See page reservoir upside down to empty it.
the coolant as soon as possible,
6-5.) 8. Install the coolant reservoir by
otherwise the effectiveness of
4. Place a container under the engine placing it in the original position,
the coolant will be reduced.
to collect the used coolant. then installing the bolts.
EWA10380
5. Loosen the radiator cap retainer
WARNING screw.
Never attempt to remove the radiator 6. Remove the radiator cap and cool-
cap when the engine is hot. ant reservoir cap.
EWA10380
5. Install the cowling. WARNING
Never attempt to remove the radiator
cap when the engine is hot.
6-14

11. Install the coolant drain bolt, and ECA10471
then tighten it to the specified CAUTION:

torque. ● If coolant is not available, use
distilled water or soft tap water
NOTE:
instead. Do not use hard water
Check the washer for damage and re-
or salt water since it is harmful
place it if necessary.
to the engine.
● If water has been used instead
Tightening torque: of coolant, replace it with cool-
Coolant drain bolt: ant as soon as possible, other-
1. Bolt 11 Nm (1.1 m·kgf, 8.0 ft·lbf)
wise the cooling system will not
9. Remove the coolant drain bolt to be protected against frost and
12. Pour the specified amount of the
drain the cooling system. corrosion.
recommended coolant into the ra-
● If water has been added to the
diator and reservoir.
coolant, have a Yamaha dealer
check the antifreeze content of 6
Antifreeze/water mixture ratio:
1:1 the coolant as soon as possible,
Recommended antifreeze: otherwise the effectiveness of
High-quality ethylene glycol anti- the coolant will be reduced.
freeze containing corrosion inhibitors
for aluminum engines 13. Install the coolant reservoir cap.
Coolant quantity: 14. Install the radiator cap and radiator
Radiator capacity (including all
cap retainer by installing the
1. Coolant drain bolt routes):
1.00 L (1.06 US qt) (0.88 Imp.qt) screw.
10. After the coolant is completely Coolant reservoir capacity (up to the 15. Start the engine, let it idle for sev-
drained, thoroughly flush the cool- maximum level mark): eral minutes, and then turn it off.
0.25 L (0.26 US qt) (0.22 Imp.qt)
ing system with clean tap water.
6-15

16. Check the coolant level in the res- EAUM1833
ervoir. If necessary, remove the Replacing the air filter element

coolant reservoir cap, add coolant and cleaning the check hose
to the maximum level mark, and The air filter element should be re-
then install the cap. placed at the intervals specified in the
17. Start the engine, and then check periodic maintenance and lubrication
the vehicle for coolant leakage. If chart. Replace the air filter element
coolant is leaking, have a Yamaha more frequently if you are riding in un-
dealer check the cooling system. usually wet or dusty areas. In addition,
18. Install the cowling, the panel and the air filter check hose must be fre-
1. Air filter case cover
the seat. quently checked and cleaned if neces- 2. Screw
sary.
4. Pull the air filter element out.
To replace the air filter element 5. Insert a new air filter element into
1. Remove the seat. (See page the air filter case as shown.
6 3-12.)
2. Remove panel B. (See page 6-5.)
3. Remove the air filter case cover by
removing the screws.
1. Air filter element
6-16

ECA10480 EAUM1910
CAUTION: Adjusting the engine idling

● Make sure that the air filter ele- speed
ment is properly seated in the The engine idling speed must be
air filter case. checked and, if necessary, adjusted as
● The engine should never be op- follows at the intervals specified in the
erated without the air filter ele- periodic maintenance and lubrication
ment installed, otherwise the chart.
piston(s) and/or cylinder(s) may The engine should be warm before
become excessively worn. making this adjustment.
1. Air filter check hose
6. Install the air filter case cover by in- NOTE:
2. If dirt or water is visible, remove
stalling the screws. ● The engine is warm when it quickly
the hose, clean it, and then install
7. Install the panel. responds to the throttle.
it.
8. Install the seat. ● A diagnostic tachometer is needed
to make this adjustment. 6
To clean the air filter check hose 1. Attach the tachometer to the spark
1. Check the hose on the side of the plug lead.
air filter case for accumulated dirt 2. Check the engine idling speed
or water. and, if necessary, adjust it to spec-
ification by turning the idle adjust-
ing screw. To increase the engine
idling speed, turn the screw in di-
rection (a). To decrease the en-
gine idling speed, turn the screw in
direction (b).
6-17

EAU21381 EAU21640
Checking the throttle cable Tires

free play To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified tires.
Tire air pressure

The tire air pressure should be checked
and, if necessary, adjusted before each
1. Idle adjusting screw
ride.
EWA10500
Engine idling speed: WARNING
1400–1500 r/min 1. Throttle cable free play
● The tire air pressure must be
The throttle cable free play should mea- checked and adjusted on cold
NOTE: sure 3.0–5.0 mm (0.12–0.20 in) at the tires (i.e., when the temperature
6
If the specified idling speed cannot be throttle grip. Periodically check the of the tires equals the ambient
obtained as described above, have a throttle cable free play and, if neces- temperature).
Yamaha dealer make the adjustment. sary, have a Yamaha dealer adjust it. ● The tire air pressure must be ad-
justed in accordance with the
riding speed and with the total
weight of rider, passenger, car-
go, and accessories approved
for this model.
6-18

EWA11020
● Check the tire condition and air
Tire air pressure (measured on cold
tires):
WARNING pressure before each ride.
0–90 kg (0–198 lb): Because loading has an enormous
Front: impact on the handling, braking,
XT660R 200 kPa (29 psi) (2.00 Tire inspection
kgf/cm²) performance and safety characteris-
XT660X 210 kPa (30 psi) (2.10 tics of your motorcycle, you should
kgf/cm²) keep the following precautions in
Rear: mind.
XT660R 200 kPa (29 psi) (2.00
kgf/cm²) ● NEVER OVERLOAD THE
XT660X 210 kPa (30 psi) (2.10 MOTORCYCLE! Operation of an
kgf/cm²) overloaded motorcycle may re-
90–186 kg (198–410 lb): sult in tire damage, loss of con-
Front:
XT660R 200 kPa (29 psi) (2.00 trol, or severe injury. Make sure
kgf/cm²) that the total weight of rider,
XT660X 220 kPa (32 psi) (2.20 passenger, cargo, and accesso- 1. Tire sidewall
kgf/cm²) 2. Tire tread depth 6
Rear:
ries does not exceed the speci-
XT660R 225 kPa (33 psi) (2.25 fied maximum load for the The tires must be checked before each
kgf/cm²) vehicle. ride. If the center tread depth reaches
XT660X 230 kPa (33 psi) (2.30 ● Do not carry along loosely
kgf/cm²)
the specified limit, if the tire has a nail or
Off-road riding: packed items, which can shift glass fragments in it, or if the sidewall is
Front: during a ride. cracked, have a Yamaha dealer re-
XT660R 200 kPa (29 psi) (2.00 ● Securely pack the heaviest place the tire immediately.
kgf/cm²) items close to the center of the
Rear:
XT660R 200 kPa (29 psi) (2.00 motorcycle and distribute the Minimum tire tread depth (front and
kgf/cm²) weight evenly on both sides. rear):
Maximum load*: ● Adjust the suspension and tire 1.6 mm (0.06 in)
186 kg (410 lb) air pressure with regard to the
* Total weight of rider, passenger, car-
go and accessories load.
6-19

