Yamaha XT660 User Manual

OWNER’S MANUAL

XT660R

XT660X

5VK-F8199-E0

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, 5VS-00, 5VX-00, 3HT-00, 5UX-00, 5UX-10, 5KS-00 and 5KS-10

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

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

Place of issue: Shizuoka, Japan

st

Date of issue: Aug. 1

2002

EAU26941

Kazuji Kawai

representative name and signature

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

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

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!

EAU10150

WARNING

Failure to follow WARNING instructions could result in severe injury or death
motorcycle operator, a bystander, or a person inspecting or repairing the motor-

to the

cycle.

CAUTION:

NOTE:

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

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

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.

IMPORTANT MANUAL INFORMATION

EAUM1010

XT660R/XT660X

OWNER’S MANUAL

©2003 by MBK INDUSTRIE

2nd edition, December 2003

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

DESCRIPTION ..................................2-1

Left view ..........................................2-1

Right view........................................2-2

Controls and instruments.................2-3

INSTRUMENT AND CONTROL

FUNCTIONS .......................................3-1

Immobilizer system .........................3-1

Main switch/steering lock ................3-2

Indicator and warning lights ............3-3

Multi-function display ......................3-5

Anti-theft alarm (optional) ...............3-7

Handlebar switches ........................3-7

Clutch lever .....................................3-9

Shift pedal .......................................3-9

Brake lever .....................................3-9

Brake pedal ..................................3-10

Fuel tank cap ................................3-10

Fuel ...............................................3-11

Catalytic converter ........................3-12

Seat ..............................................3-12

Storage compartment ...................3-13

Adjusting the shock absorber

assembly ...................................3-13

Sidestand ......................................3-14

Ignition circuit cut-off system ........3-15

PRE-OPERATION CHECKS..............4-1

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

OPERATION AND IMPORTANT

RIDING POINTS.................................5-1

Starting the engine .........................5-1

Shifting ........................................... 5-2

Tips for reducing fuel

consumption ............................... 5-3

Engine break-in ..............................5-3

Parking ........................................... 5-4

PERIODIC MAINTENANCE AND

MINOR REPAIR ................................. 6-1

Owner’s tool kit ............................... 6-1

Periodic maintenance and

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

Removing and installing cowlings

and panels ..................................6-5

Checking the spark plug .................6-7

Engine oil and oil filter element ...... 6-9

Coolant ......................................... 6-12

Replacing the air filter element and

cleaning the check hose ........... 6-15

Adjusting the engine idling

speed ........................................ 6-16

Adjusting the throttle cable free

play ........................................... 6-17

Tires .............................................. 6-17

Spoke wheels ...............................6-19

Adjusting the clutch lever free

play ........................................... 6-20

Adjusting the rear brake light

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

Checking the front and rear

brake pads ................................ 6-21

Checking the brake fluid level ...... 6-22

Drive chain slack .......................... 6-23

Lubricating the drive chain ........... 6-24

Checking and lubricating the

cables ....................................... 6-25

Checking and lubricating the

throttle grip and cable ............... 6-25

Checking and lubricating the

brake and clutch levers ............ 6-25

Lubricating the brake pedal ......... 6-26

Checking and lubricating the

sidestand .................................. 6-26

Checking the front fork ................. 6-27

Checking the steering .................. 6-27

Checking the wheel bearings ....... 6-28

Battery ......................................... 6-28

Replacing the fuses ..................... 6-30

Replacing the headlight bulb ....... 6-31

Replacing a turn signal light bulb

or the tail/brake light bulb ......... 6-32

Replacing an auxiliary light

bulb ........................................... 6-33

Supporting the motorcycle ........... 6-33

Front wheel .................................. 6-34

Rear wheel ................................... 6-35

Troubleshooting ........................... 6-37

Troubleshooting charts ................ 6-38

MOTORCYCLE CARE AND

STORAGE ..........................................7-1

Care ................................................7-1

Storage ...........................................7-3

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

CONSUMER INFORMATION.............9-1

Identification numbers ....................9-1

TABLE OF CONTENTS

SAFETY INFORMATION

MOTORCYCLES ARE SINGLE
TRACK VEHICLES. THEIR SAFE USE

1

AND OPERATION ARE DEPENDENT
UPON THE USE OF PROPER RIDING
TECHNIQUES AS WELL AS THE EX­PERTISE OF THE OPERATOR. EV­ERY OPERATOR SHOULD KNOW
THE FOLLOWING REQUIREMENTS
BEFORE RIDING THIS MOTOR­CYCLE.
HE OR SHE SHOULD:

● OBTAIN THOROUGH INSTRUC-

TIONS FROM A COMPETENT
SOURCE ON ALL ASPECTS OF
MOTORCYCLE OPERATION.

● OBSERVE THE WARNINGS AND

MAINTENANCE REQUIRE­MENTS IN THE OWNER’S MAN­UAL.

● OBTAIN QUALIFIED TRAINING

IN SAFE AND PROPER RIDING
TECHNIQUES.

● OBTAIN PROFESSIONAL TECH-

NICAL SERVICE AS INDICATED
BY THE OWNER’S MANUAL

EAU10310

AND/OR WHEN MADE NECES­SARY BY MECHANICAL CONDI­TIONS.

Safe riding

● Always make pre-operation

checks. Careful checks may help
prevent an accident.

● This motorcycle is designed to car-

ry the operator and a passenger.

● The failure of motorists to detect

and recognize motorcycles in traf­fic is the predominating cause of
automobile/motorcycle accidents.
Many accidents have been caused
by an automobile driver who did
not see the motorcycle. Making
yourself conspicuous appears to
be very effective in reducing the
chance of this type of accident.

Therefore:

• Wear a brightly colored jacket.

• Use extra caution when ap-

proaching and passing through
intersections, since intersec­tions are the most likely places
for motorcycle accidents to oc­cur.

• Ride where other motorists can
see you. Avoid riding in another
motorist’s blind spot.

● Many accidents involve inexperi-

enced operators. In fact, many op­erators who have been involved in
accidents do not even have a cur­rent motorcycle license.

• Make sure that you are qualified
and that you only lend your
motorcycle to other qualified op­erators.

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

• We recommend that you prac­tice riding your motorcycle
where there is no traffic until you
have become thoroughly famil­iar with the motorcycle and all of
its controls.

● Many accidents have been caused

by error of the motorcycle opera­tor. A typical error made by the op­erator is veering wide on a turn

1-1

SAFETY INFORMATION

due to EXCESSIVE SPEED or un­dercornering (insufficient lean an­gle for the speed).

• Always obey the speed limit and
never travel faster than warrant­ed by road and traffic conditions.

• Always signal before turning or
changing lanes. Make sure that
other motorists can see you.

● The posture of the operator and

passenger is important for proper
control.

• The operator should keep both
hands on the handlebar and
both feet on the operator foot­rests during operation to main­tain control of the motorcycle.

• The passenger should always
hold onto the operator, the seat
strap or grab bar, if equipped,
with both hands and keep both
feet on the passenger footrests.

• Never carry a passenger unless
he or she can firmly place both
feet on the passenger footrests.

● Never ride under the influence of

alcohol or other drugs.

Protective apparel

The majority of fatalities from motor­cycle accidents are the result of head
injuries. The use of a safety helmet is
the single most critical factor in the pre­vention or reduction of head injuries.

● Always wear an approved helmet.

● Wear a face shield or goggles.

Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.

● The use of a jacket, heavy boots,

trousers, gloves, etc., is effective in
preventing or reducing abrasions
or lacerations.

● Never wear loose-fitting clothes,

otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.

● Never touch the engine or exhaust

system during or after operation.
They become very hot and can
cause burns. Always wear protec­tive clothing that covers your legs,
ankles, and feet.

● Passengers should also observe

the precautions mentioned above.

1-2

Modifications

Modifications made to this motorcycle
not approved by Yamaha, or the re­moval of original equipment, may ren­der the motorcycle unsafe for use and
may cause severe personal injury.
Modifications may also make your
motorcycle illegal to use.

Loading and accessories

Adding accessories or cargo to your
motorcycle can adversely affect stabili­ty and handling if the weight distribution
of the motorcycle is changed. To avoid
the possibility of an accident, use ex­treme caution when adding cargo or
accessories to your motorcycle. Use
extra care when riding a motorcycle
that has added cargo or accessories.
Here are some general guidelines to
follow if loading cargo or adding acces­sories to your motorcycle:
Loading
The total weight of the operator, pas­senger, accessories and cargo must
not exceed the maximum load limit of
186 kg (410 lb). When loading within
this weight limit, keep the following in
mind:

1

SAFETY INFORMATION

● Cargo and accessory weight

should be kept as low and close to
the motorcycle as possible. Make

1

sure to distribute the weight as
evenly as possible on both sides of
the motorcycle to minimize imbal­ance or instability.

● Shifting weights can create a sud-

den imbalance. Make sure that ac­cessories and cargo are securely
attached to the motorcycle before
riding. Check accessory mounts
and cargo restraints frequently.

● Never attach any large or heavy

items to the handlebar, front fork,
or front fender. These items, in­cluding such cargo as sleeping
bags, duffel bags, or tents, can
create unstable handling or a slow

steering response.
Accessories
Genuine Yamaha accessories have
been specifically designed for use on
this motorcycle. Since Yamaha cannot
test all other accessories that may be
available, you must personally be re­sponsible for the proper selection, in­stallation and use of non-Yamaha

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

● Never install accessories or carry

cargo that would impair the perfor­mance of your motorcycle. Care­fully inspect the accessory before
using it to make sure that it does
not in any way reduce ground
clearance or cornering clearance,
limit suspension travel, steering
travel or control operation, or ob­scure lights or reflectors.

• Accessories fitted to the handle­bar or the front fork area can
create instability due to improper
weight distribution or aerody­namic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.

• Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerody­namic effects. Wind may at-

1-3

tempt to lift the motorcycle, or
the motorcycle may become un­stable in cross winds. These ac­cessories may also cause
instability when passing or being
passed by large vehicles.

• Certain accessories can dis­place the operator from his or
her normal riding position. This
improper position limits the free­dom of movement of the opera­tor and may limit control ability,
therefore, such accessories are
not recommended.

● Use caution when adding electri-

cal accessories. If electrical acces­sories exceed the capacity of the
motorcycle’s electrical system an
electric failure could result, which
could cause a dangerous loss of
lights or engine power.

Gasoline and exhaust gas

● GASOLINE IS HIGHLY FLAMMA-

BLE:

• Always turn the engine off when
refueling.

SAFETY INFORMATION

• Take care not to spill any gaso­line on the engine or exhaust
system when refueling.

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

● Never start the engine or let it run

for any length of time in a closed
area. The exhaust fumes are poi­sonous and may cause loss of
consciousness and death within a
short time. Always operate your
motorcycle in an area that has ad­equate ventilation.

● Always turn the engine off before

leaving the motorcycle unattended
and remove the key from the main
switch. When parking the motor­cycle, note the following:

• The engine and exhaust system
may be hot, therefore, park the
motorcycle in a place where pe­destrians or children are not like­ly to touch these hot areas.

• Do not park the motorcycle on a
slope or soft ground, otherwise it
may fall over.

• Do not park the motorcycle near
a flammable source (e.g., a ker­osene heater, or near an open
flame), otherwise it could catch
fire.

