Yamaha Xt660R Xt660X 2004 Service Repair Manual (MT046913)

Yamaha Xt660R Xt660X 2004 Service Repair Manual (MT046913)

• This manual presented for you in electronic format you can just print out the page you need then dispose of it when you have completed your task. This manual has detailed illustrations as well as step by step written instructions with the necessary diagrams or pictures. These manuals are your number one source for repair and service information, specifically written for the do-it-yourself as well as the experienced mechanics worldwide used to use this factory manual to fix your vehicle. Using this repair manual is an inexpensive way to keep your car working properly. it is this level of detail, along with illustrations, that guide the reader through each service, repairs, maintenance procedure.
• Yamaha_XT660R_XT660X_2004_Service_Repair Manual
  
  Pages 462
  
  CHAPTER 1
  
  GENERAL INFORMATION
  
  MOTORCYCLE IDENTIFICATION
  
  VEHICLE IDENTIFICATION NUMBER MODEL LABEL
  
  FEATURES OUTLINE FI SYSTEM
  
  IMPORTANT INFORMATION
  
  PREPARATION FOR REMOVAL AND DISASSEMBLY REPLACEMENT PARTS GASKETS, OIL SEALS AND O-RINGS LOCK WASHERS/PLATES AND COTTER PINS BEARINGS AND OIL SEALS CIRCLIPS
  
  CHECKING THE CONNECTIONS
  
  SPECIAL TOOLS
  
  CHAPTER 2
  
  SPECIFICATIONS
  
  GENERAL SPECIFICATIONS ENGINE SPECIFICATIONS CHASSIS SPECIFICATIONS ELECTRICAL SPECIFICATIONS CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS TIGHTENING TORQUE
  
  ENGINE TIGHTENING TORQUE CHASSIS TIGHTENING TORQUES
  
  LUBRICATION POINTS AND LUBRICANT TYPES
  
  ENGINE CHASSIS
  
  COOLING SYSTEM DIAGRAMS LUBRICATION CHART LUBRICATION DIAGRAMS CABLE ROUTING
  
  CHAPTER 3
  
  PERIODIC CHECKS AND ADJUSTMENTS
  
  INTRODUCTION
  
  PERIODIC MAINTENANCE AND LUBRICATION CHART
  
  COWLING AND COVER
  
  COVER COWLING
  
  FUEL TANK REMOVING THE FUEL TANK REMOVING THE FUEL PUMP INSTALLING THE FUEL PUMP INSTALLING THE FUEL HOSE
  
  AIR FILTER CASE REAR MUD GUARD AND REAR FENDER AIR FILTER CASE INSTALLING THE AIR FILTER CASE JOINT CLAMP
  
  ENGINE ADJUSTING THE VALVE CLEARANCE ADJUSTING THE EXHAUST GAS VOLUME ADJUSTING THE ENGINE IDLING SPEED ADJUSTING THE THROTTLE CABLE FREE PLAY CHECKING THE SPARK PLUG CHECKING THE IGNITION TIMING MEASURING THE COMPRESSION PRESSURE CHECKING THE ENGINE OIL LEVEL CHANGING THE ENGINE OIL ADJUSTING THE CLUTCH CABLE FREE PLAY CHECKING THE AIR FILTER ELEMENT CHECKING THE THROTTLE BODY JOINT CHECKING THE FUEL HOSE CHECKING THE BREATHER HOSE CHECKING THE EXHAUST SYSTEM CHECKING THE COOLANT LEVEL CHECKING THE COOLING SYSTEM CHANGING THE COOLANT
  
  CHASSIS
  
  ADJUSTING THE REAR BRAKE PEDAL CHECKING THE BRAKE FLUID LEVEL CHECKING THE FRONT AND REAR BRAKE PADS
  
  AND BRAKE PAD PINS ADJUSTING THE REAR BRAKE LIGHT SWITCH CHECKING THE FRONT AND REAR BRAKE HOSES BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJUSTING THE SHIFT PEDAL ADJUSTING THE DRIVE CHAIN SLACK LUBRICATING THE DRIVE CHAIN CHECKING AND ADJUSTING THE STEERING HEAD CHECKING THE FRONT FORK ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY CHECKING THE TIRES CHECKING AND TIGHTENING THE SPOKES CHECKING AND LUBRICATING THE CABLES LUBRICATING THE LEVERS AND BRAKE PEDAL LUBRICATING THE SIDESTAND
  
  ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY CHECKING THE FUSES REPLACING THE HEADLIGHT BULB ADJUSTING THE HEADLIGHT BEAM SETTING THE DIGITAL CLOCK
  
  CHAPTER 4
  
  CHASSIS
  
  FRONT WHEEL AND BRAKE DISC FRONT WHEEL REMOVING THE FRONT WHEEL CHECKING THE FRONT WHEEL CHECKING THE FRONT BRAKE DISC INSTALLING THE FRONT WHEEL ADJUSTING THE FRONT WHEEL STATIC BALANCE
  
  REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET REMOVING THE REAR WHEEL CHECKING THE REAR WHEEL CHECKING THE REAR BRAKE DISC CHECKING THE REAR WHEEL DRIVE HUB CHECKING AND REPLACING THE REAR WHEEL SPROCKET INSTALLING THE REAR WHEEL ADJUSTING THE REAR WHEEL STATIC BALANCE
  
  FRONT AND REAR BRAKES FRONT BRAKE PADS (XT660R) FRONT BRAKE PADS (XT660X) REAR BRAKE PADS REPLACING THE FRONT BRAKE PADS REPLACING THE REAR BRAKE PADS FRONT BRAKE MASTER CYLINDER REAR BRAKE MASTER CYLINDER DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER
  
  DISASSEMBLING THE REAR BRAKE MASTER CYLINDER CHECKING THE FRONT AND REAR BRAKE MASTER
  
  CYLINDERS ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER
  
  CYLINDER ASSEMBLING THE REAR BRAKE MASTER CYLINDER INSTALLING THE REAR BRAKE MASTER CYLINDER FRONT BRAKE CALIPER (XT660R) FRONT BRAKE CALIPER (XT660X) REAR BRAKE CALIPER REMOVING THE FRONT BRAKE CALIPER REMOVING THE REAR BRAKE CALIPER CHECKING THE FRONT AND REAR BRAKE CALIPERS INSTALLING THE FRONT BRAKE CALIPER INSTALLING THE REAR BRAKE CALIPER
  
  CHAPTER 5
  
  ENGINE
  
  ENGINE REMOVAL EXHAUST PIPES AND MUFFLERS LEADS, CABLES, HOSES, AND IGNITION COIL ENGINE INSTALLING THE ENGINE
  
  CYLINDER HEAD REMOVING THE CYLINDER HEAD CHECKING THE CYLINDER HEAD CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER
  
  CHECKING THE TIMING CHAIN TENSIONER
  
  CHECKING THE CAMSHAFT SPROCKET
  
  INSTALLING THE CYLINDER HEAD
  
  ROCKER ARMS AND CAMSHAFT REMOVING THE ROCKER ARMS AND CAMSHAFT CHECKING THE CAMSHAFT CHECKING THE DECOMPRESSION SYSTEM CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS INSTALLING THE CAMSHAFT AND ROCKER ARMS
  
  VALVES AND VALVE SPRINGS REMOVING THE VALVES CHECKING THE VALVES AND VALVE GUIDES CHECKING THE VALVE SEATS CHECKING THE VALVE SPRINGS INSTALLING THE VALVES
  
  CYLINDER AND PISTON REMOVING THE CYLINDER AND PISTON CHECKING THE CYLINDER AND PISTON CHECKING THE PISTON RINGS CHECKING THE PISTON PIN INSTALLING THE PISTON AND CYLINDER
  
  CLUTCH
  
  CLUTCH COVER PULL LEVER SHAFT CLUTCH REMOVING THE CLUTCH CHECKING THE FRICTION PLATES CHECKING THE CLUTCH PLATES CHECKING THE CLUTCH SPRINGS CHECKING THE CLUTCH HOUSING CHECKING THE CLUTCH BOSS CHECKING THE PRESSURE PLATE CHECKING THE PULL LEVER SHAFT AND PULL ROD CHECKING THE PRIMARY DRIVEN GEAR INSTALLING THE CLUTCH
  
