Yamaha XT660 2004 User Manual [ru]

2004

XT660R(S)

XT660X(S)

5VK1-AE1

SERVICE MANUAL

EAS00000

XT660R(S)/XT660X(S) 2004

SERVICE MANUAL

First edition, December 2003

Any reproduction or unauthorized use

without the written permission of

MBK Industrie

is expressly prohibited.

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NOTICE

This manual was produced by MBK Industrie primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.

Yamaha is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

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IMPORTANT MANUAL INFORMATION

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

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

WARNING

CAUTION:

NOTE:

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

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

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

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HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order.

The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS”.

Each chapter is divided into sections. The current section title is shown at the top of each page, except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s) appears.

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

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.

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

Symbols indicate parts to be lubricated or replaced. Refer to “SYMBOLS”.

A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.

Jobs requiring more information (such as special tools and technical data) are described sequentially.

GEN

SPEC

INFO

CHK

CHAS

ADJ

ENG

COOL

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SYMBOLS

The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter.

General information

Specifications

Periodic checks and adjustments

Chassis

Engine

Cooling system

Fuel injection system

Electrical system

Troubleshooting

ELEC

–+

TRBL

SHTG

EFG

HIJ

Symbols 0 to G indicate the following.

Serviceable with engine mounted

Filling fluid

Lubricant

Special tool

Tightening torque

Wear limit, clearance

Engine speed

Electrical data

Symbols H to M in the exploded diagrams indicate the types of lubricants and lubrication points.

New

KLM

Engine oil

Gear oil

Molybdenum-disulfide oil

Wheel-bearing grease

Lithium-soap-based grease

Molybdenum-disulfide grease

Symbols N to O in the exploded diagrams indicate the following.

Apply locking agent (LOCTITE

Replace the part

)

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– +

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND ADJUSTMENTS

CHASSIS

ENGINE

GEN

INFO

SPEC

CHK

ADJ

CHAS

ENG

COOLING SYSTEM

FUEL INJECTION SYSTEM

ELECTRICAL SYSTEM

TROUBLESHOOTING

COOL

ELEC

TRBL

SHTG

GEN

INFO

CHAPTER 1

GENERAL INFORMATION

GEN

INFO

MOTORCYCLE IDENTIFICATION

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

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

FEATURES

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

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

IMPORTANT INFORMATION

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

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

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

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

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

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

CHECKING THE CONNECTIONS

SPECIAL TOOLS

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

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

..................................................................1-1

.........................................................................1-4

..................................................................1-6

GEN

INFO

MOTORCYCLE IDENTIFICATION

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GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION

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VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is stamped into the right side of the steering head pipe.

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MODEL LABEL

The model label 1 is affixed to the frame. This information will be needed to order spare parts.

GEN

INFO

1 - 1

GEN

FEATURES

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FEATURES

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OUTLINE

The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In a conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective chamber. Despite the same volume of intake air, the fuel volume requirement varies with the engine operating conditions, such as acceleration, deceleration, or operation under a heavy load. Carburetors that meter the fuel through the use of jets have been provided with various auxiliary devices, so that an optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the engine. As the requirements for engines to deliver more performance and cleaner exhaust gases increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accommodate this need, this model has adopted an electronically controlled fuel injection (FI) system in place of a conventional carburetor system. This system can achieve an optimum air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to the engine operating conditions detected by various sensors. Adoption of the FI system has resulted in a highly precise fuel supply, improved engine response, better fuel economy, and reduced exhaust emissions. Furthermore, the air induction system (AI system) has been placed under computer control together with the FI system in order to realize cleaner exhaust gases.

INFO

Air cut-off valve

Air induction system

solenoid Engine trouble warn-

ing light Fuel tank

Fuel pump

Fuel hose

Fuel injector

Throttle position sen-

sor Intake air temperature

sensor Air filter case

Fuel injection system

relay

567890A

DEFGHI

Battery

Catalytic converter

ECU

Lean angle cut-off

switch Fast idle unit

Crankshaft position

sensor

Coolant temperature

sensor Spark plug

Intake air pressure

sensor Ignition coil

1 - 2

GEN

FEATURES

EAS00897

FI SYSTEM

The fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the injector at 324 kPa (3.24 kg/cm manifold pressure. Accordingly, when the energizing signal from the ECU energizes the injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open. Therefore, the longer the length of time the injector is energized (injection duration), the greater the volume of fuel that is supplied. Conversely, the shorter the length of time the injector is energized (injection duration), the lesser the volume of fuel that is supplied. The injection duration and the injection timing are controlled by the ECU. Signals that are input from the throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake air temperature sensor, and coolant temperature sensor enable the ECU to determine the injection duration. The injection timing is determined through the signal from the crankshaft position sensor. As a result, the volume of fuel that is required by the engine can be supplied at all times in accordance with the driving conditions.