● When transporting the motorcycle

in another vehicle, make sure that
it is kept upright and that the fuel
cock(s) are turned to “ON” or
“RES” (for vacuum type)/“OFF”
(for manual type). If the motorcycle
should lean over, gasoline may
leak out of the carburetor or fuel
tank.

● If you should swallow any gaso-

line, inhale a lot of gasoline vapor,
or allow gasoline to get into your
eyes, see your doctor immediately.
If any gasoline spills on your skin
or clothing, immediately wash the
affected area with soap and water
and change your clothes.

1

1-4

DESCRIPTION

Left view

2

EAU10410

1. Windshield

2. Idle adjusting screw (page 6-16)

3. Main fuse (page 6-30)

4. Battery (page 6-28)

5. Fuse box 1 (page 6-30)

6. Fuse box 2 (page 6-30)

7. Storage compartment (page 3-13)

8. Grab bar

9. Seat lock (page 3-12)

10.Shift pedal (page 3-9)

11.Engine oil drain bolt (crankcase) (page 6-9)

2-1

Right view

DESCRIPTION

EAU10420

2

1. Owner’s tool kit (page 6-1)

2. Air filter element (page 6-15)

3. Shock absorber assembly spring preload adjusting ring (page 3-13)

4. Rear brake fluid reservoir (page 6-22)

5. Front brake fluid reservoir (page 6-22)

6. Engine oil filler cap (page 6-9)

7. Engine oil drain bolt (oil tank) (page 6-9)

8. Coolant reservoir (page 6-12)

9. Engine oil filter element (page 6-9)

10.Coolant drain bolt (page 6-13)

11.Brake pedal (page 3-10)

2-2

DESCRIPTION

Controls and instruments

XT660R

2

EAU32240

1. Clutch lever (page 3-9)

2. Left handlebar switches (page 3-7)

3. Main switch/steering lock (page 3-2)

4. Multi-function display (page 3-5)

5. Right handlebar switches (page 3-7)

6. Brake lever (page 3-9)

7. Throttle grip (page 6-17)

8. Fuel tank cap (page 3-10)

2-3

XT660X

1. Clutch lever (page 3-9)

2. Left handlebar switches (page 3-7)

3. Main switch/steering lock (page 3-2)

4. Multi-function display (page 3-5)

5. Right handlebar switches (page 3-7)

6. Brake lever (page 3-9)

7. Throttle grip (page 6-17)

8. Fuel tank cap (page 3-10)

DESCRIPTION

2

2-4

INSTRUMENT AND CONTROL FUNCTIONS

Immobilizer system

3

1. Code re-registering key (red bow)

2. Standard keys (black bow)

This vehicle is equipped with an immo­bilizer system to help prevent theft by
re-registering codes in the standard
keys. This system consists of the fol­lowing.

● a code re-registering key (with a

red bow)

● two standard keys (with a black

bow) that can be re-registered with
new codes

● a transponder (which is installed in

the code re-registering key)

● an immobilizer unit

● an ECU

EAU10972

● an immobilizer system indicator

light (See page 3-3.)
The key with the red bow is used to reg­ister codes in each standard key. Since
re-registering is a difficult process, take
the vehicle along with all three keys to
a Yamaha dealer to have them re-reg­istered. Do not use the key with the red
bow for driving. It should only be used
for re-registering the standard keys. Al­ways use a standard key for driving.

ECA11820

CAUTION:

● DO NOT LOSE THE CODE RE-

REGISTERING KEY! CONTACT

YOUR DEALER IMMEDIATELY

IF IT IS LOST! If the code re-reg-

istering key is lost, registering

new codes in the standard keys

is impossible. The standard

keys can still be used to start

the vehicle, however if code re-

registering is required (i.e., if a

new standard key is made or all

keys are lost) the entire immobi-

lizer system must be replaced.

Therefore, it is highly recom-

mended to use either standard
key and keep the code re-regis­tering key in a safe place.

● Do not submerse any key in wa-

ter.

● Do not expose any key to exces-

sively high temperatures.

● Do not place any key close to

magnets (this includes, but not
limited to, products such as
speakers, etc.).

● Do not place heavy items on any

key.

● Do not grind any key or alter its

shape.

● Do not disassemble the plastic

part of any key.

● Do not put two keys of any im-

mobilizer system on the same
key ring.

● Keep the standard keys as well

as keys of other immobilizer
systems away from this vehi­cle’s code re-registering key.

● Keep other immobilizer system

keys away from the main switch
as they may cause signal inter­ference.

3-1

INSTRUMENT AND CONTROL FUNCTIONS

EAU10471

Main switch/steering lock

The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering.

NOTE:

Be sure to use the standard key (black
bow) for regular use of the vehicle. To
minimize the risk of losing the code re­registering key (red bow), keep it in a
safe place and only use it for code re­registering.

ON

EAU10570

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 re­moved.

NOTE:

The headlight comes on automatically
when the engine is started and stays on
until the key is turned to “OFF”.

EAU10660

OFF

All electrical systems are off. The key
can be removed.

EAU10680

LOCK

The steering is locked, and all electrical
systems are off. The key can be re­moved.

To lock the steering

3

1. Push.

2. Turn.

1. Turn the handlebars all the way to
the left.

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

3. Remove the key.

3-2

INSTRUMENT AND CONTROL FUNCTIONS

To unlock the steering

3

1. Push.

2. Turn.

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

WARNING

Never turn the key to “OFF” or
“LOCK” while the vehicle is moving,
otherwise the electrical systems will
be switched off, which may result in
loss of control or an accident. Make
sure that the vehicle is stopped be­fore turning the key to “OFF” or
“LOCK”.

EWA10060

(Parking)

EAU33000

The steering is locked, and the taillight
and auxiliary light are on. The hazard
light and turn signal lights can be turned
on, but all other electrical systems are
off. The key can be removed.
The steering must be locked before the
key can be turned to “”.

ECA11020

CAUTION:

Do not use the parking position for
an extended length of time, other­wise the battery may discharge.

EAU11001

Indicator and warning lights

1. Engine trouble warning light “”

2. Turn signal indicator light “”

3. Fuel level warning light “”

4. High beam indicator light “”

5. Neutral indicator light “”

6. Coolant temperature warning light “”

7. Immobilizer system indicator light “”

EAU11020

Turn signal indicator light “”

This indicator light flashes when the
turn signal switch is pushed to the left or
right.

EAU11060

Neutral indicator light “”

This indicator light comes on when the
transmission is in the neutral position.

3-3

INSTRUMENT AND CONTROL FUNCTIONS

High beam indicator light “”

EAU11080

This indicator light comes on when the
high beam of the headlight is switched
on.

EAU11360

Fuel level warning light “”

This warning light comes on when the
fuel level drops below approximately

5.0 L (1.32 US gal) (1.10 Imp.gal).
When this occurs, refuel as soon as
possible.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”.
If the warning light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir­cuit.

NOTE:

This model is also equipped with a self­diagnosis device for the fuel level de­tection circuit. If the fuel level detection
circuit is defective, the following cycle
will be repeated until the malfunction is
corrected: The fuel level warning light

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

EAU11440

Coolant temperature warning light
“”

This warning light comes on when the
engine overheats. When this occurs,
stop the engine immediately and allow
the engine to cool.
The electrical circuit of the warning light
can be checked by turning the key to
“ON”.
If the warning light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir­cuit.

ECA10020

CAUTION:

Do not operate the engine if it is
overheated.

EAU11530

Engine trouble warning light “”

This warning light comes on or flashes
when an electrical circuit monitoring the
engine is defective. When this occurs,
have a Yamaha dealer check the self-

3-4

diagnosis system. (See page 3-5 for an
explanation of the self-diagnosis de­vice.)
The electrical circuit of the warning light
can be checked by turning the key to
“ON”. If the warning light does not come
on for a few seconds, then go off, have
a Yamaha dealer check the electrical
circuit.

EAU26871

Immobilizer system indicator light
“”

The electrical circuit of the indicator
light can be checked by turning the key
to “ON”.
If the indicator light does not come on
for a few seconds, then go off, have a
Yamaha dealer check the electrical cir­cuit.
When the key is turned to “OFF” and 30
seconds have passed, the indicator
light will start flashing indicating the im­mobilizer system is enabled. After 24
hours have passed, the indicator light
will stop flashing, however the immobi­lizer system is still enabled.

3

INSTRUMENT AND CONTROL FUNCTIONS

NOTE:

This model is also equipped with a self­diagnosis device for the immobilizer
system. If the immobilizer system is de­fective, the indicator will start flashing
and the multi-function meter will display
an error code when the key is turned to
“ON”. (See “Self-diagnosis device” on

3

page 3-5 for details.)

EAUM1662

Multi-function display

1. Multi-function display

2. Clock

3. Tripmeter 1

4. Odometer/fuel reserve tripmeter/tripmeter 2

5. “SELECT” button

6. “RESET” button

7. Speedometer

The multi-function display is equipped
with the following:

● a speedometer (which shows the

riding speed)

● an odometer (which shows the to-

tal distance traveled)

● two tripmeters (which show the

distance traveled since they were
last set to zero)

3-5

● a fuel reserve tripmeter (which

shows the distance traveled since
the fuel level warning light came
on)

● a clock

● a self-diagnosis device

NOTE:

● Be sure to turn the key to “ON” be-

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

● For the U.K. only: To switch the

speedometer and odometer/trip­meter displays between kilometers
and miles, press the “SELECT”
button for at least two seconds.

Odometer and tripmeter modes

Pushing the “SELECT” button switches
the display between the odometer
mode “ODO” and the tripmeter modes
“TRIP 1” and “TRIP 2” in the following
order:
ODO → TRIP 1 → TRIP 2 → ODO
If the fuel level warning light comes on
(see page 3-3), the odometer display
will automatically change to the fuel re­serve tripmeter mode “F-TRIP” and
start counting the distance traveled

INSTRUMENT AND CONTROL FUNCTIONS

from that point. In that case, pushing
the “SELECT” button switches the dis­play between the various tripmeter and
odometer modes in the following order:
F-TRIP → TRIP 1 → TRIP 2 → ODO →
F-TRIP
To reset a tripmeter, select it by push­ing the “SELECT” button, and then
push the “RESET” button for at least
one second while the selected tripme­ter is flashing. If you do not reset the
fuel reserve tripmeter manually, it will
reset itself automatically and the dis­play will return to the prior mode after
refueling and traveling 5 km (3 mi).

Clock mode

Turn the key to “ON”.

To set the clock:

1. Push the “SELECT” button and
“RESET” button together for at
least two seconds.

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

3. Push the “SELECT” button to fix
the hours, and the minute digits
will start flashing.

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

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

Self-diagnosis device

This model is equipped with a self-diag­nosis device for various electrical cir­cuits.
If any of those circuits are defective, the
engine trouble warning light will come
on, and then the multi-function display
will indicate a two-digit error code (e.g.,
11, 12, 13).
If the multi-function display indicates
such an error code, note the code num­ber, and then have a Yamaha dealer
check the vehicle.

ECA11590

CAUTION:

If the display indicates an error
code, the vehicle should be checked
as soon as possible in order to avoid
engine damage.

This model is also equipped with a self­diagnosis device for the immobilizer
system.

3-6

If any of the immobilizer system circuits
are defective, the immobilizer system
indicator light will flash, and then the
multi-function display will indicate a
two-digit error code (e.g., 51, 52, 53)
when the key is turned to “ON”.