EWA10570
NOTE: Front tire:
WARNING
The tire tread depth limits may differ Size:
XT660R 90/90-21M/C 54S, ● Have a Yamaha dealer replace
from country to country. Always comply 90/90-21M/C 54T excessively worn tires. Besides
with the local regulations. XT660X 120/70R17 M/C 58H, being illegal, operating the
120/70ZR17 M/C 58W,
120/70ZR17 M/C 58W motorcycle with excessively
Tire information Manufacturer/model: worn tires decreases riding sta-
This motorcycle is equipped with tube XT660R METZELER/TOURANCE bility and can lead to loss of
tires. FRONT, control.
EWA10460 MICHELIN/SIRAC ● The replacement of all wheel-
WARNING XT660X PIRELLI/DRAGON,
METZELER/SPORTEC M1, and brake-related parts, includ-
● The front and rear tires should MICHELIN/RADIAL PILOT ing the tires, should be left to a
be of the same make and de- SPORT Yamaha dealer, who has the
sign, otherwise the handling Rear tire: necessary professional knowl-
characteristics of the vehicle Size: edge and experience.
6 XT660R 130/80-17M/C 65S,
cannot be guaranteed. ● It is not recommended to patch
130/80-17M/C 65T
● After extensive tests, only the XT660X 160/60R17 M/C 69H, a punctured tube. If unavoid-
tires listed below have been ap- 160/60ZR17 M/C 69W, able, however, patch the tube
proved for this model by 160/60ZR17 M/C 69W very carefully and replace it as
Yamaha Motor Co., Ltd. Manufacturer/model: soon as possible with a high-
XT660R METZELER/TOU-
RANCE, quality product.
MICHELIN/SIRAC
XT660X PIRELLI/DRAGON,
METZELER/SPORTEC M1,
MICHELIN/RADIAL PILOT
SPORT
6-20

EAU21940 EAU22041
Spoke wheels Adjusting the clutch lever free NOTE:

To maximize the performance, durabil- play If the specified clutch lever free play
ity, and safe operation of your motor- could be obtained as described above,
cycle, note the following points tighten the locknut and skip the rest of
regarding the specified wheels. the procedure, otherwise proceed as
● The wheel rims should be checked follows.
for cracks, bends or warpage, and 3. Fully turn the adjusting bolt at the
the spokes for looseness or dam- clutch lever in direction (a) to loos-
age before each ride. If any dam- en the clutch cable.
age is found, have a Yamaha 4. Loosen the locknut at the crank-
dealer replace the wheel. Do not case.
attempt even the smallest repair to
1. Locknut
the wheel. A deformed or cracked 2. Clutch lever free play adjusting bolt
wheel must be replaced. 3. Clutch lever free play
● The wheel should be balanced 6
whenever either the tire or wheel The clutch lever free play should mea-
has been changed or replaced. An sure 10.0–15.0 mm (0.39–0.59 in) as
unbalanced wheel can result in shown. Periodically check the clutch le-
poor performance, adverse han- ver free play and, if necessary, adjust it
dling characteristics, and a short- as follows.
ened tire life. 1. Loosen the locknut at the clutch le-
● Ride at moderate speeds after ver. 1. Locknut
2. To increase the clutch lever free 2. Clutch lever free play adjusting nut (crank-
changing a tire since the tire sur- case)
face must first be “broken in” for it play, turn the adjusting bolt in di-
to develop its optimal characteris- rection (a). To decrease the clutch
tics. lever free play, turn the adjusting
bolt in direction (b).
6-21

5. To increase the clutch lever free EAU22270 EAU22390
play, turn the adjusting nut in direc- Adjusting the rear brake light Checking the front and rear
tion (a). To decrease the clutch le- switch brake pads
ver free play, turn the adjusting nut The front and rear brake pads must be
in direction (b). checked for wear at the intervals spec-
6. Tighten the locknut at the clutch le- ified in the periodic maintenance and
ver and the crankcase. lubrication chart.
EAU22430
Front brake pads
1. Rear brake light switch

2. Rear brake light switch adjusting nut
6 The rear brake light switch, which is ac-

tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch 1. Brake pad wear indicator groove
as follows.
Turn the adjusting nut while holding the Each front brake pad is provided with
rear brake light switch in place. To wear indicator grooves, which allow
make the brake light come on earlier, you to check the brake pad wear with-
turn the adjusting nut in direction (a). To out having to disassemble the brake.
make the brake light come on later, turn To check the brake pad wear, check
the adjusting nut in direction (b). the wear indicator grooves. If a brake
pad has worn to the point that the wear
6-22

indicator grooves have almost disap- EAU22580
Before riding, check that the brake fluid
peared, have a Yamaha dealer replace Checking the brake fluid level is above the minimum level mark and
the brake pads as a set. Front brake replenish if necessary. A low brake fluid
level may indicate worn brake pads
EAU22500
and/or brake system leakage. If the
Rear brake pads
brake fluid level is low, be sure to check
the brake pads for wear and the brake
system for leakage.
Observe these precautions:
● When checking the fluid level,
make sure that the top of the brake
fluid reservoir is level.
1. Minimum level mark ● Use only the recommended quality
brake fluid, otherwise the rubber
Rear brake seals may deteriorate, causing
1. Lining thickness leakage and poor braking perfor- 6
Check each rear brake pad for damage mance.
and measure the lining thickness. If a
Recommended brake fluid:
brake pad is damaged or if the lining DOT 4
thickness is less than 1.0 mm (0.04 in),
have a Yamaha dealer replace the ● Refill with the same type of brake
brake pads as a set. fluid. Mixing fluids may result in a
harmful chemical reaction and
1. Minimum level mark lead to poor braking performance.
Insufficient brake fluid may allow air to

enter the brake system, possibly caus-
ing it to become ineffective.
6-23

● Be careful that water does not en- EAU22760
3. Move the rear wheel by pushing
ter the brake fluid reservoir when Drive chain slack the motorcycle to locate the tight-
refilling. Water will significantly The drive chain slack should be est portion of the drive chain, and
lower the boiling point of the fluid checked before each ride and adjusted then measure the drive chain slack
and may result in vapor lock. if necessary. as shown.
● Brake fluid may deteriorate paint- EAU22782
ed surfaces or plastic parts. Al- To check the drive chain slack Drive chain slack:
ways clean up spilled fluid 40.0–55.0 mm (1.57–2.17 in)
immediately.
4. If the drive chain slack is incorrect,
● As the brake pads wear, it is nor-
adjust it as follows.
mal for the brake fluid level to grad-
ually go down. However, if the NOTE:
brake fluid level goes down sud- When checking the drive chain slack,
denly, have a Yamaha dealer the chain tensioner should not be
check the cause. touching the drive chain.
6
1. Drive chain slack EAU22932