  OIL PUMP
  
  CHECKING THE OIL PUMP CHECKING THE OIL DELIVERY PIPES AND HOSES ASSEMBLING THE OIL PUMP INSTALLING THE OIL PUMP
  
  BALANCER DRIVEN GEAR
  
  REMOVING THE BALANCER DRIVEN GEAR AND BALANCER DRIVE GEAR
  
  CHECKING THE BALANCER DRIVEN GEAR, WATER PUMP DRIVE GEAR, PRIMARY DRIVE GEAR, AND BALANCER DRIVE GEAR
  
  INSTALLING THE BALANCER DRIVEN GEAR
  
  AND BALANCER DRIVE GEAR
  
  SHIFT SHAFT
  
  SHIFT SHAFT AND STOPPER LEVER CHECKING THE SHIFT SHAFT CHECKING THE STOPPER LEVER INSTALLING THE SHIFT SHAFT
  
  STARTER CLUTCH AND AC MAGNETO
  
  REMOVING THE AC MAGNETO ROTOR CHECKING THE STATOR COIL AND CRANKSHAFT POSITION SENSOR
  
  CHECKING THE STARTER CLUTCH
  
  CHECKING THE TORQUE LIMITER
  
  INSTALLING THE AC MAGNETO ROTOR
  
  CHAPTER 6
  
  COOLING SYSTEM
  
  RADIATOR CHECKING THE RADIATOR INSTALLING THE RADIATOR
  
  THERMOSTAT CHECKING THE THERMOSTAT INSTALLING THE THERMOSTAT
  
  WATER PUMP DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP ASSEMBLING THE WATER PUMP INSTALLING THE WATER PUMP
  
  CHAPTER 7
  
  FUEL INJECTION SYSTEM
  
  FUEL INJECTION SYSTEM WIRING DIAGRAM ECU SELF-DIAGNOSTIC FUNCTION ALTERNATE OPERATION CONTROL (FAIL-SAFE ACTION) FAIL-SAFE ACTION TABLE TROUBLESHOOTING CHART DIAGNOSTIC MODE TROUBLESHOOTING DETAILS
  
  THROTTLE BODY ASSEMBLY CHECKING THE FUEL INJECTOR CHECKING THE THROTTLE BODY INSTALLING THE THROTTLE BODY ASSEMBLY
  
  CHECKING THE FUEL PUMP CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR
  
  AIR INDUCTION SYSTEM AIR INJECTION AIR CUT-OFF VALVE AIR INDUCTION SYSTEM DIAGRAMS AIR CUT-OFF VALVE ASSEMBLY CHECKING THE AIR INDUCTION SYSTEM CHAPTER 8
  
  ELECTRICAL SYSTEM
  
  ELECTRICAL COMPONENTS
  
  CHECKING SWITCH CONTINUITY
  
  CHECKING THE SWITCHES
  
  CHECKING THE BULBS AND BULB SOCKETS TYPES OF BULBS CHECKING THE CONDITION OF THE BULBS CHECKING THE CONDITION OF THE BULB SOCKETS CHECKING THE LEDs
  
  IGNITION SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING
  
  ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM STARTING CIRCUIT CUT-OFF SYSTEM OPERATION TROUBLESHOOTING
  
  STARTER MOTOR CHECKING THE STARTER MOTOR ASSEMBLING THE STARTER MOTOR
  
  CHARGING SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING
  
  LIGHTING SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING CHECKING THE LIGHTING SYSTEM
  
  SIGNALING SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING CHECKING THE SIGNALING SYSTEM
  
  COOLING SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING
  
  CHAPTER 9
  
  TROUBLESHOOTING
  
  STARTING FAILURES ENGINE FUEL SYSTEM ELECTRICAL SYSTEMS
  
  INCORRECT ENGINE IDLING SPEED ENGINE FUEL SYSTEM ELECTRICAL SYSTEMS
  
  POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ENGINE FUEL SYSTEM
  
  FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT SHIFT PEDAL DOES NOT MOVE JUMPS OUT OF GEAR
  
  FAULTY CLUTCH CLUTCH SLIPS CLUTCH DRAGS
  
  OVERHEATING ENGINE COOLING SYSTEM FUEL SYSTEM CHASSIS ELECTRICAL SYSTEMS
  
  OVERCOOLING COOLING SYSTEM
  
  POOR BRAKING PERFORMANCE
  
  FAULTY FRONT FORK LEGS LEAKING OIL MALFUNCTION
  
  UNSTABLE HANDLING

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