NOTE:

If the multi-function display indicates er­ror code 52, this could be caused by
transponder interference. If this error
appears, try the following.

1. Use the code re-registering key to
start the engine.

NOTE:

Make sure there are no other immobi­lizer keys close to the main switch, and
do not keep more than one immobilizer
key on the same key ring! Immobilizer
system keys may cause signal interfer­ence, which may prevent the engine
from starting.

2. If the engine starts, turn it off, and
try starting the engine with the
standard keys.

3. If one or both of the standard keys
do not start the engine, take the
vehicle, the code re-registering

3

INSTRUMENT AND CONTROL FUNCTIONS

key and both standard keys to a
Yamaha dealer and have the stan-

dard keys re-registered.
If the multi-function display indicates
any error codes, note the code number,
and then have a Yamaha dealer check
the vehicle.

3

EAU12330

Anti-theft alarm (optional)

This model can be equipped with an
optional anti-theft alarm by a Yamaha
dealer. Contact a Yamaha dealer for
more information.

EAU12343

Handlebar switches

Left

1. Pass switch “”

2. Dimmer switch “ / ”

3. Turn signal switch “ / ”

4. Horn switch “”

5. Hazard switch “”

3-7

INSTRUMENT AND CONTROL FUNCTIONS

Right

1. Engine stop switch “ / ”

2. Start switch “”

EAU12350

Pass switch “”

Press this switch to flash the headlight.

EAU12400

Dimmer switch “ / ”

Set this switch to “” for the high
beam and to “” for the low beam.

EAU12460

Turn signal switch “ / ”

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

position. To cancel the turn signal
lights, push the switch in after it has re­turned to the center position.

EAU12500

Horn switch “”

Press this switch to sound the horn.

EAU12660

Engine stop switch “ / ”

Set this switch to “” before starting
the engine. Set this switch to “” to
stop the engine in case of an emergen­cy, such as when the vehicle overturns
or when the throttle cable is stuck.

EAU12710

Start switch “”

Push this switch to crank the engine
with the starter.

ECA10050

CAUTION:

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

Hazard switch “”

EAU12731

With the key in the “ON” or “” posi-
tion, use this switch to turn on the haz­ard light (simultaneous flashing of all
turn signal lights).
The hazard light is used in case of an
emergency or to warn other drivers
when your vehicle is stopped where it
might be a traffic hazard.

ECA10060

CAUTION:

Do not use the hazard light for an ex­tended length of time, otherwise the
battery may discharge.

3

3-8

INSTRUMENT AND CONTROL FUNCTIONS

Clutch lever

EAU12820

Shift pedal

EAU12870

3

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

The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handle­bar grip. To engage the clutch, release
the lever. The lever should be pulled
rapidly and released slowly for smooth

The shift pedal is located on the left
side of the engine and is used in com­bination with the clutch lever when
shifting the gears of the 5-speed con­stant-mesh transmission equipped on

this motorcycle.
clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the igni­tion circuit cut-off system. (See page
3-15.)

EAU12890

Brake lever

The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handle­bar grip.

3-9

INSTRUMENT AND CONTROL FUNCTIONS

EAU12941

Brake pedal

1. Brake pedal 1. Fuel tank cap lock cover

The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.

Fuel tank cap

2. Unlock.

To remove the fuel tank cap

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 re­move it.

EAUM1790

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
properly installed before riding.

3

3-10

INSTRUMENT AND CONTROL FUNCTIONS

Fuel

3

1. Fuel tank filler tube

2. Fuel level

Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.

WARNING

● Do not overfill the fuel tank, oth-

erwise it may overflow when the
fuel warms up and expands.

● Avoid spilling fuel on the hot en-

gine.

EAU13210

EWA10880

ECA10070

CAUTION:

Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted surfac­es or plastic parts.

EAU13390

Recommended fuel:

PREMIUM UNLEADED GASOLINE
ONLY

Fuel tank capacity:

15.0 L (3.96 US gal) (3.30 Imp.gal)

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

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

ECA11400

CAUTION:

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

curs, use a gasoline of a different
brand. Use of unleaded fuel will extend
spark plug life and reduce maintenance
costs.

Your Yamaha engine has been de­signed to use premium unleaded gaso­line with a research octane number of
95 or higher. If knocking (or pinging) oc-

3-11

INSTRUMENT AND CONTROL FUNCTIONS

EAU13430

Catalytic converter

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

EWA10860

WARNING

The exhaust system is hot after op­eration. Make sure that the exhaust
system has cooled down before do­ing any maintenance work.

ECA10700

CAUTION:

The following precautions must be
observed to prevent a fire hazard or
other damages.

● Use only unleaded gasoline.

The use of leaded gasoline will
cause unrepairable damage to
the catalytic converter.

● Never park the vehicle near pos-

sible fire hazards such as grass
or other materials that easily
burn.

● Do not allow the engine to idle

too long.

EAU13900

Seat

To remove the seat

1. Insert the key into the seat lock,
and then turn it as shown.

1. Seat lock

2. Unlock.

2. Pull the seat off.

To install the seat

1. Insert the projection on the front of
the seat into the seat holder as
shown.

3

1. Seat holder

2. Projection

2. Push the rear of the seat down to
lock it in place.

3. Remove the key.

NOTE:

Make sure that the seat is properly se­cured before riding.

3-12

INSTRUMENT AND CONTROL FUNCTIONS

Storage compartment

3

1. U-LOCK bar (optional)

2. Yamaha U-LOCK (optional)

3. Strap

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

WARNING

● Do not exceed the load limit of 3

kg (7 lb) for the storage com­partment.

EAU14421

EWA10961

● Do not exceed the maximum

load of 186 kg (410 lb) for the ve­hicle.

EAU14830

Adjusting the shock absorber
assembly

1. Spring preload adjusting ring

2. Special wrench

3. Position indicator

This shock absorber assembly is
equipped with a spring preload adjust­ing ring.

ECA10100

CAUTION:

Never attempt to turn an adjusting
mechanism beyond the maximum or
minimum settings.

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

3-13

INSTRUMENT AND CONTROL FUNCTIONS

crease the spring preload and thereby
soften the suspension, turn the adjust­ing ring in direction (b).

NOTE:

Align the appropriate notch in the ad­justing ring with the position indicator
on the shock absorber.

Spring preload setting:

Minimum (soft):

1

Standard:

2

Maximum (hard):

5

EWA10220

WARNING

This shock absorber contains highly
pressurized nitrogen gas. For prop­er handling, read and understand
the following information before
handling the shock absorber. The
manufacturer cannot be held re­sponsible for property damage or
personal injury that may result from
improper handling.

● Do not tamper with or attempt to

open the gas cylinder.

● Do not subject the shock ab-

sorber to an open flame or other
high heat sources, otherwise it
may explode due to excessive
gas pressure.

● Do not deform or damage the

gas cylinder in any way, as this
will result in poor damping per­formance.

● Always have a Yamaha dealer

service the shock absorber.

EAU15300

Sidestand

The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
vehicle upright.

NOTE:

The built-in sidestand switch is part of
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
(See further down for an explanation of
the ignition circuit cut-off system.)

EWA10240

WARNING

The vehicle must not be ridden with
the sidestand down, or if the side­stand cannot be properly moved up
(or does not stay up), otherwise the
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control.
Yamaha’s ignition circuit cut-off
system has been designed to assist
the operator in fulfilling the respon­sibility of raising the sidestand be­fore starting off. Therefore, check
this system regularly as described

3

3-14

INSTRUMENT AND CONTROL FUNCTIONS

below and have a Yamaha dealer re­pair it if it does not function proper­ly.

3

EAU15311

Ignition circuit cut-off system

The ignition circuit cut-off system (com­prising the sidestand switch, clutch
switch and neutral switch) has the fol­lowing functions.

● It prevents starting when the trans-

mission is in gear and the side­stand is up, but the clutch lever is
not pulled.

● It prevents starting when the trans-

mission is in gear and the clutch le­ver 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 be­fore riding.

3-15

INSTRUMENT AND CONTROL FUNCTIONS

With the engine turned off:

1. Move the sidestand down.

2. Make sure that the engine stop switch is turned on.

3. Turn the key on.

4. Shift the transmission into the neutral position.

5. Push the start switch.

Does the engine start?

YES NO

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?

YES NO

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?

YES NO

The system is OK. The motorcycle can be ridden.

NOTE:

This check is most reliable if performed with
a warmed-up engine.

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

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

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

3

3-16

PRE-OPERATION CHECKS

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 inspec­tion, 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.

4

WARNING

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

EAU15591

EWA11150

4-1

Pre-operation check list

ITEM CHECKS PAGE

Fuel

Engine oil

Coolant

Front brake

Rear brake

Clutch

• Check fuel level in fuel tank.

• Refuel if necessary.

• Check fuel line for leakage.

• Check oil level in oil tank.

• If necessary, add recommended oil to specified level.

• Check vehicle for oil leakage.

• Check coolant level in reservoir.

• If necessary, add recommended coolant to specified level.

• Check cooling system for leakage.

• Check operation.

• If soft or spongy, have Yamaha dealer bleed hydraulic system.

• Check brake pads for wear.

• Replace if necessary.

• Check fluid level in reservoir.

• If necessary, add recommended brake fluid to specified level.

• Check hydraulic system for leakage.

• Check operation.

• If soft or spongy, have Yamaha dealer bleed hydraulic system.

• Check brake pads for wear.

• Replace if necessary.

• Check fluid level in reservoir.

• If necessary, add recommended brake fluid to specified level.

• Check hydraulic system for leakage.

• Check operation.

• Lubricate cable if necessary.

• Check lever free play.

• Adjust if necessary.

PRE-OPERATION CHECKS

EAU15602

3-11

6-9

6-12

4

6-21, 6-22

6-21, 6-22

6-20

4-2

PRE-OPERATION CHECKS

ITEM CHECKS PAGE

• Make sure that operation is smooth.

Throttle grip

Control cables

Drive chain

4

Wheels and tires

Brake pedal

Brake and clutch levers

Sidestand

Chassis fasteners

Instruments, lights, signals
and switches

Sidestand switch

• Check cable free play.

• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and

grip housing.

• Make sure that operation is smooth.

• Lubricate if necessary.

• Check chain slack.

• Adjust if necessary.

• Check chain condition.

• Lubricate if necessary.

• Check for damage.

• Check tire condition and tread depth.

• Check air pressure.

• Correct if necessary.

• Make sure that operation is smooth.

• Lubricate pedal pivoting point if necessary.

• Make sure that operation is smooth.

• Lubricate lever pivoting points if necessary.

• Make sure that operation is smooth.

• Lubricate pivot if necessary.

• Make sure that all nuts, bolts and screws are properly tightened.

• Tighten if necessary.

• Check operation.

• Correct if necessary.

• Check operation of ignition circuit cut-off system.

• If system is defective, have Yamaha dealer check vehicle.

6-17, 6-25

6-25

6-23, 6-24

6-17, 6-19

6-26

6-25

6-26

—

—

3-14

4-3

OPERATION AND IMPORTANT RIDING POINTS

EAU15950

EWA10270

WARNING

● Become thoroughly familiar

with all operating controls and
their functions before riding.
Consult a Yamaha dealer re­garding any control or function
that you do not thoroughly un­derstand.