To adjust the drive chain slack
1. Place the motorcycle on the side- (XT660R)
stand. 1. Loosen the axle nut, then loosen
the locknut at each end of the
NOTE:
swingarm.
When checking and adjusting the drive
2. To tighten the drive chain, turn the
chain slack, there should be no weight
adjusting nut at each end of the
on the motorcycle.
swingarm in direction (a). To loos-
2. Shift the transmission into the neu- en the drive chain, turn the adjust-
tral position. ing nut at each end of the
swingarm in direction (b), and then
push the rear wheel forward.
6-24

3. Tighten the locknuts, and then
NOTE:
tighten the axle nut to the specified
Using the alignment marks on each
torque.
side of the swingarm, make sure that
both adjusting nuts are in the same po- Tightening torque: (a)
sition for proper wheel alignment. Locknut:
16 Nm (1.6 m·kgf, 11 ft·lbf) (b)
Axle nut:
104 Nm (10.4 m·kgf, 75 ft·lbf) 3
2
4 1
EAU34311 1. Axle nut
To adjust the drive chain slack 2. Drive chain slack adjusting bolt
(XT660X) 3. Locknut
1. Loosen the axle nut and the lock- 4. Alignment marks
nut on each side of the swingarm. ECA10570
2. To tighten the drive chain, turn the CAUTION:
adjusting bolt on each side of the 6
1. Axle nut Improper drive chain slack will over-
2. Drive chain slack adjusting nut swingarm in direction (a). To loos-
en the drive chain, turn the adjust- load the engine as well as other vital
3. Locknut
ing bolt on each side of the parts of the motorcycle and can lead
4. Alignment marks
swingarm in direction (b), and then to chain slippage or breakage. To
ECA10570
push the rear wheel forward. prevent this from occurring, keep
CAUTION: the drive chain slack within the
Improper drive chain slack will over- NOTE: specified limits.
load the engine as well as other vital Using the alignment marks on each
3. Tighten the locknuts, then the axle
parts of the motorcycle and can lead side of the swingarm, make sure that
nut to their specified torques.
to chain slippage or breakage. To both chain pullers are in the same posi-
prevent this from occurring, keep tion for proper wheel alignment.
the drive chain slack within the
specified limits.
6-25

EAU23022 ECA11110
Tightening torques: Cleaning and lubricating the CAUTION:
Locknut:
16 Nm (1.6 m·kgf, 11 ft·lbf) drive chain Do not use engine oil or any other lu-
Axle nut: The drive chain must be cleaned and bricants for the drive chain, as they
104 Nm (10.4 m·kgf, 75 ft·lbf) lubricated at the intervals specified in may contain substances that could
the periodic maintenance and lubrica- damage the O-rings.
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.
ECA10581
CAUTION:
The drive chain must be lubricated
after washing the motorcycle and
riding in the rain.
6
1. Clean the drive chain with kero-
sene and a small soft brush.
ECA11120
CAUTION:
To prevent damaging the O-rings, do
not clean the drive chain with steam
cleaners, high-pressure washers or
inappropriate solvents.
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive
chain with a special O-ring chain
lubricant.
6-26

EAU23100 EAU23111 EAU23140
Checking and lubricating the Checking and lubricating the Checking and lubricating the
cables throttle grip and cable brake and clutch levers
The operation of all control cables and The operation of the throttle grip should
Brake lever
the condition of the cables should be be checked before each ride. In addi-
checked before each ride, and the cation, the cable should be lubricated at
bles and cable ends should be lubricat- the intervals specified in the periodic
ed if necessary. If a cable is damaged maintenance chart.
or does not move smoothly, have a
Yamaha dealer check or replace it.
Recommended lubricant:
Engine oil
EWA10720
WARNING Clutch lever

6
Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions.
The operation of the brake and clutch

levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
6-27

EAU23180 EAU23200
Recommended lubricant: Lubricating the brake pedal Checking and lubricating the
Lithium-soap-based grease (all-pur-
pose grease) sidestand
The operation of the brake pedal

should be checked before each ride, The operation of the sidestand should
and the pedal pivot should be lubricat- be checked before each ride, and the
6 ed if necessary. sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
Recommended lubricant: necessary.
Lithium-soap-based grease (all-pur- EWA10730
pose grease)
WARNING
If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it.
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
6-28

EAU23271 EAU23280
Checking the front fork Checking the steering

The condition and operation of the front Worn or loose steering bearings may
fork must be checked as follows at the cause danger. Therefore, the operation
intervals specified in the periodic main- of the steering must be checked as fol-
tenance and lubrication chart. lows at the intervals specified in the pe-
riodic maintenance and lubrication
To check the condition chart.
EWA10750
1. Place a stand under the engine to
WARNING raise the front wheel off the
Securely support the vehicle so that ECA10590 ground.
there is no danger of it falling over. CAUTION: EWA10750
If any damage is found or the front WARNING

Check the inner tubes for scratches,
fork does not operate smoothly, Securely support the vehicle so that
damage and excessive oil leakage.
have a Yamaha dealer check or re- there is no danger of it falling over.
To check the operation pair it. 2. Hold the lower ends of the front 6
1. Place the vehicle on a level sur- fork legs and try to move them for-
face and hold it in an upright posi- ward and backward. If any free
tion. play can be felt, have a Yamaha
2. While applying the front brake, dealer check or repair the steering.
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
6-29

EAU23290 EAUM1730
Checking the wheel bearings Battery

The front and rear wheel bearings must This model is equipped with a sealed-
be checked at the intervals specified in type (MF) battery, which does not re-
the periodic maintenance and lubrica- quire any maintenance. There is no
tion chart. If there is play in the wheel need to check the electrolyte or to add
hub or if the wheel does not turn distilled water.
smoothly, have a Yamaha dealer check ECA10620
the wheel bearings. CAUTION:

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

6 3-12.)
2. Remove the battery cover by re-
moving the bolts.
6-30

working near batteries. In case 2. If the battery will be stored for more
of contact, administer the fol- than two months, check it at least
lowing FIRST AID. once a month and fully charge it if
• EXTERNAL: Flush with plenty necessary.
of water. 3. Fully charge the battery before in-
• INTERNAL: Drink large quan- stallation.
tities of water or milk and im- 4. After installation, make sure that
mediately call a physician. the battery leads are properly con-
• EYES: Flush with water for 15 nected to the battery terminals.
1. Negative battery terminal minutes and seek prompt ECA10630
medical attention. CAUTION:

2. Positive battery terminal
3. Bolt ● Batteries produce explosive hy- ● Always keep the battery
4. Battery cover drogen gas. Therefore, keep charged. Storing a discharged
sparks, flames, cigarettes, etc., battery can cause permanent
To charge the battery away from the battery and pro- battery damage.
Have a Yamaha dealer charge the bat- vide sufficient ventilation when ● To charge a sealed-type (MF) 6
tery as soon as possible if it seems to charging it in an enclosed battery, a special (constant-volt-
have discharged. Keep in mind that the space. age) battery charger is required.
battery tends to discharge more quickly ● KEEP THIS AND ALL BATTER- Using a conventional battery
if the vehicle is equipped with optional IES OUT OF THE REACH OF charger will damage the battery.
electrical accessories. CHILDREN. If you do not have access to a
EWA10760
sealed-type (MF) battery charg-
WARNING er, have a Yamaha dealer
To store the battery
● Electrolyte is poisonous and 1. If the vehicle will not be used for charge your battery.
dangerous since it contains sul- more than one month, remove the
furic acid, which causes severe battery, fully charge it, and then
burns. Avoid any contact with place it in a cool, dry place.
skin, eyes or clothing and al-
ways shield your eyes when
6-31

EAUM1740
Replacing the fuses Specified fuses:

Main fuse:
The main fuse is located behind panel 30.0 A
A. (See page 6-5.) Fuse box 1:
Headlight fuse:
20.0 A
Signaling system fuse:
10.0 A
Radiator fan fuse:
7.5 A
Ignition fuse:
1. Fuse box 1 10.0 A
2. Signaling system fuse Fuel injection system fuse:
3. Headlight fuse 10.0 A
4. Ignition fuse Backup fuse:
1. Main fuse 5. Fuel injection system fuse 10.0 A
2. Spare main fuse 6. Radiator fan fuse Fuse box 2:
6 7. Backup fuse (for odometer, clock and immo- Parking lighting fuse:
Fuse box 1 and fuse box 2 are located bilizer system) 10.0 A
under the seat. (See page 3-12.) 8. Parking lighting fuse
ECA10640
9. Fuse box 2
10.Spare fuse
CAUTION:
Do not use a fuse of a higher amper-
If a fuse is blown, replace it as follows. age rating than recommended to
1. Turn the key to “OFF” and turn off avoid causing extensive damage to
the electrical circuit in question. the electrical system and possibly a
2. Remove the blown fuse, and then fire.
install a new fuse of the specified
amperage. 3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
6-32

4. If the fuse immediately blows EAUM1750
again, have a Yamaha dealer Replacing the headlight bulb

check the electrical system. This model is equipped with a quartz
bulb headlight. If the headlight bulb
burns out, replace it as follows.
1. Remove cowling A together with
the headlight unit. (See page 6-5.)
2. Disconnect the headlight coupler,
and then remove the headlight
bulb cover.
1. Headlight bulb holder
2. Headlight bulb
EWA10790
WARNING
Headlight bulbs get very hot. There-
fore, keep flammable products away 6
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down.
1. Headlight bulb cover 4. Place a new bulb into position, and
2. Headlight coupler then secure it with the bulb holder.
ECA10660
3. Remove the headlight bulb holder
CAUTION:
by turning it counterclockwise, and
then remove the defective bulb. Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the bulb,
and the bulb life will be adversely af-
6-33

fected. Thoroughly clean off any dirt EAU24281
2. Remove the defective bulb by
and fingerprints on the headlight Replacing a turn signal light pushing it in and turning it counter-
bulb using a cloth moistened with al- bulb or the tail/brake light bulb clockwise.
cohol or thinner. 1. Remove the lens by removing the 3. Insert a new bulb into the socket,
screws. push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screws.
ECA10680
CAUTION:
Do not overtighten the screws, oth-
erwise the lens may break.
1. Do not touch the glass part of the bulb.

1. Screw
6
5. Install the bulb cover, and then
connect the coupler.
6. Install the cowling together with
the headlight unit.
7. Have a Yamaha dealer adjust the
headlight beam if necessary.
1. Screw
6-34

EAUM1820 EAU24350
a jack either under each side of the
Replacing an auxiliary light Supporting the motorcycle frame in front of the rear wheel or under
bulb Since this model is not equipped with a each side of the swingarm.
If the auxiliary light bulb burns out, re- centerstand, follow these precautions
place it as follows. when removing the front and rear
1. Remove cowling A together with wheel or performing other maintenance
the headlight unit. (See page 6-5.) requiring the motorcycle to stand up-
2. Remove the auxiliary light socket right. Check that the motorcycle is in a
(together with the bulb) by pulling it stable and level position before starting
out. any maintenance. A strong wooden
box can be placed under the engine for
added stability.
To service the front wheel

1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if 6
an additional motorcycle stand is
not available, by placing a jack un-
der the frame in front of the rear
wheel.
1. Auxiliary light bulb socket
2. Raise the front wheel off the
3. Remove the defective bulb by pull- ground by using a motorcycle
ing it out. stand.
4. Insert a new bulb into the socket.
5. Install the auxiliary light socket (to- To service the rear wheel
gether with the bulb) by pushing it Raise the rear wheel off the ground by
in. using a motorcycle stand or, if a motor-
6. Install the cowling together with cycle stand is not available, by placing
the headlight unit.
6-35

EAU24360
XT660X
Front wheel
EAUM1761
To remove the front wheel
EWA10820
WARNING
● It is advisable to have a Yamaha
dealer service the wheel.
● Securely support the motor-
cycle so that there is no danger 1. Bolt
of it falling over. 1. Wheel axle 2. Brake caliper
2. Front wheel axle pinch bolt A
1. Loosen the front wheel axle pinch 3. Front wheel axle pinch bolt B
ECA11070
bolts, then the wheel axle and the CAUTION:

brake caliper bolts. 2. Lift the front wheel off the ground
Do not apply the brake after the
according to the procedure on
6 XT660R wheel has been removed together
page 6-35.
with the brake disc, otherwise the
3. Remove the brake caliper by re-
brake pads will be forced shut.
moving the bolts.
4. Pull the wheel axle out, and then
remove the wheel.
EAUM1811
To install the front wheel
1. Lift the wheel up between the fork
legs.
1. Wheel axle
2. Insert the wheel axle.
2. Front wheel axle pinch bolt A 3. Lower the front wheel so that it is
3. Front wheel axle pinch bolt B on the ground.
6-36