Illustration is for reference only.

, 46.1 psi) higher than the intake

INFO

Fuel pump

Pressure regulator

Fuel injector

Throttle body

Intake air temperature

sensor Throttle position sen-

sor Intake air pressure

sensor

ECU

Coolant temperature

sensor Crankshaft position

sensor

Fuel system

Air system

Control system

1 - 3

IMPORTANT INFORMATION

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IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND DISASSEMBLY

1. Before removal and disassembly, remove all dirt, mud, dust and foreign material.

2. Use only the proper tools and cleaning equipment. Refer to “SPECIAL TOOLS”.

3. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly.

4. During disassembly, clean all of the parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts.

5. Keep all parts away from any source of fire.

GEN

INFO

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REPLACEMENT PARTS

Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

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GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned.

2. During reassembly, properly oil all mating parts and bearings and lubricate the oil seal lips with grease.

1 - 4

IMPORTANT INFORMATION

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LOCK WASHERS/PLATES AND COTTER PINS

After removal, replace all lock washers/plates

and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut.

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BEARINGS AND OIL SEALS

Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.

Oil seal

GEN

INFO

CAUTION:

Do not spin the bearing with compressed air because this will damage the bearing surfaces.

Bearing

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CIRCLIPS

Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Always replace piston pin clips after one use. When installing a circlip 1, make sure the sharp-edged corner 2 is positioned opposite the thrust 3 that the circlip receives.

Shaft

1 - 5

CHECKING THE CONNECTIONS

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CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for stains, rust, moisture, etc.

1. Disconnect:

• lead

• coupler

• connector

2. Check:

• lead

• coupler

• connector

Moisture → Dry with an air blower. Rust/stains → Connect and disconnect several times.

3. Check:

• all connections Loose connection → Connect properly.

NOTE:

If the pin 1 on the terminal is flattened, bend it up.

GEN

INFO

4. Connect:

• lead

• coupler

• connector

NOTE:

Make sure all connections are tight.

5. Check:

• continuity (with the pocket tester)

Pocket tester

90890-03112

NOTE:

• If there is no continuity, clean the terminals.

• When checking the wire harness, perform

steps (1) to (3).

• As a quick remedy, use a contact revitalizer available at most part stores.

1 - 6

GEN

SPECIAL TOOLS

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SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.

Tool No. Tool name/Function Illustration

Slide hammer bolt

90890-01083

Weight

90890-01084

90890-01135

Weight

These tools are used to remove or install the rocker arm shafts.

Crankcase separating tool

This tool is used to remove the crankshaft.

INFO

Attachment

90890-01243

Compressor

90890-04019

90890-01268

Pot

90890-01274

Bolt

90890-01275

90890-01304

Valve spring compressor attachment Valve spring compressor

These tools are used to remove or install the valve assemblies.

Ring nut wrench

This tool is used to loosen or tighten the steering ring nuts.

Crankshaft installer pot Crankshaft installer bolt

These tools are used to install the crankshaft.

Piston pin puller set

90890-01325

This tool is used to remove the piston pin.

Radiator cap tester

This tool is used to check the cooling system.

1 - 7

GEN

SPECIAL TOOLS

Tool No. Tool name/Function Illustration

T-handle

90890-01326

Holder

90890-01460

90890-01352

Damper rod holder

These tools are used to hold the damper rod holder when removing or installing the damper rod.

Radiator cap tester adaptor

This tool is used to check the cooling system.

INFO

90890-01362

Weight

90890-01367

Attachment

90890-01374

90890-01403

90890-01496

Flywheel puller

This tool is used to remove the A.C. magneto rotor.

Fork seal driver weight Fork seal driver attachment (ø43)

These tools are used to install the oil seal, dust seal, and the outer tube bushing of the front fork legs.

Steering nut wrench

This tool is used to loosen or tighten the steering ring nuts.

Radiator tester adapter

This tool is used to check the cooling system.

M8 × 80 mm M8 × 60 mm M8 × 150 mm

150

90890-01497

90890-01701

Radiator cap tester adapter

This tool is used to check the cooling system.

Sheave holder

This tool is used to hold the A.C. magneto rotor when loosen or tighten the A.C. magneto rotor nut.