● Never start the engine or oper-

ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con­sciousness and death within a
short time. Always make sure
that there is adequate ventila­tion.

● Before starting out, make sure

that the sidestand is up. If the
sidestand is not raised com­pletely, it could contact the
ground and distract the opera­tor, resulting in a possible loss
of control.

EAUM1670

Starting the engine

In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:

● The transmission is in the neutral

position.

● The transmission is in gear with

the clutch lever pulled and the sid­estand up.

EWA10290

WARNING

● Before starting the engine,

check the function of the igni­tion circuit cut-off system ac­cording to the procedure
described on page 3-15.

● Never ride with the sidestand

down.

1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “”.

ECAM1030

CAUTION:

The following warning lights and in­dicator light should come on for a
few seconds, then go off.

● Fuel level warning light

● Coolant temperature warning

light

● Engine trouble warning light

● Immobilizer system indicator

light
If a warning or indicator light does
not go off, see page 3-3 for the corre­sponding warning and indicator
light circuit check.

2. Shift the transmission into the neu­tral position.

NOTE:

When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical cir­cuit.

3. Start the engine by pushing the
start switch.

NOTE:

If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-

5

5-1

OPERATION AND IMPORTANT RIDING POINTS

serve the battery. Do not crank the en­gine more than 10 seconds on any one
attempt.

CAUTION:

For maximum engine life, never ac­celerate hard when the engine is
cold!

NOTE:

The engine is warm when it quickly re­sponds to the throttle.

5

ECA11040

EAU16671

Shifting

1. Shift pedal

2. Neutral position

Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the il­lustration.

NOTE:

To shift the transmission into the neu­tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.

ECA10260

CAUTION:

● Even with the transmission in

the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long dis­tances. The transmission is
properly lubricated only when
the engine is running. Inade­quate lubrication may damage
the transmission.

● Always use the clutch while

changing gears to avoid damag­ing the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.

5-2

OPERATION AND IMPORTANT RIDING POINTS

EAU16810

Tips for reducing fuel
consumption

Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:

● Shift up swiftly, and avoid high en-

gine speeds during acceleration.

● Do not rev the engine while shifting

down, and avoid high engine
speeds with no load on the engine.

● Turn the engine off instead of let-

ting it idle for an extended length of
time (e.g., in traffic jams, at traffic
lights or at railroad crossings).

EAU16841

Engine break-in

There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the follow­ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt­tle operation or any condition that might
result in engine overheating must be
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.

ECA11440

CAUTION:

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

1600 km (1000 mi) and beyond

The vehicle can now be operated nor­mally.

ECA10270

CAUTION:

If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle.

5

5-3

OPERATION AND IMPORTANT RIDING POINTS

EAU17211

Parking

When parking, stop the engine, and
then remove the key from the main
switch.

WARNING

● Since the engine and exhaust

system can become very hot,
park in a place where pedestri­ans or children are not likely to
touch them.

● Do not park on a slope or on soft

5

ground, otherwise the vehicle
may overturn.

CAUTION:

Never park in an area where there
are fire hazards such as grass or
other flammable materials.

EWA10310

ECA10380

5-4

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU17240

Safety is an obligation of the owner. Pe­riodic inspection, adjustment and lubri­cation will keep your vehicle in the
safest and most efficient condition pos­sible. The most important points of in­spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen­eral guide under normal riding condi­tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI­CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER­VALS MAY NEED TO BE SHORT­ENED.

EWA10320

WARNING

If you are not familiar with mainte­nance work, have a Yamaha dealer
do it for you.

EAU17520

Owner’s tool kit

1. Owner’s tool kit

2. Engine oil drain attachment

The owner’s tool kit is located inside the
storage compartment under the seat.
(See page 3-12.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How­ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.

NOTE:

If you do not have the tools or experi­ence required for a particular job, have
a Yamaha dealer perform it for you.

EWA10350

WARNING

Modifications not approved by
Yamaha may cause loss of perfor­mance and render the vehicle un­safe for use. Consult a Yamaha
dealer before attempting any chang­es.

6

6-1

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU17705

Periodic maintenance and lubrication chart

NOTE:

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

stead.

● From 50000 km, repeat the maintenance intervals starting from 10000 km.

● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical

skills.

NO. ITEM CHECK OR MAINTENANCE JOB

1 * Fuel line • Check fuel hoses for cracks or damage. √√√√ √

• Check condition.

2 Spark plug

6

3 * Valves

4 Air filter element • Replace. √√

5Clutch

6 * Front brake

7 * Rear brake

8 * Brake hoses

• Clean and regap.

• Replace. √√

• Check valve clearance.

• Adjust.

• Check operation.

• Adjust.

• Check operation, fluid level and vehicle for fluid leakage. √√√√√ √

• Replace brake pads. Whenever worn to the limit

• Check operation, fluid level and vehicle for fluid leakage. √√√√√ √

• Replace brake pads. Whenever worn to the limit

• Check for cracks or damage. √√√√ √

• Replace. Every 4 years

6-2

ODOMETER READING (× 1000 km)

1 10203040

√√

√√

√√√√√

ANNUAL

CHECK

PERIODIC MAINTENANCE AND MINOR REPAIR

NO. ITEM CHECK OR MAINTENANCE JOB

9 * Wheels

10 * Tires

11 * Wheel bearings • Check bearing for looseness or damage. √√√√
12 * Swingarm • Check operation and for excessive play. √√√√

13 Drive chain

14 * Steering bearings

15 * Chassis fasteners

16 Sidestand

17 * Sidestand switch • Check operation. √√√√√ √
18 * Front fork • Check operation and for oil leakage. √√√√

Shock absorber assem-

19 *

bly

Rear suspension relay

20 *

arm and connecting
arm pivoting points

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

22 Engine oil

• Check runout, spoke tightness and for damage.

• Tighten spokes if necessary.

• Check tread depth and for damage.

• Replace if necessary.

• Check air pressure.

• Correct if necessary.

• Check chain slack.

• Make sure that the rear wheel is properly aligned.

• Clean and lubricate.

• Check bearing play and steering for roughness. √√√√√

• Lubricate with lithium-soap-based grease. Every 20000 km

• Make sure that all nuts, bolts and screws are properly

tightened.

• Check operation.

• Lubricate.

• Check operation and shock absorber for oil leakage. √√√√

• Check operation. √√√√

• Change.

• Check oil level and vehicle for oil leakage.

6-3

ODOMETER READING (× 1000 km)

1 10203040

√√√√√

√√√√ √

Every 500 km and after washing the motorcycle or

riding in the rain

√√√√ √

√√√√ √

√√√√√ √

ANNUAL

CHECK

6

PERIODIC MAINTENANCE AND MINOR REPAIR

NO. ITEM CHECK OR MAINTENANCE JOB

23 Engine oil filter element • Replace. √√√

24 * Cooling system

Front and rear brake

25 *

switches

Moving parts and ca-

26

bles

Throttle grip housing

27 *

and cable

28 * Air induction system

6

Mufflers and exhaust

29 *

pipes

Lights, signals and

30 *

switches

• Check coolant level and vehicle for coolant leakage. √√√√ √

• Change. Every 3 years

• Check operation. √√√√√ √

• Lubricate. √√√√ √

• Check operation and free play.

• Adjust the throttle cable free play if necessary.

• Lubricate the throttle grip housing and cable.

• Check the air cut-off valve, reed valve, and hose for dam-

age.

• Replace the entire air induction system if necessary.

• Check the screw clamps for looseness. √√√√√ √

• Check operation.

• Adjust headlight beam.

ODOMETER READING (× 1000 km)

1 10203040

√√√√ √

√√√√ √

√√√√√ √

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.

ANNUAL

CHECK

EAUM1890

6-4

EAU18711

Removing and installing
cowlings and panels

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 re­moved and installed.

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Cowling A

1. Panel A

1. Cowling B

2. Panel B

EAUM1682

Cowling A

To remove the cowling
Remove the bolts and spacers, and
then lift the cowling up to remove it.

6-5

1. Bolt

To install the cowling

1. Place the cowling bracket tab be­tween the protector and the brack­et on each side.

1. Protector

2. Cowling bracket tab

3. Bracket

6

PERIODIC MAINTENANCE AND MINOR REPAIR

2. Place the cowling in the original
position, and then install the bolts
and spacers.

Cowling B

To remove the cowling

1. Remove the seat and panel B.
(See pages 3-12 and 6-5.)

2. Remove the bolts, remove the
quick fastener screws after turning
them 1/4 turn counterclockwise,
and then pull the cowling off at the
area shown.

6

1. Bolt

2. Quick fastener screw

EAUM1691

To install the cowling

1. Place the cowling in the original
position, and then tighten the quick
fastener screws and install the
bolts.

2. Install the panel.

3. Install the seat.

EAUM1701

Panel A

To remove the panel

1. Remove the seat. (See page
3-12.)

2. Remove the bolts and the spacer,
and then pull the panel off at the
area shown.

1. Bolt

2. Spacer

To install the panel

1. Place the panel in the original posi­tion, install spacer, and then install
the bolts.

2. Install the seat.

6-6

PERIODIC MAINTENANCE AND MINOR REPAIR

Panel B

EAUM1710

To remove the panel

1. Remove the seat. (See page
3-12.)

2. Remove the bolt, and then pull the
panel off at the areas shown.

1. Bolt

To install the panel

1. Place the panel in the original posi­tion, and then install the bolt.

2. Install the seat.

EAU19602

Checking the spark plug

The spark plug is an important engine
component, which is easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plug should be removed and checked
in accordance with the periodic mainte­nance and lubrication chart. In addition,
the condition of the spark plug can re­veal the condition of the engine.

To remove the spark plug

1. Remove the spark plug cap.

6

1. Spark plug cap

6-7

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

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Spark plug wrench

To check the spark plug

1. Check that the porcelain insulator
around the center electrode of the

6

spark plug is a medium-to-light tan
(the ideal color when the vehicle is
ridden normally).

NOTE:

If the spark plug shows a distinctly dif­ferent color, the engine could be defec­tive. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the vehicle.

2. Check the spark plug for electrode
erosion and excessive carbon or
other deposits, and replace it if
necessary.

Specified spark plug:

NGK/CR7E

To install the spark plug

1. Measure the spark plug gap with a
wire thickness gauge and, if nec­essary, adjust the gap to specifica­tion.

1. Spark plug gap

Spark plug gap:

0.7–0.8 mm (0.028–0.031 in)

2. Clean the surface of the spark plug
gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.

3. Install the spark plug with the
spark plug wrench, and then tight­en it to the specified torque.

Tightening torque:

Spark plug:

12.5 Nm (1.25 m·kgf, 9.0 ft·lbf)

NOTE:

If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci­fied torque as soon as possible.

4. Install the spark plug cap.

6-8

PERIODIC MAINTENANCE AND MINOR REPAIR

EAUM1841

Engine oil and oil filter
element

The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele­ment replaced at the intervals specified
in the periodic maintenance and lubri­cation chart.

To check the engine oil level

1. Place the vehicle on a level sur­face and hold it in an upright posi­tion.

NOTE:

Make sure that the vehicle is positioned
straight up when checking the oil level.
A slight tilt to the side can result in a
false reading.

