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Yamaha_XT660R_XT660X_2004_Service_Repair Manual
Pages 462
CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER MODEL LABEL
FEATURES OUTLINE FI SYSTEM
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY REPLACEMENT PARTS GASKETS, OIL SEALS AND O-RINGS LOCK WASHERS/PLATES AND COTTER PINS BEARINGS AND OIL SEALS CIRCLIPS
CHECKING THE CONNECTIONS
SPECIAL TOOLS
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ENGINE SPECIFICATIONS CHASSIS SPECIFICATIONS ELECTRICAL SPECIFICATIONS CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS TIGHTENING TORQUE
ENGINE TIGHTENING TORQUE CHASSIS TIGHTENING TORQUES
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE CHASSIS
COOLING SYSTEM DIAGRAMS LUBRICATION CHART LUBRICATION DIAGRAMS CABLE ROUTING
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
PERIODIC MAINTENANCE AND LUBRICATION CHART
COWLING AND COVER
COVER COWLING
FUEL TANK REMOVING THE FUEL TANK REMOVING THE FUEL PUMP INSTALLING THE FUEL PUMP INSTALLING THE FUEL HOSE
AIR FILTER CASE REAR MUD GUARD AND REAR FENDER AIR FILTER CASE INSTALLING THE AIR FILTER CASE JOINT CLAMP
ENGINE ADJUSTING THE VALVE CLEARANCE ADJUSTING THE EXHAUST GAS VOLUME ADJUSTING THE ENGINE IDLING SPEED ADJUSTING THE THROTTLE CABLE FREE PLAY CHECKING THE SPARK PLUG CHECKING THE IGNITION TIMING MEASURING THE COMPRESSION PRESSURE CHECKING THE ENGINE OIL LEVEL CHANGING THE ENGINE OIL ADJUSTING THE CLUTCH CABLE FREE PLAY CHECKING THE AIR FILTER ELEMENT CHECKING THE THROTTLE BODY JOINT CHECKING THE FUEL HOSE CHECKING THE BREATHER HOSE CHECKING THE EXHAUST SYSTEM CHECKING THE COOLANT LEVEL CHECKING THE COOLING SYSTEM CHANGING THE COOLANT
CHASSIS
ADJUSTING THE REAR BRAKE PEDAL CHECKING THE BRAKE FLUID LEVEL CHECKING THE FRONT AND REAR BRAKE PADS
AND BRAKE PAD PINS ADJUSTING THE REAR BRAKE LIGHT SWITCH CHECKING THE FRONT AND REAR BRAKE HOSES BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJUSTING THE SHIFT PEDAL ADJUSTING THE DRIVE CHAIN SLACK LUBRICATING THE DRIVE CHAIN CHECKING AND ADJUSTING THE STEERING HEAD CHECKING THE FRONT FORK ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY CHECKING THE TIRES CHECKING AND TIGHTENING THE SPOKES CHECKING AND LUBRICATING THE CABLES LUBRICATING THE LEVERS AND BRAKE PEDAL LUBRICATING THE SIDESTAND
ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY CHECKING THE FUSES REPLACING THE HEADLIGHT BULB ADJUSTING THE HEADLIGHT BEAM SETTING THE DIGITAL CLOCK
CHAPTER 4
CHASSIS
FRONT WHEEL AND BRAKE DISC FRONT WHEEL REMOVING THE FRONT WHEEL CHECKING THE FRONT WHEEL CHECKING THE FRONT BRAKE DISC INSTALLING THE FRONT WHEEL ADJUSTING THE FRONT WHEEL STATIC BALANCE
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET REMOVING THE REAR WHEEL CHECKING THE REAR WHEEL CHECKING THE REAR BRAKE DISC CHECKING THE REAR WHEEL DRIVE HUB CHECKING AND REPLACING THE REAR WHEEL SPROCKET INSTALLING THE REAR WHEEL ADJUSTING THE REAR WHEEL STATIC BALANCE
FRONT AND REAR BRAKES FRONT BRAKE PADS (XT660R) FRONT BRAKE PADS (XT660X) REAR BRAKE PADS REPLACING THE FRONT BRAKE PADS REPLACING THE REAR BRAKE PADS FRONT BRAKE MASTER CYLINDER REAR BRAKE MASTER CYLINDER DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER
DISASSEMBLING THE REAR BRAKE MASTER CYLINDER CHECKING THE FRONT AND REAR BRAKE MASTER
CYLINDERS ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER
CYLINDER ASSEMBLING THE REAR BRAKE MASTER CYLINDER INSTALLING THE REAR BRAKE MASTER CYLINDER FRONT BRAKE CALIPER (XT660R) FRONT BRAKE CALIPER (XT660X) REAR BRAKE CALIPER REMOVING THE FRONT BRAKE CALIPER REMOVING THE REAR BRAKE CALIPER CHECKING THE FRONT AND REAR BRAKE CALIPERS INSTALLING THE FRONT BRAKE CALIPER INSTALLING THE REAR BRAKE CALIPER
CHAPTER 5
ENGINE
ENGINE REMOVAL EXHAUST PIPES AND MUFFLERS LEADS, CABLES, HOSES, AND IGNITION COIL ENGINE INSTALLING THE ENGINE
CYLINDER HEAD REMOVING THE CYLINDER HEAD CHECKING THE CYLINDER HEAD CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER
CHECKING THE TIMING CHAIN TENSIONER
CHECKING THE CAMSHAFT SPROCKET
INSTALLING THE CYLINDER HEAD
ROCKER ARMS AND CAMSHAFT REMOVING THE ROCKER ARMS AND CAMSHAFT CHECKING THE CAMSHAFT CHECKING THE DECOMPRESSION SYSTEM CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS INSTALLING THE CAMSHAFT AND ROCKER ARMS
VALVES AND VALVE SPRINGS REMOVING THE VALVES CHECKING THE VALVES AND VALVE GUIDES CHECKING THE VALVE SEATS CHECKING THE VALVE SPRINGS INSTALLING THE VALVES
CYLINDER AND PISTON REMOVING THE CYLINDER AND PISTON CHECKING THE CYLINDER AND PISTON CHECKING THE PISTON RINGS CHECKING THE PISTON PIN INSTALLING THE PISTON AND CYLINDER
CLUTCH
CLUTCH COVER PULL LEVER SHAFT CLUTCH REMOVING THE CLUTCH CHECKING THE FRICTION PLATES CHECKING THE CLUTCH PLATES CHECKING THE CLUTCH SPRINGS CHECKING THE CLUTCH HOUSING CHECKING THE CLUTCH BOSS CHECKING THE PRESSURE PLATE CHECKING THE PULL LEVER SHAFT AND PULL ROD CHECKING THE PRIMARY DRIVEN GEAR INSTALLING THE CLUTCH
OIL PUMP
CHECKING THE OIL PUMP CHECKING THE OIL DELIVERY PIPES AND HOSES ASSEMBLING THE OIL PUMP INSTALLING THE OIL PUMP
BALANCER DRIVEN GEAR
REMOVING THE BALANCER DRIVEN GEAR AND BALANCER DRIVE GEAR
CHECKING THE BALANCER DRIVEN GEAR, WATER PUMP DRIVE GEAR, PRIMARY DRIVE GEAR, AND BALANCER DRIVE GEAR
INSTALLING THE BALANCER DRIVEN GEAR
AND BALANCER DRIVE GEAR
SHIFT SHAFT
SHIFT SHAFT AND STOPPER LEVER CHECKING THE SHIFT SHAFT CHECKING THE STOPPER LEVER INSTALLING THE SHIFT SHAFT
STARTER CLUTCH AND AC MAGNETO
REMOVING THE AC MAGNETO ROTOR CHECKING THE STATOR COIL AND CRANKSHAFT POSITION SENSOR
CHECKING THE STARTER CLUTCH
CHECKING THE TORQUE LIMITER
INSTALLING THE AC MAGNETO ROTOR
CHAPTER 6
COOLING SYSTEM
RADIATOR CHECKING THE RADIATOR INSTALLING THE RADIATOR
THERMOSTAT CHECKING THE THERMOSTAT INSTALLING THE THERMOSTAT
WATER PUMP DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP ASSEMBLING THE WATER PUMP INSTALLING THE WATER PUMP
CHAPTER 7
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM WIRING DIAGRAM ECU SELF-DIAGNOSTIC FUNCTION ALTERNATE OPERATION CONTROL (FAIL-SAFE ACTION) FAIL-SAFE ACTION TABLE TROUBLESHOOTING CHART DIAGNOSTIC MODE TROUBLESHOOTING DETAILS
THROTTLE BODY ASSEMBLY CHECKING THE FUEL INJECTOR CHECKING THE THROTTLE BODY INSTALLING THE THROTTLE BODY ASSEMBLY
CHECKING THE FUEL PUMP CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR
AIR INDUCTION SYSTEM AIR INJECTION AIR CUT-OFF VALVE AIR INDUCTION SYSTEM DIAGRAMS AIR CUT-OFF VALVE ASSEMBLY CHECKING THE AIR INDUCTION SYSTEM CHAPTER 8
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS
CHECKING SWITCH CONTINUITY
CHECKING THE SWITCHES
CHECKING THE BULBS AND BULB SOCKETS TYPES OF BULBS CHECKING THE CONDITION OF THE BULBS CHECKING THE CONDITION OF THE BULB SOCKETS CHECKING THE LEDs
IGNITION SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING
ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM STARTING CIRCUIT CUT-OFF SYSTEM OPERATION TROUBLESHOOTING
STARTER MOTOR CHECKING THE STARTER MOTOR ASSEMBLING THE STARTER MOTOR
CHARGING SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING
LIGHTING SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING CHECKING THE LIGHTING SYSTEM
SIGNALING SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING CHECKING THE SIGNALING SYSTEM
COOLING SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING
CHAPTER 9
TROUBLESHOOTING
STARTING FAILURES ENGINE FUEL SYSTEM ELECTRICAL SYSTEMS
INCORRECT ENGINE IDLING SPEED ENGINE FUEL SYSTEM ELECTRICAL SYSTEMS
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ENGINE FUEL SYSTEM
FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT SHIFT PEDAL DOES NOT MOVE JUMPS OUT OF GEAR
FAULTY CLUTCH CLUTCH SLIPS CLUTCH DRAGS
OVERHEATING ENGINE COOLING SYSTEM FUEL SYSTEM CHASSIS ELECTRICAL SYSTEMS
OVERCOOLING COOLING SYSTEM
POOR BRAKING PERFORMANCE
FAULTY FRONT FORK LEGS LEAKING OIL MALFUNCTION
UNSTABLE HANDLING
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