1 - 8

GEN

SPECIAL TOOLS

Tool No. Tool name/Function Illustration

Thickness gauge

90890-03079

This tool is used to measure the valve clearance.

Compression gauge

90890-03081

These tools are used to measure the engine compression.

Pocket tester

90890-03112

This tool is used to check the electrical system.

INFO

90890-03141

90890-03153

90890-03174

90890-03176

Timing light

This tool is used to check the ignition timing.

Pressure gauge

This tool is needed to measure fuel pressure.

Digital circuit tester

This tool is used to check electrical system.

Fuel pressure adapter

This tool is needed to measure fuel pressure.

Driver

90890-04058

Installer

90890-04132

Middle driven shaft bearing driver Mechanical seal installer

These tools are used to install the mechanical seal.

1 - 9

GEN

SPECIAL TOOLS

Tool No. Tool name/Function Illustration

Valve guide remover (ø 6)

90890-04064

This tool is needed to remove and install the valve guides.

Valve guide installer (ø 6)

90890-04065

This tool is needed to install the valve guides.

Valve guide reamer (ø 6)

90890-04066

This tool is needed to rebore the new valve guides.

INFO

90890-04082

90890-04086

90890-04101

Adapter

90890-04130

Spacer

90890-04144

Adaptor (Compression gauge)

This tool is needed to measure engine compression.

Universal clutch holder

This tool is needed to hold the clutch boss when removing or installing the boss nut.

Valve lapper

This tool is used for lapping the valve.

Adapter Spacer (crankshaft installer)

These tools are used to install the crankshaft.

90890-06754

Ignition checker

This tool is used to check the ignition system components.

1 - 10

GEN

SPECIAL TOOLS

Tool No. Tool name/Function Illustration

Yamaha bond No. 1215

90890-85505

This bond is used to seal two mating surfaces (e.g., crankcase mating surfaces).

INFO

1 - 11

SPEC

CHAPTER 2

SPECIFICATIONS

SPEC

GENERAL SPECIFICATIONS

ENGINE SPECIFICATIONS

CHASSIS SPECIFICATIONS

ELECTRICAL SPECIFICATIONS

CONVERSION TABLE

GENERAL TIGHTENING TORQUE SPECIFICATIONS

TIGHTENING TORQUE

ENGINE TIGHTENING TORQUE ...........................................................2-20

CHASSIS TIGHTENING TORQUES....................................................... 2-23

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE...................................................................................................2-25

CHASSIS.................................................................................................2-27

..................................................................................2-19

.................................................................................2-20

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

............................................................................2-2

........................................................................2-11

.................................................................2-16

...............................2-19

....................................2-25

COOLING SYSTEM DIAGRAMS

LUBRICATION CHART

LUBRICATION DIAGRAMS

CABLE ROUTING

.................................................................................2-30

..........................................................................2-31

.........................................................................................2-35

..................................................................2-28

SPEC

GENERAL SPECIFICATIONS

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard Limit

SPEC

Model code

Dimensions

Overall length 2,240 mm (88.2 in) (XT660R)

Overall width 845 mm (33.3 in) (XT660R)

Overall height 1,230 mm (48.4 in) (XT660R)

Seat height 865 mm (34.1 in) (XT660R)

Wheelbase 1,505 mm (59.3 in) (XT660R)

Minimum ground clearance 210 mm (8.27 in) (XT660R)

Minimum turning radius 2,400 mm (94.5 in) ----

Weight

Wet (with oil and a full fuel tank) 181 kg (399 lb) (XT660R)

Maximum load (total of cargo, rider, passenger, and accessories)

XT660R: 5VK1 (Europe)

5VK2 (AUS) 5VK3 (GB)

XT660X: 1D21 (Europe)

1D22 (AUS) 1D23 (GB)

2,150 mm (84.6 in) (XT660X)

865 mm (34.1 in) (XT660X)

1,210 mm (47.6 in) (XT660X)

870 mm (34.3 in) (XT660X)

1,490 mm (58.7 in) (XT660X)

205 mm (8.07 in) (XT660X)

186 kg (410 lb) (XT660X) 186 kg (410 lb) ----

----

2 - 1

ENGINE SPECIFICATIONS

SPEC

ENGINE SPECIFICATIONS

Item Standard Limit

Engine

Engine type Liquid-cooled, 4-stroke, SOHC ----

Displacement 660 cm Cylinder arrangement Forward-inclined single cylinder ---Bore × stroke 100.0 × 84.0 mm (3.94 × 3.31 in) ---Compression ratio 10.00 : 1 ---Engine idling speed 1,300 ~ 1,500 r/min ---Water temperature 80 °C (176 °F) ---- Oil temperature 55 ~ 60 °C (131 ~ 140 °F) ---Standard compression pressure