2. Start the engine, warm it up for 10–
15 minutes, and then turn it off.

3. Wait a few minutes until the oil set­tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in), and then remove it
again to check the oil level.

NOTE:

● The engine oil tank is located in-

side of the frame.

● The engine oil should be between

the minimum and maximum level
marks.

1. Engine oil filler cap

2. Maximum level mark

3. Minimum level mark

ECA10010

CAUTION:

Do not operate the vehicle until you
know that the engine oil level is suf­ficient.

EWA10360

WARNING

Never remove the engine oil tank
cap after high-speed operation, oth­erwise hot engine oil could spout
out and cause damage or injury. Al­ways let the engine oil cool down
sufficiently before removing the oil
tank cap.

4. If the engine oil is below the mini­mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.

5. Install the oil filler cap.

6

To change the engine oil (with or
without oil filter element replace­ment)

1. Start the engine, warm it up for
several minutes, and then turn it
off.

2. Install the engine oil drain attach­ment, provided with the owner’s
tool kit, under the drain bolt of the
crankcase.

6-9

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Engine oil drain bolt (crankcase)

2. Engine oil drain attachment

3. Place an oil pan under the engine
to collect the used oil.

4. Remove the engine oil filler cap

6

and the drain bolt to drain the oil
from the crankcase.

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

1. Engine oil drain bolt (oil tank) 1. Oil filter element cover bolt

6. Remove the oil filter element drain
bolt to drain the oil from the oil filter
element.

2. Oil filter element drain bolt

8. Remove and replace the oil filter
element and O-rings.

NOTE:

Skip steps 7–9 if the oil filter element is
not being replaced.

7. Remove the oil filter element cover
by removing the bolts.

1. Oil filter element

2. O-ring

6-10

PERIODIC MAINTENANCE AND MINOR REPAIR

9. Install the oil filter element cover by
installing the bolts and the oil filter
element drain bolt, then tightening
them to the specified torques.

Tightening torques:

Oil filter element cover bolt:

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Oil filter element drain bolt:

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

NOTE:

Make sure that the O-rings are properly
seated.

10. Install the oil drain bolts, and then
tighten them to the specified
torques.

Tightening torques:

Engine oil drain bolt (crankcase):

30 Nm (3.0 m·kgf, 22 ft·lbf)

Engine oil drain bolt (oil tank):

18 Nm (1.8 m·kgf, 13 ft·lbf)

11. Add the specified amount of the
recommended engine oil, and then
install and tighten the oil filler cap.

ECAM1060

CAUTION:

The engine oil tank must be filled in
2 steps. First, fill the engine oil tank
with 1.90 L (2.0 US qt) (1.67 Imp.qt) of
the recommended engine oil. Then,
start the engine, race it 5 or 6 times,
turn it off, and then add the remain­der of the engine oil.

Recommended engine oil:

See page 8-1.

Oil quantity:

Without oil filter element replace­ment:

2.50 L (2.64 US qt) (2.20 Imp.qt)

With oil filter element replacement:

2.60 L (2.75 US qt) (2.29 Imp.qt)

ECA11620

CAUTION:

● In order to prevent clutch slip-

page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci­fication of “CD” or oils of a high­er quality than specified. In

addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.

● Make sure that no foreign mate-

rial enters the crankcase.

12. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking, im­mediately turn the engine off and
check for the cause.

13. Turn the engine off, and then
check the oil level and correct it if
necessary.

6

6-11

PERIODIC MAINTENANCE AND MINOR REPAIR

Coolant

The coolant level should be checked
before each ride. In addition, the cool­ant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.

To check the coolant level

1. Place the vehicle on a level sur­face and hold it in an upright posi­tion.

NOTE:

● The coolant level must be checked

6

on a cold engine since the level
varies with engine temperature.

● Make sure that the vehicle is posi-

tioned straight up when checking
the coolant level. A slight tilt to the
side can result in a false reading.

2. Check the coolant level in the cool­ant reservoir.

NOTE:

The coolant should be between the
minimum and maximum level marks.

EAU20070

EAUM1721

1. Coolant reservoir

2. Maximum level mark

3. Minimum level mark

3. If the coolant is at or below the
minimum level mark, remove cowl­ing B (See page 6-5.), and then
open the reservoir cap.

4. Add coolant to the maximum level
mark, and then close the reservoir
cap.

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

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

ECA10470

CAUTION:

● If coolant is not available, use

distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.

● If water has been used instead

of coolant, replace it with cool­ant as soon as possible, other­wise the engine may not be
sufficiently cooled and the cool­ing system will not be protected
against frost and corrosion.

● If water has been added to the

coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.

EWA10380

WARNING

Never attempt to remove the radiator
cap when the engine is hot.

5. Install the cowling.

6-12

NOTE:

● The radiator fan is automatically

switched on or off according to the
coolant temperature in the radia­tor.

● If the engine overheats, see page

6-38 for further instructions.

PERIODIC MAINTENANCE AND MINOR REPAIR

To change the coolant

EAUM1801

1. Place the vehicle on a level sur­face and let the engine cool if nec­essary.

2. Remove the seat and panel B.
(See pages 3-12 and 6-5.)

3. Remove cowling B. (See page
6-5.)

4. Place a container under the engine
to collect the used coolant.

5. Loosen the radiator cap retainer
screw.

6. Remove the radiator cap and cool­ant reservoir cap.

EWA10380

WARNING

Never attempt to remove the radiator
cap when the engine is hot.

1. Radiator cap

2. Radiator cap retaining screw

3. Radiator cap retainer

4. Coolant reservoir cap

7. Remove the coolant reservoir
bolts, and then turn the coolant
reservoir upside down to empty it.

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

6-13

1. Bolt

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

6

1. Coolant drain bolt

10. After the coolant is completely
drained, thoroughly flush the cool­ing system with clean tap water.

PERIODIC MAINTENANCE AND MINOR REPAIR

11. Install the coolant drain bolt, and
then tighten it to the specified
torque.

NOTE:

Check the washer for damage and re­place it if necessary.

Tightening torque:

Coolant drain bolt:

11 Nm (1.1 m·kgf, 8.0 ft·lbf)

12. Pour the specified amount of rec­ommended coolant into the radia­tor and reservoir.

6

Antifreeze/water mixture ratio:

1:1

Recommended antifreeze:

High-quality ethylene glycol anti­freeze containing corrosion inhibitors
for aluminum engines

Coolant quantity:

Radiator capacity (including all
routes):

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

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

ECA10470

CAUTION:

● If coolant is not available, use

distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine.

● If water has been used instead

of coolant, replace it with cool­ant as soon as possible, other­wise the engine may not be
sufficiently cooled and the cool­ing system will not be protected
against frost and corrosion.

● If water has been added to the

coolant, have a Yamaha dealer
check the antifreeze content of
the coolant as soon as possible,
otherwise the effectiveness of
the coolant will be reduced.

13. Install the coolant reservoir cap.

14. Install the radiator cap and radiator
cap retainer by installing the
screw.

15. Start the engine, let it idle for sev­eral minutes, and then turn it off.

16. Check the coolant level in the res­ervoir. If necessary, remove the
coolant reservoir cap, add coolant
to the maximum level mark, and
then install the cap.

17. Start the engine, and then check
the vehicle for coolant leakage. If
coolant is leaking, have a Yamaha
dealer check the cooling system.

18. Install the cowling, the panel and
the seat.

6-14

PERIODIC MAINTENANCE AND MINOR REPAIR

EAUM1833

Replacing the air filter element
and cleaning the check hose

The air filter element should be re­placed at the intervals specified in the
periodic maintenance and lubrication
chart. Replace the air filter element
more frequently if you are riding in un­usually wet or dusty areas. In addition,
the air filter check hose must be fre­quently checked and cleaned if neces­sary.

To replace the air filter element

1. Remove the seat. (See page
3-12.)

2. Remove panel B. (See page 6-5.)

3. Remove the air filter case cover by
removing the screws.

1. Air filter case cover

2. Screw

4. Pull the air filter element out.

5. Insert a new air filter element into
the air filter case as shown.

ECA10480

CAUTION:

● Make sure that the air filter ele-

ment is properly seated in the
air filter case.

● The engine should never be op-

erated without the air filter ele­ment installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.

6. Install the air filter case cover by in­stalling the screws.

7. Install the panel.

8. Install the seat.

6

To clean the air filter check hose

1. Check the hose on the side of the
air filter case for accumulated dirt
or water.

1. Air filter element

6-15

PERIODIC MAINTENANCE AND MINOR REPAIR

EAUM1910

Adjusting the engine idling
speed

The engine idling speed must be
checked and, if necessary, adjusted as
follows at the intervals specified in the
periodic maintenance and lubrication
chart.
The engine should be warm before

1. Air filter check hose 1. Idle adjusting screw

2. If dirt or water is visible, remove
the hose, clean it, and then install
it.

6

making this adjustment.

NOTE:

● The engine is warm when it quickly

responds to the throttle.

● A diagnostic tachometer is needed

to make this adjustment.

1. Attach the tachometer to the spark
plug lead.

2. Check the engine idling speed
and, if necessary, adjust it to spec­ification by turning the idle adjust­ing screw. To increase the engine
idling speed, turn the screw in di­rection (a). To decrease the en­gine idling speed, turn the screw in
direction (b).

Engine idling speed:

1300–1500 r/min

NOTE:

If the specified idling speed cannot be
obtained as described above, have a
Yamaha dealer make the adjustment.

6-16

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU21380

Adjusting the throttle cable
free play

1. Throttle cable free play

The throttle cable free play should mea­sure 3.0–5.0 mm (0.12–0.20 in) at the
throttle grip. Periodically check the
throttle cable free play and, if neces­sary, have a Yamaha dealer adjust it.

EAU21640

Tires

To maximize the performance, durabil­ity, and safe operation of your motor­cycle, note the following points
regarding the specified tires.

Tire air pressure

The tire air pressure should be checked
and, if necessary, adjusted before each
ride.

EWA10500

WARNING

● The tire air pressure must be

checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).

● The tire air pressure must be ad-

justed in accordance with the
riding speed and with the total
weight of rider, passenger, car­go, and accessories approved
for this model.

Tire air pressure (measured on cold
tires):

0–90 kg (0–198 lb):

Front:

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

Rear:

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

90–186 kg (198–410 lb):

Front:

XT660R 200 kPa (29 psi) (2.00
kgf/cm²)
XT660X 220 kPa (32 psi) (2.20
kgf/cm²)

Rear:

XT660R 225 kPa (33 psi) (2.25
kgf/cm²)
XT660X 230 kPa (33 psi) (2.30
kgf/cm²)

Off-road riding:

Front:

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

Rear:

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

Maximum load*:

186 kg (410 lb)

* Total weight of rider, passenger, car-

go and accessories

6

6-17

PERIODIC MAINTENANCE AND MINOR REPAIR

WARNING

Because loading has an enormous
impact on the handling, braking,
performance and safety characteris­tics of your motorcycle, you should
keep the following precautions in
mind.

● NEVER OVERLOAD THE

MOTORCYCLE! Operation of an
overloaded motorcycle may re­sult in tire damage, loss of con­trol, or severe injury. Make sure
that the total weight of rider,
passenger, cargo, and accesso-

6

ries does not exceed the speci­fied maximum load for the
vehicle.

● Do not carry along loosely

packed items, which can shift
during a ride.