4. Install the brake caliper by install- EAU25080
XT660X
ing the bolts. Rear wheel
NOTE: EAUM1773
Make sure that there is enough space To remove the rear wheel
EWA10820
between the brake pads before install-
WARNING
ing the brake caliper onto the brake
● It is advisable to have a Yamaha
disc.
dealer service the wheel.
5. Tighten the wheel axle to the spec- ● Securely support the motor-
ified torque. cycle so that there is no danger
6. Tighten the wheel axle pinch bolt A of it falling over. 1. Bolt
and pinch bolt B to the specified 2. Drive chain guard
torques. 1. Remove the drive chain guard by
removing the bolts. 2. Loosen the axle nut.
7. Retighten the wheel axle pinch bolt
A to the specified torque. XT660R XT660R
8. Tighten the brake caliper bolts to 6
the specified torques.
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. Bolt 1. Axle nut
9. Push down hard on the handlebar 2. Drive chain guard 2. Drive chain slack adjusting nut
several times to check for proper 3. Locknut
fork operation. 4. Brake caliper bracket
5. Brake caliper
6-37

XT660X
4
(a)
3
2
1 1. Brake caliper
1. Axle nut NOTE: 2. Brake disc
2. Drive chain slack adjusting bolt
The drive chain cannot be disassem-
3. Locknut
bled. EAUM2140
4. Brake caliper bracket To install the rear wheel
5. Brake caliper 8. Pull the wheel backward and move 1. Install the drive chain onto the rear
6 the brake caliper away from the sprocket.
3. Lift the rear wheel off the ground
wheel. 2. Install the wheel, the washer(s)
according to the procedure on ECA11070
and the brake caliper bracket by
page 6-35. CAUTION: inserting the wheel axle from the
4. Loosen the locknut on each side of
Do not apply the brake after the left-hand side.
the swingarm.
5. Turn the drive chain slack adjust- wheel has been removed together NOTE:
ing nuts (or bolts according to the with the brake disc, otherwise the
● XT660R: Install the washer with
model) fully in direction (a). brake pads will be forced shut.
the “N” mark on the right-hand side
6. Remove the wheel axle by remov- and the washer with the “O” mark
ing the axle nut. on the left-hand side. Be sure to in-
7. Push the wheel forward, and then stall both washers with their marks
remove the drive chain from the facing outward.
rear sprocket.
6-38

● XT660X: Install the washer on the EAU25870
Tightening torque: Troubleshooting
right-hand side. Locknut:
● Make sure that the retainer on the 16 Nm (1.6 m·kgf, 11 ft·lbf) Although Yamaha motorcycles receive
swingarm is inserted into the slot in Axle nut: a thorough inspection before shipment
the brake caliper bracket. 104 Nm (10.4 m·kgf, 75 ft·lbf) from the factory, trouble may occur dur-
● Make sure that there is enough ing operation. Any problem in the fuel,
6. Install the drive chain guard by in- compression, or ignition systems, for
space between the brake pads be-
stalling the bolts. example, can cause poor starting and
fore installing the wheel.
loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and 6
know-how to service the motorcycle
properly.
1. Retainer Use only genuine Yamaha replace-
2. Slot ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi-
3. Lower the rear wheel so that it is or, have a shorter service life and can
on the ground. lead to expensive repair bills.
4. Adjust the drive chain slack. (See
page 6-24.)
5. Tighten the axle nut to the speci-
fied torque.
6-39

EAU25921
Troubleshooting charts
Starting problems or poor engine performance

EWA10840
WARNING
Keep away open flames and do not smoke while checking or working on the fuel system.
1. Fuel
There is enough fuel. Check the compression.
Check the fuel level in
the fuel tank.
The engine does not start.
There is no fuel. Supply fuel.
Check the compression.
2. Compression
There is compression. Check the ignition.
6 Operate the electric starter.
Have a Yamaha dealer
There is no compression.
check the vehicle.
3. Ignition Wipe off with a dry cloth and correct the Open the throttle halfway and operate
Wet
spark plug gap, or replace the spark plug. the electric starter.
Remove the spark plug
and check the electrodes.
The engine does not start.
Dry Have a Yamaha dealer check the vehicle.
Check the battery.
4. Battery The engine turns over

The battery is good.
quickly. The engine does not start.
Operate the electric starter. Have a Yamaha dealer
The engine turns over Check the battery lead connections, check the vehicle.
slowly. and charge the battery if necessary.
6-40

Engine overheating
EWA10400
WARNING
● Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be
blown 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 then
slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hissing
sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.
There is Have a Yamaha dealer check

The coolant level is low. leakage. and repair the cooling system.
Check the cooling system
for leakage.
There is
Add coolant. (See NOTE.)
Wait until the Check the coolant level in the no leakage.
engine has cooled. reservoir and radiator. 6
The coolant level Start the engine. If the engine overheats again, have a
is OK. Yamaha dealer check and repair the cooling system.
NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant
as soon as possible.
6-41
MOTORCYCLE CARE AND STORAGE

EAU26001
ucts onto seals, gaskets, sprock- cleaning products, solvent or
Care ets, the drive chain and wheel thinner, fuel (gasoline), rust re-
While the open design of a motorcycle axles. Always rinse the dirt and de- movers or inhibitors, brake flu-
reveals the attractiveness of the tech- greaser off with water. id, antifreeze or electrolyte.
nology, it also makes it more vulnera- ● Do not use high-pressure wash-
ble. Rust and corrosion can develop Cleaning ers or steam-jet cleaners since
even if high-quality components are ECA10770
they cause water seepage and
used. A rusty exhaust pipe may go un- CAUTION: deterioration in the following ar-
noticed on a car, however, it detracts ● Avoid using strong acidic wheel eas: seals (of wheel and swing-
from the overall appearance of a motor- cleaners, especially on spoked arm bearings, fork and brakes),
cycle. Frequent and proper care does wheels. If such products are electric components (couplers,
not only comply with the terms of the used on hard-to-remove dirt, do connectors, instruments,
warranty, but it will also keep your not leave the cleaner on the af- switches and lights), breather
motorcycle looking good, extend its life fected area any longer than in- hoses and vents.
and optimize its performance. structed. Also, thoroughly rinse ● For motorcycles equipped with
the area off with water, immedi- a windshield: Do not use strong
Before cleaning ately dry it, and then apply a cor- cleaners or hard sponges as
1. Cover the muffler outlet with a rosion protection spray. they will cause dulling or
7
plastic bag after the engine has ● Improper cleaning can damage scratching. Some cleaning com-
cooled down. windshields, cowlings, panels pounds for plastic may leave
2. Make sure that all caps and covers and other plastic parts. Use only scratches on the windshield.
as well as all electrical couplers a soft, clean cloth or sponge Test the product on a small hid-
and connectors, including the with mild detergent and water to den part of the windshield to
spark plug cap, are tightly in- clean plastic. make sure that it does not leave
stalled. ● Do not use any harsh chemical any marks. If the windshield is
3. Remove extremely stubborn dirt, products on plastic parts. Be scratched, use a quality plastic
like oil burnt onto the crankcase, sure to avoid using cloths or polishing compound after
with a degreasing agent and a sponges which have been in washing.
brush, but never apply such prod- contact with strong or abrasive
7-1