(at sea level)

650 kPa (6.5 kg/cm at 800 r/min

Fuel

Recommended fuel Premium unleaded gasoline only ---Fuel tank capacity

Total (including reserve) 15.0 L (3.30 Imp gal, 3.96 US gal) ---Reserve only 5.0 L (1.10 Imp gal, 1.32 US gal) ----

Engine oil

Lubrication system Dry sump ---Recommended oil

-20 -10 0

20 30

50 ˚C

Refer to the chart for engine oil grade. API service SE, SF, SG type or higher

SAE 10W-30

(40.27 cu · in) ----

, 92.4 psi)

----

SAE 10W-40

SAE 15W-40

SAE 20W-40

SAE 20W-50

Quantity

Total amount 2.90 L (2.55 Imp qt, 3.07 US qt) ---Periodic oil change 2.50 L (2.20 Imp qt, 2.64 US qt) ---With oil filter replacement 2.60 L (2.29 Imp qt, 2.75 US qt) ----

Oil filter

Oil filter type Paper ---Bypass valve opening pressure 40.0 ~ 80.0 kPa

(0.40 ~ 0.80 kg/cm

, 5.8 ~ 11.6 psi)

Pressure check location Oil filter chamber ----

----

2 - 2

ENGINE SPECIFICATIONS

Item Standard Limit

Oil pump

Oil pump type Trochoid ---Inner-rotor-to-outer-rotor-tip clearance Outer-rotor-to-oil-pump-housing

clearance Oil-pump-housing-to-inner-rotor-and-

outer-rotor clearance

Cooling system

Radiator capacity 1.00 L (0.88 Imp, 1.06 US qt) ---Radiator cap opening pressure 110.0 ~ 140.0 kPa

Radiator core

Width 280.0 mm (11.02 in) ---Height 158.0 mm (6.22 in) ---Depth 23.0 mm (0.91 in) ----

Coolant reservoir

Capacity 0.25 L (0.22 Imp, 0.26 US qt) --- <From low to full level> 0.15 L (0.13 Imp, 0.16 US qt) ----

Water pump

Water pump type Single-suction centrifugal pump ---Reduction ratio 27/28 (0.964) ---Maximum impeller shaft tilt ---- 0.15 mm

Starting system type Fuel injector

Model/manufacturer 297500-0390/DENSO ---Quantity 1 ----

Spark plug

Model/manufacturer × quantity CR7E/NGK × 1 ---Spark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) ----

Cylinder head

Volume 59.10 ~ 60.50 cm Maximum warpage ---- 0.03 mm

0.07 ~ 0.12 mm (0.0028 ~ 0.0047 in) 0.2 mm

0.03 ~ 0.08 mm (0.0012 ~ 0.0031 in) 0.15 mm

(1.10 ~ 1.40 kg/cm

Electric starter ----

, 16.0 ~ 20.3 psi)

(3.61 ~ 3.69 cu · in) ----

SPEC

(0.008 in)

(0.0059 in)

(0.006 in)

(0.0012 in)

----

2 - 3

ENGINE SPECIFICATIONS

Item Standard Limit

Camshaft

Drive system Chain drive (left) ---Intake camshaft lobe dimensions

Measurement A 43.488 ~ 43.588 mm (1.7121 ~ 1.7161 in) 43.338 mm

Measurement B 36.959 ~ 37.059 mm (1.4551 ~ 1.4590 in) 36.840 mm

Exhaust camshaft lobe dimensions

SPEC

(1.7062 in)

(1.4504 in)

Measurement A 43.129 ~ 43.229 mm (1.6980 ~ 1.7019 in) 42.983 mm

(1.6922 in)

Measurement B 37.007 ~ 37.107 mm (1.4570 ~ 1.4609 in) 36.886 mm

(1.4522 in)

Valve timing

Intake - open (B.T.D.C.) 25° ---- Intake - closed (A.B.D.C.) 55° ---Exhaust - open (B.B.D.C.) 60° ---- Exhaust - closed (A.T.D.C.) 20° ---Overlap angle “A” 45° ----

Maximum camshaft runout ---- 0.040 mm

(0.0016 in)

Timing chain

Model/number of links 98 × RH2010/126 ---Tensioning system Automatic ----

2 - 4

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