● Securely pack the heaviest

items close to the center of the
motorcycle and distribute the
weight evenly on both sides.

● Adjust the suspension and tire

air pressure with regard to the
load.

EWA11020

● Check the tire condition and air

pressure before each ride.

Tire inspection

1. Tire sidewall

2. Tire tread depth

The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer re­place the tire immediately.

Minimum tire tread depth (front and
rear):

1.6 mm (0.06 in)

NOTE:

The tire tread depth limits may differ
from country to country. Always comply
with the local regulations.

Tire information

This motorcycle is equipped with tube
tires.

EWA10460

WARNING

● The front and rear tires should

be of the same make and de­sign, otherwise the handling
characteristics of the vehicle
cannot be guaranteed.

● After extensive tests, only the

tires listed below have been ap­proved for this model by
Yamaha Motor Co., Ltd.

6-18

PERIODIC MAINTENANCE AND MINOR REPAIR

Front tire:

Size:

XT660R 90/90-21M/C 54S, 90/90­21M/C 54T
XT660X 120/70R17 M/C 58H

Manufacturer/model:

XT660R METZELER/TOURANCE
FRONT
XT660X PIRELLI/DRAGON
XT660R MICHELIN/SIRAC

Rear tire:

Size:

XT660R 130/80-17M/C 65S,
130/80-17M/C 65T
XT660X 160/60R17 M/C 69H

Manufacturer/model:

XT660R METZELER/TOURANCE
XT660X PIRELLI/DRAGON
XT660R MICHELIN/SIRAC A

EWA10570

WARNING

● Have a Yamaha dealer replace

excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding sta­bility and can lead to loss of
control.

● The replacement of all wheel-

and brake-related parts, includ­ing the tires, should be left to a

Yamaha dealer, who has the
necessary professional knowl­edge and experience.

● It is not recommended to patch

a punctured tube. If unavoid­able, however, patch the tube
very carefully and replace it as
soon as possible with a high­quality product.

6-19

EAU21940

Spoke wheels

To maximize the performance, durabil­ity, and safe operation of your motor­cycle, note the following points
regarding the specified wheels.

● The wheel rims should be checked

for cracks, bends or warpage, and
the spokes for looseness or dam­age before each ride. If any dam­age is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.

● The wheel should be balanced

whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han­dling characteristics, and a short­ened tire life.

● Ride at moderate speeds after

changing a tire since the tire sur­face must first be “broken in” for it
to develop its optimal characteris­tics.

6

PERIODIC MAINTENANCE AND MINOR REPAIR

Adjusting the clutch lever free
play

1. Locknut

2. Clutch lever free play adjusting bolt

3. Clutch lever free play

6

The clutch lever free play should mea­sure 10.0–15.0 mm (0.39–0.59 in) as
shown. Periodically check the clutch le­ver free play and, if necessary, adjust it
as follows.

1. Loosen the locknut at the clutch le­ver.

2. To increase the clutch lever free
play, turn the adjusting bolt in di­rection (a). To decrease the clutch
lever free play, turn the adjusting
bolt in direction (b).

EAU22041

NOTE:

If the specified clutch lever free play
could be obtained as described above,
tighten the locknut and skip the rest of
the procedure, otherwise proceed as
follows.

3. Fully turn the adjusting bolt at the
clutch lever in direction (a) to loos­en the clutch cable.

4. Loosen the locknut at the crank­case.

1. Locknut

2. Clutch lever free play adjusting nut
(crankcase)

5. To increase the clutch lever free
play, turn the adjusting nut in direc­tion (a). To decrease the clutch le­ver free play, turn the adjusting nut
in direction (b).

6. Tighten the locknut at the clutch le­ver and the crankcase.

6-20

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU22270

Adjusting the rear brake light
switch

1. Rear brake light switch

2. Rear brake light switch adjusting nut

The rear brake light switch, which is ac­tivated 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
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction (a). To
make the brake light come on later, turn
the adjusting nut in direction (b).

EAU22390

Checking the front and rear
brake pads

The front and rear brake pads must be
checked for wear at the intervals spec­ified in the periodic maintenance and
lubrication chart.

EAU22430

Front brake pads

1. Brake pad wear indicator groove

Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with­out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wear

indicator grooves have almost disap­peared, have a Yamaha dealer replace
the brake pads as a set.

EAU22500

Rear brake pads

1. Lining thickness

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

6

6-21

PERIODIC MAINTENANCE AND MINOR REPAIR

Checking the brake fluid level

Front brake

1. Minimum level mark

Rear brake

6

1. Minimum level mark

EAU22580

Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake fluid
level may indicate worn brake pads
and/or brake system leakage. If the
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.

● Use only the recommended quality

brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor­mance.

Recommended brake fluid:

DOT 4

● Refill with the same type of brake

fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.

● Be careful that water does not en-

ter the brake fluid reservoir when
refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.

● Brake fluid may deteriorate paint-

ed surfaces or plastic parts. Al­ways clean up spilled fluid
immediately.

● As the brake pads wear, it is nor-

mal for the brake fluid level to grad­ually go down. However, if the
brake fluid level goes down sud­denly, have a Yamaha dealer
check the cause.

Insufficient brake fluid may allow air to
enter the brake system, possibly caus­ing it to become ineffective.

6-22

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU22760

Drive chain slack

The drive chain slack should be
checked before each ride and adjusted
if necessary.

EAU22780

To check the drive chain slack

1. Drive chain slack

1. Place the motorcycle on a level
surface and hold it in an upright po­sition.

NOTE:

When checking and adjusting the drive
chain slack, the motorcycle should be
positioned straight up and there should
be no weight on it.

2. Shift the transmission into the neu­tral position.

3. Move the rear wheel by pushing
the motorcycle to locate the tight­est portion of the drive chain, and
then measure the drive chain slack
as shown.

Drive chain slack:

40.0–55.0 mm (1.57–2.17 in)

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

NOTE:

When checking the drive chain slack,
the chain tensioner should not be
touching the drive chain.

EAU22930

To adjust the drive chain slack

1. Loosen the axle nut, then loosen
the locknut at each end of the
swingarm.

2. To tighten the drive chain, turn the
adjusting nut at each end of the
swingarm in direction (a). To loos­en the drive chain, turn the adjust­ing nut at each end of the
swingarm in direction (b), and then
push the rear wheel forward.

6-23

NOTE:

Using the alignment marks on each
side of the swingarm, make sure that
both adjusting nuts are in the same po­sition for proper wheel alignment.

1. Axle nut

2. Drive chain slack adjusting nut

3. Locknut

4. Alignment marks

ECA10570

CAUTION:

Improper drive chain slack will over­load the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the
specified limits.

6

PERIODIC MAINTENANCE AND MINOR REPAIR

3. Tighten the locknuts, and then
tighten the axle nut to the specified
torque.

Tightening torque:

Axle nut:

104 Nm (10.4 m·kgf, 75 ft·lbf)

6

EAU23021

Lubricating the drive chain

The drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica­tion 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.

1. Clean the drive chain with kero­sene 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.

ECA11110

CAUTION:

Do not use engine oil or any other lu­bricants for the drive chain, as they
may contain substances that could
damage the O-rings.

6-24

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23100

Checking and lubricating the
cables

The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca­bles and cable ends should be lubricat­ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.

Recommended lubricant:

Engine oil

EWA10720

WARNING

Damage to the outer sheath may in­terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions.

EAU23110

Checking and lubricating the
throttle grip and cable

The operation of the throttle grip should
be checked before each ride. In addi­tion, the cable should be lubricated or
replaced at the intervals specified in the
periodic maintenance chart.

EAU23140

Checking and lubricating the
brake and clutch levers

Brake lever

Clutch lever

6

6-25

The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu­bricated if necessary.

PERIODIC MAINTENANCE AND MINOR REPAIR

Recommended lubricant:

Lithium-soap-based grease (all-pur­pose grease)

EAU23180

Lubricating the brake pedal

Checking and lubricating the
sidestand

EAU23200

The operation of the brake pedal
should be checked before each ride,
and the pedal pivot should be lubricat-

6

ed if necessary.

The operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if

Recommended lubricant:

Lithium-soap-based grease (all-pur­pose grease)

necessary.

EWA10730

WARNING

If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it.

6-26

Recommended lubricant:

Lithium-soap-based grease (all-pur­pose grease)

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23271

Checking the front fork

The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main­tenance and lubrication chart.

To check the condition

EWA10750

WARNING

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

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

To check the operation

1. Place the vehicle on a level sur­face and hold it in an upright posi­tion.

2. While applying the front brake,
push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.

ECA10590

CAUTION:

If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re­pair it.

EAU23280

Checking the steering

Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol­lows at the intervals specified in the pe­riodic maintenance and lubrication
chart.

1. Place a stand under the engine to
raise the front wheel off the
ground.

EWA10750

WARNING

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

2. Hold the lower ends of the front
fork legs and try to move them for­ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.

6

6-27

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU23290

Checking the wheel bearings

The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica­tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.

Battery

This model is equipped with a sealed­type (MF) battery, which does not re­quire any maintenance. There is no
need to check the electrolyte or to add
distilled water.

CAUTION:

EAUM1730

ECA10620

Never attempt to remove the battery
cell seals, as this would permanent­ly damage the battery.

To access the battery

6

1. Remove the seat. (See page
3-12.)

2. Remove the battery cover by re­moving the bolts.

6-28

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Negative battery terminal

2. Positive battery terminal

3. Bolt

4. Battery cover

To charge the battery

Have a Yamaha dealer charge the bat­tery as soon as possible if it seems to
have discharged. Keep in mind that the
battery tends to discharge more quickly
if the vehicle is equipped with optional
electrical accessories.

EWA10760

WARNING

● Electrolyte is poisonous and

dangerous since it contains sul­furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al­ways shield your eyes when

working near batteries. In case
of contact, administer the fol­lowing FIRST AID.

• EXTERNAL: Flush with plenty
of water.

• INTERNAL: Drink large quan­tities of water or milk and im­mediately call a physician.

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

● Batteries produce explosive hy-

drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and pro­vide sufficient ventilation when
charging it in an enclosed
space.

● KEEP THIS AND ALL BATTER-

IES OUT OF THE REACH OF
CHILDREN.

To store the battery

1. If the vehicle will not be used for
more than one month, remove the
battery, fully charge it, and then
place it in a cool, dry place.

6-29

2. If the battery will be stored for more
than two months, check it at least
once a month and fully charge it if
necessary.

3. Fully charge the battery before in­stallation.

4. After installation, make sure that
the battery leads are properly con­nected to the battery terminals.

ECA10630

CAUTION:

● Always keep the battery

charged. Storing a discharged
battery can cause permanent
battery damage.

● To charge a sealed-type (MF)

battery, a special (constant-volt­age) battery charger is required.
Using a conventional battery
charger will damage the battery.
If you do not have access to a
sealed-type (MF) battery charg­er, have a Yamaha dealer
charge your battery.

6

PERIODIC MAINTENANCE AND MINOR REPAIR

Replacing the fuses

The main fuse is located behind panel
A. (See page 6-5.)

1. Main fuse

2. Spare main fuse

6

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

EAUM1740

1. Fuse box 1

2. Signaling system fuse

3. Headlight fuse

4. Ignition fuse

5. Electronic fuel injection fuse

6. Radiator fan fuse

7. Backup fuse (for odometer, clock and
immobilizer system)

8. Parking lighting fuse

9. Fuse box 2

10.Spare fuse

If a fuse is blown, replace it as follows.