After normal use ECA10790
5. Use spray oil as a universal clean-
Remove dirt with warm water, a mild CAUTION: er to remove any remaining dirt.
detergent, and a soft, clean sponge, Do not use warm water since it in- 6. Touch up minor paint damage
and then rinse thoroughly with clean creases the corrosive action of the caused by stones, etc.
water. Use a toothbrush or bottlebrush salt. 7. Wax all painted surfaces.
for hard-to-reach areas. Stubborn dirt 8. Let the motorcycle dry completely
2. Apply a corrosion protection spray
and insects will come off more easily if before storing or covering it.
on all metal, including chrome- and
the area is covered with a wet cloth for EWA11130
nickel-plated, surfaces to prevent WARNING
a few minutes before cleaning.
corrosion.
● Make sure that there is no oil or
After riding in the rain, near the sea or wax on the brakes or tires.
After cleaning
on salt-sprayed roads ● If necessary, clean the brake
1. Dry the motorcycle with a chamois
Since sea salt or salt sprayed on roads discs and brake linings with a
or an absorbing cloth.
during winter are extremely corrosive in regular brake disc cleaner or ac-
2. Immediately dry the drive chain
combination with water, carry out the etone, and wash the tires with
and lubricate it to prevent it from
following steps after each ride in the warm water and a mild deter-
rusting.
rain, near the sea or on salt-sprayed gent. Before riding at higher
3. Use a chrome polish to shine
roads. speeds, test the motorcycle’s 7
chrome, aluminum and stainless-
braking performance and cor-
NOTE: steel parts, including the exhaust
nering behavior.
Salt sprayed on roads in the winter may system. (Even the thermally in-
remain well into spring. duced discoloring of stainless- ECA10800
steel exhaust systems can be re- CAUTION:

1. Clean the motorcycle with cold wa-
moved through polishing.) ● Apply spray oil and wax spar-
ter and a mild detergent, after the
4. To prevent corrosion, it is recom- ingly and make sure to wipe off
engine has cooled down.
mended to apply a corrosion pro- any excess.
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
7-2

● Never apply oil or wax to any EAUM1900
3. Perform the following steps to pro-
rubber and plastic parts, but Storage tect the cylinder, piston rings, etc.
treat them with a suitable care from corrosion.
product. Short-term a. Remove the spark plug cap
● Avoid using abrasive polishing Always store your motorcycle in a cool, and spark plug.
compounds as they will wear dry place and, if necessary, protect it b. Pour a teaspoonful of engine oil
away the paint. against dust with a porous cover. into the spark plug bore.
ECA10810
c. Install the spark plug cap onto
CAUTION:
NOTE: the spark plug, and then place
Consult a Yamaha dealer for advice on ● Storing the motorcycle in a the spark plug on the cylinder
what products to use. poorly ventilated room or cover- head so that the electrodes are
ing it with a tarp, while it is still grounded. (This will limit spark-
wet, will allow water and humid- ing during the next step.)
ity to seep in and cause rust. d. Turn the engine over several
● To prevent corrosion, avoid times with the starter. (This will
damp cellars, stables (because coat the cylinder wall with oil.)
of the presence of ammonia) e. Remove the spark plug cap
7 and areas where strong chemi- from the spark plug, and then
cals are stored. install the spark plug and the
spark plug cap.
EWA10950
Long-term
Before storing your motorcycle for sev- WARNING
eral months: To prevent damage or injury from
1. Follow all the instructions in the sparking, make sure to ground the
“Care” section of this chapter. spark plug electrodes while turning
2. Fill up the fuel tank and add fuel the engine over.
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
7-3