1. Turn the key to “OFF” and turn off
the electrical circuit in question.

2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.

Specified fuses:

Main fuse:

30.0 A

Fuse box 1:

Headlight fuse:

20.0 A

Signaling system fuse:

10.0 A

Radiator fan fuse:

7.5 A

Ignition fuse:

10.0 A

Electronic fuel injection fuse:

10.0 A

Backup fuse:

10.0 A

Fuse box 2:

Parking lighting fuse:

10.0 A

ECA10640

CAUTION:

Do not use a fuse of a higher amper­age rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire.

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

6-30

PERIODIC MAINTENANCE AND MINOR REPAIR

4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.

EAUM1750

Replacing the headlight bulb

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 cover

2. Headlight coupler

3. Remove the headlight bulb holder
by turning it counterclockwise, and
then remove the defective bulb.

1. Headlight bulb holder

2. Headlight bulb

EWA10790

WARNING

Headlight bulbs get very hot. There­fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down.

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

ECA10660

CAUTION:

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

6-31

PERIODIC MAINTENANCE AND MINOR REPAIR

fected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with al­cohol or thinner.

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

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.

EAU24281

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

1. Remove the lens by removing the
screws.

1. Screw

2. Remove the defective bulb by
pushing it in and turning it counter­clockwise.

3. Insert a new bulb into the socket,
push it in, and then turn it clock­wise until it stops.

4. Install the lens by installing the
screws.

ECA10680

CAUTION:

Do not overtighten the screws, oth­erwise the lens may break.

1. Screw

6-32

PERIODIC MAINTENANCE AND MINOR REPAIR

EAUM1820

Replacing an auxiliary light
bulb

If the auxiliary light bulb burns out, re­place it as follows.

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

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

1. Auxiliary light bulb socket

3. Remove the defective bulb by pull­ing it out.

4. Insert a new bulb into the socket.

5. Install the auxiliary light socket (to­gether with the bulb) by pushing it
in.

6. Install the cowling together with
the headlight unit.

EAU24350

Supporting the motorcycle

Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance
requiring the motorcycle to stand up­right. Check that the motorcycle is in a
stable and level position before starting
any maintenance. A strong wooden
box can be placed under the engine for
added stability.

To service the front wheel

1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack un­der the frame in front of the rear
wheel.

2. Raise the front wheel off the
ground by using a motorcycle
stand.

To service the rear wheel

Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor­cycle stand is not available, by placing

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

6

6-33

PERIODIC MAINTENANCE AND MINOR REPAIR

Front wheel

To remove the front wheel

WARNING

● It is advisable to have a Yamaha

dealer service the wheel.

● Securely support the motor-

cycle so that there is no danger
of it falling over.

1. Loosen the front wheel axle pinch
bolts, then the wheel axle and the
brake caliper bolts.

6

XT660R

1. Wheel axle

2. Front wheel axle pinch bolt A

3. Front wheel axle pinch bolt B

EAU24360

EAUM1761

EWA10820

XT660X

1. Wheel axle

2. Front wheel axle pinch bolt A

3. Front wheel axle pinch bolt B

2. Lift the front wheel off the ground
according to the procedure on
page 6-33.

3. Remove the brake caliper by re­moving the bolts.

1. Bolt

2. Brake caliper

ECA11070

CAUTION:

Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.

4. Pull the wheel axle out, and then
remove the wheel.

EAUM1811

To install the front wheel

1. Lift the wheel up between the fork
legs.

2. Insert the wheel axle.

3. Lower the front wheel so that it is
on the ground.

6-34

PERIODIC MAINTENANCE AND MINOR REPAIR

4. Install the brake caliper by install­ing the bolts.

NOTE:

Make sure that there is enough space
between the brake pads before install­ing the brake caliper onto the brake
disc.

5. Tighten the wheel axle to the spec­ified torque.

6. Tighten the wheel axle pinch bolt A
and pinch bolt B to the specified
torques.

7. Retighten the wheel axle pinch bolt
A to the specified torque.

8. Tighten the brake caliper bolts to
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)

9. Push down hard on the handlebar
several times to check for proper
fork operation.

EAU25080

Rear wheel

EAUM1771

To remove the rear 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
of it falling over.

1. Remove the drive chain guard by
removing the bolts.

XT660R

1. Bolt

2. Drive chain guard

XT660X

1. Bolt

2. Drive chain guard

2. Loosen the axle nut.

6

1. Axle nut

2. Drive chain slack adjusting nut

3. Locknut

4. Brake caliper bracket

5. Brake caliper

6-35

PERIODIC MAINTENANCE AND MINOR REPAIR

3. Lift the rear wheel off the ground
according to the procedure on
page 6-33.

4. Loosen the locknut on each side of
the swingarm.

5. Turn the drive chain slack adjust­ing nuts fully in direction (a).

6. Remove the wheel axle by remov­ing the axle nut.

7. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.

6

NOTE:

The drive chain cannot be disassem­bled.

8. Pull the wheel backward and move
the brake caliper away from the
wheel.

ECA11070

CAUTION:

Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.

1. Brake caliper

2. Brake disc

EAUM1781

To install the rear wheel

1. Install the drive chain onto the rear
sprocket.

2. Install the wheel, the washers and
the brake caliper bracket by insert­ing the wheel axle from the left­hand side.

6-36

NOTE:

● Install the washer with the “N”

mark on the right-hand side and
the washer with the “O” mark on
the left-hand side. Be sure to install
both washers with their marks fac­ing outward.

● Make sure that the retainer on the

swingarm is inserted into the slot in
the brake caliper bracket.

● Make sure that there is enough

space between the brake pads be­fore installing the wheel.

1. Retainer

2. Slot

3. Lower the rear wheel so that it is
on the ground.

PERIODIC MAINTENANCE AND MINOR REPAIR

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

5. Tighten the axle nut to the speci­fied torque.

Tightening torque:

Axle nut:

104 Nm (10.4 m·kgf, 75 ft·lbf)

6. Install the drive chain guard by in­stalling the bolts.

EAU25870

Troubleshooting

Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur­ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting charts
represent quick and easy procedures
for checking these vital systems your­self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace­ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi­or, have a shorter service life and can
lead to expensive repair bills.

6

6-37

PERIODIC MAINTENANCE AND MINOR REPAIR

Troubleshooting charts

EAU25921

Starting problems or poor engine performance

WARNING

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

1. Fuel

Check the fuel level in

There is enough fuel.

the fuel tank.

There is no fuel.

Check the compression.

Supply fuel.

The engine does not start.
Check the compression.

2. Compression

There is compression.

6

Operate the electric starter.

3. Ignition

Remove the spark plug
and check the electrodes.

4. Battery

Operate the electric starter.

There is no compression.

Wet

Dry

The engine turns over
quickly.

The engine turns over
slowly.

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

Have a Yamaha dealer check the vehicle.

Check the ignition.

Have a Yamaha dealer
check the vehicle.

The battery is good.

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

EWA10840

Open the throttle halfway and operate
the electric starter.

The engine does not start.
Check the battery.

The engine does not start.
Have a Yamaha dealer
check the vehicle.

6-38

PERIODIC MAINTENANCE AND MINOR REPAIR

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.

Wait until the
engine has cooled.

Check the coolant level in the
reservoir and radiator.

The coolant level is low.
Check the cooling system
for leakage.

The coolant level
is OK.

There is
leakage.

There is
no leakage.

Start the engine. If the engine overheats again, have a

Yamaha dealer check

Have a Yamaha dealer check

and repair the cooling system.

Add coolant. (See NOTE.)

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

6-39

MOTORCYCLE CARE AND STORAGE

Care

While the open design of a motorcycle
reveals the attractiveness of the tech­nology, it also makes it more vulnera­ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go un­noticed on a car, however, it detracts
from the overall appearance of a motor­cycle. Frequent and proper care does
not only comply with the terms of the
warranty, but it will also keep your
motorcycle looking good, extend its life
and optimize its performance.

Before cleaning

1. Cover the muffler outlet with a

7

plastic bag after the engine has
cooled down.

2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug cap, are tightly in­stalled.

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

EAU26000

ucts onto seals, gaskets, sprock­ets, the drive chain and wheel
axles. Always rinse the dirt and de­greaser off with water.

Cleaning

ECA10770

CAUTION:

● Avoid using strong acidic wheel

cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the af­fected area any longer than in­structed. Also, thoroughly rinse
the area off with water, immedi­ately dry it, and then apply a cor­rosion protection spray.

● Improper cleaning can damage

windshields, cowlings, panels
and other plastic parts. Use only
a soft, clean cloth or sponge
with mild detergent and water to
clean plastic.

● Do not use any harsh chemical

products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive

7-1

cleaning products, solvent or
thinner, fuel (gasoline), rust re­movers or inhibitors, brake flu­id, antifreeze or electrolyte.

● Do not use high-pressure wash-

ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar­eas: seals (of wheel and swing­arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.

● For motorcycles equipped with

a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning com­pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid­den part of the windshield to
make sure that it does not leave
any marks. If the windshield is
scratched, use a quality plastic
polishing compound after
washing.

MOTORCYCLE CARE AND STORAGE

After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.

After riding in the rain, near the sea or
on salt-sprayed roads
Since sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.

NOTE:

Salt sprayed on roads in the winter may
remain well into spring.

1. Clean the motorcycle with cold wa­ter and a mild detergent, after the
engine has cooled down.

ECA10790

CAUTION:

Do not use warm water since it in­creases the corrosive action of the
salt.

2. Apply a corrosion protection spray
on all metal, including chrome- and
nickel-plated, surfaces to prevent
corrosion.

After cleaning

1. Dry the motorcycle with a chamois
or an absorbing cloth.

2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.

3. Use a chrome polish to shine
chrome, aluminum and stainless­steel parts, including the exhaust
system. (Even the thermally in­duced discoloring of stainless­steel exhaust systems can be re­moved through polishing.)

4. To prevent corrosion, it is recom­mended to apply a corrosion pro­tection spray on all metal,
including chrome- and nickel-plat­ed, surfaces.

5. Use spray oil as a universal clean­er to remove any remaining dirt.

6. Touch up minor paint damage
caused by stones, etc.

7. Wax all painted surfaces.

8. Let the motorcycle dry completely
before storing or covering it.

EWA10930

WARNING

● Make sure that there is no oil or

wax on the brakes or tires. If
necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or ac­etone, and wash the tires with
warm water and a mild deter­gent.

● Before operating the motor-

cycle test its braking perfor­mance and cornering behavior.

ECA10800

CAUTION:

● Apply spray oil and wax spar-

ingly and make sure to wipe off
any excess.

7

7-2

MOTORCYCLE CARE AND STORAGE

● Never apply oil or wax to any

rubber and plastic parts, but
treat them with a suitable care
product.

● Avoid using abrasive polishing

compounds as they will wear
away the paint.

NOTE:

Consult a Yamaha dealer for advice on
what products to use.

7

EAUM1900

Storage

Short-term

Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.

ECA10810

CAUTION:

● Storing the motorcycle in a

poorly ventilated room or cover­ing it with a tarp, while it is still
wet, will allow water and humid­ity to seep in and cause rust.

● To prevent corrosion, avoid

damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi­cals are stored.

Long-term

Before storing your motorcycle for sev­eral months:

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

2. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.

7-3

3. Perform the following steps to pro­tect the cylinder, piston rings, etc.
from corrosion.
a. Remove the spark plug cap

and spark plug.

b. Pour a teaspoonful of engine oil

into the spark plug bore.

c. Install the spark plug cap onto

the spark plug, and then place
the spark plug on the cylinder
head so that the electrodes are
grounded. (This will limit spark­ing during the next step.)

d. Turn the engine over several

times with the starter. (This will
coat the cylinder wall with oil.)

e. Remove the spark plug cap

from the spark plug, and then
install the spark plug and the
spark plug cap.

EWA10950

WARNING

To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.

4. Lubricate all control cables and the
pivoting points of all levers and
pedals as well as of the side­stand/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. Alterna­tively, 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 plas­tic bags to prevent moisture from
entering them.

7. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex­cessively 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
6-28.

MOTORCYCLE CARE AND STORAGE

7

NOTE:

Make any necessary repairs before
storing the motorcycle.

7-4

SPECIFICATIONS

Dimensions:

Weight:

8

Engine:

Overall length:

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

Overall width:

XT660R 845 mm (33.3 in)
XT660X 865 mm (34.1 in)

Overall height:

XT660R 1230 mm (48.4 in)
XT660X 1210 mm (47.6 in)

Seat height:

XT660R 865 mm (34.1 in)
XT660X 870 mm (34.3 in)

Wheelbase:

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

Ground clearance:

XT660R 210 mm (8.27 in)
XT660X 205 mm (8.07 in)

Minimum turning radius:

2400 mm (94.5 in)

With oil and fuel:

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

Engine type:

Liquid cooled 4-stroke, SOHC

Cylinder arrangement:

Forward-inclined single cylinder

Displacement:

660.0 cm³ (40.27 cu.in)

Bore × stroke:

100.0 × 84.0 mm (3.94 × 3.31 in)

Compression ratio:

10.00 :1

Starting system:

Electric starter

Lubrication system:

Dry sump

Engine oil:

Type:

SAE10W30 or SAE10W40 or SAE15W40
or SAE20W40 or SAE20W50

-20 -10 0

Recommended engine oil grade:

API service SE, SF, SG type or higher

Engine oil quantity:

Without oil filter element replacement:

2.50 L (2.64 US qt) (2.20 Imp.qt)

With oil filter element replacement:

2.60 L (2.75 US qt) (2.29 Imp.qt)

20 30

10

SAE 10W-30

SAE 10W-40

SAE 15W-40

SAE 20W-40

SAE 20W-50

40

Cooling system:

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

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

Radiator capacity (including all routes):

1.00 L (1.06 US qt) (0.88 Imp.qt)

8-1

50 ˚C

Air filter:

Air filter element:

Oil-coated paper element

Fuel:

Recommended fuel:

Premium unleaded gasoline only

Fuel tank capacity:

15.0 L (3.96 US gal) (3.30 Imp.gal)

Fuel reserve amount:

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

Electronic fuel injection:

Manufacturer:

DENSO

Model:

297500-0390

Spark plug(s):

Manufacturer/model:

NGK/CR7E

Spark plug gap:

0.7–0.8 mm (0.028–0.031 in)

Clutch:

Clutch type:

Wet, multiple-disc

Transmission:

Primary reduction system:

Spur gear

Primary reduction ratio:

75/36 (2.083)

Secondary reduction system:

Chain drive

Secondary reduction ratio:

45/15 (3.000)

Transmission type:

Constant mesh 5-speed

SPECIFICATIONS

Operation:

Left foot operation

Gear ratio:

1st:

30/12 (2.500)

2nd:

26/16 (1.625)

3rd:

23/20 (1.150)

4th:

20/22 (0.909)

5th:

20/26 (0.769)

Chassis:

Frame type:

Diamond

Caster angle:

XT660R 27.25 °
XT660X 26.00 °

Trail:

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

Front tire:

Type:

With tube

Size:

XT660R 90/90-21M/C 54S, 90/90-21M/C
54T
XT660X 120/70R17 M/C 58H

Manufacturer/model:

XT660R METZELER/TOURANCE FRONT
XT660X PIRELLI/DRAGON

Manufacturer/model:

XT660R MICHELIN/SIRAC

Rear tire:

Type:

With tube

Size:

XT660R 130/80-17M/C 65S, 130/80­17M/C 65T
XT660X 160/60R17 M/C 69H

Manufacturer/model:

XT660R METZELER/TOURANCE
XT660X PIRELLI/DRAGON

Manufacturer/model:

XT660R MICHELIN/SIRAC A

Loading:

Maximum load:

186 kg (410 lb)
(Total weight of rider, passenger, cargo and
accessories)

Tire air pressure (measured on cold
tires):

Loading condition:

0–90 kg (0–198 lb)
Front:

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

Rear:

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

Loading condition:

90–186 kg (198–410 lb)
Front:

XT660R 200 kPa (29 psi) (2.00 kgf/cm²)
XT660X 220 kPa (32 psi) (2.20 kgf/cm²)

Rear:

XT660R 225 kPa (33 psi) (2.25 kgf/cm²)
XT660X 230 kPa (33 psi) (2.30 kgf/cm²)

Off-road riding:

Front:

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

Rear:

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

Front wheel:

Wheel type:

Spoke wheel

Rim size:

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

Rear wheel:

Wheel type:

Spoke wheel

Rim size:

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

Front brake:

Type:

Single disc brake

Operation:

Right hand operation

Recommended fluid:

DOT 4

Rear brake:

Type:

Single disc brake

Operation:

Right foot operation

Recommended fluid:

DOT 4

8

8-2

SPECIFICATIONS

Front suspension:

Type:

Telescopic fork

Spring/shock absorber type:

Coil spring/oil damper

Wheel travel:

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

Rear suspension:

Type:

Swingarm (monocross)

Spring/shock absorber type:

Coil spring/gas-oil damper

Wheel travel:

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

Electrical system:

Ignition system:

Transistorized coil ignition (digital)

Charging system:

A.C. magneto

Battery:

Model:

8

GT9B-4

Voltage, capacity:

12 V, 8.0 Ah

Headlight:

Bulb type:

Halogen bulb

Bulb voltage, wattage x quantity:

Headlight:

12 V, 55 W/60.0 W × 1

Tail/brake light:

12 V, 5.0/21.0 W × 1

Front turn signal light:

12 V, 10.0 W × 2

Rear turn signal light:

12 V, 10.0 W × 2

Auxiliary light:

12 V, 5.0 W × 1

Meter lighting:

EL

Neutral indicator light:

LED

High beam indicator light:

LED

Turn signal indicator light:

LED

Fuel level warning light:

LED

Coolant temperature indicator light:

LED

Engine trouble warning light:

LED

Immobilizer system indicator light:

LED

Fuses:

Main fuse:

30.0 A

Headlight fuse:

20.0 A

Signaling system fuse:

10.0 A

Ignition fuse:

10.0 A

Parking lighting fuse:

10.0 A

8-3

Radiator fan fuse:

7.5 A

Electronic fuel injection fuse:

10.0 A

Backup fuse:

10.0 A

CONSUMER INFORMATION

EAU26351

Identification numbers

Record the key identification number,
vehicle identification number and mod­el label information in the spaces pro­vided below for assistance when
ordering spare parts from a Yamaha
dealer or for reference in case the vehi­cle is stolen.
KEY IDENTIFICATION NUMBER:

VEHICLE IDENTIFICATION
NUMBER:

MODEL LABEL INFORMATION:

Key identification number

EAU26381

1. Key identification number

2. Code re-registering key (red bow)

3. Standard keys (black bow)

The key identification number is
stamped into the key tag. Record this
number in the space provided and use
it for reference when ordering a new
key.

Vehicle identification number

EAU26410

1. Vehicle identification number

The vehicle identification number is
stamped into the frame.

NOTE:

The vehicle identification number is
used to identify your vehicle and may
be used to register it with the licensing
authority in your area.

9

9-1

CONSUMER INFORMATION

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

EAU26540

9-2

INDEX

A

Air filter element and check hose,

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

Anti-theft alarm (optional) ....................... 3-7

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

B

Battery .................................................. 6-28

Brake and clutch levers, checking

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

Brake fluid level, checking .................... 6-22

Brake lever ............................................. 3-9

Brake pedal .......................................... 3-10

Brake pedal, lubricating ........................ 6-26

C

Cables, checking and lubricating.......... 6-25

Care........................................................ 7-1

Catalytic converter................................ 3-12

Clutch lever............................................. 3-9

Clutch lever free play, adjusting ........... 6-20

Coolant ................................................. 6-12

Coolant temperature warning light.......... 3-4

Cowlings and panels, removing and

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

D

Dimmer switch........................................ 3-8

Drive chain, lubricating ......................... 6-24

Drive chain slack .................................. 6-23

E

Engine break-in ...................................... 5-3

Engine idling speed .............................. 6-16

Engine oil and oil filter element............... 6-9

Engine stop switch.................................. 3-8

Engine trouble warning light ................... 3-4

F

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

Front fork, checking...............................6-27

Fuel .......................................................3-11

Fuel consumption, tips for reducing ........5-3

Fuel level warning light............................ 3-4

Fuel tank cap.........................................3-10

Fuses, replacing....................................6-30

H

Handlebar switches.................................3-7

Hazard switch..........................................3-8

Headlight bulb, replacing.......................6-31

High beam indicator light.........................3-4

Horn switch .............................................3-8

I

Identification numbers .............................9-1

Ignition circuit cut-off system .................3-15

Immobilizer system .................................3-1

Immobilizer system indicator light...........3-4

Indicator and warning lights ....................3-3

K

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

M

Main switch/steering lock ........................3-2

Model label..............................................9-2

Multi-function display...............................3-5

N

Neutral indicator light ..............................3-3

P

Parking....................................................5-4

Part locations ..........................................2-1

Pass switch .............................................3-8

Periodic maintenance and lubrication

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

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

R

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

S

Safety information ...................................1-1

Seat ...................................................... 3-12

Shifting.................................................... 5-2

Shift pedal............................................... 3-9

Shock absorber assembly, adjusting .... 3-13

Sidestand.............................................. 3-14

Sidestand, checking and lubricating .....6-26

Spark plug, checking ..............................6-7

Specifications.......................................... 8-1

Starting the engine.................................. 5-1

Start switch ............................................. 3-8

Steering, checking ................................ 6-27

Storage ................................................... 7-3

Storage compartment ........................... 3-13

Supporting the motorcycle .................... 6-33

T

Throttle cable free play, adjusting......... 6-17

Throttle grip and cable, checking

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

Tires...................................................... 6-17

Tool kit .................................................... 6-1

Troubleshooting .................................... 6-37

Troubleshooting charts ......................... 6-38

Turn signal indicator light........................ 3-3

Turn signal light bulb or tail/brake

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

Turn signal switch ................................... 3-8

V

Vehicle identification number.................. 9-1

INDEX

W

Wheel bearings, checking..................... 6-28

Wheel (front) ......................................... 6-34

Wheel (rear) .......................................... 6-35

Wheels ..................................................6-19

YAMAHA MOTOR CO., LTD.

PRINTED IN FRANCE

2004.02 (E)