4. Lubricate all control cables and the
pivoting points of all levers and
pedals as well as of the side-
stand/centerstand.
5. Check and, if necessary, correct
the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
6. Cover the muffler outlets with plas-
tic bags to prevent moisture from
entering them.
7. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month. 7
Do not store the battery in an ex-
cessively cold or warm place [less
than 0 °C (30 °F) or more than 30
°C (90 °F)]. For more information
on storing the battery, see page
6-30.
NOTE:
Make any necessary repairs before
storing the motorcycle.
7-4
SPECIFICATIONS
Dimensions: Compression ratio: Air filter:
Overall length: 10.00 :1 Air filter element:
XT660R 2240 mm (88.2 in) Starting system: Oil-coated paper element
XT660X 2175 mm (85.6 in) Electric starter Fuel:
Overall width: Lubrication system: Recommended fuel:
XT660R 845 mm (33.3 in) Dry sump Premium unleaded gasoline only
XT660X 860 mm (33.9 in) Engine oil: Fuel tank capacity:
Overall height: Type: 15.0 L (3.96 US gal) (3.30 Imp.gal)
XT660R 1230 mm (48.4 in) SAE10W30, SAE10W40, SAE15W40, Fuel reserve amount:
XT660X 1170 mm (46.1 in) SAE20W40 or SAE20W50 5.0 L (1.32 US gal) (1.10 Imp.gal)
Seat height: Fuel injector:
XT660R 865 mm (34.1 in) -20 -10 0 10 20 30 40 50 ˚C Manufacturer:
XT660X 875 mm (34.4 in) DENSO
Wheelbase: SAE 10W-30
Model/quantity:
XT660R 1505 mm (59.3 in) SAE 10W-40 297500-0390
XT660X 1490 mm (58.7 in) Spark plug (s):
Ground clearance: SAE 15W-40
Manufacturer/model:
XT660R 210 mm (8.27 in) NGK/CR7E
SAE 20W-40
XT660X 205 mm (8.07 in) Spark plug gap:
Minimum turning radius: SAE 20W-50 0.7–0.8 mm (0.028–0.031 in)
2400 mm (94.5 in) Clutch:
Weight: Clutch type:
With oil and fuel: Recommended engine oil grade:
API service SE, SF, SG type or higher Wet, multiple-disc
8 XT660R 181.0 kg (399 lb) Transmission:
Engine oil quantity:
XT660X 186.0 kg (410 lb)
Without oil filter element replacement: Primary reduction system:
Engine: Spur gear
2.50 L (2.64 US qt) (2.20 Imp.qt)
Engine type: Primary reduction ratio:
With oil filter element replacement:
Liquid cooled 4-stroke, SOHC 75/36 (2.083)
2.60 L (2.75 US qt) (2.29 Imp.qt)
Cylinder arrangement: Secondary reduction system:
Forward-inclined single cylinder
Cooling system:
Coolant reservoir capacity (up to the Chain drive
Displacement: Secondary reduction ratio:
maximum level mark):
660.0 cm³ 45/15 (3.000)
0.25 L (0.26 US qt) (0.22 Imp.qt)
Bore × stroke: Transmission type:
Radiator capacity (including all routes):
100.0 × 84.0 mm (3.94 × 3.31 in) Constant mesh 5-speed
1.00 L (1.06 US qt) (0.88 Imp.qt)
8-1
SPECIFICATIONS
Operation: Manufacturer/model: Rear:
Left foot operation XT660R METZELER/TOURANCE XT660R 200 kPa (29 psi) (2.00 kgf/cm²)
Gear ratio: FRONT, XT660X 210 kPa (30 psi) (2.10 kgf/cm²)
1st: MICHELIN/SIRAC Loading condition:
30/12 (2.500) XT660X PIRELLI/DRAGON, 90–186 kg (198–410 lb)
2nd: METZELER/SPORTEC M1, Front:
26/16 (1.625) MICHELIN/RADIAL PILOT SPORT XT660R 200 kPa (29 psi) (2.00 kgf/cm²)
3rd: Rear tire: XT660X 220 kPa (32 psi) (2.20 kgf/cm²)
23/20 (1.150) Type: Rear:
4th: With tube XT660R 225 kPa (33 psi) (2.25 kgf/cm²)
20/22 (0.909) Size: XT660X 230 kPa (33 psi) (2.30 kgf/cm²)
5th: XT660R 130/80-17M/C 65S, Off-road riding:
20/26 (0.769) 130/80-17M/C 65T Front:
Chassis: XT660X 160/60R17 M/C 69H, XT660R 200 kPa (29 psi) (2.00 kgf/cm²)
Frame type: 160/60ZR17 M/C 69W, Rear:
Diamond 160/60ZR17 M/C 69W XT660R 200 kPa (29 psi) (2.00 kgf/cm²)
Caster angle: Manufacturer/model: Front wheel:
XT660R 27.25 ° XT660R METZELER/TOURANCE, Wheel type:
XT660X 26.00 ° MICHELIN/SIRAC Spoke wheel
Trail: XT660X PIRELLI/DRAGON, Rim size:
XT660R 107.0 mm (4.21 in) METZELER/SPORTEC M1, XT660R 21x1.85
XT660X 94.0 mm (3.70 in) MICHELIN/RADIAL PILOT SPORT XT660X 17M/C x MT3.50
Front tire: Loading: Rear wheel:
Type: Maximum load: Wheel type: 8
With tube 186 kg (410 lb) Spoke wheel
Size: (Total weight of rider, passenger, cargo and Rim size:
XT660R 90/90-21M/C 54S, accessories) XT660R 17M/C x MT2.75
90/90-21M/C 54T Tire air pressure (measured on cold XT660X 17M/C x MT4.25
XT660X 120/70R17 M/C 58H, tires): Front brake:
120/70ZR17 M/C 58W, Loading condition: Type:
120/70ZR17 M/C 58W 0–90 kg (0–198 lb) Single disc brake
Front: Operation:
XT660R 200 kPa (29 psi) (2.00 kgf/cm²) Right hand operation
XT660X 210 kPa (30 psi) (2.10 kgf/cm²)
8-2
SPECIFICATIONS
Recommended fluid: Voltage, capacity: Fuses:
DOT 4 12 V, 8.0 Ah Main fuse:
Rear brake: Headlight: 30.0 A
Type: Bulb type: Headlight fuse:
Single disc brake Halogen bulb 20.0 A
Operation: Bulb voltage, wattage × quantity: Signaling system fuse:
Right foot operation Headlight: 10.0 A
Recommended fluid: 12 V, 55 W/60.0 W × 1 Ignition fuse:
DOT 4 Tail/brake light: 10.0 A
Front suspension: 12 V, 5.0 W/21.0 W × 1 Parking lighting fuse:
Type: Front turn signal light: 10.0 A
Telescopic fork 12 V, 10.0 W × 2 Radiator fan fuse:
Spring/shock absorber type: Rear turn signal light: 7.5 A
Coil spring/oil damper 12 V, 10.0 W × 2 Fuel injection system fuse:
Wheel travel: Auxiliary light: 10.0 A
XT660R 225.0 mm (8.86 in) 12 V, 5.0 W × 1 Backup fuse:
XT660X 200.0 mm (7.87 in) Meter lighting: 10.0 A
Rear suspension: EL
Type: Neutral indicator light:
Swingarm (monocross) LED
Spring/shock absorber type: High beam indicator light:
Coil spring/gas-oil damper LED
Wheel travel: Turn signal indicator light:
8 XT660R 200.0 mm (7.87 in) LED
XT660X 191.0 mm (7.52 in) Fuel level warning light:
Electrical system: LED
Ignition system: Coolant temperature warning light:
Transistorized coil ignition (digital) LED
Charging system: Engine trouble warning light:
AC magneto LED
Battery: Immobilizer system indicator light:
Model: LED
GT9B-4
8-3
CONSUMER INFORMATION
EAU26351 EAU26381 EAU26410
Identification numbers Key identification number Vehicle identification number

Record the key identification number,
vehicle identification number and mod-
el label information in the spaces pro-
vided below for assistance when
ordering spare parts from a Yamaha
dealer or for reference in case the vehi-
cle is stolen.
KEY IDENTIFICATION NUMBER:
1. Key identification number 1. Vehicle identification number

2. Code re-registering key (red bow)
3. Standard keys (black bow) The vehicle identification number is
stamped into the frame.
VEHICLE IDENTIFICATION The key identification number is
stamped into the key tag. Record this NOTE:
NUMBER:
number in the space provided and use The vehicle identification number is
it for reference when ordering a new used to identify your vehicle and may
key. be used to register it with the licensing
authority in your area.
MODEL LABEL INFORMATION:

9
9-1
CONSUMER INFORMATION
EAU26540
Model label
1. Model label
The model label is affixed to the frame

under the seat. (See page 3-12.)
Record the information on this label in
the space provided. This information
will be needed when ordering spare
parts from a Yamaha dealer.
9-2
INDEX
A F Pre-operation check list .......................... 4-2
Air filter element and check hose, Front and rear brake pads, checking ....6-22 R
replacing and cleaning ....................... 6-16 Front fork, checking...............................6-29 Rear brake light switch, adjusting ......... 6-22
Anti-theft alarm (optional) ....................... 3-7 Fuel .......................................................3-11 S
Auxiliary light bulb, replacing ................ 6-35 Fuel consumption, tips for reducing ........5-3 Safety information................................... 1-1
B Fuel level warning light............................3-4 Seat ...................................................... 3-12
Battery .................................................. 6-30 Fuel tank cap.........................................3-10 Shifting.................................................... 5-2
Brake and clutch levers, checking and Fuses, replacing....................................6-32 Shift pedal............................................... 3-9
lubricating ........................................... 6-27 H Shock absorber assembly, adjusting .... 3-13
Brake fluid level, checking .................... 6-23 Handlebar switches .................................3-7 Sidestand.............................................. 3-14
Brake lever ............................................. 3-9 Hazard switch..........................................3-8 Sidestand, checking and lubricating ..... 6-28
Brake pedal .......................................... 3-10 Headlight bulb, replacing.......................6-33 Spark plug, checking .............................. 6-9
Brake pedal, lubricating ........................ 6-28 High beam indicator light.........................3-4 Specifications.......................................... 8-1
C Horn switch .............................................3-8 Starting the engine.................................. 5-1
Cables, checking and lubricating.......... 6-27 I Start switch ............................................. 3-8
Care........................................................ 7-1 Identification numbers .............................9-1 Steering, checking ................................ 6-29
Catalytic converter................................ 3-12 Ignition circuit cut-off system .................3-15 Storage ................................................... 7-3
Clutch lever............................................. 3-9 Immobilizer system .................................3-1 Storage compartment ........................... 3-13
Clutch lever free play, adjusting ........... 6-21 Immobilizer system indicator light ...........3-4 Supporting the motorcycle .................... 6-35
Coolant ................................................. 6-13 Indicator and warning lights ....................3-3 T
Coolant temperature warning light.......... 3-4 K Throttle cable free play, checking ......... 6-18
Cowlings and panels, removing and Key identification number........................9-1 Throttle grip and cable, checking and
installing ............................................... 6-5 M lubricating ........................................... 6-27
D Main switch/steering lock ........................3-2 Tires...................................................... 6-18
Dimmer switch ........................................ 3-8 Model label..............................................9-2 Tool kit .................................................... 6-1
Drive chain, cleaning and lubricating.... 6-26 Multi-function display...............................3-5 Troubleshooting .................................... 6-39
Drive chain slack .................................. 6-24 N Troubleshooting charts ......................... 6-40
E Neutral indicator light ..............................3-3 Turn signal indicator light ........................ 3-3
Engine break-in ...................................... 5-3 P Turn signal light bulb or tail/brake light
Engine idling speed .............................. 6-17 Parking ....................................................5-4 bulb, replacing .................................... 6-34
Engine oil and oil filter element............. 6-10 Part locations ..........................................2-1 Turn signal switch ................................... 3-8
Engine stop switch.................................. 3-8 Pass switch .............................................3-8 V
Engine trouble warning light ................... 3-4 Periodic maintenance and lubrication Vehicle identification number.................. 9-1
chart ......................................................6-2
INDEX
W
Wheel bearings, checking..................... 6-30
Wheel (front) ......................................... 6-36
Wheel (rear) .......................................... 6-37
Wheels .................................................. 6-21
YAMAHA MOTOR CO., LTD.
PRINTED IN FRANCE
2006.07 (E)

XT660R XT660X: Owner'S Manual

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XT660R XT660X: Owner'S Manual

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OWNER’S MANUAL

Hereby declare that the product:

Kind of equipment: IMMOBILIZER

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

Place of issue: Shizuoka, Japan

Date of issue: 1 Aug. 2002

General manager of quality assurance div.

representative name and signature

MORIC CO., LTD.

Welcome to the Yamaha world of motorcycling!

IMPORTANT MANUAL INFORMATION

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

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

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

IMPORTANT MANUAL INFORMATION

1. Windshield 9. Seat lock (page 3-12 )

Controls and instruments

1. Clutch lever (page 3-9) 8. Fuel tank cap (page 3-10)

1. Clutch lever (page 3-9)

INSTRUMENT AND CONTROL FUNCTIONS

INSTRUMENT AND CONTROL FUNCTIONS

INSTRUMENT AND CONTROL FUNCTIONS

INSTRUMENT AND CONTROL FUNCTIONS

INSTRUMENT AND CONTROL FUNCTIONS

INSTRUMENT AND CONTROL FUNCTIONS

CAUTION: system keys may cause signal interfer-

INSTRUMENT AND CONTROL FUNCTIONS

INSTRUMENT AND CONTROL FUNCTIONS

INSTRUMENT AND CONTROL FUNCTIONS

Clutch lever Shift pedal Brake lever

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

INSTRUMENT AND CONTROL FUNCTIONS

Brake pedal Fuel tank cap NOTE:

1. Brake pedal 1. Fuel tank cap lock cover

To install the fuel tank cap

INSTRUMENT AND CONTROL FUNCTIONS

● Do not overfill the fuel tank, oth- CAUTION:

INSTRUMENT AND CONTROL FUNCTIONS

Catalytic converter Seat

INSTRUMENT AND CONTROL FUNCTIONS

1. CYCLELOK bar (optional)

with the straps. When the CYCLELOK CAUTION:

WARNING Adjust the spring preload as follows.

INSTRUMENT AND CONTROL FUNCTIONS

INSTRUMENT AND CONTROL FUNCTIONS

pair it if it does not function proper- Ignition circuit cut-off system

INSTRUMENT AND CONTROL FUNCTIONS

With the engine turned off:

Pre-operation check list

• Check fuel level in fuel tank.

• Make sure that operation is smooth.

OPERATION AND IMPORTANT RIDING POINTS

OPERATION AND IMPORTANT RIDING POINTS

gine more than 10 seconds on any one Shifting CAUTION:

OPERATION AND IMPORTANT RIDING POINTS

Tips for reducing fuel con- Engine break-in CAUTION:

0–1000 km (0–600 mi)

OPERATION AND IMPORTANT RIDING POINTS

PERIODIC MAINTENANCE AND MINOR REPAIR

Owner’s tool kit NOTE:

sible. The most important points of in- WARNING

PERIODIC MAINTENANCE AND MINOR REPAIR

Periodic maintenance and lubrication chart